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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
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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
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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
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.
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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
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:
service.sales@bem.fki-et.com
spares.sales@bem.fki-et.com
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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:
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.
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.
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.
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.
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, eg. heaters, current transformers etc.
1.8
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EUROPEAN DIRECTIVES
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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.
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RATINGS
Max. continuous output current:
20A
30A
50Hz to 480Hz
Auxiliary dc Supply:
50Hz or 60Hz
Accuracy of control:
0.5%
0C to +55C
-40C to +100C
Dimensions:
Weight:
14.5kg
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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:
Voltage monitoring (over/under voltage on generator terminals)
Excitation monitoring (over/under excitation with time delays)
Over flux monitoring
Control card failure
The settings for the monitor module are selected to enable the normal limiter settings to operate
first. (See Figure 2)
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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 <3VA/phase.
4) Voltage Reference Adjustment
Adjustable between upper and lower limits in increments of 0.05V using
voltage raise/lower switches or relays in the local control panel to apply the
auxiliary dc to the relevant terminal. Internal isolation is provided. (Adjustment
may also be made using the serial communications facility see Sections
6.1.15 and 6.1.16)
5) Voltage Reference Adjustment Rate
The rate of change of voltage reference is adjustable between 200ms/V (5V/s)
and 4000ms/V (0.25V/s)
6) Voltage Reference Limits
Upper limit adjustable from 100% to 125% of nominal in 5% increments.
Lower limit adjustable from 100% to 75% of nominal in 5% increments.
(Upper limit assumes no over flux limiter operation)
7) Voltage Reference Self-Centre.
The Voltage Reference is reset to nominal voltage at the voltage reference
adjustment rate by the application of the dc auxiliary supply via an external
switch. Internal isolation is provided. (Voltage Reference Self-Centre may also
be selected by the serial communications facility see Sections 6.1.15 and
6.1.16).
6.1.2
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Over-Flux Limiter
The ratio voltage/frequency is automatically limited to between 1.00 to 1.20 per
unit, the level being adjustable in increments of 0.001 per unit. (1 per unit voltage
is the nominal sensing voltage referred to in Section 6.1.1 Item 3)).
6.1.4
Soft Start
After switching on excitation, line voltage is slowly increased to the nominal level.
Ramping rate is adjustable from 5V/s to 25V/s.
Excitation should only be switched on by energising the Excite input after the
AVR Main Electronics Supply has been applied. This should be achieved using a
speed detector switch, external to the AVR, which should be set to switch at 80%
rated speed.
6.1.5
Speed Detection
The AVR provides excitation build up when 85% rated speed is reached.
Excitation is removed at 80% rated speed. Speed detection by the AVR uses PMG
frequency sensing. An external speed detector switch should also be fitted See
6.1.4 above.
6.1.6
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-10C to +55C
Adjustable from -0.2% to -1% per C rise in
0.01% increments.
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6.1.9
6.1.10
6.1.11
In Main control this LED has no function and will be turned off.
In Standby control this LED will flash when Main has not matched
standby.
It will be illuminated steadily when matching has been achieved.
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LED 2
LED 3
LED 4
LED 5
PF control selected.
LED 6
6.1.12
LED 7
LED 8
6.1.13
For details of connections to Brush power system stabilisers, please refer to the
relevant PSS Instruction Manual.
An interface board A30-INT-PSS100, Part No 963135600, is available to provide
easy connection of a PSS with a 9Vdc output e.g. Basler PSS100. The interface
board connects directly to plug 1 at the back of the A30 rack. The wiring loom then
plugs into the interface board. The purpose of the interface board is to attenuate
the analogue input signal, on terminals 107 and 108, to a suitable level for the
A30.
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Con 1
8 (A30 Terminal 107)
8.6V
1k
9V
8
Output
To A30
0.4V
Input From
PSS
69V
47
9
(Note: Pins 1 to 7 and Pins 10 to 16 are straight through)
Output Voltage
The card produces firing pulses that are supplied to a half controlled full Wave
Bridge located in the mainframe. The maximum voltage that can be applied to the
field is approximately 75% of the PMG voltage at the input to the bridge.
6.1.15
6.1.16
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Note that the AVR will not allow a set point to be adjusted beyond the
specified range, and that following receipt of a new set point, the rate of
change from the previous to the new set point will be according to the values
set during commissioning.
Note also that for the Leading PF Reference to be used, the PF Ref Leading
mode must be selected.
Set Points available are:
Voltage Reference
VAr Reference
PF Reference Lagging
PF Reference Leading
3) Mode Selection Via Comms
Note that unless Allow Mode Selection via the HMI has been activated via the
comms link, the mode will remain selectable by hard wired switch signals as
normal.
Note also that if Allow Mode Selection via the HMI has been activated, selection
of the mode by hard wired switch signals is inactive.
PF Reference Leading
P F Control
VAr Control
VAr Shed
Self Centre Voltage Reference
Reset Monitors
Allow mode selection Via Comms
A30-MON Card
Unless stated otherwise all adjustments to this card are made using the HMI.
6.2.1
6.2.2
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2) Trip Level
Adjustable between 1.00 and 1.25 per unit in increments of 0.001 per unit.
3) Time Delay
Adjustable integrating time delay having a range of 10% seconds to 100%
seconds in 1% second steps.
6.2.3
6.2.4
-10C to +55C
Compensation level:
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6.2.6
6.2.7
Spare
Monitor watchdog dropout (program fails to cycle).
Over Excitation monitor tripped.
Under Excitation monitor tripped.
Over Voltage monitor tripped.
Under Voltage monitor tripped.
Over Flux monitor tripped.
Standby Power Supply Fault.
A30-CON watchdog dropout alarm.
Spare
6.2.8
Monitor Latch/Reset
When any of the monitors trip they remain latched until the fault is removed and
the reset pushbutton on the front of the card has been operated. Relay logic in the
AVR prevents return to A30-CON card until monitors are reset.
6.2.9
Monitor Inhibit
Operation of the monitor can be inhibited if required by an external switch signal.
The auxiliary dc supply is used and internal isolation is provided.
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6.2.11
6.3
6.3.2
6.3.3
Travel Time
60s to adjust the reference from minimum to maximum, or 187s if Link 29 is fitted.
6.3.4
6.3.5
6.3.6
Method of Adjustment
By using raise/lower switch signals from the auxiliary dc supply (optical isolation is
provided). Local raise/lower pushbuttons are also provided on the Standby control
board.
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Automatic Follower
When the Main AVR channel is operating, the output of the Standby regulator is
continuously adjusted to match that of the Main AVR, so that on transfer to the
Standby regulator, there is minimal change in excitation. Note that the travel time
minimum to maximum introduces a time delay to the follower action.
After selection of Standby control, the set point remains constant unless adjusted
by the operator. If line voltage control is selected, regular adjustment of the set
point of the Standby regulator is unnecessary. This will prevent large variations of
machine output voltage (or power factor if paralleled) as the load varies which
occurs on manual regulators which control to a constant level of excitation.
6.3.8
6.3.9
6.3.10
6.3.11
Indications
LEDs provide the following indications: LED 1
LED 2
LED 3
LED 4
LED 5
LED 6
6.3.12
Output Signals
1) Optically isolated signals to control and monitor boards to indicate Standby
high, low and power supply failed.
2) Normally open relay contact which closes on detecting A30-CON card power
supply failure. Used to initiate transfer to Standby control.
3) Signal for 500-0-500 micro amp analogue null balance meter.
4) Standby at minimum. A volt-free, normally open contact wired to the rear plug
assembly. Rating as in 6.5.7.
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Power Supply
The Standby board contains its own supply independent of the Main channel and
Monitor. The power supply transformer primary is fused by FS1 and FS2
(250mA). Link selected taps that cater for the following inputs, as seen in the
following table:
Links Selected
1, 3, 6
1, 5, 6
2, 3, 4
220 - 330V
165 - 250V
110 - 165V
250 10%
187.5 10%
125 10%
The unit is rated for 125% of the maximum for 1 minute to cater for over speed
condition.
6.3.14
Output Voltage
The card produces firing pulses that are supplied to a full wave, half-controlled
bridge located in the mainframe. The maximum voltage that can be applied to the
field is approximately 75% of the PMG voltage at the input to the bridge.
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Utilities Card
6.4.1
Power Supplies
The card produces the following fused power supplies:
Card
A30-CON
A30-MON
Hand-held Terminal
Supply
Fuse
Value
15V 5%
FS4
250mA
+5V 5%
FS3
1A
15V 5%
FS2
250mA
+5V 5%
FS1
1A
+9V 1V
FS5
100mA
Note: The Hand-held Terminal Supply is not used on the A30 Excitation
Controller, and may not be fitted on later versions.
The +5V supplies are each fitted with over voltage protection.
The supplies are designed to operate in conjunction with the transformer mounted
in the mainframe, connected to the Auxiliaries Board and will operate over the
following voltage/frequency range:
Auxiliaries Board Voltage
Links Selected
1, 3, 6
1, 5, 6
2, 3, 4
220 - 330V
165 - 250V
110 - 165V
250 10%
187.5 10%
125 10%
The unit is rated for 125% of the maximum for 1 minute to cater for over speed
condition.
6.4.2
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Over Voltage
Under Voltage
Over Excitation
Under Excitation
Over Flux monitor
A30-CON card microprocessor fault
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6.5
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A30-RACK1 Mainframe
6.5.1
6.5.2
6.5.3
6.5.4
6.5.5
6.5.6
6.5.7
250V ac
5A
1000VA
: 220V dc
: 1A (resistive)
: 50W
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Fuses
The following fuses are located as shown:
On auxiliaries board accessible from front:
FS1
FS2
FS3
FS4
6.5.10
Auxiliary Supply
Units can be supplied to operate from the following dc voltages:
24V
+15% -20%
110/125V
+15% - 20%
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HARDWARE DESCRIPTION
7.1
A30-CON Card
The control card contains the microprocessor and its associated digital addressing circuitry,
digital counter timer, signal conditioning circuitry, thyristor firing pulse isolation circuitry, digital
input and output ports, and serial communication ports, see Figure 4.
This board carries a smaller mezzanine board, the A30-M188, which contains the majority of
the microprocessor-allied components. A large proportion of these are contained in an FPGA
(Field Programmable Gate Array IC4) which is configured on power up by boot ROM IC3.
The EPROM (IC11-A) containing the working software is also on this board.
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7.1.2
Serial Communication
Two serial RS232-C ports are available for local and remote communication.
A PC based HMI (Human-Machine Interface) can be connected to the local
communication port via a `Comms' link to display and adjust contract settings.
Provision is made for remote communication from a rear connector to enable
adjustment of the settings and control modes via a SCADA link. This can also be
used to display quantities measured by the control card.
7.1.3
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Link
Selection
1A
1B
1A
1B
T3 Primary
Test Current
5A
1A
1A
0.2A
AC Volts
at C1/1
5V
4.7V
1V
0.94V
DC Volts
at TP2
1.7V
1.6V
0.34V
0.32V
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A30-MON Card
7.2.1
Introduction
The A30-MON card contains the microprocessor and its associated digital
addressing circuitry, digital counter timer, signal conditioning circuitry, digital input
and output ports, and serial communication ports. A Mezzanine Board, the A30M188 carries the majority of the microprocessor components. This board is
identical to the one on the A30-CON card except for the software contained in the
EPROM.
It is similar to the A30-CON card, except it does not have the thyristor firing circuit
and the PMG voltage input. See Figure 11.
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The memory address circuits (IC6-A,IC8-A and IC9-A) produce a 17-bit address.
128K of volatile RAM is fitted (IC10_A) and 8K of non-volatile memory EEPROM is
fitted to store the commissioning and operator adjusted settings when the AVR is
shut down.
7.2.3
Serial Communication
Two serial RS232-C ports are available for local and remote communication. An
HMI can be connected to the local communication port via a `Comms' link to
display contract settings.
7.2.4
7.2.5
7.2.6
7.2.7
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7.3
Introduction
The Standby control card contains all the electronic circuitry to control the Standby
power circuit housed in the mainframe. It is designed to be independent of the
Utilities, A30-CON and A30-MON cards.
7.3.2
Power Supply
The power supply is derived from the PMG voltage applied to the primary of T3 via
FS1 and FS2. Links are used to select the correct PMG voltage.
The 12V dc supplies are produced by VT1, VT2, Reg 1 and Reg 2 and
associated components. The supply is monitored by LED 3 to provide front of
panel indications, and IC9d that provides an isolated signal to the A30-MON card
indicating the state of the Standby power supply.
Figure 12 shows the simplified circuitry associated with the Standby power supply.
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Digital Reference
IC4, 3 and 1 form a 12 bit up down counter controlled by the raise/lower logic
described in 7.3.10.
The 12 outputs are connected to a network of resistors R1 to R24 to produce a
reference signal that is adjustable in 4096 steps. This signal is supplied to the
input of amplifier IC10a whose output provides the reference current for the
Standby regulator to the input of IC15b.
The counter is limited to a maximum count when the 8 most significant bits reach
logic `1'. Under this condition the output of IC12 falls to logic `0' forcing the next
clock pulse to reduce the count.
Similarly, when the counter is in its `fully down' state the outputs will be at logic `0'
and provide minimum reference current.
At Standby minimum Pin 6 of IC4 and Pin 7 of IC1 are both zero which causes the
output of IC6c to fall to `0' and turn on FET 2 giving indication of Standby at
minimum, whilst simultaneously removing further clock pulses via IC8a and IC8c.
7.3.4
7.3.5
7.3.6
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Figure 13: Simplified Circuits Associated With Field Control And Line
Voltage Control
7.3.7
Stabilising
The field voltage signal present at C32 is smoothed by R74, 78, 79 (as
appropriate) and C21 and is then conditioned by IC11b and associated
components and supplied to the input of the error amplifier via C25, RV2 and R71.
RV1 provides adjustment of the quantity of stabilising signal provided and RV2
provides adjustment of the phase shift. Links 25, 26 and 28 are set according to
the exciter field time constant (See Appendix B - Card Link Descriptions, Link
Description 5).
7.3.8
7.3.9
7.3.10
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Applying the dc supply to S1/9 or operating PB1 on the card lowers the digital
reference. In this case, TP9 is driven to a low level to make the clock pulses
reduce the counter setting.
When the raise or lower signals are removed the counter remains at its current
setting.
7.3.11
7.3.12
Auto Follower
When operating in Main without any excitation limiters operating, internal relay
logic applies the dc auxiliary supply to S1/5 which turns on opto isolator IC9a and
drives the output of IC7a to logic 1. LED 6 on the Standby card is also turned on to
indicate `Main Control' channel operation.
If the counter is not at the upper or lower limit, an `UP' or `DOWN' signal from the
null balance detector will set TP9 to level `1' to raise or `0' to lower, and drive
TP10 to a logic `1' to gate the clock pulses to the counter.
The counter is adjusted and the reference changed which results in a change in
the voltage at TP16 and a subsequent change of Standby firing angle. By this
means, the difference between Main and Standby firing angle is minimised.
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7.3.14
7.4
Utilities Card
7.4.1
Introduction
The Utilities card contains 15V and 5V-dc power supplies, and line voltage
sensing transformers for the A30-CON and A30-MON cards. Relays associated
with AVR logic, monitoring and indication facilities, together with the diode failure
detector are also included.
Figure 14 shows the circuitry that supplies the Utilities card with typical voltage
levels indicated. Allowance should be made when measuring transformer voltages
for different PMG voltage levels to those shown.
5V DC Power Supplies
The PMG voltage on U1/5 and U1/9, supplied by the transformer T1 on the
auxiliaries board, is rectified by the diode bridges (DB2 and DB4) and smoothed
by C2 and C8. This unregulated dc voltage is then fed into a 5V dc regulator (IC1
or IC3) and the 5V output supplied to A30-CON and A30-MON cards LED's 3 & 4
provide indication that the 5V supply is energised. IC2 and IC4 monitor the 5V rail.
If an over voltage condition occurs, thyristor 1 or 2 will be fired and cause fuse
FS3 or FS1 to rupture.
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7.4.4
7.4.5
7.4.6
7.5
A30-RACK1 Mainframe
Reference is made to the A30 Excitation Controller Circuit Diagram (See Appendix E Drawings).
The mainframe is a 19", 6U rack. At the front, on the left, is a fixed panel. Next is a vertically
hinged panel and, at the right, is a printed circuit Backboard that carries four pairs of sockets
for the plug-in cards.
A printed circuit board (the Auxiliaries Board) is fixed towards the top of the left-hand side
plate. This board carries four fuses, which are accessible on the fixed front panel. At the rear
of the board there are two, 16-way sockets. The board is also associated with the transformer
that provides the ac supply for the Main channel electronics power supply. The Auxiliaries
Board also contains four small, plug-in relays, PSR, FRS, ECCS and FSCS.
On the inside of the left-hand side plate, below the auxiliaries board, are mounted two
contactors, ECC and FSC and the field discharge resistor, FSR.
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The mainframe has a substantial heat sink at the rear on which are fitted two separate, halfcontrolled, single-phase bridges. These are used for the Main and Standby excitation
systems. Also mounted on the heat sink are a ballast resistor (BR) and a small PCB that
provides voltage suppression for the two bridges.
Connections to the mainframe are via six, 16-way sockets. Two of these, mentioned above,
are on the auxiliaries board while the remaining four are mounted on the Backboard and all
provide access at the rear. Facilities for connecting the higher current cables for the PMG and
exciter field are provided on a DIN rail-mounted terminal block on the back of the unit.
Note: All the above connections are of the cage-clamp type and reference should be made to
Section 9 for wiring suggestions.
A 25-way, serial communications socket is also provided at the rear of the unit.
7.5.1
7.5.2
7.5.3
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7.5.5
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SOFTWARE DESCRIPTION
8.1
A30-CON Card
The mezzanine board on the control card has a boot ROM (IC3) and a software chip (IC11-A)
fitted. The boot ROM, Part No 962618301, contains the necessary software to configure the
FPGA (IC4) on power up. The software chip contains the control software, which can vary
depending on the application.
To establish which control software is fitted consult the QC48 document. Alternatively, with
the A30 isolated, the control card can be removed to view the software chip (IC11-A) to
determine the Part No. and Version No.
To ensure the HMI software is compatible with the control software, the HMI software Part No.
962609800 must be Version 2.1 or later.
8.1.1
8.1.2
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The new logic has been thoroughly factory tested. Further testing on site would
unnecessarily risk damage to the generator and any connected equipment and
should be avoided. If a customer wishes to see the logic demonstrated on site
then great care should be taken to ensure that any connected equipment can
withstand the temporary high voltages which would be applied and that no
damage is done to the generator. During a test the new logic will remove
excitation within approximately 6 seconds and the terminal voltage of a 13.8kV
generator would be expected to reach about 18kV. In any tests it is important to
ensure that the excitation is not allowed to exceed 200% of the no load cold
excitation value for more than 15 seconds to guarantee no damage is done to the
generator.
8.1.3
8.1.4
8.1.5
8.1.6
8.1.7
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The analogue input to the AVR is connected to terminals 107 (-ve) and 108 (+ve).
On the A30-CON card Link 6B must be fitted and Switch 1-8 on the mezzanine
board must be off. To activate the analogue adjustment feature the Enable Analog
Adjust module must be selected from the HMI. The Panel/HMI digital input going
into terminal 106 should then be selected to HMI. The voltage reference may now
be trimmed by an analogue signal of 0 to 5 Vdc. The status of the analogue adjust
facility is indicated on the HMI. When the level of the analogue input is changed
the internal voltage reference is adjusted to the value determined by the analogue
signal. The rate of change is determined by the value set in the maintenance
presets Hreg 40061 (See Table 11 Page 74) during initial set up.
To commission the analogue adjustment of the voltage reference run with the
analogue adjust facility disabled and set the reference to nominal. Set the
analogue input to the AVR terminals 107(-ve) and 108(+ve) to 2.5v and adjust
RV7 on the A30-CON card until V Ref via Analog Input shown on the HMI is
equal to nominal volts. Confirm that when the analogue input signal is raised to
5Vdc, V Ref via Analog Input increases to the maximum required value. Confirm
that when the analogue input signal is set to 0Vdc, V Ref via Analog Input
decreases to the minimum required value. Set the analogue signal to 2.5Vdc,
Enable Analog Adjust via modules button and check that variation of the
analogue signal produces the required variation of line voltage.
When analogue adjustment of the voltage reference is enabled, automatic Power
Factor or VAr control can be achieved by adjusting the analogue input signal.
If the Power Factor or VAr controller in the AVR is selected, adjustment of the set
point is via the panel PF/VAr raise lower switches.
WARNING: When turning off automatic PF/VAr control system, the set
point will return to the voltage determined by the analogue input signal,
which may not be matched to the present line voltage.
8.1.8
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The VAr reference raise/lower switch functions are disabled and the
reference of the VAr controller will be automatically matched (within the
preset limits of 50% lead to 100%lag) to the machine output Vars. On
selection of VAr control mode, the reference will be the VAr value that
applied when in the previous mode of control. On selection of VAr control,
the VAr reference raise lower switches can be used to change the VAr
reference.
iii) When In VAr Control Mode
The Voltage reference will be automatically adjusted (within its preset
limits) so that there is no change in set point on transfer from VAr control
back to voltage control.
The PF reference raise/lower switch functions are disabled and the
reference of the PF controller will be automatically matched (within the
preset limits of 0.9 lead to 0.6 lag) to the machine output PF. On selection
of PF control mode, the reference will be the PF value that applied when
in the previous mode of control. On selection of PF control, the PF
reference raise lower switches can be used to change the PF reference.
b) On Standby Channel When Not In Control
The Standby controller remains as standard, it will normally follow the output
of the Main Controller so that there is minimum shock on transfer to Standby.
8.2
A30-MON Card
The mezzanine board on the monitor card has a boot ROM (IC3) and software chip (IC11-A)
fitted. The boot ROM, Part No 962617100, contains the necessary software to configure the
FPGA (IC4) on power up and the software chip, Part No 962616700, contains the monitor
software.
8.2.1
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Installation
The A30 Excitation Controller is primarily designed for mounting into a standard 19" rack
cabinet, but can be mounted on any sturdy panel with a suitable cutout. Where the unit is
fitted into a cutout, some form of vertical stiffening is required behind the panel at each side of
the cutout to support the cantilevered weight of the unit. For fixing dimensions, refer to the
General Arrangement drawing (See Appendix E - Drawings).
In addition to the above stiffening, it is advisable to either provide support under the rear of the
unit, or to remove the unit during transit. If channels are provided either side of the AVR so
that the unit `sits' on these when in position, these will ease subsequent removal for
inspection and maintenance.
A minimum of 300mm must be provided in front of the unit to allow the plug-in cards to be
fitted into the extender card when commissioning/fault finding.
9.2
Ventilation
It is important to ensure a free air space of 150mm above and below the unit to allow
adequate thermal cooling of the unit. The top cover of the AVR is perforated to allow
ventilation, and should not be obstructed or covered.
9.3
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A sound earth connection must be made to the earth terminal at the rear of the AVR.
Care should be taken not to allow debris to drop through the cover of the AVR during
installation.
9.4
Method 1
1) Firmly secure the plug in the approximate final position (the ideal way to do
this is to insert the plug into its socket on the A30 Excitation Controller).
2) Strip back the insulation from the cable to a distance of 7mm to 8mm or fit a
crimped ferrule if a contract requirement.
3) Insert the cage clamp tool or a small screwdriver into the terminal to open the
cage clamp, and insert the cable ensuring that the clamp grips the conductor
and that no stray strands are left exposed. See Figure 16.
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Safety
The A30 Excitation Controller should be installed in a manner so the rear connections cannot
be accidentally touched when the equipment is energised.
9.6
Mechanical Details
The PRISMIC A30 Excitation Controller is a standard 19" wide rack, 6u high, of overall
dimensions 483mm wide, 266mm high, 400mm deep. Approximate weight is 14.5kg.
The General Arrangement drawing (see Appendix E - Drawings), shows the overall
dimensions of the unit, the card positions and positions of the rear connections.
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COMMISSIONING
10.1
Installation
The unit should be installed and connected so as to limit externally generated
interference levels reaching it to within the levels defined by EN 50082-2
(Immunity Generic Standard - Industrial).
This is achieved by mounting in a suitably constructed, earthed metal enclosure
and wiring in accordance with the guidelines given in paragraph 10.1.3.
Additionally, other equipment installed in a common enclosure should not produce
interference in excess of the levels prescribed by EN 50081-2 ((Emissions Generic
Standard - Industrial).
10.1.2
10.1.3
Wiring
It is recommended that the equipment is installed in accordance with the general
practices outlined in IEC 61000-5-2 1997 and 61000-5-6.
For excitation systems, for EMC purposes, signal and power cables may be
classified as follows:
1) High Level Signal Cables
Voltage and current sensing.
2) Low Level Signal Cables
Analogue input terminal of AVR such as output from auxiliary controller or
power system stabiliser.
Null balance meter connections.
Resistance temperature detectors.
(Individual shielded twisted pairs are recommended for these signals).
3) High Frequency Power Cables
Excitation sources such as PMG or excitation transformer supply.
Generator field connections.
4) Low Frequency Power Cables
Connections to auxiliary power supplies.
5) Operation
The equipment must be used for the application for which it is designed and
operated within its specified duty. All outgoing relay contacts and switches
must be used within their rating and should be suppressed when used to
switch inductive loads.
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Note: The advice given in the safety notice at the front of this Instruction Manual
should be followed during commissioning.
WARNING: If Standby control is to be used to excite the machine whilst running
short circuited either for protection testing or drying out it is essential that it is
selected for FIELD VOLTAGE control as described in 10.4.1 to 10.4.3, Item 1).
Line current and exciter field current should be carefully monitored at this stage.
10.2
Pre-Commissioning Checks
Prior to commissioning the A30 Excitation Controller unit, it is important to complete
commissioning of the protection system for the generator and associated power equipment.
Having verified that these are correct the following preliminary checks should be made on the
excitation system:
1) Check that the PMG output is correctly wired and that PMG output is not earthed in its
terminal box.
2) Check that the sensing signals (CTs and PTs) are correct in polarity and phasing.
3) Check that exciter field is correctly wired.
4) Check that all wiring external to the AVR is secure and correct to the contract circuit
diagram. Ensure that the earth stud is solidly earthed.
5) Visually check that the AVR has not been physically damaged during transit to site.
Ensure that the contactors and other auxiliary equipment have not been disturbed and
that the internal wiring is secure. Check that the plug-in cards are correctly aligned and
fully inserted.
6) Check that the correct links are fitted to the AVR as detailed in the A30 Excitation
Controller test certificate QC.48. Standby card links should be in the despatch position.
7) Check that the software version and check sums shown on the A30-CON and A30-MON
EPROMs and Boot ROM (IC11 and IC3 on the A30-M188) correspond to those given in
the A30 Excitation Controller test certificate QC.48.
8) Ensure that the auxiliary dc supply voltage corresponds to that indicated in the A30
Excitation Controller test certificate QC.48.
The A30 Excitation Controller is now ready for commissioning as detailed below.
The following information should be read in conjunction with any specific contract
commissioning notes.
10.3
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10.3.3
10.3.4
10.3.5
10.3.6
10.3.7
10.3.8
10.3.9
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10.4.2
LED 3
LED 4
LED 5
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10.5
Preliminary
1) Utilities Card
LED 1
Control
LED 2
Monitor
LED 3
Monitor
LED 4
Control
15V healthy
15V healthy
5v healthy
5v healthy
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10.5.3
10.6
10.7
10.8
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2) Confirm that the settings of the stabilising controls (prop Gain, Integral Gain, Diff Gain) are
set to the values shown in the QC (T) 48, unless optimum stabilising settings have
previously been established. Select Main.
Note: The PID stabilised settings given on the QC(T)48 are preliminary and may require
optimisation on the contract but in the event that they are unsuitable settings of P=60,
I=100 and D=50 provide a good starting point. Optimisation of the stabilising settings is
described in Section 14 of this Instruction Manual.
3) The PID stabilising settings given on the QC.48 are preliminary and may require
optimisation on the contract.
This may be carried out initially by running the machine on open circuit and using the
VRef Step Up Test facility to produce a sudden increase in the reference voltage of the
AVR. This is accessed via the 'Tests' button on the control HMI. The size of the step is
adjustable and the default setting of 5% is recommended.
Typically, the settings will be adjusted to achieve an overshoot of approximately 20% (of
the step) with an acceptable rise time. Use of the HMI to display overshoot and rise time
will help to select the best settings. The Trend Data which shows the shape of the voltage
transient will also be helpful but is not updated frequently enough to provide an accurate
trace of the voltage response.
In some cases it may be necessary to optimise the stabilising settings by performing load
application and rejection tests to check the response.
Once the required response is achieved, the response data from the HMI should be
recorded.
10.9
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10.11
10.12
Note: If the excitation requirement is less than 1.5A on open circuit the Fast OE
Limit Ref. should be reduced for this test.
10.12.2
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5) Enable the over excitation monitor. Check that the AVR trips to Standby after
approximately 5 seconds.
Note: If field current is limited to between 1.25A and 1.5A for this test, the
monitor tripping time will be correspondingly longer.
6) Check that LED 3 on the A30-MON card is turned on.
7) Turn off the X4 sensitivity on the A30-MON card. Reset the monitor using the
reset pushbutton.
10.12.4
10.12.5
10.13
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10.14
10.15
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9) Depending upon the external reactance Xe and the configuration of the system, the
amount of QCC should be reduced to a level that gives stable control of VArs as the AVR
datum is adjusted. Typically the QCC is set at 4% for Xe = 0.
10.16
10.17
10.18
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5) Adjust the PF Reference using the PF/VAr Raise/Lower panel switches to the required
setting (the set point is shown on the HMI) and check that the PF is controlled to the
required level and is stable over the full range of power.
The rate at which the PF Reference is changed may be set in the Maintenance Presets.
If it is necessary, the PF Gain and PF Slug may be used to optimise the response of the
PF Controller.
6) If it is required to adjust the PF Reference via the HMI, the Panel/HMI switch should be
set to HMI, and the PF Reference is then adjusted using the Operator Presets. In this
case it is necessary to select whether the required PF Ref is Leading or Lagging using the
'Modes' button on the HMI.
10.19
10.20
10.21
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4) Check that the VArs can be easily adjusted by changing the voltage setting point of the
Standby regulator.
Slowly load the generator to 10% of the generator MW capacity.
5) Check that the null balance meter is positioned at the centre. Transfer from `Standby' to
`Main'.
6) Slowly reduce the VArs and the MWs on the generator. Open the grid breaker.
10.22
Static Interrogation
If the PMG supply is not available because the machine is not running, it is possible to use an
alternative ac supply to power the electronics. This will allow interrogation of the AVR by using
the PC and HMI software.
Follow the procedure below:
1) Ensure that the Main Channel Supply switch (SW1) on the fixed front panel is in the off
position.
2) Temporarily remove and insulate the wires in terminals 29 and 30 of Plug 6 at the rear of
the unit. (These are the wires which route the PMG supply to the Utility, Control and
Monitor cards).
3) Set the links LK1 to LK6 on the Auxiliaries Board to suit the available supply as shown
below. (Supply can be 50 or 60Hz)
Table 2: Auxiliaries Board Link Settings
4)
5)
6)
7)
Auxiliaries Board
Voltage Links Selected
1, 3, 6
220 - 330V
250 10%
1, 5, 6
165 - 220V
187.5 10%
2, 3, 4
110 - 165V
125 10%
Connect the supply into the now empty terminals 29 and 30 of Plug 6.
Turn on the new supply.
Turn SW1 on. The LEDs 1 to 4 on the Utilities card should be illuminated.
The PC can now be used in the normal way on the A30-CON and A30-MON cards.
After working with the A30 using an alternative power supply ensure that the wiring is restored
and links re-set.
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11.2
PC Software Installation
The software runs under Windows (NT4.0 or 95/98), and should install automatically when the
CD is inserted. If Autorun is disabled on your PC the setup.exe application can be run directly
from the CD.
Using the supplied COMCAB serial commissioning cable, connect the PC COM1 serial port to
the COM2 serial port of the card requiring setup.
11.3
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On startup, the HMI will request the name and location of the event log file (see Figure 21). To
accept the default, click on open. The A30-MON and A30-CON cards have separate log files.
The HMI will remember the last card in use, and will ask for this log file on startup.
11.5
HMI Functions
When the HMI software is running, a screen should be displayed showing a diagram of the
generator and AVR system with some active values displayed. A number of other child
windows or Displays may also be viewed. The layout of the displays may be altered to suit
the task in hand. Display and window settings are retained when the software is shut down.
The different functions of the HMI software are invoked using the standard Windows menus at
the top of the HMI window, and the row of buttons across the bottom.
Actions invoked by the buttons require User confirmation by clicking Yes in a dialog box.
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Displays
Maintenance
Presets
Button
Modes
Modules
Tests
Clear
Recorded
Extremes
Abort all Tests
Description
Event Logger
Shows latest events together with time of occurrence
Trending Data, allows selection of pages, Line voltage (2 ranges),
field current (2 ranges), line current and VAr. This may be used to
view performance over the last few minutes but due to sampling rate
is unsuitable for accurately recording transient response.
(see below)
View ranges of holding bits / registers and their contents.
View Maintenance Presets view the adjustable parameters that are
setup during commissioning of the AVR
View Operator Presets
Description
Activate/Deactivate Modes allows a particular mode of operation to
be turned on or off provided mode selection via the HMI has been
selected.
Enable/Disable Modules allows software modules to be enabled or
disabled
Activate/Deactivate Tests this menu is used to initiate tests such as
step response on voltage reference. The maximum and minimum
voltages stored in the diagnostics displays can be reset from the
menu.
Reset the extreme values recorded to date
Self explanatory
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Logfile
The Event Log file records actions performed by the A30, together with a time and date
stamp.
Log files are not overwritten they are continued when the HMI program is next run.
Whenever the program is switched to controlling a different card, the log file for that card must
be specified.
11.8
11.9
Passwords
To prevent accidental or unauthorised alteration of the AVR settings, two passwords are
provided as follows:
Operator Password:
123456
Maintenance Password: 441509611511
When adjusting presets, the passwords time out after 1 minute, and must be re-entered to
make further changes.
These passwords are not changeable and are intended to provide only a medium level of
security. To provide a higher level of security, access to this Instruction Manual and the HMI
should be controlled.
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Group Title
Display 1:
Sensing
Run time
Description of Content
Actual sensing values supplied to the card. PF, Watts, VA, VAr are
single phase and based on the relationship between V(L1 L3) and
I(L2)
Display of Hours, min, sec that the card has run. (Can be reset to zero
by turning DILSW1-6 on the A30-CON & A30-M-CON card off briefly.
Do not leave the switch off. It is advised that unless there is a
particular reason, it may be more useful not to reset the run time.
Table 5: A30-CON Display 2 - Advisory States
Group Title
Display 2:
Advisory States
HMI Commands
This group shows
the status of
commands given to
the control card
from the HMI
through the Modes
button.
Description of Content
Mainly self explanatory.
An Active state means that the device is operating.
An Enabled or Disabled state indicates whether the s/w for this facility
is turned on.
Status of request to select mode via HMI, only
PF Control
applicable if mode selection method is HMI
Active
VAr Control
Active
VAr Shed Active
Self Centre
Active
PF Leading
Indicates whether leading pf reference in HMI is
Selected
selected
Reset Monitors
Indicates whether reset monitors signal is being
Selected
given by HMI
When set to switches mode is selected by panel
Mode Selection
Method
switches, when set to HMI, mode is selected by
HMI
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Panel Switches
Indicates the status
of switches, which
may be mounted on
the control panel.
Description of Content
Indicates the applicable reference settings.
Indicates the reference settings that have been set on the local or
remote HMI. These values can be can be changed via the HMI
provided the panel local/HMI switch is set to HMI. When a reference
setting has been entered via the HMI or remote comms, it will be
shown in the HMI settings box. Provided HMI control is selected,
indicated by the state of the Panel/HMI switch, the setting in use is
changed to the level demanded by the HMI at the rate of change that
has been preset in the maintenance presets.
These are functional provided the mode selection
PF Control
method is set to panel switches
VAr Control
VAr shed
Self Centre
Volts Raise
These are functional provided the panel local/HMI
Volts Lower
switch is set to panel
PF Raise
PF Lower
Main/Standby
Panel/HMI
11.10.2
Group Title
Display 4:
Response
Recorder
Description of Content
Indicates stabilising settings, and status of step response tester
Recorded Vmax
Recorded Vmin
Rise/Fall
O/shoot
U/shoot
Reset
PMG Freq
Early Fire lim
Late Fire lim
Mark
Mark Angle
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Fast OEL
Volts/Hz Lim
Description of Content
Status of software modules, enabled or disabled via
Module
display accessed via the modules button.
X4 module
T Comp module
OEL Test
Status of oel test function activated via display
accessed via tests button.
0 C limit
OEL Setting at 0 C
T Ambient
Measured ambient temperature
Actual Limit
Applicable OE Limiter setting
Field Amps
Measured field amps
Timer
Percent of timer, when above limit starts to increase
Output
Active when limiting
X8 module
Status of x8 sensitivity feature
Limit point
Applicable Fast OE Limiter setting
Field Amps
Measured field amps
Output
Active when limiting
Module
Status of software module, enabled or disabled via
display accessed via modules button.
Limit Voltage
Flux limit level at present frequency
Voltage Sensing Voltage Sensing
Output
Active when limiting
Table 9: A30-CON Display 6 - UE Lim
Group Title
Display 6:
UE Lim
Mezzdilsw1
ON = UP
OFF = DOWN
CRC Errors
Description of Content
Module
Status of software module, enabled or disabled via
display accessed via modules button.
Limit @ 0 MW
Leading VAr limit at 0 MW
VArs
Measured leading VArs, (only applicable @ leading
PF)
PF
PF lead or lag
Output
Active when limiting
SW1
On for Brushless Exciter
Off for Static Exciter
SW2
On for Brushless Exciter
Off for Static Exciter manual regulator
SW3
Spare/normally On
SW4
On = normal, Off for bench testing only
SW5
Spare/normally On
SW6 clock
Normally on to run clock, off to reset clock
SW7 presets
Normally On to use maintenance presets, off to
load defaults.
SW8 loc/rem
On to always use panel switches, Off to activate
panel local/HMI switch. Use this if it is required to
definitely disable HMI controls.
Indicates whether checksum error has been
ModeErr
detected in data stored in E2PROM. Should be
PresetErr
normal when healthy. This may be cleared by
OpAdjErr
loading defaults via SW7.
Location
Shows memory location of detected error
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Description of Content
Soft Start s/w
Field Suppressed
Line Freq < 80%
PMGFrq<80%
PMGFrq>85%
AVR Soft Start
Reset 1 On
Reset 2 On
Standby Follower
V Ref
Software Module
Matched to Standby?
QCC
RevQCC
PF/VArCon
EventLogger
VT Failure Protection
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11.10.4
11.10.5
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Min
Max
Incr
Units
40030
VT Nominal
100
120
40031
75
100
40032
100
125
40033
N/a
Nominal CT Current
40034
CT Rated Current
0.5
5.5
40035
Prop Gain
200
40036
Integral Gain
10
1000
40037
Diff Gain
800
40038
Spare
40039
Nominal Frequency
50
60
Hz
40040
PMG Frequency
50
500
Hz
40041
10
40042
1.0
1.2
PU
40043
PF Gain
40
40044
PF Slug
10
40045
QCC Percent
15
40046
15
40047
OELimit at 0C
25
40048
sec
40049
2.5
30
40050
OE Limit Delay
50
5000
%-sec
40051
Ext. Reactance
0.2
pu
40052
0.1
40053
20
100
40054
100
40055
100
40056
10
40057
No Load Excitation
10
0.01
40058
25
V/s
40059
0.2
%/degC
40060
200
4000
ms/V
40061
200
4000
ms/V
40062
20
s per 0.1
pf
40063
50
500
ms per %
40064
20
sec
40065
10
40066
10
Description
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11.10.7
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11.10.9
Normal Status
Enabled
Disabled
Enabled
Enabled
Enabled
Enabled
Enabled
Disabled
Enabled
Disabled
Disabled
Enabled
Disabled
Enabled
11.11
Description
Event Logger. Shows latest events together with time of
occurrence, and provides an option to save registers and logs.
Trending Data, allows selection of up to 6 pages, Line voltage (3
over last few minutes but due to sampling rate is unsuitable for
accurately recording transient response.
(see below)
View ranges of holding registers
Write settings to NVRAM memory.
View Maintenance Presets view the adjustable parameters
that set up during commissioning. To adjust, double click the
value in the table. Click on transmit to save your settings.
Enable/Disable Monitors allows all monitors to be reset via the
HMI, and allows the output of any monitor to be deactivated.
Enable/Disable Modules allows software modules of monitors
and event logger to be disabled.
Activate/Deactivate Tests this menu can be used in
conjunction with the Enable/Disable Monitors facility to test
monitor the monitor time delay settings.
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Description of Content
Actual sensing values supplied to the card. PF, Watts, VA, VAr
are single phase and based on the relationship between V(L1
L3) and I(L2)
Display of Hours, min, sec that the card has run. (Can be reset
to zero by turning DILSW1-6 on the A30-MON off) This switch
should be left ON.
Mainly self explanatory.
An Active state means that the device is operating.
An Enabled state means that the facility is Enabled and will
function if required.
Table 17: A-30 MON Display 2 UV, OV & Flux Monitor
Group Title
Display 2:
UV Monitor
OV Monitor
Flux Monitor
UE Monitor
Description of Content
Module
Status of software modules, enabled or disabled
using the modules button
Output
Status of monitor output, enabled or disabled
using the monitor
Trip Point Value of monitor trip point
Line Volts Measured line voltage
Timer
Percent of timer, when above trip point starts to
increase
Output
Trip/ No Trip
Module
Status of software modules, enabled or disabled
using the modules button
Output
Status of monitor output, enabled or disabled via
the monitors button
Zero
Value of monitor trip VArs at zero MW
Power
Trip Point
Present
Measured VArs (only valid when leading PF)
VArs
PF
Present PF sense
lead/lag?
Timer
Percent of timer, when above trip point starts to
increase
Output
Trip/ No Trip
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11.12.2
Description of Content
Module
Status of software modules, enabled or disabled
using the modules button
Output
Status of monitor output enable, enabled or
disabled via the monitors button
X4
Status of increased sensitivity software
module
T Comp
Status of temperature compensation
module
Amb
Measured Ambient Temperature C
Temp
0 C Trip
Nominal trip point of Monitor
Point
Field
Measured field current
Amps
Actual
Temperature compensated trip point
Trip Point
Timer
Percent of timer, when above trip point starts to
increase
Output
Trip/No Trip
Description of Content
Self explanatory
Description of Content
Status of monitor and logger software modules
Status of monitor output enable
Status of monitor test facility used for testing monitor time delays
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Opto Inputs
Flags
Analogue
Values
Mon module
Mon O/P
Test
CRC Errors
Opto Inputs
Flags
Mezzdilsw1
ON = UP
OFF = DOWN
Description of Content
Indicates whether checksum error has been
ModeErr
detected in data stored in E2PROM. Should be
PresetErr
normal when healthy. This message is reset
OpAdjErr
when default presets are loaded.
Location
Shows memory location of detected error
Status of spare opto isolated input signals
Reset 1 On
Present status of Reset1 from control card
Reset 2 On
Present status of Reset2 from control card
Man PS Fault
Status of ps monitor signal from standby card
Self explanatory
Status of monitor and logger software modules
Status of monitor output enable
Status of monitor test facility used for testing monitor time delays
ModeErr
Indicates whether checksum error has been
PresetErr
detected in data stored in E2PROM. Should be
OpAdjErr
normal when healthy. This message is reset
when default presets are loaded.
Location
Shows memory location of detected error
Status of spare opto isolated input signals
Reset 1 On
Present status of Reset1 from control card
Reset 2 On
Present status of Reset2 from control card
Man PS Fault
Status of ps monitor signal from standby card
Cont Superv
Indicates health of control card watchdog
Field Supp.
Indicates field suppressed/not suppressed
InhMonSwOn
Status of panel mon inhibit switch
Card reset Off
Status of monitor reset pushbutton
Monitor output status
UETripped
OETripped
UVTripped
OVTripped
OfluxTripped
Dump To
Indicates status of flag which allows data to be
E2Prom
saved in E2Prom on shutdown
SW1
Spare/normally on
SW2
Spare/normally on
SW3
Spare/normally on
SW4
On = normal, Off for bench testing only
SW5
Spare/normally on
SW6 clock
Normally on to run clock, off to reset clock
SW7 presets
Normally On to use maintenance presets, off
to load defaults.
SW8
Spare/normally on
11.12.4
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Min
Max
Inc
Units
40030 VT Nominal
100
120
0.5
5.5
50
60
Hz
1.0
1.25
PU
100
140
10
100
%-s
70
120
25
%-s
2.5
35
100
5000
%-s
0.2
% / C
0.1
5.5
10
0.2
PU
10
100
%-s
11.12.6
Description
Sensing transformer voltage at 100% machine
volts
Nominal CT Current
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11.12.8
Normal Status
Enabled
Enabled
Enabled
Enabled
Enabled
Enabled
Disabled
Enabled
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Protocol Data
Data rate etc:
Protocol:
Slave Number:
Supported Modbus
Function Codes:
12.2
Physical Connections
Front Connector:
Rear Connector:
12.3
Data Available
See 19 Appendix C - Holding Registers For SCADA, Page 122
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13.2
13.3
13.4
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2) The temperature transducer can be calibrated using 100 and 115 resistors (accuracy
1%) as described below:
a) Trip FSC, and open SW1 in the mainframe. Connect the 100 resistor across
terminals 116 and 117. Link terminals 116 and 118. Fit the A30-CON card into the
extender and insert in the mainframe. Close SW1 in the mainframe. Use the HMI to
check that temperature compensation software is enabled. If it is turned off, confirm
that temperature compensation is required and if so, turn the software on.
Set the HMI to indicate temperature and adjust RV1 on the control card so that the dc
voltage between C2/4 and C2/11 is zero.
Adjust the dc voltage at TP7 wrt TP1 to 1.0V using RV6. Adjust the temperature
display on the HMI to 0C using RV2.
b) Open SW1 in the mainframe. Replace the 100 test resistor by the 115 resistor.
Close SW1 and check that the HMI now indicates 40C 2C and TP7 wrt TP1 is 5V.
c) If the temperature reading is not correct adjust RV6 for range and RV2 for level.
13.5
13.6
13.7
13.8
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Step Response
Step response testing involves the sudden application of a step increase or reduction to the
regulator set point. This causes a disturbance in the output of the regulator that is reflected to
the output of the machine. The resulting transient provides information about the damping of
the regulator and is helpful when optimising the settings of the stability controls.
Step response testing is carried out in the following circumstances:
when the machine is running on open circuit when setting up the stabilising, in this case a
step up of 5% is recommended.
When the machine is running in parallel with the supply and it is required to test the
response of the under excitation limiter. In this case a step down of 2% maximum is
recommended.
when the machine is running in parallel with the supply and it is required to test the
response of a power system stabiliser. In this case a step down of 2% maximum is
recommended.
When line current greater than 0.1 per unit is present the maximum step is limited to 2%
The reference automatically returns to normal 20 sec after the step is applied.
14.2
14.3
Stabilising Adjustment.
The step response of the system may be optimised by adjusting the proportional (P), integral
(I) and differential gain (D) by accessing the maintenance presets menu.
The Integral Gain, when set correctly, has very little effect on the transient response and
should be set initially to 100.
In general increasing the Proportional Gain will give faster rise time but too much will give a
response which is difficult to damp out and probably a large overshoot.
Damping can be improved and overshoot reduced by increasing the Differential Gain
however, too much will give poor rise time and may cause fluctuations in the exciter field
voltage.
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The HMI shows the value Mark Angle and this is an indication of the variation of the
thyristor firing angle. Under steady state conditions Mark should be almost constant, and Mark
Angle will display the variation in the firing angle which should not normally exceed 10% of
the late firing limit. If this does occur it is recommended that the Differential Gain is reduced.
Integral Gain (I) will cause instability if too low typically less than 30. Instability depends on
(P), but if (P) is less than 60 then (I) will need to be higher, typically 500 for P = 35 on turbo
generators. Too high a value will give poor regulation and long rise time.
The following table of stabilising settings is a general guide:
Table 26: Stabilising Settings
Typical Ranges
20 100
50
50
100 200
100
100
20 100
40
40
The contract settings in the QC.48 document provide a good starting point. If after a 5% step
the overshoot is too high, increase the Differential Gain to reduce the overshoot. If the
Differential Gain is unusually large it may be better to reduce Proportional Gain to reduce the
overshoot. The effect of this will be to reduce the rise time.
If the line voltage is oscillatory the Integral Gain may be too low (do not reduce below 100)
Use the 5% step to optimise the overshoot to about 15% -30% of the 5% step size. The under
shoot should be much less than the overshoot, typically 0% to 6% of the step size.
In the majority of applications, an adequate response with minimal overshoot can quite easily
be achieved using step response testing on open circuit and the facilities on the HMI. If the
application requires the best possible response this will necessitate recording equipment and
possibly load application and rejection testing.
14.4
UEL Stabilising
Adjustable Proportional, Integral, and Differential gains controls have been added to the under
excitation limiter. It is recommended that they are set initially to I = 50, P = 20, D = 20.
When setting up the UEL response, steady state stability should initially have been proved by
running at zero power and slowly reducing the set point of the AVR until the under excitation
limiter turns on.
The response of the Under Excitation limiter may be tested by running the machine lightly
loaded when in parallel and initiating a step down in AVR set point. The excitation will reduce
and the machine will generate leading VArs. Check that the Under Excitation limiter turns on
immediately with no appreciable overshoot in the leading VArs. It may be necessary to
optimise the response by making adjustments to the UEL stabilising controls.
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Operating Procedures
It is important to study operating procedures for the generator and turbine/engine system
which are beyond the scope of this manual. The following instructions should be followed to
ensure correct operation of the AVR.
15.1.1
15.1.2
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Maintenance
The A30 Excitation Controller is completely solid state, apart from relays, contactors and
switches, and requires very little maintenance. It is recommended that the AVR is inspected
approximately every 12 months to check for excessive dust build-up, and that all relays, fuses
and connections are secure. Excessive quantities of dust should be removed with a soft
brush.
In common with generator protection systems, it is good practice to annually check the
calibration and the correct operation of all the various functions of the AVR because some
(monitors or limiters) may never have needed to operate since the equipment was installed.
This entails making checks that are carried out during commissioning and, if required, Brush
Service Department can provide this service.
WARNING: Take anti-static precautions when handling cards. Ensure that you are
earthed (grounded) by using a wrist strap or similar device. An earth connection
terminal is fitted in the centre or the front right hand mounting bracket of the AVR
to which a wrist strap may be clipped.
Electronic cards can be damaged by static discharge and should be carried in
anti static protective containers wherever practicable. They should always be
stored and transported in anti static bags or boxes.
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FAULT FINDING
Note: The advice given in the safety notice at the front of this Instruction Manual
should be followed when fault finding.
16.1
General Information
If the AVR does not function correctly, a test sequence is recommended in which the
generator and external wiring are first thoroughly checked before it is assumed that the fault
lies in the electronic equipment. The faultfinding procedure is designed to enable faults to be
found quickly. It is essential therefore, to follow the order in which they are presented.
In the event of finding a fault on any part of the AVR the company strongly recommends that
no attempt is made to repair the unit, but that it is replaced by a spare which should be recommissioned according to the relevant section of this Instruction Manual. The faulty unit
should be returned to the Works for repair quoting the relevant Type/Model and Contract No's,
together with the nature of the fault.
16.2
Precautions
Meggers, flash testers and bell sets must not be used to check any equipment connected to,
or incorporating semi-conductors.
If these devices are to be used to check the wiring to the AVR, first disconnect all cables to
the AVR.
WARNING: Take anti-static precautions when handling cards. Ensure that you are
earthed (grounded) by using a wrist strap or similar device. An earth connection
terminal is fitted in the centre or the front right hand mounting bracket of the AVR
to which a wrist strap may be clipped.
Electronic cards can be damaged by static discharge and should be carried in
anti static protective containers wherever practicable. They should always be
stored and transported in anti static bags or boxes.
16.3
Procedure
16.3.1
Preliminary Checks
Before commencing fault finding on the AVR unit, the following preliminary checks
should be carried out:
a) Check correct operation of the generator, ie. PMG output available (if
applicable), the field and sensing signals are correct etc.
b) Check all wiring associated with the excitation system.
c) Check all contactors, switches and other external components associated with
the AVR unit.
d) Check that all the correct links are fitted in the AVR as detailed in the contract
QC.48 document.
e) Check all fuses and replace any that have failed. Fuse ratings are given in
Section 6.
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AVR Checks
Having completed these preliminary checks, if the problem remains, the cause
may be assumed to be internal to the AVR, or in its setting up. In this event the
problem will generally fall into one of the following categories:
1)
2)
3)
4)
16.3.3
Thyristor Check
The Main and Standby power circuits are single-phase half-controlled rectifiers
each comprising two diodes (in a single module) and two thyristors (in a single
module). The thyristors can be checked in situ with the aid of a battery, ammeter
and two resistors, after isolating the AVR and temporarily removing the relevant
semi-conductor fuse (FS5 or FS6) and unplugging plug Q from the Backboard.
15 Ohm
12 W
A
12 V Battery
1 Amp Short
Term Rated
15 Ohm
0.5 W
Anode
Thyristor
Under Test
Switch
Gate
Cathode
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Page No.
92
93
94
95
96
96
96
96
97
97
98
98
98
99
99
100
100
101
101
102
102
103
103
104
105
105
105
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Symptom
Test/Check
Remedial Action
Watchdog dropout
indication LED2 on
Replace card
Overvoltage/ excitation on
open circuit
Undervoltage/ excitation on
open circuit
OEL temperature
compensation/
measurement inaccurate
Frequency display
inaccurate
10
Rectify as necessary
11
12
13
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Possible Fault
Test
Remedial Action
Governor
instability
If speed is fluctuating,
investigate governor
instability
Incorrect PID
setting
Refer to Section 14
Mainframe not
earthed
Correct as necessary
PMG phase
reference circuit
failure
PMG
measurement
circuit failure
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Possible Fault
Test
Remedial Action
b) If it is correct, continue to
test c). If not, go to test 3a)
and 3b)
a) Using extender on
Utilities, measure input to
Utilities is 110V at terminals
U2/21, U2/25 and U2/23
b) Using extender on
Utilities, measure output is
25V at terminals U2/28,
U2/26 and U2/27
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Fault Finding Table 4: Low Excitation Or Voltage On Open Circuit In Main Control Channel
No.
1
Possible Fault
Test
Remedial Action
Main channel
power circuit fault in
mainframe
a) Replace if necessary
c) Correct as necessary
Loss of auxiliary
power supply
If 3 phase sensing, check card not selected for 1phase sensing (See Appendix B - Card Link
Descriptions)
Correct as necessary
OE limiter
operating level too
low.
Correct as necessary
OEL limiter
increased
sensitivity selected
Correct as necessary
Field current
measurement
circuit failure
10
Incorrect FSC
status read by A30CON card
Incorrect selection
of power supply
links
VTP13-TP1 = 5V 0.2V
VTP19-TP1 = 15V 1.0V
VTP20-TP4 = 15V 1.0V
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Possible Fault
Test
Remedial Action
Correct as necessary
Temperature
compensation is turned off
Correct if necessary
Temperature sensing
circuit out of calibration
Fault Finding Table 6: Main Control Channel Field Current Measurement Error
No.
Possible Fault
Test
Remedial Action
Correct as necessary
Backboard failure
Possible Fault
Test
Remedial Action
Correct as necessary
a) Correct as
necessary
b) Correct as
necessary
c) If not present,
Backboard faulty and
must be replaced
d) If not, re-calibrate
according to Section
13.
Possible Fault
Test
Remedial Action
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Possible Fault
Test
Remedial Action
Watchdog dropout
indication LED2 on
Replace card
a) Enter correct
settings where
appropriate
b) If calibration
inaccurate, refer to
table indicated:
Voltage
Field Current
Line Current/Phase
Temperature
Frequency
4
A30-MON settings
inconsistent with site
conditions
Possible Fault
Test
a) If error large, go to
test b) otherwise go to
test c)
b) If correct, go to test
c), if not and Main
control sensing OK,
Backboard is faulty
Remedial Action
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Possible Fault
Test
Remedial Action
Field current
measurement failure
b) Trim if necessary
using RV3 on Backboard
after checking LK3A is
fitted. Then calibrate
according to Section 13
Possible Fault
Test
Remedial Action
Temperature
compensation is turned off
Correct as necessary
Temperature sensing
circuit fault
Re-calibrate according
to Section 13
Possible Fault
Test
Remedial Action
Calibration error
a) If not, re-calibrate
according to Section
13.
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Possible Fault
Test
Remedial Action
Symptom
Test
Remedial Action
Refer to Fault
Finding Table 16
Refer to Fault
Finding Table 17
Refer to Fault
Finding Table 18
Refer to Fault
Finding Table 19
Refer to Fault
Finding Table 20
Refer to Fault
Finding Table 21
Refer to Fault
Finding Table 21
Refer to Fault
Finding Table 21
Refer to Fault
Finding Table 22
Issue: J
Fault Finding Table 16: Failure Of A30-CON And A30-MON Card DC Supplies
No.
Possible Fault
Test
Remedial Action
No PMG feed to
supply
transformer
Fault Finding Table 17: Failure Of 15V A30-CON Card Supply (Other DC Supplies Present)
No.
Possible Fault
Test
Remedial Action
Insufficient current
available for A30-CON
card
Issue: J
Fault Finding Table 18: Failure Of 15V A30-MON Supply (other DC Supplies Present)
No.
Possible Fault
Test
Remedial Action
FS2 blown on
Utilities card
No PMG feed to
U1/19 and U1/21
Insufficient current
available for A30MON
Possible Fault
Test
Remedial Action
FS3 blown on
Utilities card
Insufficient
current available
for A30-CON
card
Issue: J
Fault Finding Table 20: Failure Of +5V A30-MON Supply (Other DC Supplies Present)
No.
Possible Fault
Test
Remedial Action
Insufficient current
available for A30-MON
card
TP11-TP1 is 5V 0.5V
3
c) Check ac volts at
backboard plug terminals
Q1/4 & Q1/5is between 15
and 23 volts
Symptom
Test
Remedial Action
Indicator permanently on
c) Reduce sensitivity of
detector by fitting LK2 and
adjusting RV1 clockwise until
LED7 turns off
Issue: J
Fault Finding Table 22: General Alarm (LED5) Given On Utilities Card
No.
1
Possible Fault
Test
Remedial Action
Symptom
Test
Excitation collapses on
transfer from Main to Standby
Remedial Action
Issue: J
Fault Finding Table 24: Standby Control Faults - No Excitation When Running On Standby
No.
Possible Fault
Test
Remedial Action
Power supply
inoperative
Standby raise/lower
signal fault
a) Replace as necessary
Issue: J
Fault Finding Table 25: Standby Card Faults - Line Voltage Unstable When Machine On Open Circuit
No.
Possible Fault
Test
Remedial Action
Governor instability
Fault Finding Table 26: Standby Control Faults - Machine Will Not Run In Parallel When Selected In
Voltage Control Mode
No.
Possible Fault
Test
Remedial Action
Make necessary
corrections
Correct as necessary
Fault Finding Table 27: Standby Control Faults - High Excitation When In Standby Control
No.
Possible Fault
Test
Remedial Action
Make necessary
connections
Make necessary
connections
Make necessary
connections
Thyristor failure
Replace module if
necessary
Issue: J
Page No.
107
108
109
110
111
112
113
114
115
Connections Chart 10: 10 Way 'Quickmate' Connector On Backboard/Auxiliaries Board Internal Connections
115
115
116
116
116
117
117
118
118
Issue: J
Description
IY Load (C,M)
SCADA COMMS RX (C)
+15V (C)
If (C)
PMG 7
15V (C)
+5V (C)
L1 25V Sens.
PMG 8
D.F.S. D.F.I. i/p
L2 25V Sens.
Con Card Sup. o/p (1 = healthy)
Mon Card Sup. I/p (1 = healthy)
AVR Firing Pulse
L3 25V Sens.
Reset 1 (low to reset/inhibit monitor)
SCADA COMMS TX (C)
Reset 2 (low to reset/inhibit monitor)
UEM. Sup. i/p
OEM. Sup. i/p
UVM. Sup. i/p
OVM. Sup. i/p
Ph.Ref. 50
Logic level 0 when Standby Low
Lim. On
Spare
Logic level 0 when Standby High
C1/28:M1/28:U1/28:S1/28:
C1/29:M1/29:U1/29:S1/29:Q1/8:155
C1/30:M1/30:U1/30:S1/30:Term.A etc.
Ground
C1/31:M1/31:U1/31:160:Term.A etc.
C1/32:M1/32:U1/32:144:108
Signal Ground
Issue: J
Description
Main V Raise
RTD 3
Main V Lower
RTD 1
P.F.Select
RTD 2
VAr Control Select
Aux. DC ve
VAr Shed
Spare
RTD 4
See C2/17(used on twin)
Self Centring
Panel Adjust/ Comms link adjust
Mark/space o/p (used on twin)
Analogue input
Standby (+ve)/Main(used on twin)
FSC (+ve Aux Sup'd)
P.F. Lower
P.F. Raise
Not Connected
Not Connected
Not Connected
Not Connected
K1 SCR1
G1 SCR1
SCADA COMMS Isolated Ground
Not Connected
Not Connected
Not Connected
K2 SCR2
G2 SCR2
Issue: J
Description
IY Load (C,M)
SCADA COMMS RX(M)
+15V (M)
If(M)
PMG 7
15V (M)
+5V (M)
L1 25V Sens
PMG 8
Not Connected
L2 25V Sens
Not Connected
Mon Card Sup. o/p
Not Connected
L3 25V Sens.
Not Connected
SCADA COMMS TX(M)
Spare
UEM. Sup. o/p
OEM. Sup. o/p
UVM. Sup. o/p
OVM. Sup. o/p
Ph.Ref. 50
Gen.Alarm Sig.
Mon.Trip Sig.
DFI Inh.
Not Connected
M1/28:C1/28:U1/28:S1/28:
M1/29:C1/29:U1/29:S1/29:Q1/8:155
M1/30:C1/30:U1/30:S1/30:Term A etc
Ground
Ground
Ground
Signal Ground
Signal Ground
Issue: J
Description
FSC(+ve Aux Sup'd)
Not Connected
Mon Inh
RTD 1
Spare
Not Connected
Spare
Aux. DC ve
Spare
Spare
RTD 4
Spare
Spare
Spare
Spare
Not Connected
Not Connected
Not Connected
Manual Power Supply Fault (0 = healthy)
Not Connected
Not Connected
Not Connected
Reset 2 (low to reset/inhibit monitor)
Not Connected
Not Connected
Not Connected
Reset 1 (low to reset/inhibit monitor)
SCADA COMMS Isolated ground
Con Card Supervisory i/p (1=healthy)
Not Connected
Not Connected
Not Connected
Issue: J
Description
+15V (C)
See U2/29 (used on twin)
15V (C)
See U1/26 (used on twin)
PMG 1
Not Connected
+5V (C)
Not Connected
PMG 2
Not Connected
15V (M)
Not Connected
+5V (M)
Not Connected
PMG 3
Not Connected
PMG 4
Not Connected
PMG 5
Not Connected
PMG 6
Not Connected
+9V (HMI) Not used on A30 Excitation
Controller
Not Connected
+15V (M)
Lim N.C. (used on twin)
Follower Inh (used on twin)
U1/28:C1/28:M1/28:S1/28:
U1/29:C1/29:M1/29:S1/29:Q1/8:155
U1/30:C1/30:M1/30:S1/30:Term.A etc.
Ground
Ground
Ground
U1/31:C1/31:M1/31:160:Term A etc.
U1/32:C1/32:M1/32:144108
Signal Ground
Signal Ground
Issue: J
Description
DFI Com
DFI N.C.
DFI N.O.
If(M)
Lim. Com.
DFI Inh.
Lim. N.C.
Lim. N.O.
Mon. Com.
Mon. N.C.
Mon. N.O.
Mon.Trip Com.
Mon.Trip N.C.
Mon.Trip N.O.
Alarm Com.
D.F.S.
Alarm N.C.
Mon.Trip Sig.
Alarm N.O.
Lim. On
L1 110V Sens.
Ph.Ref. 50
L3 110V Sens.
Gen.Alarm Sig.
L2 110V Sens.
L2 25V Sens.
L3 25V Sens.
L1 25V Sens.
See U1/2 (used on twin)
Not Connected
See U1/27 (used on twin)
Not Connected
Issue: J
Description
IY Load (S)
Spare(used on twin)
IY Machine (S)
Spare
Follower Inh.
Not Connected
Test purposes only
Not Connected
Standby V Lower
Not Connected
Standby V Raise
Not Connected
Aux. DC ve
Not Connected
Standby Power Supply Fault (0 = healthy)
Not Connected
Low when Standby Low
Low when Standby High
+15V (C)
Not Connected
15V (C)
Not Connected
Mon.Trip Com.
Mon.Trip N.O.
Mon.Trip N.O.
Not Connected
AVR Firing Pulse (used on twin)
S1/28:C1/28:M1/28:U1/28:
S1/29:C1/29:M1/29:U1/29:Q1/8:155
S1/30:C1/30:M1/30:U1/30:Term A etc.
Ground
Ground
Ground
S1/31
S1/32:Term.A etc.
Signal Ground
Signal Ground
Issue: J
Description
L1 110V Standby Sensing
L3 110V Standby Sensing
Not Connected
Not Connected
Not Connected
Not Connected
Not Connected
Not Connected
Not Connected
G3 SCR3
Field +ve
K3 SCR3
Not Connected
Not Connected
Not Connected
Not Connected
Not Connected
G4 SCR4
AC1 (PMG)
K4 SCR4
Not Connected
Not Connected
Not Connected
Not Connected
Not Connected
AC2 (PMG)
Not Connected
Not Connected
NBM +ve (ground)
Standby at min Com.
NBM ve
Standby at min N.O.
Issue: J
Wire Number
19
8
58
72
73
51
57
70
71
48
53
66
18
63
Description
Aux. DC ve
Field +ve
K3 SCR3
G3 SCR3
G4 SCR4
Not Connected
Not Connected
Not Connected
K4 SCR4
Not Connected
Not Connected
K1 SCR1
Not Connected
Not Connected
Not Connected
G1 SCR1
G2 SCR2
Not Connected
Not Connected
Mon.Trip Com.
K2 SCR2
Pos. in Standby
Mon.Trip N.O.
FSC (+ve Aux sup'd)
Connections Chart 10: 10 Way 'Quickmate' Connector On Backboard/Auxiliaries Board - Internal Connections
Connections
Q1/1:U1/19
Q1/2:U1/21
Q1/3:U1/26
Q1/4:U1/5
Q1/5:U1/9
Q1/6:U1/15
Q1/7:U1/17
Q1/8:C1,M1,U1,S1/28-30:155:D1,2/5
Q1/9:C1/5:M1/5
Q1/10:C1/9:M1/9
Wire Number
39
40
65
35
36
37
38
75
74
70
Description
PMG 5
PMG 6
Lim. N.C.
PMG 1
PMG 2
PMG 3
PMG 4
Ground
PMG 7
PMG 8
Description
SCADA COMMS TX(C) A30-CON
SCADA COMMS RX(C) A30-CON
SCADA COMMS Isolated Ground A30CON
SCADA COMMS RX(C) A30-MON
SCADA COMMS TX(C) A30-MON
SCADA COMMS Isolated Ground A30MON
Unconnected
Issue: J
Description
Main V Raise
Main V Lower
P.F.Select
VAr Con. Select
VAr Shed
P.F. Lower
Panel/HMI or SCADA comms adjust
Analogue Input
Signal Ground
Not Connected
P.F.Raise
Used on Twin System
Self Centring
Mon. Inhibit
Spare
Used on Twin System
Description
RTD 3
RTD 1
RTD 2
DFI Com.
Mon.Trip N.C.
Lim. Com.
Lim. N.C.
Spare
Mon. Com.
Mon. N.O.
Alarm Com.
Alarm N.C.
Alarm N.O.
Spare
Spare
Description
L3 110V (S)
C/T IY Machine
C/T IY Load
DFI N.C.
Lim. N.O.
Mon. N.C.
Spare
L2 110V Sensing
L1 110V Sensing
L3 110V Sensing
Used on Twin System
Used on Twin System
Signal Ground
If(C)
St'by at Min. Com.
St'by at Min. N.O.
Brush Electrical Machines Ltd. 2003
Issue: J
Description
L1 110V (S)
C/T IY Machine
C/T IY Load
St'by Volts Lower(different on twin
AVR)
St'by Volts Raise(different on twin
AVR)
Aux. DC ve
Spare
Ground
Not Connected
AC1 (PMG)
Not Connected
AC2 (PMG)
Not Connected
If(M)
NBM +ve
NBM -ve
Description
Aux DC +ve Input
Not used
Aux DC -ve Input
Not used
+ve for Standby
+ve for Main
+ve to Excite
+ve to Trip Excitation
+ve Aux D.C. Supply after FS1
+ve Aux D.C. Supply after FS1
+ve Aux D.C. Supply after FS1
-ve Aux D.C. Supply after FS2
-ve Aux D.C. Supply after FS2
Control State, Common
Control State, Closed in Main
Control State Closed in Standby
Issue: J
Description
Excitation State (Com.)
Excitation State (Closed if Excited)
Excitation State (Closed if Tripped)
Aux DC State (Com.)
Aux DC State (Closed if Healthy)
Aux DC State (Closed if Faulty)
Not used
PMG (AC1) for Main Channel P.S.
Not used
PMG (AC2) for Main Channel P.S.
Not used
Not used
Not used
Not used
Spare
Spare
Connections Chart 18: Heavy Duty Terminals At Rear Of Unit - Outgoing Connections
Connections
3
3
3
4
5
5
6
7
8
9
Comments
Normally Linked to other terminals 3 and to 4
Normally Linked to other terminals 3 and to 4
Normally Linked to other terminals 3 and to 4
Normally Linked to terminals 3
Normally Linked to other terminals 5
Normally Linked to other terminals 5
Description
PMG (AC1) Input for Main
PMG (AC1) Input for Standby
PMG (AC2) Input
PMG (AC2) for Main
PMG (AC2) after FSC-1
Exciter Field +ve Output
Exciter Field -ve Output (Earthed)
Issue: J
Description
For SCADA comms to COM 1 on front panel
For SCADA comms to REMOTE COMMS Socket on Rear Panel
For SCADA comms to COM 1 on front panel
For SCADA comms to REMOTE COMMS Socket on Rear Panel
Debugging comms to COM 2 on front panel (normally fitted)
Omit
Debugging comms to COM 2 on front panel (normally fitted)
Omit
Fit for Three-Phase Sensing (Omit LK5B)
Fit for Single-Phase Sensing (Omit LK5A)
For Analogue Input signal to bias sensing signal
For Analogue input signal to auxiliary transducer
Disable analogue input signal (Normally Fitted)
Firing angle to Standby (normally fitted on single AVR brushless system)
Disable Firing angle to Standby
Firing angle to output terminal 111 (normally omitted -used on twin system)
Disable Firing angle to terminal 111 (normally fitted)
Fit for 24/48V D.C. Aux Supply (Omit LK9B-19B)
Fit for 110/125V D.C. Aux Supply (Omit LK9A-19A)
Park position for links 9 19
High Field Current Sensitivity ( normally omitted, fit on twin system)
Normal Field Current Sensitivity ( normally fitted)
Link Description 2: A30-CON Mezzanine Board (A30-M188)
Link
1A
1B
2A
2B
2C
3A
3B
4A
4B
5A
5B
Description
Watchdog Reset (normally fitted)
Disable Watchdog Reset (omit)
Fit for excitation source frequency 251 480 Hz (4MHz clock)
Fit for excitation source frequency 50 125 Hz (1MHz clock)
Fit for excitation source frequency 126 250Hz (2MHz clock)
Debugging Interrupt selector (omit)
Normal Interrupt selector (normally fitted)
Configure FPGA on watchdog reset (normally fitted)
Configure FPGA on power up (omit)
Excitation supply zero crossing signal (normally fitted)
Alternative excitation supply zero crossing signal (omit)
Issue: J
Description
For Analogue Input signal to bias sensing signal
For Analogue input signal to auxiliary transducer
Disable analogue input signal (Normally Fitted)
Fit for Single-Phase Sensing (Omit LK2B)
Fit for Three-Phase Sensing (Omit LK2A)
SCADA comms to COM 1 on front panel (normally fitted)
SCADA comms to REMOTE COMMS Socket on Rear Panel (normally omitted)
Debugging comms to COM 2 on front panel (normally fitted)
Omit
SCADA comms to COM 1 on front panel (normally fitted)
SCADA comms to REMOTE COMMS Socket on Rear Panel (normally omitted)
Debugging comms to COM 2 on front panel (normally fitted)
Omit
Fit for 24/48V D.C. Aux Supply (Omit LK7B-14B)
Fit for 110/125V D.C. Aux Supply (Omit LK7A-14A)
Park position for links 7 14
High Field Current Sensitivity ( normally omitted, fit on twin system)
Normal Field Current Sensitivity ( normally fitted)
Link Description 4: A30-MON Mezzanine Board (A30-M188)
Link
1A
1B
2A
2B
2C
3A
3B
4A
4B
5A
5B
Description
Watchdog Reset (normally fitted)
Disable Watchdog Reset (omit)
Not applicable on monitor position does not matter
Not applicable on monitor position does not matter
Not applicable on monitor position does not matter
Debugging Interrupt selector (omit)
Normal Interrupt selector (normally fitted)
Configure FPGA on watchdog reset (normally fitted)
Configure FPGA on power up (omit)
Excitation supply zero crossing signal (normally fitted)
Alternative excitation supply zero crossing signal (omit)
Issue: J
Description
Voltage selection links for 220/330V PMG (Omit LK2,4,5)
Voltage selection links for 165/250V PMG (Omit LK2,3,4)
Voltage selection links for 110/165V PMG (Omit LK1,5,6)
Remove to inhibit Low Frequency Cut-off.
Low Frequency Cut-off, Fit for 50Hz Machine (Omit LK9)
Low Frequency Cut-off, Fit for 60Hz Machine (Omit LK8)
Power Supply Test Links (Normally Fitted)
C.T. Selector Fit for 1 Amp Metering C.T. (Omit LK13)
C.T. Selector Fit for 5 Amp Metering C.T. (Omit LK12)
Fit to select Field Voltage Control (Omit LK15)
Fit to select Line Voltage Control (Omit LK14)
Fit to select High Range Field Voltage Control 0-200V (Omit LK17)
Fit when Line Voltage Control is Required
Fit to select Low Range Field Voltage Control 0-100V (Omit LK16)
Raise/Lower with 24/48V D.C. Aux Voltage (Omit LK19)
Raise/Lower with 110/125V D.C. Aux Voltage (Omit LK18)
Auto Follower with 24/48V D.C. Aux. Voltage (Omit LK21)
Auto Follower with 110/125V D.C. Aux. Voltage (Omit LK20)
Fit for PMG Frequency of 201Hz and above
Fit for PMG Frequency of 200Hz and below
Fit to select Field Voltage Limit.
AVR Stabilising Link for Exciter Field Time Constant of 0.4 - 0.7 sec.
(Omit LK26, 27, 28)
AVR Stabilising Link for Exciter Field Time Constant of 0.1 - 0.4 SEC
(Omit LK25, 27, 28)
Fit when in Field Voltage Control (Omit LK26, 25, 28)
AVR Stabilising Link for Exciter Field Time Constant of 0.7 - 1.5 SEC
(Omit LK26, 25, 27)
Slow Clocking Link for Low Exciter Field Voltage (Normally Omitted)
Link Description 6: Utilities Card
Link
LK1
LK2
LK3
Description
Fit to increase Sensitivity of D.F.I. (Normally Omitted)
Fit to decrease Sensitivity of D.F.I. (Normally Omitted)
Fit for continued operation of Auto Follower when Limiter Operates (Normally
Omitted)
Link Description 7: Backboard
Link
LK1A
1B
2A
2B
3A
3B
Description
5 Amp Metering CT selector (Omit LK1B)
1 Amp metering CT selector (Omit LK1A)
Internal A30-CON Field Current Transducer (Normally Fitted)
External Field Current Transducer (Omit)
Internal A30-MON Field Current Transducer (Normally Fitted)
External Field Current Transducer (Omit)
Link Description 8: Auxiliaries Board
Link
LK1,3,6
1,5,6
2,3,4
LK7,8,9,10
Description
Voltage selection Links for 220/330V PMG (Omit LK2,4,5)
Voltage selection Links for 165/230V PMG (Omit LK2,3,4)
Voltage selection Links for 110/165V PMG (Omit LK1,5,6)
Fit for 24V DC Aux Supply; Omit for110/125V DC Aux Supply
Issue: J
HReg
40001
HBit
40001
0 Always FALSE
TRUE
HBit
40002
0 Always TRUE
TRUE
HBit
40003
0 PF Control Activate
Normal
Activate
HBit
40003
Normal
Activate
HBit
40003
Normal
Activate
HBit
40003
Normal
Activate
HBit
40003
Normal
Activate
Value 2
Scaled
255
No of
Decimal
Places
1
Eng.
Units
MW
HBit
40003
Normal
Activate
HBit
40003
Normal
Activate
HBit
40004
0 PF Control Deactivate
Normal
Deactivate
HBit
40004
Normal
Deactivate
HBit
40004
Normal
Deactivate
Deactivate
HBit
40004
Normal
HBit
40004
Normal
Deactivate
HBit
40004
Normal
Deactivate
HBit
40004
Normal
Deactivate
Inactive
Active
40005
HBit
40005
Inactive
Active
HBit
40005
Inactive
Active
HBit
40005
Inactive
Active
HBit
40005
Inactive
Active
HBit
40005
Inactive
Active
HBit
40005
switches
HMI
HReg
40006
Volts Reference
1400
70
2600
130
HReg
40007
-50
-50
100
100
HReg
40008
PF Reference Lagging
600
0.6
1000
HReg
40009
PF Reference Leading
900
0.9
1000
Issue: J
40014
0 V Raise Switch On
Off
On
HBit
40014
1 V Lower Switch On
Off
On
HBit
40014
2 PF Raise Switch On
Off
On
HBit
40014
3 PF Lower Switch On
Off
On
HBit
40014
Off
On
HBit
40014
HBit
40014
HBit
40014
HBit
40014
HBit
40014
HBit
40014
Off
On
Healthy
Fail
Main
Standby
Off
On
Off
On
Panel
HMI
HBit
40015
Inactive
Active
HBit
40015
1 OE Limiter Active
Inactive
Active
HBit
40015
2 UE Limiter Active
Inactive
Active
HBit
40015
Inactive
Active
Field On
Suppressed
HBit
40015
4 Field Suppressed
HBit
40015
<85%
>85%
HBit
40015
>80%
<80%
HBit
40015
Inactive
Active
HBit
40015
Brushless
Static
HBit
40015
Brushless
Static
Manual
HBit
40125
Inactive
Active
HBit
40125
Incomplete
Complete
HBit
40125
HBit
40125
HBit
40125
Inactive
Active
Mismatched
Matched
Inactive
Active
Value 2
Scaled
No of
Eng.
Decimal Units
Places
40015
10 DIL Switch 3
Normal
Off
HBit
40015
11 DIL Switch 4
Normal
Bench
Test
HBit
40015
12 DIL Switch 5
Normal
Off
HBit
40015
13 DIL Switch 6
Run
reset
HBit
40015
Use Presets
Load
Defaults
HBit
40015
Always
Local
Panel
Select
Issue: J
Value 2
Scaled
No of
Eng.
Decimal Units
Places
HBit
40016
Normal
Low
HBit
40016
Normal
High
HBit
40016
2 spare
HBit
40016
3 spare
HBit
40016
4 spare
HBit
40016
5 spare
HBit
40016
6 spare
HBit
40016
7 spare
HBit
40016
Fault
Normal
HBit
40016
Trip
Normal
HBit
40016
Trip
Normal
HBit
40016
Trip
Normal
HBit
40016
Trip
Normal
HBit
40016
13 spare
HBit
40016
14 spare
HBit
40016
15 spare
HBit
40017
Normal
Error
HBit
40017
Normal
Error
Normal
Error
255
255
1000
50
2400
120
1000
10
A
PF
40017
HReg
40018
HReg
40020
Volts Sensing
HReg
40021
HReg
40022
10000
HReg
40023
Watts Measured
11000
550
HReg
40024
VAr Measured
11000
550
VAr
HReg
40025
VA Measured
11000
550
VA
HReg
40026
3000
30
HReg
40027
255
255
Hz
HReg
40028
Line Frequency
500
50
Hz
HReg
40029
-10
3520
100
deg C
Issue: J
Quantity
1
1
1
1
1
1
1
1
1
Description
COMCAB Cable
HMI Software
Fuse, 20A (Set of 5) [Mainframe FS5, FS6]
Fuse, 5A (Set of 5) [Mainframe FS1, FS2]
Fuse, 250mA (Set of 5) [Standby FS1, FS2, FS3]
Fuse, 250mA (Set of 5) [Utilities FS2, FS4]
Fuse, 1A (Set of 5) [Utilities FS1, FS3]
Fuse, 100mA (Set of 5) [Utilities FS5]
Fuse, 2A (Set of 5) [Mainframe FS3, FS4]
Operational Spares
Part No.
Description
S961529800 Utilities Card
S962243400 Standby Control Card
S962425300 Auxiliaries Card
S962608900 A30-CON Card
S962609000 A30-MON Card
S962615901 *Contactor, 24Vdc [Mainframe ECC]
S962615902 *Contactor, 24Vdc [Mainframe FSC]
S962615903 *Contactor Latch, 24Vdc (Set of 2) [Mainframe ECC, FSC]
S962615904 *Contactor, 110Vdc [Mainframe ECC]
S962615905 *Contactor, 110Vdc [Mainframe FSC]
S962615906 *Contactor Latch, 110Vdc (Set of 2) [Mainframe ECC, FSC]
S962615907 Freewheel Diode (Set of 2) [Mainframe ECC, FSC]
S962615921 Diode Pack [Mainframe DM1, DM2]
S962615922 Thyristor Pack [Mainframe TM1, TM2]
S962615923 Bridge Rectifier [Mainframe DB1, DB2]
S962615940 Contactor Block [Mainframe ECC, FSC]
* Select 24Vdc or 110Vdc as appropriate.
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
Strategic Spares
To ensure maximum generator availability, it is recommended that a spare PRISMIC A30 Excitation
Controller should be kept in storage. If ordered after the time of manufacture of the main equipment, it
is important that your order specifies the serial number of the original unit, to enable the appropriate
spare/replacement unit to be supplied.
Issue: J
APPENDIX E - DRAWINGS
The following drawings are attached as separate additional pages:
961755200
961903800
962121900
962603000
963086400
963086500
963099600