ABB UNITROL 1010 User manual

Safety instructions
Read the safety instructions in the User Manual .
WARNING!
• Obey the safety instructions to prevent physical injury or death, or
damage to the equipment.
• Read and make sure that you understand the operating and safety
instructions before you operate the unit.
• If you are not a qualified electrician, do not do electrical installation or
maintenance work.
• Use personal protective equipment, such as, safety shoes and gloves.
Obey these safety precautions before you do work on the system:
1. Clearly identify the work location and equipment.
2. Disconnect all possible voltage sources. Make sure that reconnection is not
possible. Lock out and tag out.
•Open the main disconnecting device of the AVR.
•Disconnect any external power sources from the control circuits before
you do work on the control cables.
•If you have a permanent magnet generator connected to the AVR,
disconnect it from the AVR with a safety switch or by other means.
•After you disconnect the AVR, always wait for 5 minutes to let the
intermediate circuit capacitors discharge before you continue.
•Do not do work on the AVR when the amber warning LED flashes.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when you are near bare conductors.
5. Measure that the installation is de-energized.
•Use a multimeter with an impedance of at least 1 Mohm.
•Make sure that the voltage between the AVR input power terminals
(PWR L1, PWR L2 and PWR L3) and the grounding terminal (PE) is near
0 V.
•Make sure that the voltage between the AVR output terminals (IE+, IE-
and ExCap) and the grounding terminal (PE) is close to 0 V.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person in control of the electrical
installation work.
Residual danger areas
WARNING! Do not do work on the AVR when the amber warning LED
flashes.
When the AVR operates,
•The voltage in the power section can be up to 300 V AC and the short-circuit
current is very high.
•The voltage in the control cabinet is more than 50 V.
When the AVR is disconnected from power supplies, the large capacitors in the
AVR hold a charge for some time. Wait for at least 5 minutes for the capacitors
to discharge before you do work on the AVR. An amber warning LED flashes if
the internal voltage is more than 30 V DC.
Warning labels are attached to all of the cubicle doors to warn personnel against
opening the doors during operation.
If the device is built into a larger system, additional warning labels are attached
to the inside of the cubicle doors and to the covers of the power converter
modules.
Consider the residual danger areas when you do work on the excitation system:
•Danger from live equipment inside the excitation system, if the protective
covers are removed.
•Hazardous voltages from the rotor field winding and the secondary side of
the excitation transformer.
•Danger from charged capacitors if a cabinet door is open immediately after
the system stops.
•Danger from main and auxiliary voltages when cubicle doors are open.
Introduction
This document is a quick installation guide for the UNITROL 1010 and
UNITROL 1020 automatic voltage regulator. Make sure that you read and
understand this document before you install or use the product. This document
is meant only as a brief guide to the product. For detailed information on the
product, refer to the
User Manual .
Device description
UNITROL 1010 and UNITROL 1020 are automatic voltage regulators (AVR) for
synchronous machines of up to 80 MVA. The AVRs can be used for the excitation
of indirectly excited synchronous machines and motors. The AVRs can also
operate as a reactive power regulators, power factor regulators or field current
regulators.
Product package
Contents of the product package:
•UNITROL 1000 series AVR
•Special red USB cable that is used to power and to connect with the AVR.
Keep this USB cable in a safe place.
•Red jumper blocks (3 pcs.)
•Quick installation guide and test certificate
Make sure that all of the listed items are in the product package and that there is
no damage to the items.
Hardware overview
Primary parts of the AVR. Refer to the User Manual for more information.
Warning and status indicators
Mechanical installation
For detailed information on mechanical installation, refer to the User Manual .
Install the AVR in an indoor area that is dry and dust-free, and that does not
contain volatile gases, acid fumes or similar hazards.
Examine the installation area and refer to technical data to make sure that:
•The maximum ambient temperature is in the permitted range.
•The vibration is limited and within the permitted class.
•The ingress protection and pollution degree are suitable.
•The EMC environment is suitable.
Installation requirements:
•Install the AVR vertically to make sure that cooling operates correctly.
•Free space requirements:
•50 mm above the AVR
•20 mm below the AVR
•10 mm on the left and right sides of the AVR
•Make sure that there is sufficient cooling air flow around the AVR.
•Make sure that other devices do not blow hot air on to the AVR.
•The AVR is designed to be installed with suitable hardware to an installation
plate.
•Make sure that the frame of the AVR is electrically grounded (PE) to the
installation plate with a grounding wire (≥4 mm2) through a mounting hole.
Use toothed washers to get a good electrical ground contact.
Installation procedure:
1. Refer to Dimensions for the mounting hole dimensions.
2. Make the appropriate holes in the installation plate.
3. Attach the AVR to the installation plate with suitable hardware, for example,
M6 screws to a torque of 10 Nm. The mounting holes have a diameter of
6.5 mm.
4. Make sure that there is a good electrical ground connection between the
installation plate and the AVR. The installation plate must be electrically
grounded (PE).
Electrical installation
For detailed information on electrical installation, refer to the User Manual .
CAUTION! Separate control (I/O) cables from the excitation (power and
measurement) cables to avoid electromagnetic interference.
Cable dimension requirements:
Grounding
Connect the AVR to the protective earth at terminal 17 with a 4 mm2 grounding
wire.
Make an additional grounding connection through the mounting holes to the
installation plate (if it is connected to the protective earth) or with a 4 mm2
cable to the protective earth.
Make sure that the grounding connections are as short as possible.
Additional signal ground terminals are provided for the control cables.
Inrush current limitation
The large internal DC capacitor of the AVR can cause a high inrush current
especially with a strong voltage source.
WARNING! To prevent damage to the AVR, make sure that the inrush
current is not more than 200 A for 10 ms.
To prevent damage to the AVR from a high inrush current:
To calculate the inrush current, you can use a capacitor voltage of 0 V at startup.
The external resistor for a 200 V AC input is typically 1.5 Ω.
Power and measurement terminals
1) To reduce wiring, you can connect each phase of the excitation power inputs
(PWR) and auxiliary power supply inputs (AUX) with the included jumpers.
Commissioning
For detailed instructions on commissioning, refer to the User Manual .
Commissioning procedure overview:
1. Make sure that all of the connections are correct and safe.
2. Download the configuration file to the AVR. Make sure that the parameters
are correct.
3. Examine the digital and analog I/Os in standstill.
4. Do tests with the machine:
a) Standstill
•Measure resistance of exciter stator winding.
b) No load condition
•Increase the speed of the machine to nominal.
•Start excitation in Manual mode and increase the manual setpoint until
machine voltage is 50%.
•Use CMT 1000 to verify the AVR measurements and compare them with
other equipment used, such as protection devices.
•Increase the setpoint until the machine voltage is 100% and tune the
AVR with the AVR tuning assistant.
•Do step response tests to examine performance in Manual mode and
Auto mode.
c) Machine connected to grid
•Select AUTO (voltage regulator).
•Increase the AUTO setpoint to verify the polarity of the of IM
measurement. Q must increase.
d) Do step response tests to examine performance in Auto mode and direct
VAR regulator modes.
5. Finalizing commissioning
a) Save the parameters on the AVR and verify the status with CMT 1000.
b) Save backup files for project documentation.
WARNING! To prevent unstable regulation and damage to the machine,
do tests for all used regulator modes and limiters.
WARNING! If you use synchronization, refer to the procedure in the user
manual. Take special care with synchronization to prevent physical
injury or death, or damage to the equipment.
—
ABB EXCITATION SYSTEMS
UNITROL® 1010 and UNITROL® 1020
Quick installation guide
Color Description
Amber Warning LED
Flashes: Do not do work on the AVR! The internal voltage is more than 30 V DC.
Green Operating status
ON: Device controllers are active
Flashes: Device software is active
Yellow Excitation status
ON: Excitation is active
Flashes: A limiter is active
Red Alarm status
ON: An alarm or a trip is active
Flashes:
• Startup failure
• Parameter download failure
• Excitation output is blocked
?
LOC
REM
MENU
AUTO NoLoad
0.00 % UM
0.00 A Ie
100.0% S
12:45
SETPNT
REM
No. Description No. Description
1 Heat sink 9 RS-485 (X1300) terminal
2 Mounting holes 10 CAN (X1302) terminal
3 Unit type designation 11 Digital I/Os
4 Warning LED 12 Analog I/Os
5 Front cover 13 Power terminals
• Protective earth (PE)
• Input power UPWR
• Auxiliary power UAUX
• Excitation output
6 USB port 14 Measurement terminals
UM, UNET, IM
7 Status LEDs 15 Control panel (UNITROL 1020 only)
8 Ethernet port
12
3
45
6
8
9
10 11 12
7
13
14
2
2
2
15
SM E
2
1
3
4
5
6
7
7
8
9
10
11
12
13
14
15
16
No. Description No. Description
1 Digital I/Os
Max. cable length 30 m
9 Power electronics control (PWM)
2 Analog I/Os
Max. cable length 30 m
10 Communication MCU
3 Network voltage measurement UNET 11 Control Power Supply input AUX L1–L3
4 Machine voltage measurement UM12 Ethernet connection
Max. cable length 100 m
5 Machine current measurement IM2 13 USB connection
Max. cable length 3 m
6 External capacitor ExCap (-) 14 RS-485 connection
Max. cable length 500 m
7 Excitation output Ie & Ue15 CAN connection
Max. cable length 3 m
8 Measurement and control unit (DSP) 16 Excitation Power Supply input
PWR L1–L3
Connection type Cross-section area requirement
Excitation cables
Terminals 1 to 17 0.2 to 4 mm2AWG 24 to AWG 10
Control cables (I/O)
Terminals 20 to 77 0.2 to 2.5 mm2AWG 24 to AWG 12
Method Description
Shunt supply The excitation power is taken from the generator output over a shunt
transformer. Use an excitation supply transformer with a maximum
power of 10 kVA.
PMG supply The excitation power is taken from a permanent magnet generator
(PMG). The maximum permitted output power of the PMG is 10 kVA.
Auxiliary windings The excitation power is taken from an additional stator winding of
the generator.
Auxiliary supply The excitation power is taken from an auxiliary power source. Use an
excitation supply transformer with a maximum power of 10 kVA.
DC battery The excitation power is taken from a battery. Limit the inrush current
with a resistor.
Terminals Type Ref. Label Signal description
Power
terminals
17 PE Protective earth
161PWR L1 Input power L1
151AUX L1 (+) Auxiliary supply L1
141PWR L2 Input power L2
131AUX L2 (-) Auxiliary supply L2
121PWR L3 Input power L3
111AUX L3 Auxiliary supply L3
10 IE+ Exciter current +
9 IE- Exciter current -
8 ExCap (-) External capacitor -
Measurement
terminals
7 ML1 Machine voltage L1
6 ML2 Machine voltage L2
5 ML3 Machine voltage L3
4 NW1 Network voltage L1
3 NW3 Network voltage L3
2 MC2+ Machine current +
1 MC2- Machine current -

CMT 1000 commissioning and maintenance tool
You can set the parameters of the AVR with the CMT 1000 commissioning and
maintenance tool PC application for Microsoft Windows. CMT 1000 connects to
the AVR through the USB port or Ethernet port. An Ethernet connection permits
access to the AVR from remote locations. For more information on CMT 1000,
refer to the
User Manual .
Operation
The AVR is controlled by analog and digital I/Os. You can also use control signals
by remote access over MODBUS.
Use CMT 1000 only to set parameters and operation and not as an operator
interface.
For detailed information on operation, refer to the
User Manual .
Technical data
1) 3-phase power supply and an external 1 mF capacitor required to operate
UNITROL 1020 between 15 A and 20 A nominal excitation current.
2) Machine voltage measurement above 250 V AC requires the connection of the
machine star point to earth (PE).
UL ratings
To use the AVR in a UL compliant way, consider the following:
•Electrical ratings for 55 °C surrounding air temperature
•Maximum surrounding air temperature 55 °C – 70 °C with derating as
follows
•UNITROL 1010 maximum output capability: 5 A/150 V
•UNITROL 1020 maximum output capability: 10 A/150 V
•Use only 60/75 °C rated wires
•For use in a Pollution Degree 2 Environment
Grounding conductor terminal is green-colored or plainly identified with “G”,
“GRD”, “GND”, “GRND”, “Ground”, “Grounding” or IEC Publication 417, Symbol
5019.
Excitation inputs PWR L1, PWR L2 and PWR L3 must be protected by a circuit
breaker rated at 480Y/277 V AC, maximum 15 A when supplied from an AC
source or listed class RK5 fuse rated at 300 V DC, maximum 15 A when supplied
from a DC source.
Dimensions
UNITROL 1020
UNITROL 1010
Device connections
Certifications
The applicable certifications are shown on the product’s type label.
Related documents
Support information
ABB Switzerland Ltd
Static Excitation Systems, Voltage Regulators and Synchronizing Equipment
CH-5300 Turgi / Switzerland
Internet: http://www.abb.com/unitrol
24 h hotline for urgent service inquiries: [phone]
E-mail contact for questions and support:
unitrol1000[email protected]
Documentation, software and tools
You can get access to the latest documentation, software and tools for the AVR
on the myABB business portal.
To get access:
1. Go to https://myportal.abb.com in your web browser.
2. Select Log In.
•If you have an ABB account, you can sign in with your email and
password.
•If you do not have an ABB account, refer to How to register to the
myABB business portal.
3. After you log in, the myABB dashboard opens.
4. On the myABB dashboard, find the myExcitation widget. For information on
how to register to the myExcitation widget, refer to How to register to the
myExcitation widget.
5. In the myExcitation widget in the myABB business portal, select GO TO ABB
LIBRARY.
6. ABB Library opens.
7. In the left-hand menu, select Category >
ABB products > Power Electronics >
UNITROL Excitation Systems >
UNITROL 1000 > UNITROL 1010 or
UNITROL 1020.
8. Select your documentation. You can
search for documents by categories and
by document kind.
9. You can also download the documents to
your computer.
How to register to the myABB business
portal:
1. Select Sign up below the LOGIN button.
2. Fill in the registration form.
3. Select Sign up.
4. ABB sends you an email for activation of
your ABB account.
5. In the email, select ACTIVATE ACCOUNT.
6. You now have an access to the myABB business portal.
How to register to the myExcitation widget:
1. In the myExcitation widget in the myABB business portal, select GET
ACCESS.
2. Fill in the registration form.
After registration, you can get access to UNITROL 1000 series documents and
tools on the ABB Library.
UNITROL 1010 UNITROL 1020
Local control panel No Yes
Ingress protection rating IP20 IP20
Power electronic output
AC nominal input voltage 0 to 250 V AC 0 to 250 V AC
Frequency 25 to 600 Hz 25 to 600 Hz
DC nominal input voltage 0 to 300 V DC 0 to 300 V DC
Maximum peak input voltage
(non-sinusoidal)
420 VP420 VP
Minimum required start voltage N/A N/A
Auxiliary supply (controller input)
AC nominal input voltage 3-phase 9 to 250 V AC 9 to 250 V AC
AC nominal input voltage 1-phase 16 to 250 V AC 16 to 250 V AC
Frequency 40 to 600 Hz 40 to 600 Hz
DC nominal input voltage 18 to 300 V DC 18 to 300 V DC
Maximum peak input voltage
(non-sinusoidal)
420 VP420 VP
Excitation output
Continuous current at 55 °C 10 A DC 15 A DC
20 A DC1)
Overload current for 10 seconds at
55 °C
25 A DC 38 A DC
Exciter current measurements
Full range 0 to 38 A 0 to 38 A
Accuracy / Resolution < 1% / < 100 mA < 1% / < 100 mA
Machine and net measurements
Machine voltage, 1-, 2-, or 3-phase Up to 500 V AC2) Up to 500 V AC2)
Machine current, 1-phase 1 to 5 A AC 1 to 5 A AC
Network voltage, 1-phase Up to 500 V AC Up to 500 V AC
Frequency range 10 to 150 Hz 10 to 150 Hz
Accuracy (-40 °C to 70 °C / at
25 °C)
±1% / 0.1% ±1% / 0.1%
Voltage regulation
AVR response time (3-phase / 1-
phase measurement)
< 20 ms / < 50 ms < 20 ms / < 50 ms
PwM limitation 0.5 to 99% 0.5 to 99%
Digital inputs and outputs
Numbers of digital I/Os
(inputs / in or out / output) 4 / 8 / 0 4 / 8 / 0
Digital I/O voltage 24 V 24 V
Analog inputs and outputs
Number of analog inputs/outputs 3 / 2 3 / 2
Analog I/O range ±10 V ±10 V
Communication interfaces
Ethernet (cable length < 100 m) 10 / 100 MBit/s 10 / 100 MBit/s
USB version (use the provided red
USB cable only)
1.0, 1.1, 2.0 1.0, 1.1, 2.0
CAN (cable length < 3 m) Only for connections between UNITROL 1000 devices.
Dimensions and weights
D1 W1 W2 W3 H1 H2 Weight
mm in mm in mm in mm in mm in mm in kg lb
111 4.3 170 6.7 143.5 5.6 147.5 5.8 302 11.9 280 11.0 3.8 8.4
Dimensions and weights
D1 W1 W2 W3 H1 H2 Weight
mm in mm in mm in mm in mm in mm in kg lb
85 3.3 170 6.7 143.5 5.6 147.5 5.8 302 11.9 280 11.0 2.8 6.2
Terminal Signal Circuit
7 = ML1
6 = ML2
5 = ML3
2 = MC2+
1 = MC2-
7 = ML1
5 = ML3
7 = ML1
6 = ML2
5 = ML3
Machine Voltage three-phase
UM
• Machine L1
• Machine L2
• Machine L3
Warning: If Um > 250 V AC, then
the star point must be
connected to PE.
Machine Current single-phase
IM2
• Machine Current +
• Machine Current -
Machine Voltage single-phase
UM
• Main L1
• Main L3
Machine Voltage three-phase
with ground UM
• Machine L1
• Machine L2
• Machine L3
1) You must ground PT & CTs.
4 = NW1
3 = NW3
Line voltage measurement
single-phase UNET
Network L1
Network L3
1) You must ground PT & CTs.
37 = D1
36 = D2
35 = D3
34 = D4
31 = D5
30 = D6
29 = D7
28 = D8
39 = V1
38 = V2
33 = V3
32 = V4
20 = G2
21 = G1
Digital input/output
Digital input/output 1
Digital input/output 2
Digital input/output 3
Digital input/output 4
Digital input/output 5
Digital input/output 6
Digital input/output 7
Digital input/output 8
CAUTION!
When configured as outputs, do
not connecte DIO1…DIO8
directly to the 24 V supply
(causes a short circuit via
internal transistor).
24 V power
24 V power
24 V power
24 V power
GND
GND
53 = AI1, 52 = BI1
51 = AI2, 50 = BI2
49 = AI3, 48 = BI3
47 = ARP
45 = ARN
BRP = 46
BRN = 44
Analog Inputs
AIx/BIx
Signal bandwidth 100 Hz
+10 V pos Ref
-10 V neg Ref
GND Positive Reference
GND Negative Reference
R = 10 kΩ (±5 V input range)
D1
W1 W2
H1 H2
H1 W1
W3
D1
W1 W2
H1 H2
H1 W1
W3
ML1
ML2
ML3
ML1
ML2
ML3
L1 L2 L 3
ML1
ML3
MC2+
MC2-
SM
IM2
External
External
External
max. 500 / 0.2 VA
max. 500 / 0.2 VA
max. 500 / 0.2 VA
1A / 5 A
0.1 VA
1)
1)
1)
1)
NW1
NW3
External
max. 500 / 0.2 VA
1)
24 V
24 V
ADC
2 k
V1
V2
G1
D1
V1
V2
D1
G1
max. 150 mA
20 ... 28 V
20 ... 28 V
External
External
AI1
+
-
R
BI1
+
-
+
-
BRP
10 V DC
47 k
100 k
10 k
100 k
47 k
4.7 k
4.7 k
max.
±10 V
ARN
AI1
BI1
-10 V DC
AGND
100 k
100 k
47 k
47 k
External
External
53 = AI1, 52 = BI1
51 = AI2, 50 = BI2
49 = AI3, 48 = BI3
Analog Inputs digitally assigned
AIx/BIx
43 = AO1
41 = AO2
42 = BO1
40 = BO2
Analog Outputs
AOx to BOx
(AGND = BO1, BO2)
Max. output current: 10 mA
Document Code
UNITROL® 1010 User Manual (English) 3BHS335648 E81
UNITROL® 1020 User Manual (English) 3BHS335648 E82
UNITROL® 1000 Control SW manual (English) 3BHS399489 E02
UNITROL® 1000 Commissioning instructions (English) 3BHS399489 E01
UN1000 Modbus Address table (English) 3BHS358281 E81
UN1000 Modbus Reference Manual (English) 3BHS358281 E80
UN1000 Railway Type Test Summary (English) 3BHS258571 E44
UN1000 Type Test Summary (English) 3BHS258571 E41
Release Notes HW/SW (English) 3BHS355555 E02
Terminal Signal Circuit
ARP
AI1
Ain
BI1
4.7 k
4.7 k
100 k
100 k
10 V DC
47 k
+
-
AO1
BO1
max. ±10
+
-
DNV•GL MaritimeCE marking cUL recognized SQS
3BHS335648 E02 Rev B 2020-12-08
© 2020 ABB Switzerland Ltd. All rights reserved.