SYNC 5100 Operating instructions

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ABB Switzerland LtdSYNCHROTACT® 5Operating instructionsSYN 5100Issued Esmaeil Habashi 00.05.03 Operating instructions No of pages5 39 Checked Werner Zimmerli 00.07.25 SYNCHROTACTReleased Werner Zimmerli 00.07.25Document No Art Part Language Revision Page abb ABB Switzerland Ltd 3BHS109760 E01 en B 1Document No Art PartLanguage RevisionpageContent1 GENERAL INFORMATIONS........................................................................................32 FUNCTIONAL PRINCIPLE...........................................................................................53 HARDWARE CONSTRUCTION...................................................................................94 PARAMETERS...........................................................................................................135 ENGINEERING INSTRUCTIONS...............................................................................176 INSTALLATION AND DISPOSAL..............................................................................197 OPERATING INSTRUCTIONS...................................................................................218 COMMISSIONING......................................................................................................23 9MAINTENANCE AND FAULTS (29)10 TECHNICAL DATA.....................................................................................................31 11 SCHEMATIC...............................................................................................................35 12 RECORD AND QUESTIONNAIRE.. (37)abbABB Switzerland Ltd3BHS109760 E01en B 2Document No Art Part Language Revision page1General informations1.1IntroductionThis User Manual is aimed at persons who have a basic knowledge of working with electronic equipment, who understand electrical symbols in schematic diagrams, but who know little or nothing about working with SYNCHROTACT 5 equipment.The User Manual provides the information required in order to install, commission and operate the SYNCHROTACT 5 device of type SYN 5100.1.2 Marking of text sectionsGeneral warningThis symbol placed before the text indicates situations or conditions which can cause a risk of death or serious injury. The text describes the procedure for preventing these risks.Dangerous voltagesThis symbol indicates that, when handling the equipment, dangerous voltages occur which can cause death or serious injury.The sections of text marked with "Caution" contain information on situations which canlead to material damage or equipment failure if the instructions are disregarded. The sections of text marked with "Note" provide additional information. This must be taken into consideration in order to prevent malfunctions.Caution Note1.3 Purpose and use of the SYN 5100The digital synchronizer can be used for the following applications:• As a paralleling monitoring device (synchrocheck) for monitoring automatic or manu-al paralleling sequences including dead bus.1.4 Manufacturer’s addressABB Switzerland LtdSynchronizing devices and voltage regulators CH-5300 Turgi/SwitzerlandPhone: +41 58 589 24 86 Fax: +41 58 589 23 33 Email: pes@Internet: /synchrotact24 h - hot line for urgent service inquiries: +41 844 845 845abbABB Switzerland Ltd3BHS109760 E01en B 3Document No Art Part Language Revision page abb ABB Switzerland Ltd 3BHS109760 E01en B 42 Functional principle2.1 Brief descriptionThe digital synchronizing device SYNCHROTACT 5 is used as Synchrocheck formonitoring of automatic or manual paralleling of generators with lines as well as for theparalleling of already synchronized lines. The device is designed for system frequenciesof either 50/60 Hz or 16 2/3 Hz.The setting values are entered via the keys provided on the front side of the device.2.2 Paralleling functionsThe paralleling process can basically be divided into four function blocks:1. Measuring2. Voltage and frequency matching3. Monitoring of paralleling conditions4. Paralleling command generationThe functions measuring and monitoring of the paralleling conditions are both integratedin the application of the Synchrocheck.S00030Document No Art Part Language Revision page abb ABB Switzerland Ltd 3BHS109760 E01en B 5Document No Art Part Language Revision page2.2.1 MeasuringThe following measured variables are generated from the two single-phase measuring voltages:Voltage U1, U2U1 is the reference voltage e.g. lineU2 sit the adjustable voltage e.g. generator. Frequency f1, f2f1 is the reference frequency f2 is the adjustable frequency. Voltage difference ΔU ΔU = IU1I – IU2IΔU > 0 Adjustable voltage is lower ΔU < 0 Adjustable voltage is higher Slip s%100*21fnf f s −=s > 0 Adjustable frequency is less (e.g. generator is sub-synchronous) s < 0Adjustable frequency is greater (e.g. generator is oversynchronous)Phase-angle difference α 21ϕϕα−= α > 0 Adjustable frequency is lagging α < 0 Adjustable frequency is leadingVoltage measurementThe two input voltages U1 and U2 are passed through high-impedance input resistors and differential amplifiers. The signal for the amplitude value is formed from this by conversion and filtering . For zero-passage detection, the signal is filtered and passed through a comparator. The signals prepared in this way are passed to the processor via the A/D converter.S00023abbABB Switzerland Ltd3BHS109760 E01en B 62.2.2 Monitoring of paralleling conditionsThe monitoring of the paralleling conditions can be divided into these parallel-functioningblocks:•voltage-carrying lines•no-voltage linesParalleling of two voltage-carrying linesThe monitoring of the paralleling conditions enables a paralleling command (CHKRELEASE) if the following conditions are fulfilled simultaneously:•the phase-angle difference is within the tolerance band•the slip is within the tolerance band•the voltage difference is within the tolerance bandParalleling of no-voltage lines (dead bus)A special case for the monitoring is the paralleling of no-voltage lines. A parallelingcommand release is only issued if the external release signal is active.The monitoring issues the paralleling command if the following conditions are fulfilledsimultaneously:•the releasing signal for dead bus (digital input) is issued•the zero voltage(s) does not exceed the set threshold U0max2.3 Sequences of the synchronization processThe software is initialised after switching on the auxiliary voltage and immediatelyafterwards the synchronizing process is started. The device begins issuing theparalleling command release as soon as, and as long as the paralleling conditions arefulfilled.The synchronizing process can be interrupted by disconnecting the auxiliary voltage.Since the device has only a monitoring function as a Synchrocheck, the synchronizingprocess can remain in operation.2.4 Self-monitoring of the synchronizerExtensive monitoring includes the following functions:2.4.1 Hardware monitoringAuxiliary voltage: The internally stabilised (reference) voltages are monitored. In theevent of inadmissible deviations, the device is immediately blocked.Paralleling command circuit: Contact monitoring is provided by means of forciblyguided contacts (normally closed = NC) on the command releasing relay. The deviceshould be controlled in such a way that the switching on the auxiliary voltage as well asthe command issuing circuit is only possible by closed NC contacts.Document No Art Part Language Revision page abb ABB Switzerland Ltd 3BHS109760 E01en B 72.4.2 Software monitoringThe program sequence is interrupted and reset by the internal watchdog, if an erroroccurs. After reset, it is again started automatically. This starting procedure is carried outthree times, afterwards the device is totally blocked.2.5 Stored dataThe parameter values are permanently stored in a non-volatile memory, and are notaffected by ageing or failure of the auxiliary voltage. The parameter settings can only bechanged by means of write commands.Document No Art Part Language Revision page abb ABB Switzerland Ltd 3BHS109760 E01en B 8Document No Art Part Language Revision page3Hardware construction3.1Type code for devices2: internal code Communication B: Ethernet & Modbus C: Ethernet & Profibus D: Ethernet & Lon-Bus 0: none 1: Ethernet 2: Modbus 3. Profibus 4: Lon-BusNumber of parameter sets1: 1 Parameter set 7: 7 Parameter setsAuxiliary voltage / System frequency 1: 24...48 VDC; 50/60 Hz2: 100...125 VAC/ VDC; 50/60 Hz 3: 220...250 VDC; 50/60 HzSynchronization mode 02: Dual channel device Construction size 1: Small size 2: Middle size 3: Large size SYNCHROTACT SYN = SYNCHROTACT 5: fifth generationOptionsTypeS0001000: Synchrocheck01: Single channel device 235: 100...125 VAC/VDC; 16 / Hz 236: 220...250 VDC; 16 / Hz 4: 24...48 VDC; 16 / Hz23abbABB Switzerland Ltd3BHS109760 E01en B 9Document No Art Part Language Revision page3.2 Front panelOn the front panel of the SYN 5100 there is a status display (LED’s). The built-in control unit consisting of six keys and the display is located on the front side of the device.Status displays (LED)Designation FunctionΔU < ΔUmax s < smax α < αmax U1/U2 = 0(colour: yellow)Indicate if ΔU, α and s are within the tolerance band or at least one measuring voltage is lacking.Control unitThe parameter settings can be viewed or modified by means of the control panel. The keypad consists of 6 keys with the following functions: abbABB Switzerland Ltd3BHS109760 E01en B10An LED-display is used to display parameter values.The electrical connections are fixed with screwable connectors and spring clamps on the top and bottom of the front side.3.3 Rear of unitAt the rear side there is the snap-profile for mounting a horizontal top-hat rail.Document No Art Part Language Revision page abb ABB Switzerland Ltd 3BHS109760 E01en B 11Document No Art Part Language Revision page abb ABB Switzerland Ltd 3BHS109760 E01en B 12Document No Art Part Language Revision page4Parameters4.1Parameter tableParametersNo. Parameter name SymbolRange/resolution Unit Default setting 1. Slip limit smax 0.1 to 2.0 % 0.5 2. Angle limit αmax 5 to 40/5 DEG 15 3. Maximumvoltage differenceΔUmax 5 to 40/5 % 5 4. Maximum zero voltage U0max 0 to 50/5 % 50 5. Nominal voltageUn50 to 130/5VAC1104.2 Parameter settingsNominal voltage UnThe nominal voltage is set in volts. The nominal voltage is plant-dependent. It is typically 58 (100/3); 64 (110/3); 100; 110 VAC, but can also have a different value. Slip limit smaxThe setting value is based on different criteria, depending on the application: a) normal synchronizationb) paralleling of synchronous lines c) paralleling of asynchronous linesa) Normal synchronizationThe slip limit values set in practice are far from placing a serious load on the machine, even in large machines. Usual setting values in synchrocheck operation for monitoring of a manual paralleling: 0.1 to 0.3 %. For monitoring of automatic paralleling: larger than the limiting value of the automatic device. Default setting: 0.5 %The following are a number of points which can influence the setting value: • Smaller slip limits should be chosen for large and modern generators. • Gas turbines are more sensitive than hydrogenerators.• Lower values should be selected if fine synchronization has priority and highervalues if fast synchronization is to take place.• Lower slip values are usually selected where settings are made for synchrocheckoperation to monitor manual synchronizing. b) Paralleling of synchronous linesIf only synchronous sources are paralleled, the slip limits do not need to be setabbABB Switzerland Ltd3BHS109760 E01en B 13Document No Art Part Language Revision pagec) Paralleling of asynchronous lines:If two lines do not form a ring connection, the slip limits are restricted by the current limit permitted after paralleling. If the flow of power in a particular direction is to be avoided, the corresponding slip limit must be set to zero .Angle limit αmaxThe permissible angle limit is based on different criteria, depending on the application: a) paralleling of asynchronous sources. b) paralleling of synchronous sources.a) Paralleling of asynchronous sources:If 3,6*fn *smax *t+3 > 10 DEG (t = closing time of the circuit breaker), the value should be rounded up to whole degrees. Setting values above 15 DEG are not usual. If the calculation produces such a result, it should be checked whether the maximum slip can be reduced. For monitoring of automatic paralleling: larger than the limiting value of the automatic device.b) Paralleling of synchronous sources:The coupling reactance x K in ring mains lines and the balancing current I K flowing through these cause a phase shift between the two voltages U1 and U2.Line 2 (L.V. line)S00014abbABB Switzerland Ltd3BHS109760 E01en B 14Document No Art Part Language Revision pageThe maximum phase shift αmax permitted for paralleling is calculated from the greatest phase shift which occurs plus a reserve. αmax is limited by the current i T = f(U1, U2, x T ) flowing after paralleling.Maximum voltage difference ΔUmaxMaximum permitted amplitude difference between the two voltages. Line 1 (H.V. line)Line 2 (L.V. line)S00015• usual values for generators: 1 to 5 %• usual values for synchronous lines 3 to 10 %For monitoring of automatic paralleling: larger than the limiting value of the automatic device.Recommended setting: default settingMaximum zero voltage U0maxMaximum voltage at which the SYNCHROTACT 5 still recognises the measuring voltages as zero voltage. A different value should only be set if necessary.abbABB Switzerland Ltd3BHS109760 E01en B 15Document No Art Part Language Revision page abb ABB Switzerland Ltd 3BHS109760 E01en B 16Document No Art Part Language Revision page5Engineering instructions5.1 General advice 5.1.1Cable connectionsCables or wires with cross sections of 0.4 mm 2 to 2.5 mm 2 can be connected to all the connection terminals. It is recommended that 1 mm 2 should be used for control circuits and power supply connections; at least 1,5 mm 2 should be used for measuring circuits. Connection of more than one cable to a terminal is not permitted.The casing must be connected with the earth potential via the connection provided for this purpose.In order to prevent polarity errors, marked cables should be used for all voltage transformers (measuring circuits).5.1.2 Recommended measures for long distancesFor distances >50 m, the following measures are recommended:• The cables for the actual value measurement should have a cross section ≥ 2.5 mm 2and should be twisted or shielded.• The control circuits should be operated with a nominal voltage of ≥125 VDC in orderto prevent inductive interference.• All cables must be laid separately from high-voltage and high-current cables.5.2 Sequences of the synchronizing processSwitching on the paralleling point: measuring voltage, auxiliary voltage and command circuit are all switched-on on the device.The normally closed contact of the paralleling command release relay is provided toavoid the switching on, if the command release issuing contact (normally open) is in a closed status as a result of pre-occurred error (see also the schematic diagram).Caution abbABB Switzerland Ltd3BHS109760 E01en B 17Document No Art Part Language Revision page abb ABB Switzerland Ltd 3BHS109760 E01en B 18Document No Art Part Language Revision page6 Installation and disposalSYNCHROTACT 5 devices operate with in some cases dangerous voltages (>50 V), e.g. measuring inputs up to 170 VAC and relay outputs up to 250 VAC/VDC. Manipulations carried out on these parts can cause death or injury to the persons involved or damage to surrounding objects. If handled correctly and in the proper environment, as described in these instructions, there is no risk.All relevant regulations must be observed during installation. It is essential that these safety regulations are read before starting any work on the SYNCHROTACT 5 equipment.The safe operation of the device requires appropriate transport and proper storage,erection and installation.The equipment should be unpacked with the usual degree of care, without the use of force and using suitable tools.The device should be checked visually for any damage caused during transport. Any complaints of defects caused by improper transport should be addressed immediately to the receiving station or the last carrier.Only interior rooms which are dry and dust-free and which contain no gases, acid fumes or similar are suitable as sites for installation.Caution 6.1 Diagram of dimensionsS00024abbABB Switzerland Ltd3BHS109760 E01en B 19Document No Art Part Language Revision page6.2 FixingSnap on the device on a top-hat rail. Check for the correct fitting.6.3 Earthing and wiringThe casing must be connected with the earth potential via the connection provided for this purpose.The use of shielded cables is not necessary. If shielded cables are nonetheless used for protection against high-frequency interference, it is recommended that the shielding be connected to the earth potential at both ends over as wide an area as possible. If it is not possible to earth the cables at both ends, one of the following procedures can be taken:• Earthing of the shielding via a capacitor. The shielding is earthed directly at one endand via a capacitor at the other end.• Use of a double shielded cable: one of the two shields is earthed at one end, theother at the other end.6.4 DisposalThe inappropriate disposal of electrical equipment can lead to an environmental hazard. It is therefore important that electrical equipment be disposed of by qualified personnel. The metallic casing, cover and front frame do not present any environmental risk and can be recycled.The circuit boards must be removed and should be disposed by a licensed disposal company. Environmentally harmful elements such as capacitors must be separated from the circuit boards.The SYNCHROTACT 5 devices are environmentally friendly designed. The circuit boards are easy to remove.abbABB Switzerland Ltd3BHS109760 E01en B 207 Operating instructions7.1 Operation for commissioning and maintenance purposes7.1.1 CommandsThe following commands can be carried out using the keypad.7.1.2 DisplayAfter switching on the auxiliary voltage, all the elements light up for short time. The pointat the bottom right blinks. As soon as, one of the pre-selction key is pressed, itscorresponding setting value is displayed. The display is cleared 1 minute after the lastkey press.7.2 Operational control7.2.1 Starting and stopping the synchronizing processThe software is initialised after switching on the auxiliary voltage and immediatelyafterwards the synchronizing process is started. The device begins issuing theparalleling command releases as soon as, and as long as the paralleling conditions arefulfilled.The synchronizing process can be interrupted by disconnecting the auxiliary voltage.Since the device has only a monitoring function as a Synchrocheck, the synchronizingprocess can remain in operation.7.2.2 Use of the built-in control panelThe service controls are not normally required with commissioned devices. However, ifone wishes to use these, in order to read out setting values, this can be done bypressing the keys as shown in the table in section 7.1.1. The commands don’t changethe functionality of the SYNCHROTACT 5, as long as, the save command is not issuedwithin 30 s after modification of the setting value.Document No Art Part Language Revision page abb ABB Switzerland Ltd 3BHS109760 E01en B 21Document No Art Part Language Revision page abb ABB Switzerland Ltd 3BHS109760 E01en B 22Document No Art Part Language Revision page8Commissioning8.1Warnings and instructionsSYNCHROTACT 5 devices operate with in some cases dangerous voltages (>50 V), e.g. voltage transformer inputs up to 170 VAC and relay outputs up to 250 VAC/VDC. Manipulations carried out on these parts can cause death or injury to the persons involved or damage to surrounding objects. If handled correctly and in the proper environment, as described in these instructions, there is no risk.All relevant regulations must be observed during commissioning. It is essential that these safety regulations are read before starting any work on the SYNCHROTACT 5 equipment.After the device has been switched off, it must be ensured, by measuring, that no measuring voltages or control voltages >50 V are present at the terminals before anything is done to the device itself, e.g. unplugging the connector to replace the device. In order to prevent open voltage circuits being accidentally closed by third parties, the circuits in question should be marked at the disconnection point (e.g. with a warning sign).If work is being carried out in the environment of the SYNCHROTACT 5, e.g. on the relay controls, electronics power supply, synchronizing instruments, all voltages greater than 50 V which are connected to the system must be switched off.Before switching on, always check whether all connectors are plugged in .The device may only be opened by qualified personnel. It is essential that ESDregulations are complied with.Caution Caution 8.2 Work carried out with the machine at a standstill 8.2.1Wiring checkThe casing must be connected with the earth potential via the connection provided for this purpose. All electrical connections must be checked against the system schematic (connection point and cross section).8.2.2 First power-upInterrupt paralleling circuit(s): Bring the machine circuit breaker or circuit breaker to Test position, draw out the carriage or pull command relay.Switch on auxiliary voltage. All the elements light up on the LED-display. The the point at the bottom right blinks.abbABB Switzerland Ltd3BHS109760 E01en B 23Document No Art Part Language Revision page8.2.3Pre-setting of parametersInstructions on the correct use of the service control panel can be found in section 7 Operating instructions. Advice on the parameter settings can be found in section 4.2 Parameter settings.NoteSome parameter settings can already be determined and set while the machine is at a standstill: Un, smax, αmax, ΔUmax, U0max.Each single parameter setting after its modification must be confirmed within 30 s. If thisrule is not complied with, the old value remains in the memory.Caution 8.2.4 Comparison of measuring points and switching pointsIf there are several paralleling points, it is essential to check whether the parallelingcommand and the measuring circuits (both) go to the same circuit breaker.8.2.5 Test of the phase sequence and tuning of the measuring voltagesabbABB Switzerland Ltd3BHS109760 E01en B 24The following tasks are the most important ones during the entire commissioning.They don't concern the synchronization device itself, but their right connections at the measuring voltages. In case of ignorance, damages may be caused to the plant! It is a prerequisite for the following work and for the correct functioning of thesynchronization that the nominal voltage Un is set.When disconnecting high voltage cables, it is essential that the corresponding regulations on working on high voltage installations are complied with.Bring the circuit breaker to operating position so that it can be operated manually.Caution CautionDocument No Art Part Language Revision pageClosing the CB:• Isolate one voltage source: open either isolator on generator side or star pointisolator or isolator on busbar side• The other voltage source must be connected The three LED’s ΔU < ΔUmax, s < smax, α < αmax must light up now, in particular thelast one. Otherwise, either the measuring cables are incorrectly connected (in terms of polarity) or there is a phase shift. Incorrect polarity cannot be detected by the synchronizer. Paralleling with incorrect polarity can lead to serious damage.The synchronizing instruments (double voltmeter, double frequency meter andsynchroscope) if present, must be checked. The synchronoscope must stand at “twelve o‘clock”!If this is not the case, the measuring circuits must be checked.If the synchronoscope stands at “six o‘clock”, one voltage has been incorrectly connected. In other positions, either measuring is being carried out on incorrect phases or a phase shift caused by the connection group of a step-up transformer has not been compensated.The circuit breaker should be opened again (or brought into test position) and the paralleling circuit interrupted.If it is not possible to test the phase sequence as described above, it is still essential toCaution CautionCaution NoteabbABB Switzerland Ltd3BHS109760 E01en B 25Caution test the measuring circuits. For example, the phase positions can be tested using high voltage measuring sensors.Document No Art Part Language Revision page8.3 Work carried out while the machine is running 8.3.1Function testsChecking the parallelingAt the end of commissioning, “blind“ synchronization should be carried out several times (circuit breaker in Test position). The differential voltage and the paralleling command should thereby be recorded using a transient recorder. At the same time, the synchronizing process should be observed using the synchronizing instruments in the plant.Bring circuit breaker to operating position, adjust voltage and frequency and carry out “live“ synchronization. Record the synchronizing process.Example of a correct paralleling dU = Voltage difference u1 – u2 S1 = Manual paralleling command S2 = Paralleling command releaseby SYN 5100abbABB Switzerland Ltd3BHS109760 E01en B 26Document No Art Part Language Revision pageAngle error(switches too early) Possible causes:• α-measuring incorrect (phaseerror) • Manual paralleling switchclosed to early or automatic synchronizing device wrongly setAngle error(switches too late) Possible causes:• α- measuring incorrect (phaseerror) • Manual paralleling switchclosed to late or automatic synchronizing device wrongly setSlip too big/angle error Possible causes: • smax set too highVoltage difference Possible causes:• ΔUmax set too high • Measuring errorabbABB Switzerland Ltd3BHS109760 E01en B 278.3.2 Keeping recordsIf parameter settings are carried out, these should be entered in the settings record atthe end of this operating manual.Document No Art Part Language Revision page abb ABB Switzerland Ltd 3BHS109760 E01en B 28。