Generator set current control issue

[Caleb001]

Good day,
I have an issue on which I would appreciate input: We generate our own electricity with five 1.6MW sets usually running (No connection to the grid). Each genset has a Cummins Powercontrol 3201 operator panel. The main control signal is common to all - each set does not have it's own individual kilowatt target.
We installed a newly serviced (half-life service) Cummins engine on one of the gensets. When running it, the set synchronizes and the engine runs fine with the voltages and frequency on target. As soon as the breaker is closed, the current ramps up and continues to do so for four to six seconds, right up to and over the rated value at which point the the protection circuit switches the breaker out.
Most of the cards were installed new with the exception of the base card.
Any input would be appreciated, thank you in advance.
Caleb

 

[junkhound]

Guessing you likely had to move some control wires when replacing the engine ?

Had a similar situation aboard ship (5 ea Cat diesels driving 3 MW generators).

One fine day, one of the generators wanted to hog current and shut down.

After replacing all the rotating diodes, complete check of the generator, etc, finally found that a terminal in a Basler regulator was getting loose, heating, and changing component tolerances in the regulator.

The culprit was a push on (FAst-on) terminal that could not take the long term vibration.
You may have "Pushed over the edge" one of your control wire connections.
The preferred method if those nasty pushon connections are used with diesel vibration is to spot weld the connection.

 

[Caleb001]

Guessing you likely had to move some control wires when replacing the engine ?

Had a similar situation aboard ship (5 ea Cat diesels driving 3 MW generators).

One fine day, one of the generators wanted to hog current and shut down.

After replacing all the rotating diodes, complete check of the generator, etc, finally found that a terminal in a Basler regulator was getting loose, heating, and changing component tolerances in the regulator.

The culprit was a push on (FAst-on) terminal that could not take the long term vibration.
You may have "Pushed over the edge" one of your control wire connections.
The preferred method if those nasty pushon connections are used with diesel vibration is to spot weld the connection.

Thank you JunkHound, I'll have a good look at that.