Dec 3500 Paralleling 2015 - Classroom

Decision-Maker™ 3500 Controller
Paralleling
Welcome to the Kohler Power

Systems Decision-Maker® 3500
Paralleling concepts presentation
Paralleling
THE DECISION-MAKER® 3500 GENERATOR CONTROLLER AND PARALLELING
The Decision-Maker® 3500 is a generator controller

that also provides paralleling functionality.
While the Decision-Maker® 3500 controller can also

be used with external switchgear controlling the
speed, voltage and paralleling breaker, the Parallel
menus are used to configure settings for parallel
operation where the controller is communicating on a
network with other controllers and provides integral
paralleling functionality.
Paralleling
TYPES OF OPERATING MODES OFFERED BY THE DECISION-MAKER 3500 CONTROLLER
The Decision-Maker® 3500 controller supports three

different operational modes:
• Single generator operation (Standalone)
• External Paralleling
• Internal Paralleling modes.
It is important that the mode is matched to the application

where the generator will be used…
Paralleling
Standalone– Single generator applications require little

setup and are by far the simplest. This mode is for
applications where a single generator is:
• Connected to loads though a manually-operated circuit

breaker
Or
• Controlling a motor-operated breaker on the output of

the generator set, but there are no other generator sets
on the paralleling bus.
In these applications, there will be no chance of paralleling

with the utility or another generator and there is no
external gear provided for generator control.
The controller sets the engine speed to the target speed,

which is determined by the engine run speed from the
personality profile and the engine speed adjustment.
The output voltage of the generator set is controlled to the

voltage regulator target voltage
Paralleling
External – Many applications require paralleling with

existing generators. Because the Decision-Maker® 3500
controller is intended to parallel only with generators which
are also running Decision-Maker® 3500 controllers,
external gear is required to coordinate operation with
another generator.
External paralleling requires the external speed and

voltage bias inputs to be enabled.
• The engine speed is set based on the voltage between

SBP and SBN: 0.5 – 4.5 VDC
• The output voltage is set based on the voltage

between VBP and VBN: 0.5 – 4.5 VDC
Paralleling
Internal – Any multi-generator application where the

generators are all operated by Decision-Maker® 3500
controllers and the standard controller functionality is
sufficient for the application. This includes most standby
and prime power applications where the standard
Generator Management and load management are
sufficient to support the customer requirements.
The controller will enter internal paralleling mode

automatically if the PGEN communication wires are
connected to another controller.
In Internal Paralleling mode, all the controllers that are

communicating over PGEN will behave as a system—they
are aware of the status of the other generator sets in the
system. A start signal to any generator set in the system
will start all generator sets in the system.
Paralleling
WHAT THE DECISION-MAKER 3500 DOES
For the system to operator correctly, the Decision-Maker® 3500 is responsible for five things:
• Start and stop the generator
• Open and close breakers
• Adjust speed
• Adjust voltage
• Monitor the system

Paralleling
PARALLELING REQUIREMENTS
In order to parallel generators together, certain requirements must be met on all generators in the system.
• Must have Decision-Maker® 3500 controllers.
• Same frequency – 60Hz.
• Same rotation.
• Same voltage configuration.
• Low Wye
• High Wye
• Delta – the neutral of each generator set needs to be bonded to the same phase
• Single Phase – Bus L3, Gen L3, and I3 are unused in a single-phase configuration.
• Single-phase connection type should never be used for an alternator that is wired for three-
phase, as there is no phase rotation check in single-phase mode.
The controllers will alert if the system frequency, voltage, and phase connection in the system differ
between generators that are communicating over PGEN. They will not send a breaker close signal while
there is a difference in one of those three parameters in any generator in the system.
Paralleling
PARALLELING REQUIREMENTS
The paralleling system can have items that differ on each generator.
• Can use different fuels (for example, one LPG generator set and one diesel unit).
• Can be different kW models. For example, you can parallel one 35REOZT4 with one 175REOZT4.
• Dissimilar sized generators will share load based on percent loaded.
• The controllers calculate the percentage of load on the generator, compare those values to the
percentage of load on the system and then provide control to drive the percent of load on the
generator to the same value as the percent of load on the system.
Example of 35kW and 175kW units sharing a 150 kW system load:
Total capacity = 210 kW
35 ÷ 210 = 17% of total capacity
175 ÷ 210 = 83% of total capacity
The 35 kW unit will have 25 kW load (150 x 17%) and will be 72% loaded.
The 175 kW unit will have 125 kW load (150 x 83%) and will be 72% loaded.
Paralleling
SEQUENCE OF OPERATION
A typical sequence of operation with a paralleling system is as follows:
• PGEN communications
• Start signal
• Generators start
• First-On Logic
• Breaker close signal to dead bus
• Other generators synchronize to the live bus
• Load sharing – Real and Reactive

Paralleling
PGEN COMMUNICATIONS
PGEN is an auto-discovering, scheduled protocol that

provides the infrastructure for time-critical inter-controller
communication. PGEN stands for Paralleled Generator.
PGEN is a proprietary scheduled broadcast

communications protocol. Each node (controller) on the
network has a time slice to broadcast a packet
containing pertinent generator set information, other time
is spent listening for packets from the other nodes. All
nodes on the PGEN network will send out at least one
packet every 50 ms.
Up to 8 Decision-Maker® 3500 controllers can be

paralleled together.
Paralleling
START SIGNAL
The generator set controller supports a system start (Auto-Run, remote start contacts, CAN gauge start
signal, SiteTech start signal) and local start (pressing the run button). The paralleling system behaves
differently depending on which start command is received.
A system start command to any generator set in the system will start all generator sets that are in AUTO. If
a generator set is placed in AUTO after the start signal is applied to any generator set, that generator set
will start. A generator set does not have to be in auto to accept a start signal, but it does have to be in auto
to start. The synchronizer uses the Sync Mode in Auto parameter to determine the synchronizing settings
during a system start event. Generator Management and load management are only active during a
system start.
A local start command (RUN) to a generator set will result in only that generator set starting. The
synchronizer uses the Sync Mode in Run parameter to determine the synchronizing settings during a local
start event. Generator Management will not consider a generator set that is operating in local start mode
as available, even if it is running.
Paralleling
GENERATORS START
Upon confirmation of start signal, all generators in AUTO will perform the start sequence.
Crank Disconnect: When the engine speed exceeds the crank disconnect speed, the engine is
considered to be started/running. The paralleling logic is only solved while the engine is running.
Voltage Ramp: After the engine is running, the voltage regulator begins ramping the target voltage up at
the rate specified by the Normal Voltage Ramp Rate parameter. The voltage ramp will follow the Volts/Hz
curve if the engine speed takes longer to reach the target than the voltage does.
Voltage and Frequency OK: The Voltage and Frequency OK timer starts timing as soon as the frequency
and voltage of the generator set are within the range specified by the Acceptable Voltage Pickup and the
Acceptable Frequency Pickup parameters. The voltage and frequency for the generator set are considered
to be acceptable after the Voltage and Frequency OK delay has expired.
Paralleling
FIRST-ON LOGIC
The First-On Logic is responsible to ensure that only one generator set closes its paralleling breaker to
the dead bus. If two controllers close simultaneously, their voltage waveforms may be out of sync with
each other, potentially resulting in damage to the equipment. After one generator set closes to the
paralleling bus, the others are able to ensure synchronism with it before closing their breakers.
Permission Request: When a generator set voltage and frequency are considered acceptable, the
controller will broadcast a message to the PGEN network requesting permission to close. Each of the
other nodes must grant permission to a generator set controller before it will initiate closing the circuit
breaker to a dead bus.
Permission Receipt: If all connected PGEN nodes have granted permission to close through a full PGEN
bus scan, a generator set is permitted to close to the dead bus and removes the trip command from the
circuit breaker (as it is safe for the breaker to close).
First-On Close Delay: The First-On Close Delay is intended to give the trip coil on the breaker time to
retract, permitting the next close command to be successful on breakers that have a close inhibit in place
when the trip is active.
Breaker Close Signal: After the First-On Close Delay has elapsed, the breaker will be signaled to close.
The close signal is held until the breaker status indicates that it is closed or until the fail to close time delay
expires.
Paralleling
BREAKER CLOSE SIGNAL TO DEAD BUS
The Decision-Maker® 3500 controller monitors the following to determine if it is safe to close the paralleling
breaker to a dead bus:
•Voltage on the paralleling bus sensing connections to the controller. The paralleling bus voltage
must be below the dead bus threshold.
•The status of the paralleling breakers of the other generator sets on the paralleling bus. All the
other generator sets in the system must have open breakers if the bus is perceived to be dead for the
following reasons:
• It is potentially harmful to provide voltage to the stator of a stopped generator set.
• If the other generator set is running with it’s breaker closed but the bus sensing does not indicate
bus voltage, the bus sensing for the controller may not be connected and it may close out of
phase to a live paralleling bus.
•The voltage and frequency of the generator set. There is no benefit to closing the paralleling breaker
to a dead bus if the generator set is not producing rated voltage and frequency. The breaker will not close
until the generator set output is within spec to avoid providing power that is out of certain specifications.
•Permission from other generator sets. Only one generator set is permitted to close to the paralleling
bus when it is dead. (First-On Logic)
•System configuration parameters: Synch Mode in Auto. This parameter must be set to one of the
following for the controller to signal the breaker to close to a dead bus: Check / Passive / Active
Paralleling
SYNC MODE
The controller supports the following Sync Modes:

Off
Synchronizing is disabled—will not controller speed or voltage and the breaker will not close, even to a
dead bus.
Passive
Passiva
OThe controller
controlador will
não tentará not attempt
controlar a velocidadeto
e acontrol the speed
tensão do grupo and voltage
gerador (embora of the
isso possa ser generator
controlado set mas
remotamente), (although that can
fechará o disjuntor be a
se a tensão,
freqüência e a fase corresponderem
controlled remotely), but will close the breaker if the voltage, frequency, and phase are all matched for the
Tempo de permanência.Dwell Time. Após o fechamento do disjuntor, o controlador assumirá o controle da velocidade e da polarização de tensão para compartilhar
Dwell
carga. Time.iráAfter
O disjuntor breaker
se fechar closure,morto
para um barramento thenocontroller
modo PASSIVO will assume control of the speed and voltage bias to share
load. The breaker will close to a dead bus in Passive mode.
Check
O controlador ativa o auto-sincronizador, mas não fecha o disjuntor em um barramento vivo (mesmo se a
The controller activates the auto-synchronizer, but does not close the breaker to a live bus (even
if the
tensão, frequência e fase estão todos combinados para o tempo de permanência). O disjuntor irá fechar para um barramento morto no modo CHECK
voltage, frequency, and phase are all matched for the dwell time). The breaker will close to a dead bus in
Check mode.
Active
O controlador ativa o auto-sincronizador e fechará o disjuntor em um barramento vivo se a tensão,
The controller
frequência e fase estãoactivates the para
todos combinados auto-synchronizer,
o tempo de permanência.and will irá
O disjuntor close
fecharthe
para breaker
voltage, to morto
um barramento a live bus ATIVO
no modo if the
frequency, and phase are all matched for the dwell time. The breaker will close to a dead bus in active
mode.
Dead Field
The Synch mode cannot be set to this value in standard applications.
Paralleling
OTHER GENERATORS SYNCHRONIZE TO THE LIVE BUS
Sincronização é o processo pelo qual a saída de um grupo gerador CORRESPONDE à saída de um
Synchronizing
barramento em paralelo. is the process by which the output of a generator set is matched to the output of a
paralleling
Como bus.gerador e a tensão do barramento paralelo são sinais de corrente alternada, eles devem ter
a tensão do grupo
três quantidades para serem idênticas, frequência, tensão e fase. O controlador ajusta a tensão
alvo do regulador e velocidade do motor para combinar o grupo gerador com a tensão do barramento nas três grandezas
Because the generator set voltage and the paralleling bus voltage are AC signals, they have to match in
three quantities in order to be identical, frequency, voltage, and phase. The controller adjusts the voltage
regulator target and engine speed to match the generator set to the bus voltage in all three quantities.
Paralleling
SYNCHRONIZING
Correspondência de frequência: O sincronizador combina à frequência antes de tentar combinar a tensão ou a fase.
O ângulo de fase varia a uma taxa que está relacionada com a diferença na frequência, portanto, é difícil controlar
Frequency Match: The synchronizer matches frequency before attempting to match voltage or phase.
fase se a frequência é dramaticamente diferente
The phase angle varies at a rate that is related to the difference in frequency, hence it is difficult to control
phase if the frequency is dramatically different.
The Bus at 60 Hz and the Generator at 58 Hz
Voltage Match: The Voltage Match Control adjusts the target voltage of the voltage regulator on the
generator set to match the measured RMS voltage of the bus using the voltage bias.
Generator #1 at 470 Volts and Bus at 480 Volts

Bus
Phase Match: The Phase Match Control adjusts the target speed of the engine in the engine speed
governor using the speed bias. The engine speed is increased if the generator set voltage lags the bus
voltage, decreased if the generator set voltage leads the bus voltage. This technique is call bi-directional
synchronization.
The Bus and the Generator about 70 degrees out of phase

Paralleling
SYNCHRONIZING
In Synchronism: After the frequency, voltage and phase of the generator set matches that of the bus, the
controller considers the generator set to be ’In Synchronism’ with the paralleling bus. When in
Synchronism, the controller considers it to be safe to close the paralleling breaker. The Trip signal to the
generator set circuit breaker is removed when the breaker is safe to close, this allows the trip coil time to
clear so that the breaker will be ready to close when it is signaled to do so.
Dwell Timer: The Dwell Timer becomes active as soon as the generator set is in synchronism with the
paralleling bus. It elapses time until it expires unless the generator set falls out of synchronism with the
paralleling bus, when it is reset.
The Bus and the Generator coming into Synchronism
Breaker Close Signal: When the Dwell Timer expires, the controller will signal the paralleling circuit
breaker to close.
The Breaker Close Signal is maintained until the breaker status indicates closed, the close command is
removed, or the failure to close time delay expires.
The Contactor output from the controller is also energized at the time that the controller signals the
breaker to close (Towable applications use the contactor output for controlling the contactor assembly in
the Paralleling Box.).
Paralleling
PARALLELING CONTROL SCHEMES
When generators are paralleled they are electrically locked together and
cannot change engine speed. The more fuel, more torque, more power out.
Think of this as two gears on a chain. The Decision-Maker® 3500

must control its generator to maintain its speed and voltage to match the system.
The Decision-Maker® 3500 controller provides varying methods of paralleling control.
• Real Power Control – The real power output of a generator is related to how much mechanical power
the engine is making. When a generator is operating as a single unit, there is no good way to control
the power output of the generator without controlling the power requirements of the load. In a parallel
system, there is more than one source that can supply the load – hence the power can be shared
between the sources, allowing it to be controlled.
• Reactive Power Control – The reactive power output of a generator is related to the magnetization
energy in the alternator. When a generator is operating as a single unit, there is no good way to control
the magnetization energy in the alternator without changing the output voltage of the generator. In a
parallel system, there is more than one source than can supply reactive power to the load – hence the
reactive power can be shared between the sources, allowing it to be controlled.
• Power Factor Control – The reactive power controller measures and controls reactive power (kVAR).
Power factor is the ratio of the generator real power to the generator apparent power (which is the
geometric sum of the real and reactive power). To control power factor, the reactive power target must
vary with changing real power.
Paralleling
LOAD SHARING
Load sharing is when two or more generators are paralleled together and carry an equal percentage of its
full load rating (both kW and kVAR) on the bus. The speed controls are kept in Isochronous, thus
maintaining 60 Hz on the bus. Load sharing is done through percentages, thus equal size or unequal size
generators can be load shared together. Load sharing information is communicated across all of the units
using PGEN communications.
Each generator needs to maintain both a positive Real Power and Reactive Power.
Paralleling
LOAD SHARING
Real Power Control
The real power output (kW) of a generator set is related to how much mechanical power the engine is
making. In a parallel system, there is more than one source that can supply the load—hence the power
can be shared between the sources, allowing it to be controlled. Because the output of the generator sets
is tied together, the speed of the generator sets will remain essentially identical, regardless of the
mechanical torque that a single engine provides. This allows the Power Control logic to increase the load
(kW) on a paralleled generator set.
Generator sets that are making too much power will adjust their speed bias down, while generator sets
that are not making enough power will adjust their speed bias up. The result is that there is no net change
in the bus frequency.
Reactive Power Control
The reactive power output (kVAR) of a generator set is related to the magnetization energy in the
alternator. In a parallel system, there is more than one source that can supply reactive power to the load—
hence the reactive power can be shared between the sources, allowing it to be controlled. Because the
output of the generator sets is tied together, the voltage amplitude of the generator sets will remain
essentially identical, regardless of the magnetization energy that a single alternator provides. This allows
the Power Control logic to decrease the reactive load (kVAR) on a paralleled generator set.
Generator sets that are making too much reactive power will adjust their voltage bias down, while
generator sets that are not making enough power will adjust their voltage bias up. The result is that there
is no net change in the bus voltage.
Paralleling
OPENING BREAKER
The Decision-Maker® 3500 controller opens the paralleling breaker for any of the following conditions:
• Generator set fault
• Emergency stop
• Start signal removed
• Generator Management signals the generator to stop and the generator set is unloaded
• OFF button pressed. Load enable input is removed and the generator set is unloaded
• Output voltage too high
• Output voltage too low
• Output frequency too high
• Output frequency too low
• Output power too high
• Output current too high
• Generator set absorbing power (Reverse Power)
• Generator set absorbing reactive power (Reverse VAR)

Paralleling
PID CONTROL THEORY
In order to maintain the speed and voltage correctly to synchronize and load share, the controller needs to
obtain an accurate control of those systems. To properly maintain a steady output of these processes the
Decision-Maker® 3500 uses closed loop control systems with PID controls.
These closed loop PID controllers are used in various functions within the Decision-Maker® 3500 to adjust
voltage and speed of the generator.
• Synchronizing control for:

 Voltage Matching
 Frequency Matching
 Phase Matching
 Load sharing control to execute:

 Real Power Sharing
 Reactive Power Sharing.
A PID controller is the most common type of feedback controller. PID stands for Proportional-Integral-
Derivative, referring to the three terms which are varied to obtain the optimal response of the system.
The basic idea behind a PID controller is to read a sensor, then compute the desired output by calculating
proportional, integral, and derivative responses and summing those three components to calculate the
output.
Before we start to define the parameters of a PID controller, we shall discuss what a closed loop system is
and some of the items associated with it.
Paralleling
PID CONTROL THEORY
A closed loop system uses feedback to control the output of a system.
The Setpoint (SP) is the value that we want the process to be. For example, the Bus voltage that we want
to match is at 485 V. The summing point in the PID controller looks at the SP (485) and compares it with
the actual value or the measured Process Variable (PV) (generator voltage). The summing point looks at
the value of the sensor and sees how close it is to 485V. If the SP and PV are the same, then the
controller is satisfied. It will set its output to zero. However, if there is a difference between the SP and the
PV we have an Error and corrective action is needed. This will either be an output to raise or lower the
generator voltage depending on whether the PV is higher or lower than the SP respectively.
This is called a closed loop system, because the action of using a sensor to provide constant feedback
and calculate the desired output is continuously repeated.
Paralleling
PID CONTROL THEORY
From the summing point, the Error difference between the Setpoint reference and the Process Value is
sent to a mathematical type of system, the PID Controller.
A simple block diagram of what the PID controller looks like is:
The overview of the PID is quite

simple. The Process Value is
subtracted from the Setpoint to
create the Error. The Error is simply
multiplied by the calculated P, I and
D actions. Then the resulting “Error x
control actions” are added together
and sent to the PID output.
Paralleling
PID CONTROL THEORY
Summary of the PID controls.
•The Proportional (Kp) identifies what the PID controller's reaction to the Error - difference between
Process Value (PV) and the Setpoint (SP) will be. Think of this as how much gas the a cruise controller
gives a car for some amount of Error.
•The Integral (Ki) is how the PID controller reacts to prolonged periods of Error. If we just had a P
controller, a car would not accelerate going up hills or into the wind. This is an amount to add to the output
per period of Error.
•The Derivative (Kd) is how much reaction the controller has versus the rate of change of the Error. If we
just used a PI controller, then the P term would make the speed shoot past the target, the I term would
accumulate and pull it back, but it wouldn't "anticipate" approaching the Setpoint, and would shoot past it
again. Think of this as breaks in momentum. A car’s cruise controller knows it is going to overshoot, so it
slows it down.
Paralleling
PROTECTIVE RELAYS
The protective relays serve two purposes:
1. To protect the generator from damage
2. To protect the loads supplied by the generator from damage
The protective relays should be configured during commissioning and should be adjusted to meet site
specific considerations. These settings are often taken into consideration for breaker trip curves, load
control settings, and generator management settings. The adjustment without careful consideration of the
implications may mask a problem in the system and cause another. Properly-configured protective relays
should only trip due to a failure.
The protective relays are only active when the generator is in a paralleling scenario.
All protective relay events will trip the breaker, but will not stop the generator until the Trip to Shutdown
Delay has expired. During this time, the protective relay which tripped the breaker will be listed under the
Active Events, the warning LED will be active, and the generator will remain running. The protective relay
can be reset by pressing the AUTO button (note, if the generator is in Run, the protective relay will have to
be cleared by stopping the generator). Pressing OFF/RESET or removing the remote start signal to the
generator system also clears any active protective relays.
Paralleling
PROTECTIVE RELAYS
The controller will trip the circuit breaker and issue a warning if any of the following conditions persist
beyond the associated time delay:
Over Power. This protective function can be used to protect the generator set. The generator set
controller also has an overpower shutdown, which is set to 102% for standby applications and 112% for
prime power applications. A practical solution to the use of this protective relay is to connect the load
management connections.
Reverse Power. This protective function is intended to protect the generator set system from motoring
generator sets and to protect the fuel system of the generator set from operation in a dry state. This
condition is most commonly caused by a loss of fuel prime or damage to a fuel line. A reverse power
condition does not otherwise damage the generator set.
Over Voltage. This protective function is intended to protect the alternator from over excitation, but
primarily is used to protect the customer loads from a potentially damaging condition.
Under Voltage. This protective function is intended to protect electric motors and sensitive electronics
from damage due to undervoltage. The low voltage condition may also indicate a failure in the alternator
or in the sensing to the controller.
Paralleling
PROTECTIVE RELAYS
The controller will trip the circuit breaker and issue a warning if any of the following conditions persist
beyond the associated time delay:
Over Frequency. This protective function is intended to protect any motors that are fed by the generator
set from overspeeding and potentially damaging the equipment that they drive.
Under Frequency. This protective function is intended to protect any motors or transformers that are fed
by the generator set from potential overheating and winding damage.
Reverse VARs (Loss of Field). This protective function is required to avoid potential damage to the
generator set caused by the alternator slipping a pole. Pole slipping can occur when the generator set is
providing real power (Watts) and is absorbing reactive power (VARs). Slipping a pole can cause damage
to the engine crankshaft or the alternator and typically causes voltage spikes on the generator set
output—the condition should be avoided.
OverCurrent. This protective function can be used to protect the alternator of the generator set from
overload conditions. The controller also contains internal alternator protection that prevents thermal
damage to the alternator by stopping the engine.
Breaker Trip to Shutdown Delay: This time delay acts like a cooldown function, but does not take away
a start signal. If the protective relay is reset (pressing Auto while in Auto Run mode), the generator will
return to its sequence of operation.
Paralleling
SETTINGS TERMINOLOGY
This section will cover a few items that are in the settings of the Decision-Maker® 3500 but that will not be
covered in this module. This will just be a brief overview of those items.
Trims. The trims are the mechanism that the paralleling system uses to keep the output voltage and
frequency near the rated values when the generator system is operating. This slowly corrects any error in
the frequency or voltage due to any droop or soft loading/unloading.
The trims default is enabled on all generators.
Baseload. In Baseload mode, the control’s target output level is set at a parameter setpoint. This will drive
the output to try and maintain this fixed value. Baseload mode is not responsive to changes in the load
requirement on the paralleling bus, so placing a generator set in Baseload mode on an islanded system
may very well cause the other generator sets in the system to experience a reverse power condition if the
load decreases. Baseload mode can be used as a testing mode under supervision, but should not be used
long-term in an islanded application.
Baseload settings can be found in Real Power Control, Reactive Power Control and Power Factor Control.
System Sync Mode. System sync mode is intended to allow external switchgear to synchronize the
generator set paralleling bus to the utility. This should not be used in standard applications.
System Control Mode. This mode is not to be used in an islanded system, but will allow external
switchgear to control the entire generator set bus to soft load and unload against the utility. This should not
be used in standard applications.
Paralleling
VERIFY PARALLEL SETTINGS
SiteTech is the best way to verify the paralleling setting of the Decision-Maker® 3500 system. Using a
laptop with two USB ports SiteTech can be used to compare and easily manage the paralleling devices.
When the two controllers are connected to the laptop, simply click on the top tab labeled Manage Parallel
Devices to change the display area to show a side-by-side comparison for each generator’s settings.
Paralleling
ENGINE SPEED GOVERNOR
Set the Engine Speed Adjustment to 50 on all generators. The Engine Speed Adjustment setting must
be the same on all generators in the system.
50 is the default setting, which sets the engine speed to the nominal engine speed (for example, 1800
RPM). A setting of 52 increases the engine speed by 2 RPM; 49 decreases the engine speed by 1 RPM;
etc.
Setting the Engine Speed Adjust parameter high on a generator set will result in that generator set
providing more real power than the other generator sets. It is possible to drive the other generator sets
offline in light loading conditions.
Paralleling
GENSET SYSTEM CONFIGURATION
The first three settings under Genset System Configuration, Genset System Voltage, Genset System
Frequency and Genset Voltage Phase Connection must be the same for all generators in the system.
If using towable generators with a voltage selector switch, these settings will change automatically when
the switch is moved to a different position.
The controllers will alert if any of the settings differ between generators that are communicating over PGEN.
Paralleling
VOLTAGE REGULATOR
Voltage Regulator Average Voltage Adjustment, Voltage Regulator Volts Per Hertz Slope, and
Voltage Regulator Volts Per Hertz Cut In Frequency settings must be the same on all generators in the
system.
Setting the Voltage Regulator Average Voltage Adjustment parameter high on a generator set will result in
that generator set providing more reactive power than the other generator sets. It is possible to drive the
other generator sets offline in light loading conditions.
Paralleling
SYNCHRONIZATION CONTROL
The Synchronization Control menu is where each

generator can be set for optimal synchronization to
the bus.
Because of idiosyncrasies in each generator, some of

these settings might be unique for each unit.
Any of the corresponding PID control settings can be

adjusted during a synchronization test with one
generator on the bus and the other generator in Sync
Check mode.
Paralleling
Voltage Match Window

The voltage match window defines the maximum difference between the average line-line voltage of the
generator set and the average line-line voltage of the paralleling bus which will allow the generator set voltage
to be considered as matching the bus voltage.
• Range: 1 – 10%
• Default: 1%
Sync Frequency Window
The Frequency Window is the maximum difference in output frequency between the bus and the generator set
at which the frequency is considered to be matched.
• Range: 0.1 – 5.0Hz
• Default: 2.0Hz
Phase Match Window
The Phase Angle Window defines the threshold that the phase angle between the L1-L2 generator set voltage
and the L1-L2 paralleling bus voltage must remain below for the phase of the generator set to be considered
to be matched with the paralleling bus.
• Range: 1.0° – 20.0 °
• Default: 5.0 °
Dwell Time
The Dwell Time is the time duration that the synchronizer requires the voltage, frequency, rotation and phase
of the generator set to match that of the paralleling bus before it will signal the paralleling breaker to close.
• Range: 0.1 – 30.0 sec
• Default: 0.3 sec
Paralleling
Fail to Sync Delay

The Failure to Synchronize merely indicates that a generator set was not able to synchronize within the
expected synchronizing time.
• Range: 10 – 600 sec
• Default: 300 sec
Breaker Reclose Time
The Breaker Reclose Time controls the time delay between close attempts on the breaker. This is intended
to allow the breaker to reset to a normal state and to operate properly on the subsequent reclose attempt.
• Range: 0.5 sec - 30.0 sec
Breaker Close Attempts
The Breaker Close Attempts indicates how many failed attempts to close the breaker the controller will
accept before issuing a Fail to Close fault and requiring a fault reset to re-attempt breaker closure.
• Range: 1 - 100
• Default: 3.0
First-On Close Delay
The time between acknowledgement of victory in the first-on race and breaker closure. This time delay is
intended to ensure that the trip signal has time to be removed from the circuit breaker before the close
signal is applied.
• Range: 0.1 – 10.0 sec
Paralleling
Circuit Breaker Current Fault Limit
The internal logic is turned off for this setting so it is not functional at this time.
Circuit Breaker Current Fault Delay
Volts Hertz Okay Time Delay
The time after the voltage and frequency falls within the acceptable window that the controller waits before
the generator set is considered to be within an acceptable operating range.
• Range: 0.1 – 10.0 sec
Sync Mode in Auto / Sync Mode in Run
The Sync Mode in Auto or Run is the mode that the paralleling logic uses for synchronization control when
the generator set is operating in Auto or Run.
Sync Mode in Auto: Sync Mode in Run:

• Range: 1-4 (Off-Active) Range: 1-4 (Off-Active)
• Default: 4 (Active) Default: 3 (Check)
Paralleling
Synchronization Disabled
This is a status only of the synchronization control. This can be selected by using a digital input and
selecting digital input event as Synchronization Disabled.
• Range: False - True
• Default: **STATUS**
Circuit Breaker Phase Angle Fault Limit / Delay
Dead Bus Level
The threshold (in percent of rated voltage) below which the bus is considered to be dead (allowing closure
without synchronization).
• Range: 1.00 – 25.00%
• Default: 10.00%
Paralleling
Pickup Acceptable Voltage Window

The Voltage must remain within this percentage of the system voltage for the duration of the Volts Hertz
Okay Time Delay in order for the voltage to be considered acceptable to supply a customer’s load.
• Range: 1.00 – 50.00%
• Default: 10.00%
Dropout Acceptable Voltage Window.
Once the voltage and frequency are considered to be acceptable, the voltage has to be outside the Dropout
window before it is considered to be unacceptable again.
• Range: 1.00 – 50.00%
• Default: 30.00%
Pickup Acceptable Frequency Window
The generator set frequency must remain within this window for the duration of the Volts Hertz Okay Time
Delay before it is considered to be acceptable.
• Range: 1.00 – 50.00Hz
• Default: 2.50Hz
Dropout Acceptable Frequency Window
Once the Voltage and Frequency are considered to be acceptable, the frequency has to be outside the
Dropout window before it is considered to be unacceptable again.
• Range: 1.00 – 50.00%
• Default: 30.00Hz
Note: The Volts Hertz Timer does not run unless both voltage and frequency are within the window.
Paralleling
Stand Alone Operation
This Parameter forces the controller to solve paralleling logic, even when it is not seeing PGEN
communications with another generator set. This will make the controller behave like a paralleling controller
even if it doesn’t see another generator set on the communication lines. This is intended for an application
where the controller is controlling a motor-operated breaker on the output of the generator set, but there are
no other generator sets on the paralleling bus.
Standalone mode is usually not necessary and should not be enabled in applications where multiple
generator sets are in communication over PGEN or in applications where the generator set is controlled by
external gear that also controls the circuit breaker.
• Default: False
Paralleling
PGEN Baud Rate

All nodes must have an identical baud rate for the network to communicate effectively.
• Range: 9600/19200/38400/57600/115200
• Default: 57600
PGEN Node Id
The Node ID is an address that has been assigned to this node. The node ID is typically indicative of power
up sequence, but not always.
• Range: 1–8 or 255 (indicates short circuit on PGEN Wires)
PGEN Nodes Connected

The number of PGEN nodes that this node has seen communicating on the network in the last second.
• Range: 1–8
PGEN Nodes Disconnected

The number of PGEN nodes that have stopped replying at the appropriate time. If a node with the same
controller serial number as a disconnected one begins communicating again after being counted as
disconnected, the disconnected node count will decrease again.
• Range: 0–7
Paralleling
Fail to Open Delay
The Fail to Open Delay is the time that the controller will wait after applying a trip signal to the circuit breaker
to see the breaker status indicate open. If the breaker status does not indicate open within this time, the
controller will issue a Failure to Open warning. The controller continues to apply the trip signal to the circuit
breaker and if the breaker opens at a later time, the warning will be cleared automatically (but still stored in
the event log).
Fail to Close Delay
The Fail to Close Delay determines the time that the controller will hold the close signal on during a close
attempt. If the breaker status does not indicate that it is closed within the time allocated by the Fail to Close
Delay, the controller will remove the close signal and issue a Breaker Close Attempt Fault. After the controller
has seen a number of close attempt faults equal to the breaker close attempts, the controller will issue a
Failure to Close.
Paralleling
Voltage Match Proportional Gain
The Voltage Match Proportional Gain adjusts the Voltage Bias by an amount that is directly related to the
difference between the average generator set line voltage and the average bus line voltage. The voltage
bias is adjusted in the direction that should decrease the difference between the generator set and the
paralleling bus.
• Range: 0.01 – 100.00
• Default: 1.00
Voltage Match Integral Gain

The Voltage Match Integral Gain adjusts the Voltage Bias at a rate that is related to the difference between
the average generator set line voltage and the average bus line voltage. The voltage bias is adjusted in the
direction that should decrease the difference between the generator set and the paralleling bus.
• Range: 0.01 – 100.00
• Default: 1.00
Voltage Match Derivative Gain

The Voltage Match Derivative Gain adjusts the Voltage Bias by an amount that is related to the rate of
change of the difference between the average generator set line voltage and the average bus line voltage.
The voltage bias is adjusted in the direction that should decrease the rate of change of the difference
between the generator set and the paralleling bus.
• Range: 0.01 – 100.00
• Default: 1.00
Paralleling
Frequency Match Proportional Gain

The Frequency Match Proportional Gain adjusts the Speed Bias by an amount that is directly related to the
difference between the generator set frequency and the bus frequency. The speed bias is adjusted in the
direction that should decrease the difference between the generator set and the paralleling bus.
• Range: 0.01 – 100.00
• Default: 1.00
Frequency Match Integral Gain

The Frequency Match Integral Gain adjusts the Speed Bias at a rate that is related to the difference between
the generator set frequency and the bus frequency. The speed bias is adjusted in the direction that should
decrease the difference between the generator set and the paralleling bus.
• Range: 0.01 – 100.00
• Default: 1.00
Frequency Match Derivative Gain

The Frequency Match Derivative Gain adjusts the Speed Bias by an amount that is related to the rate of
change of the difference between the generator set frequency and the bus frequency. The speed bias is
adjusted in the direction that should decrease the rate of change of the difference between the generator set
and the paralleling bus.
• Range: 0.01 – 100.00
• Default: 1.00
Paralleling
Phase Match Proportional Gain

The Phase Match Proportional Gain adjusts the Speed Bias by an amount that is directly related to the phase
difference between the generator set L1-L2 voltage and the bus L1-L2 voltage. The speed bias is adjusted in
the direction that should decrease phase angle between the generator set and the paralleling bus.
• Range: 0.01 – 100.00
• Default: 1.00
Phase Match Integral Gain

The Phase Match Integral Gain adjusts the Speed Bias at a rate that is related to the phase difference
between the generator set L1-L2 voltage and the bus L1-L2 voltage. The speed bias is adjusted in the
direction that should decrease the phase angle between the generator set and the paralleling bus.
• Range: 0.01 – 100.00
• Default: 1.00
Phase Match Derivative Gain

The Phase Match Derivative Gain adjusts the Speed Bias by an amount that is related to the rate of change
of the phase difference between the generator set L1-L2 voltage and the bus L1-L2 voltage. The speed bias
is adjusted in the direction that should decrease the rate of change of the phase difference between the
generator set and the paralleling bus.
• Range: 0.01 – 100.00
• Default: 1.00
Paralleling
Generator Paralleling Breaker

The Generator Paralleling Breaker is a Status parameter that indicates the internal measured position of the
paralleling breaker.
External Bias Inputs Enabled

The external speed and voltage bias are set to 0 internally unless they are enabled. When enabled, they are
controlled by the voltage applied to the external bias inputs. If there are no wires connected to the inputs, the
biases will still read 0, as the inputs are pulled down to -3.3V, which is outside the normal range (0.5 to
4.5V). If a wire feeding the speed or voltage bias loses connection, the input should also revert to -3.3V (0
bias).
This should not be used in standard applications.
• Default: False
Paralleling
SYNCHRONIZATION METERING
Synchronization Metering menu is used to determine the generator status during a synchronization
process. This can be used during commissioning and when troubleshooting any issues with the
synchronization of a generator to the common bus.
These parameters are only updated if the generator set is synchronizing (in either active or check mode).
Paralleling
SYNCHRONIZATION METERING
Sync Time Remaining

The remaining time before the controller issues a fail to sync warning. If the system commissioning has been
performed properly, this warning should only occur if the system is overloaded or if there is a malfunction on this
generator set.
Dwell Time Remaining
This parameter displays the remaining time for the dwell timer in seconds. The generator set is considered to be in
Sync when the dwell timer expires.
Sync Status Generator V Hz OK
This parameter indicates that the voltage and frequency of this generator set are considered to be acceptable. This
must be true before the generator set will attempt to synchronize to the paralleling bus.
Sync Status Voltage Matched

This parameter indicates that the average line voltage of this generator set is within the Voltage Match window of
the average line voltage of paralleling bus.
Sync Status Frequency Matched

This parameter indicates that the frequency of this generator set is within the Frequency Match Window of the bus
frequency.
Sync Status Phase Matched

This parameter indicates that the phase angle between this generator set and the paralleling bus is within the Phase
Match Window.
Sync Check Matched OK
This parameter indicates that the voltage, frequency, and phase of the generator set are all within their respective
windows of the paralleling bus. This must be true before the dwell timer will start timing
Paralleling
REAL POWER LOAD SHARING
The Real Power Load Sharing menu is where each

generator can be fine tuned for desirable Real Power
Sharing between each generator.

Any of the corresponding PID control settings should

be adjusted with two generators on the bus both with
No Load and with Load on the system to obtain
optimal settings.
Use the Generator Metering menu to verify correct

Real Power Load Sharing.
Paralleling
Real Power Baseload Setpoint

The Real Power Baseload Setpoint is the final target for the load ramp when entering baseload mode and is
the target for the real power controller as long as baseload is active. Baseload mode can be used as a
testing mode under supervision, but should not be used long-term in an islanded application.
• Range: 0.0% – 100.0%
• Default: 50.0%
Real Power Disconnect Level
The Real Power Disconnect Level is the real power threshold below which the generator set circuit breaker
will be signaled to trip when the generator set is signaled to unload.
• Range: 0.0% – 25.0%
• Default: 5.0%
Real Power Ramp Rate

The Real Power Ramp Rate determines the rate that the generator set will attempt to take and remove load.
The ramp rate is used in soft-loading and soft-unloading.
• Range: 0.1%/sec – 25.0%/sec
• Default: 10.0%/sec
Real Power Droop Slope

Speed Bias
This is the status value that displays the amount that the controller is attempting to adjust the output
frequency of the generator set (100% bias = +5% on the engine speed, -100% = -5% on the engine speed).
Paralleling
Load Enable
Load Enable allows the generator set controller to ramp to a target load in any of the power control modes. Load
Enable should remain TRUE, as it can cause loss of functionality that can be rather difficult to troubleshoot.
• Default: True
Baseload Mode
Baseload Mode is intended for use in parallel with a utility source. Setting this input to true will place the
controller in baseload mode. Baseload mode should only be used in parallel with the utility except as a
troubleshooting tool.
• Default: False
System Load Control
System Load Control mode is intended for use in parallel with a utility source.
• Default: False
System Sync Control
System Sync Control mode is intended for use in applications where it is necessary to synchronize a paralleling
bus containing multiple generator sets to a utility source.
• Default: False
Trims Enabled
Trims Enabled allows activating/de-activating of the frequency and voltage trim functions that are available while
in load sharing mode. There are few applications where the trims should be disabled.
• Default: True
Paralleling
Real Power Sharing Proportional Gain
The Real Power Sharing Proportional Gain determines the contribution of the real power sharing proportional
term to the speed bias. The proportional term is directly related to the difference between the average percent
electrical loading of all gens on the bus and the percent electrical loading of this individual generator set. The
proportional term increases the speed bias when the average bus load is greater than the generator set load.
• Range: 0.01 – 100.00
• Default: 1.00
Real Power Sharing Integral Gain
The Real Power Sharing Integral Gain determines the contribution of the real power sharing integral term to the
speed bias. The integral term ramps at a rate directly related to the difference between the average percent
electrical loading of all gens on the bus and the percent electrical loading of this individual generator set. The
integral term ramps the speed bias up when the average bus load is greater than the generator set load.
• Range: 0.01 – 100.00
• Default: 1.00
Real Power Sharing Derivative Gain
The Real Power Sharing Derivative Gain determines the contribution of the real power sharing derivative term
to the speed bias. The derivative term is directly related to the rate of change in the difference between the
average percent electrical loading of all gens on the bus and the percent electrical loading of this individual
generator set. The derivative term increases the speed bias when the difference between the average bus load
and the average generator set load increases.
• Range: 0.01 – 100.00
• Default: 1.00
Paralleling
Torque Sharing Proportional Gain
Torque Sharing Integral Gain
Torque Sharing Derivative Gain
Paralleling
Frequency Trim Proportional Gain
The Frequency Trim Proportional Gain determines the contribution of the frequency trim proportional term to
the speed bias. The proportional term is directly related to the difference between the target speed bias
(typically 0) and the actual speed bias. The proportional term increases the speed bias when the speed bias
is negative.
• Range: 0.01 – 100.00
• Default: 1.00
Frequency Trim Integral Gain
The Frequency Trim Integral Gain determines the contribution of the frequency trim integral term to the
speed bias. The integral term ramps at a rate directly related to the difference between the target speed bias
(typically 0) and the actual speed bias. The integral term increases the speed bias when the speed bias is
negative.
• Range: 0.01 – 100.00
• Default: 1.00
Frequency Trim Derivative Gain
The Frequency Trim Derivative Gain determines the contribution of the frequency trim derivative term to the
speed bias. The derivative term is related to the rate of change of the difference between the target speed
bias (typically 0) and the actual speed bias. The derivative term increases the speed bias when the speed
bias decreases.
• Range: 0.01 – 100.00
• Default: 1.00
Paralleling
Real Power Baseload Proportional Gain
• Range: 0.01 – 100.00
• Default: 1.00
Real Power Baseload Integral Gain
• Range: 0.01 – 100.00
• Default: 1.00
Real Power Baseload Derivative Gain
• Range: 0.01 – 100.00
• Default: 1.00
When in Baseload mode, these PID settings control the speed bias for proper Real Power operation. This
should not be used in standard applications.
System Real Load Control Proportional Gain
• Range: 0.01 – 100.00
• Default: 1.00
System Real Load Control Integral Gain
• Range: 0.01 – 100.00
• Default: 1.00
System Real Load Control Derivative Gain
• Range: 0.01 – 100.00
• Default: 1.00
When in a System control mode, these PID settings control the speed bias for proper Real Power operation.
Paralleling
REACTIVE POWER LOAD SHARING
The Reactive Power Load Sharing menu is where

each generator can be fine tuned for desirable
Reactive Power Sharing between each generator.

Any of the corresponding PID control settings should

be adjusted with two generators on the bus both with
No Load and with some type of Reactive Load on the
system to obtain optimal settings.
Use the Generator Metering menu to verify correct

Reactive Power Load Sharing.
Paralleling
Reactive Power Baseload Setpoint

The Reactive Power Baseload Setpoint is the final target for the load ramp when entering baseload mode
and is the target for the reactive power controller as long as baseload is active. Baseload mode can be used
as a testing mode under supervision, but should not be used long-term in an islanded application.
• Range: 0.0% – 100.0%
• Default: 50.0%
Power Factor Setting
The target value that the controller will adjust the voltage bias to maintain a set Power Factor when
paralleled to a utility source.
• Range: 0.50 – 1.00
• Default: 0.80
Reactive Droop Slope
Voltage Bias
The amount that the controller is attempting to adjust the output voltage (100% bias = +10% on the output
voltage, -100% = -10% on the output voltage).
Paralleling
VAR Control Mode
The VAR Control mode parameters set the means that the controller uses to control reactive power in
baseload and system control mode. This parameter has no effect when the generator sets are islanded and
are merely sharing the power supplied to the load between them.
The modes are:
PF Control Mode = 0. Power Factor Control mode indicates that the reactive power target is related to the
real power output level.
VAR Control Mode = 1. VAR Control mode indicates that the reactive power target is not related to the real
power output.
• Range: PF Control Mode = 0, VAR Control Mode = 1
• Default: PF Control Mode
Paralleling
Reactive Power Sharing Proportional Gain
The Reactive Power Sharing Proportional Gain determines the contribution of the reactive power sharing
proportional term to the voltage bias. The proportional term is directly related to the difference between the
average percent reactive loading of all gens on the bus and the percent reactive loading of this individual
generator set. The proportional term increases the voltage bias when the average bus reactive load is greater
than the generator set reactive load.
• Range: 0.01 – 100.00
• Default: 1.00
Reactive Power Sharing Integral Gain
The Reactive Power Sharing Integral Gain determines the contribution of the reactive power sharing
proportional term to the voltage bias. The integral term ramps at a rate related to the difference between the
average percent reactive loading of all gens on the bus and the percent reactive loading of this individual
generator set. The integral term increases the voltage bias when the average bus reactive load is greater than
the generator set reactive load.
• Range: 0.01 – 100.00
• Default: 1.00
Reactive Power Sharing Derivative Gain
The Reactive Power Sharing Derivative Gain determines the contribution of the reactive power sharing
derivative term to the voltage bias. The derivative term is related to the rate of change of the difference
between the average percent reactive loading of all gens on the bus and the percent reactive loading of this
individual generator set. The derivative term increases the voltage bias when the generator set reactive load
decreases relative to the bus reactive load.
• Range: 0.01 – 100.00
• Default: 1.00
Paralleling
Voltage Trim Proportional Gain
The Voltage Trim Proportional Gain determines the contribution of the voltage trim proportional term to the
voltage bias. The proportional term is directly related to the difference between the target voltage bias (which
offsets the reactive droop) and the actual voltage bias. The proportional term increases the voltage bias when
the voltage bias is lower than the target.
• Range: 0.01 – 100.00
• Default: 1.00
Voltage Trim Integral Gain

The Voltage Trim Integral Gain determines the contribution of the voltage trim integral term to the voltage bias.
The integral term ramps at a rate related to the difference between the target voltage bias (which offsets the
reactive droop) and the actual voltage bias. The integral term increases the voltage bias when the voltage bias
is lower than the target.
• Range: 0.01 – 100.00
• Default: 1.00
Voltage Trim Derivative Gain

The Voltage Trim Derivative Gain determines the contribution of the voltage trim derivative term to the voltage
bias. The derivative term is directly related to the rate of change of the difference between the target voltage
bias (which offsets the reactive droop) and the actual voltage bias. The derivative term increases the voltage
bias when the voltage bias decreases.
• Range: 0.01 – 100.00
• Default: 1.00
Paralleling
Reactive Power Baseload Proportional Gain
• Range: 0.01 – 100.00
• Default: 1.00
Reactive Power Baseload Integral Gain

• Range: 0.01 – 100.00
• Default: 1.00
Reactive Power Baseload Derivative Gain

• Range: 0.01 – 100.00
• Default: 1.00
When in Baseload mode, these PID settings control the speed bias for proper Reactive Power operation.
Power Factor Baseload Proportional Gain

• Range: 0.01 – 100.00
• Default: 1.00
Power Factor Baseload Integral Gain
• Range: 0.01 – 100.00
• Default: 1.00
Power Factor Baseload Derivative Gain
• Range: 0.01 – 100.00
• Default: 1.00
When in Baseload mode, these PID settings control the speed bias for proper Power Factor operation.This
should not be used in standard applications.
Paralleling
System Reactive Power Control Proportional Gain
• Range: 0.01 – 100.00
• Default: 1.00
System Reactive Power Control Integral Gain
• Range: 0.01 – 100.00
• Default: 1.00
System Reactive Power Control Derivative Gain
• Range: 0.01 – 100.00
• Default: 1.00
When in a System control mode, these PID settings control the speed bias for proper Reactive Power operation.
System Power Factor Control Proportional Gain

• Range: 0.01 – 100.00
• Default: 1.00
System Power Factor Control Integral Gain
• Range: 0.01 – 100.00
• Default: 1.00
System Power Factor Control Derivative Gain
• Range: 0.01 – 100.00
• Default: 1.00
When in a System control mode, these PID settings control the speed bias for proper Power Factor operation.
Paralleling
PROGRAMMABLE INPUTS
All of the Inputs used in the paralleling component of the Decision-Maker® 3500 are hard coded and the
settings under each menu are turned off. Changing any of the settings will have no effect on the input or
function of the generator.
The Programmable Input menu can be used to determine the status of the input for troubleshooting
procedures.
Programmable Analog Voltage Input 106
Input 106 is used for generator breaker status. If the breaker is CLOSED, the Analog Voltage Input
Metered Value will display a value that is greater than -0.7 (usually 0.0) and a breaker that is OPEN will
display a value less than -0.7 (usually -3.3).
In the below example, Generator 1 breaker is CLOSED and Generator 2 breaker is OPEN.
Paralleling
PROGRAMMABLE OUTPUTS
Outputs used in the paralleling component of the Decision-Maker® 3500 need to be programmed. These
outputs are used to control the generator circuit breaker in Marine units or a contactor in Towable units
using the Paralleling Box.
Programmable Digital Output 115
Output 115 is used to open (trip) the circuit breaker.
•Digital Output Board Number: Indicates board number this IO point is located on
•Digital Output Io Number: Indicates the point number, of this IO type on this board, for this configuration
•Digital Output Status: The value of the input. Either Active or Inactive
Paralleling
Output 115 is used to open (trip) the circuit breaker.
Digital Output Enabled: Indicates whether this input is enabled. Program to On.
• Range: ON/OFF
Digital Output Logic: Setting the Digital Output Logic to ‘Active On’ will make P2 pin 5 energize (pull to
battery negative) when the ‘Event’ is true.
• Range: Active On/Active Off
Digital Output Function: Indicates the functionality of this IO point. Program to Use As A System Event
• Range: None/Use As A System Event
Digital Output Event: The parameter ID defining the function for this output. Program for Remove
Breaker Trip
Digital Output Description: Not used

Paralleling
Output 115 (CBO) is actually used to release a trip signal to the breaker. The breaker trip wiring uses a
Normally Closed contact to hold a trip on the breaker. This is used to prevent the accidental closing of the
breaker. With the controller output programmed as Remove Breaker Trip, the output will be active (battery
negative) when it is okay to close the breaker. This will energize the relay and open the contact, removing
the trip signal.
When the controller needs to open (trip) the breaker, the output battery negative is removed. This de-
energizes the relay, applying the trip signal to the breaker.
Paralleling
Output 116 is used to close the circuit breaker. The programming of this output will depend on whether the
unit is a Marine or Towable generator.
•Digital Output Board Number: Indicates board number this IO point is located on
•Digital Output Io Number: Indicates the point number, of this IO type on this board, for this configuration
•Digital Output Status: The value of the input. Either Active or Inactive
Paralleling
Output 116 is used to close the circuit breaker. The programming of this output will depend on whether the
unit is a Marine or Towable generator.
Digital Output Enabled: Indicates whether this input is enabled. Program to On.
• Range: ON/OFF
Digital Output Logic: Setting the Digital Output Logic to ‘Active On’ will make P2 pin 5 energize (pull to
battery negative) when the ‘Event’ is true.
• Range: Active On/Active Off
Digital Output Function: Indicates the functionality of this IO point. Program to Use As A System Event
• Range: None/Use As A System Event
Digital Output Event: The parameter ID defining the function for this output. Program for Close Breaker
(Marine) or Contactor (Towable)
Digital Output Description: Not used

Paralleling
Programmable Digital Output 116 – Marine
A Marine generator will use a motor operated circuit breaker. When programmed as Close Breaker, the
controller will trigger the battery negative to close the breaker. The output is connected to the ground side
of an interposing relay. When this relay is energized, the contact closure will send a signal to close the
breaker.
The Close Breaker output will be active for the length of the Fail to Close Delay or will be released upon a
Input status (Analog Voltage Input 106) that the breaker is closed.
Paralleling
Programmable Digital Output 116 – Towable
A Towable generator will use a contactor located inside the Paralleling Box. When programmed as
Contactor, the controller will trigger the battery negative to close the breaker. The output is connected to
the ground side of an interposing relay. When this relay is energized, the contact will send 240 VAC to a
rectifier and contactor assembly inside the Paralleling Box.
The Contactor output will stay active as long as the controller needs the contactor closed. When needed
to open, the output is de-energized.
Paralleling
CALIBRATION
System calibration is important for proper performance. Paralleling compares line-to-line voltages
(generator and paralleling bus), and the voltage regulator also regulates to line-to-line voltage.
During synchronization, the controller matches the generator voltage to the measured bus voltage to
ensure that the reactive power exchange is a minimum when the breaker closes. If the bus metering is not
calibrated correctly, the Decision-Maker 3500 controller will match the generator voltage to the incorrect
bus voltage. If the measured bus voltage is either higher or lower than the actual bus voltage, it will result
in reactive power transfer when the breaker closes, potentially causing a generator to disconnect from the
paralleling bus to protect itself.
Calibration is most easily done from the front panel of the controller.
Use a calibrated multimeter to measure the generator voltage and enter

the correct value in the
CONTROLLER CONFIG -> CALIBRATION screen on the controller.

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Decision-Maker™ 3500 Controller

Welcome to the Kohler Power

The Decision-Maker® 3500 is a generator controller

While the Decision-Maker® 3500 controller can also

The Decision-Maker® 3500 controller supports three

• Single generator operation (Standalone)

• Internal Paralleling modes.

It is important that the mode is matched to the application

Standalone– Single generator applications require little

• Connected to loads though a manually-operated circuit

• Controlling a motor-operated breaker on the output of

In these applications, there will be no chance of paralleling

The controller sets the engine speed to the target speed,

The output voltage of the generator set is controlled to the

External – Many applications require paralleling with

External paralleling requires the external speed and

• The engine speed is set based on the voltage between

• The output voltage is set based on the voltage

Internal – Any multi-generator application where the

The controller will enter internal paralleling mode

In Internal Paralleling mode, all the controllers that are

• Start and stop the generator

• Open and close breakers

• Monitor the system

• Must have Decision-Maker® 3500 controllers.

• Same frequency – 60Hz.

• Same voltage configuration.

• Dissimilar sized generators will share load based on percent loaded.

Example of 35kW and 175kW units sharing a 150 kW system load:

Total capacity = 210 kW

35 ÷ 210 = 17% of total capacity

175 ÷ 210 = 83% of total capacity

A typical sequence of operation with a paralleling system is as follows:

• Breaker close signal to dead bus

• Other generators synchronize to the live bus

• Load sharing – Real and Reactive

PGEN is an auto-discovering, scheduled protocol that

PGEN is a proprietary scheduled broadcast

Up to 8 Decision-Maker® 3500 controllers can be

• It is potentially harmful to provide voltage to the stator of a stopped generator set.

The controller supports the following Sync Modes:

The Bus at 60 Hz and the Generator at 58 Hz

Generator #1 at 470 Volts and Bus at 480 Volts

The Bus and the Generator about 70 degrees out of phase

The Bus and the Generator coming into Synchronism

Think of this as two gears on a chain. The Decision-Maker® 3500

Real Power Control

Reactive Power Control

• Generator set fault

• Start signal removed

• Output voltage too high

• Output voltage too low

• Output frequency too high

• Output frequency too low

• Output power too high

• Output current too high

• Generator set absorbing power (Reverse Power)

• Generator set absorbing reactive power (Reverse VAR)

• Synchronizing control for: