ALSPA CSR620

DIGITAL AUTOMATIC SYNCHRONIZER FOR GENERATOR

VERSION A1

COMMISSIONING MANUAL

DIFFUSION : CONFIDENTIELLE � RESTREINTE � CONTROLEE � LIBRE �ACCESSIBILITY CONFIDENTIAL RESTRICTED CONTROLLED FREE

DATE

NOMNAME

SIGNATURE

ETABLIESTABLISHED

BACLIN

RANGE 620

VERIFIECHECKED

CHEHU

APPROUVEAPPROVED

MONTEL

P S M 7 0 A 4 5 2 8 5REV STAT. F°/F° FIN

SH/SH ENDNb F°N of SH

C GFE 1/39 39

PA 4

00

D

abcd PowerElectrical and Control Systems

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TABLE DES MODIFICATIONS / MODIFICATIONS TABLE

REV ETABLIESTABLISHED

VERIFIECHECKED

APPROUVEAPPROVED

DATE MODIFICATIONS STAT.

A BACLIN CHEHU FERRAUT 19.01.99 First issue GFE

B BACLIN CHEHU MONTEL 12.09.00 Change of corporate name GFE

C BACLIN CHEHU MONTEL 22.02.02 Up to date for connecting details GFE

PA 4

01

C

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CONTENTS

1 EQUIPMENT ACCEPTANCE ........................................................................................ 4

2 ASSEMBLY INSTRUCTIONS........................................................................................ 5

3 CONNECTION INSTRUCTIONS.................................................................................. 6

4 EQUIPMENT ADJUSTMENTS ..................................................................................... 7

4.1 GENERAL PARAMETER CONFIGURATION .................................................................................84.2 FREQUENCY EQUALIZATION CONFIGURATION ........................................................................84.3 VOLTAGE EQUALIZATION CONFIGURATION............................................................................84.4 SYNCHRONIZING CONFIGURATION......................................................................................94.5 MEASUREMENT CONFIGURATION .......................................................................................10

5 PRELIMINARY CHECKS............................................................................................ 11

5.1 FOR AUXILIARY POWER SUPPLY 19 TO 60 VDC ...........................................................115.2 FOR AUXILIARY POWER SUPPLY 80 TO 150 VDC .........................................................12

6 PRELIMINARY TESTS ............................................................................................... 13

7 PASSWORD, DIALOGUE.......................................................................................... 16

8 APPENDICES ........................................................................................................... 17

8.1 APPENDIX 1: SYNCHRONIZER MENUS AND SUB-MENUS ........................................................17Access to main menu ..........................................................................................................178.1.2 Parameters Visualization Menu ..................................................................................188.1.3 Parameters Configuration Menu ................................................................................248.1.4 Status Visualization Menu..........................................................................................308.1.5 Default visualization menu.........................................................................................348.1.6 Default acquittal menu..............................................................................................358.1.7 Calibration menu......................................................................................................36Initial Configuration Menu...................................................................................................37

8.2 LIST OF MESSAGES ..........................................................................................................388.3 LIST OF ALARMS..............................................................................................................39

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1 EQUIPMENT ACCEPTANCE

This package corresponds to one Alspa CSR 620 Version A1 automatic synchronizerand contains:

- One appliance equipped with EEPROM memories, configured for an A1 version.

- Plug-in rear connectors for P1, P2, P3, P6 (when necessary) external connections.

- Two attaching brackets (for panel mounting).

- One set of ferrites for electromagnetic compatibility.

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2 ASSEMBLY INSTRUCTIONS

On reception of the equipment, make sure it is in good apparent condition, otherwisemake all necessary reservations with the haulage company.

Assemble the equipment either in a 1/2 rack 19" 3U or flush-mounted on a panelusing the two attaching brackets provided for the purpose.

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3 CONNECTION INSTRUCTIONS

Refer to the connection diagram of the technical manual. Connections will be onrear plug-in connectors P1, P2, P3, P6 (when necessary) by spring type connection(the spring is spread for the passage of the wire using a screwdriver with access in theupper part of the connector).

To comply with instructions concerning electromagnetic compatibility, it is advisableto :

. Clip a 1-turn ferrite onto the auxiliary power supply cable as close as possible tothe synchronizer connector.

. Clip a 1-turn ferrite onto the asynchronous side analog input cable.

. Clip a 1-turn ferrite onto the synchronous side analog input cable.

. Use the threaded rod at the back of the unit, provided for the purpose, toconnect the unit as directly as possible to ground via a flat ground braid.

. Connect ground as directly as possible to the synchronous and asynchronousvoltage measurement cable shields.

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4 EQUIPMENT ADJUSTMENTS

To ease commissioning operations, the equipment is set up with standard ex-worksvalues as indicated in the table below.

Note : At the end of the manual, consult the complete and detailed menus with their usefor display, configuration, etc.

General parameters Synchronizing

Modbus speed 9600 BaudsModbus parity evenModbus stop bit format 1 bitModbus address 1Language English/French

(depending on project)

Closing time CB1 0.20 sUS1 Nominal (depending on project)∆U max. 8%∆F max. 0.1 HzMinimum slippage 0.02 HzMin. slip time 3 sMax. dephase 1°Dead network type NoneDead Umin. 70% USDead Umax. 10% USDead network time delay 5 sDead network time (order) 0.30 sAnti-pumping 2 s

Frequency equalization

Gain F 5 s/HzPeriod 3 sAction max. 70% (of period)Action min. 10% (of period)Load sharing 0sSlip 50% ∆F max.

Voltage equalization Measurements

Gain U 5s/VInsensitivity 0% USPeriod 3 sAction max. 70% (of period)Action min. 10% (of period)

Phase compensation 0°Voltage compensation 100%Asynchronous voltage calibration Factory settingSynchronous voltage calibration Factory settingPhase calibration Factory setting

Note : Switching to the configuration mode during a synchronizer "working" phase willcause an alarm to be generated and thus inhibit its operation for the time neededfor configuration. This is a safety measure designed to avoid any risks ofinadvertent order transmissions.

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1.14.1 GENERAL PARAMETER CONFIGURATION

This menu is used for setting up the MODBUS serial link and choosing the languagefor man-machine dialogue.

1.24.2 FREQUENCY EQUALIZATION CONFIGURATION

These parameters can be left as set in the works for the initial tests, then correctedduring these tests.

Note :

The synchronizer does not ensure absolute equalization of the FA=FS frequencies. Itadjusts a very slight slippage at coupling, depending on ∆F max. (maximumfrequency deviation on coupling).

This slide is adjustable from 10% to 90% of ∆F max, with FA>FS.

This operation means that there is no need for a release pulse when the system isblocked with FA=FS and ϕ ≠ 0.

1.34.3 VOLTAGE EQUALIZATION CONFIGURATION

These parameters can be left as works settings for the first test, then corrected.

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1.44.4 SYNCHRONIZING CONFIGURATION

Synchronizing with lead time

- Adjust the closing time parameter for CB1.

This parameter corresponds to the time separating the order transmitted by thesynchronizer (at the output contact) and the effective closing of the coupling circuit-breaker. This time is the total of the circuit-breaker closing time and theintermediate relay pull-in time. The most reliable method consists in recording, forinstance using the synchronizer calibration function.

- Check that the value of rated voltage US1 corresponds accurately to the nominalrms value of PT for the synchronous voltage (circuit-breaker network side).

- Adjust ∆Umax. the maximum voltage deviation permitting coupling, to the desiredvalue.

- Adjust ∆Fmax., the maximum frequency deviation permitting coupling, to the valuedesired for coupling with the lead time.

Synchronizing without slippage:

- Set the parameters permitting coupling without slippage to the desired values:minimum slippage, time delay, maximum phase-shift.

Dead network coupling:

- Configure the dead network parameters as necessary: dead network type, voltagepresence side under-voltage, voltage absence side over-voltage, time delay,closing order duration.

Circuit-breaker anti-pumping:

- Adjust the corresponding time delay to set the minimum time to separate twosynchronizing orders.

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4.5 MEASUREMENT CONFIGURATION

- Check that the phase and voltage compensation parameters correspond to theactual installation:

. The value of the phase compensation parameter is added to the asynchronousside phase value.

. The value of the voltage compensation parameter is applied to the voltage onthe asynchronous side.

IMPORTANT NOTE:

- As a safety concern, phase and voltage compensation parameters are configuredto be inoperative in the works.

It is important to check that they agree with the installation when the synchronizer isput into operation and after any modification liable to induce a difference (phaseor voltage) between the network and generator voltages.

- The calibrations of the synchronous and asynchronous voltages, and of the phase,are carried out in the works and do not normally need to be reworked.

However, if the need does arise, it is then necessary to inject standard signals intothe network and generator inputs and to calibrate the corresponding values (menu"P.C. Meas" = measurement parameters configuration), to obtain, on theequipment:

- U synchronous = value of standard network voltage

- U asynchronous = value of standard generator voltage

- Phase differential = 0 (for network and generator standard voltages that areaccurately in phase).

("State Visualisation" menu, "Measure V." sub-menu).

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5 PRELIMINARY CHECKS

- Check the connection of the equipment on the rear connectors.

5.1 FOR AUXILIARY POWER SUPPLY 19 TO 60 VDC

- Check the rotating fields either side of the circuit-breaker, using the habitualmethod.

ABCD

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5.2 FOR AUXILIARY POWER SUPPLY 80 TO 150 VDC

- Check the rotating fields either side of the circuit-breaker, using the habitualmethod.

ABCD

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6 PRELIMINARY TESTS

- Switch out the synchronizing order supplied by the equipment by disconnecting awire or by inhibiting the circuit-breaker.

- Once the network and alternator voltages are connected, energize the equipment.The display will then indicate "CSR620 WAITING" once the starting self-test iscomplete.

- Set the alternator frequency to a value close to that of the network.

- Check that the synchronization operates properly, generating speed orderscorresponding to the system status. If necessary, readjust the speed equalizationparameters in the "Frequency Equalization Parameters Configuration" menu toobtain correct speed equalization action.

- Carry out manual coupling and check, in the "Measurement visualization" menu,that:

• The frequency deviation is zero.

• The voltage deviation is zero.

• The phase deviation is zero.

IMPORTANT :

If the phase deviation is not zero under these conditions, there are several possiblecases:

1. For a phase deviation |ϕ| ≤ 5° and ≠ 0°, readjust the phase calibration factorysettings on the circuit-breaker using the "Measurement ParametersConfiguration" on the menu. See the corresponding paragraph for thiscalibration.

2. For a phase deviation |ϕ| > 5°, there are two possibilities:

2.1 There is an error in the phase identification.

2.2 A phase adjusting has been configured on the equipment and it is notcompliant with the installation.In this case, reconfigure this parameter correctly in the "MeasurementParameters Configuration" menu.

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• When the machine is synchronized and there is no active and reactive powerexchange, if the voltage difference is more than 0, readjust the calibrationfunction settings of the synchronous and asynchronous voltages in the"Measurement Parameters Configuration" menu. See the correspondingparagraph for these calibrations.

- Unsynchronize the alternator

Form a voltage deviation between the network and the alternator, by manuallyadjusting the alternator voltage regulation. Check that the synchronizer correctsthis deviation. Observe the obtained response and if necessary, readjust theequalization parameters (in the "Voltage Equalization Parameters Configuration"menu to obtain the desired action. Repeat the test until a satisfactory response isobtained. If necessary, set insensitivity on the equalization.

- Check that the equipment supplies the synchronizing order slightly beforeswitchover into phase. This time corresponds to the lead time set on thesynchronizer.

- Check that the synchronizing order is locked when the voltage deviation exceedsthe displayed value.

- Check that operation in the dead network mode is compliant with settings for theinhibition and transmission of the corresponding synchronizing orders (validationof voltage thresholds, time delays, action direction, etc.).

- Once all these checks have been performed, it will be possible to carry out realsynchronizing.

Note:

The "Circuit-breaker closed Status" logic input switches the synchronizer to the"Waiting" mode.

The same applies in the absence of logic information such as "Circuit-breaker closingrequest" and "Authorization to close dead network". Accordingly, the equipment canremain powered and connected at all times, without needing to be switched out whencoupling is accomplished.

Precautions to be taken during commissioning:

- Avoid disconnecting the rear connectors when the equipment is energized so as notto run the risk of generating short-circuits that could cause accidental deteriorationor the inadvertent closing of the circuit-breaker.

- When the synchronizer is put into service, check the agreement of the phase andvoltage adjustment parameters with the installation.

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ADVANCE TIME CALIBRATION

This function enables Alspa CSR620 to measure the effective time between thetransmission of a coupling order and the reception of closed circuit-breakerinformation.

This means that the operator knows accurately the advance time to be set on theequipment, and thereby can obtain a zero phase-shift synchronizing.

To make this measurement, the following conditions must be established:

- Absence of voltage on both sides of the circuit-breaker (if necessary, for optimumsafety, disconnect the circuit-breaker on the network side and on the alternatorside).

- Absence of synchronizing request information.

- Absence of alarms.

- Presence of dead network closing enabling information.

Once calibration is complete, the circuit-breaker closing time duration will appear onthe Alspa CSR620 display.

The introduction of this value as an advance time is left to the initiative of theoperator.

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7 PASSWORD, DIALOGUE

- The principle of man-machine dialogue is the display of pull-down menus andpull-down sub-menus.

- All these menus and sub-menus are detailed below in the Appendix.

- When requested, enter the following password:

Left Escape Left Escape

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8 APPENDICES

8.1 APPENDIX 1: Synchronizer menus and sub-menus

8.1.1 Access to main menu

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8.1.2 Parameters Visualization Menu

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8.1.2.1 General Parameters Visualization Sub-menu

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8.1.2.2 Frequency Equalization Parameters Visualization Sub-menu

The association of gain adjustments and the ± speed pulse period contributes to thedesired correction:

- the higher the gain, the quicker the deviation will be compensated

- the shorter the period, the more ± speed orders will be transmitted.

When the calculated duration of the ± speed pulses exceeds the configured min/max.limits, the duration indicated by the corresponding limit is the one that will beapplied.

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8.1.2.3 Voltage Equalization Parameters Visualization Sub-menu

The association of the gain adjustments and the period of the ± U pulses contributesto the desired correction:

- the higher the gain, the more quickly the deviation will be compensated

- the shorter the period, the more ± U orders will be transmitted.

When the calculated duration of the ± U pulses exceeds the configured min. andmax. limits, the duration indicated by the corresponding limit is the one that will beapplied.The set insensitivity range is a way of avoiding the transmission of excessively shortpulses when the deviation to be compensated is very small. In this way, theassociated electromechanical systems are not pointlessly fatigued.

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8.1.2.4 Synchronizing Parameters Visualization Sub-menu

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8.1.2.5 Measurement Parameters Visualization Sub-menu

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8.1.3 Parameters Configuration Menu

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8.1.3.1 General Parameter Configuration Sub-menu

Notes:

� To change digits and modify the value of that digit only, move the cursor with the

or keys, then increment/decrement the digit selected by means of the or

keys.

� To validate the configuration, type .

To exit without validating the configuration, type .In both cases, the cursor then moves to the upper line of the display.

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8.1.3.2 Frequency Equalization Parameters Configuration Sub-menu

� and �: See notes in paragraph 8.1.3.1.

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8.1.3.3 Voltage Equalization Parameters Configuration Sub-menu

� and �: See notes in paragraph 8.1.3.1.

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8.1.3.4 Synchronizing Parameters Configuration Sub-menu

� and �: See notes in paragraph 8.1.3.1.

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8.1.3.5 Measurement Parameters Configuration Sub-menu

� and �: See notes in paragraph 8.1.3.1.

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8.1.4 Status Visualization Menu

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8.1.4.1 Measurements Visualization Menu

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8.1.4.2 Logic Input Visualization Menu

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8.1.4.3 Logic Variables Visualization Menu

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8.1.5 Default visualization menu

This menu contains all the internal or external alarms detected by the synchronizer.

- Some alarms will be self-acknowledged as soon as the observed default hasdisappeared.

- Other alarms must be acknowledged in the corresponding menu so as to enablethe system to return to the "working" mode. They are indicated by an "*".

- Other alarms may not be acknowledged. For this purpose, it is necessary to returnthe equipment to the works for repair.

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8.1.6 Default acquittal menu

Pressing on the key will acknowledge the displayed alarm.

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8.1.7 Calibration menu

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8.1.8 Initial Configuration Menu

Using this function, the equipment is reinitialized with the initial works configurationparameters.

Caution: These parameters are not the standard works settings of the table inparagraph 4.

These are basic parameter values enabling the software to operate, but without anytie-in with adjustments made for delivery.

Accordingly, after having activated this function, it is necessary to go through all theconfiguration parameter settings, one by one, to obtain a synchronizer havingparameters compliant with the installation (table of paragraph 4).

This is particularly true for everything concerning adjustments and calibrations inphase and voltage.

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8.2 LIST OF MESSAGES

Message Significance

Test in progress Displayed on startup, when the equipment is energizedthroughout the self-test period (a few seconds)

RAM test fault The startup self-test has detected an operating problem in theRAM

Default present! The user is attempting to enter into calibration dialogue whenthere is a fault present.

Enter password now : Type the password to obtain access to the continuation of thedialogue

Work in progress The user is attempting to access a dialogue mode (calibration orinitial configuration) while CSR 620 is in the "working" mode.Access is then denied.

ROM LSB disabled The startup self-test has detected an internal problem.

ROM MSB disabled The startup self-test has detected an internal problem.

2 ROM US disabled The startup self-test has detected an internal problem.

Out of range The visualized parameter is outside the acceptable measurementrange and therefore cannot be displayed

Wrong passwordTry again

Appears after incorrect password entry test

Wrong password Appears after second incorrect attempt at password entry

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8.3 LIST OF ALARMS

Alarm Significance

No default present Appears in default visualization menu when there is no default.

Interference IT of level Internal problem detected. This alarm disappears one secondlater unless it is fleeting. If the problem persists, return theequipment to the works for troubleshooting.

Problem xxxx task Internal problem detected

Undefined equipment The equipment has not been works customized and is unsuitablefor operation as it is

Interface missing or off Internal problem detected. If the problem persists after de-energizing then commissioning, return it to the works for repair

Interface unknown type Same as above

UCMU type 1ISYN type 2

Internal problem detected. Alarm can be acknowledged by user

Bad config. Heading Internal problem detected. Alarm can be acknowledged by user

Reconfig. via Modbus Overall downloading of configuration by MODBUS link underway

Bad config. version Internal problem detected. Alarm can be user acknowledged

Config. problemEven RAM/PROM

Internal problem detected

Config. problemOdd RAM/PROM

Internal problem detected

Config. Pb.PROM writing

Problem occurring during modification of configuration. Alarmcan be user acknowledged

Config. Pbxxxx Menu

Problem of configuration in menu concerned. Modify theincorrect parameters in this menu, then confirm the configuration

Default test channel xxxx Internal problem detected

F x FrequencyCB out range

Frequency FA or FS outside measurable range

Ux VoltageCB out range

Voltages UA or US outside measurable range

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Alarm Significance

No reread of given order Internal problem detected. Alarm can be user acknowledged

Bad CB closing time The measured circuit-breaker closing time is different by at least50% from the configured circuit-breaker closing time. Alarm canbe user acknowledged

Unjustified reread order Internal problem detected. Alarm can be user acknowledged

Offset MeasXn too large

Internal problem detected. Alarm can be user acknowledged