UNITROL 5000 User's Manual Appendix,: Unitrol 5000 AVR Controls ON-LINE Maintenance Instructions

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UNITROL 5000 Users

Manual
Appendix,
Chapter 8
UNITROL 5000 AVR Controls ON-LINE
Maintenance Instructions
3BHS122349 E01 Rev. A, 17.01.2007/ Mo

G. Meier
19.07.2002 Instruction
M Gille
22.07.2002 On line maintenance
ATPE
UN 5000 AVR controls
Based on:
Prep.
Appr.
Resp.
dept.
Document number
ABB Switzerland Ltd
3BHS122349 E01
No. of p.
18
Lang.
en
Rev. ind.
Page
Content:
1
Introduction ................................................................................................................ 3
Backup Operation (EGC active) ................................................................................ 4
D5x- Maintenance sequence.................................................................................. 4

3.1
Prerequisites .................................................................................................. 4
3.2
Note ............................................................................................................... 5
3.3
Maintenance sequence .................................................................................. 5
A5x- Maintenance sequence.................................................................................. 9

4.1
Prerequisites .................................................................................................. 9
4.2
Maintenance sequence .................................................................................. 9
Q5x- Maintenance sequence after 1st fault transfer to standby channel .......... 12
5.1
Prerequisites ................................................................................................ 12
5.2
Maintenance sequence ................................................................................ 12
Q5x- Maintenance sequence after 2nd fault transfer to EGC back up ctrl ......... 15
6.1
Prerequisites ................................................................................................ 15
6.2
Maintenance sequence ................................................................................ 15
Maintenance of a faulty EGC board ........................................................................ 15

7.1
D5x-Configuration................................................................................... 15
7.2
Q5x-Configuration .................................................................................. 15
7.2.1
EGC fault in the non active standby channel ................................. 15
7.2.2
EGC fault in the active (duty) channel ............................................ 17
Document number
ABB Switzerland Ltd
3BHS122349 E01
Lang.
en
Rev. ind.
Page
1 Introduction
ON LINE 1) maintenance of UNITROL 5000 AVR controls (MUB, COB) is possible
under following conditions:
Type Configuration
Hardware 2)
ON LINE maintenance
S5xD5xA5xQ5x-
1* (MUB, COB)
1* (MUB, COB, EGC)
2* (MUB, COB)
2* (MUB, COB, EGC)
NO
YES 3)
YES 4)
YES 5)
Single AVR
Double channel AVR
Dual AUTO channel AVR
Quadro: Dual A + Backup
chapter 3
chapter 4
chapter 5-6
Maintenance of the back up controller EGC

D5xQ5x-
Double channel AVR

Quadro: Dual A + Backup
according
1* (MUB, COB, EGC)

2* (MUB, COB, EGC)
YES 3)
YES 5)
chapter 7.1
chapter 7.2
1) ON LINE means Generator breaker closed and System synchronized to grid

2) One AVR unit (channel) includes hardware specified within brackets
3) Maintenance within single AVR unit after emergency transfer to EGC
4) Maintenance of non running (standby) AVR unit after emergency channel
transfer.
5) Maintenance of COB, MUB of the AVR unit having the active backup controller
EGC after 2 emergency transfers:
1. Duty to standby channel unit and
2. COB to EGC in the latter channel unit.
It is recommended that maintenance action should take place after the 1st
emergency transfer.
Abbreviations:
MUB Measuring Unit Board
UNS 2881
COB
Control Board
UNS 2880
EGC
Extended (back up) Gate Controller
UNS 2882
SPA
Service Panel
UNS 0874
LCP
Local Control Panel
ECT
Excitation Control Terminal
CMT
Windows
AF C094
PB D190A
based Commissioning and Maintenance Tool
DCS DOWNLOAD program
Download program
Document number
ABB Switzerland Ltd
3BHS122349 E01
Lang.
en
Rev. ind.
Page
2 Backup Operation (EGC active)

Operation is kept by the back up field current regulator BFCR. There are only limited
remote controls via the common fast I/O board FIO available:
Inputs:
1. RAISE (DI 03), LOWER (DI 04) commands for field current
2. EXCITATION STOP (DI 02) command (FCB will be tripped if this option
selected)
3. FCB TRIP (DI 10) command (e.g. TRIP from protection)
Outputs:
4. EXCITATION ON (DO 17)
5. FCB OFF command (DO 04)
6. FCB TRIP command (DO 02)
7. ALARM relay (DO 18)
8. BACK UP control active (DO 07)
All serial links may be dead or their information might be wrong depending on the
status of COB.
The local control panel LCP may indicate wrong status and measuring signals
("frozen" status and signals) due to stopped ARCnet communications while no COB
available.
The analog outputs may be wrong.
The only valid analog signal is the excitation current signal driven by EGC,
which is hard wired in parallel to the equivalent FIO output AO3 (switched by
relays on EGC and FIO)
3 D5x- Maintenance sequence
3.1 Prerequisites
1.
Spare parts:
AVR unit UNS4881 V2/V4 including MUB, COB and EGC
or separate MUB and/or COB boards.
2.
ECT or CMT and its instructions
3.
ECT: Valid Parameter file xxxx.csv "as commissioned" of the physical channel to
be repaired. (Default name: System Dump, date, time)
CMT: Valid Parameter file xxxx.qop "as commissioned" of the physical channel to
be repaired.
4.
DCS DOWNLOAD program and the valid Firmware 41D30n.rom file from release
41.304 or newer.
ECT: Check the firmware required by opening the SETTINGS, Information,
System Information AVR Settings and reading SW version from the signal 11203
and its substatus from signal 11205.
Document number
ABB Switzerland Ltd
3BHS122349 E01
Lang.
en
Rev. ind.
Page
CMT: Check the firmware required by running CMT in Off-line Mode, opening
xxxx.qop and reading SW version from the signal 11203 and its substatus from
signal 11205.
5.
Estimated repair time under this requisite is less than 2 h.
3.2 Note
1. The required firmware release which supports the following maintenance steps is
41.304 Substatus 0 or newer.
2. Maintenance will be done at a unit having the live EGC controlling the excitation.
Therefore special attention has to be taken into account while removing or
installing parts i.e. don't interrupt connection of EGC to FIO or CIN.
3. Secure start of COB and transfer back to AUTO mode is possible only if the
current is >2% of set I_EXC_SENSE_A (507) during start up of COB.
3.3 Maintenance sequence
1. Power OFF
Switch OFF the 24 VDC power to the MUB (e.g. unplugging -X1 on MUB).
2. Unplugging
All connectors to COB and/or MUB may now be unplugged in any sequence.
Be careful that no connection of the live EGC to FIO and CIN is lost.
CAUTION!
Be carefull before displugging the X3 connector of the MUB board.
An open current circuit will destroy the current transformer.
Short circuit CT terminals before disconnecting MUB board.
3. Replacing hardware
After having set up the hardware (jumpers, node address) of the new board(s)
according to the former boards the COB and/or MUB may now be replaced.
To replace the MUB, it is recommended to replace the whole hinged chassis and
reconnect its grounding link.
Up to step 7 only the interconnection between MUB and COB (-X37 and -X31) are
allowed to be plugged in to avoid any interaction to the running system (isolated
mode for configuring COB).
4. Check COB status
Switch ON the 24 VDC power to the MUB (supply connector -X1).
The COB will boot subsequently.
COB Board has BOOT SW only (DEFAULT from stock):

The COB 7-segment LED A100 (upper left one) shows "E"-"0"-"5", and
therefore the valid firmware 41.304 Substatus 0 or newer has to be
downloaded first.
Document number
ABB Switzerland Ltd
3BHS122349 E01
Lang.
en
Rev. ind.
Page
In all other cases ("F"-"1"-"3", "F"-"1"-"8" etc.):

Check the running firmware version from the signal 11203 and its Substatus
from signal 11205. If they dont comply with the required version according to
the file "as commissioned", then the valid firmware 41.304 Substatus 0 or
newer has to be downloaded first.
5. After rebooting
With the valid firmware, COB returns several Faults, Alarms and Events, e.g:
110
+ System restart
Boot event
55
CH ARCnet fault
after approx. 15 s, because -X61
disconnected
144
+Aux. DC fail
because -X1/2 disconnected
142
+Auxiliaries OFF
13
Not configured !
Configuration missing
18
Backup read fault
no valid parameter file available
6. Parameter download
Set Parameters with CMT:
- Open parameter file "as commissioned"
- Download parameter to COB
- Change mode to "Online"
- Set Clock parameters 1221 to 1227
- Start the application program (if used) by setting 2504 to 1==ENABLED
- Save the parameters by using BACKUPSTOREMODE (11202)
- Save the parameter file (ParSig, Save As) if there is any deviation to the "as
commissioned" file. This generates xxxxx.qop and xxxxx.txt files on the disk.
Set Parameters with ECT:
- Reload parameter file "as commissioned" from the hard disk ECT or an external
storage device
- Export and save the parameter file (Parameters, Snapshot, upload, save) if there
is any deviation to the "as commissioned" file. This generates xxxxx.csv file on
the hard disk or an external storage device.
- Switch OFF the power to MUB by unplugging -X1
The new COB now contains the same Parameters and Application Program as the
replaced one.
7. Reconnecting everything
Except MUB supply plug -X1, all other MUB and COB connectors shall now be
replugged.
8. Start up AVR unit (MUB, COB)
Document number
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Rev. ind.
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NOTE: this operation is save only if the excitation current is >2% of the set
value I_EXC_SENSE_A (507) during start up !
Switch ON the power to MUB (-X1). COB is recognizing that there is a running
EGC back up controller, by once reading EGC ready DI52 AND excitation current
is >2% of value set to parameter 507.
This leads to following reaction:
- All digital outputs of COB are disabled
- SR1/2 of COB are disabled and firing pulses are blocked
- Just after the EVENT 110 System restart, the EVENT 154 +EGC run at
restart is entered to the fault logger and Bit 6 of USER_EVENT_WORD (11111)
is set.
9. Check the fault logger
The EVENT 154 +EGC run at restart must have been entered, telling COB the
right status of back up operation.
If not:
- was the excitation current >2% during start up of COB
- is the firmware version correct?
The Online maintenance is only supported by release 41.304 Substatus 0 or
newer
- is the connection COB to EGC (-X5) o.k.?
10. SERVICE Mode to balance to the correct mode of operation
The COB must be put into SERVICE mode by ECT, CMT or SPA LOCAL
command and following mode of operation must be set manually:
- MANUAL control by altering signal 10302 MODE SELECTION. [Manual control
is recommended to keep the same control mode (FCR) after having transferred
back to COB]
- EXC ON by START button on SPA, ECT or CMT (sets COB to status EXC ON)
11. Back to REMOTE control
Select REMOTE control by ECT, CMT or SPA to enable EGC TEST mode.
12. EGC TEST mode of operation
To enable the transfer from EGC back to COB, EGC TEST mode must be SET by
altering 11233 to ON (==1).
Now there is the same status as if testing EGC back up functionality.
13. COB balancing to EGC
The COB (with MAN mode of operation) now follows the EGC. This has to be
checked by comparing Uc from COB [Signal U_CTRL_OUT_CH (12110)] with Uc
from EGC [Signal Uc_EGC (10508)]. Both signals have to be in the same range of
value (<5% difference between them) before the EGC to COB transfer should take
place.
14. transfer back to COB
The change over to COB (MAN) takes place with the transition of resetting the
EGC_TEST signal (11233) from ON (==1) to OFF (==0) with following reaction:
- All digital outputs are enabled
- SR1/2 are enabled and firing pulse released
- EGC stops operation by disabling SR1/2 and stopping firing pulses.
- Self reset of the EVENT 154 (-EGC run at restart) is entered to the fault logger
and the BIT 6 of the USER_EVENT_WORD 11111 is reset.
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15. and operation as needed

The operator may now select for the operation mode and condition (AUTO, VAR,
P.F. control) needed.
Document number
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Rev. ind.
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4 A5x- Maintenance sequence

4.1 Prerequisites
1.
Spare parts:
AVR unit UNS4881 V1/3 including MUB, COB
2.
3.
be repaired.
4.
41.304 or newer.
CMT: Valid Firmware 41D30n.rom file from release 41.304 or newer.
Check the firmware required by running CMT in Off-line Mode, opening xxxx.qop
and reading SW version from the signal 11203 and its Substatus from signal
11205.
5.

1. For safety reasons set the active channel to SINGLE channel configuration
by parameter 308 = S5.-. This stops the 2-channel communication and resets
the alarms coming from the faulty standby channel. The faulty (standby) channel, if
supplied, sets subsequently Fault F12 "Standby S5/D5 conf.".
2. Faulty Channel Power OFF
Switch OFF the 24 VDC power to the MUB (e.g. unplugging -X1 on MUB)
3. Unplugging faulty channel hardware
All outgoing connection cables to COB and MUB may now be unplugged in any
sequence.
CAUTION!
After having set up the hardware (jumpers, node address) of the new boards
according to the former boards the whole AVR unit UNS 4881 V1 may now be
replaced by the spare one. Reconnect the grounding link to the AVR unit.
Document number
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Rev. ind.
Page
Up to step 8 only the interconnection between MUB and COB (-X37 and -X31) are
allowed to be plugged in to avoid any interaction to the running system (isolated
mode for configuring COB).
5. Check COB status

downloaded first.

newer must be downloaded first.
6. After rebooting
with the valid firmware, COB returns several Faults, Alarms and Events, e.g:
110
+ System restart
Boot event
55
CH ARCnet fault
disconnected
144
+Aux. DC fail
142
+Auxiliaries OFF
13
Not configured !
18
Backup read fault
- Open parameter file as commissioned
- Save the parameter file (ParSig, Save As) if there is any deviation to the
as commissioned file. This generates xxxxx.qop and xxxxx.txt files on the
disk.
storage device
Document number
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3BHS122349 E01
Lang.
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Rev. ind.
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10
replaced one.
Except MUB supply plug -X1, all other MUB / COB connectors shall now be
replugged.
9. Start up repaired AVR channel
The COB will boot and show at least fault F12"Standby S5/D5 conf." (see 1.)
After booting the operation status will be set up automatically to fit with the running
channel:
- CHANNEL OFF
- EXC_ON
- AUTO or MAN control
- Imposed control OFF or ON
- Imposed control mode VAR or P.F. control
- All alarm are reset (only the dot is ON at COBs 7-segment displays) according
to the state of the active channel.
10. release full dual channel redundancy
Set the parameter 308 of the active AVR unit to correct "A5.-(1)" or "A5.-(2)"
position to release full dual channel functionality again and RESET fault F12.
11. check it
After channel balancing (follow up) has finished, channel transfer (via LCP, SPA,
ECT or CMT at LOCAL or SERVICE mode) should be done to test correct function
of the repaired channel.
12. and release it for normal operation
The operator may select for the operation mode and condition (AUTO, VAR, P.F.
control) needed after REMOTE control has been released.
Document number
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Lang.
en
Rev. ind.
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11
5 Q5x- Maintenance sequence after 1st fault transfer to standby channel

5.1 Prerequisites
1.
Spare parts:
AVR unit UNS4881 V2/V4 including MUB, COB and EGC
2.
3.
be repaired.
4.
41.304 or newer.
CMT: Valid Firmware 41D30n.rom file from release 41.304 or newer.
Check the firmware required by running CMT in Off-line Mode, opening xxxx.qop
and reading SW version from the signal 11203 and its Substatus from signal
11205.
5.

1. For safety reasons set the active channel to Double channel configuration
by parameter 308 = D5.-. This stops the 2 channel communication and resets
the alarms coming from the faulty standby channel, but still keeps the redundancy
by the EGC back up controller in this channel. The faulty (standby) channel, if
Switch OFF the 24 VDC power to the MUB and EG (e.g. unplugging MUB and
EGC
-X1)
3. Unplugging faulty channel
All outgoing connection cable to COB, MUB and EGC may now be unplugged in
any sequence.
CAUTION!
Document number
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Rev. ind.
Page
12
After having set up the hardware (jumpers, node address) of the new boards
according to the former boards the whole AVR unit UNS 4881 V2 may now be
replaced by the spare one.
Reconnect the grounding link to the AVR unit.
Up to step 8 only the interconnections between MUB and COB (-X37 and -X31)
are allowed to be plugged in to avoid any interaction to the running system
(isolated mode for configuring COB).
5. Check COB status

downloaded first.

newer must be downloaded first.
6. After rebooting
with the valid firmware, COB returns several Faults, Alarms and Events, e.g:
110
+ System restart
Boot event
55
CH ARCnet fault
disconnected
144
+Aux. DC fail
142
+Auxiliaries OFF
13
Not configured !
18
Backup read fault
- Open parameter file as commissioned
- Save the parameter file (ParSig, Save As) if there is any deviation to the
as commissioned file. This generates xxxxx.qop and xxxxx.txt files on the
disk.
storage device
Document number
ABB Switzerland Ltd
3BHS122349 E01
Lang.
en
Rev. ind.
Page
13

replaced one.
Except MUB and EGC supply plugs -X1, all other MUB, COB and EGC connectors
shall now be re plugged.
NOTE: With firmware release 41.304, never switch ON EGC supply first. In this
case the 2nd booting COB recognizes the running EGC in the standby channel and
generates the EVENT 154 "+EGC run at restart, which can only be cleared by
booting COB first.
Switch ON AVR by re plugging the MUB'
s supply connectors -X1. The COB will
boot and show at least Fault F12 "Standby S5/D5 conf." (see 1.) and Alarm A153
+EGC fault.
After COB booting the operation status will be set up automatically to fit with the
running channel:
- CHANNEL OFF
- EXC_ON
- All alarms are reset according to the state of the active channel.
Switch ON EGC by re plugging the supply connectors -X1. The EGC will boot and
COB resets Alarm A153 -EGC fault if everything is o.k.
SET the parameter 308 of the active AVR unit to correct "A5.-(1)" or "A5.-(2)"
pos ition to release full dual channel functionality again and RESET fault F12.
11. check it
ECT or CMT at LOCAL or SERVICE mode) should be done to test correct function
of the repaired channel. EGC function should be tested by EGC_TEST_CMD
(11233).
Document number
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3BHS122349 E01
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Rev. ind.
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14
6 Q5x- Maintenance sequence after 2nd fault transfer to EGC back up ctrl
6.1 Prerequisites
As for chapter 3 and 4
1. Identify active channel: EGC either SR1 or SR2 LEDs on
2. Non active Channel Power OFF
Switch OFF the 24 VDC power to the whole AVR unit (e.g. unplugging MUB and
EGC -X1)
3. Repair active channel AVR first
by following Repair Instructions of chapter 3.
4. And then the faulty standby channel
by following the Repair instructions of chapter 5.
7 Maintenance of a faulty EGC board

7.1 D5x-Configuration
In Standby Mode the EGC is not ready anymore. This will raise the Alarm 153 EGC
fault.
It is strongly recommended to replace the whole AVR unit (or EGC board only) not
before next stand still, since there is a big risk loosing excitation while ON-LINE turning
down the active MUB/COB hinged chassis to get access to the EGC board.
It could also provoke too much mechanical stress to the ARCnet connector -X61 while
turning down.
COB still has MANUAL (field current regulator) capability in case of an AVR fault.
7.2 Q5x-Configuration
7.2.1 EGC fault in the non active standby channel
While there is an Alarm 153 EGC fault in the non active (standby) channel, the
redundancy is as of an A5x- configuration and not limited until a channel fault in the
active (duty) channel occurs.
Nevertheless the EGC should be replaced as soon as possible:
1. Set the active channel to Double channel configuration
by parameter 308 = D5.-. This stops the 2 channel communication and reset the
alarms coming from the faulty standby channel, but still keeps the redundancy by
the EGC back up controller in this channel. The faulty (standby) channel, if
Switch OFF the 24 VDC power to the MUB and EG (e.g. unplugging MUB and
EGC -X1)
3. Unplugging faulty channel
All outgoing connection cable to COB, MUB and EGC may now be unplugged in
any sequence.
Document number
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Rev. ind.
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15
CAUTION!
Prepare the spare EGC (taken out from the spare AVR unit) by setting the
hardware according to the installed board.
The EGC may now be replaced, preferably after the whole AVR unit has been
taken out of the cabinet.
Reinstall the AVR unit and its ground connections.
5. Firmware and Parameters
Not changed
Except MUB and EGC supply plugs -X1, all other MUB, COB and EGC connectors
shall now be re plugged.
Switch ON by replugging the EGCs and after that the MUBs supply connectors X1.
The COB will boot and show at least fault F12"Standby S5/D5 conf." (see 1.)
After booting the operation status will be set up automatically to fit with the running
channel:
- CHANNEL OFF
- EXC_ON
- All alarms are reset (only the dot is ON at COBs 7-segment displays) according
to the state of the active channel.
8. Clock
Check the clock parameters 1221 to 1227 and set them if required [only necessary
if the AVR (MUB, COB) was shut down too long (typical several days)].
Set the parameter 308 of the active AVR unit to correct "A5.-(1)" or "A5.-(2)"
position to release full dual channel functionality again and RESET fault F12.
10. check it
ECT or CMT at LOCAL or SERVICE mode) should be done to be able to test
correct EGC function by EGC_TEST_CMD (11233).
Document number
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3BHS122349 E01
Lang.
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Rev. ind.
Page
16
7.2.2 EGC fault in the active (duty) channel

If there is an Alarm 153 EGC fault in the active (duty) channel, the redundancy is as
of a Q5x- configuration, not limited at all, because channel transfer takes place prior
to a back up controller transfer.
Nevertheless the EGC should be replaced as soon as possible to keep back up control
available after a fault of the active channel.
To do so, follow instructions 7.2.1., after channel transfer.
Document number
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Rev. ind.
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17
REVISION
Rev. Page (P) Description
Ind. Chapt.(C)
1
Maintenance of the back up controller EGC:
1 line deleted
Date
Dept./Init.
01-09-27 ICEPRU GM
5.2
Step 9.: Start sequence modified
02-07-19
ATPE GM
3 - 15
4,9,12
5,9,12,16
ECT implemented
UNS4881 V1/V3 and V3/V4
Caution: short circuit CT terminals
07-01-17 / Mo
Document number
ABB Switzerland Ltd
3BHS122349 E01
Lang.
en
Rev. ind.
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18

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3BHS122349 E01 Rev. A, 17.01.2007/ Mo

ABB Switzerland Ltd

Backup Operation (EGC active) ................................................................................ 4

D5x- Maintenance sequence.................................................................................. 4

A5x- Maintenance sequence.................................................................................. 9

Maintenance of a faulty EGC board ........................................................................ 15

ABB Switzerland Ltd

Maintenance of the back up controller EGC

Double channel AVR

1* (MUB, COB, EGC)

1) ON LINE means Generator breaker closed and System synchronized to grid

Extended (back up) Gate Controller

Local Control Panel

Excitation Control Terminal

based Commissioning and Maintenance Tool

DCS DOWNLOAD program

ABB Switzerland Ltd

2 Backup Operation (EGC active)

ECT or CMT and its instructions

ABB Switzerland Ltd

Estimated repair time under this requisite is less than 2 h.

COB Board has BOOT SW only (DEFAULT from stock):

ABB Switzerland Ltd

In all other cases ("F"-"1"-"3", "F"-"1"-"8" etc.):

ABB Switzerland Ltd

ABB Switzerland Ltd

15. and operation as needed

ABB Switzerland Ltd

4 A5x- Maintenance sequence

ECT or CMT and its instructions

Estimated repair time under this requisite is less than 2 h.

4.2 Maintenance sequence

ABB Switzerland Ltd

COB Board has BOOT SW only (DEFAULT from stock):

In all other cases ("F"-"1"-"3", "F"-"1"-"8" etc.):

ABB Switzerland Ltd

ABB Switzerland Ltd

5 Q5x- Maintenance sequence after 1st fault transfer to standby channel

ECT or CMT and its instructions

Estimated repair time under this requisite is less than 2 h.

5.2 Maintenance sequence

ABB Switzerland Ltd

COB Board has BOOT SW only (DEFAULT from stock):

In all other cases ("F"-"1"-"3", "F"-"1"-"8" etc.):

ABB Switzerland Ltd

- Start the application program (if used) by setting 2504 to 1==ENABLED

ABB Switzerland Ltd

7 Maintenance of a faulty EGC board

ABB Switzerland Ltd

ABB Switzerland Ltd

7.2.2 EGC fault in the active (duty) channel

ABB Switzerland Ltd

Step 9.: Start sequence modified

ABB Switzerland Ltd

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