ABB DS1 User manual

Medium voltage products
DS1
Technical Guideline for Installation and User Manual
Safety 3
1. Introduction 4
1.1 Environmental protection program 4
1.2 Packing and transport 4
1.3 Checking on receipt 4
1.4 Storage 5
1.5 Handling 5
1.6 End of life of product 6
1.7 Disposal methods 6
2. Product Description 7
2.1 General features 7
2.2 Reference Standards 8
2.3 Fixed capacitor-switch 8
2.4 Main electrical characteristics 8
2.5 Apparatus operating instructions 10
2.6 Description of the capacitor-switch
closing and opening operations 10
2.7 DS1 Closing and Opening switching
behaviour 11
3. Description of the control and supply electrical
interface 12
3.1 Power Supply Characteristics 12
3.2 Description of the DS1 output 12
3.3 Electrical characteristics of the outputs 12
3.4 Description of DS1 inputs 13
3.5 Special INPUT - Only for commissioning
and maintenance 13
3.6 Electrical characteristics of the INPUT 14
3.7 Input Acceptance Logic 14
3.8 DS1 functional descriptions 14
4. DS1 Diagnostics 16
4.1 Base Module Diagnostics 16
4.2 Master Diagnostics 16
4.3 Synchronization Diagnostics 17
4.4 Diagnostics Table 17
5. Installation Guideline 18
5.1 General 18
5.2 Before installing the apparatus: 18
5.3 Installation requirements 18
5.4 Installation of fixed apparatus 19
5.5 Additional installation recommendations 19
5.6 Preliminary operations 19
6. Fixed Apparatus power circuit connections 20
6.1 General directions 20
6.2 Mounting the connections 20
6.3 Mounting procedures 20
6.4 Three-phase power line connections 21
6.5 Load connection 21
6.6 Synchronization sensor 22
6.7 Voltage Sensor Connections 23
6.8 Earthing 23
6.9 Auxiliary circuit connection 23
7. Commissioning 24
7.1 General procedures 24
7.2 Startup and maintenance features 24
7.3 Pressure Monitoring 25
7.4 Interface summary for Maintenance and
Commissioning 25
7.5 Commissioning - Test with no power,
no sync 26
8. Periodical inspections 28
8.1 General 28
8.2 Checking program 28
8.3 Measurement of air pressure inside poles 28
8.4 Dry Air filling 28
8.5 Dry air filling procedure 28
8.6 Measurement of resistance across closed
contacts of poles 29
8.7 Replacement due to System malfunctions 29
8.8 Spare parts and accessories 29
Annex A - Terminal Block for auxiliary control circuit 30
Annex B - External drawing for DS1 Integration 31
B.1 Overall dimensions 31
B.2 Internal connections 31
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IMPORTANT
DS1 is a special purpose capacitor switch
specifically designed to manage capacitive
loads. DS1 is not designed to perform any
safety function.
When a DS1 is installed in a system, the
safety functions must be provided by
system integration.
There must always be at least one
upstream protection (e.g. a circuit breaker)
and preferably also a second level of
protection (e.g. fuses).
Maintenance must not be performed when
the system is energized by the MV supply.
In addition, coordination or security keys
must always be present to prevent operator
errors from causing the device to function
in a situation for which it is not designed
(e.g. closing on a grounded capacitor).
In general, especially when large capacitor
banks are operated, the power involved,
the danger of electrical phenomena and
the impact of a potential failure on the
capacitor bank make it very dangerous to
remain near the live equipment (especially
during transients).
Use of compartments able to contain the
internal arc in case of failure are recom-
mended.
Work performed by operators in rooms
housing live equipment containing capaci-
tors or operating means is always strongly
discouraged.
DS1 internally creates an auxiliary voltage
bus at 350 VDC. Additional energy is stored
inside a capacitor. Maintenance must
not be performed when DS1 is supplied
and when electrical equipment must be
touched (apparatus or internal auxiliary
equipment). After system shut down wait at
least one minute (until the control system
consumes the energy stored inside the
internal capacitor) for the control system
to shut down (internal leds turn off) before
touching any of the electrical equipment.
Additional precautions for the internal
capacitor must be observed, especially if
it has been disconnected by the control
system or if maintenance is performed
for a suspected a control system failure.
When performing this operation, always
use all mandatory safety PPE for electrical
maintenance.
Safety
For your safety!
Make sure that the installation site (spaces, divisions and
ambient) is suitable for the electrical apparatus.
Check that all the installation, putting into service and
maintenance operations are carried out by qualified personnel
with in-depth knowledge of the apparatus.
To ensure that the installation conforms to the rules of good
working practice and safety in the workplace, make sure that
the standard and legal prescriptions are complied with during
the installation work, putting into service and maintenance
operations.
Strictly comply with the information given in this instruction
manual.
Do not exceed the rated performance of the apparatus during
service.
Pay special attention to the danger notes indicated in the
manual by the following symbol:
Make sure that the personnel operating the apparatus are
provided with this instruction manual as well as all the necessary
information for correct operation.
Responsible behaviour safeguards your own and others’
safety!
Please contact the ABB assistance service for any requests.
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1. Introduction
This publication contains the information required for installing,
commissioning and servicing DS1 medium voltage special
purpose capacitor switches.
To ensure the product is used correctly, please read this manual
carefully.
Please refer to the relevant instructions to ensure that
accessories and/or spare parts are installed correctly.
Similarly to all the apparatus manufactured, DS1 capacitor
switches are designed for different installation configurations.
For this reason, the information given below does not always
cover special configurations.
Apart from this booklet, it is always necessary to refer to the
latest technical documentation available (circuit diagram,
wiring diagrams, assembly and installation drawings, any
studies of protection co-ordination, etc.), especially with regard
to any modifications to the standard configurations that may
be required.
System integration, installation guidelines and checks to be
performed during the installation work are provided in the
following section.
In addition, a description of the internal diagnostics, substation
interfacing and monitoring is provided for the purpose of
integrating DS1 with the remote control room.
All operations regarding installation, putting
into service, operation and maintenance must
be performed by suitably qualified personnel
with in depth knowledge of the apparatus.
Parts must only be replaced with original
spares.
1.3 Checking on receipt
On receipt, check the state of the apparatus, make sure that the
packing is undamaged and that the nameplate data correspond
(see fig. 1) to the specifications in the order acknowledgement
and the delivery note.
Also make sure that all the materials described in the shipping
note are included in the supply.
If damage or discrepancies are discovered when the apparatus
is unpacked, notify ABB (directly or through the agent or
supplier) as soon as possible and in any case within five days
of receipt.
The apparatus is only supplied with the accessories specified at
the time of order and confirmed in the order acknowledgement
sent by ABB.
The following documents are included in the shipping packing:
− Instruction manual (this document)
− Test certificate
− Identification tag
− Fiscal copy of shipping note
− Circuit diagram.
These other documents are sent prior to shipment:
− Order acknowledgement
− Original copy of shipping note
− Drawings or documents regarding special configurations/
conditions (if applicable).
1
3
4
2
Nameplate
1. Type of apparatus
2. Symbols and compliance with
Standards
3. Serial number
4. Apparatus characteristics
5. Characteristics of the operating
auxiliaries
1.1 Environmental protection program
DS1 capacitor switches comply with ISO 14000 Standards
(Environmental Management Guidelines).
The production system of the Medium Voltage factories
complies with the environmental protection regulations in terms
of energy consumption, raw materials and waste disposal.
The environmental impact of the product life cycle is assessed
by the LCA - Life Cycle Assessment procedure, which is also
the result of a well-focused design phase when it comes to
selecting materials, processes and packaging.
The production techniques ensure that the components can be
easily dismantled and separated at the end of the life cycle of
the apparatus, while optimizing the recycling process.
1.2 Packing and transport
The apparatus is shipped in special packing in the open
position with absolute pole pressure corresponding to the
service value.
Each piece of apparatus is protected by plastic film to prevent
water from infiltrating during the loading and unloading stages
and to keep the dust out during storage.
Figure 1. Product identification label
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1.4 Storage
When the apparatus must be stored for a certain period of
time, our workshops can provide (on request) suitable packing
for the specified storage conditions.
On receipt, the apparatus must be carefully unpacked and
checked as described in Checking on receipt (chap. 2).
If immediate installation is not possible, apparatus must be
repacked in its original packing materials.
Insert at least one packet of hygroscopic substance inside the
packing of each piece of apparatus.
Should the original packing be unavailable and immediate
installation is not possible, store the apparatus in a covered,
well-ventilated, dry, dust-free, non-corrosive place, well away
from flammable materials and at a temperature between –15 °C
and +55 °C.
In any case, avoid accidental impact or positions which could
stress the structure of the apparatus.
1.5 Handling
When handling the apparatus, always take great care not to
stress the insulating parts or the apparatus terminals.
The apparatus must not be handled by inserting lifting devices
directly under it.
If this method is unavoidable, place the apparatus on a sturdy
supporting surface (see fig. 2).
Use the tool (1) in (fig. 2) to lift and handle
the apparatus.
Insert the hooks (2) into the holes made in
the apparatus frame and lift. Take care when
lifting tools are used: the load is not perfectly
balanced (it is unbalanced toward the poles).
Unhook the lifting tools after having com-
pleted the operation (in any case before put-
ting into service).
Figure 2. Hooks and lifting holes for DS1
Figure 3. DS1 carrying method
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1.6 End of life of product
ABB complies with the relevant laws and other environmental
protection requirements in accordance with standard ISO 14 001.
The duty of companies is to facilitate subsequent recycling or
disposal at the end of product life. Always act in accordance
with the local laws in force when disposing of the product.
1.7 Disposal methods
The apparatus can be disposed of either thermally, in an
incineration plant, or in a waste site, whichever is the best
solution as regards materials, limitation of environmental impact
on the environment and compliance with the local laws in force.
Raw material Recommended disposal method
Metal material
(Fe, Cu, Al, Ag, Zn, W, others)
Separation and recycling
Thermoplasts Recycling or disposal
Epoxy resin Separation of metal material and
disposal of the rest
Rubber Disposal
Packing material – wood Recycling or disposal
Packing material – foil Recycling or disposal
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6 35
4214 4
non incluso
5
7
4 4 4
3
6
1
2
not included
2. Product Description
2.1 General features
DS1 are dry air insulated special purpose capacitor switches for
indoor installation. Please refer to the corresponding technical
catalogue code (1VCF000580) for the electrical performance
data.
For special installation conditions, please contact ABB. Please
also note that the apparatus is unable to make or break fault
conditions and that protection on the supply side must
always be installed.
The following photos illustrate the DS1 main assembly. DS1
is a special purpose capacitor switch specifically designed for
managing capacitive loads in symmetric and balanced systems.
The load layout must be the full capacitive, star configura-
tion and floating center-load type.
The device uses diode-switching technology and is dry air
insulated (see Pressure Monitoring section for details).
One additional upstream voltage sensor for MV network
synchronization is required for correct installation (see specific
sensor characteristics in the following section).
Figure 4. ABB DS1 Capacitor Switch
1. Control unit
2. Supply unit
3. Switching capacitor
4. Servo-motors
5. Pressure switch
6. Terminal block
7. Voltage sensor (not included )
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2.2 Reference Standards
The DS1 series apparatus complies with the following
Standards: IEC 62271-103 Special Purpose Capacitor Switch
with no making and breaking capability. IEC62271-100 has
been applied for capacitive switching (with some exclusions),
since is more demanding.
2.3 Fixed capacitor-switch
The fixed capacitor-switch (see fig. 4) corresponds to the basic
version complete with a front protection shield and frame.
The anchoring holes are drilled in the lower part of the frame.
The terminal board connection, fixed on the upper protection, is
available for connecting the auxiliary circuits of the apparatus.
The earthing screw is located on the side of the apparatus.
For further details, consult the “External Drawing for DS1
Integration” at the end of this document.
2.4 Main electrical characteristics
The main electrical ratings of DS1 are:
Rated Voltage 17.5 kV at 50 Hz
15 kV at 60 Hz
Rated current 630 A at 50 Hz
600 A at 60 Hz
Short Time Current 20 kA for 0.5 s
Figure 5. Typical circuit for integration with MECB
An additional safety interlock should be used
in order to prevent DS1 from operating in the
maintenance mode (due to incorrect wiring
of the upstream CB interlock).
See specific section for details of the
upstream interlock feature.
ABB declines all liability for the product
following failure to comply with these
guidelines when DS1 is installed.
Since it is a special purpose capacitor switch based on diodes
for switching, DS1 is unable to break and make a fault
current. It can switch up to its rated current, indicated above.
However, it has a short time withstand current of 20 kA for 0.5
s that allows the upstream protection to operate and interrupt
the fault, thus preventing the DS1 and capacitors from being
damaged.
A supply side protection must always be present (circuit
breaker), and it is preferable for fast fuses to be installed as
well.
Additional interlocks are strongly recommended in order to
prevent DS1 from operating in the following conditions:
− During a fault (when an upstream protection is tripping)
− When a downstream earth switch has not been opened (e.g.
after maintenance).
DS1 has a generic interlock (Pin 10 internally performs loop
with Pin 20 of terminal block) with the scope of implementing
this interlocking function. See specific section.
Coordination signals and interlocks (mandatory) are described
in the following section.
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We strongly recommend use of unbalanced load protection
(together with other standard protections tailored to suit the
system) that functions when the upstream circuit breaker trips
if the load is not balanced on the three phase system.
The capacitor bank unbalanced protection layout shown above
is strongly recommended because allows a capacitor with im-
paired performance to be identified, thereby reducing the im-
pact of a capacitor bank fault.
Operating Conditions:
DS1 is designed for indoor applications. The following operat-
ing conditions apply:
Maximum Operating Temperature of DS1: -15 °C +55 °C
Note: The pressure inside the device depends on the temperature.
However, DS1 has been tested at minimum pressure.
Please note that if unlikely circumstances occurs (temperature variation in the filling
stage and tolerance of the pressure meter) when DS1 is operating at minimum
temperature (-15 °C), the pressure could drop to a value able to trigger the warning
level.
However, functionality at the DS1 pressure warning level of is fully ensured.
The device stops operating at blocking pressure.
Relative Humidity 93%
DS1 has been designed to work in indoors where the relative
humidity is high.
The design technique includes conformal coating of all elec-
tronic boards inside the control system.
In addition, vertical positioning of the electronic components is
another important feature with regard to humidity during opera-
tion.
The apparatus has been tested for up to 93% relative humidity
both when it is operating and not operating.
However, as in every indoor device, to prevent condensation
from forming, rapid temperature changes should be mitigated
in particular cases where the temperature drops very quickly in
conjunction with high relative humidity. This precaution must
always be considered when MV applications are present, be-
cause condensation may form in any part of the compartment.
Lastly, pre-conditioning in a controlled environment should be
performed before using DS1 when it has been stored for a long
period in an uncontrolled environment.
Altitude <1000 m
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MV input side
To load output side
2.5 Apparatus operating instructions
DS1 capacitor switches ensure a minimum
degree of protection (IP2X) if installed in the
following conditions:
–fixed version, with protective netting.
Under these conditions, the operator is protected against ac-
cidental contact with moving parts.
Take care of moving parts if mechanical operations are per-
formed on the apparatus with the protective netting removed.
After the mechanical and movement operations have been
completed, remember to remove the protection net before en-
ergizing the MV bus bars.
If the operations are obstructed, do not force the mechanical
interlocks but check that the operation sequence is correct (re-
fer to the Installation Guidelines section).
2.6 Description of the capacitor-switch
closing and opening operations
The apparatus can only be operated electrically. Manual opera-
tion is NOT allowed.
A new capacitor switch concept has been developed by com-
bining of a mechanical contact system and diodes. The me-
chanical contact system is operated by a servomotor con-
trolled by a drive unit. The pole switch is illustrated in Figure
2, which shows the cross section of a power part and relative
kinematic chain.
IMPORTANT
The Input and Load (output) sides must not
be inverted.
DS1 must not be assembled upside down.
Note:
The illustration is indi-
cative and not binding.
We reserve the right to
make changes without
notice in the course of
technical development
of the product.
Figure 6. Section of DS1 power part
By turning the drive shaft through approx. 140 degrees, the
power contacts will change from the closed to the open state
while the reverse movement will close them again.
The purpose of the device is to connect and disconnect the
capacitor bank in conjunction with a precise motion profile and
reliable synchronization.
Transitory commutation is performed by power diodes without
an arc during opening and inrush during closing.
Figure 7. Internal layout of DS1
1. Independent servo motors
2. Control unit for each phase:
a. Synchroniation
b. Actuation
c. System diagnostics
d. Micro Motion Control
3. Dry air pressure sensor
4. Operation capacitor
5. Power supply unit
Note: The illustration is indicative and not binding.
We reserve the right to make changes without notice in the course of
technical development of the product.
A specific real-time control completes the three-phase system.
The system is fully integrated inside the DS1 and complete di-
agnostics of the three-phase system application has been de-
veloped.
53
1
2 4
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2.7 DS1 Closing and Opening switching
behaviour
DS1 performs synchronous switching with the control system
constantly engaged with the upstream voltage reference. To
do this, the signal from a voltage divider (mandatory phase to
ground on phase R) is detected by its control system.
When an Open command or Close command is transmitted
to DS1, switching is performed by the control system using
network synchronization and not the command as the trigger.
In addition to this feature, a precise ability to coordinate three-
phase system movement and diode technology achieve very
performance-oriented switching capability without significant
inrush, AC voltage distortions or high frequency disturbance,
as well as precise zero crossing current cut-off.
Typical DS1 switching behaviour is outlined below, where main
circuit making and breaking possess the characteristics de-
scribed above since DS1 contains the diode that naturally
makes and breaks the current.
Figure 8. DS1 behaviour during a power test at 17.5kV 630A
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3. Description of the control and supply
electrical interface
3.1 Power Supply Characteristics
The DS1 power supply characteristics are:
Parameter Symbol Value Unit
Vaux – Voltage input range Vaux Vin 93 to 300 VDC
Vaux – Max (active) power consumption Vaux PMAX 150 W
Vaux – Max current consumption 2,5 ARMS
Vaux – Maximum VA consumption 220 VA
Vaux – Inrush limiter (peak current) Vaux IILIM 2 APEAK
Table 1. Auxiliary supply input characteristics
3.2 Description of the DS1 output
DS1 provides the following 3 outputs, depending on the switch
status:
− Ready (dry contact closed when DS1 is ready to operate).
− Watchdog (solid-state output blinks to indicate that DS1 is
energized and processing its functions).
− Alarm (dry contact closed when DS1 shows functions in a
faulty way during operations)
Consult Outputs/Inputs in the following sections for more
details about the DS1 outputs.
Additional outputs are installed in the device so as to monitor
the internal pressure status as follows:
− Pressure OK (Output is high (+VSupply) when pressure is
OK)
− Pressure Warning (Output is high (+VSupply) when pressure
is below a first threshold)
− Pressure Low (Output is high (+VSupply) when pressure is
below a blocking threshold)
DS1 Position Sensing indication (Close/Open).
Closed (dry contact is closed when DS1 is in the closed
position).
Opened (dry contact is closed when DS1 is in the open
position).
3.3 Electrical characteristics of the outputs
The Ready and Alarm outputs are AC/DC insulated outputs
(dry contact).
Their electrical characteristics are illustrated in the graph
below. Compliance with the current rating is mandatory so as
to prevent damage to the dry contact.
The contact data and maximum DC load breaking capacity are
indicated in the table and graph below.
Contact data
Contact configuration Watch-Dog NC, others NO
Contact set single contact
Type of interruption micro disconnection
Rated current 6 A
Rated voltage / max switching voltage AC 240/400 VAC
Maximum breaking capacity AC 1500 VA
Limiting making capacity, max 4 s,
duty factor 10%
10 A
Figure 9. Ready and Alarm aux contact electrical ratings
0.1 0.2 0.5 1 2 5 10
10
20
30
40
50
100
200
300
resistive load
DC current (A)
DC voltage (VDC)
Max. DC load breaking capacity
Figure 10. DC load break capacity of Ready and Alarm contacts
If the installation requires higher current, an auxiliary relay can
be used in order to replicate the contact and perform higher
current capability.
The Watchdog Output is a solid-state output that blinks in
order to verify system integrity, including monitoring of SW run-
ning inside the device.
Since this kind of output is continuously turning on/off (every
0.2 Sec), replication of this function by a mechanical relay with
higher current is not recommended.
The electrical characteristics of the Watchdog output are given
below.
Characteristics Recommended Operating Conditions
Supply Voltage 250 VDC/AC
On-state current ION <100mA
Operating Temperature -20 °C +65 °C
Table 2. Watchdog output characteristics
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Pressure Monitoring is performed by a pressure switch with
two thresholds: 4.1 bar (absolute) and 3.7 bar (absolute)
The maximum absolute ratings for the contacts are:
Voltage Resistive Load (cos(fi)=1) Inductive Load (cos(fi)=0.6 – 0.7)
125 VAC 3A 2A
250 VAC 3A 2A
30 VDC 3A 2A
125 VDC 0.4A 0.05A
Table 3. Pressure sensor output characteristics
Note: In the DC current condition the time constant must be
less than 7ms for inductive loads.
DS1 Position Sensing the (Close/Open) indication is given by
dry contacts.
The recommended operating conditions are summarized be-
low:
Position Switch Electrical Characteristics
Rated Insulation Voltage AC 380V
Rated Operating Voltage AC DC 250V
Rated Operating Current AC 250V/16A; DC 250V/0.3A
Power Frequency withstand Voltage 2000 VAC
Contact Resistance <=30mOhm
Table 4. Position Sensing output characteristics
If the installation requires higher current, an auxiliary relay can
be used in order to replicate the contact and perform higher
current capability.
3.4 Description of DS1 inputs
The following input signals can be transmitted to DS1 in order
to provide the required operations.
−Open (DS1 is requested to perform an Open operation when
the switch is closed)
−Close (DS1 is requested to perform a Close operation when
the switch is open)
Additional inputs are installed in order to provide additional
control features as follows:
−Interlock (prevents DS1 from operating when the interlock
loop is open)
The Interlock circuit is used by the control system logic to pre-
vent operation when this circuit is open. The standard DS1
internal cabling opens the interlock circuit when the pressure
reaches its minimum value. You are strongly advised to coor-
dinate the interlock hierarchy according to substation interlock
requirements (opening of the interlock loop when DS1 must be
prevented from operating).
Since DS1 does not allow fault making and fault breaking
events, you are also strongly advised to ensure safe coordina-
tion of the interlock circuit when:
− the upstream CB is operated (requested by control room OR
protection fault TRIP)
− when the downstream earth switch is closed.
In both the above situations, you are strongly advised to coor-
dinate the interlock function in order to open the interlock loop
and prevent DS1 from operating.
3.5 SpecialINPUT-Onlyforcommissioning
and maintenance
A special input is installed for the purpose of providing special
control features:
Upstream CB Interlock
Special inputs are installed in order to provide special control
features during commissioning or maintenance.
Homing
DS1 only controls the position of the power part when this is,
within certain limits, in the Closed or Open Condition. A Hom-
ing command can be provided when, during maintenance or
commissioning, the position of the switch is not in the Open or
Closed position. DS1 will process the request and initialize its
position in the Open condition. The homing command is only
processed when the upstream CB Interlock is provided (the MV
bus bar are de-energized).
Reset
DS1 is equipped with an advanced diagnostic runtime. Its sta-
tus is continuously monitored both when DS1 is Idle (operating
condition waiting for a command) and operating.
When an alarm event TRIPS (something wrong has happened
during operation), DS1 completes the requested operation and
then sets to the Alarm status.
If this occurs, it is advisable to stop all operations and call
ABB’s representative for assistance.
The upstream CB Interlock is an input
that is only used for maintenance or
commissioning. Excitation allows DS1 to
operate without synchronization in order
to perform CO sequences without MV
power on the bus bars.
Excitation of this input when MV is
supplied is absolutely forbidden since DS1
will operate without synchronization and
its integrity could be compromised.
Please refer to the commissioning proce-
dure for details.
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Note: DS1 is equipped with an internal event recorder that re-
cords all the events and operations the switch is requested to
perform. ABB’s service technician can detect any misuse of the
reset, homing and upstream CB functions.
The warranty and ABB’s liability for the DS1 will become void
following misuse of the special input.
When a reset command is given, DS1 resets
the alarm and returns to its operating state.
This operation can only take place if DS1
has been de-energized.
Is strictly forbidden to reset an Alarm that
occurs when DS1 is in service in order to
enable it to become operative again.
ABB declines all liability for the DS1 fol-
lowing failure to comply with this rule.
IMPORTANT
Operators who manage the DS1 must
be informed that use of the upstream
CB Interlock (maintenance mode) when
the switch is energized by MV can result
in serious malfunctioning of the entire
apparatus.
3.6 Electrical characteristics of the INPUT
The DS1 input electrical characteristics are summarized in the
table below:
Description Activation
Voltage
Average Power
Required
Reaction
time
Open 24 VDC 5W 20 ms
Close 24 VDC 5W 20 ms
Interlock 24 VDC <1W 1 sec
Reset 24 VDC 5W 20 ms
Homing 24 VDC 5W 20 ms
UP STREAM CB 24 VDC <1W 1 sec
Table 5. DS1 - Description of the input
3.7 Input Acceptance Logic
When the system is ready to operate, the Input Acceptance
Logic is as follows:
− Level-triggered Open Trip command
− Edge-triggered Close Trip
Consult the detailed functional description and diagnostics
section for a description of the condition that enables opera-
tion.
3.8 DS1 functional descriptions
DS1 performs synchronous switching with the control sys-
tem constantly engaged with the upstream voltage reference.
To achieve this, the signal from a voltage divider (mandatory
phase to ground on phase R) is detected by its control system.
When commissioning has terminated, DS1 is ready to operate
2-3 seconds after its control system has measured the AC volt-
age reference (the Ready relay is closed at this stage).
−Close command, DS1 closes the circuit.
−Open command, DS1 opens the circuit.
Open/Close are accomplished by synchronizing the move-
ment of the power part in order to energize and de-energize
the power capacitor bank with the internal power diode when
requested by the substation.
In addition to its main function, DS1 is equipped with a pow-
erful diagnostics able to identify internal faults (motor, control
system, etc.) in the system before the operation.
Ready Output OFF (Not ready Condition)
The switch is not ready to operate. This situation:
− can be temporary at power up (for the time required by the
DS1 Control System to charge the main capacitor and per-
form system diagnostics);
− can occur when upstream voltage is not present;
− can occur when the interlock circuit has been opened;
− can occur when the time required for the MV capacitor bank
to discharge after an Open operation has not elapsed (DS1
allows a configurable time to discharge the MV capacitor
bank by applying a mask on close command-close com-
mand inhibition).
Standard Close command inhibition is 5 minutes. DS1 ap-
plies the same Close command inhibition setting at startup.
Please contact ABB for special close command inhibition
times or to bypass this function;
− can occur when the control system is overheated (automati-
cally recovered when the temperature returns below a trip-
ping threshold). The maximum admissible operating temper-
ature for DS1 (external to the switch) is +55 °C;
− can be due to internal diagnostic faults (e.g. communica-
tion lost between the three controls, incorrect internal volt-
age power rails, or encoder coherence test not passed). All
the internal diagnostic faults automatically recover when the
system re-acquires full functionality.
Alarm Output ON (Alarm Condition)
The alarm status of the switch will be provided by a clean con-
tact that is normally open when the switch is fully operating.
This contact will be closed by the DS1 control system when a
faulty condition is detected. An alarm status also implies Ready
output OFF (Not Ready Condition)
−Ready ON: the switch is fully operating. The dry contact of
the ready status is closed. Installation of a lamp (conforming
to the current capability of the contact) is recommended.
The lamp (or the contact) will be OFF (or open) if a faulty
condition occurs and prevents synchronized switching.
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Note: When the system is not energized, the ready status
will be OFF due to absence of the MV sensor signal allowing
switching synchronization. When the system is energized with
at least 1.5 kV rms (at the suggested voltage divider) and the
frequency range is within the nominal +/- 1.4 Hz value, varia-
tion within this range is fully accepted and compensated by the
control system setting to the ready condition (Ready ON).
−Watchdog Green (solid-state output) OR Lamp ON: the
system shows that it is fully alive. The watchdog is internal
hardware circuitry that constantly checks the integrity of the
system and ensures that the software is running properly.
The watchdog signal will be OFF when a faulty switch status
that could be caused by a hardware problem is present.
−Alarm ON. The dry contact of the alarm status is closed.
Installation of a lamp (conforming to the current capability
of the contact) is recommended. Alarm ON indicates a fault
concerning power part positioning OR a response to internal
diagnostics, as described below:
• Incorrectpositioningatstartup(whichcanbeadjustedby
means of the commissioning procedure described below
(only feasible in a de-energized condition)
• Bad behaviour during actuations (can be adjusted by
means of the commissioning procedure but only feasible
in a de-energized condition and only by qualified ABB
personnel)
• BadresponsetotheMicroMotionself-check(canbead-
justed by means of the commissioning procedure but only
feasible in a de-energized condition and only by qualified
ABB personnel)
Note: the Micro Motion Test is self-executed by the system
when 24 hours have elapsed without operation with the sys-
tem in the closed position. This diagnostic check produces a
negligible movement of the power part but is sufficient to allow
the system to check the actuators, power part response and
feedback coherence of the redundant position sensing built in
the system.
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4. DS1 Diagnostics
DS1 is equipped with internal powerful diagnostics system able
to identify system faults and increase the reliability of opera-
tions in the network.
The following diagram illustrates the diagnostic hierarchy at-
tached below the system architecture of DS1:
Figure 11. DS1 system architecture
Part of the diagnostics concerns the individual subsystem and
is performed individually (eg. each unit with its circuits, motors
etc.).
In addition to subsystem diagnostics, DS1 includes System di-
agnostics concerning the status of the whole apparatus.
DS1 performs an operation by only applying an Open or
Close command when the master system (system diagnos-
tics) is in the READY condition.
4.1 Base Module Diagnostics
Startup Diagnostics for all subsystems
At power up, the first step is to check communication start-
up in the three-phase system (integrity of CPU and versions is
checked).
When this step has terminated, the green led of the three con-
trol subsystems starts blinking fast.
The capacitor charger starts charging capacitor storage at
350 VDC.
After this step, all the following functionalities are continuously
checked by every subsystem as follows:
− Internal power rails.
− Internal temperatures.
− Encoder.
− Motor port Integrity.
− Motor connections and motor winding integrity.
− Tank capacity estimation
This operation is performed by each module at a time since
capacitor excitation performed by just one module can dis-
turb the measurement performed by another one.
− Pole position check
If the position is within certain limits (almost Open or Closed),
the subsystem adjusts the position (see shaft supervision
monitoring function). If the position is too far from the Open
or Closed position the system stops and requires a Homing
procedure to restore it to the Open condition.
If one of the three positions is wrong, the red led will be on
for the entire unit (the shaft supervision function is blocking
all the modules).
If the pole positions are ok and other diagnostics checks are
performed successfully, the units will be ready to operate
(the red led on the control system will now turn off), with the
exception of the Master system unit.
The Master system not only allows the individual subsystem
diagnostics to operate but the System Diagnostics as well.
Position Supervision Function
The motion controller turn off (sleep status) in order to reduce
power consumption and power dissipation. An additional su-
pervision function continuously checks the position of the shaft
and wakes up the motion controller if a significant movement is
detected. At this point, the motion controller block reacts im-
mediately and corrects the shaft position.
Master Diagnostics at startup
At this stage, the Master is not providing the ready condition
because other steps are still required:
The Ready condition is inhibited at startup (if the device is in
the Open condition).
DS1 implements an internal timer (default is 5 mins) that pre-
vents closing after opening since the power capacitors are not
discharged.
Note that in a de-energized condition (upstream CB input high)
the close mask function (close inhibition) is by-passed.
Contact your ABB representative support or sales to request
removal or a customized version of the “close inhibition time”
function. (It can be programmed in the control system).
4.2 Master Diagnostics
The Ready condition can be inhibited at any time by a sub-
system that is preventing operation due to failed subsystem
diagnostic steps.
The Ready condition is inhibited by the master due to an ab-
sent synchronization signal (in the operative mode without the
upstream CB input energized).
The Ready condition is inhibited if low pressure (blocking the
pressure sensor) opens the interlock loop (see circuit dia-
grams).
The Ready Condition is inhibited when the position supervisor
is tripping.
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4.3 Synchronization Diagnostics
Synchronization Diagnostics frequency variations from the
nominal value are automatically accepted and compensated if:
(Nominal Frequency -1.4 Hz) <Frequency measured< (Nominal
Frequency +1.4 Hz)
Synchronization Diagnostics inhibit the Ready condition when
the signal from the voltage sensor is less than 100mV (corre-
sponding to 1.7 kV on the bus bars).
Synchronization Diagnostics inhibit the Ready condition when
the harmonic content is too high.
Synchronization diagnostics cannot detect an imbalance
between the three-phase systems and cannot prevent an
operation if this imbalance leads to a significant error in
power contact timing.
An additional protection to prevent this type of operation
should be installed in the up-stream CB or in the system.
4.4 Diagnostics Table
DS1 Pressure Sensor Description Actions
Status Ready Alarm OK Warming Low
OPEN Ready –OK – – DS1 is ready to perform a
close operation.
–
OPEN Ready – – Warning –DS1 is ready to perform
a close operation. Check
'Actions'.
Check pressure level. If it is not ok, plan a refill.
If it is ok and the Warning signal persists, contact
ABB and plan a check.
DS1 can still perform a close and open operation.
OPEN – – OK – – DS1 is not ready to
perform a close operation.
Check 'Actions'.
This condition occurs when there is no voltage on
busbar side, at start up or when the Interlock loop
is open.
DS1 can perform open and close operations by
providing power to Upstream CB interlock input.
If this condition occurs when voltage is present
on busbar side, check the interlock loop. If it is
closed, contact ABB and plan a check.
OPEN – – – Warning Low DS1 is not ready to
perform a close operation.
Check 'Actions'.
Check pressure level. If it is not ok, plan a refill.
If it is ok and this condition persits, contact ABB
and plan a check.
OPEN –ALARM OK – – DS1 is not ready to
perform a close operation.
DS1 reached the final position after an open
operation, but an anomaly was detected during
the operatios.
Contact ABB and plan a check.
Incoherent –ALARM OK – – DS1 is not ready to
perform a close operation.
DS1 is in alarm mode.
Check ‘Actions’.
Pole position is not coherent.
Contact ABB and plan a check.
CLOSE Ready –OK – – DS1 is ready to perform a
close operation.
–
CLOSE Ready – – Warning –DS1 is ready to perform a
close operation.
Check ‘Actions’.
Check pressure level. If it is not ok, plan a refill.
If it is ok and the Warning signal persists, contact
ABB and plan a check.
DS1 can still perform a close and open operation.
CLOSE – – OK – – DS1 is not ready to
perform a close operation.
Check ‘Actions’.
This condition occurs when there is no voltage on
busbar side. at start up or when the Interlock loop
is open.
DS1 can perform open and close operations by
providing power to Upstream CB interlock input.
If this condition occurs when voltage is present
on busbar side, check the interlock loop. If it is
closed, contact ABB and plan a check.
CLOSE – – – Warning Low DS1 is not ready to
perform a close operation.
Check ‘Actions’.
Check pressure level. If it is not ok, plan a refill.
If it is ok and this condition persits, contact ABB
and plan a check.
CLOSE –ALARM OK – – DS1 is not ready to
perform a close operation.
DS1 is in alarm mode.
Check ‘Actions’.
DS1 reached the final position after a close
operation, but an anomaly was detected during
the operatios.
Contact ABB and plan a check.
Figure 12. DS1 Diagnostic indications
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T S R
5. Installation Guideline
5.1 General
Correct installation is of prime importance.
The instructions given by the manufacturer
must be carefully studied and followed. It is
good practice to wear gloves to handle the
parts during installation.
All the safety recommendations at the beginning of the docu-
ment must be complied with during installation and commis-
sioning.
5.2 Before installing the apparatus
Please refer to all installation requirements as indicated in prod-
uct catalogue.
IMPORTANT: Check the sense of rotation in the power plant
before installing a DS1.
Effectiveness of the diode method depends on the correct
sense of rotation setup of the MV Power Bus Bars.
DS1 is designed for a direct sense of rotation (R, S, T or A,
B, C in time domain). Swap the S (or B) and T (or C) phases
with each other if the sense of rotation in the installation is in
reverse.
Figure 13. Identification of DS1 phases
5.3 Installation requirements
Indoor
The design of the DS1 makes the synchronous switch suitable
for indoor applications.
Harmonic distortion on voltage
The DS1 can perform synchronous operations even with high
values of total harmonic distortion on voltage (THDV).
However, this value must not be such that it will cause multiple
zero-crossing of the voltage waveform.
Rated frequency
The DS1 can perform synchronous operations even when the
power frequency is subject to variations compared to the rated
value, by automatically adjusting its actuation time.
Such variations must not, however, exceed ±1.4 Hz.
Ungrounded capacitor banks
The synchronization signal acquisition logic of the DS1 is suit-
able for operating only on capacitor banks. These capacitors
must have an ungrounded centre of the star.
In case of retrofit on an existing capacitor bank with inrush
reactors, such reactors must be eliminated or the DS1 must be
electrically located downstream with respect to them.
Capacitor discharge
When a capacitor bank is disconnected from the network, the
capacitor units remain charged to the voltage at which they are
disconnected. These must therefore be discharged to a voltage
value less than or equal to 50 V within 5 minutes, before being
connected again, according to the standard IEEE C37.99.
To prevent reclosing before the capacitors are discharged,
once the opening operation has been performed, the DS1 clos-
ing command is inhibited for 5 minutes by the control unit, thus
ensuring that it is impossible to perform closing operations on
the charged capacitor banks.
The DS1 is can perform the following operational sequence:
C – 300 ms – O – 5 min – C
Contact ABB if the inhibition time needs to be changed.
In any case, the closing of a non-discharged bank must never
be carried out with DS1.
Voltage sensor
The DS1 requires the measurement of busbar voltage on phase
R (A) by means of a voltage sensor. Only one sensor is needed,
since the load is symmetrical (floating star centre) and purely
capacitive.
DS1 has been tested and certified with the ABB KEVA 24 A3
sensor. ABB recommends the use of an ABB KEVA 24 A3 sen-
sor or equivalent.
The ABB KEVA 24 A3 sensor is not included in the DS1.
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Direct phase rotation
The logic on which the opening and closing operations are
based requires the sequence of the primary three-phase power
supply network to follow the direct phase rotation R, S, T (A,
B, C).
Fault-making
The DS1 cannot perform a fault-making operation. For this rea-
son, the DS1 must be properly integrated into the system so as
to minimize the likelihood and impact of this event.
If necessary, contact ABB to get technical support to assess
these requirements.
5.4 Installation of fixed apparatus
5.5 Additional installation recommenda-
tions
Comply with the following recommendations when DS1 is inte-
grated into a metal-enclosed system:
• RefertotheofficialexternaldrawingsprovidedbytheABB
sales representative for positioning in the compartment and
use the base of the device to provide support. An example
is enclosed at the end of the document (Annex B).
• Do not install the apparatus without providing a sound
support on which to fix the DS1 base mainframe. DS1
weighs about 130 kg and during the switching process it
will produce significant vertical oscillations. An unsecure
support can lead to excessive stress on the power contact
when connected to MV bus bars.
This can cause serious malfunctions in the apparatus and
also create problems involving the fastening components of
the bus bars in the compartment (e.g. bushings, etc).
•
It is forbidden to reverse the supply side with the load side.
• It is forbidden to install DS1 upside down.
5.6 Preliminary operations
You are strongly advised to use use type-
approved compartments able to hold the
internal arc in case of failure because the
apparatus is not designed to meet any safety
requirements in the event of faluts.
Clean the insulating parts with a clean dry rag and check that
the upper and lower terminals are clean and free from deforma-
tion caused by shocks received during transport or storage.
The apparatus can be mounted directly on the supporting
frames. The supporting frames must be on the same horizontal
plane to prevent the switch frame from becoming distorted.
Do not install the apparatus without providing a sound support
on which to fix the DS1 base mainframe.
The anchoring holes are drilled in the lower part of the frame.
Fit the isolating partitions if provided.
A minimum degree of protection (IP2X) must be guaranteed
from the front towards live parts.
It is advisable to use type-approved com-
partments able to hold the internal arc in
case of failure because the apparatus is not
designed to meet any safety requirements in
the event of faluts.
The apparatus can be mounted directly on the supporting
frames provided by the customer.
The areas on which the supporting frames are mounted must
be on the same horizontal plane to avoid any risk of distortion
in the breaker frame.
Do not install the apparatus without providing a sound support
on which to fix the DS1 base mainframe. Failure to do this can
lead to serious malfunctions in the apparatus.
Fit the isolating partitions if provided.
A minimum degree of protection (IP2X) must be guaranteed
from the front towards live parts.
Comply with the following recommendation when DS1 is inte-
grated into a compartment.
Refer to the official overall dimensions (ANNEX B) for position-
ing in the compartment and use the base of the device to pro-
vide support.
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6. Fixed Apparatus power circuit
connections
6.1 General directions
Make the connections using only the square terminals supplied
with the apparatus.
Select the conductor cross-section according to the operating
and short-circuit current of the installation.
Suitable supporting insulators sized to suit the electrodynamic
stress that may be produced by the short-circuit current of the
installation must be provided near the terminals of the fixed
version apparatus or enclosure.
6.2 Mounting the connections
Check that the connection contact surfaces are perfectly flat
and free from burrs, traces of oxidation or deformation due to
drilling or impact.
Perform the operations described in the table on the contact
surface of the conductor, depending on the conductive mate-
rial and surface treatment used.
6.3 Mounting procedures
Place the connections in contact with the apparatus terminals.
Fit a spring washer and a flat washer between the head of the
bolt and the connection.
Tighten the bolt, taking care not to subject the insulating parts
to stress (see table-tightening torque).
Make sure that the connections do not exert force on the ter-
minals.
In the case of cable connections, carefully comply with the
manufacturer’s instructions for terminating the cables.
Table of tightening torque
Screw Tightening torque
M6 10 Nm
M8 30 Nm
M10 40 Nm
M12 70 Nm
Bare copper Silver-plated copper
or aluminium
Bare aluminium
Clean with a fine file or
emery cloth
Clean with a rought
dry rag
Clean with a metallic
brush or emery cloth
Fully tighten and smear a
film of industrial vaseline
grease over the contact
surfaces
In case of tough
oxidation traces only,
clean with a very fine
emery cloth, taking
care not to remove the
surface layer
Immediately smear
a film of industrial
vaseline grease over
the contact surfaces
Interpose the copper-
aluminium bi-metal
with restored surfaces
between the aluminium
connection and the
copper terminal (copper
side in contact with
the terminal; aluminium
side in contact with the
connection)
If necessary,
recondition the
surface treatment
Figure 14. DS1 power connections
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