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INSTRUCTION MANUAL

FOR
AUTO-SYNCHRONIZER
Model: BE3-25A
Part Number: 9 1661 00 100

Publication Number: 9 1661 00 990


Date: February, 1985
Revision H: June, 1999

WARNING
To prevent personal injury or equipment damage, only
qualified technicians/operators should install, operate, or
service this device.

CAUTION
Meggers and high potential test equipment should be
used with extreme care.
Incorrect use of such
equipment could damage components contained in the
device.

CONFIDENTIAL INFORMATION
of Basler Electric Company, Highland, IL. It is loaned for
confidential use. Subject to return on request and with the
mutual understanding that it will not be used in any manner
detrimental to the interests of Basler Electric Company.

It is not the intention of this manual to cover all details and


variations in equipment, nor does it provide data for every
possible contingency regarding installation or operation. The
availability and design of all features and options are subject
to change without notice. Should further information be
required, call Basler Electric Company, Highland, IL.

Rev
G
Rev
H

ECA
15587
ECO
2275

Table of Contents
Paragraph

Title

Page

SECTION 1 GENERAL INFORMATION


1-1 Description .......................................................................................................1-1
a. General Description ..................................................................................1-1
b. Basic Unit Description...............................................................................1-1
c. Frequency/Phase Angle Matching System ..............................................1-2
d. Voltage Matching Option ..........................................................................1-2
e. Dead Bus Closing Option .........................................................................1-3
1-2 Specifications ...................................................................................................1-3
1-3 Style Chart........................................................................................................1-4
SECTION 2 THEORY OF OPERATION
2-1 System Theory of Operation............................................................................2-1
a. Basic Unit (Without Options) ....................................................................2-1
b. Basic Unit (With Options) .........................................................................2-1
2-2 Synchronizer Theory of Operation...................................................................2-2
a. Power Supply............................................................................................2-2
b. Basic Unit ..................................................................................................2-2
c. Dead Bus Option.......................................................................................2-3
d. Frequency/Phase Matching Option ..........................................................2-3
e. Voltage Matching Option ..........................................................................2-3
SECTION 3 CONTROLS, INDICATORS, & JUMPERS
3-1 Controls ............................................................................................................3-1
3-2 Indicators..........................................................................................................3-1
3-3 Jumpers............................................................................................................3-7
SECTION 4 INSTALLATION & OPERATION
4-1 Installation ........................................................................................................4-1
4-2 Interconnection.................................................................................................4-1
a. Power and Sensing Connections .............................................................4-1
b. Circuit Breaker (SYNC) Connection.........................................................4-4
c. Voltage Regulator and/or Governor "Raise/Lower" Connections ............4-4
d. Summing Point Governor Connection......................................................4-4
e. Summing Point Voltage Regulator Connection........................................4-7
4-3 Operation..........................................................................................................4-9
a. Initial Set-up ..............................................................................................4-9
b. Pre-Operational Check-Out....................................................................4-10
c. Operation ................................................................................................4-10
SECTION 5 MAINTENANCE
5-1 Preventive Maintenance ..................................................................................5-1
5-2 Troubleshooting ...............................................................................................5-1
SECTION 6 REPLACEMENT PARTS
6-1 General.............................................................................................................6-1

List of Illustrations
Figure
1-1
2-1
2-2
3-1
3-1A
3-1B
3-1C
3-1D
3-2
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-17

Title

Page

BE3-25A Style Chart................................................................................. 1-4


System Block Diagram ............................................................................. 2-1
Synchronizer Block Diagram .................................................................... 2-4
Controls, Indicators, and Jumpers ........................................................... 3-2
Style A2N .................................................................................................. 3-3
Style B1D .................................................................................................. 3-4
Style C2D .................................................................................................. 3-5
Style W1D ................................................................................................. 3-6
Governor Stability Jumper ........................................................................ 3-7
BE3-25A Outline Drawing......................................................................... 4-1
Power and Sensing Connection, 240 Vac, Power from Bus ................... 4-2
Power and Sensing Connection, 240 Vac, Power from Generator ......... 4-2
Power and Sensing Connection, 120 Vac, Power from Bus ................... 4-3
Power and Sensing Connection, 120 Vac, Power from Generator ......... 4-3
Raise/Lower Contact Interconnection ...................................................... 4-4
Barber Coleman DYN1 Interconnection................................................... 4-5
Barber Coleman ILS Interconnection ....................................................... 4-5
Woodward 2301 Interconnection ............................................................. 4-6
Woodward 1712-1724 Interconnection.................................................... 4-6
Woodward 2301A Interconnection........................................................... 4-6
AMBAC International CU673C Interconnection....................................... 4-7
KR, SR-F, SR-E, SR-H Interconnection................................................... 4-7
SR4A and SR8A Interconnection............................................................. 4-8
XR2001, XR2002, and XR2003 Interconnection ..................................... 4-8
SSE and SER-CB Interconnection........................................................... 4-8
SSR Interconnection................................................................................. 4-9

List of Tables
Table
1-1
1-2
3-1
3-2
3-3
4-1
5-1
6-1

Title

Page

Physical Specifications .............................................................................1-3


Electrical Specifications ............................................................................1-4
Controls.....................................................................................................3-1
Indicators...................................................................................................3-1
Jumpers ....................................................................................................3-7
BE3-25A and Breaker Connections .........................................................4-4
Troubleshooting Chart ..............................................................................5-1
Replacement Parts ...................................................................................6-1

ii

SECTION 1
GENERAL INFORMATION
1-1. DESCRIPTION
a. General Description.
The Basler BE3-25A Auto-Synchronizer provides automatic
synchronization of an oncoming generator with a bus or another generator. The Synchronizer
supplies correction signals to the oncoming generator to match it to the bus or to another generator
for frequency, phase angle, and voltage before being closed into the circuit. Options allow for dead
bus closing and a variety of output configurations for frequency/phase matching and voltage
matching. Construction consists of a case enclosed circuit board with external terminal connections.
A TEST/OPERATE switch, LED SYNC and POWER indicators and all operational adjustments are
located on the front panel or are accessible through access holes in the front panel.
b. Basic Unit Description.
(1) The basic BE3-25A Auto-Synchronizer monitors both the oncoming generator and bus
voltages then permits synchronizing the generator to an energized station bus or to another generator when the following predetermined conditions are satisfied:
(a) The frequency of the oncoming generator and the bus are matched to within 0.1 Hertz.
This corresponds to a slip frequency of 0.1 Hertz or less.
(b) The phase angle between the oncoming generator voltage and the bus voltage is less
than or equal to the allowable limit determined by the front panel setting. This limit is
established by the position of the front panel BREAKER CLOSING ANGLE switch with
settings of 5, 10, 15, and 20.
(c) The difference between the generator and bus voltage is less than the selected voltage
difference setting which is continuously adjustable over the range of 5% to 15% of the
bus voltage.
(2) When a jumper is connected across the 0.75 Second Time Delay terminals of the Synchronizer (terminals D1 and D2), the generator will be synchronized only when the generator output
voltage is within the selected voltage difference setting and the measured phase angle and difference (slip) frequency are less than the following:
Phase Angle
Setting

Max. Slip
Frequency

0.037 Hz

10

0.074 Hz

15

0.1 Hz

20

0.1 Hz

(3) When the phase angle, frequency, and voltage are within predetermined limits, the Synchronizer energizes the isolated synchronizing output relay to initiate generator circuit breaker closure.
The front panel SYNC indicator will illuminate and the frequency and phase angle correction signals
are automatically reset. The correction signals can be reset manually by connecting a normally open
contact between the Reset terminals of the Synchronizer (terminals R1 and R2). Closure of the
synchronizing output relay within the synchronizing parameters will automatically reset the correction
output signals.

1-1

(4) Upon a loss of power (power input falls below 85 Vac for 50 and 60 Hertz systems) or
removal of either the bus or generator sensing input voltage, the Synchronizer will immediately
remove all output correction signals to the governor or voltage regulator.
(5) A built-in "operational test" mode can be used to verify Synchronizer operation when
connected to the generator. The Sync Output Relay is inhibited from operating when the
TEST/OPERATE switch is set to the TEST position. A red LED (SYNC) on the front panel will
illuminate whenever the frequency, phase angle, and voltage are all within the contact closure
parameters.
c. Frequency/Phase Angle Matching System.
(1) The frequency/phase angle matching options in the Synchronizer provide correction signals
to the generator governor control. Two types of frequency/phase angle matching are available:
(a) "Bipolar" governor correction signals (summing point) for use with most common
electronic type governor controls manufactured by AMBAC International, Barber Coleman, and
Woodward. Summing point frequency correction signals are output at maximum until the generator
frequency is corrected to within 3 Hertz of the station bus frequency. Once the 3 Hertz limit is
attained, the output signals become proportional to the amount of the difference frequency (i.e.: the
output for a 3 Hertz difference is larger than the output for a 1 Hertz difference).
(b) A "raise/lower" output contact signal for use with hydraulic type governors and motor
operated controls. Contact type correction signals are output as a contact closure. When the phase
angle is 0 or within the front panel setting for acceptable phase conditions, the contacts open and
remain open. At any phase angle greater than the front panel setting, the contacts are closed.

NOTE
If the governor control, actuator, and associated linkage are
not properly adjusted, the BE3-25A output may not be able to
drive the governor far enough to allow synchronization.

(2) The output signals will continue until the conditions for breaker closure are satisfied.
d. Voltage Matching Option.
(1) When the voltage matching option is specified, the Synchronizer provides correction signals
to the generator voltage regulator or excitation system when the voltage difference between the
generator voltage and the bus voltage exceeds the 1% to 5% of the bus voltage range as determined by the front panel setting.
(2) Two types of voltage matching are available:
(a) "Bipolar" regulator correction signals for use with the summing point input of Basler
Electric voltage regulators (types: SSR, SR, KR, and XR) and exciter regulators (types: SSE and
SER-CB).
(b) A "raise/lower" output contact signal for with motor operated controls (Basler Electric
type: MOC).
(3) The voltage differential is selectable in 1% increments over a range of 1% to 5% by a
front panel accessible rotary switch.

1-2

(4) The correction signals are proportional to the magnitude of the sensed voltage difference
only for summing point outputs. The signals are output until the conditions for breaker closure are
satisfied. For output contacts, the contacts are closed until the conditions for acceptable breaker
closure are attained.

NOTE
If the voltage regulator is not properly adjusted, the BE3-25A output
may not be able to drive the regulator far enough to allow synchronization.

e. Dead Bus Closing Option. Upon detection of a dead bus condition, and when the generator
output voltage is above the minimum voltage level, the Synchronizer will automatically close the
breaker. The maximum allowable dead bus voltage is adjustable from 10 V to 50 V (at the 120 V
tap) by a front panel accessible potentiometer. This option can be disabled by the removal of a
terminal strip mounted jumper. For this option to function, input power must be from the generator or
from an external source other than the bus.

1-2. SPECIFICATIONS
Refer to Table 1-1 for the physical specifications and to Table 1-2 for the electrical specifications.

Table 1-1. Physical Specifications.


Storage Temperature:

-85F (-65C) to +185F (+85C)

Operating Temprature:

-40F (-40C) to +158F (+70C)

Shock:

Withstands up to 15 G's in any of three mutually perpendicular


axes.

Vibration:

Withstands the following:


5 to 18 Hz at 0.06 inch double amplitude
18 to 30 Hz at 1 G
30 to 48 Hz at 0.02 inch double amplitude
48 to 70 Hz at 2.5 G's

Weight:

4 lbs. (1.82 kg)

1-3

Table 1-2. Electrical Specifications.


Input Sensing and Operating Power:

120 Vac Nominal (80 - 140 Vac); 50 Hz,


120 Vac Nominal (87 - 153 Vac); 60 Hz,
240 Vac Nominal (180 - 264 Vac); 50 Hz,
240 Vac Nominal (167 - 304 Vac); 60 Hz.

Input Power Burden:

Operating: 11 VA,
Sensing: 2 VA.

Output Contact Rating:

Sync Contact (Close Breaker):


120 Vac @ 10 A resistive,
220 Vac @ 7.5 A resistive,
28 Vac @ 10 A resistive.
Raise/Lower (Voltage/Frequency Matching):
120 Vac @ 10 A resistive,
240 Vac @ 6 A resistive,
28 Vac @ 6 A resistive.

Summing Point Frequency Matching Output


(Open Breaker Condition):

Option A: +10 Vdc to 0 Vdc to provide 3 Hz of Control.


Option B: 4 Vdc to provide 3 Hz of Control.
Option W: 7 Vdc to provide 3 Hz of Control.

Summing Point Voltage


Matching Output (Open
Breaker Condition):

Option 1: +10 Vdc maximum.

1-3. STYLE CHART


The model number of the Synchronizer is a combination of letters and numbers indicating the
features and options. Refer to Figure 1-1 for the style chart which shows the various options and
features.

Figure 1-1. BE3-25A Style Chart.

1-4

SECTION 2
THEORY OF OPERATION
2-1. SYSTEM THEORY OF OPERATION (Refer to Figure 2-1)
a. Basic Unit(without Options) System Theory of Operation.
(1) As the prime mover brings the oncoming generator up to rated speed, the generated voltage
is applied to the Synchronizer. When the generator output voltage reaches 85 Vac for 50 Hertz and
60 Hertz systems, the Synchronizer will begin sensing both the generator and bus for frequency,
phase angle, and voltage.
(2) When the Synchronizer senses that all parameters for the oncoming generator are matched
with the bus, the Breaker Close Contact is energized to initiate a breaker closure that will connect the
oncoming generator to the bus.

Figure 2-1. System Block Diagram.


b. Basic Unit (With Options) System Theory of Operation.

NOTE
Even though the BE3-25A always has frequency matching, for purposes of discussion, it is considered an option because of the two
types that may be selected (summing point or contacts).

(1) Frequency/Phase Correction Option.


(a) If the output is a summing point type, then the frequency correction output signals are at
maximum until the generator frequency is corrected to within 3 Hertz of the station bus frequency.
Once the 3 Hertz limit is reached, the output signals become proportional to the difference

2-1

frequency (i.e.: the output for a 3 Hertz difference is larger than that for a 1 Hertz difference.) If the
Reset jumper is installed to provide internal operation, the signals will continue being output until the
phase angle is within the front panel setting. If the Reset function is being controlled externally, the
correction signals will continue until the external reset contacts are closed.
(b) If the output type is a contact closure, then the contacts are closed at any phase angle
greater than the front panel setting and are open only if the phase angle is 0 or if the phase angle is
within the front panel setting for acceptable phase conditions.

(2) Voltage Correction Option. An optional voltage option may be installed. When this option
is installed, it operates as follows:
(a) If the output is a summing point type, the Synchronizer outputs a "bipolar" correction
signal that is proportional to the amount of voltage difference (i.e.: the larger the voltage difference
between the bus voltage and the generator voltage, the larger the correction signal). If the Reset
jumper is installed to provide internal operation, the signals will continue being output until the
difference voltage is within the front panel setting. If the Reset function is being controlled externally,
the correction signals will continue until the external reset contacts are closed.
(b) If the output type is a contact closure, then the contacts are closed at any difference
voltage greater than the front panel setting and are open only if the difference voltage is within the
front panel setting for acceptable synchronizing conditions.

(3) Dead Bus Connection Option. This option will allow a breaker closure to occur even
though the bus is dead or extremely low (i.e.: a maximum of 10 - 50 Vac is present).

2-2. SYNCHRONIZER THEORY OF OPERATION (Refer to Figure 2-2)


a. Power Supply Theory of Operation. Either the oncoming generator or the bus voltage is fed to
the Synchronizer Power Supply. The Power Supply steps the voltage down and rectifies it to provide
a +12 Vdc and a -12 Vdc output.
b. Basic Unit Theory of Operation.
(1) Generator and Bus Sensing. The oncoming generator and bus voltages are monitored
and processed by the Generator Sensing and Bus Sensing Circuits. The outputs of these circuits
are applied to the 0.1 Hertz Frequency Difference Comparator, the Phase Angle Comparator, and
the Voltage Difference Comparator. The Sensing Circuit outputs are also applied to the following
Option Circuits: Dead Bus, Frequency/Phase Matching, and Voltage Matching.

(2) 0.1 Hertz Frequency Difference Comparator. The 0.1 Hertz Frequency Difference
Comparator compares the frequencies of the bus and the oncoming generator. IF the frequencies
are within 0.1 Hertz of each other, an output signal is applied to the Gating Network.
(3) Phase Angle Comparator. The Phase Angle Comparator compares the phase angle of
the bus to that of the oncoming generator. When the phase angle difference becomes less than 5
to 20 (as selected by the front panel potentiometer), the resulting output signal will be applied to
the Gating Network.
(4) Voltage Difference Comparator. The Voltage Difference Comparator compares the
voltage of the bus to that of the oncoming generator. When the voltage difference becomes less
than 5% to 15% (as selected by the front panel potentiometer), the resulting output signal will be
applied to the Gating Network.
(5) Gating/Time Delay Circuitry. When the 0.1 Hertz Frequency Difference Comparator
output, Phase Angle Comparator output, and the Voltage Difference Comparator output are all
present at the Gating Circuitry input, the Time Delay Circuit will be triggered to start counting down.
All three inputs must be present for at least 0.75 seconds before the Closing Contact Circuit is

2-2

energized. If any one of these input signals is removed prior to the end of the countdown (or timing)
period, the Closing Contact Circuit will not be enabled. Removal of the 0.75S DELAY jumper will
bypass this time delay function and thereby provide instantaneous operation of the Closing
Contact Circuit.

(6) Closing Circuit.


(a) When energized, the Closing Contact will cause the front panel SYNC indicator to illuminate and the Breaker Closing Output Contacts to close. A reset signal will also be generated to
cause a reset of all control signals.
(b) The front panel TEST switch, when in the TEST position, will allow the front panel
SYNC indicator only to function. The Closing Contact Circuit will be inhibited.
c. Dead Bus Option Theory of Operation. When the sensed bus voltage is less than the dead bus
setting, an output signal is applied to the output circuit to energize the Sync Output Relay and to
illuminate the front panel SYNC indicator. A front panel accessible potentiometer determines the
voltage level for a "dead bus".
d. Frequency/Phase Matching Option Theory of Operation.

NOTE
Even though the BE3-25A always has frequency matching, for purposes of discussion, it is considered an option because of the two
types that may be selected (summing point or contacts).

(1) The Frequency/Phase Matching Circuit will output signals proportional to the difference
frequency and input them to the Gate Circuit. When the slip (difference) frequency exceeds 3
Hertz, these correction signals will be at their maximum level. Frequency correction signals are
applied to the output circuits when the sensed input voltages (bus and generator) are above the
minimum voltages given in Table 1-1.
(2) The frequency correction output will either be a "raise/lower" contact for use with motor
operated control (MOC) type governors or a "bipolar" type output for use with summing point type
electronic governors.
e. Voltage Matching Option Theory of Operation.
(1) When the voltage difference between the bus and the oncoming generator is greater than
1% - 5% of the bus voltage (as preselected by a switch), the Voltage Matching Circuit will apply a
signal to the Gate Circuit. Voltage correction signals will be applied to the output circuits when the
sensed input voltages (bus and generator) are above the minimum voltages given in Table 1-1.
(2) The voltage correction signals will drive either a "raise/lower" contact type output for use with
motor operated control (MOC) type voltage regulators or a "bipolar" type output for use with the
summing point type input of Basler Electric voltage regulators (types SSR, XR, SR, and KR) and for
exciter regulators (types SSE and SER-CB).

2-3

Figure 2-2. Synchronizer Block Diagram.

2-4

SECTION 3
CONTROLS, INDICATORS, & JUMPERS
3-1. CONTROLS
The BE3-25A controls are shown in Figure 3-1 and are described in Table 3-1.

NOTE
Not all controls are on all styles.
Table 3-1. Controls.
CONTROL

FUNCTION

TEST/OPERATE Switch

Selects either the TEST or the OPERATE Mode.

% VOLT MATCH (5-15)


Potentiometer

Selects the maximum voltage difference between the generator


and the bus prior to allowing breaker closure.

BREAKER CLOSING
ANGLE Switch (5 - 20)

Selects the maximum allowable phase angle difference (in 5


increments) between the generator and the station bus prior to
breaker closure.

% VOLT MATCH (1, 2, 3, 4,


5) Switch

Used to select the voltage difference when using the voltage


matching option.

DEAD BUS (10 V - 50 V)


Potentiometer

Used to set the "dead bus" threshold.

GOV STAB Potentiometer

Used to adjust the stability and response time of the governor.

REG STAB Potentiometer

Used to adjust the stability and response time of the voltage


regulator.

OFFSET ADJ Potentiometer

Used to adjust the amount of offset voltage required for the


AMBAC International CU673C governor.

3-2. INDICATORS
The BE3-25A controls are shown in Figure 3-1 and are described in Table 3-2.
Table 3-2. Indicators.
INDICATOR

FUNCTION

POWER Indicator

Illuminates to indicate that power is applied to the Synchronizer.

SYNC Indicator

Illuminates to indicate that the generator is synchronized with


the bus.

3-1

NOTE
The front panel shown in Figure 3-1 is a composite to illustrate the
location of the controls and indicators. All of these may not be
included on a given style number. For the right-hand terminal strip
terminal designations, refer to Figure 3-2 and to Section 4.

INC

GOV.
STAB.

AUTO-SYNCHRONIZER
MODEL: BE3-25A
B240

BUS
SENSE
VOLTS
50/60HZ

B120
BC

LI

S T ED

UL

G240

GEN
SENSE
VOLTS
50/60HZ

G120
GC
P240

POWER
VOLTS
50/60HZ

P120
PC

5o

2 U 2

10o 15o o
20

+- B R E A K E R
CLOSING ANGLE
OFFSET
ADJ.

POWER

R1
RESET
R2
D1

5
15
% VOLT
MATCH

0.75 S.
DELAY

D2

INC
REG
STAB
DEAD
BUS

10V
50V
DEAD
SYNC
BUS
CONTACT
RATING

SC
SNO
SNC

10A AT 120 VAC OR 28 VDC


7.5A AT 220 VAC

Basler Electric
Highland, Illinois

2 3 4

SYNC

DB1
DB2

% VOLT
MATCH

TEST

Figure 3-1. Controls, Indicators, and Jumpers.

3-2

OPERATE

INC

GOV.
STAB.

AUTO-SYNCHRONIZER
MODEL: BE3-25A
BUS
STYLE: A 2 N

B240

SENSE
VOLTS
50/60HZ

B120
BC

LI

S T ED

UL

G240

GEN
SENSE
VOLTS
50/60HZ

G120
GC
P240

POWER
VOLTS
50/60HZ

P120
PC

2 U 2

10 o 15 o o
5
20
o

+- B R E A K E R
CLOSING ANGLE

G1

OFFSET
ADJ.

POWER

G2
LVC
LVNO

R1
RESET

LVNC

R2
D1

RVC

0.75 S.
DELAY

D2

RVNO
RVNC

SC
SYNC

SNO

DEAD
BUS

CONTACT
RATING

SNC

10A AT 120 VAC OR 28 VDC


7.5A AT 220 VAC

Basler Electric
Highland, Illinois

2 3 4

SYNC
5

% VOLT
MATCH

Figure 3-1A. Style A2N.

3-3

TEST

OPERATE

INC

GOV.
STAB.

AUTO-SYNCHRONIZER
MODEL: BE3-25A
BUS
STYLE: B 1 D

B240

SENSE
VOLTS
50/60HZ

B120
BC

ILS
L

I S T ED

UL

G240

GEN
SENSE
VOLTS
50/60HZ

G120
GC
P240

POWER
VOLTS
50/60HZ

P120
PC

2 U 2

WP

10 o 15 o o
o
5
20

+- B R E A K E R
GOV.
CLOSING ANGLE STABILITY
RANGE
POWER

G1
G2
VR1

VOLTAGE
REGULATOR

R1

VR2

RESET
R2

REGULATORY
POLARITY

D1

0.75 S.
DELAY

D2

DEAD
BUS DB1

SYNC

SNO

CONTACT
RATING

SNC

10A AT 120 VAC OR 28 VDC


7.5A AT 220 VAC

1
R

Basler Electric
Highland, Illinois

VR4

INC
REG
STAB

10V
50V
DEAD
BUS

SC

VR3

2 3 4

SYNC

DB2

% VOLT
MATCH

Figure 3-1B. Style B1D.

3-4

TEST

OPERATE

INC

GOV.
STAB.

AUTO-SYNCHRONIZER
MODEL: BE3-25A
BUS
STYLE: C 2 D

B240

SENSE
VOLTS
50/60HZ

B120
BC

LI

RAISE
FREQ.

S T ED
R

G240

GEN
SENSE
VOLTS
50/60HZ

G120
GC

POWER
VOLTS
50/60HZ

PC

20 o

LOWER
FREQ.

LFNC

POWER

LVC
LOWER
VOLTAGE

R1
RESET

RVC

0.75 S.
DELAY

D2

RAISE
VOLTAGE

10V
50V
DEAD
BUS

SC

SNC

DEAD
BUS DB1

10A AT 120 VAC OR 28 VDC


7.5A AT 220 VAC

1
R

Basler Electric
Highland, Illinois

RVNO
RVNC

SYNC
CONTACT
RATING

SNO

LVNO
LVNC

R2
D1

LFNO

+- B R E A K E R
CLOSING ANGLE

P240
P120

10 15
o

LFC

2 U 2

RFNO
RFNC

UL

RFC

2 3 4

SYNC
5

% VOLT
MATCH

Figure 3-1C. Style C2D.

3-5

DB2

TEST

OPERATE

INC

GOV.
STAB.

AUTO-SYNCHRONIZER
MODEL: BE3-25A
STYLE: W 1 D
BUS

B240

SENSE
VOLTS
50/60HZ

B120
BC

C
1712/1724

I S T ED

2301

UL

G240

GEN
SENSE
VOLTS
50/60HZ

G120
GC
P240

POWER
VOLTS
50/60HZ

P120
PC

10 15

2301A

2 U 2

20 o

+- B R E A K E R
CLOSING ANGLE

GOV.
STABILITY
RANGE

POWER
VOLTAGE
REGULATOR

R1
RESET
R2

REGULATOR
POLARITY

D1

0.75 S.
DELAY

D2

INC
REG
STAB
DEAD
BUS

50V
10V
DEAD
SYNC
BUS
CONTACT
RATING

SC
SNO
SNC

10A AT 120 VAC OR 28 VDC


7.5A AT 220 VAC

1
R

Basler Electric
Highland, Illinois

2 3 4

SYNC

G2
VR1
VR2
VR3
VR4

DB1
DB2

% VOLT
MATCH

Figure 3-1D. Style W1D.

3-6

G1

TEST

OPERATE

3-3. JUMPERS
The BE3-25A jumpers are shown in Figure 3-1 and Figure 3-2 and are described in Table 3-3.

NOTE
Not all jumpers are required for all styles.
Table 3-3. Jumpers.
JUMPER

FUNCTION

RESET Jumper

Used to enable the internal reset function. Refer to paragraph


1-1.b.3 and 2-1.b.1.a.

0.75 S DELAY Jumper

Used to enable the 0.75 second delay to occur between


synchronization and breaker closure enable.

GOV STABILITY RANGE


Jumper

Used to select the governor stability range (system response


time). Refer to Figure 3-2.

REGULATOR POLARITY
Jumper

Used to select the Synchronizer polarity output for correct


regulator operation.

DEAD BUS Jumper

Used to enable the Dead Bus Option.

Figure 3-2. Governor Stability Jumper

3-7

SECTION 4
INSTALLATION & OPERATION
4-1. INSTALLATION
The unit is convection cooled and should not be mounted near heat generating equipment or
inside of totally enclosed switchgear where the temperature rise could exceed the Synchronizer's
operating limit. Vertical mounting is recommended to obtain optimum convection cooling. Refer
to Figure 4-1 for dimensions and mounting holes.

1.0 (25)

6.5 (165)
4.5 (114)

2.9 (73)
2.6 (65)
0.218 (6) DIA.
MOUNTING
4 PLACES

0.5
(13)

6-32 TERMINAL
SCREW ON
0.375 CENTERS
TYP. 32 PLCS.

9.0
(229)

9.5
(241)

8.5
(216)

NOTE: ALL DIMENSIONS ARE IN INCHES (MILLIMETERS).

Figure 4-1. BE3-25A Outline Drawing.

4-2. INTERCONNECTION
a. Power and Sensing Connections. Connect the power and sensing inputs to the BE3-25A as
shown by Figures 4-2 through 4-5.

4-1

Figure 4-2. Power and Sensing Connection, 240 Vac, Power From Bus.

Figure 4-3. Power and Sensing Connection, 240 Vac, Power From Generator.

4-2

BE3-25A

Figure 4-4. Power and Sensing Connection, 120 Vac, Power From Bus.

Figure 4-5. Power and Sensing Connection, 120 Vac, Power From Generator.

4-3

b. Circuit Breaker (SYNC) Connection. Connect the circuit breaker to the BE3-25A as given in
Table 4-1.
Table 4-1. BE3-25A and Breaker Connections.
Breaker Input

BE3-25A SYNC Output

SC

NO

SNO

NC

SNC

c. Voltage Regulator and/or Governor "Raise/Lower" Connections. Connect the "raise/lower"


contact outputs as shown by Figure 4-6.
FREQUENCY
MATCHING OPTION
"C"
(SEE NOTE 1)

VOLTAGE
MATCHING OPTION
"2"
(SEE NOTE 2)

OR

RAISE

NOTES:
1. TERMINALS ARE DESIGNATED WITH
PREFIX RF OR LF.
2. TERMINALS ARE DESIGNATED WITH
PREFIX RV OR LV.

LOWER

BE3-25A
C

NO

NC

NO

NC

TO VOLTAGE
REGULATOR
OR
GOVERNOR
INPUT
VOLTAGE

AUXILIARY LIMIT SWITCHES


-

+
4

10

11

12

13

11

12

13

CW

BASLER
MOTOR OPERATED
CONTROL

Figure 4-6. Raise/Lower Contact Interconnection.


d. Summing Point Governor Connections. Connect the summing point governor to the BE325A as shown by Figures 4-7 through 4-12.

4-4

Figure 4-7. Barber Coleman DYN1 Interconnection.

Figure 4-8. Barber Coleman ILS Interconnection.

4-5

Figure 4-9. Woodward 2301 Interconnection.

Figure 4-10. Woodward 1712-1724 Interconnection.

Figure 4-11. Woodward 2301A Interconnection.

4-6

Figure 4-12. AMBAC International CU673C Interconnection.

e. Summing Point Voltage Regulator Connection. Connect the voltage regulator to the BE325A as shown by Figures 4-13 through 4-17.

Figure 4-13. KR, SR-F, SR-E, and SR-H Interconnection.

4-7

Figure 4-14. SR4A and SR8A Interconnection.

Figure 4-15. XR2001, XR2002, and XR2003 Interconnection.

Figure 4-16. SSE and SER-CB Interconnection.

4-8

Figure 4-17. SSR Interconnection.

4-3. OPERATION
a. Initial Set-Up.

NOTE
Perform only those steps that are applicable to your BE3-25A as
indicated by parenthesis.

NOTE
If the governor and the voltage regulator are not properly adjusted
(refer to the individual governor and voltage regulator manuals),
the BE3-25A may not be able to drive the governor or voltage
regulator enough to allow synchronization.

(1)

(All Models.) Set the front panel TEST/OPERATE switch to the TEST position.

(2)

(All Summing Point Models.) If the internal reset feature is desired, connect the external jumper (if not already installed) across terminals R1 and R2. If the reset function
is to controlled externally, remove the jumper and connect the external control contacts (a switch or 52a contacts) across the terminals.

(3)

(All Models.) To enable the 0.75 second delay between synchronization and breaker
closure, connect an external jumper (if not already installed) across terminals D1 and
D2. To provide instantaneous time between synchronization and breaker closure,
remove any jumper connected across these terminals.

(4)

(Option D Only.) To enable the dead bus option, connect an external jumper (if not
already installed) across terminals DB1 and DB2. To disable this option, remove any
jumper connected across these terminals.

(5)

(Option 1 Only.) Refer to Figures 4-13 through 4-17 as appropriate, and either remove or install the Regulator Polarity Jumper at terminals VR3 and VR3 as directed
therein.

4-9

(6)

(Options A, B, or W Only.) Refer to Figure 3-2 and connect the Governor Stability
Jumper for medium response time at terminals G1 and G2.

(7)

(Options 1 or 2 Only.) Rotate the front panel % VOLT MATCH switch to select the
desired voltage difference (1%, 2%, 3%, 4% or 5%) that is required for synchronization.

(8)

(All Models except Options 1 and 2.) Set the front panel % VOLT MATCH potentiometer to midrange.

(9)

(All Models.) Set the front panel BREAKER CLOSING ANGLE switch to the desired closing angle (5, 10, 15, or 20).

(10)

(All Models.) Set all other controls to midrange.

(11)

(Option A Only.) Set the governor offset as follows:


(a)

Install the reset jumper to terminals R1 and R2.

(b)

While observing a frequency meter, adjust the generator frequency until the
front panel SYNC indicator is illuminated.

(c)

Adjust the front panel OFFSET ADJ potentiometer until there is no frequency
correction signals output from the Synchronizer.

(d)

If external reset is desired, remove the jumper from terminals R1 and R2, and
then connect the external contacts to the terminals.

(12)

(All Models Except Options 1 and 2.) Adjust the voltage difference between the bus
and the generator to the desired level. Then adjust the front panel % VOLT MATCH
potentiometer until the front panel SYNC indicator just goes out.

(13)

(Option D Only.) Decrease the bus voltage to the desired "dead bus" threshold and
then adjust the front panel DEAD BUS 10 V - 50 V potentiometer until the front panel
SYNC indicator just lights. Return the bus voltage to the previous level.

(14)

(All Models.) Shut down the prime mover and then restart the prime mover while observing the generator frequency and voltage. If needed, adjust the governor Stability
and/or the voltage regulator Stability potentiometers for the best response time with
frequency or voltage hunting (oscillations).

b. Pre-Operational Check-Out.
(1)
Verify that all connections are correct per the appropriate interconnection diagram.
(2)

Check that the front panel TEST/OPERATE switch is in the OPERATE position.

(3)

Verify that all jumpers are either installed or removed per the application of the
Synchronizer.

(4)

Ensure that all controls are set per the application of the Synchronizer.

c. Operation.
(1)
When power is applied, observe that the front panel POWER indicator illuminates.
(2)

When the Synchronizer has synchronized the oncoming generator with the bus, observe that the front panel SYNC indicator is illuminated.

4-10

SECTION 5
MAINTENANCE INSTRUCTIONS
5-1. PREVENTIVE MAINTENANCE

A periodic inspection of the unit should be made to


ensure that it is clean and free from accumulations of dust and moisture. Ensure that all wire connections are clean and secure.

5-2. TROUBLESHOOTING
The more common malfunctions and their appropriate repair procedures are listed in Table 5-1.
Table 5-1. Troubleshooting Chart.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. POWER Indicator Does Not Illuminate.
Step 1. Check all wiring for proper connections.
If wiring is not proper, reconnect wiring.
If wiring is proper, proceed to step 2.
Step 2. Verify that input power is of correct value.
If voltage is not of correct value, connect proper level of voltage to Synchronizer.
If voltage is of correct value, proceed to step 3.
Step 3. Replace Synchronizer if the above steps fail to correct the problem.

2. No Governor Control.
Step 1. Check all wiring for proper connections.
If wiring is not proper, reconnect wiring.
If wiring is proper, proceed to step 2.
Step 2. Check for defective governor.
If governor is defective, refer to the governor instruction manual.
If governor is not defective, proceed to step 3.
Step 3. Measure Synchronizer output contacts with a meter or measure the Synchronizer Vdc
output with a high impedance meter (VTVM or DVM with 1M ohm input) for summing
point output.
If output is defective, replace Synchronizer.
5-1

Table 5-1. Troubleshooting Chart - Continued.


MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
3. No Voltage Regulator Control.
Step 1. Check all wiring for proper connections.
If wiring is not proper, reconnect wiring.
If wiring is proper, proceed to step 2.
Step 2. Check for defective voltage regulator.
If voltage regulator is defective, refer to the voltage regulator instruction manual.
If voltage regulator is not defective, proceed to step 3.
Step 3. Check for defective motor operated control.
If motor operated control is defective, refer to the motor operated control instruction manual.
If motor operated control is not defective, proceed to step 4.
Step 4. Measure Synchronizer output contacts with a meter or measure the Synchronizer Vdc
output with a high impedance meter (VTVM or DVM with 1M ohm input) for summing
point output.
If output is defective, replace Synchronizer.
4. SYNC Indicator Illuminates, But Breaker Does Not Close.
Step 1. Check position of TEST/OPERATE switch.
Set switch to OPERATE if in TEST position.
If switch was in OPERATE position, proceed to step 2.
Step 2. Check all sync connections and wiring for proper connections.
If wiring is not proper, reconnect wiring.
If wiring is proper, proceed to step 3.
Step 3. Check for defective breaker.
If breaker is defective, refer to the breaker instruction manual.
If breaker is not defective, proceed to step 4.
Step 4. Replace Synchronizer if the above steps fail to correct the problem.

5-2

Table 5-1. Troubleshooting Chart - Continued.


MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
5. SYNC Indicator Does Not Illuminate.
Step 1. Check all sync connections and wiring for proper connections.
If wiring is not proper, reconnect wiring.
If wiring is proper, proceed to step 2.
Step 2. Check that phase angle, voltage difference, and/or slip frequency limits are not being
exceeded.
If limits are being exceeded, adjust governor and/or voltage regulator.
If limits are not being exceeded, proceed to step 3.
Step 3.

Replace Synchronizer if the above steps fail to correct the problem.

5-3

SECTION 6
REPLACEMENT PARTS
6-1. GENERAL
The following list (Table 6-1) describes the components and assemblies of the generator excitation system that have maintenance significance. Refer to the appropriate manual for replacement
parts information. When ordering parts from Basler Electric Company, be sure to specify the system number (9 1661 00 100), reference, Basler part number, quantity, and description.

Table 6-1. Replacement Parts


Basler
Reference

Part Number

Qt

Description

K1

17311

Relay

K201,K202,
K801,K802

15514

Relay

K701

17049

Relay

---------------

9 1661 01 100

Printed Circuit Board (Specify Style Number when


ordering)

6-1

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