ABB Unitrol 1000-PM40 User manual

We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Copyright 2002 ABB. All rights reserved.
Prep. Peter Moor 04-12-13
User’s Manual No. of p.
Appr. Sami Karttunen 04-12-13
Power Module 40 A 19
Resp.
dept.
ATPE
Document number Lang. Rev. ind. Page
ABB Switzerland Ltd 3BHS200200 E80 en A 1
UNITROL1000-PM40
Power Module 40 A
User’s Manual
Power Module
Compact power module for the regulation of
synchronous machines up to 40 A exciter current.

Document number Lang. Rev. ind. Page
ABB Switzerland Ltd 3BHS200200 E80 en A 2
Important Notice
Our experience has shown that, if the information and recommendations contained in this Operating
Instructions are observed, the best possible reliability of our products is assured.
The data contained herein purports solely to describe the product and is not a warranty of performance
or characteristics. It is with the best interests of our customers in mind that we constantly strive to
improve our products and keep them abreast of advances in technology. This may, however, lead to
discrepancies between a product and its "Technical Description" or " Operating Instructions".
This document has been carefully prepared and reviewed, however should in spite of this the reader find
an error, he is requested to inform us at his earliest convenience.
It is scarcely possible for the operating instructions for technical equipment to cover every eventuality,
which can occur in practice. We would therefore request you to notify us or our agent in the case of all
unusual behaviour, which does not appear to be covered by these operating instructions.
It is pointed out that all local regulations must be observed when connecting and commissioning this
equipment in addition to these operating instructions.
We cannot accept any responsibility for damage incurred as a result of mishandling the equipment
regardless of whether particular reference is made in these operating instructions or not.
We lay particular stress on the fact that only genuine spare parts should be used for replacements.
All rights with respect to this document, including applications for patent and registration of other
industrial property rights, are reserved. Unauthorized use, in particular reproduction or making available
to third parties, is prohibited.
Manufacturer’s address
ABB Switzerland Ltd
Excitation Systems, Voltage Regulators
and Synchronizing Equipment
CH-5300 Turgi / Switzerland
Telephone: [phone]
Fax: [phone]
Email: [email protected]
Internet: http://www.abb.com/unitrol
24 h - Hotline for urgent service inquiries: [phone]

Document number Lang. Rev. ind. Page
ABB Switzerland Ltd 3BHS200200 E80 en A 3
Contents
1SAFETY INSTRUCTIONS ................................................................................................ 5
1.1 General................................................................................................................................................5
1.2 Safety Instructions...............................................................................................................................6
2DEVICE DESCRIPTION.................................................................................................... 7
2.1 Introduction..........................................................................................................................................7
2.2 Area of application...............................................................................................................................7
2.3 Hardware.............................................................................................................................................8
2.3.1 Interface to the Power Module ............................................................................................................9
2.3.2 Functional Description.......................................................................................................................10
2.3.3 Device connections ...........................................................................................................................11
2.3.4 Protective Functions, Alarms ............................................................................................................12
2.3.5 Display LED’s ....................................................................................................................................12
2.3.6 Potential free Output Alarm...............................................................................................................13
2.3.7 Start up Sequence, LED Display.......................................................................................................13
3INSTALLATION AND DISPOSAL .................................................................................. 14
3.1 Mechanical installation ......................................................................................................................14
3.2 Earthing and wiring............................................................................................................................14
3.3 Disposal.............................................................................................................................................15
4COMMISSIONING .......................................................................................................... 16
4.1 Safety regulations..............................................................................................................................16
4.2 Setting Aids, Set in Operation with the Machine...............................................................................16
5MAINTENANCE AND FAULTS ...................................................................................... 17
5.1 Safety regulations..............................................................................................................................17
5.2 Maintenance......................................................................................................................................17
5.3 Trouble shooting................................................................................................................................17
5.4 Repair................................................................................................................................................17
6APPENDIX...................................................................................................................... 18
6.1 General Data .....................................................................................................................................18

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ABB Switzerland Ltd 3BHS200200 E80 en A 4
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ABB Switzerland Ltd 3BHS200200 E80 en A 5
1 SAFETY INSTRUCTIONS
1.1 General
The safety instructions shall be followed during installation, commissioning, operation and maintenance
of the excitation system. Read all instructions carefully before operating the device and keep this manual
for future reference.
Required Qualification
Personnel involved in installation work and commissioning of the UNITROL 1000-15 and the UNITROL
1000-PM40 must be familiar, specially instructed and informed about the residual danger areas
according to the regulations currently in force.
Operating personnel is not permitted to work at the control system.
Specially instructed personnel must only carry out maintenance and repair work.
The maintenance personnel must be informed about the emergency shutdown measures and must be
capable of turning off the system in case of emergency.
The maintenance personnel must be familiar with the accident prevention measures at their workplace
and must be instructed in first aid and fire fighting.
Responsibilities
It is the owner’s responsibility to ensure that each person involved in the installation and commissioning
of the UNITROL 1000-15 and the UNITROL 1000-PM40 has received the appropriate training or
instructions and has thoroughly read and clearly understood the safety instructions in this chapter.

Document number Lang. Rev. ind. Page
ABB Switzerland Ltd 3BHS200200 E80 en A 6
1.2 Safety Instructions
The safety instructions always appear at the beginning of each chapter and/or precede any instruction in
the context where a potentially dangerous situation may appear. The safety instructions are divided into
five categories and emphasized by the use of the following layout and safety signs:
DANGER!
This symbol indicates an imminent danger resulting from mechanical
forces or high voltage. A non-observance leads to life-threatening
physical injury or death.
WARNING!
This symbol indicates a dangerous situation. A non-observance may lead
to bad or life-threatening physical injury or death.
CAUTION!
This symbol indicates a dangerous situation. A non-observance may lead
to physical injury or cause damage to the converter.
NOTICE!
This symbol emphasizes important information. A non-observance may
cause damage to the converter or to objects close to it.
IMPORTANT!
This symbol indicates useful information. Not to be used to indicate
dangerous situations.
!

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ABB Switzerland Ltd 3BHS200200 E80 en A 7
2 DEVICE DESCRIPTION
2.1 Introduction
UNITROL 1000-PM40 is a power module of the latest design for the regulation of synchronous
generators and synchronous motors. The unit contains the most advanced microprocessor technology
together with IGBT semiconductor technology (Insulated Gate Bipolar Transistor).
Five LED's are integrated to provide status data in the cover, which signal the operating condition of the
equipment.
The mechanical structure consists of a heat sink mounted with a printed circuit board, two sidewalls and
a cover. This mechanical construction is extremely compact and robust. The plug connectors and the
connection terminals are integrated into the front of print circuit board.
2.2 Area of application
This advanced-design power module is used for the excitation of indirectly excited synchronous
machines. This unit is only suitable for this one area of application in connection with the automatic
voltage regulator UNITROL 1000-15.

Document number Lang. Rev. ind. Page
ABB Switzerland Ltd 3BHS200200 E80 en A 8
2.3 Hardware
Structure:
A solid heat sink with two sidewalls and a cover made
of metal form the equipment assembly.
The semiconductors are mounted on the heat sink and
electrically connected with the printed circuit board,
which is fastened on top of it.
The terminals are at the front side of the unit.
Installation:
The site of installation must be dry and free of dust.
Mounting:
Power module is designed for wall or rack mounting.
For optimal cooling a distance of approx. 200 mm
around the unit must be kept free.
Wall mounting
UNITROL 1000
Power Module 40 A

Power ON
Excitation ON
Overcurrent
Overtemperature
Alarm
CAN ALARM Ie Upwr
+- L3L1 L2
200 mm
200 mm
Rack mounting
154 mm
Dismantling the cover:
Both system plugs X102 and X103 are to unbolt
and to remove.
Subsequently, unbolt the four screws on the cover.
Now the cover can be raised and removed from the
side of the connector.
open screws
remove connectors
CAN ALARM
X103X102
Cover
Connectors: Cover removed
- Phoenix system plugs X102, X103
(CAN, ALARM)
- Screw connections M5 on printed
circuit board (Ie, Upwr)
- Screw connection M5 on front of
heat sink (Earth)
L1 L2 L3
+Ie
-Ie
X103X102
1 1
Upwr
ALARMCAN
Printed circuit board mounted on the heat sink

Document number Lang. Rev. ind. Page
ABB Switzerland Ltd 3BHS200200 E80 en A 9
2.3.1 Interface to the Power Module
Structure of automatic voltage regulator and power module:
Automatic Voltage Regulator
UNITROL 1000-15 Power Module 40 A Miniature Circuit- Breaker
UNITROL 1000
Ab b R
UNITROL 1000
Power Module 40 A
Ab b
Power ON
Excitation ON
Overcurrent
Overtemperature
Alarm
CAN ALARM Ie Upwr
+- L3L1 L2
OK
ESC
CAN BUS
S283- UC-Z
Connection diagram machine, voltage regulator UNITROL 1000-15 and Power module:
PWM
-
+
Measurement
and control
inputs
~ / =
=
Auxiliary supply UAUX
L1 L2 L3
(+) (-)
AVR
Supply
power electronics
L1
L2
L3
Digital in- and outputs
Analog in- and outputs
UNET
UM
IM2
Ie
UN1000-15
E
SM E
for control electronics
RS-232
RS-485
Power Module 40 A
CAN Bus
=
= ALARMPWM
or
Upwr

Document number Lang. Rev. ind. Page
ABB Switzerland Ltd 3BHS200200 E80 en A 10
2.3.2 Functional Description
Power Module:
The power module consists of an input rectifier, soft start facility for the current-limited loading of the
intermediate circuit, the IGBT power semiconductor with free-wheeling diode and over voltage
protection.
The average value of the output voltage is always positive. The output is current-limited and thus short-
circuit-proof.
Control and Monitoring:
The voltage regulator UNITROL 1000-15 does the communication between machine and excitation
systems. In this unit all machine data is set, feedbacks processed and the necessary parameters
adjusted. For the power module no special parameters are to be adjusted in the voltage regulator. The
transmission of the control signals to the power module is made by CAN Bus.
Alarm output:
A potential free relay contact is available.
LED display:
Five LED's inform about the operating condition of the unit. See description in section 2.3.5.
DSP
Power Module 40 A
+Ie
X102:4
TIGBT
X102:5
X103:1
X103:2
A/D
X103:3
>
Driver
Overcurrent lim
Power ON
Excitation ON
Alarm
X102:3
X102:2
X102:1
Upwr
Overcurrent
Overtemperature
CAN_GND
CAN_L
L1
L2
L3
PE
CAN_SHIELD
CAN_H
CAN_POWER
Alarm
CAN
Aux. Power
-Ie
Soft start intermediate circuit
+
CAN
Temperature measurement
Voltage measurement
measurement
Current
NO
COM
NC

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ABB Switzerland Ltd 3BHS200200 E80 en A 11
2.3.3 Device connections
Terminal designation Signal Circuit
L1
L2
L3
Auxiliary supply UAUX
- AC input voltage 3-phase
(0 to 600 Hz) or
- AC input voltage 1-phase
(40 to 600 Hz)
or
- DC input voltage
3~
9 to 250 V~ L1,L2,L3
1~
30 to 250 V~ L1,L2
2=
16 to 300 V= L1,L2
External Power module
Power module
Power module
*)
*)
*)
*) Circuit breaker
Type: S283 UC-Z 50 for 50 A, for
DC and AC current
Trip characteristics Z
(Semiconductor protection)
+Ie
- Ie Excitation current output Ie
40 A =
+
-E
0 to 350 V=
ExternalPower module Ie
Ie
COM = X103:1
NO = X103:2
NC = X103:3
Potential free relay contact
for alarm signal
Relay contact:

250 V AC/DC

2 A
X103:1
X103:2
X103:3
ALARM
Power module
NC
NO
COM
CAN_GND = X102:1
CAN_L = X102:2
CAN_SHIELD = X102:3
CAN_H = X102:4
CAN_POWER= X102:5
CAN Bus
Shielded cable:
2x 2x 0,34 mm2,
Impedance 120

,
Length of cable < 30 m
X102
2
3
4
53
55
52
54
gnd
-
+
CAN_GND
CAN_L
CAN_SHIELD
CAN_H
1
UNITROL 1000-15 Power Module
CAN_POWER
5
120R
J4
Earth Earth connection

Document number Lang. Rev. ind. Page
ABB Switzerland Ltd 3BHS200200 E80 en A 12
2.3.4 Protective Functions, Alarms
Event Description
Interruption of CAN
communication for
100 ms during
Excitation ON
An internal shutdown occurs after 100 ms.
This shutdown and the alarm signal can be reseted only by turning off and
restarting the supply voltage Upwr.
Heat sink temperature

95 °C An internal shutdown occurs, when heat sink temperature reaches 95 °C. This shutdown and the alarm signal can be reseted only by turning off and
restarting the supply voltage Upwr.
Heat sink temperature

80 °C Alarm signal, when the heat sink temperature reaches 80 °C.
Excitation current

80 A Alarm signal after 10 s overcurrent.
Second alarm signal If the alarm signal is already active, the LED alarm lights off for 1 s and the
relay contact drops for 1 s, if a new alarm signal occurs.
Alarm inactive - CAN Bus connection active,
- No internal shutdown active,
- Peak value of the excitation current < 75 A (15 minutes after response),
- Heat sink temperature < 75 °C (15 minutes after response).
Alarm relay output,
Alarm LED display The alarm signal from the relay output or the LED display is identical.
ICL recovery faults
ICL= Inrush current
limiter
An internal shutdown occurs, when the ICL was activated because of inrush
current above 250 A and the SW can not restart the unit.
This shutdown and the alarm signal can be reseted only by turning off and
restarting the supply voltage Upwr.
2.3.5 Display LED’s
LED Description
Power ON, green LED lights up, when the power module is powered on and the DC-link
voltage is higher than 11 V DC.
Excitation ON, green LED lights up, when the excitation command is received from CAN Bus.
LED blinks, if there is no CAN Bus connection.
Overcurrent, red LED lights up, when the excitation current peak reaches 80 A.
LED keeps blinking for 15 minutes before it turns off, when the peak current
has dropped below 75 A.
Overtemperature, red LED lights up, when the heat sink temperature reaches 80 °C.
LED keeps blinking for 15 minutes before it turns off, when the temperature
has dropped below 75 °C.
Alarm, red See Protective Functions, Alarm, section 2.3.4

Document number Lang. Rev. ind. Page
ABB Switzerland Ltd 3BHS200200 E80 en A 13
2.3.6 Potential free Output Alarm
Signal Description
Relay turned off Normal operation
Relay turned on Alarm
The relay can indicate the alarm only, if the unit is powered. Otherwise the
relay is turned off!
2.3.7 Start up Sequence, LED Display
When the supply voltage Upwr powers the unit shows the following sequence with LED’s:
Time Action
Normal operation
LED Power ON lights up only
LED Power ON and that LED which had led to the last interruption lights up:
- Interruption CAN Bus connection -> LED Excitation ON lights up
- Overtemperature -> LED Overtemperature lights up
- ICL recovery fault -> LED Excitation ON and LED Overtemperature lights up
LED Power ON lights up only
All LED’s except the LED alarm light up
[s]
0
1
2
3
4
5
Normal operation
(No alarm signal possible)
Normal operation: see display LED’s, section 2.3.5

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ABB Switzerland Ltd 3BHS200200 E80 en A 14
3 INSTALLATION AND DISPOSAL
The unit should be unpacked with the usual degree of care, without use of force and using suitable tools.
The unit should be inspected visually to check for any damage caused during transport. Complaints
regarding defects resulting from inappropriate transport are to be addressed immediately to the receiving
station or the last carrier.
NOTICE!
The unit is visible damaged.
The safe operation is not possible.
The unit must not be installed and taken in operation
3.1 Mechanical installation
The unit is mounted in place by means of four screws.
See dimensional diagram for fixing holes and spacing.
The unit should only be installed in indoor areas which are dry
and dust-free and which do not contain any gases, acid fumes
or similar.
UNITROL 1000
Power Module 40 A

Power ON
Excitation ON
Overcurrent
Overtemperature
Alarm
CAN ALARM Ie Upwr
+- L3L1 L2
180 mm
256 mm
9mm
3.2 Earthing and wiring
Cross sections of the terminals:
- L1...L3, +Ie and –Ie:Screw terminal power circuits, max. 16 mm2, (AWG 5)
- CAN BUS: Shielded signal cable, 2x 2x 0,34 mm2, Impedance 120 Ohm
- ALARM: Signal cable, max. 2,5 mm2, (AWG 13)
- Earth: at least 6 mm2(AWG 9), however not smaller than wiring of power circuits
The cables of the power circuits
are recommended to wire with
shielded cables.
The screw terminals and the
grounding connection are to be
tightened with a torque of 3 to
5 Nm
L1 L2 L3
+Ie
-Ie
X103X102
1 1
Upwr
after assembly of the cover
cable tie

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ABB Switzerland Ltd 3BHS200200 E80 en A 15
3.3 Disposal
Improper disposal of electrical devices can lead to environmental damage. It is therefore
important that qualified personnel carry out the disposal of electronic equipment.
The metallic casing does not present any risk to the environment and can be recycled.
The printed circuit boards are simple to remove. The boards must be removed and should
be disposed by a licensed disposal company.
Environmentally hazardous elements such as capacitors must be separated from the
boards.

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ABB Switzerland Ltd 3BHS200200 E80 en A 16
4 COMMISSIONING
4.1 Safety regulations
WARNING!
UNITROL 1000 units operate with dangerous voltages of up to 250 VAC.
Manipulation of live parts can lead to death or injury to the persons
involved or damage to the surroundings.
Possible risks are largely excluded if the unit is handled properly in
accordance with these instructions.
WARNING!
The secondary voltage of the excitation transformer and the rotor field
voltage are fed into the excitation cabinet.
These components present a great danger of electric shocks.
Commissioning work shall only be carried out on the electrical installation
if the system has been switched off and protective grounds installed.
After the unit has been switched off, it must be ensured by measurement that no measuring voltages or
control voltages >50 V are present at the terminals. At an interrupted field circuit the input capacitor is
slowly discharged through internal circuits. The LED power ON indicates likewise whether the internal
intermediate circuit is still loaded.
In order to prevent unintentional closing of open voltage circuits by third parties, the circuits in question
should be identified at the point of interruption (e.g. by means of a warning sign).
Before switching on, check whether the connection terminals are wired up according to the plant
schematic.
4.2 Setting Aids, Set in Operation with the Machine
The settings of the parameters and the procedure of start-up is to be studied from the user’s manual
UNITROL 1000-15. On the power module no settings can be made.
!
!

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ABB Switzerland Ltd 3BHS200200 E80 en A 17
5 MAINTENANCE AND FAULTS
5.1 Safety regulations
WARNING!
The secondary voltage of the excitation transformer and the rotor field
voltage are fed into the excitation cabinet.
These components present a great danger of electric shocks.
Maintenance work shall only be carried out on the electrical installation if
the system has been switched off and protective grounds installed.
5.2 Maintenance
When the system is at a standstill, the screwed terminals, which can loosen due to vibrations, should be
checked for tightness. Dusty cooling flanges should also be cleaned.
5.3 Trouble shooting
In order to locate the disturbance, the displays of the LED's are to be controlled. See section 2.3.5,
Display LED’s.
5.4 Repair
A defective unit should be sent in for repair. See manufacturer’s details on page 2.
!

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ABB Switzerland Ltd 3BHS200200 E80 en A 18
6 APPENDIX
6.1 General Data
Ordering information
Product designation UNITROL

1000-PM40
Device designation Power Module 40 A
Type UNS 2114A-Z
Order number: Basic equipment 3BHE015411 R0001
Mechanical data
Weight 6.7 kg
Protection class IP20
Dimensions (LxWxH) 220x285x154 mm
Climatic stability
Temperature range for operation 0 to +55 °C
Temperature range for storage -20 to +75 °C
Vibration IEC 60255-21-1, class 2
Shock IEC 60255-21-2, class 2
Seismic IEC 60255-21-3, class 2
Electrical data
Power supply Upwr:- DC 16 to 300 V DC, DC
- Single phase 30 to 250 V AC, 40 to 600 Hz
- Three phase 9 to 250 V AC, 0 to 600 Hz
Excitation output current Ie: - Maximum continuous current until 55 °C 40 A
- Overload for maximum 10 s 80 A
Excitation output voltage 0 to 350 V DC
Test voltage:
Power supply Upwr against case, relay contact and CAN Bus 3 kV DC, 2 s
Relay contact against case 2 kV AC, 1 min.
Relevant standards, CE conformity
EMC directive: 89/336/EEC
Generic emission standard *) IEC 61000-6-4
Product standard emission IEC 61800-3, Annex D
Generic immunity standard IEC/EN 61000-6-2
*) The emission limit values are kept only if the supply circuits Upwr is fed through a filter and the
power circuits are fitted with shielded cables.
User’ Manual
Automatic voltage regulator UNITROL 1000-15 3BHS201795 E80

Document number Lang. Rev. ind. Page
ABB Switzerland Ltd 3BHS200200 E80 en A 19
REVISION
Rev.
ind. Page (P) Chapt. (C) Description (or number of revision) Date Dept./Init.
A 2.3.4 and ICL recovery fault 13.12.2004 / Mo
2.3.7