LH-WLT02 User Manual Maintenance and Fault Disposition DRWN/DIB__ Gen Xan CHKD./CHEQ Chen Xan APRV./APRB wont, Ler REV. A. Wuhan Lianhua Electric Co., LtdLH-WLT02 User Manual Maintenance and Fault Disposition uh DRWN/DIB__ Cen Xin CHKD./CHEQ_ Chea Xm APRV./APRB _ Wong, Zor REV, A. Wuhan Lianhua Electric Co., LtdContents 1.1.1, ADOPTION OF TOP GRADE 32 DIGIT MICROCOMPUTER, 4 1.1.2. ADOPTION OF SPECIAL BUS ORGANIZED STRUCTURES. 4 1.1.3. NETWORK ACCESS. : 4 1.1.4, MALFUNCTION WAVE RECORDING AND ACCIDENT ANALYSIS. 4 5 1.1.5. METRICAL CAPABILITY. 1.1.6. INTELLIGENT POWER SCREEN. 1.1.7. PSS FUNCTION 1.2. APPLICATION ENVIRONMENT. 1.3. MAJOR FUNCTION OF LH-WLTO2 EXCITER SET... — oe 6 1.3.1. FIVE OPERATION MODES 6 1.3.2, AUTOMATIC OPERATION EXCITING MODES " 6 1.3.3 EXCITATION LIMITS, 7 8 9 9 1.3.4. FAULT TOLERANT MEASURES, 1.3.5. LATEST TECHNOLOGIES : Sonn 66. DUAL-PC EXCITATION REGULATORS THAT ARE DIFFERENT FROM DOMESTIC ONES 1.3.7. PACKAGE WORK STATION OR TOUCH SCREEN... 9 1.3.8. LH-WLT02 HARDWARE CHARACTERISTICS. é see 10 1.3.9. PEOPLE-MACHINE INTERFACE oro: " 10 1.4, TECHNICAL INDEXES OF LH-WLT02 EXCITATION DEVICE.. 1.5. SCREEN OF LH-WLTO02 EXCITATION SYSTEM. 1.5.1. SCREEN OF LH-WLTO2 DUAL PC EXCITATION SYSTEM IS DIVIDED INTO THE FOLLOWING ‘TYPES : 12 1.5.2. SCREEN COMPONENT COLLOCATION B 1.5.3. SCREEN SIZE AND COLOR vss 2B 1.6. LH-WLT02 PC EXCITATION REGULATOR 1.6.1, PERFORMANCE INTRODUCTION. . 3 1.6.2. APPLICABLE RANGE. 15 1.6.3. TECHNICAL PERFORMANCE AND FUNCTION OF REGULATOR 15 1.6.4. SIGNAL. : = is 1.6.8, INTRODUCTION 10 LH-WLTO2 REGULATOR BOARD 16 1.6.6. INTRODUCTION 10 LH-WLT02 REGULATOR OPERATION PANEL 19 1.6.7. LH-WLT02 PC EXCITATION REGULATOR LCD DISPLAY AND OPERATION oss. 22 1.7, LH-WLT02 EXCITATION SYSTEM SINGLE-SCREEN STRUCTURE ILLUSTRATION 34 2, EXCITATION EQUIPMENT MAINTENANCE AND TROUBLESHOOTING 2.1. SAFETY RULE: 2.2. CONSEQUENCE BY NEGLIGENCE. 36 2.3. REQUESTS FOR WORKING STAFF, 37 2.4. DESCRIPTIONS OF EMERGENCIES, 37 2.5, FIRST-AID MEASURES FOR ELECTRICAL DEVICES, 38 22 OPEN-LOOP TEST... 2.2.1, WIRING 2.2.2. SAFETY MEASURES. 2.2.3, REQUIREMENTS FOR MAINTAINERS. 2.2.4. DISPOSITION OF EMERGENT CASES, 2.3. MAINTENANCE OF EXCITATION EQUIPMENT .. 2.3.1. OVERVIEW 44 2.3.2. WORKING CONDITIONS FOR MAIN 2.3.3, MAINTENANCE TIMETABLE, 452.3.4, ONCE-EVERY-3-MONTHS MAINTENANCE 2.3.5. ONCE-EVERY-1-YAR MAINTENANCE. 3. EXCITATION PANEL INSTALLATION MANUAL. 3.1. SUMMARY 3.1.2. ACCEPTANCE... 3.1.3. TRANSPORTATION OF PACKAGED EQUIPMENTS. 3.1.4. STORAGE. 3.1.5. UNPACK AGING 32. INSTALLATION OF CABINET. 33, ELECTRIC CONNECTION 3.4, SEALING. 35. COMPLETION 36, EXAMINATION 37. CLARIFICATION. 4. INSTALLATION AND MAINTENACE MANUAL OF TRANSFORMERS. 4.1. PRODUCTS OVERVIEW. 4.2. SERVICE CONDITIONS... 4.3. LOADING AND UNLOADING 4.4, TRANSPORTATION... INSPECTION UPON RECEIPT... 47. INSTALLATION .. 48. INSPECTION BEFORE OPRATION 4.9. TEST BEFORE OPRATION, 4.10. OPERATION oso 4.11, SURVEILLANCE AND MAINTENANCE... 4.12 SAFETY NOTICE1. LH—WLT02 Microcomputer Excitation Device 1.1 Introduction LH—WLT02 Double-microcomputer Excitation Device (hereinafter short for LH — WLTO02) is the upgrade production base on the successful run of the WL03 Double-microcomputer Excitation Device(V40). The main improvements are as follows: 1.1.1. Adoption of top grade 32 digit microcomputer LH-WLT02 adopts INTEL32 digit industry 80386EX processor, inserts with DPS. High lever of integration, low power consumption, rapid operation speed and better reliability are its characteristics. 1.1.2. Adoption of Special Bus Organized Structures The merits of LH_WLT02 Bus Organized Structures are as follows: LH-WLTO02 adopts platelet frame and possesses superiority in mechanical strength, anti-rupture, anti-seismic, ageing resistance, and anti-jamming and so on. LH-WLT02 compartmentalizes molding board according to its function that the user could choose different molding board to assemble system, and it is easy to expansion and upgrade. Molding board frame enhances the maintainability of system. To the user, systematic maintenance is based on the surface of the molding board: dismantle the broken molding board, and then insert the same functional molding board. Presently, the average time of systematic maintenance is less than 5 minutes. It is in compact structure, and the adjuster connects to the terminal directly with less connection with exterior. 1.1.3. Network access LH-WLTO02 provides one RS232, one RS485 and one CAN wire with optical insulation. And it can exchange data with computer monitor system or others intelligent sets expediently. The message velocity of CAN Bus Organized can reach 1M. 1.1.4. Malfunction Wave Recording and Accident Analysis LH-WLT02 introduces test and malfunction wave recording in function. Between 6.25seconds before accident and 6.25seconds after accident, 8 category information quantum, which pass RS485 (CAN ) Bus Organizednetwork junction to exchange data with computer monitor system or others intelligent sets expediently. With PC online debugging internet applications. it amends parameter and measures the adjuster hardware, and it is easy to debug, determine ,examine and repair the excitation regulator. Adding triggering synchronous signal losing (discontinuer) fault tolerant function which still can guarantee the triggering completed controlling bridge correctly when trigger signal losing. 1.1.5. Metrical Capability The 24 points interflow sampling of LH-WLTO02 enhances the measure precision, and 24 points Fu clan arithmetic calculating P, Q improves the power measuring precision, accordingly improving difference adjustment, under-excitation limit and otherwise control precision. 1.1.6, Intelligent Power Screen LH-WLTO02 Excitation Device power screen adopts intelligent average electric current technique, automatic recognition process, and monitor each group of rectification bridge temperature and their output electric current in real-time. 1.1.7. PSS function PSS inserted in the adjuster of LH-WLT02 Excitation Device. According to user’s requirement, the user could choose to insert PSS with active power P feedback function or PSS with frequency F feedback function which can restrain the low frequency oscillatory of power network effectively. (1) Wide range of application Applicable for large and medium sized self-shunt excitation, self compound excitation, external excitation starting of normal operation and phase regulating operation of generators. Small size units may use as a reference. Controllable rectifying bridge can be full controlled or semi-controlled. (2) Others Adopting station service alternating current, local alternating current and station direct current to ensure the power reliability. Adopting double power amplifier, double pulse and doubleexcitement modes to enhance excitement reliability. 1.2. Application Environment (1)Environment temperature: -5°C ~+45'C, with an average temperature of lower than 35°C for 24 hours. (2)Humidity no more than 90%, (3)Compatible with flying dust caused by hydraulic power plant and fossil-fuel power plant, vibration and interference from electromagnetic excitation. (4)Avoid direct exposure to the sun. 1.3. Major Function of LH-WLT02 Exciter Set 1.3.1. Five operation modes (1) Automatic operation mode (constant Uf mode, Uf: terminal voltage of generator) (2) Manual operation mode (constant IL mode, IL: exciting current ) Maintain exciting current of generator on decided IL level. (3) Constant Q operation mode (Q: reactive power) (4) Constant COS® operation mode (COS®: power factor) (5) Constant a mode (a: ilicon-controlled trigger angle) When external excitation starting system is operating or testing, maintain fully controlled bridge’s control angel on decided level. 1.3.2, Automatic operation exciting modes (1) Automatic (constant pressure) normal excitation starting Constant Uf mode and excitation starting in non-experimental status: in light of normal voltage of busbar (115%Ue=busbar voltage >85%Ue, Ue: rated voltage), track bus bar voltage excitation starting, that is the generator voltage should be equal to the bus bar voltage after excitation starting. In the light of abnormal bus bar voltage (bus bar voltage >115%Ue or <858&Ue, rated voltage excitation starting, that is the generator voltage should be equal to the rated voltage after excitation starting.) (2) Excitation starting Automatic mode (constant pressure) excitation startingConstant Uf mode and excitation starting in non-experimental status: press the test button on the operation panel to enter experimental status. The rated value of excitation starting should be controlled by the add-excitation and subtract-excitation buttons. Designed range of excitation starting is from 20% to 130% of rated voltage. (3) Constant (excitation) current excitation starting Excitation starting in constant IL mode: press the constant IL button on the operation panel to enter constant IL excitation starting mode. Here, starting-up will build the voltage automatically to about 20% of rated voltage. 1.3.3 Excitation limits (1) Instant limit of largest excitation current: limit value should be within 1.5-2.0 times of rated excitation current based on national standards. (2) Inverse time-lag over-excitation time-delay limit: excitation current of inverse time-lag time-delay limit curve can be determined according to the requirements of power plant. (3) Qmin=A*P+B) Under-excitation limit: under-excitation limit curve cam be determined according to the requirements of power plant (under-excitation limit equation: Qmin=A*P+B) (4) Single unit forced excitation limit: generator, before incorporating into the power network, should lock out strong excitation to avoid over voltage to generator end. (5) Power cabinet local malfunction excitation limit: lock out strong excitation when power cabinet is fused, power draw is withdrawn and shut down of blower fan. (6) Instant limit of stator over voltage: during test run, over voltage is 1.30Ue and 1.15Ue in other conditions (according to the requirements of power plant). In case of excessive voltage at generator end, restrictor should immediately reverse and limit the power. (7) Frequency ratio limit: Proportion of single generator limited end voltage to frequency should be no more than rated limit. (8)Reactive over load limit: when reactive power is more than 1.2 times rated reactive power, limit starts to reduce the excitation automaticallyuntil reactive power is less than the upper limit 1.3.4, fault tolerant measures LH-WLT02 adopts various fault tolerant measures to greatly improve the operation reliability of device. (1) Excitation regulator fault tolerant measures LH-WLT02 excitation device adopts two same regulators, one for operation and the other for hot reserve. Working unit will automatically withdraw and switch into reservation once there is a malfunction with automatic tracking unit to ensure no impact during automatic shift. Manual shift is available for normal operation. (2) PT wire breakage fault tolerant measures During single generator idling operation, end voltage =MAX (adjusting voltage, instrument transformer voltage) During operation after incorporating into the power network, end voltage =MID (adjusting voltage, instrument transformer voltage and bus bar voltage transformer voltage) MAX: — take maximum value MID: — take medium value (3) Simultaneous signal missing fault tolerant measures Simultaneous signal adopts self-excitation rectifier transformer and adjustable change to support each other. (4) Add and subtract-excitation operation fault tolerant measures Add-excitation is invalid in the following conditions: Over-excitation current, over generator end voltage, over reactive power, exceed the upper limit of adjustable range. add-excitation is invalid in the following conditions: under excitation limit, exceed the lower limit of adjustable range. It is invalid to run excitation increase/reduction for 5 seconds successively in any condition (around 3%Uf of rated pressurization and decompression) to avoid reduce excitation to its limit by mistake. (5) Power bridge fault tolerant measures To adopt two groups of rectification bridges. In case of one group of rectification bridge shuts down, the machine can withdraw from it. 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For some small or medium sized units that need dual passage pe excitation device, they can not choose package work station or touch screen due to shortage in fund. 1.3.8. LH-WLT02 hardware characteristics LH-WLT02 adopts 32-bit microprocessor produced by American INTEL Co., Ltd with high integration, quick calculation speed and super number processing ability to realize sampling, pulse formation and shift control, and malfunction wave recording by software. Furthermore, the application of super large scale online programmable integration CPLD can do self-diagnosis, self restoration, missing pulse detect and fault tolerance. 1.3.9. People-machine interface Beside package workstation or touch screen, LH-WLTO2 also has large character lattice LCD screen and touch keys for the communication between people and machine. All the control parameters of regulator can be regulated and displayed on line so that regulation, determination, operation and maintenance are very convenient. Pulse shift and dual pulse formation adopt software to improve hardware. Six-phase pulse is average and the regulation to its width is very convenient. 1.4. Technical indexes of LH-WLT02 excitation device The function and performance indexes of LH-WLT02 excitation device is up to national standard Technical Conditions of Large and Medium Scaled hydraulic turbine Generator Static Rectification Excitation System and Device DL/TS83-2006, Installation and Acceptance Standards of Large and Medium Scaled hydraulic turbine Generator Static Rectification Excitation System and Device DL490-92 and requirements of DL491-2008 as well as GB14285-2006, DL/T583-2006, DL/T5081-1997, IEC and IEEE. The majortechnical indexes of LH-WLT02 excitation device are as follows: 1. The device can operate successively the largest excitation current, ie., 1.1 rated excitation current. 2. The response of excitation system voltage to shift time is no more than 0.06S and to reduction time is no more than 0.10s. 3. Excitation system can maintain the non-vibration of generator stator voltage under stable load and its voltage precision is better than 0.2% under any load permitted by generator. 4. The range of excitation current regulator (FCR) is from 10% empty load excitation current to 110% rated capacity excitation current. 5. Automatic voltage regulator should regulate within the rated value range of generator empty load 70% - 110% smoothly and stably. 6. After generator loses rated load (under rated power factor), the voltage of generator is not over 10% of rated value within Is with less than 3 times of vibration. 7. Launch excitation when rated rotation speed of generator is within 95%-105%. Excitation regulator increases end voltage of generator from 0 to 100% rated voltage, and no evident vibration will be caused within 3s. 8. AVR shall enable the rated range of generator end voltage to be within £15%. Difference adjustment property is linear. 9. During empty load operation, excitation regulator should ensure the change of end voltage of generator be within +0.25% of rated value in case of every 1% change in frequency value. 10. During empty load operation, the voltage change of AVR and FCR should be within 1%-0.3%/s of rated voltage. (Adjustable) 11. Excitation system top value voltage is 2 times rated excitation voltage. In case that generator positive sequence voltage is 80% rated value, tion top value voltage should be ensured. ex 12. Permissible time of excitation system should be no less than 30S with 2 times excitation current. 13. Excitation system can ensure the operation with range of generator end frequency of 45-77 .SHZ.14. Rectification bridge’s uniform current and voltage coefficients of excitation system reach over 0.95 15. Deviation range of alternative 380/220V system voltage is 15% of rated value, and that of frequency is -3-+2Hz, and that of direct 220V voltage is-20-+10% of rated value. 16. When generator operates long with less than 1.1 times rated excitation current, the biggest instant value of excitation winding both ends voltage should not be more than 30% of its voltage value in earth voltage test. 17. Under any condition, excitation system should ensure the biggest instant value of both end voltage of excitation winding should not be more than 70% of its voltage value in earth voltage test. 18. The annual non-rate of utilization of excitation system should be no more than 0.01%, and the first malfunction should not last more than 50000h after it is used in business operation, and the shelf life should be no less than 20 years. 19. Excitation regulator has upper and lower limit. Setting value can return automatically to empty load value. The upper and lower limit and voltage idling setting value can be adjusted through a long distance. 20. Excitation regulator provides the following two interface modes to exchange information with computer monitoring system, one is digital communication mode and other is I/O interface mode. There is usually a LBD at each position of I/O interface board of excitation regulator to indicate its status. Photoelectrical insulation should be available at each 1/0 position. 21. Excitation regulator computer shall be set in synchronization with computer monitoring system’s clock at power plant with a deviation of no more than Sms. 1.5. Sereen of LH-WLTO2 Excitation System 1.5.1. Sereen of LH-WLT02 dual pe excitation system is divided into the following types 1.5.1.1. Single screen structure, namely regulator, rectification bridge and de-excitation are sealed on one side panel (rectifier transformer shall be placed separately)1.5.1.2. Double screen structure refers to two screens, namely regulator screen, power and de-excitation screen, constitute the whole set of excitation system (rectifier transformer shall be placed separately). 1.5.1.3. Three-screen structure refers to three screens, namely regulator screen, power screen and de-excitation screen, constitute the whole set of excitation system. (Rectifier transformer shall be placed separately) 1.5.1.4. Four or more screens structure refers to add of power screen based on three-screen structure. The number of power screen can be decided by the volume of output of excitation system. (Rectifier transformer shall be placed separately) 1.5.1.5. Please refer to attached plan for cabinet layout 1.5.2. Screen component collocation 1.5.2.1. Regulator screen is equipped with visible pointer end voltmeter, reactive wattmeter, I and II regulator indication lights, power malfunction indication light, package machine (subject to client’s option), two units of LH-WLT02 pe excitation regulators, switch buttons, indication lights and shift devices. 1.5.2.2. The power screen is equipped with excitation voltmeter and current wattmeter, on/off buttons and indication light of cooling air machine, fusion indication light and controllable silicon rectification bridge. 1.5.2.3. De-excitations screen is equipped with excitation voltage detect meter and option buttons, excitation ammeter of excitation system, over voltage protection, de-excitation resistance and switches. . Seren size and color 800*800*2260mm (width*depth*height). In case of special requirements, clients should Screen with international —_ convention: specify in the order, Screen color is determined by clients. In case of no specific requirements, screen color will be gray (international standard). 1.6, LH-WLT02 PC Excitation Regulator 1.6.1. Performance introduction1.6.1.1. LH-WLT02 PC excitation regular is equipped with CPU Intel386EX produced by INTEL for industrial application with DSP function. Timing and counting units (8254), two serial control units (SCU), two interruption control units (ICU), two DMA units (DMAU), clock management units, memory freshing, door dog and programmable logic units are integrated in 80386EX. Furthermore, there are control units, such as 14-bit analog-to-digit conversion module (ADC) and large-scale online programmable gate array CPLD. 1.6.1.2, LH-WLT02 dual PC excitation regulator adopts PC automatic passage structure. Two passages have the same hardware structure and software configuration. In normal operation, when one passage works, the other one reserves heat. Automatic tracing and shifting devices can ensure smooth and quick passage shift with high operation reliability and without impact. In terms of signal collection, pulse formation and shift control, the system adopts latest hardware-software techniques, drops complicated P and Q electric energy transmitter and induction pulse formation and shift controlled circuits so that regulator’s hardware structure has been greatly simplified and its performance reliability has been enhanced. 1.6.1.3. LH-WLT02 adopts the most superior excitation control and boasts high capacity to stabilize voltage and restrict low frequency oscillation of electrical system. It is applied in large-scale units and long distance electric power transmission to improve the stability of electrical system. 1.6.1.4. Fault detecting function, fault detect of voltage stabilizing power, induction pulse missing detect, PC main parts self-detection, etc. Signal for failure which is used in automatic switch device and/or audio and optical alarm can indicate the location of failure and recover it quickly. 1.6.1.5. online such operation parameters as P, Q, Uf, IL, a and F, It can also Online display and parameter revising function: it can display revise online such control parameters as feedback gain, difference adjustment coefficient, over-excitation limit, low excitation limit and frequency ratio limit. 1.6.1.6. Various standard communication ports are available forcommunication with back stage computer to realize reactive group adjustment and concentrated control of the whole plant. | 1.6.1.7. Event recording function is available to assist in accident analysis 1.6.1.8. LH-WLTO02 with complete functions can satisfy clients’ different requirements. It is equipped with excitation limit and protection function to secure the safety operation of units. 1.6.1.9. The functions and performance indexes of LH-WLT02 are up to . or superior to the national standards. 1.6.2. Applicable range Applicable for large and medium sized self-shunt excitation, self compound excitation, external excitation starting of normal operation and phase regulating operation of generators. Small size units may use as a reference. Controllable rectifying bridge can be full controlled or semi-controlled. 1.6.3. Technical performance and function of regulator See LH-WLTO2 excitation system technical indexes and functions. 1.6.4. Signal 1. signal to indicate operation status a, disconnect operation; by inverted de-excitation; cy add excitation operation; d, subtract-excitation operation 2. signal to indicate abnormal status ay failure in direct stabilizing power: b, failure in PC main part detection; cy failure in synchronous signal circuit; d\ regulator failure e. missing induction pulse; f, PT wire breakage (modulation, instrument transformer and bus bar change); gs Power cabinet failure (broken fusion, withdrawal from power cabinet and blower machine included); hy instantaneous/time-delay over-excitation limit;i, low excitation limit; js frequency ratio limit. 3. Major input signals a, three-phase modulation voltage signal (100v alternating current); b, three-phase instrument transformer voltage signal (100v alternating current); cy three-phase bus bar voltage signal (100v alternating current); d. three-phase stator current signal (5A alternating current); es three-phase rectification bridge alternating current signal (SA alternating current) and rotor loop shunt voltage signal (7SMV direct current); f, three-phase rectification bridge alternative synchronous voltage signal; @» tum on “off “signal (on/off signal); hy inverted de-excitation signal (on/off signal): i, generator circuit breaker DL signal (normally off junction) ; js master high voltage circuit breaker DL signal (normally off junction); k, add-excitation and subtract-excitation signal (on/off signal) of central control room; 1, power cabinet wind stop and withdrawal signal (on/off signal); my Plant alternating current power, direct +220V power and self shunt excitation rectification transformer side voltage input. 1.6.5. Introduction to LH-WLT02 Regulator board LH-WLT02 has nine templates as follows: (1) 80386EX main board (2) signal shift board 1 (3) signal shift board 2 (4) switching value input and output board (5) pulse amplifier and detect board | (6) pulse feed amplifier and pulse detect panel 2 (7) bus connection panel (8) LCD display panel(9) power panel In the above nine templates, main board 80386EX is the 6-level main board designed by us and manufactured overseas. The rest are special purpose templates manufactured domestically. 1, PC display (1) drive circuit of 24-channel_ LED indication light (2) display and its drive circuit and program; (3) 8 buttons and 9 interfaces of thin-film keys. 2, signal shift board 1 Analog signals that have been input are processed into analog and digital signals that are easy for PC to accept and process. The board consists of the following circuits: (1) IL excitation current transmitter The transmitter switches rectification I alternating current sensor (rectification change low voltage) signal into SV voltage and supplies it to PC as excitation current measurement signal (2) IL lexcitation current transmitter The transmitter switches rectification II alternating current sensor (rectification change low voltage) signal into SV voltage and supplies it to PC as excitation current measurement signal (3) temperature transmitter The transmitter switches PT 100 resistance value into SV voltage and supplies it PC as rectification bridge temperature measurement signal (4) wind pressure transmitter The transmitter switches cooling wind pressure value into SV voltage and supplies it to PC as cooling wind pressure measurement signal. (5) sequence judgment The circuit shifts rectifi tion bridge alternating three-phase voltage and supplies it to PC as phase sequence judging measurement signal. 3, Signal Shift Board 2 Analog signals that have been input are processed into analog and digital signals that are easy for PC to accept and process, The boardconsists of the following circuits: (1) Ufl voltage transmitter The transmitter switches change 100V alternating current signals from instrument voltage transformer into SV voltage and supplies it to PC as instrument transformer voltage measurement signal. (2) Uf2 voltage transmitter The transmitter switches alternating current signals from regulating transformer into SV voltage and supplies it to PC as bus bar voltage measurement signal. (3) US voltage transmitter The transmitter switches changes 110V alternating current signal from bus bar transformer voltage into SV voltage and supplies it to PC as bus bar voltage measurement signal. (4) ILAC excitation current transmitter The transmitter switches current signals from low voltage side of rectifier transformer into SV voltage by alternating current sensor and supplies it to PC as excitation current measurement signal. (5) ILDC excitation current transmitter The transmitter uses Hall current transmitter to switch voltage 75mA from rotor current divider into SV voltage by alternating current sensor and supplies it to PC as excitation current measurement signal. (6) IF stator current interface The circuit supplies the filtered stator alternating current signals to PC which calculates active and reactive power output by generator according to the signals. (7) ambling synchronous signal circuit The circuit filters modulation alternating current signals and alters them to square wave synchronous signals and supplies them to PC as the sampling synchronous signals of stator current to determine the power factor angle between voltage and current. (8) Induction synchronous signal circuit The transmitter filters communication synchronous signals from low voltage side of rectifier transformer and alters them to square wave ynehronous signals and supplies them to PC as reference signals forfrequency measurement and pulse shift. (9) Voltage measurement unit featuring stator over empty load protection The unit measures stator voltage and compares it with over voltage protection and outputs over load protection signals. 4, Switching value Input and output board Switching value input and output board comprises 16 route input interface circuit and 8 route output interface circuit, both input and output which are equipped with relay and photoelectrical insulation. 5. Pulse amplifier and detect board 1 The board can amplify small pulse to silicon controlled induction pulse through big power amplifier pipe and pulse transformer and supply them to rectification bridge 1 as well as switches a series of subsequent pulses for CPU detection. 6, Pulse amplifier and detect board 2 The board can amplify small pulse to silicon controlled induction pulse through big power amplifier pipe and pulse transformer and supply them to rectification bridge 2 as well as switches a series of subsequent pulses for CPU detection. 7, Power panel Plant alternating current, generator alternating current and plant direct current work together. 8, Bus connection panel The panel is used to integrate the input and output signals of the above-mentioned boards as a whole. 9. main function of failure alarm and shift panel The panel is the support facility of PC regulator. Its main function is to alarm the power failure signal, PC failure signal and small pulse missing signal as well as shift logic control of dual generator non main and minor shift mode. 1.6.6. Introduction to LH-WLT02 Regulator Operation Panel LH-WLT02 operation panel is mainly used in regulation and test, and usually not used in normal operation.LH-WLT02 operation panel consists of the following: (1) 8 buttons (5 with automatic lock): (2) 24 LED indication lights (24 for I and II generator each): (3) 9 thin-film buttons; (4) wide screen LCD screen in English wording. Below is their function and application: 1. 8 buttons (5 with automatic lock) 14 buttons are: add-excitation, subtract excitation, de-excitation, constant IL, constant Q, constant COS, test and excitation starting. [Add-excitation] and [subtract excitation] _ buttons: personnel conduct add-excitation and subtract excitation operation beside the generator by pressing buttons and LED lights will be on. {Test} button (with automatic lock): in trial test status, regulator’s upper limit of adjustment is expanded to 130%UEN and step test for set value of voltage is permitted. In normal condition, change it to non test status by releasing [test] button. (Constant IL] button (with automatic lock): let regulator change into constant excitation current operation by pressing button and LED indication light will be on. {Constant Q] button (with automatic lock): let regulator change into constant reactive power by pressing button and LED light will be on. [Constant COS] button (with automatic lock): let regulator change into constant power factor operation mode by pressing buttons and LED light will be on. [{De-excitation] button (with automatic clock): let regulator change into inverted de-excitation status by pressing buttons and LED light of de-excitation will be on (it is invalid to press de-excitation button after network integration) [Excitation starting] button: cannot start excitation automatically, use manual excitation- in case of low residual voltage istance operation excitation starting for voltage building: Constant COS button junction: let regulator change into constant COS operation and network integration is valid (invalid before network integration)Constant Uf operation mode is available if constant IL, constant a and constant COS are all invalid, this is the fundamental operation mode of regulator. If more than one modes are running after network integration, press the buttons in sequence of [constant COS] , [constant a] , {constant IL ] and constant Uf] . 2. 24 LED indication lights are: network integration, zero boost, under excitation, over excitation, add excitation, subtract _ excitation, de-excitation, constant IL, constant a, rotor over pressure, collection 1, collection 2, bus bar zero pressure, modulation wire breakage, instrument transformer wire breakage, synchronous unconventionality, test, excitation starting, power cabinet failure, excitation-assistance operation, constant COS, stator over pressure, signaling 1 and signaling 2. Network integration is used to indicate whether generator is integrated into the network. If it is on, it means it has been integrated. Zero boost panels is used to indicate whether LH-WLTO2 inner zero boost panel has been pressed (short circuit). If there is short circuit, the light will be on. Under excitation limit is used to indicate under excitation limit action. Over excitation limit is used to indicate over excitation limit action. Bus bar zero pressure is used to indicate whether bus bar voltage is in normal status. In case bus bar voltage is between 80% and 115% of rated voltage, it indicates that bus bar voltage is normal, otherwise, it is abnormal. If it is abnormal (fusion of bus bar voltage measurement loop included), turn on the light of bus bar zero pressure. Modulation wire breakage is used to indicate whether modulation measurement loop has malfunction (fusion of modulation measurement loop included). If so, the light will be on. Instrument transformer wire breakage is used to indicate whether instrument transformer measurement loop has malfunction (fusion of instrument transformer measurement loop included). If so, the light will be on. Stator over pressure is used to indicate empty load stator over pressure protection.Rotor over pressure is used to indicate rotor over pressure protection. Power cabinet malfunction is used to indicate whether silicon controlled power cabinet draw is loose or withdrawn. In case of fusion and stop of blower machine, the light will be on. Synchronous unconventionality is used to indicate whether synchronous signal is normal. In case of problem with synchronous signal loop, the light will be on. There are usually two reasons for synchronous unconventionality: breakage of synchronous signal measurement loop or breakage of modulation and instrument transformer at the same time. Test is used to indicate the working mode of regulator. If the light is on, it means regulator is in test mode. Test allows 135% voltage upper limit and +10% voltage step. Constant IL is used to indicate the working mode of regulator. If the light is on, it means regulator is in constant IL mode. Subtract excitation is used to indicate the status of regulator. If the light is on, it means the regulator is in subtract-excitation mode. If it is in under excitation limit status, it can lock automatically to subtract excitation. Add excitation is used to indicate status of regulator. If the light is on, it means the regulator is in add-excitation mode. If it is in over excitation limit status, it can lock automatically to add excitation. De-excitation is used to indicate status of regulator. If the light is on, it means the regulator is in de-excitation mode. 3. 9 thin-film buttons: (7,({1,{>1,€<—], (+1, ([—1, [confirm], [cancel] , restore] . 9 buttons are used to detect, check and revise excitation system operation parameters and status. Please see operation manual of regulator LCD display for more detail 1.6.7. LH-WLT02 PC excitation Regulator LCD Display and OperationUPALTO2 a Atco nna et er mm ORM OR Oe MI OME oR cE Ok ofM oammeonmie oma em m ce te om me 9a wat xa a aan SRR AAASLH-WL02 Generatar Micromputer Excitation Unit 1@ \® 1e 1@ @ 1@ '@ Regulator LCD display consists of 6 parts: 1, Main menu is used for clients to check all the functions as below: . operation parameter and state . control parameter revision and inquiry . alarm and malfunction record . power adjustment . motor parameter display You can select each menu by the thin-film button } or |. When the arrow points to a certain menu, you can enter the menu by pressing thin-film button confirm.2, Operation parameter and status menu consists of three small menus to detect from time to time the operation parameters and status. See below: Operation parameter and state] » Frequency busbar voltage: P+$0.00 US=63000 Difference adjustment instrument transformer:U1=6300 U2=6295" excitation current: 11-6300 12=6295" Voltage current determination: Uge6300 Ig-350- Qen4500 Cgn0.85~ ai-67.78 ak67.780 2001.05.12—-16:45:234 ‘The first menu displays parameter voltage frequency F, bus bar voltage US, generator end modulation voltage Ul, end instrument transformer voltage U2, excitation current direct current value Il, alternating current value 12, voltage index value Ug in constant voltage mode, excitation current index value Ig in constant current operation, reactive constant current index value Qg, constant power factor Cg, integral quantity of controlled silicon ai, output control angle of controlled silicon ak and real time clock display. You can return to the main menu or the second menu of operation parameter and state by pressing thin-film buttons for].excitation voltages UL=100.5 based voltage unit active power: P=04300 ‘Ube6312 ‘unit reactive power: Q=03200 mL =0000 output current of bridge arm The second menu displays excitation voltage UL, unit active power P, unit reactive power Q, lower end of reactive power Q, based voltage value Ub, output current 1IL of bridge arm I and 2IL of bridge arm II. Switch value input is divided into 3 groups. 1 is remote input 18 route, 2 is remote switch input 9-16 routes, 3 is 8 buttons on the panel and output is 8 route output. In case input and output corresponding state is 8, it means no signal, while in case it is 1, it means there is signal. In case corresponding state of limit state and alarming signals is 1, it means there has been an action. Thin-film button fis used to return to the former menu, and button|is used to go to the following menu. Button cancel can be used to return to the main menu.LR 2 3 4, Stator current: la=000 “Power cabinet temperature: T1=000 1b=000 Ic-000 The third menu displays unit stator secondary current Ia, Ib, Ic, rectification bridge temperature T1 and T2, pulse detect data M1, M2, M3 and M4, 2 route synchronizing signal difference of phase angle XIC, limit state and alarming signal information. In case that corresponding state of limit state and alarming signal is 1, it means there has been an action. Thin-film button fis used to return to the former menu, and button cancel can be used to return to the main menu. 3. Menu of control parameter revision and inquiry. The menu consists of 4 sub-menus as follows: control parameter revision and inquiry KPV=042 6, KPI=035 KIV=003 7, KII=003 KDV=005 8. KDI=007 UCN0=56395 9, KVF=0L15 UCN1=56895 10, KQ=32168 ¥v v‘The first menu displays: (1) voltage proportion coefficient KPV, (2) voltage integral coefficient KIV, (3) voltage differential coefficient KDV, (4) initial value of constant voltage excitation starting integral UCNO, (5) initial value of constant current excitation starting integral UCN1, (6) excitation current proportion coefficient KPI, (7) excitation current integral coefficient KII, (8) excitation current differential coefficient KDI, (9) frequency ratio limit coefficient KVF, (10) difference adjustment coefficient KQ. Password is needed to revise control parameters, then serial number and step value for one addition/subtraction of corresponding control parameter. Press thin-film button confirm to enter the state of parameter revision, and there is a rectangle cursor flashing constantly. Press thin-film button + or — to revise parameters according to the prefixed step length. If password is incorrect, this can not be done. Press thin-film button — or < to move the cursor to input password, serial number and step value, then press + or — to input 0-9 numbers in corresponding places. In case corresponding state is 0, — is invalid, while it is 9, + is invalid. After parameter revision, press cancel to withdraw from the state of parameter revision, and the rectangle cursor will disappear. Press button|to enter the next menu of control parameter, and the press of cancel in state rather than parameter revision will lead to main menu.step length:00000 & DVMAX=0335 DVMIN=0714 INCLC=06144 DECLC=06144 GLIL=03520 SLXS=003 KDL=350 ¥ The second menu displays: (11) active PSS proportion coefficient KPP, (12) active PSS integral coefficient KIP, (13) active PSS differential coefficient KDP, (14) set value of reactive power limit curve AP, (15) set value of reactive power limit curve BQ, (16) unit power measurement and correction factor SIN, (17) unit power measurement and correction factor COS, (18) permissible increase in generator end voltage Dvmin, (19) permissible decrease in generator end voltage DVmin, (20) range of instant increase in excitation INCLC, (21) range of instant decrease in excitation DECLC, (22) excitation current set value GLIL, (23) excitation current system JLXS, (24) strong excitation multiple DIL Please see the above for control parameter revision. Thin-film button tis used to return to the former menu, and | is used to enter the next menu, and button cancel can be used to return to the main menu.step length:00000 & RAMTOEEP TGG=00001 FILE TO FEP UCI=60415 EEPTORAM UCK=63487 TBSC=04292 ‘VG=04003 KPQ-015, KPF=0100 KIQ=003 KIF=0020 KDQ=005 KDF=0007 ¥ The third menu displays: (25) solidification of RAM TO EEP after parameter revision, (26) default parameter application FILE TO RAM, (27) revised parameter application EEP TO RAM, (28) synchronizing difference of phase angle set TBSC, ((29) constant reactive proportion coefficient KPQ, (30) constant reactive integral coefficient KIQ, (31) constant reactive differential coefficient, (32), (33), (34) and (35) are internal parameters, (36) frequency PSS proportion coefficient KPF, (37) frequency PSS integral coefficient KIF, (38) frequency PSS differential coefficient KDF. Please see the above for control parameter revision and parameter solidification and application, When parameter revision state is entered, any operation with + or — is of the same function with correct password. Generally, the control parameters should be the ones revised in excitation adjustment. Any revision should not be made to control parameters to avoid affecting unit’s normal operation. Thin-film button fis used to return to the former menu, andJis used to enter the next menu, and button cancel can be used to return to the main menu.Serial No.:00 step length00000 ID=001 40, CIMIN=05120 41, CIMAX=13312 42, CKMIN=02048 PSSBZ=0255 43, CKMAX=15360 50, ULN=0260 44, TBSCI=03640 51, ILN=0680 45, TBSC2=00140 52, MCJC=0255 ¥ v ‘The fourth menu displays: (39) communication station point ID, (40) PID minimum integral angle CIMIN, (41) PID maximum integral angle, (42) minimum output control angel CKMIN, (43) maximum. output control angle CKMAX, (44) lower end of synchronizing unconventionality TBSC1, (45) upper end of synchronizing unconventionality TBSC2, (46) PSS operation/switch off soft board (operation if not 0) PSSBZ, (47) unit rated active power PN, (48) unit rated reactive power QN, (49) unit rated voltage UN, (50) unit rated excitation voltage ULN, (510 unit rated excitation current ILN, (52) pulse detect operation/switch off (operation if not 0) MCIC. Please see the above for control parameter revision and parameter solidification and application. When parameter revision state is entered, any operation with + or — is of the same function with correct password. Generally, the control parameters should be the ones revised in excitation adjustment. Any revision should not be made to control parameters to avoid affecting unit’s normal operation. Thin-film button fis used to return to the former menu, and is used to enter the next menu, and button cancel can be used to return to the main menu. 4, Accident and failure recording picture which is mainly used to make real time records of alarm and failure signals during the operation of excitation system, such as PT wire breakage, over excitation limit, power cabinet limit action, dual generator failure and missing generator pulse,etc, The picture is shown as follows: [Alrm and malfunction record) PI wire breakage 2004.01.18—14:54:38 Communication abnormality 2003.12.11—10:54:18 The picture can contain 4 records of accidents and failures. The former ones are sent to industrial control machine or back-stage monitoring PC to store as history. Each record shows the type of accident or failure and real time clock information of each action. Once accident or failure occurs, the picture pops up automatically to remind clients to check. Cancel button is used to return to the main menu. 5, Power adjustment menu is used to adjust measurement value from regulator to output power. The large tolerance of reactive power measurement value gives direct impact on unit from excitation system. Integrate into the power network in manual mode of exciter set with more than 50% load, input measurement value of active and reactive pointer. Press confirm and the regulator will calculate automatically the revved parameters SIN and COS which will be input into control parameters 17 and 18. Cancel button is used to return to the main menu. The picture is shown as follows:Please input the active power readings of current pointer P=00000 Please input the reactive power readings of current pointer Q=00000 Revision parameter output ‘SIN-00000 = COS=00000 6, Unit parameter picture shows such rated parameters of the working unit as: rated active power, rated reactive power, rated voltage: rated excitation voltage, rated excitation current. The picture is shown as follows: rated active power rated reactive power QN rated motor voltage = UN=10500V rated excitation voltage ULN=260V1.7. LH-WLT02 Excitation System Single-screen structure illustration LH-WLTO2 excitation system with single-screen structure is mainly applicable in units with excitation current of less than 500A. The regulator, newly developed by our company, boasts compact structure, high reliability, complete function and wide-screen LCD display in English. Being user friendly, it is up to national standards in various performance indexes. The single-screen structure of excitation system of small and medium-sized units without cables can further improve the reliability of the total system. It boasts convenient and easy test, installation and maintenance, and saves site occupancy, providing perfect plans for some clients. (Please refer to LH-WLTO2 exciter set function and performance for more information.)2. Excitation equipment maintenance and troubleshooting 2.1. Safety Rules While working inside excitation cubicle, there must be warning signs, or serious personal injury may be caused by contact with live components. So, the live components above 50V inside excitation cubicle are protected during system design. Maintainers without necessary training and prevention measures are not allowed to work in the excitation cubicle. The following descriptions are applicable to the unusual conditions for the high voltage excitation system. ‘The components directly connected with excitation transformer auxiliary side and generator rotor magnetic field windings inside excitation cubicle, such as radiators, copper banks etc, have such extremely high voltage that it’s very dangerous to touch with them. So, safety protection barrier must be set up with a certain distance away from the live items to perform electrical component measure for the equipment in operation. It’s reiterated that maintainers must be trained properly, which is an absolutely necessary job and must be done. Caution: There may be large short-circuit current inside excitation cubicle because high voltage exists at the excitation transformer auxiliary side and generator rotor magnetic field windings. It’s specially indicated that great danger of electric shock exists because the discharging resistors of deexcitation switch and magnetic field loop are directly connected with generator rotor windings. Protection equipment are needed to be installed in excitation cubicle for personal safety.If protection equipment are moved, maintainers must stay faraway from dangers by high voltage and large current. While control cubicle door is opened during operation, maintainers should pay attention to high voltage (above SOV) inside. Voltage inside rectifier cubicle may be above 1000V and current is very great. High voltage danger should be warned. Maintenance work must be done under power off and with protection measures. If not, the following precaution work must be done: Keeping away from operation zones and putting yellow signs of “high voltage! Danger!” in security zones. Disconnected switches are closed because of control faults or wrong operations. To avoid such cases, corresponding protection measures are needed, such as switch with keys to avoid switch connections by wrong operations again. 2.2. Consequence by Negligence Not abiding by safety rules may cause serious damage to equipment. Warning: if there are not protection equipment inside cubicle with electricity, it’s increasing great risk of danger for not only operation staff but also other personnel near to the live equipment. If the required maintenance work is not finished or only done partly, it may result in hazards and serious. Especially when there’s debris and dust left inside rectifier cabinet, high voltage flashover will occur and cause hazards.2.3. Requests for Working Staff Maintainers must be familiar with installation and operation and need to be trained on maintenance. They shall be familiar with control principles and corresponding operation and the alarms not only from excitation equipment itself (on-site control) but also control center (remote control, see operation instructions). They shall not only have a great deal of experience about excitation equipment power source and such faults as emergency shut-down but also are capable of shutting down the system under emergent cases. They must know well on measures for prevention of accidents at working field and be trained on first-aid and fire extinguishing. 2.4, Descriptions of Emergencies Outbreak of fire Working staff must know positions of fire extinguisher and emergency exit and be capable of using fire extinguisher, including types of halogen, C02 and foam ete. (A). CO2 fire extinguishers are used for extinguishing fire on electrical equipment, which have no direct harm on persons. (B). Foam fire extinguishers are made for extinguishing fire on non-electrical equipment and not used for electrical equipment fire extinguishing. Otherwise, it will cause direct harm to persons. In case of outbreak of fire in the system, first cut off excitation on site or from control center and start emergency shut-down device if necessary (see operation instructions), then cut off all power supply for the system. While extinguishing fire inside cabinet with electricity, only CO2 fireextinguisher can be used and foam or water type must not be used! 2.5. First-aid Measures for Electrical Devices First, cut off excitation on site or control center and start emergency shut-down device if necessary (see operation instructions), then cut off all system power supply. Rescue the wounded from dangerous zones, then lay them down and offer trained aid to them. At the same time, consider possible consequences of electrical equipment and ask for help.2.2 Open-loop Test Open-loop text measures are briefly stated as following: 2.2.1. Wiring Test connection has two modes: a). Disconnect machine terminals and use electricity delivered reversely from the system. In this type, potential transformers, current transformers and rectifier transformers of excitation system are used and the whole excitation system can be checked simultaneously. The wiring principle system diagram is show as fig 1. Fig 1 Pri iple Diagram of Excitation System ) Use three-phase voltage regulator to simulate input of potential transformers and rectifier transformers. Wiring principle system diagram is shown in fig 2. Fig 5 Excitation regulation cabinetLtesares | ape flee | Regulator} | — FH HaACe wreren > | ws 1 | |= +4 a « | Daren rd w [Sew | & ee | Fig 2 Open-loop test principle diagram (11) In mode a, disconnect three phases at the outlet of generator end. The output cables or busbars have electricity under test and necessary protection measures need to be taken. In mode b, lead wires from generator terminal potential transformers to terminals of excitation regulation cabinet shall be cut off. Switches of rectifier bridge AC input shall be cut off simultaneously to avoid inducing voltage at primary side of current and voltage transformers. In addition, if the rated voltage at auxiliary side of rectifier transformers is very high, synchronous transformers ratio shall be adjusted to the lower grade during test in order to ensure normal synchronized signal while synchronous transformer input is lower. In the above two modes, rotor cables at output of deexcitation switch shall be disconnected and electric stoves or resistances are connected as load (power of load shall be considered, silicon-controlled rectifier can be conducted reliably with 1A above excitation current) and load capacity shall be considered. While silicon-controlled rectifier (SCR) is completely opened, output voltage at DC side can reach twice as rated excitation voltage. Oscilloscope is connected with load to observe output wave form of SCR. It’s cautionedthat additional damping resistance needs to be connected in the system, while the highest output voltage exceeds the scope of oscilloscope. uw Fig3 Excitation voltage wave form in open-loop test Open-loop test procedure: each button of excitation regulator is on working position; open-loop small current test is done through channel I and II. Excitation output wave form can be observed from oscilloscope when adjusting regulation buttons from above two channels. While output : wave form of SCR is normal, the wave form is symmetrical six-wave-head without phase loss and changing smoothly from the smallest to the largest without control loss along with given input (along with magnetic increase or decrease), as shown in Fig 3. 2.2.2. Safety Measures In the main circuit, one side of deexcitation switch is directly connected with generator rotor and input side of Rectifier Bridge is directly connected with auxiliary windings of excitation transformer, so there is high voltage in main circuit during excitation equipment running. Contact with equipment in main circuit shall be avoided during normal running or test in order to avoid electric shock accidents. It’s worth cautioning that rotor excitation circuit connected with deexcitation switch shall must not be touched because of over voltage under deexcitation with large current.Maintenance and overhaul works shall be done under completely out of power supply. It’s better to establish striking warning lines in the working zones to prevent the access by people other than workers. As for not-switching-on breakers, deexcitation switches and isolators during maintenance, wrong operation prevention measures must be taken, for example, a prohibition sign of “Working, Switching on Forbidden!” is hung to avoid accidents by wrong operation. Unsuitable safety measures, such as wrong connections of switches during maintenance may cause not only personal injury accidents but also damages to equipment, which will increase repair costs. In addition, ignorance of equipment maintenance may shorten their service life and even affect normal working in case of serious situation. For example, accumulated dust on silicon assemblies may cause voltage flashover, which affects insulation of main circuit and may seriously damage the equipment. 2.2.3. Requirements for Main © Maintainers must be familiar with related drawings and reference materials. © Maintainers must be trained or proficient in operation and installation and can fulfill completely maintenance and overhaul works. Maintainers must know well all kinds of signal meanings in equipment running and can take corresponding measures under necessary condition. ‘Maintainers must have capability for handling emergent cases, such as disconnecting deexcitation switch and cutting off power supply.2.2.4. Disposition of Emergent Cases At first, disconnect deexcitation switch and cut off all power supply connected with excitation equipment on site or from control center. If fire alarms occur, CO2 fire extinguisher can be directly sprayed on live afire equipment but not on afire persons. Foam fire extinguisher can only be used on non-live equipment must not be operated for live ones. Howver they can be used for afire persons.2.3.M: tenance of Excitation Equipment 2.3.1. Overview A majority of electrical components have no wearing indications except some minor aging signs, but there are some electromechanical devices inside excitation equipment, such as breakers, contactors, air blowers which will have mechanical wear. Fault system keeps scanning working channels and backup channels under normal condition and moreover, fault inspection system itself may be supervised. But fault inspection system cannot detect all faults, for example, whether the switching relay is normal, so it’s necessary to make periodical inspections of equipment inspection. During periodical inspection, the following functional inspection checks must be done besides cleaning the equipment and components or replacing fasteners equipment. Dust may be easily accumulated on silicon components because of air circulation in power rectifier cabinet and so are other circuits. Vibration may cause looseness at joints of terminals or other bolt connections. There are high voltage and large current in excitation circuit. Dust accumulated on equipment and conductor surface increase risk of equipment component damages by voltage flashover. Periodical inspection maintenance can decrease such risk significantly. 2.3.2. Working Conditions for Maintenance While doing maintenance job, the actual conditions of excitation system shall be paid attention to. Different inspection and maintenance items are executed under different conditions. Work condition (1), close off all power supply of excitation equipmentand cut off all external electrical connection. Work condition (2), only auxiliary power and DC are supplied. Work condition (3), open-loop test condition. Work condition (4), equipment is running. 2.3.3. Maintenance Timetable ‘Number | Items Once every 1 month _| Once every 1 year | Excitation transformer 1 Excitation Check surface dust and | Check surface dust and transformer debris and abnormal debris and abnormal noise. noise. Rectifier cabinet 2 Air blowers Check dust and debris | Check dust and debris and and normal wind power | normal wind power and and abnormal noise. _| abnormal noise: 3 | Radiators, air | Check dust and debris | Check dust and debris and | vents and working working temperature ete. temperature etc. 4 Silicon-controlled Check trigger circuits of all rectifier (SCR) SCR. | Deexcitation cabinet | 5 Deexcitation | Check dust, contacts and arc switch extinguish chamber etc. 6 Cross-over Check dust and debris | Check dust and debris ete. etc.. 7 Demagnetizing | Check dust and debris | Check dust and debris and resistance etc. whether electric fuse is intact (only for nonlinear resistance demagnetizing), | ‘Adjusting cabinet8 [pcs Check dust and debris ete, 9 Functional channels switching Check fault switching | inspection (switching to main function. channel after short-time | running through backup channel). Items in above table will be described below in detail. Once-every-3-months inspection shall be separated from once-every- 1-year inspection. No maintenance is required if the regular inspections every 3 months find no abnormality. The effective maintenance jobs are done during once-every-1-year inspection. Cleaning jobs are not only limited to the items in the above table and can be done for the whole excitation equipment including excitation cabinet body and the structural components. In the first year after system starting up, maintenance jobs are carried out exactly according to the above timetable. The following feasible time interval of maintenance work can be adjusted according to the first year maintenance results. If dust accumulates quickly, maintenance time interval shall be shortened. If working condition is good and very clean, maintenance time interval can be prolonged properly. 2.3.4. Once-every-3-months Maintenance Once-every-3-months maintenance can be done under work condition (4). 1. Excitation Transformers: Check dust and noise in excitation transformers. 2. Power Rectifier Cabinet:Check whether serious debris is on air blower surface and blades, whether air blow is normal and whether noise is normal. Because air blower is not easily dismantled for lubricating rotor, backup air blower can be used during next maintenance job while air blower noise is obviously high 3. Air Blower in Power Cabinet: Air blower in power cabinet is usually fixed on the top or bottom of cabinet roof, where air blows upward. Air blower is easily worn because of long service durations. Make sure the air blows upward when air blower is replaced. Check dust on air vent of cabinet door and air blower cover of power cabinet. Remove the cover for cleaning in case of much dust. Clean dust on air blower blade and electric motor. 4. Regulator Cabinet: Regulator does not send abnormal signals. Data on the panel such as excitation voltage, excitation current, generator active power, generator reactive power, generator voltage and other analog parameters and readings of other meters in control room shall stay in allowable error ranges. If data of regulator I and II can be shown simultaneously, the data in two channels shall be same ( within allowable error range). In regulators with two-channels system, channel I is usually chosen as main working channel. In order to ensure normal switching function and redundant channel function, checking switching function between two channels is necessary. Under manual switching, switching can be done under that control signals in backup channel shall be same with working channel. Generator terminal voltage or reactive power has no obvious fluctuation after channel switching. If fluctuation is large, switch back to former channeland identify the reasons. 2.3.5. Once-every- -year Maintenance On the basis of once-every-3-months maintenance, once-every- 1-year maintenance is described as following: Deexcitation switch maintenance shall be specially paid attention to in once-every-1-year maintenance. Surface debris and body damage of deexcitation switch firstshall be checked first. Movable contacts of usual subject to wear are checked next. If deexcitation switches act seldom, its connection and disconnection operations shall be done to check whether action is normal to avoid accidental lock. 2.3.5.1, Excitation Transformer Under work condition (1), carefully clean dust and debris over transformer cover and conductor joints with dry cloth, vacuum cleaner or compressed air (not high pressure)., No any solvent cleaner shall be used. 2.3.5.2. Rectifier Cabinet Under work condition (2) or (3), check dust, debris, wind blow and noise of air blower and clean air blower if necessary. Dust screen. Clean or replace dust screen if it’s very dirty. Check SCR: (1) Open front inside door of power cabinet. (2) Open organic glass face panel of power units. (3) Check SCR radiators for indications of rust, erosion, creepage and carbonization and take timely measures or replacement. (4)Clean dust on SCR radiator surface with brush, vacuum cleaner or compressed air (not high pressure). No solvent cleaner shall be used. After cleaning, reinstall organic glass face panel of power units.10.5.3. Deexcitation Circuit and Deexcitation Switch Under work condition (1) , check dust, debris and contacts buming. Clean switch body with brush or dry cloth. Open arc extinguishing chamber and check contacts and polish burned parts with fine sand paper if any. After deexcitation switches is disconnected after servicing under rated current or above, check chamber and contacts and blow away smoke in the chamber with compressed air. Polish bumed parts of contacts if necessary. Check bolt connections. Under condition (1), check whether bolt connections of copper banks and bolts at the connection of SCR cross-over (only for nonlinear resistance deexcitation)are loose or not. Check insulation problems by dirt and bolts looseness: under work condition (1), clean the joints with dry cloth if necessary. It’s suggested to tighten all bolts including connection ends after one-year running and do the same job once every 4 years. 10.5.4. Regulator Cabinet Check whether PCB is clean. Under work condition (1), clean PCB with compressed air (not too high pressure). Check whether pins of pluggable components on PCB are dusty and whether the joints are dusty. If dust and debris accumulated at such positions, PCB malfunction may be caused. Clean with compressed air (not too high pressure) or vacuum cleaner. Don’t clean with any solvent cleaner. Check regulator function. Under work condition (4), check whether signals on panel are normal, whether IOP indicators are normal and whether backup channel working is normal. 10.5.5. Open-loop TestOpen-loop test is done for the complete excitation equipment if necessary. Both simulation of control circuit and excitation output wave form can be checked in this test. Simulation of input and output signals needs to be done according to electrical drawings and related test documents. 10.5.6, Fault Disposition 10.5.6.1. Conditions of Fault Disposition 10.5.6. 2. Safety rules need to be read before fault disposition. All power supply and outside electrical connections must be cut off to ensure personal and device safety if components of equipment need to be replaced. Plugging components with electricity is usually prohibited. Some components, as CMOS components, are sensitive to static electricity and are easily damaged under static electricity, so it shall be very careful not to touch them when changing such components or PCBs with such components. At first, cut off power supply and it’s better to wear discharging sleeves on wrists under operation. In emergent cases, touch the unpainted metal places of non-live cabinets with hand before replacement to discharge static electricity on hand to decrease the risk of components damages by static electricity on hand. It’s better to usé the replacement components provided by our company, which are inspected in our factory and can replace the original parts directly without the needs of wire jumper and new configuration. 10.5.6.3. Fault Disposition In most cases, all normal functions of excitation system are continuously monitored by excitation faults monitor system. The monitor system will send alarms and give fault information while excitation functions go wrong. Faults shall be eliminated in the ways described below. (1) PT FaultsPT faults signals sent from regulator means that there are faults at 1PT used by channel I or 2PT used by channel II. In such case, faults alarm display pops up on screen with flicker warning and excitation system sends PT faults output signals to the monitor and control system. When faults occur in the current working channel, regulator can automatically switch to backup channel. PT faults are usually caused by PT three-phase voltage imbalance. If PT goes wrong in channel I, check first whether IPT three-phase voltage is balanced at terminal board of regulator cabinet external connection. If three-phase voltage is imbalanced, faults are located outside excitation cabinet and then check whether IPT high voltage side fuse is intact and whether connection terminal board is fixed well. If three-phase voltage is balanced, faults happen inside excitation cabinet, where IPT internal connection shall be checked or analog value measure modules of IPT signals shall be checked too. PT faults in channel II are handled of the same way as channel | , 2PT voltage signals are checked only according to above procedure. (2) AC Power Loss AC power loss means that AC contactors for auxiliary power circuit power off, which means the loss of both section I and section II of auxiliary power. Auxiliary power provides power for lighting, heaters and air blowers of excitation system. Because there is a time restriction of power cabinet running without air blowers, it’s necessary to handle auxiliary power loss faults as quickly as possible although excitation regulator can work normally after auxiliary power is lost. While AC power loss faults occur, fault alarm display pop up on screen with flicker warning. Under AC power loss faults, check first whether AC breakers is closed in the power supply circuit of auxiliary power system.If breakers are closed and faults remain there, then check if the two parts of auxiliary power are sent to excitation panel. (3) DC 220V Power Supply Loss DC power supply loss means that DC 220V operational power supply goes wrong. When generator is synchronized, even though excitation system can work normally with DC power loss, the deexcitation switch will refuse any operation, so it’s necessary to handle such faults as quickly as possible. While DC power loss faults signals are sending, fault alarm display pops up on screen with flicker warning. If DC 220V power is truly lost, the alarm of 24V power faults displays too because 24V power is provided by DC 220V operational power supply. While DC power supply loss faults occur, check first DC voltage at external connection terminal board of power circuit fuse. If the voltage is disappearing, faults are located outside excitation cabinet; otherwise, the two fuses shall be checked. If the two fuses are intact, check supervisory relay of DC operational power according to drawings. If operating coils of supervisory relay are damaged or there is contacts conglutination, DC power loss signals may also appear. If fuses are broken, fuse of small capacity shall be used (ensure no short circuit in excitation system operational circuit before replacement). (4) Over-voltage Protection Actions Over-voltage protection actions are rotor protection actions on over-voltage (only limited to sending warning of over-voltage protection). Rotor protection actions on over-voltage include forward over-voltage protection actions and backward over-voltage protection actions. Over-voltage protection devices mainly use ZNO to absorb all probableforward and backward over-voltage in rotor under any cases. When over-voltage protection signals occur, fuses series connection with ZNO resistance shall be checked and changed if fuse indicator pops. Check whether ZNO resistance is intact. In order to record times of over-voltage protection actions, counter cannot be cleared randomly. (5) Initial Excitation Failure Initial excitation failure is that generator terminal voltage is still less than 10% of rated terminal voltage after 10 seconds from automatic initial excitation beginning and the regulator sends initial excitation failure signals at this time. Afier initial excitation failure signals are sent, first check whether regulator is in normal start-up preparation status before initial excitation, for example, AC and DC knife switches, deexcitation switches, knife switches at PT high voltage side and initial excitation power switches are all closed and there is no shut-down signals. (In such case, regulator can be powered on again to preset). Then check whether there is initial excitation power, whether PT fuses is broken and whether connections of PT circuit are loose. If all above is normal and initial excitation can be done in another channel, faults may be located inside the current channel. If initial excitation cannot be done normally, check whether there’s grounding or short circuit for initial excitation circuit, pulse public circuit, SCR and rotor circuit. After initial excitation failure signals are sent and fault reasons are found, manual instructions of inversion deexcitation are sent to reset initial excitation failure signals and then i instructions can be released again to build up voltage. If regulator does not send initial excitation failure signals and the unit can’t start excitation automatically, initial excitation from local excitation panel or remote manual excitation can be done. Causes of automatic initial excitation failure can be found by checking whether signals of 95% units rotating speed and excitation actuation are sent to excitation paneland whether signal are shaking. If excitation start on-site and from remote control center, check whether the generator set frequency exceeds 45HZ. If excitation current has been delivered to generator excitation windings inside excitation equipment and generator voltage fails to be built up, excitation current may be not big enough and we can properly adjust current-limiting resistance for excitation start and increase excitation current to test and check. (6) Overexcitation Protection Overexcitation protection is that excitation current goes beyond 2 to 3 times rated excitation current, which is serious and may be caused by rotor short circuit or excitation control loss. When overexcitation protection acts, excitation equipment will simultaneously send signals to generator protection devices which will disconnect generator breakers and deexcitation switches. Operating value of overexcitation protection is usually set as 2 to 3 time rated excitation current. Exact data refer to ex-work test report. Under overexcitation protection, rotor circuit and excitation system shall be examined completely. First, check if there’s short circuit in rotor circuit and if the SCR and fast-acting fuse in power cabinet and nonlinear resistance and fast-acting fuse in deexcitation cabinet are damaged. Then check whether excitation system is working normally under small current test. PT, CT at auxiliary side of excitation transformer and synchronous transformer at auxiliary side of excitation transformer shall be checked carefully before start-up to make sure that circuit and phase are normal. Don’t start the machine rashly for excitation before fault reasons are identified.(7) Regulator Faults in Channel I (I) Regulator faults in channel I (II) are that there are hardware and software faults of regulators in channel I (II). In such case, flicker warning displays on screen. When such faults occur in working channel, regulator will automatically switch to backup channel If software faults are caused by disturbance, regulator shut-down or reset can be tried to see if the faults will disappear. (8) Pulse Loss in Channel I (11) Pulse loss is that pulse in channel I (II) has been lost before being sent out. While such faults occur in working channel, regulator will automatically change to backup channel. If signals of pulse faults in channel I (II) remains there, there may be no synchronous signals. (9) 24V Faults 24V faults are that there are faults in 24V power supply provided by double 24V switching power supply. In such case, indicators of 24V power supply faults appear on the panel and alarms are sent. To handle 24V faults, check related input and output of switching power supply modules to check whether power supply modules are damaged and then take corresponding measures. (10) Air Blower Faults in Power Cabinet Air blower faults in power cabinet include power supply faults of airblower, phase loss of air blower and air volume too low, which are monitored by relay installed inside excitation power cabinet. In phase loss faults in air blower, running sound of air blower is abnormal and air blower can’t keep working stably. The faulty air blower shall be shut down by manual control. Check first whether three-phase balance of air blower power supply is maintained and then check the function of blower internals. When power cabinet is in working status and air blowers do not work because there’s no power supply or the power source relay remains disconnected, excitation system will send signals of air blower faults of power cabinet. In such case air blower power supply and the relay shall be checked. (11) Fast-acting Fuse Broken in Power Cabinet Fast-acting fuse broken faults in power cabinet results from the breaking of the fuse connecting power cabinet with SCR in series. Fast-acting fuse broken is a serious fault. First find which fuse is broken. (when fast-acting fuse connected with SCR is broken, the indicator on the fast-acting fuse is automatically popped out and indication signal is sent out.) If fast-acting fuse in the SCR circuit is broken, the SCRs connected in series shall be checked (cathode and anode of SCR will have a short circuit when SCR is damaged). Small-current test shall be done before start-up to verify whether output wave form of power cabinet is normal. Don’t start the machine for excitation before identifying reasons of fast-acting fuse broken and eliminating such faults.3. Excitation Panel Installation Manual 3.1. Summary This section includes specification on storage, transportation and installation of excitation system. It’s prepared specially for those who are qualified for installation of electric equipments. Any installation personnel must familiarize the documents and safety precautions regarding installation emergency likely to occur at power plants! The following safety precautions shall be read carefully before commencement of installation! 3.1.1. Safety Precautions The safety instructions stated below shall be followed without failure during the whole period of installation, debugging and maintenance. The safety instructions and the following safety warnings shall be read carefully before commencement of any operation in relation to the excitation system. Caution! © The circuit diagram of relevant power supply must be read carefully before commencement of any operation! © Certain temporary power supply (such as for lighting, electric tools and ete) is necessary for installation and shall be supplied with special attention! eAll power supplies must be disconnected before any operation! And the disconnected power supplied must be measured with voltage so as to determine zero potential without failure! © Once the excitation system is electrified, any other testing equipments shall be prohibited to connect to the terminals! ® Static discharge may cause circuit failure, be cautious not to contact any electronic parts! 3.1.2. Acceptance All goods shall be unpackaged for checking during delivery. The packages shall be visually inspected for any damage before unpacking. If yes, the equipments shall be unpacked for checking in the presence of the underwriter and manufacturer concerned. Any visual damage of the packages must be recorded in the relevant Packing List! Any damage discovered during unpacking inspection must be reported in written form to the underwriter and manufacturer within one (1) week! Importation! The buyer shall be exempted from any liability if the manufacturer fails to receive the damage report!3.1.3. Transportation of Packaged Equipments The excitation system needs to unload with extra care from the transporter by crane, shovel loader or forklift. The packages must be lifted gently along the arrowed direction during unloading, and the symbols attached to the packages are marked in accordance with relevant national standards. If the shovel loader is used for lifting and handling the packages, the fork must be inserted underneath and in parallel to the container bottom. To avoid slant and overturn of packages, extra care must be given to i the center of gravity (Marked with special symbol). Figure 1 Package Handling 3.1.4, Storage To avoid degraded quality and damage led by improper storage, relevant safety precautions must be observed during the whole course from equipments stock-in as of stock-out for installation. 3.1.4.1, Storage Conditions The equipments must be stored indoor with intact packaging and placed on the shelf or wooden rack. The keeper is responsible to control the storage entrance and manage strictly. The storage shall be equipped with extinguishers of compatible types and fire control materials of operable condition. The storage shall be remained clean, dry and ventilating, and the placement of articles shall be logic, any wastes and used packing must be removed! To prevent equipments against contamination and damage, pests and vermin must be prohibited from entrance. The following requirements shall be followed for proper storage:© Permissive Storage Temperature: -25°C~+55°C Relative Humidity (No condensation is permitted): 5 % ~85% 3.1.4.2. Inspection during Storage To ensure proper environment and quantity, regular inspection is required (At least once for 2 months). Any slight variation must be given due attention and corrected in a timely manner! The inspection shall be carried out as the follows: © Marking © Covering & sealing © Dryness © Mechanical damage © Cleaning 3.1.5. Unpack aging 3.1.5.1. Unpacking the Package Casing Unpack the package casing as per the following processes: 1. Unpack the package top cover 2. Remove all inner supports 3. Remove side board and plastic membrane 4. Visual inspection of damage by transportationFront Figure 2 Unpacking Equipments/Cabinet 3.1.5.2. Transportation of Equipments and Cabinet The unpacked equipments shall be transported to the installation site by crane or forklift. The equipments shall only be allowed to place on flat and even ground! Special attention shall be paid to ensure the equipments against turnover during handling. The equipments/cabinet need to lift with sling fastening at the top (See Figure 4). The following instructions shall be followed if eye rings are used for lifting: © Check whether the bolts of eye rings are loose, if yes, the bolts shall be screwed down before lifting. © The sling shall be ensured of sufficient loading capacity. © The spacing between sling and hook shall not be too long so that prevent the cabinet from swing during lifting, © The cabinet can only be placed on level ground!Figure 4 Lifting with Eye Rings 3.2. Installation of Cabinet In general, relevant preparation as that for site installation of the equipments is completed at the workshop, including connection between cabinets, embedded holes on the bottom, sides and top of the cabinet and etc. The lighting and passage for site installation must be available. Condensation is likely to occur at the installation site where it’s humid and with varied temperature. However, condensation is avoidable by heating at the installation site. 3.2.1. Summary The following processes shall be followed for cabinet installation 1. Cabinet Array and positioning 2. Inspection 3. Cabinet fixing 4, Unscrew bolts of eye ring 5. Sealing 3.2.2. Cabinet Array & Positioning Generally, the equipments are packaged in separate cabinets during transportation, and upright placement of cabinet is required during transportation! After unpacking as instructed above, array the cabinets in order as per the design layout.3.2.3. Inspection Once the cabinets are arrayed properly and before fixing, all doors and covers shall be checked for intactness and for smooth opening/closing or free from distortion. 3.2.4, Foundation Fixing Channel steels are embedded in the installation structure of the power plant, where the equipment cabinet shall be fixed to the channel steels by riveting welding, Cabinet Screw Figure 4 Foundation Fixing Once the cabinets are arrayed and fixed to the foundation firmly, the eye rings and bolts can be removed and kept at a safe place! 3.3. Electric Connection 3.3.1. Electric Wiring The inner wiring diagram of excitation equipment is designed by the manufacturer; when the cabinets are assembled during site installation, the preset wiring and connection to corresponding terminals are available as per the shop drawing, Connection of the excitation equipment to other installations of the powerplant shall be completed by design institute or installation contractor, including signal circuit, control, power circuit and the like. In selecting cables and wires, special attention shall be paid to ensure the length of cables sufficient and the method of cabling. Increased voltage drop may ity, and the cables of equal length may also cause less impair sens sensitivity. The control cable from and to the control room is generally connected to the terminals of regulating cabinet or de-excitation cabinet; the minimal section of cables is stated in detail in the circuit diagram. The clamps or tapes for bundling cables shall be attached to the cabinet bottom, so that prevent the cables joints from overstress. The cable clamps can also be used for cable electromagnetic shield grounding. 3.3.2. Copper Terminal Blocks Before connection of copper terminal blocks, the user shall wipe up the bottom and connecting surface with soft cloth. The contaminated connecting surface may be cleaned with detergent (E.g. alcohol) or soft brush. The connecting surface shall be absolutely free of dirt and oil. Proper grease may be applied evenly on the connecting surface with sponge rubber pad; a thin film is applicable. The copper terminal blocks shall be connected immediately after cleaning. The bolts of various units for electric connection must be screwed down at the torque as listed in the following form. And the bolts shall be greased in advance at the section to contact. Bolt Size: MS | M6 |M8 [M10 [M12 [M16 [M20 [M24 _| [Torque (Nm): | 2.2 [3.7 [9 [18.8 [31.2 75.5 [1525/1462 | Connection of copper cables and copper terminal blocks is illustrated in the following diagram.Screw Gasket Copper plate Nut \ ‘ / Figure 5 Cable Connection 3.3.3. Grounding Key copper terminal blocks for grounding shall be paved on the cabinet bottom, and key cables for grounding shall be bolted to the copper terminal blocks for grounding. Figure 7-6 shows a design option.Copper Terminal Blocks UO OoO000°0 | el Figure 6 Option of Key Copper Terminal Blocks for Grounding 3.4. Sealing According to the designed and required protection rating, the intersection between cabinet bottom rack and foundation must be sealed with airproof washer. Caution! Open foundation must be sealed airtight after debugging, for the pests or dirt is likely to inroad! 3.5. Completion All conveyers shall be removed, such as wooden support in the equipments (If any). All unused articles around shall be removed, such as packaging materials or cable scraps in the cabinet and so on. Wipe up the isolation section with a antistatic rag, no any solvent is prohibited! 3.6. Examination © Check connections of all bus bars and housing, for these connectionsare open during transportation. © Check the foundation fixing. © Check whether the protection rating of equipments are satisfactory, particularly the cable entry at the bottom and cabinet top. © General visual inspection: Appearance, intactness, marking, impurity, cleanliness. Check whether the cable connection and wiring are correct and complete at the installation site. © Check whether the grounding of shielding cable at the cabinet entry is correct (Cable clamp bracket or gland)? © Check whether all protection wires are correct and connected? © Close the cabinet doors. 3.7. Clarification In the case of interrupted installation and wiring, the following tasks shall be completed for preventing the equipments from contamination, damp and inroad of impurity: © Close all cabinet doors. © Cover the cabinet properly with plastic cloth. Heating at the installation site or power on the heater in the cabinet (If the heater is installed).4. Installation and Maintenace Manual of Transformers The instruction manual is suitable for the loading and unloading, transportation, storage, installation, operation, and maintenance of the cast resin dry type transformers with no-load or load ,rating 25000Kva, 35KV or below, manufactured by Hainan Jinpan Electric CO.,Ltd. 4.1. Products overview JST cast resin dry type transformer is made of superior quality materials through the vacuum cast equipments of German HUBERS and George Cut-to-length Line. The product complies with GB6450 and TEC60076-11 standards and the characteristic of the products is as follows: (1) perform good at fireproof, safe and reliable operation, suitable for the load center; (2) low-energy; (3) small size, light weight, and convenient to install; (4) no pollution and no need for special maintenance; (5) damp-proof, (6) low partial discharge; (7) high mechanic intension and no cracking. JST products are widely used in power transmission system, hotels, skyscrapers, business centers, stadiums, petrochemical plants, power plants, airports, stations, sea platforms and especially for sites with limited installation room near to the load center and special demands for fireproof ,which sufficiently reflect the superiority of small size and good fireproof. 4.2. Service conditions 4.2.1. Cooling method includes air-natural cooling (AN) and air-forced cooling (AF). Both AN and AF transformers, a well ventilated site is required. If the site is not well ventilated, such as a basement, the ventilation of 4m3/min each KW loss should be ensured. 4.2.2. Enclosure protection degree: IP00, IP20, IP23 etc. 4.2.3. The transformer should be installed in locations where the altitude is less than 1000 m and ambient temperature is no more than 40°C. If not, corresponding adjustment should be conducted according to GB6450.Wuhan Lianhua Electronics Co., Lid. 4.3. Loading and unloading 4.3.1. Device: Choose a crane with proper tonnage. When loading and unloading, the products should be handling with care, strictly according to the relevant regulations. 4.3.2. Lifting from the bottom: When lifting, hitch the steel wire to the blocks under the four corners of the package, as figure 1 shows. Lifting from the bottom Figure 1 4.3.3. Lifting from the top (with package): when lifting the transformer from top with package, do as Figure 2 shows. After handling, repackage 4 Lifting from the topWuhan Lianhua Electronics Co., Ltd. 4.3.4, Lifting without package: when lifting a transformer without package or out from its package, four lifting lugs/holes provided on the top of the core and coil structure should be used, see Figure 3&4.Wuhan Lianhua Electronics Co., Lid Use the four lifting holes Figure 3 Figure 4 4.4. Transportation 4.4.1. During transportation, the transformer should be thoroughly protected against rain, snow, moisture, dust and avoid damage from dragging and pulling. 4.4.2. During transportation, the oblique angle of the transformer should not exceed 15°.‘Wuhan Lianhua Electronics Co., Ltd, 4.4.3. In regard to transformer with wheelbarrow, usually unload wheels in order to avoid moving during transportation. 4.4.4. When lifting with a forklift, bars should be used between forks and the lower clamps to avoid damage to the core. Measure must be taken to prevent leaning of the transformer. 4.4.5. Binding and pulling coils, insulations, supports, down-leads and other fragile parts are strictly prohibited. 4,5. Inspection upon receipt The transformer shall be inspected on its arrival. 4.5.1. Check whether the data on the nameplate is consistent with ordering contracts in terms of product type, rated capacity, rated voltage, tap range, connection type, impedance, etc. 4.5.2. Check whether the documents attached to the transformer (the installation and service manual, qualification certificate, routine test report, packing list and etc.) are complete. 4.5.3. Check whether the elements and accessories listed in the packing list are inside the package. 4.5.4. Check whether the transformer has been damaged during transportation. Note should be made of loose or broken connections, damaged or displaced parts, cracked insulators, dirt or foreign material. The temporary brace that have been employed for transportation must be removed. 4.5.5. Identify all units and check them against the shipping list to ensure complete. 4.5.6. If the transformer is not to be put into use immediately after the inspection, repackage it and store it at dry and safe places where it is immune to damage and brigandage. 4.6. Storage 4.6.1. If the transformer must be stored, the package should be kept. Repackage the transformer afier the inspection. 4.6.2. The products that should be stored for a long time should be stored in clean and dry warehouse. Don’t store the active chemicals and corrosive things close to the transformer. 4.6.3. Stacking products is not allowed.Wuhan Lianhua Electronics Co., Ltd. 4.6.4. The products that are placed outdoors for a short time should be padded by woods, of which the height is not less than 100mm. 4.7. Installation 4.7.1, Before installation, the user must read this manual, the nameplate and outline drawing carefully. Besides, the user must know the weight of product, the way of installation, and prepare the corresponding equipments and tools for lifting. 4.7.2. The installation location should keep off: harmful smog or steam, superfluous corrosive dust, vapor, smog, condensation, drip, ete. 4.7.3. Transformer installation 4.7.3.1. Commonly, a transformer is ready for installation if its wheels are unloaded. For transformers with tamperproof and other special requirements, anchor bolts in transformer’s foundation should be fastened. 4.7.3.2. Safety should be taken into consideration when designing the transformer installation to ensure that human body is kept from touching live parts after the transformer is energized. For those without enclosure, isolation barrier should be installed. Hazard-waming signs should be put up on the striking places of the core, the cabinet and the barrier. 4.7.3.3. For the sake of safety, within 1000m above sea level, the safe insulation clearance between transformer live parts and the ground should not be less than: voltagetkV) <1 3 6 1 | 15 | 20 7 35 25 [ @ | 90 [as [is | as | 300 Safety clearance (mm) | And the safe clearance between transformer live parts and the working area of operator should not be less than:‘Wuhan Lianhua Electronies Co., Ltd. voltage(kV) | <10 15~35 Clearance with | | 350 600 barrier(mm) | | Clearance without 700 1000 | barrier(mm) 4.7.4. Enclosure installation 4.7.4.1. If the transformer has enclosure, make sure that the bottom of enclosure and that of the transformer (unloading the wheels) are on the same level except meeting the installation condition of its core & coil, but also to meet the condition that. And the relative site between core & coil and enclosure should be considered, according to the outline drawing of the transformer. 4.7.4.2. The enclosure is divided into spares, so it is convenient to transport and assemble. For further details please refer to “Enclosure Installation and Usage Instruction”. 4.7.5, Electrical connections 47.5.1. All the terminals must be connected correctly. The connection of cables and bus bars must be up to standards and the safe insulation clearance regulations described in 7.3. Cables and bus bars must be supported with fixed braces. 4.7.5.2. If terminals on the core & coil are to be connected with other hard-wire, it is proposed to connect a soft transition between them, which should be appropriately extended and slackened off. 4.7.5.3. Both high and low voltage sides of the transformer, cables entry are either from the top or the bottom. On the top of enclosure, the bracket is prepared. For entry from the bottom of enclosure, cable is fitted on enclosure to fix income wire as figure 4 shows.Wuhan Lianhua Electronics Co., Lid Hy side with the ‘cab clips, fixed the ‘cab The distances, betwee cables and other parts should be accordance with Arti 7.3.3 of the prospect requirements of t corresponding 4.7.6. The grounding bolt of the transformer, the enclosure and the barrier must be well engaged to protect grounding system that should comply with relevant regulations. 4.8. Inspection before opration 4.8.1. Check all of the fasteners, connectors and the standard parts, if they are loose, fasten again. 4.8.2. Check whether the parts disassembled during transportation are installed well, and check whether there are any foreign articles on the transformer. 4.8.3. Check whether the cooling fans, temperature monitors and other accessories are working normally. 4.8.4. Check whether the transformer, the enclosure and the core are grounded well. 4.8.5. Check carefully whether there are metal or non-metal foreign matters falling into the transformer while installation. 4.9. Test before opration Test should be performed before operation. The steps on the warning sign 26‘Wuhan Lianhua Electronics Co., Ltd, should be carried out before the test. Tests are as follows: 4.9.1. Test the Winding DC resistance. 4.9.2. Check the voltage ratio of all the taps. 4.9.3. Check the three-phase connection symbol. 4.9.4. Check whether the transformer and the core are grounding well, and check the insulation of the screw (if there is) is all right. 4.9.5. Check whether the insulation resistance of the coil meets the requirement. Generally, insulation resistance value must be as follows:: HV~LV and ground>300MQ 2500V M Ohmmeter LV~ground>100 MQ 2500V M Ohmmeter In dry environmental condition, the insulation resistance value above are easily achieved. But in the relatively wet environmental condition, the insulation resistance value of transformer will decline. Generally, for per 1000V rated voltage, its insulation resistance is not less than 2 MQ, and the transformer can be put into operation normally. However, when the extremely wet environment lead to the condensation of dew, regardless of‘Wuhan Lianhua Electronics Co., Lid. the insulation resistance of the transformer, it should be dried before test or operation. 4.9.6. Test the insulation resistance of core, in general, insulation resistance must be as follows: Coil ~ Clamps and ground>2MQ. 2500V M Ohmmeter Screw ~ Coil and ground >2MQ 2500V M Ohmmeter 4.9.7. It takes one minute to complete external power-frequency withstand voltage test, with the voltage accounting for 85% of the rated voltage. 4.9.8. If the transformer is load tapping, inspection and test should be performed before operation, according to the operation manual. 4.10. OPERATION 4.10.1. Clean every part of the transformer before operation. 4.10.2. tap changer should be connected according to the mark in the nameplate when changing the voltage in no-load situation. 4.10.3. When change the voltage in load situation, please refer to the OLTC tap manual, set the over-current protection value to HV rated current value. The transformer can perform after the tap switch has been set. 4.10.4. If the transformer is installed with temperature monitor system, please refer to the manual of the temperature controller. 4.10.5. When the transformer is put into operation, the closing peak current up may up to 8 ~ 10 times of the rated current, the protection current value should be set larger than the closing peak current. 4.10.6. After all the protection devices are equipped, and no-load impulse test is performed for 5 times (each separated by 10 minutes), there should be no abnormalities happen. 4.10.7, After the transformer is put into operation, the load can be increased gradually and the check should be carried out at the same time. Big load should not be connected blindly at a time. 4.10.8. After the transformer is shut down, it can be restarted normally. However, if the temperature is high and any condensation is found on its 28SO SS ee Wuhan Lianhua Electronics Co., Ltd, surface, it will be restarted only after being dried. 4.11. SURVEILLANCE AND MAINTENANCE To guarantee the normal operation, surveillance and maintenance should be carried out regularly. 4.11.1, Watch the the value on temperature monitor regularly in order to master the running status of the transformer, and watch for any abnormal noise and vibration 4.11.2. If any imbalance between the loads on the three-phase transformer occurs, more attention should be paid to the phases with the highest current and the highest temperature. The highest current through the neutral wire in the transformer that is wired as Yyn0, is allowed to account for 25% of that through the LV wire. In the transformer that is wired as Dyn11, the highest neutral current can be the same as the LV current. 4.11.3. Operation value should not run at higher capacity as the nameplate shows in the condition such as abnormal operation of the blower, incorrectly -displayed temperatures and cracks in the cast resin winding shell. Find out the causes or consult the manufacturer. 4.11.4. Normally, the maintenance and inspection of transformer should be carried out once a year or even longer if it is located in a dry and clean space. If surrounded by dirt or foul air, it should be done every 3-6months. In heavy pollution area, the transformer shall be serviced under the power cut every month. 4.11.5. During the inspection, a mass of dust must be removed to ensure good ventilation and avoid insulation discharge, but may not use volatile depurative. More attention should be paid to the cleaning of the insulator, the top and bottom of coil installation with dry compressed air to remove dust in ventilating flue. The flow direction of compressed air is opposed to that of cooling air during when the transformer is running. 4.11.6. Check the fasteners and connectors in case of looseness. Electric-conductive elements and other parts, should be checked to ensure their immunity from rust and corrosion. In addition, any cracks on the cast resin layer of the winding, as well as any trace of electric and carbonization, should be paid attention to. It is necessary to take 2»Wuhan Lianhua Electronics Co., Ltd. corresponding measure to deal with if any problem is found. 4.12 SAFETY NOTICE 4.12.1. The transformer, as well as its enclosure and the barrier should be grounded well and marked with a safety warning signs. 4.12.2. When the transformer is energized, it is forbidden to touch its core so as to avoid accident. Don’t adjust the voltage of the off-circuit tap changing transformer when it is electrified. 4.12.3. Before the high-voltage test, the cable of temperature sensor should be unloaded from in order to prevent damage to the temperature monitor. All the temperature sensors, sensing lines and the second controlling line are forbidden to contact with the live parts of the transformer. voltage 13. The distance from the live parts should accord with the demand of related