Basler Electric BE1-25A User Manual

INSTRUCTION MANUA L

FOR

AUTO SYNCHRONIZER

BE1-25A

Publication: 9146600990
Revision: S 10/14

INTRODUCTION

This instruction manual provides information about the operation and installation of the BE1-25A Auto
Synchronizer. To accomplish this, the following information is provided:

• General Information and Specifications

• Controls and Indicators

• Functional Description

• Installation

• Maintenance

WARNING!

To avoid personal inj ury or equipment damage, only qualified personnel should
perform the procedures in this manual.

NOTE

Be sure that the BE1-25A is hard-wired to earth ground w ith no smaller tha n 12
AWG copper wire attache d to the ground terminal on the rear of the unit case.
When the BE1-25A is configured in a system with other devices, it is
recommended to use a separate lead to the ground bus from each unit.

9146600990 Rev S BE1-25A Introduction i

First Printing: July 1985

WARNING

Basler Electric does not assume any responsibility to compliance or noncompliance with national code,
understood prior to installation, operation, or maintenance.

For terms of service relating to this product and software, see the Commercial Terms of Products and
Services document available at www.basler.com/terms.

This publication contains confidential information of Basler Electric Company, an Illinois corporation. It

procedures, contact Basler Electric for the latest revision of this manual.

The English-language version of this manual serves as the only approved manual version.

Printed in USA

© 2014 Basler Electric, Highland Illinois 62249 USA

All Rights Reserved

October 2014

READ THIS MANUAL. Read this manual before installing, operating, or maintaining the BE1-25A.
Note all warnings, cautions, and notes in this manual as well as on the product. Keep this manual with
the product for reference. Only qualified personnel should install, operate, or service this system.
Failure to follow warning and cautionary labels may result in personal injury or property damage.
Exercise caution at all times.

local code, or any other applicable code. This manual serves as reference material that must be well

is loaned for confidential use, subject to return on request, and with the mutual understanding that it will
not be used in any manner detrimental to the interests of Basler Electric Company and used strictly for
the purpose intended.

It is not the intention of this manual to cover all details and variations in equipment, nor does this
manual provide data for every possible contingency regarding installation or operation. The availability
and design of all features and options are subject to modification without notice. Over time,
improvements and revisions may be made to this publication. Before performing any of the following

BASLER ELECTRIC

12570 STATE ROUTE 143

HIGHLAND IL 62249 USA

http://www.basler.com, [e-mail]

PHONE [phone] FAX [phone]

ii BE1-25A Introduction 9146600990 Rev S

REVISION HISTORY

Revision and Date

Change

The following informat ion provides a historical su mmary of the ch anges made t o the BE1-25A instruction
manual (9146600990). Revisions are listed in reverse chronological order.

Manual

S, 10/14

R, 03/11

Q

P, 05/10

O

N, 12/09

• Added note about sync output closure in Sections 1 and 5.

• Added note about Reset switch functionality in Sections 2 and 5.

• Updated the MCU Sync Module Readings label in Figures 2-1, 2-2,

5-2, and drawing on front cover.

• This revision letter not used.

• Corrected definition of 3. POWER under Locator B in Table 2-1.

• Improved definition of SYNC LED under Locator M in Table 2-1.

• Updated Storage stat em ent in Section 4.

• Improved Verification and Calibration procedure in Section 5.

• This revision letter not used.

Section 2

• Updated Additional Modules, Frequency Matching Module F5
description.

• Updated Additional Modules, Frequency Matching Module F5, F1
Function, Pulse Contact Closure description.

• Updated Additional Modules, Frequency Matching Module F5, F3
Function, Continuous Correction Pulse description.

• Under Additional Modules, Frequency Matching Module F5, F5
Proportional Frequency Correction, changed “+12 Vdc = raise pulse;

−12 Vdc = lower pulse” to “+5 Vdc = raise pulse; −5 Vdc = lower
pulse”.

• Under Additional Modules, Frequency Matching Module F5, F5 Phase
Correction, changed “+12 Vdc = raise pulse; −12 Vdc = lower pulse”

to “+5 Vdc = raise pulse; −5 Vdc = lower pulse” and removed
sentence “The frequency of the target pulses is approximately 1.5
percent of the correction pulse width setting loaded into the
microprocessor.”

Section 3

• Corrected numbering of Figures. Figure 3-6 was skipped.

• Under Frequency Matching Modules, Frequency Correction, changed

“+12 Vdc = raise pulse; −12 Vdc = lower pulse” to “+5 Vdc = raise
pulse; −5 Vdc = lower pulse”.

• Under Frequency Matching Modules, Phase Correction, changed
“+12 Vdc = raise pulse; −12 Vdc = lower pulse” to “+5 Vdc = raise
pulse; −5 Vdc = lower pulse” and removed sentence “The frequency
of the target pulses is approximately 1.5 percent of the correction
pulse width setting loaded into the microprocessor.”

Section 4

• Deleted Dielectric Test. This is in Section 5, Testing.

• Added Maintenance and Storage from original Section 6.

Section 6

• Moved Section 7, Relay Differences to Section 6, Relay Differences.

• Corrected references to several figures.

9146600990 Rev S BE1-25A Introduction iii

Manual

Revision and Date

Change

M, 05/08

L, 06/06

K, 05/05

J, 11/99

I

H, 08/98

G, 10/97

F, 07/96

E, 03/94

D

C

B

A

—, 07/85

• Corrected Max Slip Control range in Sections 1 & 2.

• Corrected Breaker Operating Time range in Section 2.

• Added manual part number and revision to footers.

• Corrected wording in Section 2 paragraph describing F3 function.

• Added metric weights to the specifications of Section 1.

• Changed name of the glossary to Appendix A, Glossary.

• Moved contents of Section 8, Manual Change Information, to the

• Changed all front panel illustrations to reflect changes to the panel of

• Updated Figure 4-1 to show new front panel and dimensions.

• Updated Figure 4-2 to show height of panel cutout.

• Added UL and CSA data to the specifications.

• In the cutout dimensions illustration, added clearance holes for

• This revision letter not used.

• Added US patent declaration to the specifications.

• Updated the manual format.

• Made various, minor changes to text.

• Revisions made to accommodate changes to firmware (version 5.02)

• Revised manual in response to option F5 being made standard.

• Divided Installation and Testing section into two sections.

• Changed all front panel illustrations to reflect changes in the controls

• Changed all references to voltage difference adjustment (option A2)

• Corrected dead bus VOLTS control from dc to ac.

• Deleted note attached to the SLIP HIGH LED.

• Added manual change information sec t ion to the man u al.

• Specification for max slip adjustment was corrected.

• Specification for isolation added.

• UL and CSA approval cited.

• Test procedures simplified.

• Manual completely revised to reflect the incorporation of a

• Relay differences section added.

• General editorial revisions.

• Initial release

manual introduction and deleted Section 8.

the power supply module.

attaching the cover.

which improved the performance of F1 and F3 type frequency
correction.

and indicators.

from 1-50 Vac to 1-10 Vac .

microprocessor in the synchronizer module (renamed the MCU Sync
module), and related changes beginning with product serial number

300.

iv BE1-25A Introduction 9146600990 Rev S

CONTENTS

SECTION 1 • GENERAL INFORMATION ................................................................................................ 1-1

SECTION 2 • HUMAN-MACHINE INTERFACE ....................................................................................... 2-1

SECTION 3 • FUNCTIONAL DESCRIPTION ........................................................................................... 3-1

SECTION 4 • INSTALLATION .................................................................................................................. 4-1

SECTION 5 • TESTING ............................................................................................................................ 5-1

SECTION 6 • RELAY DIFFERENCES...................................................................................................... 6-1

APPENDIX A • GLOSSARY ..................................................................................................................... A-1

9146600990 Rev S BE1-25A Introduction v

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vi BE1-25A Introduction 9146600990 Rev S

SECTION 1 • GENERAL INFORMATION

TABLE OF CONTENTS

SECTION 1 • GENERAL INFORMATION ................................................................................................ 1-1

DESCRIPTION ...................................................................................................................................... 1-1

OPTIONS ............................................................................................................................................... 1-1

MULTI-GENERATOR OPERATION ...................................................................................................... 1-1

APPLICATION ....................................................................................................................................... 1-2

General ............................................................................................................................................... 1-2

Generator-to-Bus Applicat i on ............................................................................................................. 1-2

Bus-to-Bus Application ....................................................................................................................... 1-2

Application Checklist .......................................................................................................................... 1-3

Defining the Parameters..................................................................................................................... 1-4

MODEL AND STYLE NUMBER............................................................................................................. 1-5

SPECIFICATIONS ................................................................................................................................. 1-6

SPECIFICATIONS OF OPTIONS .......................................................................................................... 1-8

Voltage Acceptance Option A1 .......................................................................................................... 1-8

Voltage Acceptance Option A2 .......................................................................................................... 1-8

Frequency Matching Option F5 .......................................................................................................... 1-8

Voltage Matching Option V1............................................................................................................... 1-8

Voltage Matching Option V2............................................................................................................... 1-8

Voltage Matching Option V3............................................................................................................... 1-8

Dead Bus Option D1 .......................................................................................................................... 1-8

Figures

Figure 1-1. Slip, Advance Angle, and Breaker Clos in g Time .................................................................... 1-4

Figure 1-2. Style Number Identification Chart ........................................................................................... 1-5

9146600990 Rev S BE1-25A General Information i

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ii BE1-25A General Information 9146600990 Rev S

SECTION 1 • GENERAL INFORMATION

DESCRIPTION

A basic BE1-25A Auto-Sy nchronizer consists of three rack -mounted modules that determine the proper
time to in itiate c los ing of a break er to paral lel a gen erator and a bus . The thr ee s tand ard m odules are t he
master control unit ( MCU) s ync modu le, the test module, and t he pow er s upply. Optio nal p lug-in mod ules
are available for installation (at initial purchase, or at any later time) to enhance this basic capability.
Among the options are the frequency matching and v oltage matching modules t hat direct the generator
control system to adjust vol tage or frequency ( or both) to meet sys tem requireme nts. The unit is not tru ly
an automatic synchronizer unless one or more of the matching options is incorporated.

An ideal closing is one that minimizes electrical and mechanical transients. Because the ideal closing
occurs when the voltages are in phase, the initiating signal must be delivered ahead of phase coincidence
by a factor equal to the operating speed of the breaker. This factor (termed the advance angle) is
calculated by the M CU sync module. This module is essentially a d edicated computer tha t monitors the
voltages on both sides of t he breaker to be closed, calculates th e slip frequency, and then (taking int o
consideration the operating speed of the breaker) calculates the required advance angle.

Closure will occur only if the slip frequency is less than the limit established by the slip setting. Once
breaker closure has been initiated, the BE1-25 A is inhibited from further operat ion for a minimum of 15
seconds. If the breaker reopens dur ing this 15-second inhibit period, the unit enter s a lockout condition
that prevents further operation until the unit is reset.

OPTIONS

Plug-in options can extend the capability of the basic unit. These are briefly summarized here as to
overall function. (They are explained in detail in the later sections of this manual.)

• A voltage acceptance module may be added to the basic synchronizer to assure that the
oncoming generator voltage is withi n a pre-selected magnitude with respect to the bus voltag e
before breaker closur e is allowed. Th is option is required if o ne of the vo ltage matc hing modules
is to be used.

• Voltage matching modules provide RAISE and LOWER signals to the voltage regulator of the
oncoming generator to bring the machine voltage within the limits defined by the voltage
acceptance module.

• Frequency matching (i.e., speed control) module provides RAISE and LOWER signals to the
governor to bring the oncoming generator s peed to within the slip frequency limit that is preset
into the Auto-Synchronizer. If the slip is very smal l and the p hase ang le is large, a target puls e is
initiated to change the generator speed in the direction of the closest phase coincidence.

• A dead bus module allows selection of various low bus voltage conditions to enable breaker
closing without synchronization. This provides a black start capability for the system.

MULTI-GENERATOR OPERATION

BE1-25A relays can contr ol more than one ge nerator by simultaneo usly switchin g all of the relay relevant
inputs and outputs fr om one generator to t he next. Those inputs a nd outputs are: the generator sensing
voltage, breaker 52b and closing coil circuits, and the leads associated with options (such as the
frequency and voltage matching lines to regulator or governor). All of these must be switched
simultaneously by a ganged switch called the synchronizing select switch. (This switch is installed
external to the BE1-25A un it, and is not supp lied with t he relay. Inst allation d etails are giv en in Section 4 ,
Installation.)

In addition to the re lay relevant inputs and output s, settings for the system oper ational parameters are
entered using the MCU fro nt panel LOAD/FUNCTION select switc h. Settings for six generator systems
can be entered and stored into MCU memory.

9146600990 Rev S BE1-25A General Information 1-1

APPLICATION

General

From large, single or multip le generator s to sma ll, mult iple-unit a pplications , slip fr equenc y synchr onizers
such as the BE1-25A provide fas t, accurate, synchronization of g enerator-to-bus or bus-to-bus break er
closures if a slip rate exists between the two s ides of the open break er. For the BE1-25A to be capable of
closing the breaker, the ph as e ang le bet wee n the tw o v oltag e in put s must first pass through 180 elec tric a l
degrees and maintain a slip rate until the synchronizer issues a breaker close signal.

Excluded from this discussion are phase lock type synchronizers (such as the BE3-25A) that do not
require nor allow a slip to occur between the oncoming generator and the bus.

Generator-to-Bus Application

For a slip frequency sync hronizer to oper ate pr op er ly i n a gener at or -to-bus application, the followi ng list ed
operational parameters are entered into the memory of the synchronizer using the front panel
LOAD/FUNCTION select switch.

• Generator breaker closing time (calculates advance angle)

• Generator speed correction pulse width(maximum correction pulse width)

• Generator speed correction pulse interval (maximum correction pulse interval)

• Maximum slip frequency (maximum slip frequency and still allow breaker closing)

• Generator undervoltage (inhibits synchronization below this limit)

• Lockout ON/OFF (arms or disarms lockout feature)

Synchronization is enabled when the slip frequency is less than the maximum slip setting and the
generator voltage is greater than the generator undervoltage setting. Synchronization is NOT enabled
(inhibited) when th e slip fr equency is greater than the maxim um slip s etting, th e generat or voltage is less
than the generator u ndervoltage setting, or a lockout condition exists. If a voltage acceptance optio n is
included, synchronization is NOT enabled if the bus voltages are out of limits, the voltage difference
between generator and b us is greater than the setting, or the p hase angle difference is greater than the
calculated advance angle. If a dead bus option is included, immediate sync hronization is enabled if the
bus voltage is less than the setting and the dead bus enable input is closed.

When generator spee d correction pulses are required, pr oportional pulses are generated bas ed on the
slip frequency and the max imum slip freque ncy s etting. If the slip freq uency is gre ater than four times the
maximum slip frequenc y setting, proportional pulse are generat ed that are equal to 100 percent of the
correction pulse wi dth. Correction pulses proporti onally reduce in duty cycle (rati on of ON time to OFF
time) down to zero for s lip frequencies less than four times the max imum slip frequency setting. At one­half the setting, correction pulses are disabled. If the slip frequency falls below one-sixteenth of the
maximum slip frequency s etting for ten sec onds, targe t pulses are gener ated to prev ent a hung-scope or
non-slip condition.

Bus-to-Bus Application

Some transmission c ircuits, when sp lit apart , ass ume a phas e ang le diff erence t hat s tabil izes as a s teady
offset. When this occurs , it is possible to reclose by supervisory means (usually supervised by a sync­check relay) if the angle is small eno ugh or the shoc k to the system c an be tolerated. In cases where a
slip exists, re-connection can be attained us ing a BE1-25A. In this case, one of the follo wing conditions
must be met for the BE1-25A to initiate closure.

• A slip frequency exists the prescribed limit (i.e., within the setting adjustment of the synchronizer).

• The phase angle difference is less than three degrees, with no system slip. In this case, the

phase angle between the two systems must have passed through 180 degrees to enable the
synchronizer.

If either of the two conditio ns is met, the BE1-25A will operate in a bus-to-bus environment as it would in
the case of an oncoming generator . It provides a closure comman d so that breaker closur e occurs when
the phase difference is near zero. To achieve this advance timing, the closing time of the controlled
breaker must be set into the synchronizer memory.

1-2 BE1-25A General Information 9146600990 Rev S

Application Checklist

When developing the appropriate operating parameters and safeguards for synchronizing a generator
with a bus, the foll owing items should be considered.

1. Secondary potential transformer voltage waveforms should be carefully compared with the
primary voltages. Consider the following:

a. Are the secondary and primary voltages identical for both bus and generator?
b. Is there a power transformer involved? (Suppose, for example, that the generator is

operating at 2,400 volts, delta, and the bus at 34,500 volts, wye. Are the power
transformer secondary voltages the same when the bus and generator voltages are

proper?)
c. Is there a phase shift?
d. Is the phase rotation correct?
e. Do the potential transformers reflect the actual primary voltage changes without

significant delay?

2. When switching the auto-synchronizer from one generator to another, ALL of the auto­synchronizer/generator cont rol inputs mus t be si multan eously trans ferred t o the co rrec t oncomin g
breaker and the associate d generator. During this trans fer, the 52b contact of the breaker m ust
be closed. Otherwise, an interlock (in the software) prevents the auto-synchronizer from
operating. The signals that must be switched include (but are not limited to):

a. Breaker status signal (i.e., 52b)
b. Generator voltage
c. Breaker close (contact input) circuit
d. Breaker closing time

3. Whenever frequency or voltage c ontrol options are used, their outp uts must also be switched to
the correct machine governor and voltage regulator.

4. The frequency correc tion pulse width (the amount of tim e a raise or lower signal rema ins ON)
should be coordinated with the speed of respons e of the governor, the fuel system, and the pr im e
mover to minimize the time required bringing the generator frequency into the required
relationship with the bus frequency without excessive overshoot or hunting.

5. The voltage correction puls e width and frequency should be c oordinated with the response tim e
of the voltage regulat or/exc iter/g enerator com bination t o mini mize the ti me require d to cor rect t he
voltage without overshooting or hunting.

6. If a dead bus closin g is des ired − i.e., if the m achin e can b e star ted without the b us (to w hich it is
to be synchronized) be ing energ ized tw o con ditions m us t be met:

a. Operating power for the s ynchronizer must come fro m a separate sourc e (like a bat tery)

or from the generator bus.

b. A dead bus option must be included in the uni t and be programmed to allow c losure to a

dead bus.

7. Some systems, where speed of synchronizing is a primary consideration, allow an oncoming
generator to be closed o nto the bus from ei ther the fast or s low side, and with t he voltage either
high or low.

a. Fast means that the machine is running with a positive slip (faster than the bus).
b. Slow indicates a negative slip (i.e., slower than the bus).
c. High is generator voltage greater that bus voltage.
d. Low is generator voltage less than bus voltage.

Most systems include a pr ovision to permit c losing only with th e speed fast and v oltage high. This allow s
the generator to pick up some watt and var load at once, thus stabilizing the system quickly.

By contrast, when the sp eed is slow and the voltage low, the sys tem must feed watts and reactive VA to
the machine (to add power to the pr ime mover and excitation to the exc iter field), thereby raising both
speed and voltage. S ince this ac tion is con trolled only by th e sub-s ynchr onous reac tance of the machi ne,
it can cause uncontrolle d swings of both vars and watts. The resulting tend ency toward destabilization

9146600990 Rev S BE1-25A General Information 1-3

may cause winding, iro n, or shaft stress. Accordingly, the selection of closing direc tion and permissible
limits should consider these and other pertinent application data.

Defining the Parameters

These application notes are not intended to cover every possible set of circumstances, but rather to
provide a basic description of slip frequency synchronization. The relationship between slip, advance
angle (or window), and breaker closing time is shown in Figure 1-1, and described by the formula:

= 360(+ 

)







where:

A

= advance angle in degrees. This is the time, measured in electrical degrees, between

A

initiation of breaker closure and the actual closure of the breaker contacts.

360 = degrees per slip cycle.
T

= the closing time of the circuit br eaker in secon ds. This is the t ime required fr om the c losure

CB

of the synchronizer output contact to the actual closing of t he circuit breaker contacts .

T

CB

is preset in synchronizer memory for each different break er controlled by the synchronizer .
EXCEPTION: In some applications ,

T

may re present the c haracteristic closing time of a

CB

group of breakers all having the same closing time.

T

= response time, in seconds, of the synchronizer breaker close output relay. (A non-

R

adjustable parameter approximately 0.008 second.)

F

= slip frequency in cy cles per second. This is the onc oming generator frequency minus the

S

bus frequency: positive for a generator speed higher than bus, negative for lower.

The relationships defined above should prove helpful in determining the settings for the auto­synchronizer. Note that re ducing the advance angle (or window) also reduces the absolute v alue of the
slip frequency (which is the maximum permissible sp eed difference for which the mach ine is allowed to
close onto the bus). Lower slip frequenc ies are softer (i.e., les s liable to produce sy stem disturbance or
machine damage).

Higher frequencies, on the other hand, ar e quicker (i.e., allow sync hronizati on to be ac complis hed fas ter).
Again, these considerations should be balanced against others such as:

1. How fast do I need to be on line?

2. How critical is the machine?

3. How expensive is the machine as against possible outage (down) times?

A proper synchronizer application will take int o account the considerat ions mentioned above, as well as
others that may be unique to the system under consideration. See Figure 1-1.

Figure 1-1. Slip, Advance Angle, and Break er Closin g T ime

1-4 BE1-25A General Information 9146600990 Rev S

MODEL AND STYLE NUMBER

BE1-25A Auto-Synchronizer style numbers define the features of a specific device. Each pair of
characters within the style number is associated with a specific feature or option that m ay be selected
from the style chart on the following page.

For example, if the f irst two digits of the style number are A2, t he unit has the capab ility of deferring it s
closure command to the br eaker for any of the fo llowi ng reasons: (1) the bus is under a specif ied voltag e;
(2) the bus is over a spec ified volt age; and ( 3) the bus -to-genera tor voltage is less than a selecte d value.
Another consideratio n: If a voltage matching opt ion is desired (let assume it is), including one of the A
options is essential.

The second pair of digits determines the manner in which the Auto-Synchronizer commands the
generator to change s peed. This relay uses option F5, whic h can initiate two different types of sp eed­change commands: (1) pr oportional cor rection pulse s, that are issued w hen the slip freq uency is abov e
the allowable limit; and (2) target correction pulses, that automatically f orces synchronization when ever
an out-of-phase condition coincides with a near-zero slip rate.

The third pair of digits s elects the voltage matching c apabilities that are required for an application. We
might look first at the voltag e matc h ing m odu le w ith th e mos t features, V3. Let examine these capabilities,
and how they might be useful to a specific application.

Option V3 (like Option V2) can automatically initiate c orrective pulses to bring the generator voltage to
within the limits estab lished by O ption A1 or A 2. However, w hen the voltage differenc e between bus and
generator is less th an 20.0 volts, V3 has the a dditional capability of r educing the width of t he corrective
pulses by an amount proportional to the correction required. This feature can significantly reduce
overshoot where inert ia is particularly high (as in th e control of sluice gates). If this is beneficial to our
hypothetical application (let assume it is) then the matter is decided: the third pair of digits is V3.

Finally, we choose D1 as the last pair of digits because we want the capability of obtaining a closure
when a dead bus is det ected. ( D1 a lso has t he me ans of sett ing a thresh old vo ltage to define a de ad bus
condition.)

When ordering, it is recom mended that the s tyle nu mber be prec eded by th e mo del nu mber. Accor dingly ,
the style number now looks like (Figure 1-2):

BE1-25A A2 F5 V3 D1

where:
BE1-25A = the model number
A2 = 3-parameter voltage restraint
F5 = both proportional correction pulse and target pulse capability
V3 = proportional correction pulse capability
D1 = automatic closure capability upon recognition of a dead bus

Figure 1-2. Style Number Identification Chart

9146600990 Rev S BE1-25A General Information 1-5

SPECIFICATIONS

General specifications for the BE1-25A system are provided in the following paragraphs. For
specifications that apply only to particular options, see the ensuin g subsection entitled Specificat ions of

Options.

Voltage Sensing Inputs 70 to 150 Vac, 50/60 Hz. Burden: Les s than 6 VA for the generator
(Bus and Generator) input; less than 2 VA for the bus input.

Contact Sensing Inputs Requires a user-supplied contact with a minimum rati ng of 0.05 A at

250 Vdc.

Power Supply Power for the internal circuitry may b e derived from 90 to 132 Vac at

50/60 Hz (single phase), o r 70 to 150 Vdc. B urden: Less than 20.0
VA.

Outputs Output contacts are rated as follows:
Breaker Closing

Normally open. Make and carry 30 A at 250 Vdc for 1 second, 7 A
continuously, and break 0.3 A at 250 Vdc. (L/R = 0.04).

Voltage, Frequency (Speed) Correction, and Lockout
Form C (SPDT). Make and break 5 A at 250 Vac (80% PF), 5 A at 28

Vdc (resistive), and 0.5 A at 120 Vdc (resistive).

Tolerances
Advance Angle The command for breaker closure occurs within ±3.0° of phase

coincidence of bus and generator. (Closure will not occur if the
calculated advance angle exceeds 40°.)

Lockout Occurs when breaker reopens within 15 ±10% seconds after the

initiation of breaker closure.

F

Slip Frequency (

) ±0.001 Hz

S

Generator Undervoltage ±1.0 V
Inhibit

Control Ranges The following parameters are settable over the indicated ranges.
MAX SLIP Adjustable from 0.01 to 0.500 in steps of 0.001.
BRKR TIME The characteristic breaker time settings are adjustable from 0.02 to

0.8 seconds.

NOTE

When a sync output closure is initiated, the sync output contact will be held
closed for the duration of the Breaker Operating Time setting (or 250 ms
minimum).

Generator Undervoltage Adjustable from 40 to 110 Vac.

Inhibit

1-6 BE1-25A General Information 9146600990 Rev S

Generator Speed Adjustable between 0 to 99.9 seconds in 0.1 second increments.

Correction Pulses

Shock In standard tests, the relay withstood 15 G in each of three mutually

perpendicular axes without structural damage or degradation of
performance.

Vibration In standard tests the relay withstood 2 G in each of three mutually

perpendicular axes swep t o ver the r ange of 10 to 50 0 Hz for a total of
six sweeps, 15 minutes each sweep, without structural damage or
performance degradation.

Isolation 1,500 Vac at 60 Hz for one minute in accor dance wit h IEC 2 55-5 and

ANSI/IEEE C37.90-1978 (Dielectric Test).

Surge Withstand Capability Qualified to ANSI/IEEE C37.90.1-1989, Standard Surge Withstand

Capability Tests, and to IEC 255-5, Impulse Test and Dielectric Test.

Radio Frequency Interference Field tested using a five-watt, hand-held transceiver operating at

random frequencies centered around 144 MHZ and 440 MHZ, with
the antenna located six inches from the relay in both horizonta l and
vertical planes.

Maintains proper operation when tested for interference in
accordance with IEC C37.90-1989, Trial-Use Standard Withstand

Capability of Relay Sys tem s to Radiated Electromagn etic Int er ferenc e
from Transceivers.

Patent Patented in U.S., 1998, Patent No. 5761073.

UL Listed UL listed per Standard 508, UL File Number E97033.

C.S.A. Certification CSA certified per Standard CAN/C.S. A.-C22.2 Number 14.

CE Qualification This product meets or exceeds th e standards r equired for distribution

in the European community.

GOST-R Certification GOST-R certified per the relevant standards of Gosstandart of

Russia.

Temperature

Operating –40 to 70°C (–40 to 158°F)
Storage –65 to 100°C (–85 to 212°F)

Weight 16.0 lb (7.26 kg) net for basic synchr onizer (Includes the rac k frame,

MCU module, and power supply module.)

9146600990 Rev S BE1-25A General Information 1-7

SPECIFICATIONS OF OPTIONS

To eliminate repetiti on, only the spec ifications that un iquely apply to a par ticular option are g iven below.
Specifications that are applicable throughout the unit (including the options) are stated above.

Voltage Acceptance Option A1

VOLTAGE DIFFERENCE CONTROL Minimum threshold adjustable from 0.5 to 5% of

generator voltage. (Generator voltage minus bus
voltage)

Weight 6.6 oz (186.0 g)

Voltage Acceptance Option A2

BUS VOLTAGE UPPER LIMIT CONTROL Maximum threshold adjusta ble from 100 t o 150 Vac.
BUS VOLTAGE LOWER LIMIT CONTROL Minimum threshold adjustable from 80 to 120 Vac.
VOLTAGE DIFFERENCE CONTROL Minimum threshold adjustable from 1 to 10 Vac of

generator voltage. (Generator voltage minus bus
voltage)

Weight 8 oz (226.8 kg)

Frequency Matching Option F5

CORRECTION PULSE WIDTH CONTROL Adjustable from 0 to 99.9 seconds.
CORRECTION PULSE INTERVAL CONTROL Adjustable from 0 to 99.9 seconds.
Weight 6.6 oz (186.0 g)

Voltage Matching Option V1

Weight 5 oz (140.6)

Voltage Matching Option V2

CORRECTION PULSE WIDTH CONTROL Adjustable from 0.1 to 5.0 seconds.
CORRECTION PULSE INTERVAL CONTROL Adjustable from 0.2 to 10.0 seconds.
Weight 7.0 oz (200.0 g)

Voltage Matching Option V3

CORRECTION PULSE WIDTH CONTROL Adjustable from 0.1 to 5.0 seconds.
CORRECTION PULSE INTERVAL CONTROL Adjustable from 0.2 to 10.0 seconds.
Weight 8.5 oz (240.4 g)

Dead Bus Option D1

VOLTS CONTROL Adjustable from 10.0 to 40.0 Vac.
Weight 6.6 oz (186.0 g)

1-8 BE1-25A General Information 9146600990 Rev S

SECTION 2 • HUMAN-MACHINE INTERFA CE

TABLE OF CONTENTS

SECTION 2 • HUMAN-M ACHINE INTERF ACE ....................................................................................... 2-1

INTRODUCTION ................................................................................................................................... 2-1

ADDITIONAL MODULES ....................................................................................................................... 2-5

Voltage Acceptance Module A1 ......................................................................................................... 2-5

Voltage Acceptance Module A2 ......................................................................................................... 2-6

Frequency Matching Module F5 ......................................................................................................... 2-6

Voltage Matching Module V1 ........................................................................................................... 2-10

Voltage Matching Module V2 ........................................................................................................... 2-10

Voltage Matching Module V3 ........................................................................................................... 2-11

Dead Bus Module D1 ....................................................................................................................... 2-12

Figures

Figure 2-1. Location of Controls and Indicators ........................................................................................ 2-1

Figure 2-2. Test Module in Test Position ................................................................................................... 2-2

Figure 2-3. Proportional Corr ec tion Pulses ............................................................................................... 2-4

Figure 2-4. Module A1 ............................................................................................................................... 2-5

Figure 2-5. Module A2 ............................................................................................................................... 2-6

Figure 2-6. Module F5 ............................................................................................................................... 2-6

Figure 2-7. F3 Function Correction Pulse and Slip Frequency Relationship ............................................ 2-7

Figure 2-8. Proportional Relationship when GF>BF Switch is Open ........................................................ 2-8

Figure 2-9. Proportional Relationship when GF>BF Switch is Closed ...................................................... 2-9

Figure 2-10. Module V1 ........................................................................................................................... 2-10

Figure 2-11. Module V2 ........................................................................................................................... 2-10

Figure 2-12. Module V3 ........................................................................................................................... 2-11

Figure 2-13. Pulse Duration Timing for Option V3 .................................................................................. 2-11

Figure 2-14. Module D1 ........................................................................................................................... 2-12

9146600990 Rev S BE1-25A Human-Machine Interface i

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ii BE1-25A Human-Machine Interface 9146600990 Rev S

SECTION 2 • HUMAN-MACHINE INTERFACE

INTRODUCTION

A basic BE1-25A Synchronizer (without options) is shown in Figure 2-1 and described in Table 2-1.
Figure 2-2 shows the Test Module in its offset position as required for testing. The remaining figures
describe the various options currently available.

Figure 2-1. Location of Controls and Indicators

9146600990 Rev S BE1-25A Human-Machine Interface 2-1

Figure 2-2. Test Module in Test Position

Table 2-1. BE1-25A, Controls and Indicators (Refer to Figures 2-1 and 2-2)

Locator A - GENERATOR SEL ECT Control
When the Test Module is i n the tes t p os it ion (as s how n in Figure 2-2), this c ontro l s elect s one of t h e six

possible generator operation times that are stored in the memory of the MCU Sync module. This
selection process all ows the stored constant for a particular gen erator to be employ ed as a reference
for test purposes. This control has no function when the Test Module is in the operate position (as
shown in Figure 2-1.)

Locator B - Test Jacks
When the Test Module is in the test p osition (Figure 2-2), t he tip jac ks faci litate t esting in the follo wing

described manner. Wh en the Test Module is in the n ormal position (Figure 2-1), certain jacks s erve as
monitoring points as described in the following paragraphs.

Starting from the top, the seven pairs of jacks are:

1. BUS Voltage. When th e t est module is in t es t p os iti on , a simulated bus volta ge c an b e in jec ted
for test purposes. In normal position, monitors the bus voltage.

2. GEN (Generator) Voltage. When the test module is in the test position, allows a simulated
generator voltage to be injected for test purposes. In normal position, allows the generator
voltage to be monitored.

3. POWER. When th e test module is i n tes t position, allows the op er ati ng pow er t o be s u ppl ie d t o
the BE1-25A relay. In the normal p osition, allows the supp ly voltage from terminals 21 and 22
of TB1 to be monitored.

4. 52b. When the test module is in the test pos it ion, provides a means of simulatin g a 52b c ontac t
closure (by applyin g a jumper or closing a switch across thes e jacks). In the no rmal position,
allows the 52b contact input to be monitor ed. (Measur es approxi mately 10 0 Vdc when t he 52b
contact input is open, 0 Vdc otherwise.)

5. GF>BF. When the module is in the tes t position, provides the input term inals for a simulated
GF>BF contact closure. In the normal position, these jacks have no function.

2-2 BE1-25A Human-Machine Interface 9146600990 Rev S

6. GV>BV. When the test module is in the test position, provides the input terminals for a

appears. The appropriate character appears until the INCREMENT/DECREMENT switch is

simulated GV>BV contact closure. In the normal position, these jacks have no function.

7. DEAD BUS. When the module is in the test position, provides the input terminals for a
simulated Dead Bus Enable signal. (This signal is useful only if the Dead Bus option is
present.) In the normal position, these jacks have no function.

Locator C - POWER LED
LED lights to indicate that the power supply is operating correctly.

Locator D - LOAD/FUNCTION SELECT Switch
A three-position switch with the following two active positions. (The switch is spring loaded to the

center position.)
FUNCTION SELECT. Each time the switc h is depres sed, it adv ances the displ ay (F) to s how the next

register (in the sequence listed in SETTINGS/READINGS chart (E)). The leftmost character of the
display may be found in the left c olumn of SETTINGS/READINGS chart wh ich describes the use o f
each register.

LOAD. Used to store data into memor y . To do s o, hold the s witc h in the raised position until the display
flashes (disappears and r eappears) (this takes approximately 1 second). The da ta showing in the four
rightmost digits of the display is now recorded in memory.

Locator E - SETTINGS/READINGS Chart
This chart lists various computer registers that control the sy nchronizer or monitor the system. Each

register is identified by the associated character in the left-hand column of the chart. This dig it also
appears as the left-m os t d i git of d is pl ay F w hen ev er th at register has been ac c ess ed by sw itc h D − i.e.,
the characters displayed in the righ tmos t d igi ts of the di splay repr es ent th e generator selected or status
of the particular register identified by the character in the left column of the chart.

The SETTINGS registers are:
0 (GEN SELECT). When f unction 0 is se lected, a — or a digit (1 through 6) appears as th e rightmost

character. After powering up or after reset, a — appears, but once a generator is selected, a digit
incremented. The I NCREMENT/DECR EMENT switch must be held for approximately one-half secon d

for the change to occur. The sequence is from — to 1 and incrementing to 6, and then wrapping
around to 1.

After a generator is sel ected an d t he FUN CTION SEL ECT sw itch is de press ed, t he dis play c hanges to
indicate the setting number (1 through 6) in the leftmost position and the constant (value) in the four
rightmost display characters. If a setting is changed, it must be loaded by operating the LOAD switch.

1 (BREAKER TIME). These registers ho ld the charac teristic op erating t imes of th e various bre akers in
the system. Numbers may be entered to represent break er operating time over the range of 0. 02 to

0.800 seconds.
2 (CORRECT WIDTH). The number in this regist er represents the raise and lower speed cor rection

pulse width. The pulse w idth is settable from 0 to 99.9 sec onds in 0.1 second increments. (Refer to
Figure 2-3.)

3 (CORRECT INTVL). The number in this register represents the raise and lower speed correction
pulse interval. The pu lse int er v al is s e ttab le from 0 to 99.9 seco nds i n 0 .1 sec o nd i nc r ements. (Refer to
Figure 2-3.)

9146600990 Rev S BE1-25A Human-Machine Interface 2-3

Figure 2-3. Proportional Co rr ection Pulses

4 (MAX SLIP). The number in this register represents the maximum slip rate that is acceptable for
closure of any breaker t hat is under the supervision of the Sy nc Acceptor Relay. When the slip r ate
exceeds this setting, t he sy nc acc eptor clos ure out put is inhibite d. Th e maximu m slip limit is adjusta ble
over the range of 0.01 to 0.500 Hz in 0.001 Hz increments.

5 (GEN. UV). The number in th is register represents the m inimum voltage output that the generator
must have before an operator breaker closure attempt is enabled. This value is adjustable over the
range of 40 to 110 Vac in 1.0 volt increments . If the generator voltage is below this setting, voltage
correction pulses are inhibited.

6 (LOCKOUT ON/OFF). This regist er indicates whether or not the lockout feature is enabled. When
enabled, the BE1-25A rel ay will automatically enter L OCKOUT whenever the break er re-opens within
15 seconds after closure by the synchronizer. This prevents another clos ure of the breaker from this
source until LOCKOUT is terminated by (1) manually resetting the unit, using either the front panel
RESET control or an external (remote) contact; or (2) by removing, then reapplying power.

The READINGS registers are:
A (ADVANCE ANGLE). This r epresents the number of degr ees that the breaker closur e signal must

precede actual closure so t hat the latter will occur at, or c lose to, a phase difference of zero degr ees.
This compensation takes into consideration the operating speed of the breaker, as well as the armature
operation time of the outpu t relay. (This register perfo rms a monitoring function only. N o provision for
adjusting the data.)

b (BUS VOLTS). A d igital voltmeter with a range of 0 to 135 Vac th at reads the bus voltage. (This
register performs a monitoring function only. No provision for adjusting the data.)

C (GEN VOLTS). A digita l voltmeter with a range of 0 to 135 Vac that r eads the output v oltage of the
generator being addressed. (This register performs a monitoring function only. No provision for
adjusting the data.)

d (ACTIVE BREAKER). Displays an identifying digit (1 through 6) that represents the particular
breaker whose operating time, b-contact, closing circuit, and associated generator voltage is being
addressed by the BE1-25 A relay. (In some situations, this number can represent a group of breakers
having an identical operating time.)

P (SYNC ANGLE). This variable i ndicates the instantaneo us phase angle differenc e across the open
breaker. (This register performs a monitoring function only.)

Locator F - Five-Digit , 7-Segment Display
The leftmost digit indicates the functio n selected, while the remaining four digits indicat e the present

value held in memory for that function.
Locator G - INCREMENT/DECREMENT Switch

The constants and gen erator (SETTINGS) that may b e viewed in Display E (but not the R EADINGS,
such as bus voltage, etc.) may be a ltered in value by means of th is switch. When th e switch is ra ised
for approximately one-ha lf second and released, the number on the display is incremented. But wh en
held raised, the number o n the display is incremented repeatedly − at first slowly, then much f aster.
Similarly, when the s witch is depr essed, a decreme nt oc curs , and then rep eats sl owly, t hen fas ter − as
long as the switch is held down.

The switch is spring loaded to return to the center position from both directions.
Locator H - LOCKOUT LED

This LED lights to indicate t he occ urrenc e of a lock out c onditio n. During l ockout , the out put of the r elay
is inhibited from signaling the breaker to close. Lockout may be cleared by the front panel RESET
switch, by a (continued) remotely located contact, or by powering down and then powering up.

Locator I - RESET Switch
When momentarily raised, this switch restores the relay to operation after a lockout has occurred.
This switch is also used to return to the READING registers after changing settings.

Locator J - SIG (Signal)/COM (Common) Test Points

2-4 BE1-25A Human-Machine Interface 9146600990 Rev S

Used to monitor the output breaker closure signal during testing or calibration.

Locator K - GEN UV (Generator Undervoltage) LED
An LED that lights when the generator voltage is below an acceptable range of the synchronizer. Under

this circumstance, the synchronizer is not allowed to close the breaker. (The acceptable range is
defined by the GEN UV setting of register 5.)

Locator L - SLIP INH LED
An LED that lights when the s lip frequency exceeds the para lleling tolerance establis hed by the MAX

SLIP setting. The breaker close output is inhibited whenever this LED is ON.
Locator M - SYNC LED

This LED is in parallel with the coil of the sync output relay. This LED will light (turn ON) during the time
that the sync output is energiz ed – i.e. only once each time the s ync conditi ons are met an d the output
is energized.

ADDITIONAL MODULES

Controls and indicators of the additional plug-in modules for the BE1-25A relay are described in the
following paragraphs.

Voltage Acceptance Module A1

Option A1 introduces an a dditional enabling factor for the breaker
closing signal. This additional parameter, ∆V, represents the
difference in voltage o n the two sides of the circuit br eaker. I.e., if
∆V is greater than the setting established by the VOLTAGE
DIFFERENCE co nt ro l (Figure 2-4), the closure c o mm a nd out put o f
the BE1-25A unit is inhibited.

Note that the magnitude of the VOLT AGE DIFF EREN CE setti ng is
expressed as a percentage of the bus voltage: the voltage
difference (in %) = |∆V| * 100/V

An LED indicator, ∆V HIGH, illuminates when the voltage
difference exceeds the setting and the synchronizer is inhibited.

As will be seen later , this option or option A2 is a prerequisite of,
and a controller of, any Voltage Matching option that may be
present.

BUS

.

9146600990 Rev S BE1-25A Human-Machine Interface 2-5

Figure 2-4. Module A1

Voltage Acceptance Module A2

Voltage acceptance mo dule A2 can use as many as three voltage
parameters to add constraints to the issuance of breaker
command signals. This option or option A1 is a prerequisite of,
and a controller of, any voltage matching option that may be
present. Figure 2-5 illustrates the following descriptions.

1. The UPPER LIMIT control establishes a maximum bus
voltage. No closure is to be attempted when the bus
voltage is above the upper limit.

2. The LOWER LIMIT control establishes a minimum bus
voltage. No closure is to be attempted when the bus
voltage is below the lower limit.

3. The VOLTAGE DIFFERENCE control establishes the
maximum acceptabl e voltage difference between t he two
sides of the circuit breaker (generator voltage minus bus
voltage). No closure is to be attempted continuously
variable over the range of 1 to 10 Vac.

An LED to the left of each c ontrol lights whenever the associated
parameter is beyond the ra nge set by the control. As a result, the
breaker closure is inhibited.

Figure 2-5. Module A2

Frequency Matching Module F5

The F5 frequency matching module (Figure 2-6) provides a frequency-corrective (speed) signal that is
compatible with motor-oper ated m achi ne speed c ontro ls. Begin ning on A pril 30, 1 996, (BE1-25A, revis ion
R), the optional F5 frequency matching module includes the functionality of F1, F3, and F5 modes of
operation. The F1 mode of operation pr ovides fixed width puls es, fired pro portional to the slip fre quency.
The F3 mode of operation prov ides a continu ous correc tion signal unt il the measur ed slip is les s than the
slip setting. The F5 mode of operation issues correction pulse width proportional to the slip frequency.

F1 Function, Pulse Contact Closure

The F1 function generates a fixed-width correction pulse s ettable
from 0.1 to 99.9 seconds in 0.1 secon d increments . These pu lses,
though fixed in pulse width, are sent more often at higher slip
frequencies and less often as the slip decreases. In this (F5)
implementation, the fixed width pulse is fired proportional to the
slip frequency. The F1 function is implemented by setting the
correction pulse width to any non-zero value and setting the
correction pulse interval to zero. The F1 function provides a
continuous correction signal at high slip frequencies.
Approximately when the inverse of the slip frequency is greater
than the pulse width setting, the c ontinuous correction signal will
become a fixed-width correction pulse with a pulse interval
approximately equal to the inverse of the slip frequency.
Correction pulses are issued until the slip frequency is within 0.5 of
the slip setting. Sync closure can occur any time below the slip
setting if no correction pulses are being issued.

Figure 2-6. Module F5

2-6 BE1-25A Human-Machine Interface 9146600990 Rev S

F3 Function, Continuous Correction Pulse

Correction

area

Correction

area

Neg

Slip

Pos
Slip

Max

Slip

Max

Slip

Slip =

0

GF > BF Sw

Open

Correction

area

Correction

area

Neg

Slip

Pos
Slip

Max

Slip

Max

Slip

Slip =

0

Correction Dead Zone

And

Synchronization Zone

Correction Dead Zone

And

Synchronization Zone

GF > BF Sw

Closed

D

2610-07

10-03-97

The F3 function provides a continuous correction signal until the measured slip is less than the slip
setting. The F3 funct ion is implemented by setti ng the correction pulse w idth to zero and the correc tion
pulse interval to zero or an y non-zero number . The correc tion pulse is continuo us (full-on) as long as the
slip frequency is greater t han the slip setting. No cor rections are issued if the s lip frequency is less than
the slip s etting. One exception would be t o bump the target pulse if the slip fre quency is very close to
zero. Figure 2-7 shows the F3 function correction pulse and slip frequency relationship.

Figure 2-7. F3 Function Correction Pulse and Slip Frequency Relationship

9146600990 Rev S BE1-25A Human-Machine Interface 2-7