KG-1500

Controller
Introduction
The KG-1500 series provides the user with a selection of bias signals to operate
numerous speed controls and voltage regulators. The KG-1500 series may be
configured to use analog voltage and/or current signals, PWM signals, or
raise/lower contacts to increase or decrease the speed and voltage reference
point.

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Introduction – What means “to Control”?
• Measure the actual value
• Compare with set point
• Adjustment

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Controller
Analog / PWM controller
• Proportional Gain
• Integral Gain
• Derivative ratio

Frequency / power controller and voltage / power factor controller

• Adjustable bias signal (+/-20mA / +/- 10V) or
• 500 Hz PWM (duty cycle signal)
Example:
-10V 3 7 10V

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Controller
P (Proportional gain)
The proportional gain indicates the closed-loop control system gain. By increasing
the gain, the response is increased to permit larger corrections to the variable to be
controlled. The further out of tolerance the process is the larger the response
action to return the process to the control set point. If the gain is configured too
high, the result is excessive overshoot/undershoot of the desired value.

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Controller
I (Integral gain)
The integral gain represents the I-component of the PID controller. The integral
corrects for any offset (between set point and process variable) automatically over
time by shifting the proportioning band. Integral gain automatically changes the
output requirements until the process variable and the set point are the same. This
parameter permits the user to adjust how quickly the integral attempts to correct
for any offset.

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Controller
D (Derivative ratio)
The derivative represents the D-component of the PID controller. By increasing this
parameter, the stability of the system is increased. The controller will attempt to
slow down the action of the throttle in an attempt to prevent excessive overshoot or
undershoot. Essentially, derivative acts as the brake for the process.

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Controller
63
62
61
60
59
58
57

TIME

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Controller
Analog / PWM controller bias signal
The analog outputs are used for the bias signals
• Speed bias (F/P control)
• Voltage bias (V/PF control)

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Controller
Three step controller (raise/lower/off)
- Time pulse (minimum energize time)
- Gain factor
- Dead-band adjustment
- Expand dead-band function

Frequency / power controller and Voltage / power factor controller (raise / lower)
are possible through configuration of the LogicsManager.

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Controller
Three Step controller
The time interval between the raise / lower pulse depends on the actual difference
between set point and actual value.

Raise/lower pulse

Time delay

Difference between setpoint and real value

1 2 3 4 5 6 7 8

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Controller
Controller tuning
The analog and three-step controllers should ramp in a similar manner as shown
below when properly tuned.

120 Volts
Need to change rated
voltage to suit customer
90 Volts
Ramp of Voltage
Controller is determined
by the Gain
30 Volts
Point at which Controller
takes control

0 Volts

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Set points
Set point helps us to verify the Voltage/ Frequency biasing before sync of the genset. We can even adjust
the KW and PF if the genset is synchronized with the grid or any other power source.
The setpoint can be adjust in AUTO mode and MANUAL.
Below few slides will show us how these set points can be changed or varifried in Auto and Manual mode

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Set points
External Set points in “AUTOMATIC” operation mode
• Frequency set point (Hz)
• Voltage set point (Voltage)
• Power set point (KW)
• Power factor set point (PF)
We can control the above mentioned set points of the genset in 3 different ways as below:

Analog inputs
0/4 to 20 mA or 0 to 500 Ohm
Discrete inputs
Raise/lower set point via momentary switch
Interface
Modbus

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Set points
Analog Inputs

User defined is in relation to the

Rated power (in %).

0 Min. value ( 0% of rated)

10000 Max. value (100.00 %)
From home screen Press Down Arrow -> Setpoints

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Set points
Discrete Input for raise/lower

The power ramp always starts at the current measured value. If the breaker is
opened this set point automatically resets to 0 kW.

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Set points
Interface power set point

From home screen Press down Arrow -> Setpoints

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Set points
External Set points in “MANUAL” operation mode
• Frequency set point (Hz)
• Voltage set point (V)
• Power set point (KW)
• Power factor set point (PF)

In manual mode the above mentioned set points can be changed via HMI as shown below

Increase Set point Selected set point appears in BOLD

This arrow button to select

set point (KW, PF, V and Hz)
Decrease Set point
From home screen Press down Arrow -> Setpoints

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Load Sharing
Load sharing over the CAN bus
• Real load sharing is performed as a utilization factor. (Generators compare measured
load: generator rating)
• Reactive load sharing is performed as a utilization factor. (Generators compare measured
reactive load: generator rating)
• Maximum of 16 units can load-share
• Split bus applications are possible with up to two bus bars (different segment numbers)

Load sharing with Woodward legacy products like GCP-30 Series, EGCP-2 and analog load share
lines is possible using LSG gateway.

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Load Sharing
Connection between the units via CAN 1

The units need different

CAN 1 device numbers

Generator 1

CAN 1

Generator 2 Parameter -> System management

Uptill 16
units

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Load Sharing
Active power load sharing
• Maintain frequency / maintain power utilization factor
• Weighting factor may be applied to load sharing
(> 50% more frequency, < 50% more power utilization)

Reactive power load sharing

• Maintain voltage / maintain reactive power utilization factor
• Weighting factor may be applied to reactive load sharing
(> 50% more voltage, < 50% more reactive power utilization)

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Load Sharing
Segment numbering for multiple common
busses
• General segment definition
• One alternative segment for use with bus
tie breaker
• Only those generators connected to the
same segment number may load share
together

Configuration -> Application Config. -> Controller

Config. -> Load Share config.

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Load Sharing
Segment 1

Load

Segment 1
Load

Check Sync Relay

Segment 2
Load

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Load Sharing
Segment 1

Load
Segment #2 TRUE

Segment 1
Load
Segment #2 TRUE

Check Sync Relay

Segment 2
Load

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FAQ

A. How can I configure my controller bias signal output?

B. How can I limit the generator load when the cooling water temperature is
below a desired threshold?

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FAQ

A. How can I configure my controller bias signal output?

There are two possible types:

- Three step controller (raise / lower outputs)

 Relays via LogicsManager

- Analog controller (bias signals) / PWM  Analog output

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FAQ
A. How can I configure my controller bias signal output?
Three step controller (raise / lower outputs)  LogicsManager
Configuration -> Application Config. -> Controller Config. -> Frequency control config.

LogicsManager input commands:

03.20 Governor raise 03.22 AVR raise
03.21 Governor lower 03.23 AVR lower

Select freely configurable Digital O/P relay and program them accordingly for raise/ lower as shown below:
Go to Configuration-> Application Config. -> Inputs/Outputs Config -> Discrete Output config.

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FAQ
A. How can I configure my controller bias signal output?
Analog controller (bias signals)  Analog output
Test controller range with
Configuration -> Application Config. -> Controller Config. -> Frequency control config. initial state

Go to Configuration-> Application Config. -> Inputs/Outputs Config -> Analog Output config.

Data source:
00.02 Voltage bias
00.03 Speed bias

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FAQ
B. How can I limit the generator load when the cooling water temperature is
below a desired threshold?
The warm up load limit permits a partial load warm up with a lower set point
whenever the generator runs parallel to mains.
Configuration -> Application Config. -> Controller Config. -> Load control config.

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FAQ
B. How can I limit the generator load when the cooling water temperature is
below a desired threshold?
Use the “warm up limit” of the active load controller
The KG-1500 controls the warm up load limit (in % of rated power)
whenever the measured value of the analog
input crosses the
threshold.

Configuration -> Application Config. -> Controller Config. -> Load control config.

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 Any Questions

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 ALWAYS INNOVATING FOR A BETTER FUTURE

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