ABB UniGear Digital User manual

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DISTRIBUTION SOLUTIO NS
UniGear Family
UniGear Digital
Commissioning and testing Guide

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DISTRIBUTION SO LUTIO NS
UniGear Family
UniGear Digital
Commissioning and testing Guide

NOTICE
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reference to one or more standards that may be generally relevant to the ABB products. The presence of any
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Products described or referenced in this document are designed to be connected and to communicate infor-
mation and data through network interfaces, which should be connected to a secure net-work. It is the sole
responsibility of the system/product owner to provide and continuously ensure a secure connection between
the product and the system network and/or any other networks that may be connected.
The system/product owners must establish and maintain appropriate measures, including, but not limited to,
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ABB performs functionality testing on the products and updates that we release. However, system/product
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disclosed only in accordance with the terms of such license. This product meets the requirements specified in
EMC Directive 2014/30/EU and in Low Voltage Directive 2014/35/EU.
TRADEMARKS
All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.
Copyright © 2016 ABB.
All rights reserved.
Release: December 2019
Document Number: 1VLG500017
Revision: C

TABLE O F CO N TE NTS
I
Table of Contents
1Introduction ................................................................................................................................1
1.1 This manual ................................................................................................................................... 1
1.2 Intended users..............................................................................................................................1
2UniGear Digital............................................................................................................................2
3Ethernet network verification...................................................................................................3
3.1 Protection relays ..........................................................................................................................3
3.2 Managed Ethernet switches......................................................................................................7
3.2.1 Basic Settings ............................................................................................................ 8
3.2.2 Time Settings............................................................................................................. 9
3.2.3 Switching Settings (VLAN).....................................................................................10
3.2.4 PRP and HSR Redundancy Settings .....................................................................13
3.3 Interconnections ........................................................................................................................14
4Primary testing .........................................................................................................................18
4.1 Recommended primary testing device.................................................................................18
4.2 Current sensors..........................................................................................................................19
4.2.1 Supervision................................................................................................................19
4.2.2 Installed busbars in the switchgear panel ........................................................ 20
4.2.3 Non-installed busbars in the switchgear panel or restricted
access to the busbar compartment.................................................................... 23
4.2.4 Non-installed busbars in the switchgear panel ............................................... 26
4.3 Voltage sensors......................................................................................................................... 29
4.3.1 Supervision............................................................................................................... 29
4.3.2 Voltage sensor installed in the cable compartment ....................................... 30
4.3.3 Voltage sensor installed on busbars .................................................................. 33
5Apparatus control testing....................................................................................................... 36
5.1 Panel internal interlocking ...................................................................................................... 36
5.1.1 Circuit breaker truck (Disconnector).................................................................. 36
5.1.2 Circuit breaker ......................................................................................................... 39
5.1.3 Earthing switch ....................................................................................................... 42
5.2 Interlocks between panels...................................................................................................... 44
5.2.1 Busbar earthing switch / truck............................................................................44
5.2.2 Circuit breaker failure protection (CBFP) .......................................................... 49
5.2.3 Logic busbar protection (LBBP) .......................................................................... 53
5.2.4 Overpressure flaps inter-trip................................................................................ 57
5.2.5 Arc protection inter-trip ........................................................................................ 59
6Secondary testing of protection relays................................................................................. 63
6.1 ESSAILEC test blocks ............................................................................................................... 64
6.2 Secondary test setups............................................................................................................. 68
7Recommended Troubleshooting tools ...................................................................................77

LIST O F FIGUR ES
III
List of Figures
Figure 1: UniGear Digital and its key components.................................................................................2
Figure 2: IP address setting for rear port(s)............................................................................................3
Figure 3: Network topology setting and its Redundancy mode........................................................ 4
Figure 4: PTP priority setting for Master clock...................................................................................... 5
Figure 5: PTP priority setting for Slave clock ......................................................................................... 5
Figure 6: IEEE 1588 master clock status.................................................................................................. 6
Figure 7: IEEE 1588 slave clock status...................................................................................................... 6
Figure 8: Properties dialogue of discovered Ethernet switch by AFS Finder ..................................7
Figure 9: Login window................................................................................................................................7
Figure 10: Port configuration dialogue.................................................................................................... 8
Figure 11: PTP Global dialogue................................................................................................................... 9
Figure 12: PTP Transparent Clock Global dialogue ............................................................................... 9
Figure 13: Transparent clock Port dialogue ...........................................................................................10
Figure 14: Switching VLAN Global dialogue in AFS67x........................................................................10
Figure 15: Switching Global dialogue in AFS66x...................................................................................10
Figure 16: VLAN Configuration dialogue ................................................................................................ 11
Figure 17: VLAN Port dialogue...................................................................................................................12
Figure 18: VLAN Configuration dialogue (Port 6 is connected to SCADA) .....................................12
Figure 19: HSR configuration ....................................................................................................................13
Figure 20: Example of HSR Network overview diagram .....................................................................14
Figure 21: Interconnection of protection relays into HSR ring ..........................................................14
Figure 22: Example of PRP network overview diagram.......................................................................15
Figure 23: Interconnection of protection relays into PRP networks ................................................15
Figure 24: Example of Plant Structure in PCM600...............................................................................16
Figure 25: GOOSE / SMV alarm is activated on a configurable LED ................................................ 17
Figure 26: Measurements view, voltage receiver protection relay is not synchronized with the
Master clock.................................................................................................................................................. 17
Figure 27: Measurements view, voltage receiver protection relay is synchronized with the
Master clock.................................................................................................................................................. 17
Figure 28: Primary test system CPC 100 from Omicron .....................................................................18
Figure 29: Example of a current sensor label ....................................................................................... 20
Figure 30: Current sensor parameters................................................................................................... 20
Figure 31 Primary test setup for current sensors when busbars are installed..............................21
Figure 32 Measurements view..................................................................................................................22
Figure 33: Example of a current sensor label ....................................................................................... 23
Figure 34: Current sensor parameters................................................................................................... 23
Figure 35: Test setup for current sensors testing when busbars are not installed or there is
restricted access to the busbar compartment.................................................................................... 24
Figure 36: Measurements view................................................................................................................ 25
Figure 37: Example of a current sensor label........................................................................................ 26
Figure 38: Current sensor parameters................................................................................................... 26
Figure 39: Test setup for current sensors when busbars are not installed....................................27
Figure 40: Measurements view................................................................................................................ 28
Figure 41: Example of a voltage sensor label ....................................................................................... 30
Figure 42: Voltage sensor parameters................................................................................................... 30
Figure 43: Test setup for voltage sensors installed in the cable compartment............................31
Figure 44: Measurements view, injected phase 1................................................................................ 32
Figure 45: Example of a voltage sensor label....................................................................................... 33
Figure 46: Voltage sensor parameters .................................................................................................. 33
Figure 47: Test setup for voltage sensors installed on busbars ...................................................... 34
Figure 48: Measurements view, injected phase 1................................................................................ 35

LIST O F FIGUR ES
IV
Figure 49: Measurements view, injected phase 1................................................................................ 35
Figure 50: Blocking conditions of the circuit breaker truck in PCM600 ........................................ 36
Figure 51: Single line diagram, the circuit breaker is open and in the test position ................... 36
Figure 52: Single line diagram, the earthing switch shutter is open ...............................................37
Figure 53: Single line diagram, the earthing switch shutter is closed ............................................37
Figure 54: Single line diagram, the circuit breaker is in the intermediate position .................... 38
Figure 55: Blocking conditions of the circuit breaker in PCM600 ................................................... 39
Figure 56: Single line diagram, the circuit breaker is closed and in the test position................ 39
Figure 57: Single line diagram, the circuit breaker is open and in the test position...................40
Figure 58: Single line diagram, the circuit breaker is in the intermediate position ....................40
Figure 59: Single line diagram, the circuit breaker is closed and in the service position ...........41
Figure 60: Blocking conditions of the earthing switch in PCM600................................................. 42
Figure 61: Single line diagram, the circuit breaker is open and in the test position ................... 42
Figure 62: Single line diagram, the circuit breaker is in the intermediate position .................... 42
Figure 63: Single line diagram, the earthing switch is closed.......................................................... 43
Figure 64: Example of Process bus application in medium voltage switchgear..........................44
Figure 65: Logic scheme of the busbar earthing truck interlock .................................................... 45
Figure 66: Logic scheme of the busbar earthing switch interlock.................................................. 45
Figure 67: Single line diagram, the circuit breaker is in the test position ..................................... 46
Figure 68: Single line diagram, the circuit breaker is in the intermediate position .................... 46
Figure 69: Logic scheme of trucks interlock by the busbar earthing truck .................................. 47
Figure 70: Logic scheme of trucks interlock by the busbar earthing switch................................ 47
Figure 71: Single line diagram, the circuit breaker is in the test position...................................... 48
Figure 72: Logic scheme of CBFP............................................................................................................ 49
Figure 73: Single line diagram, the circuit breaker in the service position.................................... 49
Figure 74: Single line diagram circuit, the circuit breaker is closed and in the service position
........................................................................................................................................................................ 50
Figure 75: Entering test mode................................................................................................................. 50
Figure 76: Activating backup trip.............................................................................................................51
Figure 77: Deactivating backup trip ........................................................................................................51
Figure 78: Entering test mode................................................................................................................. 52
Figure 79: Logic scheme of the Logic busbar protection.................................................................. 53
Figure 80: Single line diagram, the circuit breaker is in the service position............................... 53
Figure 81: Entering test mode ................................................................................................................. 54
Figure 82: Activating START signal ......................................................................................................... 54
Figure 83: Activating blocking mode ..................................................................................................... 55
Figure 84: Deactivating START signal .................................................................................................... 55
Figure 85: Deactivating blocking mode................................................................................................. 56
Figure 86: Entering test mode................................................................................................................. 56
Figure 87: Logic scheme of Ith limiters trip.......................................................................................... 57
Figure 88: Single line diagram, the circuit breaker is in the service position ............................... 58
Figure 89: Single line diagram, the circuit breaker is closed and in the service position .......... 58
Figure 90: Logic scheme of ARC trip...................................................................................................... 59
Figure 91: Single line diagram, the circuit breaker is in the service position................................ 59
Figure 92: Entering test mode.................................................................................................................60
Figure 93: Single line diagram, the circuit breaker is closed and in the service position ..........60
Figure 94: Activating OPERATE signal ....................................................................................................61
Figure 95: Deactivating OPERATE signal................................................................................................61
Figure 96: Entering test mode................................................................................................................. 62
Figure 97: Changing correction factors for amplitude ...................................................................... 63
Figure 98: Changing correction factors for angle............................................................................... 63
Figure 99: ESSAILEC® RJ45 test block (the plug, the lid and the socket)....................................... 64
Figure 100: Low Voltage Compartment door of UniGear panel with ESSAILEC® RJ45 test
blocks ............................................................................................................................................................ 64

LIST O F FIGUR ES
V
Figure 101: ESSAILEC® Trip test block – Testing.................................................................................. 65
Figure 102: ESSAILEC® RJ45 test block – Testing................................................................................ 65
Figure 103: The testing (one phase testing setup is shown on the picture)................................. 66
Figure 104: ESSAILEC® RJ45 test block – Normal operation ............................................................ 66
Figure 105: ESSAILEC® Trip test block – Normal operation .............................................................. 67
Figure 106: 3 phases test setup for the Omicron testers.................................................................. 68
Figure 107: Linear current sensor instead of the Rogowski setting in the Omicron tester....... 69
Figure 108: 1 phase test setup for the Omicron tester ...................................................................... 70
Figure 109: Connecting cable with RJ45 connector and banana contacts (it is available on
client request) ............................................................................................................................................. 70
Figure 110: Setting of high voltage analogue outputs in the Test Universe program .................71
Figure 111: Phasor diagram on the protection relay’s WebHMI.........................................................71
Figure 112: Measurements view................................................................................................................71
Figure 113: 3 phases test setup for the Megger tester .......................................................................72
Figure 114: 1 phase test setup for the Megger tester ........................................................................ 73
Figure 115: Connecting cable with RJ45 connector and banana contacts (it is available on
client request) ............................................................................................................................................. 73
Figure 116: Setting of high voltage analogue outputs on the Freja 300 HMI ................................74
Figure 117: Setting of high voltage analogue outputs in the Megger configuration program. 75
Figure 118: Setting of high voltage analogue outputs in the Megger configuration program 75
Figure 119: Measurements view............................................................................................................... 76
Figure 120: ITT600 – Explore SV – two selected streams and the polar diagrams are shown...77
Figure 121: Home page for Testing and Commissioning pages ...................................................... 78
Figure 122: GOOSE Receiving Page......................................................................................................... 78
Figure 123: GOOSE Sending Page ........................................................................................................... 79
Figure 124: SMV Receiving Page.............................................................................................................. 79
Figure 125: SMV Sending Page.................................................................................................................80
Figure 126: Example of captured packets by Wireshark .....................................................................81
Figure 127: GridEx IEC 61850 test tool....................................................................................................81

LIST O F TA B LES
VII
List of Tables
Table 1: Current metering accuracy.........................................................................................................19
Table 2: Zero-clamping limits....................................................................................................................19
Table 3: Voltage metering accuracy........................................................................................................ 29
Table 4: Zero-clamping limits .................................................................................................................. 29
Table 5: Inter-tripping rules for Ith limiters .......................................................................................... 57

I NT RO D U CT IO N T HIS MA NU A L
1VLG5 00 0 17 C 1
1Introduction
1.1 This manual
The maintenance and commissioning guide provides information about maintenance and
commissioning activities on the UniGear Digital solution by providing details about its main
components and proven testing methods.
1.2 Intended users
This manual is intended to be used by protection relay, test and service engineers. The pro-
tection relay engineer needs to have a thorough knowledge of protection systems, protection
equipment, protection functions, configured functional logic in the protection relays and IEC
61850 engineering. The test and service engineers are expected to be familiar with the han-
dling of electronic equipment and medium voltage switchgear.

INT EN DED US ER S UN IG E AR D IG ITA L
2 1VLG5 00 0 17 C
2UniGear Digital
UniGear Digital is a new solution implemented to a traditional UniGear switchgear. It is
accomplished by using well-proven components such as current and voltage sensors, Relion®
protection relays and IEC 61850 digital communication. Commissioning is very similar to
commissioning activities run on traditional UniGear switchgear. Differences in procedures
are corresponding to implementation of Process bus and GOOSE functionalities and usage of
sensors. The traditional method of commissioning activity starts with primary injections,
then continues with protection relays testing, apparatus functionality verification, etc., and
ends with testing of the communication if applicable. In UniGear Digital, commissioning
must start with verification of IEC 61850 digital communication, particularly with the Ether-
net network check. After commissioning of the Ethernet network, there is no restriction re-
garding the order of other commissioning activities.
Figure 1: UniGear Digital and its key components

ET HER N ET N E T W OR K V ER IF ICATIO N PROTE CT IO N R E LAYS
1VLG5 00 0 17 C 3
3Ethernet network verification
The Ethernet network interconnects protection relays in a substation. As the GOOSE and Pro-
cess bus are used, to make the network functional is essential for most of the tests. The net-
work is set up and tested in the factory. Therefore, after switchgear assembly onsite, it is
only necessary to verify its functionality. Before starting any testing of the communication,
properly set the Ethernet settings in the protection relays, set the Ethernet switches and,
only then, interconnect the Ethernet network according to the project documentation.
It is supposed that the protection and control circuits are powered from the power supply.
3.1 Protection relays
Before starting any secondary testing of the protection relay functions, verify if the IP ad-
dresses, the network topology and time synchronization settings are in accordance with the
project documentation.
IP address setting
Check communication board setting according to documentation (for example Network
Overview diagram …).
On the protection relay LHMI go to -> Main Menu/Configuration/Communication/
Ethernet/Rear port(s)
–IP address = for example, 172.16.2.1
–Subnet mask = for example, 255.255.0.0
Figure 2: IP address setting for rear port(s)
Network topology setting
Check the network topology setting according to the documentation.
On the protection relay LHMI go to -> Main Menu/Configuration/Communication/
Ethernet/Redundancy/Redundant mode
–Redundancy mode = None
–Redundancy mode = HSR (High-availability Seamless Ring)
–Redundancy mode = PRP (Parallel Redundancy Protocol)

PROTE CT IO N R E LAYS ET HE R N ET N E T W OR K V ER IF ICATIO N
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Figure 3: Network topology setting and its Redundancy mode
Time synchronization setting
Check the setting of time synchronization. For Process bus functionality, the IEEE 1588 proto-
col must be set up.
On the protection relay LHMI go to -> Main Menu/Configuration/Time/
Synchronisation/Synch source
–Synch source = IEEE 1588
Protection relays, Ethernet switches and Time Synchronization Clocks must be in the same
PTP domain ID (PTP = precision time protocol).
On the protection relay LHMI go to -> Main Menu/Configuration/Time/Synchronisation/
PTP domain ID
–PTP domain ID = 0
In case of Grandmaster clock (Satellite controlled clock) failure, it is necessary to have one
protection relay defined as the Master clock and one protection relay as the Backup master
clock. It is a matter of PTP priority setting. Devices with a lower PTP priority 2 value become
the first master clock.
Voltage sender protection relays
On the protection relay LHMI go to -> Main Menu/Configuration/Time/Synchronisation
–PTP priority 1 = 127
–PTP priority 2 = 128-255 to be different in each protection relay

ET HER N ET N E T W OR K V ER IF ICATIO N PROTE CT IO N R E LAYS
1VLG5 00 0 17 C 5
Figure 4: PTP priority setting for Master clock
Other protection relays
On the protection relay LHMI go to -> Main Menu/Configuration/Time/Synchronisation
–PTP priority 1 = 128
–PTP priority 2 = 128
Figure 5: PTP priority setting for Slave clock
If both, Master and Backup master clocks fails, the protection relays establish a new
primary source for time synchronization information automatically.
Check time synchronization status at the voltage sender protection relay.
On the protection relay LHMI go to -> Main Menu/Monitoring/IED status/
Time synchronisation
–Synch source = IEEE 1588 master

PROTE CT IO N R E LAYS ET HE R N ET N E T W OR K V ER IF ICATIO N
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Figure 6: IEEE 1588 master clock status
Check the time synchronization status at other protection relays.
On the protection relay LHMI go to -> Main Menu/Monitoring/IED status/
Time synchronisation
–Synch source = IEEE 1588 slave
Figure 7: IEEE 1588 slave clock status

ET HER N ET N E T W OR K V ER IF ICATIO N MA NAG ED E T HER NET SW ITC HE S
1VLG5 00 0 17 C 7
3.2 Managed Ethernet switches
To create a reliable Ethernet network for IEC 61850 communication, a managed Ethernet
switch is recommended to be used. The most important settings of ABB’s AFS family Ether-
net switches to be observed are highlighted in this section.
AFS Family
If the IP address is unknown, disconnect all Ethernet cables from the switch or turn other
Ethernet switches off. After connecting a notebook with the AFS Finder SW tool to any port
on the Ethernet switch, the following dialogue screen appears (shown in Figure 8). AFS Finder
automatically searches the network for those devices, which support the AFS finder protocol.
The next dialogue, open by double clicking on the respective switch in AFS finder defines the
IP address and net mask.
Figure 8: Properties dialogue of discovered Ethernet switch by AFS Finder
The user-friendly web-based interface of AFS switches offers the possibility of operating the
device from any location in the network via a standard browser such as Mozilla Firefox or Mi-
crosoft Internet Explorer. Being a universal access tool, the web browser uses an applet which
communicates with the device via the Simple Network Management Protocol (SNMP). The
Web-based interface allows the device to be graphically configured.
Login
Default User name to configure the AFS67x family is admin and the password is admin.
Default User name to configure the AFS66x family is admin and password is abbadmin.
Figure 9: Login window

MA NAG ED E T HER N ET SW I TC HES ETHER NET NETWO R K VER IF I CAT IO N
8 1VLG5 00 0 17 C
3.2.1 Basic Settings
Basic Settings / Port configuration
Check Port setting according to the UniGear Digital Engineering Guide. It is recommended to
assign a bay to port name according to the project documentation (for example Network
Overview diagram). Interconnect the Ethernet cable from the bay (protection relay) to the
Ethernet switch port.
Figure 10: Port configuration dialogue