PARALLELING SETUP INSTRUCTIONS

MGC-3000 Series Generator to Generator in Island

SCOPE ........................................................................................................................................................ 2
DEFINITION(S) ............................................................................................................................................ 2
ABBREVIATED SEQUENCE OF OPERATION ................................................................................................. 2
SYSTEM OPERATION .................................................................................................................................. 3
PARALLELING CONTROLS, EQUIPMENT, AND INTERFACING (SUPPLIED BY MTU ONSITE ENERGY) .......... 3
PROGRAMMING AND LOGIC ...................................................................................................................... 4
REFERENCE ................................................................................................................................................ 4
HARDWARE VERIFICATION ......................................................................................................................... 5
SOFTWARE VERIFICATION .......................................................................................................................... 6
SYNCHRONIZING VERIFICATION .............................................................................................................. 18
TESTING AND TUNING .............................................................................................................................. 19

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PARALLELING SETUP INSTRUCTIONS
MGC-3000 Series Generator to Generator in Island

SCOPE
The purpose of this document is to provide instructions for connecting and tuning MTU Onsite Energy
generator sets in a Generator to Generator in Island Operation configuration.

DEFINITION(S)
Generator to Generator in Island Operation
Island refers to the application of the system. Generator to generator in island refers to an isolated
system in which the generator sets will not be paralleled with any source other than the generator sets
within the system. The generator sets will be connected to a common bus.

Master Control Panel (MCP)

A master control panel is a third party device responsible for monitoring automatic transfer switch (ATS)
start requests, issuing transfer inhibits and load priority commands to the ATSs, adding and shedding
loads, and issuing start requests to generator sets.

Automatic Transfer Switch (ATS)

An automatic transfer switch connects an electrical load to either of two different sources. Typically, one
source is considered Normal and the other source is considered Emergency. The ATS has the ability to
sense the stability and availability of either source and can issue transference of load between either
source.

System Manager
The System Manager is the MGC-3000 Series controller with the lowest, non-zero sequencing ID. This
controller is responsible for dead bus arbitration between generator sets. The System Manager can be
one of any controllers in the generator set system.

Intergenset Communication Network

The intergenset communication network consists of generator set controllers connected together via
Cat5 cable and an industrial Ethernet switch. Dead bus arbitration, generator set sequencing, and load
sharing commences between generator sets over this network.

Dead Bus Arbitration

Dead bus arbitration is achieved by selecting the primary generator set that will close onto a dead bus. It
only allows one unit to close onto a dead bus. Dead bus arbitration control minimizes the time for the first
generator set to close onto a dead bus.

Generator Set Sequencing

Generator set sequencing is the starting and stopping of generator sets based on load factor and
available capacity.

ABBREVIATED SEQUENCE OF OPERATION

Instability or failure of the Normal power source is detected by the ATS controllers.
ATS controllers send start requests to the MCP.
1. MCP sends individual start requests to the group of generator sets.
2. Generator sets start and build rated voltage and frequency.
3. Dead bus arbitration commences between the generator sets through the intergenset
communication network.

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a. The System Manager grants the first generator set to reach the voltage and frequency
thresholds permission to close to the dead bus.
b. All off-line generator sets at this time are inhibited from closing their circuit breakers to
the bus until voltage is sensed.
c. The highest priority ATS transfers to Emergency power when voltage and frequency are
within the ATS controller thresholds.
d. The remaining off-line generator sets synchronize and close to the live generator bus.
4. The remaining ATSs wait for release of transfer inhibit from the MCP before connecting to
Emergency power. The MCP monitors the bus and the number of generator sets online to
ensure that there are enough generator sets connected to the bus to support the load
requirements.
5. Online generator sets actively share load via the intergenset communications network.

ATS controllers detect when the Normal power source has returned to stable conditions and all delay
timers have expired.
1. ATSs return to Normal position, removing start signals to the MCP.
2. MCP removes all start requests for Emergency power from the generator sets.
3. The generator sets open their respective circuit breakers (disconnecting from the generator
bus).
4. The generator sets enter a controller-appointed cool-down period.
5. The group of generator sets stops, returns to standby, and awaits the next start request.

SYSTEM OPERATION
 Real power load sharing (via intergenset communication network)
 Reactive power load sharing (via intergenset communication network)
 Dead bus arbitration

PARALLELING CONTROLS, EQUIPMENT, AND INTERFACING (SUPPLIED BY

MTU ONSITE ENERGY)
 MGC-3000 Series digital generator set controller (referred to as the controller)
 Current transformers (CTs) and potential transformer (PT) (as needed)
 Permanent Magnet Generator (PMG)
- DVR2000E(+) digital voltage regulator (standard)
- DVR2000EC(+) digital voltage regulator (optional)
 Motor operated circuit breaker (may or may not be mounted to the generator set)*
 The following circuit breaker accessories
– Shunt trip
– Shunt close
– Auxiliary switch (breaker position)
– Motorized spring charger

*If a circuit breaker is selected, MTU Onsite Energy will supply a motor-operated breaker of the
indicated configuration.

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ADDITIONAL PARALLELING CONTROLS, EQUIPMENT, AND INTERFACING (SUPPLIED BY

THIRD PARTY)
 Master Control Panel (MCP) with connections for monitoring ATS start requests, issuing transfer
inhibits and load priority commands to ATSs, adding and shedding loads, and issuing start
requests to generator sets
 ATS(s), paralleling switchgear, circuit breakers, and/or disconnects
 Paralleling bus and cabling
 Start signal source connection to generator sets
 Main bus sensing connection to generator sets
 Industrial Ethernet switch for intergenset communications network
 Cat5 cable connection from Ethernet switch to all generator sets for intergenset communications
network

PROGRAMMING AND LOGIC

 Basic programming and logic will be provided to start, synchronize, and load share with other
MTU Onsite Energy supplied generator sets.
 Site programming and system tuning are required by the customer for proper onsite operation.
 MCP integration and programming are required by the customer for proper onsite operation.

REFERENCE
Document Location
MGC-3000 Series Controller Manual Contact your local MTU Onsite Energy Distributor
®
BESTCOMSPlus www.mtuonsiteenergy.com

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HARDWARE VERIFICATION
The following mechanical verifications must be made for all generator sets in the system.
1. Install main load lead connections between the generator set bus and the paralleling bus (L1,
L2, L3, N, and GND). At a minimum, size the L1, L2, L3, and N conductors for full load rated
current. Please be sure to follow local practices and regulations regarding grounding and
neutral bonding practices.
2. Install an Ethernet cable (CAT5 or better with a length not greater than 300 feet) into each
controller. If there are only two controllers in the system, you may use a crossover cable.
3. If there are more than two generator sets in the system, connect the Ethernet cables to an
industrial Ethernet switch. MTU Onsite Energy recommends an ADAM-6520 5-port Industrial
10/100 Mbps Ethernet Switch.
4. Install two wires to the remote start contacts of the generator set. Closing this circuit will
initiate a start request when the controller is in Auto.
5. Install bus sensing wires to the terminals indicated below. At a minimum, use 14 GA. THHN (or
equivalent) wire fused with KTK 10 (or equivalent) fuses.

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SOFTWARE VERIFICATION
The following software setting verifications must be made for all generator sets in the system.
1. Verify the DGC-2020HD Style Number.

This must be
viewed while
connected to the
DGC-2020HD.

2. Verify that the Application Version Number is set to >= 1.00.02 or greater.

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3. Verify Speed Demand Switch is set to Analog ECU.

These settings are appropriate

for MAU/CAN Bridge
equipped MTU Series1600,
2000, and 4000 engines.

4. Verify System Type is set to Multiple Generator.

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5. Verify that application-specific TCP/IP settings are implemented for the Ethernet Port on each
controller (configured through BESTCOMSPlus®).

All MGC-3000s that are

connected on the intergenset
communications network
must share the same subnet
address (i.e. 10.132.25.##).
Unique for each MGC-3000

6. Verify No Load Cool Down Time (min) is set to 5 minutes or more.

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7. Verify paralleling-specific Pre-Alarms are all enabled.

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8. Verify Generator Protection settings are appropriate for the system or application.
 Voltage
- Undervoltage (27), Overvoltage (59), Phase Imblance (47)
 Frequency
- Frequency (81)
 Current
- Overcurrent (51)
 Power
- Reverse Power (32), Loss of Excitation (40Q)
 Loss of MAINS Protection
- Vector Shift (78)

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9. Verify the Breaker Hardware settings.

These settings are

intended for a stored
energy circuit breaker
that can close in
five cycles.

10. Verify Gen Condition Detection settings are appropriate for the system or application.
 Generator Condition Settings
- Dead Gen Threshold
- Dead Gen Activation Delay
- Gen Failed Activation Delay
 Generator Stable
- Overvoltage Pickup & Overvoltage Dropout
- Undervoltage Pickup & Undervoltage Dropout
- Overfrequency Pickup & Overfrequency Dropout
- Underfrequency Pickup & Underfrequency Dropout

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11. Verify Bus 1 Condition Detection settings are appropriate for the system or application.
 Bus Condition Settings
- Dead Bus Threshold
- Dead Bus Activation Delay
- Bus Failed Activation Delay
 Bus Stable
- Overvoltage Pickup & Overvoltage Dropout
- Undervoltage Pickup & Undervoltage Dropout
- Overfrequency Pickup & Overfrequency Dropout
- Underfrequency Pickup & Underfrequency Dropout

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12. Verify the Synchronizer settings.

These settings are

an appropriate
starting point and
may need to be
adjusted during
the tuning phase.

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13. Verify the AVR Bias Control Settings.

These settings are an appropriate starting point and may need to be adjusted during the tuning phase. Please
Note: These settings are configured to allow the generator sets to share VARs via Ethernet.

14. Verify the Governor Bias Control Settings.

These settings are an appropriate starting point and may need to be adjusted during the tuning phase. Please
Note: These settings are configured to allow the generator sets to share kW isochronously via Ethernet.

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15. Verify the AVR Output settings.

These settings are

appropriate for a
DVR2000E,
DVR2000E+,
DVR2000EC, or
DVR2000EC+
voltage regulator.

16. Verify the Governor Output settings.

These settings are

appropriate for
MTU Series1600,
2000, and 4000
engines.

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17. Verify the Demand Start/Stop settings.

If sequencing is required, Demand Start Stop Enable must be

enabled. Some example settings have been provided, but this is wholly
dependent on the system or application.

18. Verify the Generator Sequencing settings.

Every controller must have a

unique, non-zero value in the
Sequencing ID field. The
controller with the smallest
number will be considered the
System Manager and will conduct
dead bus arbitration. If sequencing
is required, a sequencing Mode
may be selected (i.e. Staggered
Service Time, Smallest Size First,
etc…).

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19. Verify the Network Configuration settings.

Enter Sequencing IDs for all controllers in the system in these fields. For IDs beyond the number of units in the
system, it is acceptable to leave the extra ID fields as zeros.

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20. Verify BESTlogic™Plus Programmable Logic is configured for the application.

The logic indicated will provide

basic paralleling and load
sharing functionality. The logic
must be customized to meet
the specific application or
system.

21. Verify the intergenset communications network is functional, all controllers are communicating,
there are no intergenset communications failure pre-alarms, and there is system manager
agreement (METERING  ALARMS-STATUS  NETWORK STATUS).

All controllers must agree on the system

manager and list the Sequencing IDs of the
controllers that are on the intergenset
communications network.

SYNCHRONIZING VERIFICATION
The following verifications must be made to ensure the proper synchronization of the generator sets.
1. Connect an appropriately rated phase rotation meter to verify that all generator sets in the
system have the same phase rotation (ABC or CBA).
2. Disable breaker closing on a particular generator set by removing the interposing relay
between the controller and the circuit breaker as indicated below.
3. Connect an appropriately rated voltage meter across the circuit breaker on the same phase as
indicated below.
4. Initiate a start request to another generator set in the system by closing the remote start input
(controller must be in Auto). Its breaker should close and energize the bus.

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5. Initiate a start request to the generator set (with the breaker close command disabled) by
closing the remote start input. The generator should achieve rated frequency and voltage and
begin synchronizing to the live bus.
6. The Synchronizer screen should automatically override the controller’s LCD screen. Verify the
synchronizer actively tries to keep the indicator in the 12 o’clock position.
7. The voltage meter across the circuit breaker should indicate no voltage or a voltage less than
~30 VAC when the synchronizer is in the 12 o’clock position.
8. If the synchronizer is not in the 12 o’clock position, or the voltage meter is indicating a voltage
higher than ~30VAC, the generator set is not synchronized to the live bus. Most likely, the bus
voltage sensing cables are not connected correctly.
9. Remove the start request and restore the circuit breaker close command. This generator set
can be considered ready for paralleling operation and tuning.
10. Repeat steps 2 through 9 for all generator sets in the system.

TESTING AND TUNING

The following tuning is required for proper generator set paralleling operation:
1. Synchronizer tuning for proper operation
a. If the synchronizing period is excessively long due to voltage matching, increase the Sync
Voltage Gain under Synchronizer settings.
b. If voltage matching is erratic and unstable during synchronizing, decrease the Sync
Voltage Gain under Synchronizer settings.
c. If the synchronizing period is excessively long due to slow, sluggish speed matching,
increase the Sync Speed Gain under Synchronizer settings.
d. If speed matching is erratic and unstable during synchronizing, decrease the Sync Speed
Gain under Synchronizer settings.
2. Voltage Controller tuning for proper operation
a. If the bus voltage does not match rated voltage, increase Kg Loop Gain under the Voltage
Controller under AVR Bias Control Settings.
NOTE: If you are utilizing voltage droop for sharing VARs, it will not be possible to match
the bus voltage to rated voltage.

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3. var/PF Controller tuning for proper operation (assuming var sharing via Ethernet)
a. If the stabilization period of var sharing between generator sets in a system is excessively
long or never occurs, increase Kg Loop Gain under the var/PF Controller under AVR
Bias Control Settings.
b. If var sharing between generator sets is erratic and unstable, decrease Kg Loop Gain
under the var/PF Controller under AVR Bias Control Settings.
4. Speed Controller tuning for proper operation
a. If the bus frequency does not match Speed Trim Setpoint (Hz), increase Kg Loop Gain
under the Speed Controller under Governor Bias Control Settings.
b. If the bus frequency is erratic or unstable, decrease Kg Loop Gain under the Speed
Controller under Governor Bias Control Settings.
5. kW Controller tuning for proper operation
a. If the stabilization period of kW sharing between generator sets in a system is excessively
long or never occurs, increase Kg Loop Gain under the kW Controller under Governor
Bias Control Settings.
b. If kW sharing between generator sets is erratic and unstable, decrease Kg Loop Gain
under the kW Controller under Governor Bias Control Settings.
6. Other circumstances that will prohibit proper load sharing
a. Governor bias control circuit polarity is incorrect.
b. Voltage bias control circuit polarity is incorrect.
c. Engine is not configured to accept an analog speed bias signal.
d. Lack of reactive load to ensure proper var sharing.
7. Supplementary tuning of the Voltage, Var/PF, Speed, and kW Load Controllers is possible.
Please consult Tuning PID Settings in the MGC-3000 Series Controller Manual for more
details.

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© MTU Onsite Energy. Subject to alteration due to technological advances. 2015-02

Generator to Generator in Island Operation (MTU Onsite Energy generator sets only)

The dashed line (– – –) denotes wiring/equipment supplied by a third party

MTU Onsite Energy

A Rolls-Royce Power Systems Brand

www.mtuonsiteenergy.com // Page 21 of 21