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Instruction Manual PRISMIC A32 EXCITATION CONTROLLER

Manual No: TP0001096 Issue: C Date: 5 August 2010

BRUSH Electrical Machines Ltd. Falcon Works, Nottingham Road, Leicestershire. LE11 1EX. United Kingdom Telephone: +44 (0) 1509 611511 Fax: +44 (0) 1509 612009 E-Mail: [email protected] Web Site: http://www.brush.eu

PRISMIC A32 EXCITATION CONTROLLER Manual No: TP0001096

Issue: C

Date: 5 August 2010

Page: 2 of 95

CONTENTS 1 INTRODUCTION TO MANUAL .................................................................................................... 5 1.1 General.......................................................................................................................................... 5 1.2 How To Use the Manual................................................................................................................ 5 1.3 Copies & Revisions ....................................................................................................................... 6 1.4 Feedback....................................................................................................................................... 6 1.5 Service & Spares .......................................................................................................................... 6 1.6 Contact Address............................................................................................................................ 6 1.7 Health & Safety At Work Act (1974............................................................................................... 7 1.8 Protection And Monitoring Devices............................................................................................... 8 2 EU DIRECTIVES........................................................................................................................... 9 3 INTRODUCING THE PRISMIC A32 EXCITATION CONTROLLER.......................................... 10 4 RATINGS .................................................................................................................................... 11 5 FEATURES................................................................................................................................. 13 6 SPECIFICATION ........................................................................................................................ 16 6.1 General........................................................................................................................................ 16 6.2 Controls ....................................................................................................................................... 16 6.2.1 Voltage Control ...................................................................................................................... 16 6.2.2 Quadrature Current Compensation (QCC) ............................................................................ 16 6.2.3 Over-Flux Limiter ................................................................................................................... 17 6.2.4 Soft Start ................................................................................................................................ 17 6.2.5 Speed Detection .................................................................................................................... 17 6.2.6 Power Factor Or Reactive Current (VAr) Control .................................................................. 17 6.2.7 Over Excitation Limiter........................................................................................................... 17 6.2.8 Under Excitation Limiter......................................................................................................... 18 6.2.9 Fast Acting Field Current Limiter ........................................................................................... 18 6.2.10 Automatic Tracking Of Active Regulator................................................................................ 18 6.2.11 Indications .............................................................................................................................. 18 6.2.12 Output Signals........................................................................................................................ 19 6.2.13 Output Voltage ....................................................................................................................... 19 6.2.14 Local Serial Communication Ports......................................................................................... 19 6.2.15 Remote Communications Facility .......................................................................................... 19 6.3 Monitors....................................................................................................................................... 20 6.3.1 General .................................................................................................................................. 20 6.3.2 Over Voltage Monitor ............................................................................................................. 20 6.3.3 Over Flux Monitor .................................................................................................................. 20 6.3.4 Under Voltage Monitor ........................................................................................................... 20 6.3.5 Over Excitation Monitor.......................................................................................................... 20 6.3.6 Under Excitation Monitor........................................................................................................ 21 6.3.7 Monitor Indications................................................................................................................. 21 6.3.8 Monitor Output Signals .......................................................................................................... 21 6.3.9 Monitor Latch/Reset............................................................................................................... 21 6.3.10 Monitor Inhibit......................................................................................................................... 21 6.3.11 Local Serial Communication Port........................................................................................... 21 6.3.12 Remote Serial Communications Facility ................................................................................ 21 7 A32 ENCLOSURE OVERVIEW ................................................................................................. 22 7.1 A32 Front Panel .......................................................................................................................... 22 7.2 A32 Rear Connections ................................................................................................................ 23 8 FUNCTIONAL DESCRIPTION ................................................................................................... 24 8.1 Generator Terminal Voltage Regulation Loop ............................................................................ 24 8.2 Generator Terminal Voltage Reference ...................................................................................... 25 8.3 Generator Terminal Voltage With Reactive Power Compensation............................................. 26 8.4 Power System Stabiliser PSS2B ................................................................................................ 27 8.5 Limiters........................................................................................................................................ 31 8.5.1 Over Excitation Limiter (OEL) ................................................................................................ 31 8.5.2 Stator Current Limiter (SCL) .................................................................................................. 32 8.5.3 Under Excitation Limiter (UEL) .............................................................................................. 34 8.5.4 Over Flux (V/Hz) Limiter ........................................................................................................ 35 8.5.5 Generator Terminal Voltage Limiter....................................................................................... 36 8.6 Automatic Voltage Regulator (AVR) ........................................................................................... 36 TP0001096 (C) PRISMIC A32 Excitation Controller.doc

© BRUSH Electrical Machines Ltd. 2010

PRISMIC A32 EXCITATION CONTROLLER Manual No: TP0001096 8.7 8.7.1 8.7.2 9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 10 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 10.13 10.14 11 11.1 11.2 11.3 11.4 11.5 12 12.1 12.2 12.2.1 12.2.2 12.2.3 12.2.4 12.2.5 13 13.1 13.2 13.3 13.4 13.5 13.5.1 13.5.2 13.6 13.7 14 14.1 14.2 14.3 14.4 14.5 14.6 14.6.1 14.6.2

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Date: 5 August 2010

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Add On Regulators...................................................................................................................... 38 Reactive Power (Q) Regulator (Or VAr Control) and Power Factor (PF) Regulator ............. 38 Field Current Regulator.......................................................................................................... 38 A32 CAPABILITY DIAGRAM EDITOR ...................................................................................... 40 Using The Editor ......................................................................................................................... 40 Edit Options................................................................................................................................. 40 Saving And Reloading Data ........................................................................................................ 41 Using The Custom Data File ....................................................................................................... 41 Curve Editor ................................................................................................................................ 42 Power Factor Lines ..................................................................................................................... 43 Label Editor ................................................................................................................................. 44 Scales Editor ............................................................................................................................... 45 WINDOWS HMI COMMISSIONING SOFTWARE...................................................................... 46 Introduction ................................................................................................................................. 46 Commissioning Parts .................................................................................................................. 46 Commissioning PC...................................................................................................................... 46 PC Software Installation.............................................................................................................. 46 Running the HMI Application....................................................................................................... 46 HMI Configuration ....................................................................................................................... 46 Exiting The HMI Application ........................................................................................................ 46 HMI Displays Available ............................................................................................................... 46 Trending ...................................................................................................................................... 46 Presets ........................................................................................................................................ 46 HMI Default Passwords............................................................................................................... 46 Changing A Preset, Setting A Parameter ................................................................................... 47 Maintenance................................................................................................................................ 47 Logging........................................................................................................................................ 47 PSS TESTING ............................................................................................................................ 49 General........................................................................................................................................ 49 Test Modes Of The PSS ............................................................................................................. 50 Switching Off Filters .................................................................................................................... 50 Test Signals ................................................................................................................................ 51 Testing Window........................................................................................................................... 52 ANALOG DATA LOGGING........................................................................................................ 54 ‘Logging Chart’ Parameters: ....................................................................................................... 54 Analog Logging Wizard ............................................................................................................... 56 Analog Logging Wizard Step 1 .............................................................................................. 56 Analog Logging Wizard Step 2 .............................................................................................. 57 Analog Logging Wizard Step 3 .............................................................................................. 57 Analog Logging Wizard Step 4 .............................................................................................. 58 Analog Logging Wizard Step 5 .............................................................................................. 59 INSTALLATION AND MECHANICAL DETAILS ....................................................................... 61 Introduction ................................................................................................................................. 61 Installation ................................................................................................................................... 62 Ventilation.................................................................................................................................... 62 Wiring To The A32 Excitation Controller..................................................................................... 62 Wiring To The Plug ..................................................................................................................... 63 Method 1 ................................................................................................................................ 63 Method 2 (Using The Special Lever To Open The Cage Clamp).......................................... 63 Safety .......................................................................................................................................... 64 Mechanical Details ...................................................................................................................... 64 COMMISSIONING ...................................................................................................................... 65 Introduction ................................................................................................................................. 65 The Per Unit System ................................................................................................................... 65 Commissioning Software ............................................................................................................ 65 Applying Test Steps To Vref ....................................................................................................... 65 Protection Testing (Exciter Field Current Control) ...................................................................... 66 A32 Parameters And Set Up....................................................................................................... 67 Explanation Of The Commissioning Presets ......................................................................... 67 The Operating States............................................................................................................. 69

TP0001096 (C) PRISMIC A32 Excitation Controller.doc

© BRUSH Electrical Machines Ltd. 2010

PRISMIC A32 EXCITATION CONTROLLER Manual No: TP0001096 14.6.3 14.6.4 14.6.5 14.6.6 14.6.7 14.6.8 14.6.9 14.6.10 14.6.11 14.6.12 14.6.13 14.6.14 14.6.15 14.6.16 14.6.17 14.6.18 14.6.19 14.6.20 14.6.21 14.6.22 14.6.23 14.6.24 14.7 14.7.1 14.7.2 15 16

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Pre-Commissioning Checks................................................................................................... 69 Calibration Of Exciter Field Current ....................................................................................... 70 Calibration Of Exciter Field Voltage Sensor .......................................................................... 71 Adjustment Of Terminal Current Sensing .............................................................................. 72 Adjustment Of Terminal Voltage Sensing.............................................................................. 73 Automatic Excitation To 80% Terminal Voltage..................................................................... 73 Checking Voltage Reference Range - No Load..................................................................... 74 No Load Step Response Testing ........................................................................................... 75 Smooth Transfer Between Channels And Between Operation States .................................. 76 Testing the V/f Limiter ............................................................................................................ 77 Testing The Terminal Voltage Limiter.................................................................................... 79 Checking Reactive Power Sensing Polarity........................................................................... 79 Testing The Over Excitation Limiter....................................................................................... 81 Testing The Stator Current Limiter......................................................................................... 82 Testing Under Excitation Limiter ............................................................................................ 84 Testing Under Voltage Monitor (Minimum Terminal Voltage Monitor, Utmin Monitor) .......... 85 Testing Over Flux Monitor (Also Called U/F Monitor) ............................................................ 86 Testing Over Voltage Monitor (Also Called Maximum Terminal Voltage Monitor Or Utmax MON)...................................................................................................................................... 87 Testing Over Excitation Monitor (OEM) ................................................................................. 88 Testing Under Excitation Monitor (UEM) ............................................................................... 88 Testing Quadrature Current Compensation........................................................................... 90 Reactive Load Rejection ........................................................................................................ 90 VAr And Power Factor Regulation .............................................................................................. 91 Check Of VAr Regulation....................................................................................................... 92 Check Of PF Regulation ........................................................................................................ 93 SPARE PARTS........................................................................................................................... 94 ATTACHMENTS & DRAWINGS ................................................................................................ 95

TP0001096 (C) PRISMIC A32 Excitation Controller.doc

© BRUSH Electrical Machines Ltd. 2010

PRISMIC A32 EXCITATION CONTROLLER Manual No: TP0001096

Issue: C

Date: 5 August 2010

Page: 5 of 95

1

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. 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 Prior to undertaking any installation, commissioning, operation or maintenance activities on the equipment, it is recommended that 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.

TP0001096 (C) PRISMIC A32 Excitation Controller.doc

© BRUSH Electrical Machines Ltd. 2010

PRISMIC A32 EXCITATION CONTROLLER Manual No: TP0001096 1.3

1.4

1.5

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Date: 5 August 2010

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Copies & Revisions Additional copies of the latest available version of manuals are available from BRUSH Aftermarket 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. 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 BRUSH Aftermarket at the contact address given hereafter. Service & Spares Quotations for Service and Spares can be obtained from BRUSH Aftermarket at the contact address given hereafter. Spare parts information, including prices and lead times, can be obtained from the Web Site address given hereafter.

1.6

BRUSH Aftermarket provides service support 24 hours a day, 7 days a week. We supply first class replacement parts, carry out service inspections and maintenance programmes, upgrades and repairs, and comprehensive training programmes for both BRUSH and third party generators and ancillary products. Further information on BRUSH Aftermarket can be found on our website (see details below). Contact Address BRUSH Aftermarket BRUSH Aftermarket Falcon Works Tř. Edvarda Beneše 39/564 Nottingham Road 301 00 Plzeň Loughborough Czech Republic Leicestershire LE11 1EX T: +420 37 8210717 United Kingdom F: +420 37 8210337 E: [email protected] T: +44 (0) 1509 611511 F: +44 (0) 1509 612436 BRUSH Aftermarket 15110 Northwest Freeway E: [email protected] Suite 150 Houston BRUSH Aftermarket PO Box 3007 Texas 77040 2980 DA USA Ridderkerk The Netherlands T: +1 281 580 1314 F: +1 281 580 5801 T: +31 (0) 180 445500 E: [email protected] F: +31 (0) 180 445445 E: [email protected]

TP0001096 (C) PRISMIC A32 Excitation Controller.doc

© BRUSH Electrical Machines Ltd. 2010

PRISMIC A32 EXCITATION CONTROLLER Manual No: TP0001096

Issue: C

BRUSH Aftermarket PO Box 111209 Abu Dhabi United Arab Emirates T: +971 4362 6391 F: +971 2550 1920 E: [email protected] BRUSH Turbogenerators World Trade Centre Suite 1803 500 Guangdong Road Shanghai 200001 P.R. China

Date: 5 August 2010

Page: 7 of 95

BRUSH Aftermarket Lot 7 Jalan Majustret U1/26 Hicom Glenmarie Ind. Park 40150 Shah Alam Selangor DE Malaysia T: +60 3 705 3736 F: +60 3 703 9625 E: [email protected]

T: +86 21 63621313 F: +86 21 63621690 E: [email protected]

1.7

Company Web Site: http://www.brush.eu http://www.eshop.brush.eu Spares Web Site: 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. 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.

TP0001096 (C) PRISMIC A32 Excitation Controller.doc

© BRUSH Electrical Machines Ltd. 2010

PRISMIC A32 EXCITATION CONTROLLER Manual No: TP0001096

Issue: C

Date: 5 August 2010

Page: 8 of 95

Adjustment and fault finding on live equipment must be by qualified and authorised personnel only, and should be in accordance with the following rules: • Read the Instruction Manual. • Use insulated meter probes. • Use an insulated screwdriver for potentiometer adjustment where a knob is not provided. • Wear non-conducting footwear. • Do not attempt to modify wiring. • Replace all protective covers, guards, etc. on completion.

1.8

Operation & Maintenance: Engineers responsible for operation and maintenance of equipment supplied under this contract should familiarise themselves with the information contained in this manual and with the recommendations given by manufacturers of associated equipment. They should be familiar also with the relevant regulations in force. • 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 machine is started. • All adjustments to the 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. • 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. • When power is restored to the equipment, personnel should not be allowed to work on auxiliary circuits, e.g. Heaters, temperature detectors, current transformers etc. 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.

TP0001096 (C) PRISMIC A32 Excitation Controller.doc

© BRUSH Electrical Machines Ltd. 2010

PRISMIC A32 EXCITATION CONTROLLER Manual No: TP0001096 2

Issue: C

Date: 5 August 2010

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EU DIRECTIVES

TP0001096 (C) PRISMIC A32 Excitation Controller.doc

© BRUSH Electrical Machines Ltd. 2010

PRISMIC A32 EXCITATION CONTROLLER Manual No: TP0001096 3

Issue: C

Date: 5 August 2010

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INTRODUCING THE PRISMIC A32 EXCITATION CONTROLLER The PRISMIC A32 Excitation Controller is designed to control the excitation of a brushless generator. Incorporating a wide range of features, the A32 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 A32 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 A32 in the form of a BRUSH QC(T)48 document. When provided with a BRUSH generator, the A32 factory setup data will be matched to the generator. The QC(T)48 document should be available when commissioning the A32.

Figure 1: A32 Excitation Controller Scheme

TP0001096 (C) PRISMIC A32 Excitation Controller.doc

© BRUSH Electrical Machines Ltd. 2010

PRISMIC A32 EXCITATION CONTROLLER Manual No: TP0001096 4

Date: 5 August 2010

Issue: C

RATINGS Max. continuous output current:

25A

Max. 10 second output current:

40A

Excitation supply voltage:

a.c. 110V to 330V single phase

Control circuitry supply voltage:

a.c. 115V to 270V single phase or d.c. 24V +15%, -20% or d.c. 110/125Vdc +15%

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(a.c. and d.c. supplies may be used together for increased integrity and to enable adjustment of settings with only d.c. available) Excitation supply frequency:

50Hz to 480Hz

Auxiliary dc Supply:

24Vdc +15%, -20% or 110/125Vdc +15%

Nominal sensing voltage:

100V to 120V selectable in 0.1V steps

Voltage sensing phases:

Three phase with single phase option

Voltage sensing input burden:

Less than 0.5VA per phase

Nominal generator frequency:

50Hz or 60Hz

*Current transformer input nominal:

5A or 1A.

Current transformer input burden:

Less than 0.5VA

Max. field voltage for forcing:

75% of single phase supply RMS voltage

Min. field voltage for negative forcing:

-75% of single phase supply RMS voltage

Accuracy of control:

±0.25%

Operating temperature range:

-20ºC to +55ºC

Storage temperature range:

-20ºC to +80ºC

Dimensions:

Width 483mm, Height 266mm Depth (Without Handle) 406mm Depth (With Handle) 446mm

Free air space requirement:

For Ife continuous