Allen-Bradley 1407-CGCM User manual

Combination Generator Control Module
Catalog Numbers 1407-CGCM
User Manual

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
Allen-Bradley, Rockwell Software, Rockwell Automation, ControlLogix, Logix5000, and RSLogix are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 1407-UM001H-EN-P - November 2014 
3UMMARYOF#HANGES
This manual contains new and updated information. Changes throughout this
revision are marked by change bars, as shown to the right of this paragraph.
.EWAND5PDATED
)NFORMATION
This table contains the changes made to this revision.
4OPIC 0AGE
Updated the dimension diagrams 14
Updated the Configuration Messaging section 129
Added information for the Network status indicator 164
Added information for the Module status indicator 165
Updated the Get Attributes All (service code 0x01) table for Identity
Object Instance 1 198
Updated the Get Attributes All (service code 0x01) table for Identity
Object Instance 2 199
Added a Device Status for Identity Object Instance 2 199
Updated the Certification information in the Agency Certifications
table 210

Rockwell Automation Publication 1407-UM001H-EN-P - November 2014
3UMMARYOF#HANGES
.OTES

Rockwell Automation Publication 1407-UM001H-EN-P - November 2014 
4ABLEOF#ONTENTS
0REFACE
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
#HAPTER
'ENERAL)NFORMATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
#HAPTER
)NSTALLATION
Mounting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
#HAPTER
#'#-5NIT/PERATION
Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operational Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
#HAPTER
#'#-5NIT#ONFIGURATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Overview of the Configuration Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Create a New Module in the ControlLogix Controller . . . . . . . . . . . . . . 72
Device Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
#HAPTER
#'#-5NIT3TARTUP
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Recommended Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Recommended Start-up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Document Configuration Parameter and Wiring Changes. . . . . . . . . . 125
#HAPTER
#'#-5NIT3OFTWARE)NTERFACE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
CGCM Unit User Program Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
CGCM Unit Data Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
#HAPTER
4ROUBLESHOOTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
!PPENDIX!
4IME/VERCURRENT
#HARACTERISTIC#URVES
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Curve Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Time Over-current Characteristic Curve Graphs. . . . . . . . . . . . . . . . . . . 170

Rockwell Automation Publication 1407-UM001H-EN-P - November 2014
4ABLEOF#ONTENTS
!PPENDIX"
#'#-5NIT-ATH-ODELS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Synchronous Machine Terminal Voltage Transducer and Load
Compensator Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
VAR/Power Factor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Limiters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
V/Hz Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Soft Start Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Field Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
!PPENDIX#
!DDITIONAL#ONTROL.ET.ETWORK
)NFORMATION
ControlNet Application Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
!PPENDIX$
3PECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
!PPENDIX%
$ETAILED#'#-5NIT4AG
$ESCRIPTIONS
Generator Parameters and Configuration Status . . . . . . . . . . . . . . . . . . . 213
General Excitation Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
AVR Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
FCR Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Power Factor Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
VAR Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Excitation Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Synchronizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Load Sharing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
!PPENDIX&
#ONFIGURATION2ECORD
7ORKSHEET
Generator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
)NDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Rockwell Automation Publication 1407-UM001H-EN-P - November 2014 
0REFACE
The information in this manual applies to the 1407-CGCM module, Series D,
Revision A, with host firmware revision 4.25 and ControlNet firmware
revision 1.07. The manual notes differences with earlier versions of the product
where they occur.
!DDITIONAL2ESOURCES
These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at http://www.rockwellautomation.com/
literature/. To order paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.
2ESOURCE $ESCRIPTION
Safety Guidelines for the Application,
Installation and Maintenance of Solid State
Controls, publication SGI-1.1
Describes some important differences between
solid-state equipment and hard-wired
electromechanical devices.
ControlNet Coax Media Planning and
Installation, publication CNET-IN002 Provides installation procedures for the
ControlNet network.
Logix5000™ Controllers Common Procedures,
publication 1756-PM001 Provides information about RSLogix™ 5000
software.
CGCM Release Notes, publication 1407-RN001 Provides information on compatible RSLogix
5000 software versions and ControlLogix®
controller firmware revisions.
Industrial Automation Wiring and Grounding
Guidelines, publication 1770.4.1.Provides general guidelines for installing a
Rockwell Automation industrial system.
Product Certifications website,
http://www.ab.com Provides declarations of conformity, certificates,
and other certification details.

Rockwell Automation Publication 1407-UM001H-EN-P - November 2014
0REFACE
.OTES

Rockwell Automation Publication 1407-UM001H-EN-P - November 2014 
#HAPTER 
'ENERAL)NFORMATION
)NTRODUCTION
The Combination Generator Control Module (CGCM unit) is a
microprocessor-based control and protection device. The CGCM unit is
designed to integrate with a Logix family programmable controller to provide
generator control, protection and synchronization functions. Programmability of
system parameters, regulation settings, and protective functions enable the
CGCM unit to be used in a wide range of applications.
&UNCTIONS
The following sections outline the functions of the unit.
'ENERATOR2EGULATIONAND#ONTROL&UNCTIONS
This list contains the generator regulation and control functions:
•Four excitation control modes
•Automatic voltage regulation (AVR)
•Manual or field current regulation (FCR)
•Power factor (PF)
•Reactive power (VAR)
•Soft start voltage buildup with an adjustable ramp in AVR and FCR
control modes
•Over-excitation (OEL) and under-excitation (UEL) limiting in AVR,
VAR, and PF control modes
•Under-frequency compensation (Volts/Hertz)
•Line drop compensation
•Auto-tracking between operating modes and between redundant CGCM
units
•Automatic transfer to a back-up CGCM unit in redundant systems
•Generator paralleling with reactive droop compensation or cross-current
(reactive differential) compensation
•Generator paralleling with real power load sharing
•Synchronizing for one or two circuit breakers

 Rockwell Automation Publication 1407-UM001H-EN-P - November 2014
#HAPTER General Information
'ENERATOR0ROTECTION&UNCTIONS
This list contains the generator protection functions:
•Loss of excitation current (40)
•Over-excitation voltage (59F)
•Generator over-voltage (59)
•Generator under-voltage (27)
•Loss of sensing (60FL)
•Loss of permanent magnet generator
(PMG/Excitation power) (27)
•Reverse VAR (40Q)
•Over-frequency (81O)
•Under-frequency (81U)
•Reverse power (32R)
•Rotating diode monitor
•Phase rotation error (47)
•Generator over-current (51)
-ETERING&UNCTIONS
This list contains the metering functions:
•Voltag e
•Current
•Frequency
•Real Power
•Apparent Power
•Reactive Power
•Power Factor
•Real Energy (kWh)
•Apparent Energy (kVAh)
•Reactive Energy (kVARh)
•Controller Excitation Current and Voltage
•Diode Monitor Ripple Level
•Load Share Error
•Synchronization Parameters