Atlas Copco Qc4003 User manual

Transformer Maintenance
Instruction Manual
English

ATLAS COPCO - PORTABLE ENERGY DIVISION
www.atlascopco.com
Printed matter N°
2954 6170 04
02/2016
Original instructions
Transformer Maintenance

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Warranty and Liability Limitation
Use only authorized parts.
Any damage or malfunction caused by the use of unauthorized parts is not covered by
Warranty or Product Liability.
The manufacturer does not accept any liability for any damage arising from modifications,
additions or conversions made without the manufacturer's approval in writing.
Neglecting maintenance or making changes to the setup of the machine can result in major
hazards, including fire risk.
While every effort has been made to ensure that the information in this manual is correct,
Atlas Copco does not assume responsibility for possible errors.
Copyright 2016, Grupos Electrógenos Europa, S.A.U., Zaragoza, Spain.
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.

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Transformer Maintenance
Contents
1 Introduction.................................4
2 Transformer Maintenance
Box ...............................................4
2.1 Description .........................................4
2.2 Specifications.....................................4
2.3 Safety precautions.............................5
2.4 Main components..............................5
2.4.1 Display ................................................5
2.4.2 Turn switches .....................................5
2.4.3 Lamp and buzzer ................................5
2.4.4 Voltage connection ............................5
2.4.5 Shutdown ...........................................5
2.4.6 Component overview ........................6
3 Setting Qc4003™ for
transformer maintenance ..........7
4 Before starting ............................9
5 Transformer maintenance
procedure...................................10
5.1 OFF status.........................................10
5.2 Start generator.................................11
5.3 Synchronise the generator..............12
5.4 Deload Mains....................................13
5.5 Island operation ...............................14
5.6 Back synchronisation to the
Mains.................................................15
5.7 Manually restore fuses ....................16
5.8 Deload the generator.......................17
5.9 Stop the generator...........................18
5.10 Settings to increase stability ..........19
5.10.1 PID regulation...................................19
5.10.2 Power factor settings .......................20
5.10.3 Closing settings................................20
6 Voltage mains
measurement............................ 21
6.1 Three-phase measurement .............21
6.2 One-phase measurement ................21
7 Cable and plug connection...... 22
7.1 Cable specifications .........................22
7.2 CAN communication........................22
7.3 Cable overview.................................22
Congratulations on the purchase of your Qc4003™ affiliated Transformer Maintenance Box. It is a solid, safe and reliable tool for transformer maintenance, built
according to the latest technology. Follow the instructions in this booklet and we guarantee you years of troublefree operation. Please read the following instructions
carefully before starting to use your Transformer Maintenance Box.
While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors. Atlas Copco
reserves the right to make changes without prior notice.

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1 Introduction
By introducing the Qc4003™ Transformer
Maintenance application, Atlas Copco offers you the
possibility of performing transformer maintenance
without any power supply interruption for the
consumers.
The main principles of transformer maintenance are:
Take load from the Mains
To repair or to preform service on a transformer, the
Mains should be disconnected.
1. Synchronise the generator with the busbar to
connect to the system.
2. When the generator is synchronised, the generator
breaker will close and the generator takes the load.
3. When the Mains power is zero, the mains breaker
can be switched off or the fuses can be removed.
Back synchronisation to the Mains
1. The generator will synchronise back to the mains.
2. When this static synchronisation is ok, manually
close the mains breaker or connect the fuses.
The generator can be deloaded.
3. After deload, the generator breaker is opened and
the generator stops.
2 Transformer
Maintenance Box
2.1 Description
To facilitate transformer maintenance a Transformer
Maintenance Box (TM-box) has been developped.
The TM-box complies with the demands of a remote
control box and the new flexibility of a maintenance
mobile system.
These demands are:
– Safe maintenance at transformer substations or
other electrical installations
– Interface panel close to the connection points
– No interruptions of power supply for the
consumers
To comply with these demands a TM-box with
following features has been introduced:
– Easy user interface
– Designed to be simple in control
– Step-by-Step sequences
– Visual and audible indication
2.2 Specifications
The TM-box is only to be applied together with a
Qc4003™. The Qc4003™ is a power management
controller, carrying out generator control, supervision
and protection.
Communication between the generator and the TM-
box is established via CAN-communication.

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2.3 Safety precautions
When installing/operating the TM-box, keep
following safety precautions in mind:
Electrostatic discharge awareness
Sufficient care must be taken to protect the terminals
against static discharges during the installation. Once
the unit is installed and connected, these precautions
are no longer necessary.
Safety issues
Installing and operating the unit implies work with
dangerous currents and voltages. Therefore, the
installation should only be carried out by authorised
personnel who understand the risks involved in
working with live electrical equipment.
2.4 Main components
2.4.1 Display
The box contains a display, which has the same
functions as the display mounted directly on the
generator’s Qc4003™. This gives the operator the
possibility to read out the same values from both
displays, such as synchroscope, menus, activity texts,
etc. The display will show different views in each
function step to give the necessary information.
The display on the TM-box is set as secondary
display. The display on the generator remains the
primary display.
Press for 3 seconds and enter password 2003 to
change this setting.
2.4.2 Turn switches
Power set point adjustments are made by means of a
spring return selector switch (4) that returns to zero
when being released.
To select a function, the operator uses a multiposition
‘Function select’ switch (3) that is turned clockwise
in sequential steps to make the generator carry out the
functions indicated until it completes 360 degrees.
Then the generator will stop and it is ready for a new
job cycle.
2.4.3 Lamp and buzzer
The ‘Connect mains’ lamp (2) is activated together
with an internal buzzer as soon as back
synchronisation to the Mains is accomplished.
2.4.4 Voltage connection
Voltage measurements can be quickly and easily
connected directly to the TM-box (5). It is possible to
have a 1- or 3-phase measurement.
2.4.5 Shutdown
The shutdown function is to protect the system.
Pressing the ‘Shutdown’ button (6) will trigger an
emergency stop which will result in loss of power for
the consumer.
The TM-box can be connected or disconnected
without tripping the generator.
Be aware of the hazardous live
currents and voltages. Do not touch
any AC measurement inputs as this
could lead to injury or death.
Be aware that in some cases a second
source may still provide power to the
busbar without giving notice.

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2.4.6 Component overview
1Display
2 Connect mains lamp
3 Function select switch
4Powerswitch
5 Voltage measurement point
6 Shutdown button
7 U/F OK LED
Island
Qc4003
G
!
OK
LOG
Function select
Deload mains
Start generator
OFF
NL1
L2
L3
Stop
Deload generator
Generator
synchronisation
Power
0
Voltage mains
Shut down
Connect
mains
Synchronisation to mains
2
1 7 6
345

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3 Setting Qc4003™ for transformer maintenance
Hardware installation
– TM-box
– 2 TM cables (one CAN communication cable and
one cable for 230-400V measurement)
Setting up the Qc4003™ controller
1. Make sure application 1 is selected:
• Go with the JUMP button to parameter 9160.
• Check if A1 (application 1) is active.
If not, activate A1 by pushing ENTER on A1
and select this application with settings
“1 DG” and “1 Mains” (default settings).
2. Set the controller in “Remote Maintenance”
mode:
• Go with the JUMP button to parameter 6070.
• Select genset mode “Remote Maintenance”.
3. Set communication ID:
• Press navigation left, up and right button
together for 3 seconds.
• Enter service password.
•Select‘ID1’.
1 Transformer Maintenance Box (1626 4629 00)
2 Control cable (25 m) (1626 4630 00)
3 Sensing cable (25 m) (1626 4631 00)
Genset 1
G
X41
X41
X40
X40
2
1
3
Qc4003
G
!
OK
LOG
G 0 0 0V
ENTER MENU NO.1 9160
ENTER
Qc4003
G
!
OK
LOG
G 0 0 0V
Standard plant
1DG, 1Mains, 0BTB
A1 A2 A3 A4 INACT
Qc4003
G
!
OK
LOG
G 0 0 0V
Standard plant
1DG, 1Mains, 0BTB
RESET SELECT
Qc4003
G
!
OK
LOG
G 0 0 0V
Standard plant
1DG, 1Mains, 0BTB
A1 A2 A3 A4 ACT

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Setting the TM-box display as primary display
1. Set communication ID:
• Press navigation left, up and right button
together for 3 seconds.
• Enter service password.
•Select‘ID2’.
2. Set display priority:
• Press the “view” button for 2 seconds.
• Enter service password.
• Select ‘Priority 1’.
Make sure following actions have been carried
out:
– Remove Earth leakage relay in both units (S13).
– TM Limit relay set at 0sec. (PAR. 5110)
To protect the unit and the load, a
suitable protection installed on the
power cables between the Mains and
the generator should be foreseen by
the end-user.

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4 Before starting
1. Adjust following parameter settings
• Parameter 1425: Turn OFF ROCOF.
• Parameter 1434: Turn OFF Vector jump.
• Parameter 6001/6011: Check Frequency from
mains and adjust Nominal setting of the
generator towards it.
• Parameter 6004/6014: Check Voltage from
mains and adjust Nominal setting of the
generator towards it.
• Parameter 6053/6063: If Voltage has been
adjusted, also adjust the Busbar settings to the
same value.
2. Set the diplay of the TM-box as the primary
display (for details see “Setting the TM-box
display as primary display” on page 8).
3. Switch off earth leakage protection S13 inside the
cubicle.
4. Remove the P-link inside the cubicle (check
electrical drawing inside the cubicle).
5. Correct connection of sensing to TM-box.
Measure the rotation of both generator and mains
and connect cables and sensing accordingly.
6. Before backsynchronising check frequency and
voltage of mains and set the generator equal to
mains (parameters 6001/6004/6053 or 6011/6014/
6063).
Following preliminary actions
should be carried out before starting
Transformer Maintenance!
Mains Mains
Generator Generator
SensingSensing

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5 Transformer maintenance procedure
5.1 OFF status
TM-box
The ‘Function select’ switch is in the OFF position.
Flow
1. Manually connect the power cables from the
generator to the busbar.
2. Connect the cables from the TM-box to the
generator.
3. Select remote maintenance mode in parameter 6070.
4. Measure Active power, Reactive power and Power
Factor.
5. Set power factor setpoint according the measured
value in parameter 7050.
Island
Function select
Deload mains
Start generator
OFF
Stop
Deload generator
Generator
synchronisation
Power
0
Connect
mains
Synchronisation to mains
A live connection has to be made, take all
necessary safety measures. Always check
the phase sequence when connecting.

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5.2 Start generator
TM-box
Turn the ‘Function select’ switch to Start generator.
Flow
1. The generator starts up.
2. When the generator is running (shown on TM-box
display), make sure that voltage and frequency are
OK.
This is indicated by the U/F OK LED (7) on the TM-
box display.
Island
Synchronisation to mains
Function select
Deload mains
Start generator
OFF
Stop
Deload generator
Generator
synchronisation
Power
0
Connect
mains

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5.3 Synchronise the generator
TM-box
Turn the ‘Function select’ switch to Generator
synchronisation.
Flow
1. The generator is forced to make a dynamic
synchronisation to the Mains and closes the
generator breaker.
The synchronisation will be shown on the TM-box
display.
2. The generator will run with a minimum of load.
Island
Synchronisation to mains
Deload generator
Function select
Deload mains
Start generator
OFF
Stop
Generator
synchronisation
Power
0
Connect
mains

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5.4 Deload Mains
TM-box
Turn the ‘Function select’ switch to Deload mains for
load take over.
Flow
1. Adjust the generator power by means of the ‘Power
switch’.
2. Measure the current from the mains with a hand-held
ampere meter.
3. When ‘Power Mains ≈0’, manually disconnect the
Mains by opening the mains breaker or removing the
fuses.
The generator will stay in fixed power mode and take
over the load.
4. When the fuses are opened, switch the function
selector switch ASAP to Island mode.
As long as the generator is in fixed power, load
variation will result in rising or lowering frequency
to unacceptable levels for the consumers and the
generator might trip.
5. In case of instability, please consult section 5.10.
Island
Synchronisation to mains
Deload generator
Stop
Function select
Deload mains
Start generator
OFF
Generator
synchronisation
Power
0
Connect
mains

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5.5 Island operation
TM-box
Turn the ‘Function select’ switch to Island as quickly as
possible to prevent frequency variation due to load
changes.
Flow
1. The generator runs in a normal island operation with
frequency regulation.
2. It is now possible to disconnect the TM-box.
The generator will continue running in island mode.
Meanwhile the TM-box can be removed to ensure
that only authorised personnel is operating the
system, or the TM-box could be used in another
application.
3. When reconnecting the TM-box to the application
the system will only react when the ‘Function select’
switch is turned to the Island position.
Island
Synchronisation to mains
Deload generator
Stop OFF
Function select
Deload mains
Start generator
Generator
synchronisation
Power
0
Connect
mains
When reconnecting with the ‘Function
select’ switch in Island position nothing will
happen. Switch back and forward to Island
to reactivate the system
Be aware that in some cases a second source may provide power to the busbar without the operator's knowledge. When the fuses to one of the
transformers are removed and the system is set to island operation, the frequency regulation will indicate this by starting to “fight” the Mains to
keep the nominal setting. This will cause the generator to accelerate, and high current will run through the transformer cable. In this case, switch
back to “Deload mains” (fixed power) to avoid instability in the system and breaking/destroying the cable.

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5.6 Back synchronisation to the Mains
Flow
Connect the voltage measurement line between the TM-
box and the mains connection point (fuses/breaker).
Do not forget to check the phase sequence of these
measuring cables. See also section 6 for the difference
between three phase and single phase measurement.
TM-box
1. Turn the ‘Function select’ switch to
Synchronisation to mains.
2. The generator starts static synchronization.
2 regulators will become active :
• frequency synchronisation: regulates the voltage
towards the closing window,
• phase angle synchronization: takes over in the
closing window.
3. For improved stability, synchronization behaviour
can be adjusted in parameters 2040 and 2060. For
details, please check section 5.10.
4. For improved accuracy, the closing window and
delay setting can be changed in parameters 2033 and
2034.
Island
Synchronisation to mains
Deload generator
Stop OFF
Start generator
Function select
Deload mains
Generator
synchronisation
Power
0
Connect
mains

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5.7 Manually restore fuses
TM-box
When the synchroscope in the display is stable at 12
o'clock, the Connect mains lamp will light up and a
buzzer will be activated.
Flow
Manually close the mains breaker or reconnect the fuses
to reconnect the Mains.
Island
Synchronisation to mains
Deload generator
Stop OFF
Start generator
Function select
Deload mains
Generator
synchronisation
Power
0
Connect
mains

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5.8 Deload the generator
TM-box
Turn the ‘Function select’ switch to Deload generator.
Flow
The generator deloads and opens the generator breaker.
The speed of deload can be selected in parameter 2620
where the ramp down %/s can be adjusted. Set deload
speed slow enough to assure smooth load transfer from
the generator to the mains.
Island
Synchronisation to mains
Deload generator
Stop
Generator
synchronisation
Function select
Deload mains
Start generator
OFF
Power
0
Connect
mains

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5.9 Stop the generator
TM-box
Turn the ‘Function select’ switch to Stop to stop the
generator.
Flow
1. After the cooldown time, set by the operator, the
generator will stop automatically.
2. The generator can be disconnected and moved to
another job.
Island
Synchronisation to mains
Deload generator
Function select
Deload mains
Start generator
OFF
Stop
Generator
synchronisation
Power
0
Connect
mains

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5.10 Settings to increase stability
5.10.1 PID regulation
To fine-tune synchronisation when switching back to the Mains, it is recommended to adjust PID regulation.
To improve stability of the active power regulation following parameters can be used/adjusted:
Parameters can be found on the display menu structure: SETUP/ CTRL / SYNC or by entering the number in the JUMP menu.
Two different PID regulators are used to adjust the frequency at static synchronisation:
– Use following parameters to adjust the frequency synchronization PID:
– Use following parameters to adjust the phase PID:
When the voltage vector is outside the closing window, the “f sync.” regulator will be active, when the voltage vector is inside the closing window the phase PID regulator
will be active.
Reg 2530 Power PID
Reg 2531 Kp Proportional
Reg 2532 Ti Integrative
Reg 2533 Td Derivative
Sync 2041 f sync. Kp 74 5
Sync 2042 f sync. Ti 75 2 s
Sync 2043 f sync. Td 76 0 s
Sync 2061 Phase Kp 78 8
Sync 2062 Phase Ti 79 1.2 s
Sync 2063 Phase Td 80 0.3 s