Instruction Manual PRISMIC A30 EXCITATION CONTROLLER
Manual No: HB959202000 Document No: TP00000021 Date: 30 May 2003
Issue: J
Brush Electrical Machines Ltd. PO Box 18, Loughborough, Leicestershire, LE11 1HJ, England Telephone: +44 (1509) 611511 Telefax: +44 (1509) 610440 E-Mail:
[email protected] Web Site: http://www.fki-et.com/bem
PRISMIC A30 Excitation Controller Manual No: HB959202000
Issue: J
Date: 30 May 2003
Page: 2 of 126
CONTENTS 1 INTRODUCTION TO MANUAL ................................................................................................................. 4 1.1 General................................................................................................................................................ 4 1.2 How To Use The Manual .................................................................................................................... 4 1.3 Copies ................................................................................................................................................. 4 1.4 Feedback............................................................................................................................................. 5 1.5 Service & Spares................................................................................................................................. 5 1.6 Contact Address.................................................................................................................................. 5 1.7 Health & Safety At Work Act (1974).................................................................................................... 5 1.8 Protection And Monitoring Devices ..................................................................................................... 6 2 EUROPEAN DIRECTIVES ........................................................................................................................ 7 3 INTRODUCTION ........................................................................................................................................ 8 4 RATINGS ................................................................................................................................................... 9 5 FEATURES .............................................................................................................................................. 10 6 SPECIFICATION...................................................................................................................................... 12 6.1 A30-CON Card .................................................................................................................................. 12 6.2 A30-MON Card.................................................................................................................................. 18 6.3 Standby Control Card........................................................................................................................ 21 6.4 Utilities Card ...................................................................................................................................... 24 6.5 A30-RACK1 Mainframe..................................................................................................................... 26 7 HARDWARE DESCRIPTION .................................................................................................................. 28 7.1 A30-CON Card .................................................................................................................................. 28 7.2 A30-MON Card.................................................................................................................................. 34 7.3 Standby Control Card........................................................................................................................ 36 7.4 Utilities Card ...................................................................................................................................... 40 7.5 A30-RACK1 Mainframe..................................................................................................................... 41 8 SOFTWARE DESCRIPTION ................................................................................................................... 44 8.1 A30-CON Card .................................................................................................................................. 44 8.2 A30-MON Card.................................................................................................................................. 47 9 INSTALLATION AND MECHANICAL DETAILS, CARD FITTING AND REMOVAL ............................. 48 9.1 Installation ......................................................................................................................................... 48 9.2 Ventilation.......................................................................................................................................... 48 9.3 Wiring To The A30 Excitation Controller ........................................................................................... 48 9.4 Wiring To The Plug............................................................................................................................ 49 9.5 Safety ................................................................................................................................................ 50 9.6 Mechanical Details ............................................................................................................................ 50 9.7 Card Fitting and Removal ................................................................................................................. 51 10 COMMISSIONING ................................................................................................................................ 52 10.1 EMC Installation And Operation Guidelines...................................................................................... 52 10.2 Pre-Commissioning Checks.............................................................................................................. 53 10.3 Check Operation Of DC Contactors, Switches And Indications With Machine At Standstill ............ 53 10.4 Check Standby Control ..................................................................................................................... 55 10.5 Check A30-CON And A30-MON Settings ......................................................................................... 56 10.6 Check Display Of Measured Parameters On The A30-CON And A30-MON Card .......................... 57 10.7 Check Null Balance Indication When In Standby.............................................................................. 57 10.8 Set-up Stability In Main Channel....................................................................................................... 57 10.9 Check The Voltage Range Of The A30-CON Card .......................................................................... 58 10.10 Check Soft Start............................................................................................................................. 59 10.11 Check For Smooth Changeover From Standby To Main Channel................................................ 59 10.12 Check/Set-Up Over Excitation Limiters And Monitors................................................................... 59 10.13 Over Voltage And Over Flux Monitors........................................................................................... 60 10.14 Set/Check The Under Voltage Monitor Level ................................................................................ 61 10.15 Check Parallel Operation............................................................................................................... 61 10.16 Check Under Excitation Limiter ..................................................................................................... 62 10.17 Check Under Excitation Monitor .................................................................................................... 62 10.18 Check Power Factor Control (If Applicable) .................................................................................. 62 10.19 Check VAr Control (If Applicable).................................................................................................. 63 10.20 Check The VAr Shed (If Applicable).............................................................................................. 63 10.21 Check Parallel Operation In Standby Line Voltage Control .......................................................... 63 HB959202000 (J) A30 Excitation Controller.doc
© Brush Electrical Machines Ltd. 2003
PRISMIC A30 Excitation Controller Manual No: HB959202000
Issue: J
Date: 30 May 2003
Page: 3 of 126
10.22 Static Interrogation ........................................................................................................................ 64 11 USING THE WINDOWS HMI COMMISSIONING SOFTWARE........................................................... 65 11.1 Setup Of the A30 Using An Alternative Power Supply...................................................................... 65 11.2 PC Software Installation .................................................................................................................... 65 11.3 Running the HMI Application............................................................................................................. 65 11.4 Exiting the HMI Application ............................................................................................................... 66 11.5 HMI Functions ................................................................................................................................... 66 11.6 A30-CON Card – HMI Displays Available ........................................................................................ 67 11.7 Logfile................................................................................................................................................ 68 11.8 Saving Presets And Registers .......................................................................................................... 68 11.9 Passwords......................................................................................................................................... 68 11.10 Using The A30-CON HMI Displays ............................................................................................... 69 11.11 A30-MON Card - HMI Displays Available...................................................................................... 76 11.12 Using The A30-MON HMI Displays ............................................................................................... 77 12 USING THE SCADA COMMUNICATIONS PORT .............................................................................. 82 12.1 Protocol Data..................................................................................................................................... 82 12.2 Physical Connections ........................................................................................................................ 82 12.3 Data Available ................................................................................................................................... 82 13 TRANSDUCER CALIBRATION PROCEDURE................................................................................... 83 13.1 Line Voltage Calibration On The A30-CON Card ............................................................................. 83 13.2 Field Current Calibration On The A30-CON Card............................................................................. 83 13.3 Line Current Calibration On The A30-CON Card.............................................................................. 83 13.4 Temperature Transducer Calibration on the A30-CON Card............................................................ 83 13.5 Line Voltage Calibration on the A30-MON Card ............................................................................... 84 13.6 Field Current Calibration on the A30-MON Card .............................................................................. 84 13.7 Line Current Calibration on the A30-MON Card ............................................................................... 84 13.8 Temperature Transducer Calibration on the A30-MON Card ........................................................... 84 14 STEP RESPONSE TESTING............................................................................................................... 85 14.1 Step Response.................................................................................................................................. 85 14.2 Step Response on Open Circuit........................................................................................................ 85 14.3 Stabilising Adjustment....................................................................................................................... 85 14.4 UEL Stabilising .................................................................................................................................. 86 15 OPERATING PROCEDURES AND MAINTENANCE ......................................................................... 87 15.1 Operating Procedures ....................................................................................................................... 87 15.2 Maintenance...................................................................................................................................... 88 16 FAULT FINDING .................................................................................................................................. 89 16.1 General Information........................................................................................................................... 89 16.2 Precautions ....................................................................................................................................... 89 16.3 Procedure.......................................................................................................................................... 89 16.4 Fault Finding Tables.......................................................................................................................... 91 17 APPENDIX A - CONNECTIONS CHARTS ........................................................................................ 106 18 APPENDIX B - CARD LINK DESCRIPTIONS................................................................................... 119 19 APPENDIX C - HOLDING REGISTERS FOR SCADA...................................................................... 122 20 APPENDIX D - RECOMMENDED SPARES...................................................................................... 125 21 APPENDIX E - DRAWINGS ............................................................................................................... 126
HB959202000 (J) A30 Excitation Controller.doc
© Brush Electrical Machines Ltd. 2003
PRISMIC A30 Excitation Controller Manual No: HB959202000 1
Issue: J
Date: 30 May 2003
Page: 4 of 126
INTRODUCTION TO MANUAL 1.1
General The purpose of this manual is to provide information and advice on supplied equipment. Warning symbols used in the manual are as follows: Mandatory Notice - Instruction to be followed. Danger, General - Caution to be exercised. Appropriate safety measures to be taken. Danger, Electricity - Caution to be exercised. Appropriate safety measures to be taken. Danger, Harmful or Irritating - Caution to be exercised. Appropriate safety measures to be taken. Information is given for guidance only and we do not accept any responsibility for the manner in which the information is used, nor the consequences thereof. The design and manufacture of equipment is subject to constant review and as a result the information provided herein may vary from that manufactured. Verbal or written modifications to the information contained herein have no legal status unless confirmed in writing by the Technical Director or his nominated deputy. The manual, and any amendments, should be maintained for the lifetime of the equipment. It is important that any persons responsible for equipment installation, commissioning, operation and maintenance are provided with access to this manual.
1.2
How To Use The Manual It is recommended that prior to undertaking any installation, commissioning, operation or maintenance activities on the equipment, this manual and any associated documentation should be read in their entirety in order to gain an understanding of system operation. The manual is written as a 'stand-alone' document, but should be read in conjunction with any referenced or associated documentation. All pages and topic headings are numbered for easy reference. Cross-reference(s) to associated paragraphs and documentation is included where appropriate. When referencing particular paragraphs in communications, it is important to specify the Manual Number and the Issue Reference. Referenced drawings are attached as additional (unnumbered) pages.
1.3
Copies Additional copies of the latest available version of manuals are available from our Service Department at the contact address given hereafter. A nominal charge may be made for this service. The information provided remains the copyright of Brush Electrical Machines Ltd., and is not to be copied or disclosed to a third party without the written approval of the Technical Director at the contact address given hereafter.
HB959202000 (J) A30 Excitation Controller.doc
© Brush Electrical Machines Ltd. 2003
PRISMIC A30 Excitation Controller Manual No: HB959202000 1.4
Issue: J
Date: 30 May 2003
Page: 5 of 126
Feedback We are constantly seeking to improve the quality and reliability of our products, and we actively encourage user feedback. Any comments should be addressed to your usual representative, or to our Service Department at the contact address given hereafter.
1.5
Service & Spares Quotations for Service and Spares can be obtained from our Service Department at the contact address given hereafter. Authorised users can also access spare parts information provided at the Web Site address given hereafter.
1.6
Contact Address Brush Electrical Machines Ltd. PO Box 18 Loughborough Leicestershire LE11 1HJ England Telephone: +44 (1509) 611511 (Switchboard) Telefax: +44 (1509) 612436 (Service Department) E-Mail:
[email protected] [email protected]
Web Site: http://www.fki-et.com/bem 1.7
Health & Safety At Work Act (1974) The information hereunder is supplied in accordance with Section 6 of the Health and Safety at Work Act 1974 with respect to the duties of manufacturers, designers and installers in providing health and safety information to Customers. The information advises of reasonably foreseeable risks involved with the safe installation, commissioning, operation, maintenance, dismantling, cleaning or repair of products supplied by Brush Electrical Machines Ltd. Every precaution should be taken to minimise risk. When acted upon, the following precautions should considerably minimise the possibility of hazardous incidents. Delivery Checks: Check for damage sustained during transport. Damage to packing cases must be investigated in the presence of an Insurance Surveyor. Installation: Where installation is made by engineers other than Brush Electrical Machines Ltd. personnel, the equipment should be installed by suitably qualified personnel in accordance with relevant legislation, regulations and accepted rules of the industry. In particular, the recommendations contained in the regulations with regard to the earthing (grounding) must be rigorously followed.
HB959202000 (J) A30 Excitation Controller.doc
© Brush Electrical Machines Ltd. 2003
PRISMIC A30 Excitation Controller Manual No: HB959202000
Issue: J
Date: 30 May 2003
Page: 6 of 126
Electrical Installation: IMPROPER USE OF ELECTRICAL EQUIPMENT IS HAZARDOUS. It is important to be aware that control unit terminals and components may be live to line and supply voltages. Before working on a unit, switch off and isolate it and all other equipment within the confines of the same control cubicle. Check that all earth connections are sound. WARNING: Suitable signs should be prominently displayed, particularly on switches and isolators, and the necessary precautions taken to ensure that power is not inadvertently switched on to the equipment whist work is in progress, or is not yet completed. Adjustment and fault finding on live equipment must be by qualified and authorised personnel only, and should be in accordance with the following rules: Ø Read the Instruction Manual. Ø Use insulated meter probes. Ø Use an insulated screwdriver for potentiometer adjustment where a knob is not provided. Ø Wear non-conducting footwear. Ø Do not attempt to modify wiring. Ø Replace all protective covers, guards, etc. on completion. Operation & Maintenance: Engineers responsible for operation and maintenance of equipment should familiarise themselves with the information contained in this manual and with the recommendations given in associated documentation. They should be familiar also with the relevant regulations in force. Ø It is essential that all covers are in place and that all guards and/or safety fences to protect any exposed surfaces and/or pits are fitted before the associated machine is started. Ø All adjustments to the associated machine must be carried out whilst the machine is stationary and isolated from all electrical supplies. Replace all covers and/or safety fences before restarting the machine. Ø When maintenance is being carried out, suitable WARNING signs should be prominently displayed and the necessary precautions taken to ensure power is not inadvertently switched on to the equipment whilst work is in progress, or is not yet complete. Ø When power is restored to the equipment, personnel should not be allowed to work on auxiliary circuits, eg. heaters, current transformers etc. 1.8
Protection And Monitoring Devices WARNING: It is essential that any protection or monitoring device for use with generators or ancillary equipment should be connected and operational at all times unless specifically stated otherwise herein. It should not be assumed that all necessary protection and monitoring devices are supplied as part of Brush Electrical Machines Ltd. scope of supply. Unless otherwise agreed, it is the responsibility of others to verify the correct operation of all protection and monitoring equipment, whether supplied by Brush Electrical Machines Ltd. or not. It is necessary to provide a secure environment that ensures operator safety and limits potential damage to the generator and ancillary equipment. If requested, Brush Electrical Machines Ltd. would be pleased to provide advice on any specific protection application issues or concerns.
HB959202000 (J) A30 Excitation Controller.doc
© Brush Electrical Machines Ltd. 2003
PRISMIC A30 Excitation Controller Manual No: HB959202000 2
Issue: J
Date: 30 May 2003
Page: 7 of 126
EUROPEAN DIRECTIVES
HB959202000 (J) A30 Excitation Controller.doc
© Brush Electrical Machines Ltd. 2003
PRISMIC A30 Excitation Controller Manual No: HB959202000 3
Issue: J
Date: 30 May 2003
Page: 8 of 126
INTRODUCTION The PRISMIC A30 Excitation Controller is designed to control the excitation of a brushless generator. Incorporating a wide range of features, the A30 is housed in a 19" rack assembly requiring only external instruments and control switches to provide the complete excitation system as shown in Figure 1. For setup and commissioning of the A30 a PC is required. PC based software and two serial communications cables are provided. A copy of the factory test record and factory setup data is provided with the A30 in the form of a Brush QC(T)48 document. When provided with a Brush generator, the A30 factory setup data will be matched to the generator. The QC(T)48 document should be available when commissioning the A30.
Figure 1: A30 Excitation Controller Scheme HB959202000 (J) A30 Excitation Controller.doc
© Brush Electrical Machines Ltd. 2003
PRISMIC A30 Excitation Controller Manual No: HB959202000 4
Issue: J
Date: 30 May 2003
Page: 9 of 126
RATINGS Max. continuous output current:
20A
Max. 10 second output current:
30A
Excitation supply voltage:
Single phase 110Vac to 330Vac
Excitation supply frequency:
50Hz to 480Hz
Auxiliary dc Supply:
24Vdc or 110/125Vdc +15%, -20%
Nominal sensing voltage:
100V to 120V selectable in 5V steps
Voltage sensing phases:
Three phase with single phase option
Voltage sensing input burden:
Less than 3VA per phase
Nominal generator frequency:
50Hz or 60Hz
Current transformer input nominal: 5A or 1A selectable Current transformer input burden:
Less than 1VA
Max field voltage for forcing:
75% of single phase supply RMS voltage
Accuracy of control:
±0.5%
Operating temperature range:
0ºC to +55ºC
Storage temperature range:
-40ºC to +100ºC
Dimensions:
Width 483mm, Height 266mm, Depth 400mm
Weight:
14.5kg
HB959202000 (J) A30 Excitation Controller.doc
© Brush Electrical Machines Ltd. 2003
PRISMIC A30 Excitation Controller Manual No: HB959202000 5
Issue: J
Date: 30 May 2003
Page: 10 of 126
FEATURES 1) Complete System Housed In A Single 19” 6U Rack Includes power semiconductor and control circuits, power supply transformers, contactors for excitation changeover and field suppression and field suppression resistor. 2) Independent Main And Hot Standby Excitation Channels The unit contains two power semiconductor circuits, one acting as a hot standby to the other. Each circuit is controlled by an independent control card with automatic following to enable smooth transfer from one to the other. Transfer to the standby system is initiated by a separate monitor module in the following circumstances: Ø Voltage monitoring (over/under voltage on generator terminals) Ø Excitation monitoring (over/under excitation with time delays) Ø Over flux monitoring Ø Control card failure The settings for the monitor module are selected to enable the normal limiter settings to operate first. (See Figure 2)
Figure 2: Generator Capability Diagram 3) PC Based Setup And Maintenance Software The unit is provided with PC based setup and maintenance software and cable for connection to a standard PC 9 pin serial port. A PC is required to setup the A30. 4) Communication Port #1 For SCADA Communications Provided to allow plant supervision computers to adjust setpoints and inspect generator and excitation system data. Implemented using Modbus protocol. 5) Communication Port #2 For Set Up And Maintenance Provided for connection to an RS232 port on a standard PC for commissioning. 6) Choice Of Setpoint Adjustment Method Either external raise/lower contacts or SCADA communications may be used. 7) Line Voltage Control Mode In Line Voltage Control Mode, line voltage is controlled to a constant adjustable setpoint. In this mode, parallel running capability is provided using quadrature current compensation (QCC) with an adjustable droop setting. 8) Power Factor Control Mode Available when parallel running.
HB959202000 (J) A30 Excitation Controller.doc
© Brush Electrical Machines Ltd. 2003
PRISMIC A30 Excitation Controller Manual No: HB959202000
Issue: J
Date: 30 May 2003
Page: 11 of 126
9) VAr Control Mode Available when parallel running. Also incorporates VAr shed facility. 10) Soft Start Facility After switching on excitation, line voltage is increased to the nominal level at an adjustable rate. 11) Fast Acting Field Current Limiter Limits excitation current to prevent excessive line current during power system faults. 12) Over Excitation Limiter Using inverse time delay and temperature compensation if required, this facility is provided to prevent overheating of the generator rotor. 13) Under Excitation Limiter This facility enables operation of the generator at maximum capability with a leading power factor but avoiding the danger of the generator pole slipping. 14) Over Flux Limiter Excitation is controlled to ensure that generator line voltage is limited to a preset adjustable voltage/frequency ratio to avoid over fluxing of the generator. 15) Selectable Standby System Control Mode The standby system may be setup to operate in either Generator Voltage or Exciter Field Current Control Mode. 16) Rotating Diode Failure Alarm Detection of failed rotating diode or fuse is achieved by monitoring the ripple content of exciter field current. 17) Adjustable Step Response This facility enables an adjustable step increase in setpoint to be applied to evaluate the stability settings of the excitation system. The PID parameters of the AVR may then be adjusted accordingly. The rise time and overshoot values are recorded to help with commissioning. The step reduction in setpoint may be used to evaluate the response of the underexcitation limiter. 18) Event Recorder A log of major events, such as limiter and monitor operations, and field suppression is maintained within the unit. The events may be displayed using a PC connected to the commissioning communications port.
HB959202000 (J) A30 Excitation Controller.doc
© Brush Electrical Machines Ltd. 2003
PRISMIC A30 Excitation Controller Manual No: HB959202000 6
Issue: J
Date: 30 May 2003
Page: 12 of 126
SPECIFICATION 6.1
A30-CON Card Unless stated otherwise, all adjustments on this card are made using the HMI. 6.1.1
Voltage Control 1) Three Phase Or Single Phase Sensing Selected by a link. 2) Accuracy ±0.5% of mean voltage. 3) Nominal Sensing Voltage Selectable from 100V to 120V in 5 volt increments. Frequency 50/60Hz ±10%. Burden
