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MICROPROCESSOR-BASED
ACCURATE SYNCHRONIZER
USER MANUAL
ZX400 SERIES
MICROPROCESSOR-BASED
ACCURATE SYNCHRONIZER
USER MANUAL
VER. 11.1W
MANUAL SERIAL NO GR-200-019W
CONTENTS
Chapter 1
1. Features ......................................................................................... 1
2. Technical Specification .........................................................................................................3
3. Classification and naming .....................................................................................................4
Chapter 2
Chapter 3
1. Overview .............................................................................................................................20
2. System Requirements ..........................................................................................................21
3. Operation.............................................................................................................................21
Chapter 4
Chapter 1
1. Features
l High safety and reliability
Equipped with state-of-art 16 bit single-chip microprocessor, ZX400 is of dual CPU and
redundant structure. Its major switch-in output consists of two series-connected sub
output unit. So the device has very high safety and reliability.
l Quick synchronization speed and high precision
Using the modern control theories and the artificial intelligence concepts, ZX400 can
accurately estimate the switch-in angle. Using the PID regulation, it can accurately track
the voltage and the frequency of power system, insuring complete switch-in at the first
synchro point.
l High stability and strong ability in anti-interference
Built with low power-consumption electronic parts and high-quality switch power supply
as well as advanced multi-layer printed circuit, ZX400 is of characteristic of heat-stable,
well adoptive to voltage change. All input/output and power supply circuits are designed
as anti-wave with various reliable isolation measure deployed. It has passed through the
test of the electromagnetism compatibility and radiation, electrical fast pulse crowd
meeting to the national standards.
l The PT secondary cycle broken and lower voltage protection
The syn. voltage will drop in the cases of the broken PT circuit or the excitation loop
abnormity. In this situation ZX400 will alarm and refuse to send out synchronization
signal. It will display the lower voltage of the system or the generator on the screen.
Criteria of lower voltage value can be set up respectively.
ZX400 can automatically compensate the difference of phase angle and the
difference of voltage caused by the main transformer /Y wiring, thus it is not
necessary to use phase angle transformer.
2. Technical Specification
2.1 Power Supply:
AC85~260V or DC110~370V,
Power consumption: <50W.
2.2 Input Signals:
Secondary Voltages of voltage transformer (TV) on both sides of the synchronization
point.
Voltage:
AC50~140V,
Frequency:
44Hz~56Hz,
Power consumption: <1VA.
2.3 On-off Signal Input:
All are passive empty contacts.
2.4 On-off Signal Output:
Relay empty contact.
Contact capacity: DC220V/5A.
2.5 Synchronization Object: 14 / 8 / 4
2.6 Set-up range of frequency difference:
-0.30Hz~+0.30Hz, calibration: 0.01Hz.
2.7 Set-up range of voltage difference:
-10V~+10V, calibration: 0.1V
2.8 Set-up range of Lead-time:
10ms~990ms, Calibration: 10ms.
2.9 Working temperature:
-10C~50C
2.10 Working humidity:
5%~80%, no coagulation
2.11 Dimension:
483322133mm
3
CPU
Object
Object
Voltage
No-voltage
Test
Switch-in
Switch-in
M0dule
LCD
No.
ZX400F
Gen / Line
14
* *
ZX400F/8
Gen / Line
* *
ZX400F/4
Gen / Line
* *
ZX400G/X
Gen / Line
* *
ZX400F(T)
Gen / Line
16
* *
Notice:
*: The function of speed and voltage regulation is only for generator object.
**: The function of no-voltage Switch-in can just take effect only when the object type is the
line,generator and it need no-voltage function only.
3.4 This User Manual only applies to the types of ZX400, ZX400/8 and ZX400/4
microprocessor-based automatic accurate synchronization control devices.
Chapter 2
Hardware Specification
ZX400
RUN
SYNCHRONIZER
NONV
SYN
f+
U+
ORDER
f-
U-
ERROR
GORI
2
Fig 2.1
Fig 2.2
Terminal X1
No.
Definition
Remark
In/Output
1
2
3
4
5
6
L220V(+)/110V(+)
AC/DC power+
AC/DC power-
NOOP
NOOP
* System side voltage
System side voltage
Input
Input
/
/
Input
Input
7
8
9
TVG
TVG
Input
Input
Inc. f
Output
10
COM
Output
11
12
Dec. f
Output
V+
Inc. V
Output
13
VCOM
Voltage regulation
common terminal
Output
14
15
16
V-
Dec. V
Output
CL
Switch-in
Switch-in
Output
N220V(-)/110V(-)
NC
NC
TVS
TVS
CL
Output
Note: There will be no output from 9~14 terminals when the SYN. objects are set be LINE.
Table 2.2:
Terminal X2
No.
Definition
.f
1
.f
2
FLT
3
FLT
4
NC
5
TXD
6
RXD
7
Remark
In/Output
SYN check-up
Output
SYN check-up
Output
Output
Output
Empty
Communication interface
Output
Communication interface
Output
8
9
10
11
12
13
14
15
16
Table 2.3:
GND
Communication interface
Output
QF1
#1 Object chosen
Input
QF2
#2 Object chosen
Input
QF3
#3 Object chosen
Input
QF4
#4 Object chosen
Input
QF5
#5 Object chosen
Input
QF6
#6 Object chosen
Input
QF7
#7 Object chosen
Input
QF8
#8 Object chosen
Input
Remark
In/Output
QF9
#9 Object chosen
Input
QF10
Input
QF11
Input
QF12
Input
QF13
Input
QF14
Input
NO-U
NU
Input
TR-M
QF time
Input
NC
Empty
NC
Empty
TRIPS
SYN starting
Input
TRPS-COT
Input
24VGND
Input
24VGND
Input
24VGND
Input
24VGND
Input
Terminal X3
No.
Definition
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Fig 2.3
2. Connection
ZX400 series microprocessor-based automatic accurate synchronization control device
can be operated both manually or through automatic control order from DCS system.
Matched GR-3 circuit selector (or YAC-2000 intelligent operating case), it can make the
circuit design of multi-object SYN switch-in controlled by DCS system simple and the
voltage switch more safe and reliable.
2.1 The exemplar of ZX400 multi object circuit wiring for manual control
Manually controlled ZX400 device means it can be put into operation through DTK
switch. The circuit switching of object selecting and speed regulation and voltage
regulation through TK SYN switch The Wiring is shown in Fig 2.4 and Fig 2.5.
Notes:
1. Objects #1, #2 and #3 are generators. Other objects are lines in Fig. 2.4
2. The SYN voltages of each object can be connected to the SYN voltage buses by the
SYN switches of each object.
3. The speed or voltage regulation of objects #1, #2 and #3 can be output through
middle relay 1-4zzJ and also be output directly form the device while the middle
relay 1-4zzJ is not needed. If the output of speed regulation need to suit with DEH, it
can concatenate the empty contact from DEH to the circuit of corresponding public
terminal of speed regulation output.
4. X3-8 should be disconnected from X3-14 when not to measure the switch-in time of
breaker.
5. The way of starting the device is as follows:
A) When DTK is in test position (short circuit X3-11, X3-12 and X3-16), The device can
repeat started by itself and send out switch-in pulse if the SYN condition is satisfied.
B) When DTK is in ON position (short circuit X3-11 and X3-16 only). The device can
started by itself once and send out switch-in pulse only one time. Thus can prevent the
accident because of sending out repeatedly switch-in pulses when the breaker is fault.
6. The device can start once at pressing one time when the DTK contacts 30 and 32 are
canceled (X3-12 is empty) and connect a starting button between X3-11 AND X3-16.
7. The no-voltage permission contact UN connected between X3-7 and X3-16. It can
not make no-voltage switch-in when the contacts is break and It can make no-voltage
switch-in when the contacts is connected. If the object is line and the corresponding
SYN switch contacts replace the UN contacts, it also can achieve no-voltage
switch-in.
8. If the phase angle difference of two SYN voltage is not 0 because of the influence of
the Y/ wiring transformer, so the contacts of the SYN checking relay JJ should be
canceled in corresponding circuit of switch-in output.
9
Fig.2.4 SYN circuit wiring 1 for multi object and manual control
2THM
3THM
TEST
1TK
2TK
29
OFF
ON
31
14TK
1TK
Object 1 switching-in
2TK
Object 2 switching-in
14TK
Object 14 switching-in
1TK
Object 1 +
1TK
Object 1 -
2TK
Object 2 +
2TK
Object 2 -
3TK
Object 3 +
3TK
Object 3 -
1TK
Object 1 V+
1TK
Object 1 V-
2TK
Object 2 V+
2TK
Object 2 V-
3TK
Object 3 V+
3TK
Object 3 V-
1TK
com
2TK
3TK
1TK
V com
2TK
3TK
Fig.2.5 SYN circuit wiring 2 for multi object and manual control
10
2.2 The exemplar of ZX400 multi objects circuit wiring matched GR-3
2.2.1 The circuit wiring of power supply and SYN voltages is shown in Fig 2.6.
Notes:
1. The power supplies of ZX400 and GR-3 are controlled by DTK at the manual / DCS
positions.
2. The circuits of I / II / III / IV are SYN voltages of object 1 / 2 / 3 / 4.
11
220V(+)
220V(-)
KK
KK
GR-3
DTK
OFF DCS
M
1
A1-1
DTK
OFF DCS
A1-2
ZX400FZX400F/8ZX400F/4
X1-1
X1-2
GR-3
ZX400FZX400F/8ZX400F/4
A3-1
I
II
A3-2
A2-3
A3-3
A3-4
A2-4
A3-13
A2-5
A3-14
A3-15
A2-6
X1-5
X1-6
X1-7
X1-8
A3-16
A4-1
III
A4-2
A4-3
A4-4
A4-13
A4-14
IV
A4-15
A4-16
Fig.2.6
The circuit wiring of power supply and SYN voltages matched GR-3
2.2.2 The circuit wiring of choosing objects and SYN starting is shown in Fig 2.7.
Notes:
12
1. After the power supplies and SYN voltages are switched in, the SYN object will be
chosen by DCS1-1~DCS1-4 at remote mode or by 1TK~4TK at manual mode. Then
the SYN operating will start and send out the switching-in order at the adequate SYN
conditions.
2. No-V switching-in permission will be controlled by NU at remote mode or by WK at
manual mode when the adequate No-V switching-in conditions no matter the type of
SYN objects.
3. The contacts above should be retentive. If the remote signals are short pulses,
DTK-14 to GR-3:A1-9 must be shorted and the signal for remote reset must be
effective.
4. If the phase angle difference of two SYN voltage is not 0 because of the influence of
the Y/ wiring transformer, so the contacts of the SYN checking relay JJ should be
canceled in corresponding circuit of switch-in output.
GR-3
DCS1-1
1TK
2
ZX400F
A1-3
A2-17
X2-9
A1-4
A2-18
X2-10
A1-5
A2-19
X2-11
A1-6
A2-20
X2-12
A1-7
A2-22
X3-7
DCS1-2
2TK
2
DCS1-3
3TK
2
DCS1-4
4TK
2
NU
WK
2
R-RESET
DTK
OFF
A1-10 A2-21
X3-11
A2-24
X3-13
DCS
13
14
A1-9
10
A1-12
11
12
first. Then the final signal for switching-in will be outputted by GR-3 at the SYN
conditions passing master.
2. The signals for +/- and V+/- will be effective only when the object type is generator.
3. The circuits for+/- and V+/- need not be connected when the object type is line.
ZX400F
GR-3
A3-5
X1-9
A2-7
A3-6
A3-7
X1-10
com
X1-11
X1-12
V+
A2-10
A3-11
X1-13
Vcom
A2-11
A3-12
X1-14
V-
A2-12
X2-1
X2-2
X1-15
A2-8
A2-9
A3-8
A3-9
A3-10
SYN check
SYN check
I ~ IV
A4-17
A2-13
A4-18
A4-19
A2-14
A4-20
A4-21
A4-22
A4-23
Alarming
X2-4
X3-9
X3-10
Fig.2.8
} V+ output
} V- output
A2-16
Switching-in
X2-3
} + output
} - output
A2-15
Switching-in
X1-16
}Switching-in output
A4-24
}Switching-in output
} + output
} - output
} V+ output
} V- output
Fig.2.9
2. The circuit wiring of communication for devices is shown in Fig 2.10. The real SYN
messages can be shown on the background computer from the RS-485/232
interface.
Fig.2.10
be released.
2. Remote operation (NO-V switching-in )Set DTK to DCS position DCS be
connected to supply power NU be connected and holding (Choose NO-V SYN)
DCS1-1~DCS1-4 be connected and holding (Choose SYN object)
Automatically start by device Send switching-in order from ZX400 to GR-3 at the
SYN conditions Output the switching-in order from GR-3 Complete the SYN
operation DCS1-1~DCS1-4 be released.
(If the remote signals are short pulses, DTK-14 to GR-3:A1-9 must be shorted and the
signal for remote reset must be effective.)
3. Local operationSet DTK to M position, the switches and buttons will instead of the
DCSs contacts. The operation sequences will be similar to the sequences above.
2.3 The exemplar of ZX400 multi objects circuit wiring matched YAC-2000
YAC-2000 Synchronization Intelligent Operator will be matched with ZX400 when the
objects number is more than four to simplify further the connection and to reduce the
middle relay in periphery circuit and then reduce fault because of bad contact.
A single YAC-2000 may be used for eight SYN-objects, NO.1~NO.3 are used for
generator, the others NO.4~NO.8 all for power line. Two YAC-2000 operators may be
used for sixteen SYN-objects and so on.
Notes:
1. All input control signals of YAC-2000 are dead contacts without electricity. Except the
P.S. of the synchronizer all output control signals of YAC-2000 are also dead
contacts without electricity. Thus the security and reliability of the equipment work are
guaranteed. By means of control signals, YAC-2000 control ZX400 to complete
synchronizing paralleling work of generator or power line. The speed and voltage
adjustment and the switch-in output all by means of YAC-2000 without transfer relays.
Thus predigest connection greatly if more SYN-objects.
2. Without manual operation in such hardware control work, if completed by DCS or
ECS system automatically. And each operating result may be back-checked in
control process.
3. Such hardware control mode is also applicable for manual local operation.
4. On background computer with menu display By means of RS485 interface to control
YAC-2000 operation to realize synchronizing paralleling of generator or power line.
Each operation step all get back-check signals in operation process. To permit next
step operation after affirm this operation step success. Thus the operation is very
security.
16
YAC-2000
ZX400F
SYN voltages
Choose object
Operating control
Power supply
Background computer
RS-232
RS-232
RS-485
+/- output
V+/- output
Switching-in output
Alarm signal
Re-check signal
Fig.2.11
17
Fig.2.11
18
Fig.2.12
(2) Display real time data: The value of the voltage and frequency, the difference of
voltage, the difference of frequency and the difference of phase in the system and
generator in the process of switch-in.
(3) Display data log: It will show lead-time, the value of voltage and frequency, the
difference of phase angle in the system and generator; the actual switch-in time of
the breaker when switch-in succeed. If switch-in fails user can check out the audit
trail and message.
(4) Calibrating: When calibrated according to the correct method, it will show
calibrating succeed, otherwise it will show calibrating error. Calibration should
be done by connecting the device with special telecommunication cable.
(5) Display the object to be switched in, it shows the number of object and the
objects equipment number.
(6) Display the setting of the device:
It shows baud rate, voltage compensation factor and phase angle of the SYN
voltage in the device.
4.7. Voltage difference setting
As show in Attached Fig.13, QF is the SYN breaker, T is the voltage-raising transformer.
.
If
II
is the rating voltage (Ex. 220KV, 110KV etc.) and T is the voltage-raising
.
GN
, the voltage
.
of high voltage side of transformer is greater than the rating voltage of system U II
(If the voltage of high voltage side of transformer is 242KV, K%10. If 236kV
K
236 220
220
7.3. If 121kV
121110
110
10.)
II
is at rating value,
U II 100V to make
19
.
I
equal toU II
.
U GN
100
corresponding to U G
When the
1+K%
1+K%
voltage compensate factor of generator side is 1.1 (see the parameter 12 in Chapter 3),
UG
110
U G 1+K% . Obviously when K10,
U G' 1.100
voltage compensate factor of generator side is 1.1, the voltage difference setting is the
same as the one without voltage-raising transformer. For instance -3VU3V.
If K10that is K10take KK-10. If 12then 2. Here we only need
to subtract from the upper limit and lower limit of voltage difference. For above
example it is 5VU1V.
If K10 (that is K<10)take KK-10. If 7.5then 2.5The setting
is just like above. For above example, it is 0.55.5V.
Fig.2.13
Chapter 3
Software Specification
1. Overview
The parameters configuration software of ZX400 series microprocessor-based automatic
20
2. System Requirements
Hardware Requirement:
Main Computer:
3. Operation
GRsynF program is used specially in ZX400 for setting up 14 objects parameters. Each
object has 25 parameters.
3.1
Startup
Fig.3.1 shows the user interface after GRsynF startup. Each object parameters are
initially set to default value. User can modify all these parameters.
21
3.2
Fig.3.1
Fig.3.2
Object Selection
22
The user interface for selecting object is shown in Fig.3.2. User can select different
objects by clicking the object in the menu.
3.3 Parameter Modification
After selecting the object, user can modify its parameters. The definition of parameters is
as follows:
Parameter 1: Unit Name
Unit name is the number that identifies a specific object. It consists of 11 ASCII
characters.
Parameter 2: Type
It is the object type and can be set as Generator or Line.
Parameter 3: Tpre
It is the time period from the point that the switch-in order is sent out to the point that the
breakers main contact closes. This parameter should be measured at real time. The
value scope of the parameter is 10ms~990ms with the calibration of 10 ms. The device
can only be used when this parameter is properly set.
Parameter 4: Difference allowed voltage difference
It is the allowed maximum voltage difference (as input to ZX400 device) between two
sides of the undergoing synchro switch-in connection. It can be positive or negative, and
the positive value needs not to be equal to the negative value. The less this parameter is,
the less the reactive power impact is in switch-in process, but the switch-in time may be
lengthened accordingly. The value scope of the parameter is -10V~+10V with the
calibration of 0.1V. The typical value of voltages difference is -3V~+3V. This parameter
needs not to be modified unless for some special situation.
Parameter 5: Difference - allowed frequency difference
It is the allowed maximum frequency difference (as input to ZX400G/X device) between
the two sides of the breaker of the undergoing switch-in. It may be positive or negative
and the positive value needs not to be equal to the negative value. The less this
parameter is, the more time of speed regulation the switch-in process may take. The
value scope of the parameter is -0.3Hz~+0.3Hz with the calibration of 0.01Hz. The
typical value of frequency difference is -0.2Hz ~+0.2Hz. The parameters value needs not
to be modified unless for some special situation.
Parameter 6: Dfai allowed phase angle difference in ring grid connection
This parameter is invalid when the object type is generator unit.
Parameter 7: Coefficient kU - Voltage compensation factor in system
It is the factor used to compensate the amplitude change which is aroused by the
transform of Y/. The value can be set to 1.0, 1.1 or 1.732. The typical value is 1.0. The
value needs not to be modified if no transformer wiring of /Y or Y/.
Parameter 8, 9: Umin / Umax - Voltage upper and lower limit in system
When the voltage in system is over the setting value, the device will send out alarm.
23
Parameter 10, 11: fmin / fmax - Frequency upper and lower limit in system
When the frequency in system is over the setting value, the device will send out alarm.
Parameter 12: Line Voltage Coefficient KU - compensation factor at switched-in
side
It is the factor used to compensate the voltage amplitude change at switched-in side
which is aroused by the transform of Y/ and the ratio of the voltage-raising transformer.
The values can be set to 1.0, 1.1 or 1.732. The typical value is 1.0.
Parameter 13, 14: Umin / Umax - Voltage upper and lower limit values at
switched-in side
They are similar to parameter 8 and 9.
Parameter 15, 16: fmin / fmax - Frequency upper and lower limit values at
switched-in side
They are similar to parameter 10 and 11.
Parameter 17: Phase-Shift Angle/dfal Phase angle compensation
There is a difference of phase angle between synchro voltage which is aroused because
of the presence of Y/ wiring transformer. The device can automatically compensate the
difference of phase without using a phase angle transformer. The value scope of the
parameter is 180~+180 degree with the calibration of 30 degree (Note: It will be
negative for leading voltage and positive for lag voltage). The typical value is 0 degree.
The parameter values needs not to be modified if no change to the transformers /Y or
Y/ wiring.
Note: Phase compensation applied to both CPU should be kept equally. So a CPU is
achieved by needle plug according to the real value of another one.
Parameter 18: period / TV - The cycle of voltage regulation
The scope of the value is from 1000 ms to 15000 ms.
Parameter 19-21: PID Coefficient / Kpv / Kiv / Kdv - PID parameter of voltage
regulation
It can be obtained from experiment. The scope of each parameter is from 0 to 100.
Parameter 22: period / Tf - The period of speed regulation
The scope of the value is from 1000ms to 15000ms.
Parameter 23-25: PID Coefficient / Kpf / Kif / Kdf - PID parameter of frequency
regulation
It can be obtained from experiment. The scope of each parameter is from 0 to 100.
Press SAVE key (or click the menu item shown in Fig 3.3) to save the change to the
parameters.
24
Fig.3.3
25
Fig.3.4
Fig.3.5
Interface of communication
26
Chapter 4
Device Test
1. Calibration test
1.1 Connect AC100V/50Hz standard signal source to the input terminal Us and Ug of
the device. Switch on the device.
1.2 Press Calibrate button to start the calibration (Note: The special communication
cable should be connected).
1.3 The screen will show the message of Calibration successful in
about 5 seconds.
1.4 Filling out the test result in Table 4.1.
l
l
l
l
l
l
l
l
l
l
3. Function test
3.1 For Generator Object
The parameters of object 1 are as above example . Test wiring is shown as Fig4.1
28
3.1.8. If alarm pops up during working process, the full content of alarm can be shown
on the screen in Chinese and English. Meanwhile the alarm lamp light and empty
contact output.
3.2 For Generator Object
The parameters of object 1 are as above example. Test wiring is shown as Fig4.1
3.2.1. Synchronization switch-in
3.2.1.1. Disconnect NU
3.2.1.2. Switch on ZX400. Make the difference of voltage and frequency be in the setting
scope by adjusting the button of speed and voltage regulation. Thus the device can
automatically send out switch-in pulse. It can be monitored if is consistent with the actual
switch-in time. There are no speed and voltage regulation output in the whole process of
testing.
3.2.2. Ring grid connection under the same frequency.
3.2.2.1. Disconnect NU
3.2.2.2. Make the frequency of the two SYN voltage the same.
3.2.2.3. Adjusting the phase angle regulation button to make the difference of phase
angle of the two SYN voltage fall into the setting range, start ZX400G/X and it will send
out switch-in pulse.
3.2.3.
Switch-in under condition of no-voltage
3.2.3.1. Disconnect the input signal to X1-5, X1-6 and connect X1-5, X1-6.
3.2.3.2. Switch on NU.
3.2.3.3. Switch-on ZX400 and start it, will send out switch-in pulse.
3.2.3.4. Switch-in for no-voltage of TVG+ and TVG- or both synchro sides is the same as
above.
3.2.3.5. If NU is disconnected, no switch-in pulse is sent out in the above tests.
Appendix 1
Outline of ZX400
30
Appendix 2
Appendix 3
Appendix 4
31