GENCON(R)II PRO

Automatic sequencing of multiple generator-sets

Wexler
c CSD Ltd.
Email: info@wexler.co.il
May 15, 2003

1 General The sequencing logic skips calling up generator-sets

GENCON(R) controllers, in a multiple generator-set plant
with equal size engines, can automatically start and stop
their generator-sets according to the plant active (kW)
load. The sequence in which the generator-sets start and
stop can be changed by the operator from any controller
panel.
The sequencing logic is designed for plants with a
slowly varying load level. Hotels, hospitals and large res-
idential and office blocks fall into this category. The ob- 2.2 Definitions
jective of the sequencing logic is to keep the number of
parallel running generator-sets to the minimum.
In this application all the controllers are in configura-
tion #3 and the {System Auto Start} option is 1.
Note: Sequencing service for gen-sets of arbi-
trary size and automatic run-time count balancing for
equal size engines is provided through the manage-
ment subsystem of COMM2(phone). Contact Wexler
for more details.
2 Starting and stopping rules
2.1 General
The order in which generator-sets start when the load in- α : Denotes the set-point {+%kW/Xre→ Start}. α is the
creases and the order in which they stop when the load
decreases is determined by the plant operator through
the SEQUENCE command. With a “→ 2 → 3 → 1” se-
quence the generator-set with controller ID no. 2 has the
highest running priority. If one generator-set cannot start,
the next one from the sequence automatically starts.
with pending shutdown faults and generator-sets that
are not in auto mode – those with active In#3 SLEEP
and In#16 AUTOSTART DISABLE 1 commands. Note
that having an active In#16 command does not prevent
the generator-set from being started through In#1 RUN
WITH LOAD and In#2 TEST W/O LOAD. Figure 1
shows a typical mode switch wiring.
N : Denotes the number of generator-sets that currently
run in parallel.
U nity : The engine {Xre: Rated kW} parameter in BA-
SICS is defined as “one unit of power”. The follow-
ing α, β and λ variables use this unit. For example, if
Xre is 800kW then a 50% λ level represents a 400kW
load.
λ : Denotes the generator-set load. Note that (1 − λ) is
the spare generator-set power and N ∗ (1 − λ) is the
total spare power in the parallel running generator-
sets, i.e., how much extra load the running generator-
sets can safely take.
total spare power threshold that requires an increase
in the number of parallel running generator-sets. α
can be larger than 100% and its value must be the
same in all the controllers.
1 In#16 AUTOSTART DISABLE is available from V2.5n

1
β : Denotes the set-point {+%kW/Xre→ Stop}. 1 + β is
the total spare power threshold that requires a de-
crease in the number of parallel running generator-
sets. β can be larger than 100% and its value must
be the same in all the controllers. Make sure that
α < β or otherwise one generator-set will start and
stop incessantly.
T1 : Denotes the {Parll Start} time delay for the α
threshold. Its value must be the same in all the con-
trollers.
T0 : Denotes the {Parll Stop} time delay for the β thresh-
old. Its value must be the same in all the controllers.
2.3 The rules
1. One generator-set should start and take the load im-
mediately when the condition N ∗ (1 − λ) ≤ 0 is
true. This condition is true when:
• N = 0, i.e., the plant must have at least one
generator-set powering the load.
• λ ≥ 1, i.e., the load on the current number of
parallel running generator-sets is too high.
2. A generator-set should start and join the parallel
running generator-sets T1 time after the condition
N ∗ (1 − λ) ≤ α becomes true. I.e., when the to-
tal spare power in the parallel running generator-sets parallel. As the load increases the following table shows
is α or lower.
3. A generator-set should stop T0 time after the con-
dition N ∗ (1 − λ) ≥ 1 + β becomes true. I.e., even
after stopping one generator-set the total spare power
in the remaining generator-sets, N ∗ (1 − λ) − 1, is
β or higher.
4. When a generator-set connects to the bus or when a load levels when the N -th generator-set stops:
generator-set disconnects from the bus, rules 1-3 are
suspended for {LS Settling} seconds. These rules are
suspended to avoid false decisions while the load is
re-distributed among the new number of generator-
sets.
5. “Black start”:
Before software version 2.5n When the generator-
set controllers mode changes from Sleep to
Auto by simultaneously deactivating their In#3
command lines, all the generator-sets start and
connect to the bus. The generator-sets run in
parallel for T0 time and then, according to the
bus load level (rule 3), some of the generator-
sets stop.
From software version 2.5n When the In#16 com-
mand lines are simultaneously deactivated all
the generator-sets start and connect to the
bus. The generator-sets run in parallel for T0
time and then, according to the bus load level
(rule 3), some of the generator-sets stop.
6. When the generator set controllers mode changes
from Auto to Manual by simultaneous activation of
their In#1 terminals, all the generator-sets connect to
the bus. When the controllers mode changes back to
Auto by simultaneous deactivation of their In#1 ter-
minals, according to the bus load level (rule 3) some
of the generator-sets stop without delay.
3 Start/stop rules example
A power plant has five generator-sets, each has the fol-
lowing set-points: {Xre: Rated kW}=400, α = 25% and
β = 30%. Assume that N generator-sets currently run in
the load levels when the (N + 1)-th generator-set starts:
N Total bus load Generator-set load
1 300 300
2 700 350
3 1100 367
4 1500 375
As the load decreases the following table shows the
N Total bus load Genset load
2 280 140
3 680 227
4 1080 270
5 1480 296
This and other examples can be computed by the as-
tart.exe program.
2
4 A real application
A, B and C denote the controllers of three equal size
generator-sets that serve for mains failure standby; The
sequence is “→ 1 → 2 → 3”; The Automatic Transfer
Switch (ATS) logic is external.

• Let the signal x = A.In#16 = B.In#16 = C.In#16 (ver-

sion 2.5n onward).
• When the mains is healthy the ATS should hold “x”
active.
• Upon mains failure the ATS releases the signal “x”
2
. All the generator-sets start together according to
rule 5; the generator-set that has stabilized first con-
nects to the (dead) bus without delay and becomes
the “bus master” 3 . The other “slave generator-
sets” connect to the bus after synchronization4 . The
generator-sets run in parallel for T0 ={Parll Stop}
time and then, if the load is low enough, generator-
sets 3 and 2 stop (no. 2 stops {LS Settling} time after
no. 3)

2 The expected plant load is unknown. Probably it will be at its peak

because of the need to recharge the UPS.

3 The generator-set whose governor and AVR determine the bus fre-

quency and voltage.

4 If the master stops, the remaining set with the lowest ID number

becomes the new bus master.

3
 G1 G2 G8
OFF OFF OFF
In#3 In#3 In#3
AUTO AUTO AUTO
TEST TEST TEST
In#2 In#2 In#2
MAN MAN MAN
In#1 In#1 In#1

Closed contact inhibits In#16 In#16 In#16

automatic sequencing

Figure 1: Typical mode switch wiring