Basler Electric BE1-25A User Manual

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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

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, info@basler.com

PHONE +1 618.654.2341 FAX +1 618.654.2351

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

P, 05/10

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

H, 08/98

G, 10/97

F, 07/96

E, 03/94

—, 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

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:

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

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

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

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

may re present the c haracteristic closing time of a

group of breakers all having the same closing time.

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

adjustable parameter approximately 0.008 second.)

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

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.

Slip Frequency (

) ±0.001 Hz

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 =

GF > BF Sw

Open

Correction

area

Correction

area

Neg

Slip

Pos Slip

Max

Slip

Max

Slip

Slip =

Correction Dead Zone

And

Synchronization Zone

Correction Dead Zone

And

Synchronization Zone

GF > BF Sw

Closed

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

F5 Function, Proportional Frequency Correction

Max Slip

4 *

Max Slip 4 *

Max Slip

12.5%

25%

50%

2 *

Max Slip

100

25%

Max Slip

2 *

Max Slip

Pos Slip (GF>BF)

100%

Target Slip

Band

Min Slip &

Sync Range

Zero Slip

Correction Width

Setting Value

Correction Width

Setting Value

Percentage Correction

Pulse Width

Neg Slip

(GF<

BF)

Slip Inhibit LED On

Proportional Correction

1/2 Max Slip

/2 Max Slip

Frequency Correction Dead Band

Proportional Correction

Range

Proportional Correction

Range

D2610-08

10-03-97

A proportional correc tion pulse train is issued when the slip frequency is greate r than 50 percent of the maximum slip frequency setting. The pulses are steered (as appropriate) to operate one of the two speedadjust output relays . The contacts of one relay are used to signal the ge nerator to r aise speed, w hile the contacts of the other relay are used to signal the generator to lower its speed. The period of the correction pulses is determine d by the settings loaded into the microprocessor. That is, the period is equal to the sum of the correctio n p uls e int erv al plus the correction pulse w idth . T he period remains cons tan t o nc e th e correction pulse width and correction pulse interval are set. The proportional correction pulse is determined by the percent of correction required. If the slip frequency is greater than four times the maximum slip allowed, the proportional c orrection pulse train is a t 100 percent of the sett ing (correction pulse interval settin g plus correction pulse width sett ing). If the slip frequency is equal to the maximum slip setting, the proportio nal correction pulse width is at 25 percent of the origina l setting. The correction pulse interval (wait time) will increase t o maintain a consisten t correction pulse period (total of the pulse interval and pulse width). Figure 2-8 shows the proportional relationship when the GF>BF switch is open.

Proportional correction is linear between 100 percent (four times maximum slip frequency setting) and

12.5 percent (equal to one-half maximum slip frequency setting). Synchronization is enabled at slip frequencies less than the maximum slip setting. Although sync hronization is enabled at slip frequenc ies below 50 percent of the maximum slip allowed, n o cor r ection pu ls es are is sued . T he pu ls es is s ued by t his option (to direct the output relays ) may be monitored at the SIG and COM jack s. (+5 Vdc = raise pulse;

−5 Vdc = lower pulse.) Figure 2-9 shows the proportional relationship when the GF>BF switch is closed.

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

2-8 BE1-25A Human-Machine Interface 9146600990 Rev S

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

1/2 Max Slip

Max Slip

4 * Max Slip

12.5%

25%

50%

2 * Max Slip

100%

50% 25%

12.5%

Max Slip

Pos Slip

(GF>BF)

100%

Target Slip

Band

Min Slip &

Sync Range

Percentage Correction

Pulse Width

Neg Slip

(GF<BF)

Slip Inhibit LED On

Zero Slip

Correction Width

Setting Value

Frequency Correction

Dead Band

Proportional

Correction

Correction Width

Setting Value

Proportional Correction

3-1/2 * Max Slip

1-1/2 * Max Slip

D2610-05

10-06-97

Phase Correction

A target pulse is issued to the cor rection pulse train when the bus and generator are freque ncy matched (within approximately six percent of the maximum slip setti ng) but not phase matched. The pulses are steered to induce a s lip fre quency that may be a djusted to fall wit hin the all owable limits of th e correcti on pulse train. The contacts of one r elay are used to signal the generat or to raise speed, while the cont acts of the other relay are used to signal the generat or to lower its speed. The tar get pulses issued may be monitored at the SIG and CO M jacks and are additional pulses to the correc tion pulse train. (+5 Vdc = raise pulse; −5 Vdc = lower pulse .)

NOTE

If the generator voltage is less than the generator undervoltage setting, correction pulses are inhibited.

9146600990 Rev S BE1-25A Human-Machine Interface 2-9

Voltage Matching Module V1

Option V1 (Figure 2-10) issues a correc tive signal whose pur pose is to increase or decrease the generator termi nal voltage to within the voltage difference limit determined by the setting of the Voltage Acceptance Optio n A1 or A2 (whichever is present). The signal is in the form of a continuous closed-contact output.

Control and indicators are limited to:

a. RAISE LED, that lights when a raise voltage signal is

being output (at which time the raise output contact is closed).

b. LOWER LED, that lights when a lower voltage signal is

being output (at which time the lower output contact is closed).

Figure 2-10. Module V1

Voltage Matching Module V2

Option V2 (Figure 2-11), like opti on V1, issues corrective signals that increase or decrease the generator voltage to within the voltage difference limit determined by the setting of whichever Voltage Acceptance o ption is present (A1 or A2). In the case of this option, however, the c orrective signal is not c ontinuous (as in V1), but rather is in the form of a pulsing output contact.

Pulse duration and interval are independently controlled by the CORRECTION PULSE WIDTH control, and by th e CORRECTION PULSE INTERVAL control.

When correction pulses are issued, the direction of the c orrection is indicated by either the RAISE or the LOWER LED. This also indicates which of the two output relays (and w hich set of output contacts) is delivering the pulses: the raise output relay or the lower output relay.

The pulses issued by this option (to direc t the output relays) may be monitored at the SIG and COM jacks. (+12 Vdc = relay deenergized; 0 Vdc = relay energized.)

Figure 2-11. Module V2

2-10 BE1-25A Human-Machine Interface 9146600990 Rev S

Voltage Matching Module V3

Option V3 (Figure 2-12) is similar to O ption V2, in that it initiates corrective pulses that are used to increase or decrease the generator voltage to within the voltage difference limit as determined by the Voltage Acceptance mod ule (either A1 or A2). Both V2 and V3 are functionally identical when the voltage difference between genera tor and bus is equal to or greater than

20.0 Vac. But when the voltage differ ence is less than 20.0 Vac, Option V3

differs in this respect: the duration of the corrective pulses no longer follows in lockstep with the setting of the CORRECTION PULSE WIDTH control. Instead, the duration of the corrective pulses is reduced by an amount proportional to the correction required (Figure 2-13). Note that the minimum pulse duration is

0.1 seconds. The CORRECTION PULSE INTERVAL control determines the

period of the pulse train. (Unlike the PULSE WIDTH control, the INTERVAL control does NOT vary from the set ting as a function of voltage difference.)

The pulses issued by this option (to direct either the raise or the lower output relay) may be monitor ed at the SIG and COM jacks. (+12 Vdc = relay de-energized; 0 Vdc = relay energized.)

Figure 2-12. Module V3

Figure 2-13. Pulse Duration Timing for Option V3

9146600990 Rev S BE1-25A Human-Machine Interface 2-11

Dead Bus Module D1

When the external d ead bus c ontact is close d, module D1 ( Figure 2-14) determines when the bus is dead, and acts upon this determination (if the br eaker is detected op en) by init iating a close breaker signal. This signal is terminated as soon as the sync acceptor recognizes the breaker as having closed, or when 100 milliseconds have passed (whichever occurs first).

The VOLTS control defi nes a dead b us condi tion by establ ishing a voltage threshold between 10 and 40 Vac.

The DEAD BUS indicator i s an LED that lights whenever the bus voltage is below the control setting.

Figure 2-14. Module D1

2-12 BE1-25A Human-Machine Interface 9146600990 Rev S

SECTION 3 • FUNCTIONAL DES CRIPTION

TABLE OF CONTENTS

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

SYSTEM OPERATION .......................................................................................................................... 3-1

INPUT CIRCUITS .................................................................................................................................. 3-3

Contact Inputs .................................................................................................................................... 3-3

Front Panel Inputs .............................................................................................................................. 3-3

Analog Inputs ..................................................................................................................................... 3-3

MICROPROCESSOR CIRCUITRY ....................................................................................................... 3-3

OUTPUTS .............................................................................................................................................. 3-4

OPTIONS ............................................................................................................................................... 3-4

VOLTAGE ACCEPTANCE MODULE A1 .............................................................................................. 3-6

VOLTAGE ACCEPTANCE MODULE A2 .............................................................................................. 3-7

FREQUENCY MATCHING MODULE F5 .............................................................................................. 3-8

Frequency Correction ......................................................................................................................... 3-8

Phase Correction ................................................................................................................................ 3-8

VOLTAGE MATCHIN G M ODULE V1 .................................................................................................... 3-9

VOLTAGE MATCHIN G M ODULE V2 .................................................................................................. 3-10

VOLTAGE MATCHIN G M ODULE V3 .................................................................................................. 3-11

DEAD BUS MODULE D1 ..................................................................................................................... 3-12

Figures

Figure 3-1. System Block Diagram ............................................................................................................ 3-1

Figure 3-2. Auto-Synchronizer Block Diagram .......................................................................................... 3-2

Figure 3-3. Synchronizer Flow Diagram .................................................................................................... 3-5

Figure 3-4. Voltage Acceptance Module A1 Block Diagram ..................................................................... 3-6

Figure 3-5. Voltage Acceptance Module A2 Block Diagram ..................................................................... 3-7

Figure 3-6. Frequency Matching Module F5 Block Diagram ..................................................................... 3-8

Figure 3-7. Voltage Matching Module V1 Bl ock Diagram.......................................................................... 3-9

Figure 3-8. Voltage Matching Module V2 Block Diagram........................................................................ 3-10

Figure 3-9. Voltage Matching Module V3 Block Diagram........................................................................ 3-11

Figure 3-10. Dead Bus Module D1 Block Diagram ................................................................................. 3-12

9146600990 Rev S BE1-25A Functional Description i

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ii BE1-25A Functional Description 9146600990 Rev S

SECTION 3 • FUNCTIONAL DESCRIPTION

SYSTEM OPERATION

As the prime mover brings the oncoming gener ator up to speed, t he BE1-25A Au to-Synchronizer (Figure 3-1) compares the generat or output with the bus. When the m onitored frequency and phase angle (and, optionally, the voltage) are within preset limits as described below, the BE1-25A Auto-Synchronizer signals the controlled breaker to close.

Figure 3-1. System Block Diagram

To accomplish closur e qu ic k ly and with the least stress on th e sy s tem, a m ic ropr o c ess or in the MCU s y nc module calculates (and thu s anticipa tes) the adv ance angle neces sary to compen sate for br eaker c losure time, as well as for operation time of the output relay. To do so, it utilizes data stored in memory concerning the characteristic closing times of the generator breaker to which it is connected.

As detailed in Section 4, the BE1-25A Auto-Synchronizer can be set-up to co ntrol multiple generators. Each generator may be associated with a breaker whose closing time may b e different from the others . The various closing times are stored in the synchronizer memory and called up according to which generator/breaker combination the BE1-25A Auto-Synchronizer is connected. (The connecting is performed by user-installed switches.)

After breaker closur e has been initiated, the Auto-Synchronizer is inhibited from fur ther operation for 15 ±1.5 seconds.

9146600990 Rev S BE1-25A Functional Description 3-1

A functional block diagram of the Auto-Sync hronizer is given in Figure 3-2, and is ref erred to in the circui t descriptions that foll ow. A black box approach is tak en, with the emphasis on t he inputs and outputs to the external world. Omitted from the diagram are the internal signals that communicate between the various modules of t he system. Note that t he output relays show n in the lower right corn er of the figure are not present unless the controlling options are installed.

Later in this section, additional functional diagrams are provided that describe the options.

Figure 3-2. Auto-Synchronizer Block Diagram

3-2 BE1-25A Functional Description 9146600990 Rev S

INPUT CIRCUITS

Contact Inputs

At the upper left corner of Figure 3-2 are the contact sensing inputs. N ote that opto-isolator s protect the internal circuits from the unwanted noise that is present on unconditioned lines. The inputs are:

• 52b - An input th at monitor s the 5 2b aux iliary c ontac t of th e contr olled breaker . (The 52b contac t, when closed, indicates that the breaker is open.)

• Reset - An input that may be used to monitor a remotely located reset switch. (Not to be confused with the RESET switch on the front panel of the unit.)

• GF>BF - An input that may be used to monitor a remotely located switch, that when closed, enables the closure output of the Auto-Synchronizer if (and only if) t he generator frequency is greater than the bus frequency. When this contact is open, closure is allowed from both directions.

• 2, 3, 4, 5, 6 - Thes e five input contacts, in conjuncti on with the c ommon c ontact, p rovide a mea ns of informing the Auto-Synchronizer which generator (and which generator breaker) has been connected to the Auto-Synchronizer. A sixth generator /break er com bi nat ion ( gen e r ator/br eak er 1) may be recognized by opening all five inputs, 2 throu gh 6. This is a d efault input tha t addresses the first generator/breaker combination.

The various contact input signals are directed to input-conditioning circuitry, where they are translated into binary notation and strobed into the microprocessor. Notice that power for the contact inputs is isolated by means of a transformer supplied by the generator voltage sensing input.

At the lower left corner of Figure 3-2 are tw o inputs that go directly to optiona l modules. They are als o translated into binary notation and strobed into the microprocessor. They are:

• GV>BV - If one of the volt age ac ceptanc e op tions is present, this input may be us ed to m on itor a remotely located switch, t hat when cl osed, enab les the closur e output of the A uto-Synchronizer if (and only if) the generator voltage is greater than the bus voltage. When this contact is open, closure is allowed from both directions.

• Dead Bus Enable - If the dead bus enable option is installed, the clos ure of this contact input coupled with a dead bus condition will bring about an immediate breaker close output.

Front Panel Inputs

Front panel inputs (Figure 3-2, abo ut one-third down at the left), represent (1) the LOAD & FU NCTION switch, (2) the INCREMENT-DECREMENT switch, and (3) the LOCKOUT RESET switch of the MCU sync module. Switches (1) and (2) control the d isplay and the memory of the Auto-Synchronizer. Switch (3), when momentarily raised, restores the operation of the Auto-Synchronizer to the initialized condition.

Analog Inputs

Generator and bus volta ge inputs together mon itor both sides of the break er, and have a nominal rat ing of 150 Vac at 50/6 0 Hz. Internal tra nsformers provide isolation and s caling. After the transformers, the analog inputs enter squaring circuits. These circuits allow the phase information to be represented by precise square waves nee ded to accurately determ ine the zero crossings . Additional circuitry pr ovides a dc-analog representation of voltage magnitude for evaluation by the microprocessor and associated circuits.

To conclude the inp ut description, a source of pow er for the digital circuits is r equired. Internal diod es steer these voltages so tha t no polarity needs to be obs erved in makin g connect ions . These terminals will accept either ac or dc, provided that it is within the voltage range of 70-150 V (and 50/60 Hz if ac).

MICROPROCESSOR CIRCUITRY

The microprocessor, with the as soci ated me mory a nd dec odin g log ic, perf orms a ll calc u lations, makes all decision, and controls t he display and out put circuitry. Thes e functions are f or the most part, d etermined by the software in the manner illustrated by the flow diagram of Figure 3-3.

Returning to Figure 3-2, a crystal os cillator provides a precise tim e reference for determining frequ ency and phase relationships.

The power up/down r eset logic (at th e lower left corner) moni tors the intern al logic v oltages. If any of the voltages fall below a critical threshold, the microprocessor is placed in a park mode. All decision making is

9146600990 Rev S BE1-25A Functional Description 3-3

then inhibited until such time as all vital voltages return to normal. (Because all settings and vital, programming instructions are held in non-volatile memory (EEPROM), and are not erased if power is lost.)

Microprocessor operation is monitored by the watchdog circuitry. If some transient condition has disrupted the normal pattern of o peration, the watchdog oper ates the alarm output, rese ts the microproces sor, and initializes the program. The reset restarts the microprocessor. After the third such reset operation (perhaps indicative of s ome hardware failure) , the microprocessor is stopped and shuts do wn the entire unit. This condition remains until operating power is disconnected, then reapplied. (An inoperative microprocessor usually appears as a display that is frozen and probably inappropriate or meaningless.)

OUTPUTS

Again referencing Figure 3-2, the Output Driv ers provi de the interfac e required between the logic circ uits and the final outputs, which are the LED indicators and the output relays. The Breaker Close relay provides a normally open contact. The other output relays are of the plug-in type, and are only incorporated into the unit upon the addition of the relevant option(s). Note that these supplementary relays provide both norma lly open and normally closed cont acts for each function represente d. (For the terminal numbers of these contacts see Section 4, Installation.)

OPTIONS

The various options available for the BE1-25A Auto-Sy nchronizer Relay are described on the following pages. Note that they are grouped into four categories: Voltage Acceptance, Voltage Matching, Frequency Matching, and Dead Bus. Only one option from each category can be used at one time.

The basic Synchronizer m ay be upgraded to Automatic Sync hronizer status by incorporat ing one of the voltage matching options and/or one of the frequency matching options. This may be accomplished at any time − i.e., at original purchase or at any time thereafter.

Legend for Figure 3-3.

ADVANCE ANGLE - Number of degrees that the close breaker signal must precede

actual closure of the breaker so that the closure occurs at (or very close to) zero degrees of phase difference

BF - Bus frequency

CLOSE BREAKER - Represent the closure of the BE1-25A output contact to provide

closing current to the breaker

DEAD BUS - A condition wher e the bus voltage is less than the s etting of module

D1, VOLTS control GF - Generator fr equ enc y GV - Generator voltage MAX SLIP - Maximum slip frequency setting F UV - Undervoltage Setting

- Slip frequency

3-4 BE1-25A Functional Description 9146600990 Rev S

Figure 3-3. Synchronizer Flow Diagram

9146600990 Rev S BE1-25A Functional Description 3-5

VOLTAGE ACCEPTANCE MODULE A1

The sensed bus and generator voltages are rectified and output to the balance circuit. Any inequality detected in the balanc e c ircuit re pres ents the v olt age differe nce ( )V) betw een the bus an d the g enera tor. And the polarity of the difference represents the direction required for any corrective signal to the generator.

The balance error signal (o r output) is am plified and di rected to the precision ful l wave rec tifier and to the output gates. The output g ates provide a signal (utilized by any voltage ma tching module present) that indicates the desir ed direction that any speed-corrective command should have. This takes the form of either a raise signal or a lower signal, according to the polarity of the error.

A comparator monitors the VOLTAGE DIFFERENCE control. If the voltage difference betw een the two sides of the breaker ()V) is found to be greater than the setting of the control, the breaker closure command of the synchron izer is inhibited. (Th is infor mation is also used by any voltag e matching mo dule in the system to determine whether corrective signals are required.)

Additional circuitry mon itors the external enable contact. The pres ence of a GV>BV signal (i.e., contact closed) inhibits the sy nchronizer closure output un less the generator voltage is i ndeed greater than the bus voltage. See Figure 3-4.

Figure 3-4. Voltage Acceptance Module A1 Block Diagram

3-6 BE1-25A Functional Description 9146600990 Rev S

VOLTAGE ACCEPTANCE MODULE A2

Note: The first three paragraphs below repeat the material on the previous page. The sensed bus and generator voltages are rectified and output to the balance circuit. Any inequality

detected in the balanc e c ircuit re pres ents the v olt age differe nce ( )V) betw een the bus an d the g enera tor. And the polarity of the difference represents the direction required for any corrective signal to the generator.

Module A2 differs from A1 by having additional comparators that monitor the UPPER LIMIT and the LOWER LIMIT controls. Th e added c ircuitry serv es to inhibit op erat ion unless the bus voltage is less than the upper limit, and greate r than the lower limit. Additional circuits mon itor the external enable contact. The presence of a G V>BV signal (i .e., con tact close d) inh ibits the s ynchron izer clos ure output unless t he generator voltage is indeed greater than the bus voltage. See Figure 3-5.

Figure 3-5. Voltage Acceptance Module A2 Block Diagram

9146600990 Rev S BE1-25A Functional Description 3-7

FREQUENCY MATCHING MODULE F5

Frequency Correction

A proportional correc tion pulse train is issued when the slip frequency is greate r than 50 percent of the maximum slip frequency setting. The pulses are steered (as appropriate) to operate one of the two speedadjust output relays . The contacts of one relay are used to signal the ge nerator to r aise speed, wh ile the contacts of the other relay are used to signal the generator to lower the speed. The period of the correction pulses is determined by the settings loaded into the microprocessor. That is, the period is equal to the sum of the cor rection pulse interval plus the correction pulse width . The period remains c onstant once the correction p ulse width and c orrection puls e interval are s et. The pro portional corr ection puls e is determined by the percent of correction required. If the slip frequency is greater than four times the maximum slip allowed, the proportional c orrection pulse train is a t 100 percent of the sett ing (correction pulse interval settin g plus correction pulse width sett ing). If the slip frequency is equal to the maximum slip setting, the proportio nal correction pulse width is at 25 percent of the origina l setting. The correction pulse interval (wait time) will increase t o maintain a consisten t correction pulse period (total of the pulse interval and pulse width).

Proportional correction is linear between 100 percent (four times maximum slip frequency setting) and

12.5 percent (equal to one-half maximum slip frequency setting). Synchronization is enabled at slip frequencies less than the maximum slip setting. Although sync hronization is enabled at slip frequenc ies below 50 percent of the maximum slip allowed, n o cor r ection pu ls es are is sued . T he pu ls es is s ued by t his option (to direct the output relays) may be monitored at the SIG and COM j acks. (+5 Vdc = raise pulse;

−5 Vdc = lower pulse.)

Phase Correction

A target pulse is issued to the corr ection pulse train when the bus and generator are freque ncy matched (within approximately six percent of the maximum slip setti ng) but not phase matched. The pulses are steered to induce a s lip fre quency that may be a djusted to fall wit hin the a llowable li mits of the c orrecti on pulse train. The contacts of one relay are us ed to signal the generator to r aise speed, while the contac ts of the other relay are used to signal the genera tor to lower the speed. The target puls es issued may be monitored at the SIG and CO M jacks and are additional pulses to the correc tion pulse train. (+5 Vdc = raise pulse; −5 Vdc = lower pulse.) See Figure 3-6.

Figure 3-6. Frequency Matching Module F5 Block Diagram

3-8 BE1-25A Functional Description 9146600990 Rev S

VOLTAGE MATCHING MODULE V1

Module V1 issues corr ective signals to the generator control system that caus e the voltage to approach the voltage of the bus. The corrective output signal is in the form of a continuous contact closure.

This module is, in turn, controlled by whichever voltage acceptance module is in the system. (One of these, either A1 or A2 must be present in order for module V1 to function.)

An inhibit signal fr om the A module, AINH, wi ll disable the V1 output (Figure 3-7). Additio nal A-module signals, raise and lower, determine whether the output will raise or lower the generator voltage.

If the generator voltage is less than the generator undervoltage setting, voltage correction pulses are inhibited. See Figure 3-7.

Figure 3-7. Voltage Matching Module V1 Block Diagra m

9146600990 Rev S BE1-25A Functional Description 3-9

VOLTAGE MATCHING MODULE V2

Like the V1 module, m odule V2 issues corr ective signals to the generator contro l system that caus e the generator voltage to ap proach the voltag e of the bus. In the case of th is module, howev er, the corr ective signal is not contin uous , bu t r ath er a tr ain o f p ulses . The pulse width an d pulse frequency are ad jus ted by front panel controls.

Module V2 (Figure 3-8) is controlled by whichever voltage acceptance module (A1 or A2) is in the system. (Either A1 or A2 must be present in order for this module to function.)

An Inhibit signal from t he A module, AINH, will disab le the V2 output (Figure 3-8). Additional A-module signals, raise and lower, determine whether the output will raise or lower the generator voltage.

If the generator voltage is less than the generator undervoltage setting, voltage correction pulses are inhibited. See Figure 3-8.

Figure 3-8. Voltage Matching Module V2 Block Diagram

3-10 BE1-25A Functional Description 9146600990 Rev S

VOLTAGE MATCHING MODULE V3

Like the V2 module, module V3 issues corrective signals in the form of p ulses to the generator control system. The corrective s ignals are used to adjust the generator voltage toward the v oltage of the bus. In fact, this module is function ally identical to module V2 so long as the voltage differ ence between the two sides of the breaker is greater than 20.0 Vac.

However, when the voltage difference is less than 20.0 Vac, the duration of the corrective pulses is proportionally reduced fr om the duration called for by the setting of the CORRECTION PULSE WIDTH control. I.e., the dur ation falls of f by a ratio t hat is dire ctly proportion al to the red uced differ ence between the two voltages.

A constant current gener ator ( Figure 3-9, bottom le ft) outp uts a cur rent that is used to char ge a c apacitor . (The magnitude of the current is established by the CORRECTION PULSE WIDTH control.) The comparator weighs the c apacitor rising charg e against the output of t he precision full wave r ectifier. The interval pulse will then have the duration trimmed by an amount directly proportional to the capacitor charge. This additional constraint is then input to the gate.

For other circuit features, refer to the functionally similar module V2 description on the previous page. Module V3 is control led by whichever voltage ac ceptance modu le (A1 or A2) is in the sy stem. (Either A1

or A2 must be present in order for this module to function.) See Figure 3-9.

Figure 3-9. Voltage Matching Module V3 Block Diagram

9146600990 Rev S BE1-25A Functional Description 3-11

DEAD BUS MODULE D1

Sensed bus voltage (up per left of Figure 3-10) is rectified, s caled to logic levels, and then presented to the comparator. The co mparator determ ines whether or not t he bus is dead, as defined by the setti ng of the VOLTS control. Not e that this control can define dead as any condition under a thr eshold setting in the range of 10 to 40 volts.

If the bus voltage is les s than the VOLT S control set ting, the outpu t gate logic is enabled. At th is point, if the output gate logic detects an enabling jumper (described below) and an undervoltage signal, the DEAD BUS indicator is illumina ted and the 1-second timer is star ted. If, for the ensuing second, the 1-second timer continues to receive a qualifying signal from the output gate logic (and a lockout state is not evidenced), a DB (dead bus) signal is passed to the MCU sync module, that causes the MCU sync module to generate a breaker close signal.

This module is enabled by an external contact closure in one of three ways:

1. By an external jumper across the terminals 9 and 10 of terminal strip TB1 (on the rear of the case).

2. By a manually-controlled external switch (same terminals).

3. By an automatically controlled enabling signal (same terminals). See Figure 3-10.

Figure 3-10. Dead Bus Module D1 Block Diagram

3-12 BE1-25A Functional Description 9146600990 Rev S

SECTION 4 • INSTALLATION

TABLE OF CONTENTS

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

INTRODUCTION ................................................................................................................................... 4-1

RELAY OPERATING GUIDELINES AND PRECAUTIONS .................................................................. 4-1

MOUNTING............................................................................................................................................ 4-1

CONNECTIONS .................................................................................................................................... 4-3

General ............................................................................................................................................... 4-3

Multi-Generator Operation.................................................................................................................. 4-3

MAINTENANCE ..................................................................................................................................... 4-5

STORAGE.............................................................................................................................................. 4-5

Figures

Figure 4-1. Overall Dimensions ................................................................................................................. 4-2

Figure 4-2. Cutout Dimensions (for Non-Rack Mounting) ......................................................................... 4-3

Figure 4-3. Connection Diagram (Units Serial Number 546 and Higher) .................................................. 4-4

Figure 4-4. Controlling 6 Breakers with One BE1-25A .............................................................................. 4-5

9146600990 Rev S BE1-25A Installation i

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ii BE1-25A Installation 9146600990 Rev S

SECTION 4 • INSTALLATION

INTRODUCTION

BE1-25A relays are s hipped in sturdy cart ons to prevent damage during transit. Upon receipt of a re lay, check the model an d style number a gainst the r equis ition and p acking l ist to s ee that they agree . Inspec t the relay for shipping dama ge. If ther e is ev idenc e of d amage, f ile a cl aim wi th the carr ier, and not ify y our sales representative or Basler Electric.

If the relay wi ll not be insta lled immed iately, s tore it in i ts original sh ipping car ton in a moistur e- and dustfree environment. Before placing the relay in service, it is recommended that the test procedures of Section 5, Testing be performed.

RELAY OPERATING GUIDELINES AND PRECAUTIONS

Before installing or operating the relay, note the following guidelines and precautions. When the unit is installed, the controls should be protected by the plastic cover supplied. This limits

access to the control settings.

NOTE

Be sure that the BE 1-25A is hard-wire d to earth ground w ith no smaller tha n 12 AWG copper wire attached to the ground terminal on t he rear of the case. When the BE1-25A is config ured in a system with ot her devices, it is rec ommended to use a separate lead to the ground bus from each device.

MOUNTING

BE1-25A Synchronizer s are designed to be rack-mounted. The ov erall dimensions are shown in Figure 4-1. Alternatively, the un it may be panel-m ounted, using the c utout dimensions of Figure 4-2 as a guide. The unit may be mounted at any convenient angle.

9146600990 Rev S BE1-25A Installation 4-1

Figure 4-1. Overall Dimensions

4-2 BE1-25A Installation 9146600990 Rev S

Figure 4-2. Cutout Dimensions (for Non-Rack Mounting)

CONNECTIONS

General

Incorrect wiring may result in damage to the unit. Connections for Auto-Synchronizer terminals are identified in Figure 4-3. Terminals are suitable for use with wir e sizes 14 AWG or lar ger.

When one BE1-25A unit is us ed to contro l more tha n one gen erator, r efer to Mult i-Generator Operation in this section for a connection diagram.

Multi-Generator Operation

BE1-25A Auto-Sync hronizers can be used on mult iple-genera tor systems by s imultaneously switching all relevant inputs and ou tputs from one generator to the next. Figure 4-4 is an interc onnect diagram for a typical multiple-generator system controlled by one BE1-25A. This includes the generator sensing voltage, the breaker 52b and closing coil circuits, and any leads associated with options (such as the frequency and voltage matching lines to regulator or governor). Note that the closing time of each generator breaker is entered into the memory of the BE1-25A, and is recalled by positioning the SYNCHRONIZING SELECT SWITCH accordingly.

9146600990 Rev S BE1-25A Installation 4-3

Figure 4-3. Connection Diagram (Units Serial Number 546 and Higher)

4-4 BE1-25A Installation 9146600990 Rev S

Figure 4-4. Controlling 6 Breakers with One BE1-25A

MAINTENANCE

BE1-25A relays requir e no preventative m aintenance other than a period ic operational c heck. If the relay fails to function properly, contact Technical Sales Support at Basler Electric to coordinate repairs.

STORAGE

This device contains long-life aluminum electro lytic c apac itors. For dev ices t hat a re not in serv ice (sp ares in storage), the life o f these capacitors can be maximized by energ izing the device for 30 minutes once per year.

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4-6 BE1-25A Installation 9146600990 Rev S

SECTION 5 • TESTING

TABLE OF CONTENTS

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

INTRODUCTION ................................................................................................................................... 5-1

OPERATING PRECAUTIONS ............................................................................................................... 5-1

DIELECTRIC TEST ............................................................................................................................... 5-1

APPLICATION ....................................................................................................................................... 5-1

General Information ............................................................................................................................ 5-1

Maximizing Auto-Synchronizer Performance ..................................................................................... 5-2

APPLICATION EXAMPLE ..................................................................................................................... 5-2

Example Parameters .......................................................................................................................... 5-2

Recommended Procedure ................................................................................................................. 5-2

VERIFICATION AND CALIBRATION .................................................................................................... 5-3

General ............................................................................................................................................... 5-3

Equipment Required ........................................................................................................................... 5-3

Preliminary Instructions ...................................................................................................................... 5-3

VERIFICATION TESTS ......................................................................................................................... 5-6

General ............................................................................................................................................... 5-6

Undervoltage (UV) Inhibit Verification Test ........................................................................................ 5-7

Slip Frequency Verification Tes t ........................................................................................................ 5-7

Sync Signal Verification Test ............................................................................................................. 5-7

Lockout and Reset Verification Test .................................................................................................. 5-8

Advance Angle Verification Tes t ........................................................................................................ 5-8

VERIFICATION TESTING OPTIONS .................................................................................................... 5-9

General ............................................................................................................................................... 5-9

Voltage Acceptance Module A1 Verification Test .............................................................................. 5-9

Voltage Acceptance Module A2 Verification Test ............................................................................ 5-10

Frequency Matching Module F5 Verification Test ............................................................................ 5-10

Voltage Matching Module V1 Verification Test ................................................................................ 5-11

Voltage Matching Module V2 Verification Test ................................................................................ 5-11

Voltage Matching Module V3 Verification Test ................................................................................ 5-11

Dead Bus Module D1 Verification Test ............................................................................................ 5-12

Figures

Figure 5-1. Bench Test Setup .................................................................................................................... 5-4

Figure 5-2. Test Setup for Installed Unit .................................................................................................... 5-5

Figure 5-3. Option V2 Waveform ............................................................................................................. 5-11

Tables

Table 5-1. Advance Angle Test Parameters (Maximum slip rate must be set at 0.5000 Hz.) .................. 5-9

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ii BE1-25A Testing 9146600990 Rev S

SECTION 5 • TESTING

INTRODUCTION

BE1-25A Auto-Synchronizers are calibrated and tested for correct operation at the factory and all calibration pots are sealed. Immediately upon receipt of the relay, or after extended service, it is recommended that the VERIFICATION T ESTS in this sec tion be performed. The se comprehensive tes ts verify all operating parameters.

OPERATING PRECAUTIONS

Before operation, note the following precautions.

• Always be sure that extern al operatin g (mon itored) co nditions are stab le befor e removi ng a BE1- 25A unit from service.

• The BE1-25A is a solid-state device and has been type tested in accordance with the requirements defined below under Dielectric Test. If a wiring insulation test is required on the switchgear or panel assembly of which this unit is a part, see Dielectric Test below.

• Be sure that the BE1-25A c ase is hard wired to earth ground using th e ground terminal (A1) on the rear of the unit.

• When the unit is in service , the controls should be protected by th e plastic cover supplied. This limits access to the control settings.

DIELECTRIC TEST

In accordance with IEC 255 -5 and ANSI/IEEE C37.90-1978 , one-minute dielectric (high pot ent ial) tes ts up to 1500 Vac (45-65 hertz) may be performed. Note that:

• Decoupling capacitors are employed from all termin als to ground. Accordi ngly, a leakage current of approximately 20 milliamperes is to be expected when high potting at 1500 Vac, 60 hertz.

• Varistors are connected across all terminal-pairs of terminal strip TB1, and across terminals 21/22 of TB2. Do NOT high pot from terminal to terminal across these varistors. Normal high pot procedures (high potting from terminal to frame) are not affected by these varistors.

• A one megohm resistor is u sed in t he cont act sens ing i nput circu it betw een th e minus s upply a nd the chassis. High pot ential testing on these contact sensin g inputs (TB1, termi nals 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 15, and 16), (TB2, terminals 21 and 22) m ay da mag e the internal resistor . Us e a high resistance tester (megger) or alternate means to test these contacts.

APPLICATION

General Information

Although operation of BE1-25A Auto-Synchronizers is straightforward, the following suggestions are offered.

• When using the LOAD switch, there is a built-in delay before the display responds to the command. This delay is for the purpose of security — so that a deliberate ac tion is required to effect a change, not an accidental bump. (If the switch is released before display acknowledgment, the original setting is retained.)

• Dashes in the display indicate an open input or out-of-range condition.

• When power is first ap plied to the unit, the display defaults to Function P, at which position the

display functions as a digital synchroscope. This default also occurs whenever the unit is RESET.

• In an ideal system, a smo other c losing res ults when th e generator speed a nd voltage ar e exactly in synchronism with the sy stem. Depending on the system, this usu ally is not possible. Closing from the high side with GF > BF usually results in less str ess on system components. Contact sensing inputs can be set so that the synchronizer only allows closing when GF > BF and/or GV > BV.

9146600990 Rev S BE1-25A Testing 5-1

• Setting MAX SLIP to o low can result in ex cessive hunting by the governor. A l ow inertia system driven by an internal comb ustion pr ime mover is es pecially prone to this, since the power s trokes can (prior to breaker closure) mod ulate the fun damental freque ncy of the gener ator outp ut. If the resulting sidebands (or jitt er) exc eed the MA X SLIP freque ncy, overs hoot and prolonge d delay in reclosing will likely occur.

• Because installations may have different characteristics, there is no standard value for the generator speed correction pulse width and interval settings. Refer to the following paragraph Maximizing Auto-Synchr onizer Perfor mance for a reco mmended proce dure to ac hieve values for the generator speed correction pulse width and interval settings.

• Whenever the LOAD switch is raised, the BE1-25A becomes inactive (non-functional) for 1.0 second.

Maximizing Auto-Synchronizer Performance

Disconnect the breaker from the Auto-Synchronizer output. Select a pulse width and interval setting based on governor sens itivi ty. Rec ord the sy nchron izin g time ( that ti me fro m when the Auto-Synchronizer initiates correction pulses to when the Auto-Synchronizer issues the breaker close signal).

If excessive overshooting occurs, reduce the correction pulse width and increase the correction pulse interval. If the gener ator sp eed increas es too sl owly, t hen increas e the c orrection puls e width and reduc e the correction pulse interval.

Maximum performance is achieved if sy nchronization oc curs within one to tw o minutes provi ding that the Auto-Synchronizer takes control of the generator within a two hertz slip frequency window.

APPLICATION EXAMPLE

Example Parameters

• A generator breaker whose characteristic closing time is 385 milliseconds.

• A maximum allowable slip rate of 0.1 hertz. (This slip rate suggests that our hypothetical

generator is of greater than average size.)

• A generator undervolta ge of 65 Vac. (I.e., at this volt age or b elow, no effor t shall be made by the Auto-Synchronizer to control the generator voltage.)

• For this example, the gen erator is designat ed West. This gener ator breaker closi ng time is to be stored as generator breaker 2 in the Auto-Synchronizer memory.

Recommended Procedure

Step 1. Bring the me mory register f or the test generator int o view by depressing th e FUNCTION s witch

once (MCU disp lay should show 0 in the left-most d igit and—in the right-most dig it), and then depress the increment swit ch twice to select generator br eaker 2 (MCU display shows 2 in the right-most digit).

Step 2. Depress the FUNCTION switch once and observe that the display left-most digit shows 1.

Change the display to r ead 1.38 5, the .385 represents the new breaker-closing t i me in sec onds. This is done by h old in g a nd /or stepping the INCREM E NT /DECR EM ENT switch until th e des ire d number is displayed. (Note the two-speed response as the switch is held depressed. This feature greatly speeds up the selec tion proces s.) Raise the LOAD switch , and hold it raised for at least two seconds. The display will blank out and then, after about one second, will read

1.385. This is to acknowl edge that the characteristic closing t ime for the breaker that controls the West generator has been recorded.

Step 3. Depres s the FUNCTION s witch once and observe that the d isplay left-most digit shows 2. Use

the INCREMENT/DECR EMENT switch to select a value/sett ing for the correction pulse width. Raise the LOAD switch, a nd hol d it rais ed for abou t tw o seconds . The d isplay will blank out an d then return, indicating that the new correction pulse width has been stored in MCU memory.

Step 4. Depress the FUNCTION s witch once and observe that the d isplay left-most digit shows 3. Us e

the INCREMENT/DEC REM ENT switc h to s elect a v alu e/setti ng for the c orrec tion pulse int erval. Raise the LOAD switch, a nd hol d it rais ed for abou t tw o seconds . The d isplay w ill bla nk out an d then return, indicating that the new correction pulse interval has been stored in MCU memory.

5-2 BE1-25A Testing 9146600990 Rev S

Step 5. Depress the FUNCTION SELECT switch twic e to cause the f igure 4 to app ear as the left-most

digit of the display. As indicated on the front panel chart, this is the register that stores the maximum slip rate. Using the INCREMENT/DECREMENT switch, adjust the display digits to read .100, then rais e the LO AD swit ch and hold it r aised f or ab out two sec onds until th e dis play goes from blank to 4.100. The maximum slip rate is now loaded.

Step 6. Step th e display to the nex t register which is 5 (G ENerator UnderVoltag e). Enter and load 65,

using the previous procedures.

CAUTION

Before placing the Auto-Synchronizer into service, be sure that the LOCKOUT ON/OFF register (6) is set to system requirements. When OFF, the AutoSynchronizer is free to repeatedly close the breaker into a fault.

Step 7. To chan ge the LOCKOUT condition (i. e., from ON to OFF to ON, etc. ): Select function 6 and

raise the LOAD switch for approximately two seconds. The disp lay will toggle to the opposite condition that it held. (Lon stands for lockout ON, Lof for lockout OFF.)

The setup procedure is c ompl ete. If y ou wis h to place the rel ay into s ervic e, you can park the disp lay at a parameter that you wish to monitor, such as ADVANCE ANGLE or BUS VOLTS.

NOTE

Operate the Reset lever to return to the READING registers after changing settings.

VERIFICATION AND CALIBRATION

General

This paragraph is an introduction to the specific ver ification and calibration proc edures given lat er in this section.

Equipment Required

• Two dynamic frequency sources calibrated to 1.0% accuracy

• One oscilloscope

• One digital voltmeter

• One counter

• One stopwatch

• One phase angle meter

Preliminary Instructions

The various verification tests may be done independently. However, certain assumptions and blanket instructions apply as given in the steps that follow.

CAUTION

The BE1-25A Auto-Synchronizer can be tested before installation using the bench-test setup shown in Figure 5-1.

9146600990 Rev S BE1-25A Testing 5-3

Figure 5-1. Bench Test Setup

CAUTION

After installation, it is inconv enient to remove the many connec tions on the bac k of the unit. For this reason, spec ial provisions for tes ting have been incorp orated that require the following procedures of steps 1 through 5.

5-4 BE1-25A Testing 9146600990 Rev S

Step 1. Loosen th e (4) screws that secure the test module and ex tract it from the case. This removes

external electrical connections at TB1 of the BE1-25A.

Step 2. Note that two sets of tr acks hav e been provi ded for th e test module. Carefully enter the modu le

into the right-hand track s (upper and lower), and gent ly push the module forward. (If a bind or obstruction is felt, pull the module back slightly and check that it is properly entered into the right-hand pair of tracks.) Figure 5-2 shows the module fully entered into the offset—or test mode—position.

WARNING!

Do NOT apply Test power to tip-p lugs until they are ins erted into the test m odule POWER jacks.

Step 3. Apply operating power to the BE1-25A through the POWER jacks of the test module. The power

supply module POWER LED should be ON to indicate that the BE1-25A unit is functioning.

Figure 5-2. Test Setup for Installed Unit

9146600990 Rev S BE1-25A Testing 5-5

Step 4. With the sens ing connections to the BE1-2 5A (via the rear case terminals) now disconnected,

all inputs for testing must be supplied by the jacks of the test module. At this time the jacks have the following functions (functions are illustrated in Figure 5-2).

• BUS - Apply simulated bus voltage here.

• GEN - Apply simulated generator voltage here.

• POWER - These jacks are used to supply operating power. (Reference step 4.)

• 52b - Plug in a normally closed momentary pushbutton switch into these jacks to

simulate a 52b signal from the auxiliary contact of the breaker.

• GF>BF - Short these jacks together to simulate the closing of the GF>BF contact sensing input terminals 13 & 14 of TB1 (reference Figure 5-2). When shorted, the BE1-25A will not issue a breaker closure signal unless the generator frequency is greater than the bus frequency.

• GV>BV - (Only used when an A option is installed.) Short these jacks together to simulate the closing of the GV>BV contact sensing input terminals 11 & 12 of B1 (reference Figure 5-2). When s horted, the BE1-25A will not iss ue a breaker closure signal unless the generator voltage is greater than the bus voltage.

• DEAD BUS - (Only used when a D option is installed.) Short these jacks together to simulate the closing of t he dead bus c ontac t input t erminals 9 & 10 of TB1 (r efer ence Figure 5-2). When shorted—AND if the dead bus opt ion is incorporated—the BE125A will issue a breaker-closure signal when the bus voltage drops below the set threshold that defines a dead bus.

Step 5. Monitor the outputs as follows:

With test module in the test position—Operation of the Br eaker Closure (i.e., SYNC) relay may be monitored at the SIG & COM jack s of the MCU sync module, usin g an oscilloscop e, as illustrated in Figure 5-2. Each time the SYNC LED turns ON, the SIG voltage should be th e same as the COM jack voltage. At all other times th ere should be 12 Vdc betw een these jacks (with SIG +). (Note that this monitoring procedure only confirms that an operating voltage is being extended to the output relay. It does not confirm a contact closure by this relay.)

NOTE

When the test module is in test position, all output relays are de-energized.

For bench testing (with test module in normal operating position)—If any of the plug-in (option) relays are present , the pull-in of the relay armature(s ) may be observ ed by open ing the hinged door at the rear of the unit.

Sync output—For many test purposes, the most conveni ent monitor of the sync output is the SYNC LED. (Lit when sync relay is closed.) However, the bench test setup of Figure 5-1 has the advantage of verifying the sync output plug-in relay is working properly.

VERIFICATION TESTS

General

Five test procedures cover the three basic modules (MCU sync module, test module, and power s upply). Testing of the optional modules is covered in individual verification tests. The five test procedures are:

• Undervoltage (UV) Inhibit Verification Test

• Slip Frequency Verification Tes t

• Sync Signal Verification Test

• Lockout and Reset Verification Test

• Advance Angle Verification T est

5-6 BE1-25A Testing 9146600990 Rev S

NOTE

Verification test procedures for Auto-Synchronizers prior to serial number 300, and for discontinued Options B3, B5, F1, F2, F3, F4, and V4, are given in Section

7. All option modules should NOT be installed when performing the basic

verification tests because they affect the basic unit effective parameters.

Undervoltage (UV) Inhibit Verification Test

Step 1. For a benc h test, connect the unit as in Figure 5-1. Otherwise c onnect the unit as described

previously in steps 1 throu gh 4, and illustrated in Figure 5-1. Leave GF>BF, GV>BV, a nd dead bus open (i.e., OFF) at this time. Set the s imulated bu s and generator volt ages at 120 Vac, 60 hertz.

Step 2. Set the GEN UV register to 40 V ac. Reduce the sim ulated generator volta ge until the GEN UV

LED turns ON. This s hould occur as the simu lated generator vo ltage goes below 40 ±1.5 Vac . (Beginning here, the word simulated shall be understood without repeating it.)

Step 3. Return the GEN UV register to 110 Vac : the GEN UV LED should rema in ON. Increase the

generator input voltage until the GEN UV LED turns OFF. This should occur as the input voltage rises above 110 ±1.5 Vac .

NOTE

If there is a slip r ate, the SYNC LED will b egin flash ing (inste ad of extinguis hing) as synchronization is detected.

Slip Frequency Verification Test

Step 4. Set the GEN UV register to 40 Vac. Set the MAX SLIP register for 0.500 hertz. Step 5. Adjust the bus input and the generator input to 120 Vac at 60.00 hertz. Step 6. Slowly adj ust the generator input frequency lower. At 59.49 ±0.01 her tz, the SLIP HIGH LED

should turn ON. Slowly move the generator frequency above and below the threshold and observe that the LED acknowledges the slip frequency status within the stated tolerance.

Sync Signal Verification Test

Step 7. With th e b us input at 120 Vac, 60.00 her tz , a djust the generator input to 120 Vac at 59 .90 her tz .

Set MAX SLI P (the # 4 reg ist er) for 0.2 50 hertz. Ro tat e the GEN ER ATOR S ELE CT contr ol knob to the generator position of choice. Set the register of the active breaker to 0.40 seconds.

NOTE

Always load in all new breaker timer settings, and always verify the active breaker by momentar ily selecting item d from th e MCU read ings menu. ( Breaker settings, unlike other settings, must be loaded before they can take effect.)

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).

Step 8. Using an extern al sync hroscope, c heck that the SYNC LED turns O N at 14 ±3°, and O FF at 0°.

The breaker closure outp ut (as monitored by a lamp (Figure 5-1), or an oscilloscope (Figure 5-1)) should follow the SYNC LED.

Step 9. Install a jumper at the GF>BF jacks of the test module. The SYNC LED should immediately stop

flashing. Remove jum per to bring back the flashing SYNC L ED. (The flash ing is caused by t he slip r ate. Note that (with this jumper ap plied) the gene rator frequenc y must be greater than that of the bus for a sync output to be initiated.)

9146600990 Rev S BE1-25A Testing 5-7

Step 10. Return the display to MAX SLIP (t he #4 setting). Use the DECREMENT switch to r educe the

setting fr om the initial (0. 250) value to 0. 090. Use the LOAD switch to s ave the new M AX SLIP setting into memory. Raise the LOCKOUT RESET switch: the SYNC LED should cease flashing and the SLIP HIGH LED should turn ON.

Step 11. Return the MAX SLIP s etting to 0.250 and use the L OAD switch to save th e new MAX SLIP

setting into mem ory. The SYNC LED should res ume flashing and the SLI P HIGH LED should turn OFF.

Step 12. Vary the bus and generat or inputs over the range of 70-150 Vac. Vary the power s upply over

the range of 90-132 Vac. Neither operation should affect the flashing rate of the LED.

Step 13. Set the GENerator U nderVolta ge setti ng (5) to 80 Vac . Reduce t he gener ator output t o 70 Vac,

then raise it until the UV LED just turns OFF. This should occur at 80 ±1.5 Vac.

Step 14. Raise the generator voltag e to 120 Vac , an d the n reduce it to the value w here th e G EN UV L ED

just turns ON. At this point, the generator input voltage should be 79 ±1.5 Vac.

Lockout and Reset Verification Test

Step 15. Set the bus input to 1 20 Vac at 60.0 0 hertz; the gene rator input to 12 0 Vac at 60.04 her tz; the

MAX SLIP setting to 0.250 hertz; the generator 2 breaker time to 0.40 seconds; the GENERATOR SELECT control to 2; and LOCKOUT ON/OFF (setting 6) to ON.

NOTE

A stopwatch is recommended for the following steps.

Step 16. Simulate a breaker trip us ing a normally-closed pushbutton switch i n series with the 52b test

jacks. After the SYNC LED turns ON, depress the 52b pushbutton switch and releas e the s witc h within 15 seconds. The LOCKOUT LED should turn ON, and the SYNC LED should quit flashing.

Step 17. Pressing the front panel LOCKOUT RESET pushbutton switch should clear the lockout and

enable the sync output. Step 18. Repeat step 16, but depress the switch for a minimum of 17 seconds. No lockout should occur. Step 19. Set the LOCKOUT (enable ) setting to OFF, then re peat step 16. This t ime the LOCKOUT LED

should not turn ON. Return the LOCKOUT setting to ON.

Advance Angle Verification Test

Step 20. Set the bus input to 120 Vac at 60.0 hertz; set the generator input to 120 Vac at 60.1 hertz.

NOTE

Step 21. Connect a counter or a n oscilloscope to th e front panel SIG/COM jacks. Adjust the cou nter or

scope to measure negativ e pulse w id th. S et gen erat or 3 br eak er time f or a char ac teris tic c los ing

time of 0.800 seconds. Turn the GENERATOR SELECT knob to 3. Step 22. Short out the 52b jacks to induce a closure cycle. At closure (or sync), the length of the negative

12 V pulse at the SIG/COM jacks should be 800 ±5.0 ms. Step 23. Repeat step 22 except, wh ile the SIG/COM pulse is still negative, open a nd immediately close

the 52b jacks. This should terminate the sync pulse. Lockout will occur if automatic lockout

(setting 6) is enabled. The lockout can be canceled by raising the RESET switch. Step 24. Set the generator 4 breake r time to 0.020 s econds. Turn the GEN ERATOR SELECT knob t o 4.

Repeat step 22. The SIG/COM pulse width should be 250 ±2 ms (minim um pulse dur ati on). Step 25. A 40°-inhibit feature preven ts a c losure output for any advanc e angle i ntern-a lly calc ulate d to be

greater than 40°. Arrange a test for this as follows. (a) Increase the generator input to 60.2

5-8 BE1-25A Testing 9146600990 Rev S

hertz. (b) Set gen erator 5 breaker time to the maximum valu e — 0.800 seconds. (c) Tur n the GENERATOR SELECT knob to 5. (d) Set the display to read setting A (ADV ANGLE).

Step 26. Short the 52b jacks to simulate breaker open. There should be no illumination of the SYNC

LED, and the ADV ANGL E setting should display dashes to indicate that th e required advance angle is beyond range.

Step 27. While monitoring the phas e difference between generator and b us with a phase angle meter,

set generator 5 breaker time 0.500. Set the display to read ADVance ANGLE and wait 15 seconds. The SYNC LED should p ulse ON/OFF , and t he ADVanc e ANGLE s etting s hould read 36 ±3° at sync.

Step 28. To check that the advance angle is within specif ied accuracy , use the set up parameters give n

in Table 5-1. When running the tests, the phase angle meter should provide the indicated readings within ±3°. Note that no Br eaker Closure output will occur when the parameter s are such that the advance angle is beyond 40°.

Table 5-1. Advance Angle Test Parameters

(Maximum slip rate must be set at 0.5000 Hz.)

Sensed Generator Frequency

(With Bus at 60.00 Hz.)

Gen. Under Gen. Over 100 ms 400 ms 700 ms

59.6 60.4 14.4° No Sync No Sync

59.8 60.2 7.2° 28.8° No Sync

59.98 60.02 0.72° 2.88° 5.04°

59.995 60.005

Advanced Angle (±3°) for Indicated Breaker Closing Times

0.18° 0.72° 1.26°

VERIFICATION TESTING OPTIONS

General

Before performing any of the following procedures for the first time, be sure to review the paragraphs entitled VERIFICATION AND CALI BR ATI ON, General. Ther e y ou wil l find pr el imin ar y instr uct ions that ar e common to virtually all test and calibration procedures. Also, you will f ind many terms defined, a list of recommended equipme nt, and two basic setup diagrams . Test procedures for discont inued options B3, B5, F1, F2, F3, F4, and V4 are provided in Section 6.

Voltage Acceptance Module A1 Verification Test

The VOLTAGE DIFFERENCE control is calibrated in terms of percentage, using the bus voltage as a reference. The following definitions apply.

/



 =|

ΔV% = the setting of the VOLTAGE DIFFERENCE control

= 100|

Step 1. Perform t he test setup illustrated in Figure 5-1, and move the tes t module into the offset (i.e.,

test) position.

Step 2. Set the simulated bus voltage and the simulated generator voltage (at the voltage sensing

inputs) to 1 20 V, 60 her tz. Rotat e the VOLT AGE DIFF ERENCE c ontrol of t he A1 modu le to the minimum setting (0.5%).

Step 3. Slowly ad just the gen erator v oltage to 0.6 ±0. 3 V abov e, and then to 0.6 ±0.3 V below t he initia l

120 Vac setting. The ΔV HIGH LED should turn ON whenever above or below this range.

Step 4. Repeat steps 2 and 3 with the VOLTAGE DIFFERENCE control at maximum (5%). The ∆V

HIGH LED should tur n ON whenever the generator voltage swin gs 6 V (±1%) above or below the initial 120 Vac position.

9146600990 Rev S BE1-25A Testing 5-9



 



 



Step 5. Test the G V>BV f uncti on by setting the g enera tor volt age to a v alue 2 .0% lower than t hat of the

bus. Set the VOLTAGE DIFFERENCE control to 5%. Shorting the GV>BV jacks on the test

module should inhibit SYNC LED operation. Removing the short should restore the output.

Voltage Acceptance Module A2 Verification Test

Step 1. Provid e the test setup illustrated in Figure 5-1, and move the tes t module into the offset (i.e.,

test) position. Step 2. Set the b us voltage to 120 Vac at 60.0 hertz, and th e generator voltage to 120 Vac at 60.1 0

hertz. Set the UPPER LIMIT control to 150, and the LOWER LIMIT control to 80. Set the

VOLTAGE DIFFERENCE control to 10. Step 3. Increase the generator voltage until the HIGH LED turns ON (approximately 130 Vac). Step 4. Decreas e the gener at or voltage tow ards 120 Vac and obs er ve tha t the HIGH LED turns OFF. Step 5. Set the b us voltage to 120 Vac at 60.0 hertz, and th e generator voltage to 120 Vac at 60.1 0

hertz. Set the VOLTAGE DIFFERENCE control to 1. Step 6. Increase the generator voltage until the HIGH LED turns ON (approximately 121 Vac). Step 7. Decrease the generator voltage towards 120 Vac and observe that the HIGH LED turns OFF. Step 8. Set the s imulated bus voltage to the desir ed upper limit. Adjust the UPPER LI MIT control until

the HIGH LED just turns OFF. The high limit is now set. Step 9. Set the simulated bus volt age to the desired lower limit. Adjust the LOWER LI MIT control until

the LOW LED just turns OFF. The low limit is now set. Step 10. Verify that the SYNC LED will not operate whenever the bus voltage is above or below the

UPPER LIMIT or LOWER LIMIT s ettings. A LIMIT HI GH LED or a LIM IT LOW LED wil l confir m

that the bus voltage is out of range.

Frequency Matching Module F5 Verification Test

Step 1. Provid e the test setup illustrated in Figure 5-2, and move the test module into the offset (i.e.,

test) position. Step 2. Establish a slip rate of 1 hertz using the following parameters for generator 1. On MCU display, set the following parameters and load them into MCU memory.

• Generator select (register 0) = 1.

• Breaker time (register 1) = 0.200 second.

• Correction pulse width (register 2) = 5.0 seconds.

• Correction pulse interval (register 3) = 5.0 seconds.

• Maximum slip (register 4) = 0.250 hertz.

• Generator undervoltage (register 5) = 90 volts.

• Lockout ON/OFF (register 6) = Lon.

On the test setup, set the following parameter s .

• Generator voltage = 120 Vac at 59 hertz.

• Bus voltage = 120 Vac at 60 hertz.

• GF > BF switch to OPEN.

• 52b contacts CLOSED.

• Activate RESET switch.

Step 3. Measure t he correction pulse width by timing the ON time of the F5 m odule RAISE LED (time

should be appr oximat ely 5.0 s econds). M easure the c orrec tion pulse in terval by timing the O FF

time of the F5 mo dule RAISE LED (time should be approximate ly 5.0 seconds). Tota l time for

ON and OFF is approximately 10.0 seconds. Observe that the SLIP INH LED is ON. Step 4. Set the generator voltage = 120 Vac at 59.5 hertz. Step 5. Measure t he correction pulse width by timing the ON time of the F5 module RAISE LED (t ime

should be appr oximat ely 2.5 s econds). M easure the c orrec tion pulse in terval by timing the O FF

5-10 BE1-25A Testing 9146600990 Rev S

time of the F5 mo dule RAISE LED (time should be approximate ly 7.5 seconds). Tota l time for ON and OFF is approximately 10.0 seconds. Observe that the SLIP INH LED is ON.

Step 6. Increas e the generator frequency until th e SLIP INH LED goes OUT (should be approximately

59.75 hertz). This should be the point at which synchronization is enabled.

Step 7. Continue to increase the generator frequency until the SYNC LED flashes. Observe that the

generator frequency is greater than 59.75 hertz.

Step 8. Increas e the generator frequency to 60 hertz. Observe the SYNC ANG LE (register P) on the

MCU display. If the display indicates a negative angle, then raise pulses are issued. If the display indic ates a positive angle, the n lower pu lses ar e issued. T he pulse period (total time for ON and OFF) should be approximately 10.0 seconds.

Voltage Matching Module V1 Verification Test

An A1 or A2 module must be installed to perform this test. Step 1. Provid e the test setup illustrated in Figure 5-1, and move the tes t module into the offset (i.e.,

test) position.

Step 2. Set the s imulated generator voltage to a value th at is higher than the bus by an amo unt that

exceeds the option A VOLTAGE DIFFERENCE control setting. The LOWER LED should be ON.

Step 3. Set the simulated generator voltage to a value that is lower t han the bus by an amount that

exceeds the Option A VOLTAGE DIFFERENCE control setting. The RAISE LED should be ON.

Step 4. Randomly check one or two points where the difference is less than the option A voltage

difference.

Neither of the LEDs should be ON.

Voltage Matching Module V2 Verification Test

An A1 or A2 module must be installed to enable this option. Step 1. Provid e the test setup illustrated in Figure 5-1, and move the tes t module into the offset (i.e.,

test) position.

Step 2. Set the s imulated generator voltage to a value that i s higher than the bus by an amount that exceeds the option A VOLTAGE DIFFERENCE control setting.

Step 3. Connect an oscilloscope or frequency counter to the jacks on the front panel of the V2 module. Observe the following waveform (Figure 5-3).

Figure 5-3. Option V2 Waveform

Step 4. Adjust the PULSE WIDTH contr ol for the desired puls e width. The LOW ER LED should be ON

for the duration of the pulse width.

Step 5. Adjust the PULSE INTERVAL control for the desired interval. The LED should NOT be ON

during the interval.

Step 6. Set the simulated generator voltage to a value that is lower t han the bus by an amount that

exceeds the Option A VOLTAGE DIFF ERENCE contr ol setting. The RAIS E LED should be O N for the duration of the pulse width.

Voltage Matching Module V3 Verification Test

An A1 or A2 module must be insta lled to enable this option. Use average-read ing voltmeters scaled in RMS.

9146600990 Rev S BE1-25A Testing 5-11

Step 1. Provid e the test setup illustrated in Figure 5-1, and move the tes t module into the offset (i.e.,

test) position. Step 2. Set bus voltage to 120 Vac, and generator voltage to 130 Vac. Adjust the A1 or A2 option as

follows. Option A1: Set VOLTAGE DIFFERENCE to minimum. Option A2:

Set VOLTAGE DIFFERENCE to minimum, UPPER LIMIT to 135, and LOWER LIMIT to 100.

Step 3. Connec t an oscilloscope or frequency counter t o the front panel jacks of the V3 modu le. Note

that the pulse w idth gen erat ed by this modul e for differ enc es of les s than 2 0 volts is determined

by the following formula.

  = (   

where:

∆V = the absolute voltage difference between bus and generator.

Step 4. With refer ence to th e wavef orm (Figure 5-1), adjust the PULS E WIDTH cont rol for a pulse width

of two s econds. The LOWER LED will turn O N for the dura tion of the pulse width if the voltag e

difference exceeds the VOLTAGE DIFFERENCE setting on the option A module. Step 5. Note that increasing the voltage difference between generator and bus will cause the pulse

width to increase. Decreasing the voltage difference will cause the pulse width to decrease. Step 6. Adjust the C ORRECTIO N PULSE INT ERVA L control to the d esired interv al. (Th e interval is not

affected by the voltage difference.) Step 7. Set the generator v oltage lower th an the bus; the RAISE LED should be ON for the dur ation of

the pulse width if the voltage difference ex ceeds the VOLTAGE DIFFEREN CE setting on the

option A module.

Dead Bus Module D1 Verification Test

Step 1. Provid e the test setup illustrated in Figure 5-1, and move the tes t module into the offset (i.e.,

test) position. Step 2. Turn O N the dead b us opt ion by ins tallin g a jump er acr oss the D EAD BU S termin als on th e test

module. Step 3. Complete the setup by providing the following adjustments.

• Set GENerator UnderVoltage (Setting 5) to 110 Vac;

• Set bus at 120 Vac, 60 hertz;

• Set generator at 120 Vac, 60.4 hertz;

• Set MAX SLIP to 0.2 hertz, and verify that the SLIP HIGH LED is ON.

Step 4. Reduce the bus voltage to a poi nt below the VOLTS contr ol setting (on the dead bus option).

The SYNC LED should turn ON within 1 second after the DEAD BUS LED turns ON. Step 5. Set the generator voltage to 100 Vac. Disable the automatic lockout feature (by setting the

LOCKOUT ON/OFF set ting to OFF). Actuate the LOCKO UT RESET switch . Turn OFF the bus

voltage: The DEAD BUS LED shou ld not turn ON. (Note that when a generato r undervoltage

condition is in force, the breaker closure output is inhibited.) Step 6. Enable the automatic lockout feature ( by setting t he LOCKO UT ON/ OFF s etting to O N). Set t he

generator to 120 Vac; act uate th e LOCKOUT RESET switch; an d turn ON the bus v oltage (120

Vac). To get sync activity, turn bus voltage OFF, and wait 1 second. Immediately after the

SYNC LED turns ON, depress and immediately release the momentary pushbutton that

represents a 52b input ─ signifying the open ing of the breaker. (Refere nce Figure 5-2.) Verify

that the LOCKOUT LED is ON. Actuate the LOCKOUT RESET switch. Step 7. Repeat step 6, only this time wait 17 seconds after the SYNC LED turns ON before opening and

closing the simulated 52b input. This time, lockout should not occ ur.

)

/20

5-12 BE1-25A Testing 9146600990 Rev S

SECTION 6 • RELAY DIFFERENCES

TABLE OF CONTENTS

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

INTRODUCTION ................................................................................................................................... 6-1

PRODUCT DESIGN CHANGES............................................................................................................ 6-1

CONNECTIONS .................................................................................................................................... 6-1

AUTOMATIC SYNCHRONIZER ............................................................................................................ 6-4

Functional Description ........................................................................................................................ 6-4

Calibration Instructions ....................................................................................................................... 6-6

Pre-Calibration Procedure .................................................................................................................. 6-7

Basic Synchronizer Calibrat ion .......................................................................................................... 6-7

BREAKER TIME EQUALIZATION MODULES (OPTIONS B3 AND B5)............................................... 6-8

Description and Application ................................................................................................................ 6-8

Functional Description ........................................................................................................................ 6-8

B3 and B5 Calibration ........................................................................................................................ 6-9

FREQUENCY MATCHING MODULES (OPTIONS F1, F2, F3, and F4)............................................. 6-10

Description and Application .............................................................................................................. 6-10

Frequency Matching Module F1 ....................................................................................................... 6-10

Frequency Matching Module F3 ....................................................................................................... 6-10

Frequency Matching Module F2 ....................................................................................................... 6-11

Frequency Matching Module F4 ....................................................................................................... 6-12

F2 and F4 Calibration ....................................................................................................................... 6-13

VOLTAGE MATCHING M O D UL E V4 .................................................................................................. 6-14

Description and Application .............................................................................................................. 6-14

V4 Functional Description ................................................................................................................ 6-14

Figures

Figure 6-1. BE1-25A Connection Diagram (Serial Numbers 299 and Lower)........................................... 6-2

Figure 6-2. BE1-25A Connection Diagram (Serial Numbers 300 to 9616001N) ....................................... 6-3

Figure 6-3. Synchronizer Module .............................................................................................................. 6-4

Figure 6-4. Synchronizer Module (Relays Serial Number 299 and Lower) ............................................... 6-5

Figure 6-5. Module B3 ............................................................................................................................... 6-8

Figure 6-6. Module B5 ............................................................................................................................... 6-8

Figure 6-7. Module B3 Block Diagram ...................................................................................................... 6-9

Figure 6-8. Module B5 Block Diagram ...................................................................................................... 6-9

Figure 6-9. Module F1 ............................................................................................................................. 6-10

Figure 6-10. Module F3 ........................................................................................................................... 6-10

Figure 6-11. Module F2 ........................................................................................................................... 6-11

Figure 6-12. Module F4 ........................................................................................................................... 6-11

Figure 6-13. Module F2 Block Diagram ................................................................................................... 6-12

Figure 6-14. Module F4 Block Diagram ................................................................................................... 6-13

Figure 6-15. Connection Diagram for F2 and F4 Modules ...................................................................... 6-13

Figure 6-16. Pulse Interval Wavefor m ..................................................................................................... 6-14

Figure 6-17. Module V4 ........................................................................................................................... 6-14

Figure 6-18. Module V4 Connection Diagram ......................................................................................... 6-15

Figure 6-19. Module V4 Block Diagram................................................................................................... 6-15

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ii BE1-25A Relay Differences 9146600990 Rev S

SECTION 6 • RELAY DIFFERENCES

INTRODUCTION

This section contains information concerning previous versions of BE1-25A Auto-Synchronizer Relays.

PRODUCT DESIGN CHANGES

Synchronizer Modules are the primary control modules of the original BE1-25A Auto-Synchronizer. However, beginning with serial number 300, a redesigned module was introduced that featured a microprocessor. The redesigned module was rena med the MCU sync module to distinguish i t f rom the ol d module. It is theoretically possible to upgrade the original version of the BE1-25A by replacing the synchronizer module w ith an MCU sync mod ule. However, t his is definitely no t recommended. When a microprocessor bas ed synchronizer sys tem is wanted, a n entirely new un it − with improved acc essibility and numerous other refinements − would be the most cost-effective choice.

Because of the greater power of the MCU sync module over the original module, it was possible to incorporate t he funct ions of sev eral opti ons. Those options w ere th e bre aker ti me equa lizatio n opti ons B 3 and B5. In addition to these, several other former options are no longer supported in the new design. They are the F2, F4, and V4 options. The discontinued options, B3, B5, F2, F4, and V4 are not to be used when the new MCU sync module is installed.

Effective with BE1-25A relays, revision R and subsequent (Apr il 30, 1996, serial number 9616002N and later), options F1 an d F3 became obsolete . Options F0 and F5 are the only freq uency matching options available. The functions of options F1 and F3 were m ade availab le as part of t he F5 frequency matching option.

The software of revision U BE1-25A relays was changed to Version 5.02. These software changes improved the performance of the F1 and F3 types of frequency correctio n which are available as p art of the F5 option.

Options that are compatible with the both the new and the old versions of the BE1-25A system, are described in the mai n s ec ti on of t he m anu al alo ng w ith the s tan dar d m odu les . Those modules are t he t es t module, the MCU Sync modul e, and the power supply module. Discontinued opt ions are described later in this section.

The power supply was redesigned for the new series beginning with S/N 300. Both the old and new designs of the power supply are of the switching type, and operate from the same nominal voltages. Therefore, because this manual is not involved with minute details of the internal circuitry, no special coverage of the old version is detailed here.

While the two pow er supply designs are theoretically inter c hang eab le, any such substitutio n h as n ot bee n subjected to the extens ive verific ation t esting that is n ecess ary to ens ure that t he publ ished s pecif ications are supported. Accordingly, we strongly recommend against any reverse substitution.

CONNECTIONS

Terminals are suitable for u se with wir e sizes 14 AWG or larger. Incorrect wir ing may res ult in damage to the unit. Terminal connections for Automatic Synchronizers with serial numbers 299 and lower are identified in Figure 6-1. Not e that this diagram ( unlike the diagra m in Section 4 a nd Figure 6-2) does not provide a ground terminal at TB2-1. Instead, a direct ground connection may be secured by any of the rack-attachment scr ews. Terminal connections for Automat ic Synchronizers with serial numbers 300 to 9616001N are identified in Figure 6-2.

9146600990 Rev S BE1-25A Relay Differences 6-1

Figure 6-1. BE1-25A Connection Diagram (Serial Numbers 299 and Lower)

6-2 BE1-25A Relay Differences 9146600990 Rev S

Figure 6-2. BE1-25A Connection Diagram (Serial Numbers 300 to 9616001N)

9146600990 Rev S BE1-25A Relay Differences 6-3

AUTOMATIC SYNCHRONIZER

BE1-25A Auto-Synchronizers, serial number 299 and previous use the synchronizer module shown in Figure 6-3. A functional description and calibration instructions are provided in the following paragraphs.

Figure 6-3. Synchronizer Module

Functional Description

See Figure 6-4 to follow the functio nal desc ript ion. The sensed bus and generat or s ine wave voltag es are input to the separate Square Wave Generators.

The squ are wave generators' outputs ar e used by the generator frequenc y greater than bus frequency circuit. T he g enera tor and bus fr equenc ies ar e comp ar ed and, if the exter nal GF >BF switch is clos ed a nd the bus frequency is higher, the GF>BF signal is output to inhibit the sync circuits until the generator frequency is greater than the bus frequency. This allows the generator to pick up load more quickly.

The exclusive-or circuit out puts a pulse tha t has a w idth propor tional to the p hase diff erence. T he pulse is then input to a low pass filter and c onverted to a triangular waveform whos e instantaneous amplitu de is proportional t o the phase difference of the inp ut square waves. The low pas s filter waveform is input to the breaker time compensation circuit, the 40° inhibit sync circuit, and the differentiator.

6-4 BE1-25A Relay Differences 9146600990 Rev S

Figure 6-4. Synchronizer Module (Relays Serial Number 299 and Lower)

9146600990 Rev S BE1-25A Relay Differences 6-5

The differentiator produces a dc voltage proportional to the rate of change of the input triangular waveform, and outputs this voltage to th e breaker time compensat ion circuit, the in sync /in phase circuit, the comparator, and the precision full wave r ectifier. The dc output of the precision full wave rec tifier is further smoothed by the sample and hold circuit. The sample and hold circuit output is input to the in sync/in phase circuit and to the slip frequency comparator.

If the input signal to the slip frequency comparator exceeds the front panel SLIP FREQUENCY adjustment setting (i.e. the reference) , an inhibit signa l is delivered t o the output gate an d the front pan el FS HIGH indicator illuminates. When the input slip frequency signal is less than the front panel SLIP FREQUENCY setting, an enable signal is sent by the inhibit gate to the in-sync output gate to permit breaker closure when the other conditions are met.

If the phase angle is greater than 40°, the 40° inh ibit sync circuit outputs an inhibit signal to the inh ibit gate.

The lockout circuit will generate an inhibit signal such that if the generator breaker opens within 15 seconds aft er closing, the synchroniz er will not attempt to recl ose the relay. The lockout c ircuit outputs are sent to the sy nc cir cuits, the timer, and t o a ny options. In addition, t he fr ont pa nel LOC KOUT indicator will illuminate. This function may be reset by use of the LOCKOUT RESET switch, or by an external contact closure. A c ircuit-board-mounted switch ( S2 o f the c ircuit board) c an b e used t o disab le or en ab le this function.

The inhibit gate receives the generator frequency greater than bus frequency (GF>BF) signal, the differentiator output, and a ny option outputs. These are compared, and whe n the generator frequency, bus frequency, and phase angle are within limits , an enable signal is output to the in sync output gate. This is acknowledged by the illumination of the SYNC indicator.

The breaker time ti mer will start ti ming as soon as th e close signal is sent to the ge nerator breaker. The period of this t imer is adjusted by the BREAK ER CLOSING TIME control. When the timer times out (at 0°), a reset signal is output to the i n sync output g ate to remove t he close break er signal, and a remove correction signal is output to the V and F options.

When the in sync/ in phase circuit inputs (fro m the differentiator circuit an d the sample and hold cir cuit) indicate less than 0.008 Hz fr equency differ ence and less than a 3° ±1° phase angle differenc e, the timer will time o ut provided ther e are no inhibits present. After two s econds, a 100 ms pulse is ou tput to the relay driver to close the controlled breaker.

The sensed bus voltage is rectified and output to the comparator shown at bottom left of Figure 6-4, where it is compared to a reference level that is contr olled at the fro nt panel. If the bus is belo w the front panel setting, a dead bus signal is output.

Sensed generator voltag e is rectified and output to tw o comparators s hown at bottom right o f Figure 6-4. One comparator compares the generator volt age to the front panel UN DERVOLTAGE INHIBIT ADJUST reference. When th e generator voltage is below the reference, it produces an undervo ltage signal and illuminates the UNDERVOLTAGE INHIBIT indicator. The other comparator compares the generator voltage to a fixed reference. If the generator volta ge is bel ow the f ixed r eferenc e, a dea d gener ator signal is output.

An out-of-range signal (righ t c enter of Figure 6-4) is generate d if th e dif fer ent iat or out p ut in dicat es that th e bus and generator frequency difference is greater than a preset value, thereby inhibiting synchronization.

Calibration Instructions

Equipment Required

• Two frequency-adjust able voltage sourc es for the generator and bus sensi ng inputs. Requires a low-distortion outpu t with a voltage range of 70-150 Vac, and a freque ncy that is adjustable in

0.005 Hz increments. (The use of less accurate sources will result in less accurate settings.)

• Input power source capable of either 90-132 Vac at 50/60 Hz, or 70-150 Vdc

• Oscilloscope or counter for measuring pulse width

• AC Voltmeter

• Synchroscope

• Switches or jumpers for enabling the 52b, GF>BF, GV>BV, and dead bus functions

6-6 BE1-25A Relay Differences 9146600990 Rev S

Pre-Calibration Procedure

1. Verify that all external interconnections are correct according to Figure 6-1 or 6-2.

2. Verify that all modules are pr oper ly inst a lled.

3. Install the test module into the test position.

4. Connect the input power source to the POWER pin jacks on the test module.

5. Connect the bus voltage source to the BUS pin jacks on the test module.

6. Connect the generator voltage source to the GEN pin jacks on the test module.

7. Connect a normally closed switch to the 52b pin jacks on the test module.

8. Connect a normally open switch to each of the following pin jacks on the test module: a. GF>BF b. GV>BV c. DEAD BUS

NOTE

Perform only those proced ures that apply to your synchronizer and its ins talled options, and in the order the procedures are given.

Basic Synchronizer Calibration

1. Turn on Input Power. The POWER LED (on the power supply module) should be ON.

2. Turn the bus sensing voltage and the generator sensing voltage on.

3. Adjust magnitude of the generator sensing voltage to the level at which synchronization should be inhibited. Adjust the UNDERVOLTAGE INHIBIT ADJUST control to the point where the front panel LED just illuminates.

4. Set the BREAKER CLOSING TIME control to 0.02 (CCW).

5. Adjust the bus and generator voltage source frequencies to provide the maximum desired slip frequency.

6. Adjust the front panel SLIP FREQUENCY control so that the F

HIGH LED just turns off.

7. Conn ect the frequency c ounter or oscilloscope to th e synchronizer modul e front panel pin jacks . Set the trigger to pick up negative going (+12 to O V) pulses. Set up a su itable slip frequency (with the generator and bus sensing voltages being equal), so that a sync signal is generated.

8. Adj ust the BR EAKER CLO SING TIME ( front pane l) control f or the desir ed closing time. Note that this does not include the pickup time of the internal relay (a nominal 15 ms).

9. To test the lockout function: Immediately after a sync is generated, open the 52b switch (or remove the jumper). The LOCKOUT LED should illuminate. Press the RESET pushbutton to clear the lock out function. Repeat, this ti me waiting 15 ±1.5 seconds before opening the 52b switch. The LOCKOUT LED should not illuminate.

10. To test the GF>BF f unc ti on , c lose t he sw itch ( or install a jumper). Set up a sui tab l e sli p frequency with the generator frequen cy higher than the bus frequency. Sync signals should be gener ated. By setting the generator frequency lower than the bus frequency, sync signals should be inhibited.

NOTE

If an installation includes machines of diverse vintage or man ufacture, attempts to adjust the frequency and/or voltage matching options for optimum performance of every machine may not be possi ble . In an i ns tal lat ion of this type, some machines may not respond as quickly as othe rs because the front panel settings are a compromise.

9146600990 Rev S BE1-25A Relay Differences 6-7

BREAKER TIME EQUALIZATION MODULES (OPTIONS B3 AND B5)

Beginning with serial number 300, options B3 and B5 were discontinued. For reference purposes, portions of an ear lier edition of this ma nual that covered t hese discontinued opt ions are reprinted in t he following paragraphs.

Description and Application

Two breaker time equa lization options (Figures 6-5 and 6-6) provide individually adjustab le time delays that may be adjusted to match the characteristic closing times of the controlled breakers. Option B3 provides three additional time delays, while option B5 provides five additional delays (i.e., additional to the one that is present without any option).

These options are not curr ently offered b ecause th eir functi on was incor porated in the MC U sync hronizer module (beginning with chassis serial number 300).

Functional Description

(Refer to Figures 6-7 and 6-8.) A remote s elector switch is used to select and e nable the Transmission Gate to be used. All gates are inhibited except the one selected.

The signal from the Br eak e r T ime Tim er ( of t he Sy nc hr oniz er Module) is delivered to th e fr o nt p ane l TIME SET controls, and then to the Transmission Gates.

The Advance Angle s ignal (from the Breaker Time Compensatio n circuit of the Sy nchronizer Module) is delivered to the front pane l TIME SET controls, and then to t he Transmission Gates. The Transmission Gate output of the selected breaker is then used to determine when the Breaker Close signal is generated.

Figure 6-5. Module B3

6-8 BE1-25A Relay Differences 9146600990 Rev S

Figure 6-6. Module B5

Figure 6-7. Module B3 Block Diagram

Figure 6-8. Module B5 Block Diagram

B3 and B5 Calibration

1. Conn ect the oscilloscope o r frequency counter to th e synchronizer modul e front panel pin jacks . Set the trigger to detect negative going (+12 to O V) pulses.

2. Set the front panel BREAKER SELECT switch to A.

3. Adjust the A control on the breaker time equalization option module for the desired time. Note that the internal relay pickup time (nominal 15 ms) is not included in the above measurement.

4. Repeat the above steps for breaker times B, C, D, and E as desired.

9146600990 Rev S BE1-25A Relay Differences 6-9

FREQUENCY MATCHING MODULES (OPTIONS F1, F2, F3, AND F4)

Description and Application

When the oncoming generator frequency is not within the paralleling tolerance, but is within +20% or

−40% of the bus frequency, one of the freq uency matching options − F1, F2, F3, or F4 − can supply a correction signal to the prime mover governor to adjust the generator speed to within the required paralleling tolerance.

Frequency Matching Module F1

Option F1 (Figure 6-9) provides a sp eed-correc tive sig nal that is c ompatible with motor -operate d controls of machine speed. The signal can operate in two modes, depending upon slip rate and phasing.

Mode 1

A correction pulse train is i ssued when the slip frequenc y is greater than the allowable limit . The pulses are steered (as appropr iate) to operate one of the t wo speed-adjust output relays . The contacts of one relay are used to s ignal the generator to rais e speed, while the contac ts of the other relay are us ed to signal the generator to lower its speed. The frequency of the correction pulses is identical to the slip frequency, while the width of the pulses is governed by the CORRECTION WIDTH PULSE con trol that has a range of 0.1 to 1.0 seconds.

Mode 2

In the event that generator and bus are frequency matched but not phase matched, bump pulses are issued to induce a slip freq uency that, in turn , may be adjusted to f all within the allowable limit by m eans of mode-1 correction pulses. The bump pulses are matched to system requirements by the BUMP PULSE WIDTH and the BU MP PULSE INTERVAL con trols (Figure 6-9). Bump pulses and c ontrol pulses share the same output relays: one for raise speed, the other for reduce speed. They also share the same indicators. As the output commands are issued, the two LED in dicators, RAISE and LOWER, illuminate accordingly. The pulses iss ued by this option (to direct the output relays) may be monitore d at the SIG and COM jacks. (+12 Vdc = relay de-energized; 0 Vdc = relay energized.)

Frequency Matching Module F3

Option F3 (Figure 6-10) is identical to Option F1, described previously, except that the F3 mode-1 correction signal is continuous rather than pulsed.

Figure 6-9. Module F1

6-10 BE1-25A Relay Differences 9146600990 Rev S

Figure 6-10. Module F3

Options F1 and F3 differ from F2 and F4 by not providing a direct signal to the summing input of the governor. Options F2 and F4 provide a bipolar dc voltage to the summing point of the prime mover governor. The magnitude of the correction signal is proportional to the slip frequency, with maximum amplitude being a nominal ±8 Vdc. The rate of change is controlled by the STA BILITY contr ol (Figur es 611 and 6-12). The output sign al is not terminated until breaker closure . To this point we have discussed features shared by all of the F options. We will now consider the differences between F2 and F4.

The F2 option (Figure 6-11), is eq uipped with a n AMPLITUDE control that limits the outpu t control si gnal to the summing point. T h is opt ion is c omp ati ble w ith t h e Woo dwar d 2 301 , 171 2, 1 724, a nd 2301A, as well as with the Barber Colman ILS, DYNA, and Load Commander governors.

The F4 option (Figure 6-12), instead, has an OFFSET control which is used to adjust the neutral reference of t he output signal to match the neutra l reference of the governor. This option is compa tible with the United Technologies/American Bosch CU 673C.

Figure 6-11. Module F2

Frequency Matching Module F2

(See Figure 6-13.) If the bump pulser circuit does not receive the 180° out-of-phase signal before the adjustable interval has timed out, a bump pulse (whose width is determined by the front panel BUMP PULSE WIDTH control) is output to the gates to change the generator speed slightly to decrease the phase angle.

The bump pulser output, to gether with either the freq uency low or frequ ency high signal, are in put to the gate. Unless disabled by a slip frequency inhibit signal, the gates will then generate an output to the discriminator.

9146600990 Rev S BE1-25A Relay Differences 6-11

Figure 6-12. Module F4

The discriminator output is modified by the stability circuit (controlled by the front panel STABILITY control) to prod uce the proper polarity s ignal for correc ting the gener ator frequen cy. Unless inhibited by a dead bus or by a 52b relay contact signal input, the stability output is amplified and delivered to a summing point type governor. Note tha t a bump pulse is issued only when the generator is frequency matched but not phase matched.

A dead bus condition or 52b auxiliary contact closure causes the module outputs to go to zero volts.

Figure 6-13. Module F2 Block Diagram

Frequency Matching Module F4

(See Figure 6-14.) If the bump pulser circuit does not receive the 180° out-of-phase signal before the adjustable interval has timed out, a bump pulse (whose width is determined by the front panel BUMP PULSE WIDTH control) is output to the gates to change the generator speed slightly to decrease the phase angle.

The bump pulser signal, togeth er with the frequency low or frequency high signal, is input to the gate. Unless disabled by a slip frequency inhibit signal, the gates will then generate an output to the discriminator.

The discriminator output is modified by the stability circuit (controlled by the front panel STABILITY control) to prod uce the proper polarity s ignal for correc ting the gener ator frequen cy. Unless inhibited by a dead bus or by a 52b relay contact sig nal, the s tability output is a mplified an d then de livered to t he offset amplifier. Note that a bump pulse issued on ly when the generator is frequency matched b ut not phase matched.

The offset amplifier adds the offset (adjustable by the front panel OFFSET control) to the correction signal, and outputs the result to a summing point type governor.

A dead bus condition or 52b auxiliary contact closure causes the module outputs to go to zero volts.

6-12 BE1-25A Relay Differences 9146600990 Rev S

Figure 6-14. Module F4 Block Diagram

F2 and F4 Calibration

1. Connect module F2 or F4 in accordance with Figure 6-15.

Figure 6-15. Connection Diagram for F2 and F4 Modules

WARNING!

Do not attempt to use options F2 or F 4 in any chassi s of serial number 300 and up. On these units, terminal 1 is ground for the chassis.

9146600990 Rev S BE1-25A Relay Differences 6-13

2. Set the bus and generator sensing voltages to equal values.

3. Set the bus and genera t or s ens ing frequ enc ies equ al and abo ut 90° out of phase.

4. Connect the oscilloscope or frequency counter to the module front pan el pin jac ks .

5. Confirm the following waveform (Figure 6-16).

NOTE

On the F2 and F4 modules, the waveform is not the summing point output but the input to the summing point driver.

Figure 6-16. Pulse Interval Wavef orm

VOLTAGE MATCHING MODULE V4

Description and Application

Option V4 modules (Figure 6-17) provide an isolated, bipolar dc correction signal to a summing-input type of voltage regulator, or to generator excitation equi pment. Examples of the former: Basler SSR, SR, or KR regulators. Examples of the latter: Basler SSE or SER-CB static exciter-regulators. Figure 6-18 shows the connections for V4 modules.

The STABILITY control provides a rate-ofchange adjustment for the correction signal to match the correction signal to the generator regulator response.

V4 Functional Description

(See Figure 6-19.) The raise or lower voltage signal is output to the appropriate gate and, in turn, to either the positive or negative amplifier. The amplifier signal is directed first to the stability circuit (whose out put is buffered by the output buffer) and then to an external s umming point voltage regulat or. A circuit-board-mounted switch is used to invert (if necessary) the output polarity so as to match a particular voltage regulator requirements.

A voltage inhibit signal from the A option, or a remove corrections s ignal from th e synchronizer module will inhibit further output changes. A dead bus input or a 52b aux iliary c ontact clos ure will cause the output to go to zero volts.

Figure 6-17. Module V4

6-14 BE1-25A Relay Differences 9146600990 Rev S

Figure 6-18. Module V4 Connection Diagram

Figure 6-19. Module V4 Block Diagram

9146600990 Rev S BE1-25A Relay Differences 6-15

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6-16 BE1-25A Relay Differences 9146600990 Rev S

APPENDIX A • GLOSSARY

INTRODUCTION

This appendix provides definitions for selected nomenclature used in this manual.

DEFINITIONS

Advance Angle. Th e angle in degrees prior to phase coincidence that the generator voltage w aveform

will change relative t o the bus voltage waveform dur ing the period of time betw een initiation of breaker closing and the actual closing of the circuit breaker contacts. This can be expressed by the equation:

∅ = 360 × 𝐹 × 𝑇

Where: Φ is the advance angle in degrees F is the slip frequency in hertz T is the breaker closing time in seconds

Automatic Synchronizing System. A relaying scheme that uses a s ynchronizing relay with one or more elements that: 1) take into account the closing time of the controlled breaker to calculate when the advance angle is proper to initiate closing, 2) cause the output contacts to open when a zero phase difference between the se nsed voltages oc curs, and 3) monitor and c ontrol the frequenc y and voltage of the generator.

Bump Pulse. If the oncoming generator and t he bus a re freque ncy matc hed but n ot phase match ed (an d if the Auto Synchronizer is equipp ed w ith a Fr equ enc y Matching option), these pulses (or, more prec isely , contact closures) are used to alter generator speed an d, in turn, to induce a slip fr equency that is within the capture limits of the synchronizer.

Corrective Pulse. A contac t closure initi ated by the F requency Matching Opt ion F1 to c hange generat or speed. A situation ca lls for Corrective Pulses when the slip fre quency is greater than the allowable l imit but within the capture range.

. Slip frequency: the difference between the system frequency and the generator frequency.

GF>BF. 1 An internal signal that inhibits the breaker closure signal unless the generator frequency is

greater than the bus frequency. 2 The designation of an exter nal signal (or the terminals thereof) which causes the Auto Synchronizer to not issue a breaker closure signal unless the generator frequency is greater than the bus frequency.

GV>BV. 1 An internal signal that inhibits the breaker closure signal unless the generator voltage is greater than the bus voltage. 2 The designation of an external signal (or the terminals thereof) which causes the Auto Synchronizer to not issue a breaker closure signal unless the generator voltage is greater than the bus voltage.

LO, HI. Two internal signals developed by the MCU Sync module in response to the speed of an oncoming generator relative to the bus frequency. These signals are used by the various options to determine the direction of any correction or bump pulses issued by the Auto Synchronizer.

Raise, Lower. 1 Refers t o exter nal signals delivered to the generator's control system to adjust frequ enc y or voltage (as the c as e m a y be) i n th e d es ired direction (up or d ow n). 2 The names of t wo int er nal sig nals developed by the Volt age Acceptance module to indic ate to other modules the desired direc tion of any corrective pulses to be issued.

SYNC. An alternate name for the breaker closure signal.

∆V. The difference voltage between the bus and the generator. 180° Out of Phase. An internal pulse that is gener ate d when th e v olta ge of t he bus and the voltage of th e

generator vectorial pass e ach other (as components of t he slip frequency). Each pulse t hus generated occurs at the midpoint of t he slip frequency period. T hese pulses are used to st robe the Correction and Bump pulses.

9146600990 Rev S BE1-25A Glossary A-1

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Basler Electric BE1-25A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

REVISION HISTORY

CONTENTS

DESCRIPTION

OPTIONS

MULTI-GENERATOR OPERATION

APPLICATION

General

Generator-to-Bus Application

Bus-to-Bus Application

Application Checklist

Defining the Parameters

MODEL AND STYLE NUMBER

SPECIFICATIONS

SPECIFICATIONS OF OPTIONS

Voltage Acceptance Option A1

Voltage Acceptance Option A2

Frequency Matching Option F5

Voltage Matching Option V1

Voltage Matching Option V2

Voltage Matching Option V3

Dead Bus Option D1

INTRODUCTION

ADDITIONAL MODULES

Voltage Acceptance Module A1

Voltage Acceptance Module A2

Frequency Matching Module F5

Voltage Matching Module V1

Voltage Matching Module V2

Voltage Matching Module V3

Dead Bus Module D1

SYSTEM OPERATION

INPUT CIRCUITS

Contact Inputs

Front Panel Inputs

Analog Inputs

MICROPROCESSOR CIRCUITRY

OUTPUTS

OPTIONS

VOLTAGE ACCEPTANCE MODULE A1

VOLTAGE ACCEPTANCE MODULE A2

FREQUENCY MATCHING MODULE F5

Frequency Correction

Phase Correction

VOLTAGE MATCHING MODULE V1

VOLTAGE MATCHING MODULE V2

VOLTAGE MATCHING MODULE V3

DEAD BUS MODULE D1

INTRODUCTION

RELAY OPERATING GUIDELINES AND PRECAUTIONS

MOUNTING

CONNECTIONS

General

Multi-Generator Operation

MAINTENANCE

STORAGE

INTRODUCTION

OPERATING PRECAUTIONS

DIELECTRIC TEST

APPLICATION

General Information

Maximizing Auto-Synchronizer Performance

APPLICATION EXAMPLE

Example Parameters

Recommended Procedure

VERIFICATION AND CALIBRATION

General

Equipment Required

Preliminary Instructions

VERIFICATION TESTS

Undervoltage (UV) Inhibit Verification Test

Slip Frequency Verification Test

Sync Signal Verification Test

Lockout and Reset Verification Test

Advance Angle Verification Test

VERIFICATION TESTING OPTIONS