Doosan G250 Manual

Synchronisation G250, G400, G500
OPERATION & MAINTENANCE MANUAL
46553375-EN (02-13) Rev. B © Doosan Company 2012
Original Instructions
EN

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Table of contents
1.ABOUT THIS DOCUMENT.............................................................................................................3
GENERAL PURPOSE....................................................................................................................................3
INTENDED USERS.......................................................................................................................................3
CONTENTS/OVERALL STRUCTURE .............................................................................................................3
2.WARNINGS AND LEGAL INFORMATION.................................................................................4
LEGAL INFORMATION AND RESPONSIBILITY..............................................................................................4
ELECTROSTATIC DISCHARGE AWARENESS.................................................................................................4
SAFETY ISSUES..........................................................................................................................................4
DEFINITIONS .............................................................................................................................................4
3.EARTHING SYSTEMS....................................................ERROR! BOOKMARK NOT DEFINED.
4.DISPLAY PUSH-BUTTONS AND LEDS........................................................................................9
PUSH-BUTTON FUNCTIONS ........................................................................................................................9
LED FUNCTIONS .....................................................................................................................................12
5.DISPLAY AND MENU STRUCTURE..........................................................................................14
LCD DISPLAY..........................................................................................................................................14
MENU STRUCTURE ..................................................................................................................................14
STATUS LINE TEXT ..................................................................................................................................16
RUNNING MODES....................................................................................................................................20
6.OPERATION MODES....................................................................................................................21
7.ALARM HANDLING AND LOG LIST.........................................................................................27
ALARM HANDLING ..................................................................................................................................27
ALARM LIST ............................................................................................................................................28
LOG LIST .................................................................................................................................................30
8.CHECK SYNCHRONIZATION ....................................................................................................30

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1. About this document
General purpose
This document is the Operator’s Manual for Doosan PowerSource generators equipped with the
synchronization option. The document mainly includes general product information, display
readings, push-button and LED functions, alarm handling descriptions and presentation of the
log list.
The general purpose is to give the operator important information to be used in the daily
operation of the unit.
Intended users
This Operator’s Manual is mainly intended for the daily user. On the basis of this document, the
operator will be able to carry out simple procedures such as start/stop and control of the
generator set.
Contents/overall structure
The document is divided into chapters, and in order to make the structure simple and easy to
use, each chapter will begin from the top of a new page.
Please make sure to read this handbook before working with the multi-line 2
controller and the gen-set to be controlled. Failure to do this could result in
damage to the equipment or human injury.

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2. Warnings and legal information
Legal information and responsibility
Improper operation of this equipment can cause severe injury or death.
Read this document supplied with this machine before operation or service.
The installation, wiring and commissioning of Doosan generators with synchronization option
can only be performed by personnel who has been duly trained by either Doosan or DEIF.
The synchronization option has been developed according to the most common
standards in Europe. Any modification required to meet specific local legislations is the
sole responsibility of the local, duly trained Doosan dealer, and can only be performed
with the express written consent of Doosan.
Modification or alteration of this machine CAN result in severe injury or death. Do not alter or
modify this machine without the express written consent of the manufacturer.
If there is any doubt about how to install or operate the generator set controlled by the unit, the
company responsible for the installation or the operation of the set must be contacted
Electrostatic discharge awareness
Sufficient care must be taken to protect the controller’s terminals against static discharges
during the installation. Once the unit is installed and connected, these precautions are no longer
necessary.
Safety issues
Installing the unit implies work with dangerous currents and voltages. Therefore, the
installation should only be carried out by authorised personnel who understand the risks
involved in working with live electrical equipment. In this equipment, 4 poles breakers are used.
An installation can have up to 3 neutral systems, the generator’s one, the consumer’s one and
the mains’ one. It is the responsibility of the person who connects the installation to make sure
the 3 neutral systems are wired according to the local grounding regulations. See chapter 3 for
earthing systems.
Definitions
Throughout this document a number of notes and warnings will be presented. To ensure that
these are noticed, they will be highlighted in order to separate them from the general text.
Notes
Warning
The notes provide general information which will be helpful for the reader to
bear in mind.
The warnings indicate a potentially dangerous situation which could result in
death, personal injury or damaged equipment, if certain guidelines are not
followed.
Be aware of the hazardous live currents and voltages. Do not touch any live
parts as this could lead to injury or death.

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3. Earthing systems

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4. Display push-buttons and LEDs
Push-button functions
The display unit holds a number of push-button functions which are described below.
Shifts the display to show the alarm list.
Resets horn output
Tools.
Shifts the display to viewing of measured values. There are 20 different views.
Scroll through the views using the or button.
Shifts the display to show the event and alarm list. There are 4 lists to select
from: Event log, Alarm log, battery test log and engine interface alarm log (CAN
J1939 engine controller interface)
Parameter list selection
Moves the cursor left for manoeuvring in the menus.
Increases the value of the selected set point (in the setup menu). In the daily
use display, this button function is used for scrolling the displaying of generator
values.
Selects the entry in the display.
Decreases the value of the selected set point (in the setup menu). In the daily
use display, this button function is used for scrolling the displaying of generator
values.
Moves the cursor right for manoeuvring in the menus.
ESC Jumps one step backwards in the menu (to previous display or to the entry
window).
START Start of the gen-set if ‘SEMI-AUTO’ or ‘MANUAL’ is selected.
STOP Stop of the gen-set if ‘SEMI-AUTO’ or ‘MANUAL’ is selected.
Manual activation of close breaker sequence if ‘SEMI-AUTO’ or ‘MANUAL’ is
selected.
Manual activation of open breaker sequence if ‘SEMI-AUTO’ or ‘MANUAL’ is
selected.

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AUTO Selects AUTO running mode
SEMI Selects SEMI-AUTO running mode. Pushbutton commands are used for
start/stop and so on.
MAN Selects MANUAL running mode. Like SEMI, but regulators are OFF.
OFF Selects OFF mode. All functions except protections are switched off.
TEST Selects TEST RUN of the generator. Check test in Island
Lamp test.

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The push-buttons are placed as follows:
START:
Start of the gen-set if ‘SEMI-AUTO’ or ‘MANUAL’ is selected.
STOP:
Stop of the gen-set if ‘SEMI-AUTO’ or ‘MANUAL’ is selected.
Alarm list
GB and MB open / close
AUTO mode
Parameter settings
Tools
MANUAL mode
SEMI-AUTO mode
OFF mode
TEST mode
Lamp test
Silence horn
Enter
Step backwards
View of measured values
Log lists

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LED functions
The display unit holds 10 LED functions. The colour is green or red or a combination in different
situations.
Alarm: LED flashing indicates that unacknowledged alarms are present.
LED fixed light indicates that ALL alarms are acknowledged, but some are still
present.
Power: LED indicates that the auxiliary supply is switched on. If it is green, the AGC
200 is operational. If it is red the self check has failed.
Run LED indicates that the generator is running.
Hz/V OK: LED green light indicates that the voltage/frequency is present and OK.
GB ON LED indicates that the generator breaker is closed.
MB ON LED indicates that the mains breaker is closed.
Mains OK LED is green if the mains is present and OK.
LED is red at a mains failure.
LED is flashing green when the mains returns during the ‘mains OK delay’ time.
Auto LED indicates that auto mode is selected.
MAN LED indicates that manual mode is selected.
SEMI LED indicates that SEMI AUTO mode is selected.
OFF LED indicates that OFF mode is selected.

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The display LEDs are indicating as follows:
Mains breaker ON
Generator frequency/voltage OK
Mini Announciator
Generator breaker ON
AUTO mode
Manual mode
SEMI-AUTO
d
OFF mode
Engine running
Alarm.

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5. Display and menu structure
LCD display
The display is a backlit LCD graphical display. There is no control of the display light intensity
(no dimmer). Basically, all measured and calculated values can be read in the display.
Menu structure
The display includes two menu systems which can be used without password entry:
View menu system
This is the commonly used menu system. 20 windows are configurable and can be
entered by using the arrow push-buttons.
Setup menu system (not commonly used by the operator)
This menu system is used for setting up the unit, and if the operator needs detailed
information that is not available in the view menu system.
Changing of parameter settings is password protected.
Entry window
When the unit is powered up, an entry window appears. The entry window is the first window of
the view menu system. It can always be reached by pushing the BACK push-button 3 times.
MAINS FAILURE
U- supply 24.1 V
G 0.00I PF 0 kW
G 0kVA 0 kvar
AGC 200
2009-09-23 08:59:08

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View menu
The view menu is the daily use menu for the operator.
First display line
Operational status
Second, third and fourth display lines
Measurements
Fifth display line
Total energy produced by the generator
Sixth display line
Running hours
Display view indicator
Placed over view button selected
In the view menu, various measured values are on display.
View menu navigation
Display of measured values according to the selections made during configuration.
The views contains up to 20 different windows which can be selected using the and
push-buttons located on the right hand side of the display.
ISLAND SEMI
U- supply 24.1 V
G 0.00I PF 0kW
G 0kVA 0kvar
Energy Total 0kWh
Run absolute 0hrs
1/20

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Status line text
This table explains the different messages.
Status text Condition Comment
BLOCK Block mode is activated
SIMPLE TEST Test mode is activated
LOAD TEST
FULL TEST
SIMPLE TEST ###.#min Test mode is activated and test timer
counting down
LOAD TEST ###.#min
FULL TEST ###.#min
ISLAND MAN Gen-set stopped or running and no
other action taking place
ISLAND SEMI
READY ISLAND AUTO Gen-set stopped in Auto
ISLAND ACTIVE Gen-set running in Auto
AMF MAN Gen-set stopped or running and no
other action taking place
AMF SEMI
READY AMF AUTO Gen-set stopped in Auto
AMF ACTIVE Gen-set running in Auto
FIXED POWER MAN Gen-set stopped or running and no
other action taking place
FIXED POWER SEMI
READY FIXED P AUTO Gen-set stopped in Auto
FIXED POWER ACTIVE Gen-set running in Auto
PEAK SHAVING MAN Gen-set stopped or running and no
other action taking place
PEAK SHAVING SEMI
READY PEAK SHAV AUTO Gen-set stopped in Auto
PEAK SHAVING ACTIVE Gen-set running in Auto
LOAD TAKEOVER MAN Gen-set stopped or running and no
other action taking place
LOAD TAKEOVER SEMI
READY LTO AUTO Gen-set stopped in Auto
LTO ACTIVE Gen-set running in Auto
MAINS P EXPORT MAN Gen-set stopped or running and no
other action taking place
MAINS P EXPORT SEMI
READY MPE AUTO Gen-set stopped in Auto

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Status text Condition Comment
MPE ACTIVE Gen-set running in mains power export
mode
DG BLCKD FOR START Generator stopped and active alarm(s)
on the generator
GB ON BLOCKED Generator running, GB open and an
active ‘Trip GB’ alarm
SHUTDOWN OVERRIDE The configurable input is active
ACCESS LOCK The configurable input is activated, and
the operator tries to activate one of the
blocked keys
GB TRIP EXTERNALLY Some external equipment has tripped
the breaker An external trip is logged in the event log
MB TRIP EXTERNALLY Some external equipment has tripped
the breaker An external trip is logged in the event log
IDLE RUN The ‘Idle run’ function is active The
gen-set will not stop, until a timer has
expired
IDLE RUN ###.#min The timer in the ‘Idle run’ function is
active
COMPENSATION FREQ. Compensation is active The frequency is not at the
nominal setting
Aux. test ##.#V ####s Battery test activated
DELOAD Decreasing the load of the gen-set in
order to open the breaker
START DG(s) IN ###s The start gen-set setpoint is exceeded
STOP DG(s) IN ###s The stop gen-set setpoint is exceeded
START PREPARE The start prepare relay is activated
START RELAY ON The start relay is activated
START RELAY OFF The start relay is deactivated during
the start sequence
MAINS FAILURE Mains failure and mains failure timer
expired
MAINS FAILURE IN ###s Frequency or voltage measurement is
outside the limits The timer shown is the mains failure delay Text in mains units
MAINS U OK DEL ####s Mains voltage is OK after a mains
failure The timer shown is the mains OK delay
MAINS f OK DEL ####s Mains frequency is OK after a mains
failure The timer shown is the mains OK delay
Hz/V OK IN ###s The voltage and frequency of the gen-
set is OK When the timer runs out it is allowed to operate the generator
breaker

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Status text Condition Comment
COOLING DOWN ###s Cooling down period is activated
GEN-SET STOPPING This info is shown when cooling down
has finished
EXT. STOP TIME ###s
PROGRAMMING LANGUAGE This info is shown if the language file is
downloaded from the PC utility software
Generator is synchronizing The dot marks the actual
generator phase angle position in
the synchronization When the dot
is at 12 o’clock, the generator
and busbar are in synchronism
The second dot indicates when
the relay output for the generator
or mains breaker is activated
Generator running too slow during
synchronizing
Generator running too fast during
synchronizing
EXT. START ORDER A planned AMF sequence is activated There is no failure on the mains
during this sequence

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View menu example
Start view:
Press Press
Press Press Press
Press
MAINS FAILURE
U- supply 24.1 V
G 0.00I PF 0 kW
G 0kVA 0 kvar
AGC 200
2009-09-23 08:59:08
1/20
MAINS FAILURE
P 0kW 0 %
Q 0kvar 0 %
S 0kVA 0 %
AGC 200
2009-09-23 08:59:08
20/20
MAINS FAILURE
Event log .
Alarm log
Battery test log
MAINS FAILURE
MAINS FAILURE .
Wed Sept 23 13:36:23
MB OFF
Wed Sept 23 13:36:33
The scrollbar
indicates that more
readings are
available below
MAINS FAILURE
Setup menu
1000 protection .
2000 Synchronization
2500 Regulation
3000 Binary input
MAINS FAILURE
Setup menu
1000 G –P> 1 .
1010 G –P> 2
1030 G I> 1
1040 G I> 2
MAINS FAILURE
1000 G –P> 1
Set point : -9.0% .
Timer: 10.2s
Output A: Not used
Output B: Not used

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Running Modes
The running modes are selected using the buttons as follows:
Mode Description
SEMI - The display push-buttons (START, STOP, GB ON, GB OFF) are active and can
be used by the operator.
- The regulators are also active, i.e. the speed control will bring the generator to
nominal speed upon start.
- When pushing a breaker button for closing, the AGC 200 will synchronise (if
allowed) the breaker. When the breaker closes, the controls stop.
TEST - The unit will start the generator, carry out the test sequence (predefined time
period) and stop the generator again. Subsequently, the generator will return to
AUTO or SEMI-AUTO mode. The mains breaker will remain closed, and the
generator breaker will remain open. NOTE: The test running can be: Simple test:
starting the gen-set without closing the GB, Load test: Parallel to the mains and
take load to a predefined value. Full test: Transfer the load to the gen-set and
open the MB.
AUTO - The unit will automatically carry out the control type selected (AMF, fixed power
etc.).
- The display control push-buttons (START, STOP, GB ON, GB OFF) are
disabled.
- If the selected running mode is fixed power, mains power export, load take over
or island, timer start/stop (week watch) or binary input, then start/stop can be
used.
MAN - The display push-buttons (START, STOP) are active and can be used by the
operator.
- The regulators are not active, i.e. speed (and voltage) control has to take place
using external controls for generator speed and possibly generator voltage
control.
- The breakers will be able to open or close at any time. A synchronisation check
will always be performed to ensure safe closing of the breakers.
OFF - The unit will not be able to start. OFF mode can be selected during standstill and
the password is needed to go away from OFF mode. If the OFF mode is
selected while the gen-set is running, the mode will have no effect until the gen-
set is stopped. To select another mode after the OFF mode, the password must
be entered.