01 3BHS110389 E01 PDF

UNITROL 5000
for Excitation Systems
Functional Description
CONTENT
Functional Description.................................................................................................. 2
1. Overall system description..................................................................................... 2
2. Mechanical Design .................................................................................................. 5
3. UNITROL 5000 Control Electronics..................................................................... 9

3.1 General ................................................................................................................. 9
3.2 Configuration and mechanical design ................................................................... 9
3.3 Main control boards ............................................................................................ 12
3.4 Communication within the excitation system ...................................................... 15
3.5 Human-Machine Interface................................................................................... 15
3.5.1 Service Panel (SPA) .................................................................................... 15
3.5.3 Local Control Panel (LCP) ........................................................................... 16
3.5.3 CMT-Tools – Commissioning and Maintenance Tools ................................ 18
3.5.4 Remote Diagnostic ...................................................................................... 20
3.6 Control Interface to the Power Station Control System....................................... 21
3.6.1 Conventional control interface (with opto-coupler inputs and relay outputs) 21
3.6.2 Serial Communication with the Power Station Control System.................... 22
4. Voltage Regulation, Monitoring and Protection Functions................................ 23

4.1 Functions covered by the control electronics ...................................................... 23
4.2 Set point Generation and Voltage Regulation..................................................... 25
4.3 Limiter functions.................................................................................................. 26
4.4 Temperature dependent field current limiters ..................................................... 33
4.5 Superimposed Reactive Power or Power Factor Control.................................... 34
4.6 Power System Stabilizer ..................................................................................... 35
4.7 APSS - Adaptive Power System Stabilizer ......................................................... 36
4.8 Manual control .................................................................................................... 37
4.9 Monitoring and protective functions .................................................................... 38
4.9.1 Software functions of the Control Board (COB) ........................................... 38
4.9.2 Other monitoring and protection functions ................................................... 41
5. Thyristor Converter ............................................................................................... 43

5.1 Power Electronics ............................................................................................... 43
5.2 Twin Configuration.............................................................................................. 44
5.3 N - 1 Configuration.............................................................................................. 44
5.4 Converter Interface (CIN) ................................................................................... 45
5.5 Gate Driver Interface (GDI)................................................................................. 45
5.6 Current Sensor (CUS) ........................................................................................ 45
5.7 Converter Display (CDP) .................................................................................... 45
6. Field suppression.................................................................................................. 46
7. Field flashing ......................................................................................................... 47
3BHS 110 389 E Page1/47

Functional Description
Introduction
UNITROL 5000 is the 5th generation of the UNITROL products family, which are used for
voltage regulation and static excitation systems for synchronous machines. This new system
includes the know-how gained from its predecessors UNITROL F, and UNITROL P and
takes advantage of all the facilities and actual state of the art digital technology, presently
available. The control electronics of UNITROL  5000 has been based on UNITROL F
platform, in which new elegant solutions and facilities such as dynamic current distribution
mechanism for parallel operation of thyristor bridges, start-up from the residual machine
terminal voltage and better communication and diagnostics facilities were integrated. The
UNITROL F’s software package for application programming (GAD Engineering tool) as
well as the Commissioning and Maintenance Tools have been maintained. The ARCnet field
bus facility of UNITROL P for serial communication between devices within the excitation
system has been also implemented in the new system.
1. Overall system description

A static excitation system regulates the terminal voltage and the reactive power flow of the
synchronous machine by direct control of the field current using thyristor converters.
According to the block diagram of an UNITROL 5000 Excitation System for approximately
3500 A, which is shown on Figure 1, the entire system can be divided into four major
function groups:
• Excitation transformer -T02

• Excitation Modules with Control Electronics (-A10, -A20)
• Thyristors’ Converter units -G31 … -G34
• Field flashing (-R03, -V03, -Q03) and field suppression equipment (-Q02, -F02,
-R02)
In static excitation systems (so-called shunt excitation or self-excitation), the excitation power
is taken from the machines terminals. The field current of the synchronous machine flows
through the excitation transformer -T02, the field circuit-breaker -Q02, and the power
converter G31 … G34 (thyristor converter). The excitation transformer reduces the generator
terminal voltage to the required input voltage for the thyristor converter, provides the galvanic
isolation between the machine terminals and the field winding and acts at the same time as
the commutating reactance for the thyristor converter. The power converter G31 … G34
converts the AC current into a controlled DC current If.
At the beginning of the starting sequence the field flashing energy is derived from the
residual machine terminal voltage. As soon as 10 to 20 V at the input of the thyristor
converter are reached, the thyristor converter and control electronics are ready for the
normal operation and a soft-start sequence takes place. The new start up facilities and
design of the field flashing equipment (-R03, -V03, -Q03), which have been developed for
UNITROL 5000, are more described in Item 7 of this document.
23.04.02\Functional Description \11:42 3BHS110389 E Page 2/47

After synchronizing with the network the excitation system can operate in AVR mode
regulating the generator terminal voltage and reactive power or can operate in one of the
superimposed mode. That is, machine’s Cos-phi control or MVAr (reactive power) control. In
addition, it can be included in an overall joint voltage and reactive control of the power plant.
The purpose of the field suppression equipment is to disconnect the excitation system from
the excitation transformer and to discharge the field winding energy as fast as possible. The
field suppression circuit consists basically of the field circuit breaker -Q02, the field
suppression resistor -R02 and the CROWBAR thyristors -F02 with their associated triggering
electronics. The field suppression with field circuit breaker on the AC side of the thyristor
converter is described in greater detail in Item 6 of this document.
Based on the system requirements the control electronics is configured as a single AVR-
channel (-A10) or double AVR-channel (-A20). One channel comprises basically one
Excitation Module with a Control Board (COB) and a Measuring Unit Board (MUB), forming
an individual processing system. Each channel contains the Software for the machine
terminal voltage regulation, field current regulation, excitation monitoring/protection functions
and a programmable logic control. In a single AVR-channel configuration a separate
controller so called Extended Gate Controller (EGC) is employed as a back-up channel, that
is a MANUAL controller.
In addition to control electronics interface cards such as Fast Input / Output (FIO) and Power
Signal Interface (PSI) are employed to provide the galvanic separation of the measuring and
control signals. Further, each thyristor bridge is equipped with a set of the converter interface
cards including Converter Interface (CIN), Gate Driver Interface (GDI) and Converter Display
(CDP).
UNITROL 5000 has a facility, by extension, for connection to a serial communication link.
For example a Modbus type serial interface can be applied. Within the excitation system the
exchange of the control and status signals is performed serially over the ARCnet Fieldbus.
The field-breaker tripping circuits are additionally hard-wired.

U BATT. U AUX.
EXCITATION
-T02 TRANSFORMER
-Q02
T EXTERNAL I/O
23.04.02\Functional Description \11:42

-F05
PSI1 PSI2
INTERNAL I/O
AD A D -Q90
-T05 AC AUX. BUS

DC BUS
-Q80 AC BUS
-G05
MBA 24VDC SUPPLY BUS
-Q15 -Q05 DC
FIO2 FIO1
-A10 DC
-G15 -G34
-G33
COB LEGEND: -R03
-G32
MUB
AC70 Advant Controller 70 -G31
AIO Analog Input Output -V03
Interface
CDP Converter Display
CIN Converter Interface
COB Control Board -Q03
SPA -R06
CUS Current Sensor
DII Digital Input Interface
3BHS110389 E
EGC Extended Gate Controller GDI -F02 -F04
MBA FBC Fieldbus Coupler CIN
FC Field Communication M
Interface
FIO Fast I/O
-A20 GDI Gate Driver Interface -R04
LBI Local Bus Interface -R05 -C71
OR LCP Local Control Panel -C04 -C72
MBA Modbus Adapter CDP -C05
MBP Modbus Plus Adapter -R02
COB MUB Measuring Unit Board
OR MUB OBI Optical Bus Interface
PBA Profibus Adapter
ARCNET
PSI Power Signal Interface
FIELD BUS
PTI PT100 Interface
Figure 1: Block diagram of a typical UNITROL 5000 Excitation System

ROI Relay Output Interface
SPA Service Panel
-F75
OPTION: CMT TOOL
WITH FIBRE CABLE LCP
PULSE BUS
FBC FBC REF
DII ROI LBI AIO PTI OBI
Page 4/47
2. Mechanical Design
General:
Excitation system assembly of an UNITROL 5000 is a compact mechanical structure
based on the ABB’s Modular Low Voltage Switchgear System; known as OJALA. The
functional units are fully modularized and standardized with respect to the usual rates of the
field currents and the ceiling parameters. The design works for standardization were
facilitated by introduction of the dynamic current distribution function. The equipment is
arranged in their modules, which are prepared on the stock according to the forecast. A
typical layout assembly, which is shown on Figure 2, comprises of a control electronics
cubicle; ac inlet with AC Field Circuit Breaker; the series of thyristor converter units; field
flashing, field suppression and DC Outlet.
Dynamic Current Distribution: The Effect on Mechanical Design:
In the recent history, the current distribution among the thyristor bridges was always a
problem. None of the applied methods, such as positioning of the ac inlet, current coils at the
inlet of each thyristor bridge, were totally effective. In the best case an asymmetry of 10% of
rated current as acceptable amount was more a theoretical than practical. Thanks to the
dynamic current distribution, which is a software function, the near equal currents flow
through the various thyristor bridges. In most cases for the higher current ranges, one
thyristor bridge can be saved on the account of the dynamic current distribution since the
asymmetry doesn’t need to be calculated. Further, the positioning of the ac inlet can be on
the left or on the right side of the series of the thyristor bridges. This is because appropriate
magnetic paths from the secondary to the thyristor bridges do not need to be considered.
Accordingly, the internal interconnection of the ac bus bars is now uniform and standardized.
Therefore, the workmanship and costs for the internal interconnected bus bars are
considerably reduced. Based on the forecast, most of the power parts are prepared as
modules in advance. Therefore the procurement of the material and manufacturing time
becomes easier, faster and more cost effective.
Mechanical Protection Degree:

The mechanical Protection Class of the panel enclosure is based on the IEC 529 and DIN 40
050 standards. The Protection Classes such as IP21, IP31 and IP54 are usually applied
according to the system requirements. For tropical conditions the attention is additionally
paid to the cubicle heating, paint-works and gland plates.
Panel Structure:
The basic mechanical construction comprises the steel base frame, cubicle frames and
cladding. Separate steel rails on the upper length of the cubicle are provided for the transport.
The cubicle frames are constructed of C-shaped galvanized sheet-steel girders with 2-mm
thickness. This provides a rigid and self-supporting construction for all of the elements of an
excitation system assembly. The cubicle frames are clad by the steel sheets, 1.5 mm in
thickness, serving only for a touching and atmospheric protection (e.g. against dust) and are
not for equipment support.

Painting Characteristic:
Before being assembled the surfaces of the cubicle frames and steel sheets pass a
comprehensive painting procedure:
• Pre-treatment including de-greasing, purging, galvanizing and a high pressure

steam cleaning,
• Priming with stove enamel primer
• Finish paint with RAL7032, satin finish
The total coating thickness amounts 55 + 5µ (primer + 1st. and 2nd. coats), whereas the
outside coat is structured inside is smooth. A higher coating thickness is provided optionally.
Door Handles:
The door handles are of a double keyway type. As an option the T - handles with cylinder
lock and two keys may be provided.
Power Circuits:
The power circuits from ac-input to the field breaker, including all interconnections between
the thyristor bridges, up to the dc – power outlets are made of bus bars.
Wiring:
The stranded wires with the tinned copper conductors, according to IEC 228 Class 5
standard, are used. The isolation is flame resistant and PVC-free. This means, in the case of
combustion, it develops very little toxic fumes. The prefabricated system cables are used for
the standard electronics connections.
Wiring Gauge:
The standard wire gauges are as follows:
• Control circuits: 1.0 mm2
• Measuring circuits:
PT’s circuits: 2.5 mm2
CT’s circuits: 2.5 mm2
• Auxiliary supply: 2.5 mm2
• Power circuits:
According to the international standards.
Wiring Colors:
Blue cable is used for the DC Control circuits and their distribution circuits as well as for the
neutral wire. Black cable is used for all the other circuits. The earth is yellow/green. Other
colors are optional.

Wire Marking:
Marking is provided at the interface terminals.
Terminals:
Terminals for the measuring and supply circuits are of PHOENIX disconnecting type for a
maximum gauge of 2.5 mm2. The terminals for the control and signal circuits are of the
PHOENIX clamps type for 2.5 mm2.
Designations of Components:
The components’ designations comply with the IEC 750 and DIN 40719 Part II standards.

Thyristor Thyristor Thyristor Field
Control Electronics AC Field Breaker flashing
Converter 1 Converter 1 Converter N
Field
AVR AVR suppression
CDP CDP CDP
Channel I Channel II
Usyn

COB COB
MUB
MUB
PSI
AC-Field Breaker
PSI
SPA
Converter Electronics
FIO
3BHS110389 E
LCP
CT
CT
CUS CUS CUS
M M M
FIO
AC-Inlet
ARCnet Fieldbus
Pulse Bus
DC-Outlet
24V Supplybus
PT's & CT's

Measurements
Control I/O
Figure 2: Basic layout of UNITROL 5000 Excitation System for approx. 3500 A
DC/DC AC/DC
Page 8/47
3. UNITROL 5000 Control Electronics
3.1 General
UNITROL 5000 is the microprocessor based control system. The platform for the control
electronics is an enhanced version of DCS 500 System mainly intended for the control and
regulation of the large static drive systems. By development of the control electronics several
elegant solutions and facilities for of the excitation systems were introduced, for example
dynamic current distribution mechanism for parallel operation of thyristor bridges and start up
from the residual machine terminal voltage. Further, the communication and diagnostic
features were also improved. In its special versions UNITROL 5000 has facilities to be
supplied from the network frequency of 162/3 Hz or from the high frequencies exciter
machines up to 500 Hz.
3.2 Configuration and mechanical design

The core of the control electronics is a Control Board (COB) for all the regulation and
control functions as well as for the pulse generation. In addition, a Measuring Unit Board
(MUB) with a digital signal processor is applied for the fast processing of the actual
measuring values. These boards are attached together in a way to reassemble a double
layer board and are assembled in a metallic case, making up an individual processing
channel. In such a configuration an Extended Gate Controller (EGC), which is mechanically
separated, is used as a back-up channel for the field current regulation. In a fully redundant
system a second double layer board assembled in a separate metallic case is provided
(second channel). That is, both channels are mechanically separated, enabling an easy
maintenance on-line. Each channel of the control electronics can control one or more parallel
connected thyristor converters with the system rated current up to 10’000A.
The interface devices such as Fast I/O card and Converter Interface (CIN) are applied for
the galvanic separation and matching of the control signals and are placed where the signals
are originated, e.g. one converter interface is placed into each thyristor unit. The
communication within the excitation system, if not time critical, is performed serially over the
ARCnet Field Bus.
Possible Configurations with UNITROL 5000 System are shown on the Figures 3 … 9. The
abbreviations to the figures are as follows:
AVR – Automatic Voltage Regulator

FCR - Field Current Regulator
BFCR - Backup Field Regulator
UG – Measuring signal of the generator terminal voltage
IG - Measuring signal of the generator terminal current
IF - Measuring signal of the generator field current
The two controller states are “on-line” and “stand-by”. The latter is a backup for the “on-line”
controller.

COB
Figure 3: Type D5E – Single
UG
THYRISTOR CONVERTER
Channel and Back up Control
IG AVR with a Single Converter
IF
FCR
Figure 3 shows a minimum
BLOCK
EGC
configuration of UNITROL 
IF
BFCR
5000 System. The main
control ,Control Board (COB),
provides all regulation and
control functions including a field current regulator. The Backup Regulator, which function is
included in the Extended Gate Controller (EGC), follows the main control and takes over
automatically in case of failure of the main control. One thyristor bridge without redundancy
is employed in this configuration.
Figure 4: Type D5T – Single

COB THYRISTOR CONVERTER
UG Channel and Back up Control
IG AVR with fully Redundant Twin
IF
FCR
converters.
BLOCK
EGC BLOCK In this configuration, so
IF
called Twin Configuration,
BFCR
two fully redundant
converters are employed.
Any of these can be chosen
as the “on-line” converter,
whereas the other is in “stand by”. This configuration is usually applied for the rated currents
up to 2000 A.
THYRISTOR CONVERTER
Figure 5: Type D5S – Single
COB
UG
1 Channel and Back up Control
IG AVR with Redundant n – 1
IF Converters.
FCR
BLOC EGC In D5S configuration all

K
2 thyristor bridges are
IF
BFCR simultaneously in operation.
In case of the fault in one of
the thyristor bridge, it will be
blocked automatically and a
smooth taking over of the
n load takes place by the
remaining thyristor bridges.
The thyristor converter is
designed to support all
operating conditions without
any restriction, when one of the thyristor bridges fails.

In the followings configurations, Figures 6 .. 8, a full redundant dual channel control is
employed. Each of the control channels can be “on line” or in a “stand by” mode. In addition
to the automatic voltage regulation each channel also includes software functions for PSS,
limiters, protections and monitoring as well as the Manual Control.
Figure 6: Type A5E – Full

COB 1 THYRISTOR CONVERTER
UG redundant dual channel
IG AVR
control with Single Converter.
IF
FCR
BLOCK
COB 2
UG
IG AVR
IF
FCR
Figure 7: Type A5T – Full redundant COB 1 THYRISTOR CONVERTER

dual channel control with Twin UG
IG AVR
Converters
IF
FCR
BLOCK BLOCK
COB 2
UG
IG AVR
IF
FCR
Figure 8: Type A5S – Full Redundant

THYRISTOR CONVERTER Dual Channel Control with Redundant n-
COB 1 1
UG 1 Converters
IG AVR
IF
FCR
BLOCK
COB 2 2
UG
IG AVR
IF
FCR

THYRISTOR CONVERTER Figure 9: Full Redundant
COB 1 1
UG Dual Channel Control with
IG AVR Back up Field Current
IF
FCR Regulator and n-1 Converter
EGC 1 Redundancy
IF
BFCR
2 In this configuration, which is
COB 2
UG for the highest level of
IG AVR redundancy, each channel is
IF
FCR
supplemented with the sub-
EGC 2 units for many functions such
IF
BFCR as the back up of field current
n
regulation.
3.3 Main control boards

• Control Board (COB)
Implementation of the automatic voltage regulation, limiters, protection and control functions
into a single processing board was possible due to its high performance and computing
power of the Control Board (COB). It basically contains an enhanced microprocessor, AN
80186 AM, which operates with 32MHz clock. An ASIC (Application Specific Integrated
Circuit) takes care of exchange and storage the data, control pulse generation, A/D and D/A
conversion and interfacing with other devices within excitation system (ARCnet Fieldbus
coupler). It supports the communication with the local control, service panels and CMT-Tools.
Further, it provides serial ports and has a self-diagnostic function (watchdog). For the rapid
diagnostics and fault tracing purposes Control Board is equipped with a seven-segment
alarm display.
A typical configuration of the double channel system is shown on Figure 10.
Further, for the diagnostics purposes the control board is equipped with a transient recorder
and fault logger. These are handled with the CMT-Tools (Commissioning and maintenance
tools). The fault logger and transient recorder can also be synchronized with the real time
clock.
The particular functions and merits of the system are described in separate items of this
document.

Station Field Bus
Local
Service Control
Panel Panel
CMT
SPA AC70 FIO FIO LCP ARCnet
/

Basis Extension DI/DO
NxxA
ARCnet
Field
Bus
AVR - Channel II CONVERTER 4
CONVERTER 3
AVR - Channel I
CONVERTER 2
COB CONVERTER 1
(Control Board)
Converter
AVR Uc Electronics
3BHS110389 E
Monitoring CIN
(Converter Interface)
MUB
Protection
Figure 10: Typical configuration of the double channel system

Field Current Regulator GDI
(Measuring Board)
G31
(Gate Driver
Interface)
Logic Control
Converter Display
EGC (Extended Gate Controller)

(Option)
FIELD FLASHING
Page 13/47
SM
FIELD SUPPRESSION
• Measuring Unit Board (MUB)
Measuring Unit Board (MUB) consists of a Digital Signal Processor (DSP) and the Intel DSP
56303. This provides fast processing of the actual measuring values, galvanic separation
and level matching.
The following functions are implemented in the Measuring Unit Board (MUB):
- Filtering and digitizing.
- Calculation of field current and voltage; input currents and voltages of the
thyristor converter; active and reactive power; Cos-phi and machine’s
frequency.
- Power System Stabilizer (PSS) with accelerating power and frequency
input signals, in which the control algorithm is based on IEEE Std. 421-
Type 2A.
- Adaptable Power System Stabilizer (an alternative to the PSS).
• Extended Gate Controller (EGC)

Extended Gate Controller (EGC) is employed as a back-up controller in single automatic
channel configurations and for the pulse generation of the system rated frequencies different
from 50/60 Hz. In latter case, its typical application is for the automatic voltage regulators
supplied from the high frequency pilot exciters, whose rated frequency can be up to 500 Hz.
Further, it is applied in excitation systems for the generators of 162/3 rated frequency for
railway networks. This controller is assembled in the same case as the above-mentioned
boards but is mechanically separated. The following functions are also implemented in this
board:
- Field current regulation.
- Follow up control for the smooth change over in case the control board
(COB) fails.
- Back-up overcurrent relay, instantaneous (ANSI 50).
- Back-up overcurrent relay, inverse-time (ANSI 51).
- DC short circuit protection.
- Thyristor converter conduction monitoring based on the ripple monitoring
principle.
- Inherent power supply.
• Power Signal Interface (PSI)

Power Signal Interface (PSI) is used for the galvanic separation and matching of the field
measurement signals, before being sent to the Measuring Unit Board (MUB).
• Power Supply of the Control Electronics

All electronic devices are supplied from a 24VDC bus. The 24VDC bus is derived from two
fully redundant power packs; a DC/DC-power pack which is supplied from a DC source (e.g.
station battery) and an AC/DC-power pack which is usually supplied from the secondary side
of the excitation transformer.

3.4 Communication within the excitation system
The communication within the excitation system is performed serially via the so-called
ARCnet field bus. For example, this internal communication link is employed for the
exchange of the control and status signals to/from the thyristor converter. Further, the
measured values and the alarms for the Local Control Panel (LCP) as well as the local
control commands are sent through this link.
3.5 Human-Machine Interface
3.5.1 Service Panel (SPA)
Figure 11: Service Panel (SPA)
The Service Panel (SPA) in a multi-purpose

device for service and maintenance purposes.
It is equipped with the functions for local
operation of the excitation system, parameter
setting and application programming. Data for
the excitation system (e.g. generator terminal
voltage, field current and voltage), parameter
setting and the alarms can be displayed.
Further, it has the facility for fault logger
handling. The alarms are displayed in real time.
Panel control is through the membrane keys.
Connection with the Control Board (COB) is
established by a fibre optic cable. Since it is
intended to be used only for the service and
maintenance purposes, it is attached into the
one of the Excitation Module within the cubicle.

3.5.3 Local Control Panel (LCP)
An user-friendly Local Control Panel (LCP) can be used for the local control and
supervision of the excitation system. It can be located in the Power Station Control Room,
serving for the remote control.
The panel offers following facilities:
• Display of measuring and processing signals on 8 display lines, each containing 40
characters (240 x 64).
Either 8 analogue signals or 4 with analogue – bar display in scale from 0 to 120% can be
displayed simultaneously. A maximum of 32 pre-defined signals can be selected. Display
mode is enabled with the function keys. Signal selection is performed by means of the scroll
key or page keys. A display line is chosen with the cursor key.
Figure 12: Local Control Panel (LCP) in a typical operation

• Alarm annunciation
In case of their appearance the excitation system alarms take precedence over the
measuring signal display.
The displayed alarm includes its alarm number and description text of 40 characters. 8 alarm
messages can be displayed simultaneously. The first occurred alarm appears on the first line
and following alarms appear in order of their alarm numbers. If more than 8 alarms appear,
they can be displayed by the scroll key. Maximum 80 alarms can be displayed.
On the alarm function key there is an alarm LED, that blinks by each alarm occurring. After
pressing the confirmation key the alarm LED changes to a steady light as long as an alarm
exists. When the alarm disappears, the alarm LED switches off.
• Printing of the signals and alarm messages
The information saved by the control panel can be printed out over its serial interface port
RS-232.
• Indication of the selected mode

Each of selected mode keys is equipped with a LED for mode indication.
• Local operation control
16 function keys with LED’s for status indication are available for local operation control of
the excitation system.

3.5.3 CMT-Tools – Commissioning and Maintenance Tools
CMT-Tools are MS-WindowsTM based tools intended for the testing, commissioning and
maintenance of the UNITROL 5000 System. CMT-Tools can be purchased as a stand alone
software package or installed into a PC, which is preferably a Laptop. For connection to the
Control Board (COB) a PCMCIA card for PC and a fibre-optic cable are also integrated parts
of the package. CMT-Tools are based on the windows with menu items and provides the
functions described in the followings.
• An image of the Local Control Panel can be displayed on the PC screen with
modern user visual interface like push buttons, status signal, reference value setting
indication, etc. Their controls are performed by the mouse click or by the PC keyboard.
Please refer to the Figure 13.
Figure 13: CMT-Tools, display on the PC Screen
• Trending function is provided for optimising the transient response of the regulation
closed loop during commissioning and therefore for verification and final tuning of the
AVR’s and other regulating parameters. In fact, it replaces the conventional testing
equipment such as testing terminals, external provision for the step signals (e.g. +/-
10% to the reference value) and other typical testing ancillaries. Six freely chosen
measuring signals (six channels) can be displayed. The provision for scaling of the
signals and their scanning rate is also included. All trending can be stored and
subsequently used for the Commissioning Report.

• Handling of the Transient Recorder is provided for visualization of the recorded data.
Together with Fault Logger the Transient Recorder serves for the diagnostics of the
excitation system faults. Six freely chosen measuring signals (six channels) can be
recorded and visualised. The appearance of a record is similar to the trending function
shown in Figure 13. The storing capacity of each channel is 1000 samples. The
recording time is dependent on the selected scanning rate. A record can be start on
an event or after a triggering signal level is reached and is subsequently stored into a
buffer memory of the Control Board (COB). An event, triggering signal level, pre-fault
time as well as the post-fault time are also adjustable. The starting time is noted on
the record’s time axis. This time is determined by a precise internal quartz timer,
which is a consisted part of the Control Board (COB). The quartz timer can be
synchronized with the real time by an external pulse given per each hour.
• Handling of the Fault Logger with storing capacity up to the 100 events and alarms
with the system’s real-time stamp. The same recorded alarms/events can be
displayed on LCD of the Local Service Panel (SPA) in clear English test.
• Displaying of the Software Diagrams in real time, which are functional blocks of the
various functions such as logic control, AVR, limiters, protection and monitoring. This
function possesses the facility for measuring the input and output signals of the
particular function blocks in real time and for modification the system parameters (like
AVR parameters).
• Programming facilities for modification of the application program. That is, some
function blocks can be implemented into the control sequence.

3.5.4 Remote Diagnostic
The CMT-Tools described in the previous section can be handled remotely via the public
telephone network (via satellite). For this purpose two personal computers should be
provided; a host PC and a remote PC, both equipped with the CMT-Tools, the
communication software and modems. For the practical reason, an operator making a
remote diagnostic does not have a direct access to the CPU, but coordinate the diagnostic
with the operator on the host side. ABB can propose the remote diagnostic package,
including the service agreement on request.

3.6 Control Interface to the Power Station Control System
3.6.1 Conventional control interface (with opto-coupler inputs and relay outputs)
The digital and analogue command and status signals are interfaced via the Fast Input /
Output boards (FIO). Each fast Input / Output board (FIO) is equipped with:
- 16 Digital inputs with opto-couplers, rated for 24 VDC. The control inputs are activated
using a local 24 VDC from the internal power packs.
- 18 output relays with change over contacts for status indications and alarms.
- 4 multipurpose analogue inputs + 10 V or + 20 mA
- 4 multipurpose analogue outputs 4 … 20 mA
- 3 analogue inputs for excitation transformer temperature measuring PTC or PT100
A maximum number of two Fast Input / Output boards can be implemented per system,
which is sufficient for most system requirements. In case that more digital inputs and outputs
are requested, the system can be supplemented with Digital Input Interface (DII) and Relay
Output Interface (ROI). These are connected to the ARCnet Field Bus over a Field Bus
Coupler (FBC).
Standard interface signals are assigned according to Table 1.
Order Commands Status and Alarm Signals
- Excitation Start - Excitation On

- Excitation Stop
- Field Breaker On - Field Breaker On
- Field Breaker Off - Field Breaker Off
- Generator Breaker On Line
- AUTO On - AUTO On
- MANUAL On - MANUAL On
- Imposed Control On - Imposed Control On
(Cos-phi or VAR Control) (Cos-phi or VAR Control)
- Imposed Control Off
(Cos-phi or VAR Control)
- Set Point Raise - Set Point Max
- Set Point Lower - Set Point Min
- Local operation On
- Over excitation limiter Active
- Under excitation limiter Active
- Ready for change AUTO/MAN
- Back up Controller On
(BFCR), if applicable
- Common Alarm On
- Machine Speed > 80 %
Table 1: List of standard remote control, status and alarm signals.

Two separate hard-wired signals of the internal trip are available for the generator protection
system. Two trip signals from the generator protection are expected to act directly on the
excitation trip circuits.
3.6.2 Serial Communication with the Power Station Control System

Apart from the conventional I/O interfaces using potentially free contacts (dry contacts), the
UNITROL 5000 excitation systems can be equipped with a serial link for communication with
a higher hierarchical control system with different protocols. All the required signals for
operation, including converted analogue signals, can be received and transmitted via such a
link.
One of the following serial interfaces can be applied to handle the serial link communication
with another intelligent system:
• NMBA-01, Modbus Adapter
• NMBP-01, Modbus Plus Adapter
• NMBA-02, Profibus Adapter
• AC70BAS, Advant
Other protocols can be supplied on request and are subject to negotiation.
Depending on the control requirements, certain function blocks must be added to the
application program during the project engineering.

4. Voltage Regulation, Monitoring and Protection Functions
®
An overview of the main control functions implemented into the UNITROL 5000 is provided
in the following items.
4.1 Functions covered by the control electronics

The main objective of an automatic voltage regulator (AVR) is the accurate control and
regulation of the terminal voltage and the reactive power of a synchronous machine. In order
to fulfil this requirement, the field voltage must react quickly to changes of the operating
conditions, i.e. with a response time that does not exceed a few milliseconds. To accomplish
this, a high-speed controller is required. It shall compare continuously the actual values with
the set-point values and vary the final control element (firing angle for the thyristor converter)
with an insignificant delay.
®
The UNITROL 5000 digital voltage regulator calculates the controlled variable from the
measured and the set-point value in very short time intervals. The result is a quasi-
continuous behavior with a negligible time delay (comparable with an analogue regulator).
The calculations are fully digital. Analogue measurement signals such as terminal voltage
and current are converted into digital signals by analogue/digital converters, which are parts
of the Measuring Unit Board (MUB). The set points and limit values are already defined in
digital form.
Figure 15 shows the overall software’s functions of an AVR, which are implemented into a
®
standard UNITROL 5000 static excitation system. For a better understanding of those
software’s functions, they are split into functional blocks followed by the short functional
description. The numbers within the functional blocks correspond to those mentioned in the
descriptions.

Excitation System
ϑ °C
Ug
Uf ALARM
Fault logger
Uc
Fast I/O (FIO)

CH FAIL
PSS Usyn
If
MONITORING
(13) Over-excit.
Limiters
Software Isinphi
TRIP
EVENTS
(8) Icosphi
If If Limiter Max.
Gate
Ig IG Limiter
AVR-PID
User Limiter
(11)
(12) Gate
Control
Ug
Σ Σ
IEEE, Type ST2A
Measuring Board (MUB)
(14) Under-excit. (20) Unit

V0 V A/M Uc
Limiters
(9)
IG Limiter Min.
(10) Parameter
Gate Selector
If Limiter
Ta1 Tb1
SET 1 Ta2 Tb2
P/Q Limiter SET 2 Ta3 Tb3
(4) V/Hz-limiter (5) Soft-start

(2) P-static UV/Hz Ramp
U
P P Σ f t
(6) Follow-up
T
delay
0 Run Σ
(3) Q-static
Ch. II
U
Q
Q
(7) Uc (Ch. II) Σ
(1) AVR-setpoint
generator Man
AVR Integrator
Set
ref.
∫
value
Fast I/O (FIO)
CONTROL
LOGIC (15) Q-Reg.
RAISE raise
Set
LOWER lower
ref.
COSPHI ON CosPhi/
Var value
VAR ON AUTO/ Σ
AUTO ON MANUAL
MAN ON CH I / CH II
CH I ON Field Braker (16) Cos- P, Q
CH II ON ON/OFF phi Reg. Cos
Excitation -phi
BREKER ON ON/OFF
BREAKER OFF Set
EXC ON ref.
value
EXC OFF Σ
(19) Manual Restrict

(17) Field current set point P (18) MANUAL-PI
Ifmin=f(P)
Set AVR
ref.
value Man ∫ Σ
SM
3
®
Fig. 15: Internal structure of UNITROL 5000 Automatic Voltage Regulator

4.2 Set point Generation and Voltage Regulation
Set point adjustment
(1) AVR set point generator can be raised, lowered or reset to a pre-set value using digital
input commands or analog input signals or through the serial communication link. The
excursion time from minimum to maximum limits can be adjusted independently from the set
point range.
Active and reactive power compensation

(2) P-static and (3) Q-static, are intended to add additional signals proportionally to the active
or the reactive power to the set-point value. The reason is the compensation of the voltage
drop caused by the active or reactive power across the unit transformer and/or the
transmission line. The reactive power signal is also necessary for parallel operation of two
and more generators connected to the same bus. In this case, the Q-Static signal shall
reduce the AVR set point proportionally to the increase of reactive power. The rate of change
of the set point as function of the active and/or reactive power can be adjusted in the range
of -20%..+20%.
V/Hz Limiter
(4) V/Hz limiter is provided in order to avoid over fluxing of the transformers. If the set point
of the AVR is too high for a certain frequency, the set point will reduce smoothly according to
a pre-adjusted V/Hz characteristic. The limiter becomes active after an adjustable delay time.
Soft-start
(5) Soft start facility prevents overshoots of the terminal voltage when building up the
excitation (field flashing). As soon as the excitation is switched on and after the initial field
flashing is complete (approx. 10% of generator voltage), the soft-start-signal increases the
machine terminal voltage with an adjustable gradient. This signal is given priority until its
value exceeds the signal from the set point generator.
Automatic follow-up control

In each Control Board (COB), including an Automatic Voltage Regulator (AVR) and a Field
Current Regulator (FCR), the automatic follow-up control ensures a bump-less changeover
from automatic voltage control mode (AUTO mode) to the field current regulation (MANUAL
mode). The change over may be initiated either by the loss of the PT’s measuring signal or
by the operator (e.g. from the Local Control Panel (LCP)). The difference signal derived from
the control signals of the AVR and the FCR (Follow up block (6)) is used for the follow-up
control of the regulator, which is not active. The follow-up is guaranteed for both the AVR
and FCR.
In a double automatic channel configuration the change over is normally from AUTO mode of
the active channel to the AUTO Mode of the stand-by channel. Indeed, any of channels may
be active or stand-by. In case the change over to the AUTO Mode of stand-by channel is not
possible, a change over to the MANUAL mode will be initiated. Only in case that both of
channels are inoperable a trip command will be given. In this configuration the follow-up
signal to the inactive channel is derived from the difference of the control signals of the
active and inactive channels (Follow up block (7)).
In a Single Channel and Back up control configuration the Back up Field Current Regulator
(BFCR) automatically follows up the Control Board (COB). In case the Control Board (COB)

fails the automatic follow-up ensures a bump-less changeover from the Control Board (COB)
to the BFCR, i.e. to the field current regulation (MANUAL mode). As already mentioned the
BFCR is a software function of the Extended Gate Controller (EGC),
Limiter gates
The limiter gates (8) and (9) determine the priority of the over excitation or under excitation
limiters over the terminal voltage control. In order to avoid that two limiters are active at the
same time (e.g. in case of system fault), a priority flag can be set choosing which of the
limiter groups (over excitation or under excitation) acts first.
PID Controller
The input voltage of the PID controller (11) represents the voltage error that is the difference
between an actual value and a set point. The output of the PID controller, which is so called
control voltage Uc, is required as an input signal for the gate control unit (12).
The feedback parameters of the PID controller are automatically adjusted in a way to
achieve an optimum control performance of the synchronous machine. Depending on that,
which limiter becomes active, the Parameter Selector (10) activates the appropriate set of
PID parameters (SET1/SET2). This contributes to the transient stability of the synchronous
machine.
4.3 Limiter functions

The purpose of the limiters is to maintain the operation point of the machine within
permissible limits and therefore to avoid its undesired shut-down by operation of the
protective relays.
Figure 16 shows a typical power chart of a salient pole synchronous machine with the
corresponding operation limits in steady state condition for 1 p.u. terminal voltage.
region of underexcitation region of overexcitation

active power P
capacitive generator current limiter inductive generator current limiter
maximum turbine power

reactive power limiter maximum
(P/Q-limiter) I fn field current limiter
minimum
field current limiter I GN
ϕ
U2act-1
Xi
δ
reactive power Q
-1 Xq -1 -1 Xd 0 1
Fig.
16: Power chart of a salient pole synchronous machine
®
UNITROL 5000 excitation system provides the following limiter functions:

(13) Over excitation limiters
• Maximum field current limiter (Figure 17)
• Stator current limiter over excited (Figure 19)
(14) Under excitation limiters

• P/Q limiter (Figure 20)
• Stator current limiter under excited (Figure 19)
• Minimum field current limiter (Figure 17)
Philosophy of the limiters
All the limiters have an actual value, which represents the value to be limited, and a set point
at which the limiter should actuate. Each limiter generates an error signal ∆ resulting from
the difference between the actual value and the set point.
When the over-excitation limiter acts, it will reduce the excitation to a maximum permissible
level and when an under-excitation limiter acts, it will increase the excitation to a minimum
required level. During normal operation, the machine is operated inside the permissible
range of the power chart. The input of the PID controller is the main error signal ∆act-ref
(Uact-Uref). If for some operational reason the error signal ∆lim- of the over-excitation limiter
becomes lower than the main error signal, it gets priority over the main error signal. That is,
the PID controller will receive in this particular case the lowest error signal. The same
philosophy is applicable for the under excitation limiters but obviously in the other direction.

The error signals ∆lim- of the over excitation limiters, error signals ∆lim+ of the under
excitation limiters and the main error signal ∆act-ref are applied to the logic gates, Maximum
Gate (8) and Minimum Gate (9), which decide over the priority of these signals. In order to
permit a stable operation of the machine when a limiter is acting, the gain of each limiter
error signal can individually be matched to an optimum value K. In addition, new values of
PID parameters of the automatic voltage regulator are set by the Parameter Selector (10).
Maximum field current limiter with inverse time characteristic
Maximum field current limiter is used to protect the rotor and excitation power circuits from
overheating.
It has basically two different set points, for the ceiling limitation (field forcing) and for the
thermal limitation (maximum continuous). The feature of the thermal limitation is determined
with two additional set points, which represent the equivalent time for overheating and
cooling-down of the rotor.
From the above mentioned the basic set values are listed are follows:
• Limit for ceiling field current Imax 1/2

• Limit for thermal field current Itherm 1/2
• Equivalent overheating time constant of the rotor Tequiv
• Equivalent cooling-down time constant of the rotor Tcooling
With these settings, the maximum field current limiter is able to reproduce the maximum
permissible thermal energy ∆Emax in the field winding. The parameters’ settings and
functional blocks of this limiter are shown on Figure 17.
Maximum Field Current Limiter

Reference value
selector
Imax 1/2
Itherm 1/2
Surpluscurrent
Surplus power Overheat detector
integrator
Overcurrent
∫ ∆i dt
2
Detector
+
∫ ∆i dt
2
Σ max ∫ ∆i 2 dt
2
-
t
∆E max 0
Tequiv Tcooling
+ ∆ifield
Actual
Actual field field current
current Ifield Σ K
-
To Gate Logic
Minimum Field Current Limiter

+ ∆ifield
Imin Σ K
-
Figure 17: Maximum and Minimum field current limiters

Operating principle:
During normal operation of the synchronous machine (no limiter acting), the effective set
point of the maximum field current limiter corresponds to the required ceiling current Imax.
This means, the AVR is able to reach ceiling condition whenever necessary. Supposing now,
a particular system fault, which requires ceiling condition for the fault clearance, occurs. As
soon as the actual value of the field current exceeds the thermal set point Itherm, an
Overcurrent Detector actuates a so-called Surplus Power Integrator. It further integrates the
value ∆i2 (where ∆i = Ifield -Itherm). The result of this integral is proportional to the thermal
energy ∆E of the field winding. If the field current stays a longer time higher than the thermal
set point, the output value of the integrator ∫∆i2dt = ∆E will raise. As soon as the output of the
integrator exceeds ∆Emax, the set point of the maximum field current limiter will be reduced
from Imax to Itherm. This condition is detected by an Overheat Detector. If the field current
drops to its normal value (below the value Itherm) the integrator's output will start to
decrease with the cooling down time constant Tcooling.
If an another fault in the system occurs which forces the excitation again to a current higher
then Itherm, before the cooling down time has elapsed, the permissible time for ceiling will
obviously be shorter than in the first fault since the value of ∆Emax will be reached earlier.
The limiter will only allow the field current to remain at ceiling level during Tceiling if the
cooling down time has elapsed (reset).
The thermal set point Itherm can be influenced by an external signal, e.g. representing the
machine cooling air temperature. This signal is added to the internal set point Itherm.
The transient behavior of the maximum field current limiter in operation for two different
cases is shown on Figure 18.
If [A]
prospective value of
field current
Ifmax
(1,6*Ifn) Case 1
Case 2
Iftherm
(1,05*Ifn)
Tequiv
(10 s)
t [s]
Figure 18: Maximum field current limiter in operation

• Case 1: IfPROSPECTIVE > Ifmax
• Case 2: IfPROSPECTIVE > Iftherm
The time for the activation of thermal limiter is given by the following expression:
2
 Im ax1 / 2−0,9 
t =  •Tequiv
 If −0 ,9 

Minimum field current limiter
The main task of the minimum current limiter is to prevent the interruption of the field current.
This function is usually applied for the hydro generators, which may operate deeply in under-
excitation range of the power chart, i.e. close to zero current. In this range the minimum field
current limiter keeps on the field current to a minimum value, which is necessary for the
current commutation purposes. In addition, it may be employed to protect the rotor pole caps
from excessive overheating.
The minimum field current limiter has only one set point corresponding to the permissible
minimum field current and it acts immediately. The main parameter setting and functional
blocks of this limiter are shown on Figure 17.
Stator current limiter over and under excited
This limiter prevents excessive heating of the generator’s stator windings, in both the over-
excited and under-excited operating ranges.
It is based on the similar operation principle as the maximum field current limiter. The main
difference in operation is related to the set value of the ceiling limitation (maximum stator
current), which has no a definite value. Theoretically, the limiter curve may reach an infinite
value (Imax = ∞) for the operation time close to zero. With appropriate setting of the
parameters an inverse time limiting characteristic can be achieved, which approaches to the
maximum permissible thermal energy ∆Emax of the stator winding.
Stator Current Limiter

Reference value
selector
I∞ + ∆ig
Σ K
To Gate Logic
- Lead
Itherm 1/2 ∆ig
+
Σ K
- Lag
Actual stator current
Surplus power Overheat detector

integrator
Overcurrent
∫ ∆i dt
2
detector
+
∫ ∆i dt
2
Σ max ∫ ∆i 2 dt
-
t
∆E max 0
Tequiv. Tcooling
Fig. 19: Stator current limiter for over and under excited mode of operation

The actual value for both limiters is the mean value of the stator current. When the machine
is overexcited, the under excited limiter is blocked and vice versa. A logic circuit ensures a
correct action of the stator current limiters in both directions by taking into consideration the
load power factor.
Obviously, the stator current limiter can not influence the active current. If the value of the
active current reaches a level higher than the set point of the stator current limiter, the
reactive power is regulated close to zero in order to avoid incorrect operation of the limiter.
The P/Q limiter
The P/Q limiter is basically an under excitation limiter which is intended to avoid the machine
being operated beyond the stability limit. The limiting curve can be set by 5 reactive power
values for five levels of active power (P=0%, P=25%, P=50%, P=75% and P=100%). These
values are defined for the rated machine voltage. The limiting characteristic is shifted
proportionally to the deviation from the actual to the rated machine voltage as the stability
limit is shifted.
Maximum Field Current Limiter Iq correction

P/Q-Limter =f(Ug)
P
Ug actual
P/Q-Limiter function for Ug=1

P Q
Iq=f(0P Iq=f(P)
Ug
0,25P;
Iq K ref
0,5P; Ug*
0,75P; Iq
1P) Q Σ
∆ifield
K To Gate
Iq actual
act Logic
Fig. 20: P/Q limiter

4.4 Temperature dependent field current limiters
For some excitation systems it is necessary to introduce a field current and/or stator current
limiter, which is dependent on the cooling medium temperature. A typical application is found
in excitation systems for gas turbine machines, in which the temperature of the cold gas can
vary under certain circumstances. As a result, the maximum permissible field current should
be reduced. The evaluation of the cooling medium temperature is part of the machine
monitoring equipment. From this a control signal (usually 4 ... 20 mA) is further introduced
into the temperature dependent limiter circuits of the AVR. A typical temperature-dependent
field current limiter characteristic for the gas turbine machines of ABB’s type GT13E2 is
shown in Figure 21.
If Therm
(%)
105
100
85
60
I fmax = f(ϑ)
40
20
ϑ ROTO
20 40 60 80 100 (%)
75 90 120 150 ( °C)
Fig. 21: Temperature dependent field current limiter

4.5 Superimposed Reactive Power or Power Factor Control
Reactive power control (15) or Power factor Control (16) can be applied as a superimposed
control to the automatic voltage regulator. The regulation functions are shown on Figure 22
for the Reactive Power (Q or Var) Control and Figure 23 for the Power Factor (Cos Phi)
Control. In both cases, the control signal is derived from the difference between the actual
and set point value of the chosen control mode. Further, the control signal acts through an
integrator to the summing point of the automatic voltage regulator.
Q-Regulation Function
P lower rise
raise
lower
ϕ
Qreg
pre-
set
reset
Q1 Q2 Q
Figure 22: Reactive Power Control Block Diagram
The operation points within the power chart of the chosen superimposed control mode can
be adjusted:
• Locally from the Local Control Panel (LCP) or Service Panel (SPA).
• Remotely by Raise and Lower commands.
• Remotely by a mA signal.
• Remotely through a serial communication link.
Cos-phi Regulation Function
P rise
raise lower
lower ϕ
pre- cosϕ1 cos ϕ 2
set
reset
Qcosphi reg. Q
Fig. 23: Power Factor Control Block Diagram

4.6 Power System Stabilizer
®
The Power System Stabilizer is a standard attribute of UNITROL 5000 System. This
function implemented into the software of Measuring Unit Board (MUB). The purpose of
the PSS is to establish a stabilizing signal required to improve the damping of the
synchronous machine’s oscillations and of the power system’s oscillations and therefore
to contribute to the stability of the entire system. The PSS’s control algorithm is based on
IEEE Std.421-Type 2A. The stabilizing signal corresponds to the acceleration power
signal resulting from a combination of the electrical power and rotor angular frequency
input signals. A comprehensive functional description can be provided on request. The
entire computer representation of the PSS is shown on Figure 24.
Pe-Washout Torsional PSS Gain Lead-Lags Output

oscilation filter Limit To
Pe sTW1 sTW2 1+sT8 N
1+sT1 1+sT3 AVR
1+sTW1 1+sTW2 Σ (1+sT9)
M Σ KS1
1+sT2 1+sT4
Adaption
KS3
∆ω-Washout ∆P-Integrator
∆ω sTW3 sTW4 KS2

1+sTW3 1+sTW4 1+sT7
Figure 24: Power System Stabilizer Block Diagram

4.7 APSS - Adaptive Power System Stabilizer
Adaptive Power System Stabilizer may be selected as an alternative to the PSS. The APSS
function is to improve the long-term low frequency oscillations in an electrical power system.
For a previously defined linear model of a power system the APSS operates to improve the
damping characteristics of the entire system. That is, the poles in z plane are shifted in a
direction of a better damping position.
The Figure 25 shows the block diagram with the integrated APSS.
GOVERNOR
P
SY. MACHINE Ug
THYRISTOR CONVERTER
Σ AVR
IDENTIFIER
Σ CONTROLLER
WHITE NOISE APSS
Figure 25: APSS Block Diagram
A 3rd. order, linear model algorithm of the power system is applied. This provides a good
approach and a compromise between the quality of results and the computation time. The
model parameters are estimated during operation and used by the controller.
The regulation algorithm calculates the characteristic equation of the closed loop. It also
adjusts the parameters of its own function in a way that the desired pole excursion achieves
a better damping position.
Additionally, a White-noise program is implemented. This is a random sequence with zero
average value and a relatively small magnitude. This signal is needed when the system is
stable. Namely, if the power system reaches an appropriate stability, the parameters can not
be identified from the almost constant power system output signal.

4.8 Manual control
The manual control mode (18) may be used for test purposes (for example during
commissioning or maintenance of the equipment) or as back-up control mode in case of
incorrect operation of AVR (e.g. loss of actual value due to pt-failure).
®
When operating in the manual control mode, UNITROL 5000 controls the field
current of the synchronous machine. The actual value of the field current Ifield is
taken inside of the excitation cubicle in order to ensure a control loop which is
independent of external measuring circuits and/or transducers.
The set-point function (17) for the manual control mode has the same facilities of the set-
point function as the AVR control mode. The minimum and maximum set points as well as
the different running times can be adjusted. When operating in manual mode, the set point
for field current may be controlled by raise or lower commands.
An immediate reset input is provided in order to avoid over voltages caused by reactive load
rejections when operating in manual mode. In case the machine breaker trips, a pulse
command is applied to the reset input, which sets the field current immediately back to a pre-
set value which normally corresponds to 90..100% of the no-load field current of the
synchronous machine.
In case a so-called Manual Restrict (19) is desired, the minimum and maximum set-points
of the manual control are calculated as function of the present active and reactive power
levels as well as a function of the machine actual voltage. For the manual restrict function,
measured values from the machine PT's and CT's are required.
An automatic follow-up control (6) ensures a surge-free changeover from automatic to

manual mode. When operating in the automatic mode, the difference signal between Uc
from automatic and manual is used for the automatic follow-up. This difference signal is also
used as feedback signal for the channel, which is presently not in operation. This is
necessary for a stable balancing between automatic and manual.
The resulting error signal at the output of the summing point is applied to a filter circuit with
PI characteristic.
The output of the PI-Filter is applied to a signal selector (20) which transmits either the Uc
signal from the AVR (automatic mode) or Uc from the field current controller (manual mode)
to the gate control unit depending on which control mode has been selected in the logic
control.

4.9 Monitoring and protective functions
4.9.1 Software functions of the Control Board (COB)
Actual value monitoring (PT-failure detection)
The actual value monitor is based on the comparison of two different measuring voltages.
That is, the machine terminal voltage measured by PT's is continuously compared with the
voltage at the secondary side of the excitation transformer. If the difference between these
two voltages exceeds a pre-adjusted threshold value, the control logic will initiate a change
over. If only one set of the PT’s is available, a change over will be from automatic to manual
mode of operation. In case two sets of PT’s are available, one set per channel, a change
over will be from automatic mode of the incorrect channel, if it was in operation, to the
automatic mode of the stand by channel. If, however, both sets of PT’s fail the change over
will be to a manual channel. A change over takes place when the mean value between both
compared signals exceeds a pre-set threshold value of 15% of the rated machine terminal
voltage.
Rotor temperature measuring
The principle of the rotor temperature measuring is based on the calculation of the field
winding resistance according to the following expressions:
Uf
− U B − if ⋅ ( RB + RL )
pT 1
Rf =
if
Td 0'
T1 =
Tdl
Where:
Uf = Field voltage
If = Field current
Lf = Field inductance
UB = Voltage drop on brushes
RB = Resistance of brushes
RL = Resistance of the power conductors between measuring point for
field voltage and brushes
Td1 = Equivalent time constant
Td0’ = Field time constant
Tdl = Load time constant (between Td’ and Td0’)
p = Laplace’s operator
Based on the calculation result for the field winding resistance, the temperature is calculated
from the following expression:

Rf
−1
Tf = Rfo
α
Where
Tf = Rotor temperature
Rfo = Rotor temperature at 0 oC
α = Resistance temperature coefficient of field winding material [ 1/ oC]
The result for Tf may be displayed locally and / or remotely and can be used for alarm
indication.
Overcurrent protection
The overcurrent protection basically includes two protection functions:
• Inverse time characteristic overcurrent protection.
• Instantaneous overcurrent protection.
The overcurrent protection operates in conjunction with the Maximum Field Current Limiter
Function described in Item 4.3. Both operating characteristics are similar, whereas the
overcurrent protection characteristic is adjusted to operate above the limiter characteristic.
The operation is also time delayed with respect to the limiter characteristic.
Loss of field protection (P/Q protection)
The loss of field protection is intended to trip the synchronous machine in case of operation
beyond its stability limit.
The desired operating characteristic is set by the five operation points within the power chart,
according to Figure 26, Loss of Field Protection Block Diagram. The operation characteristic
is similar to the P/Q Limiter operation characteristic. Both characteristics are coordinated in a
way that the P/Q Protection characteristic is shifted for five to ten percent left from the P/Q
Limiter characteristic. Since the stability limit of a synchronous machine depends on the
machine terminal voltage, the operating characteristic are also corrected proportionally to the
machine terminal voltage.
Iq correction
Los of Excitation Protection =f(Ug)
P
Ug actual
P/Q-Limiter function for Ug=1

P Q
Iq=f(0P Iq=f(P)
Ug
0,25P;
Iq K ref
0,5P; Ug*
0,75P; Iq Detection Delay
1P) Q Σ
TRIP
T 0
Iq actual
act
Fig. 19: Loss of Field Protection Block Diagram

As soon as the operating point of the machine exceeds the operating characteristic, a timer
is activated and the machine trip command is given after an adjustable time delay. The timer
start signal may also be used for alarm purposes.
Over-fluxing protection (V/Hz relay)
This protection is intended to avoid the over-fluxing of the synchronous machine and block
transformer in case their maximum V/Hz characteristic is exceeded. The protection function
is based on the comparison of the reference voltage, which depends on the machine
frequency with the actual value of the machine voltage. If the reference value is exceeded, a
timer is activated. If the voltage does not return to the permissible value, before the adjusted
time delay has elapsed, a trip signal is initiated.
V/Hz-Protection
V/Hz-function
f UV/Hz
Detection Delay
f TRIP
Ug
T 0
Ug
Fig. 27: V/Hz Protection Block Diagram
Excitation Transformer Temperature Measurement
The measurement of the excitation transformer winding temperature is performed within the
®
UNITROL 5000 software. The measurement of the temperature is derived either from the
PTC or PT100 Sensors. These are built into the hot-spot place of each phase of the
secondary winding. If the solution with PTC Sensors is chosen, two sensors per phase are
employed. Each set is serially connected and led to their assigned analog inputs of the Fast
Input / Output Boards (FIO). Two analog inputs are used. The temperature condition is
detected for two predefined temperature’s thresholds for Stage one and Stage two. The first
stage initiates an alarm and the second stage causes the trip of the excitation system.
In case the PT100 Sensors are chosen, one sensor per phase is employed and connected to
its assigned analog input of the Fast Input / Output Boards (FIO). In this solution three
analog inputs are used. The temperature of the excitation transformer is continuously
measured. The measuring signal of the real temperature can be displayed on the Local
Control Panel (LCP), Local Service Panel (LSP) or can be transmitted to the Control Room.
Similar to the former solution the temperature condition is detected in software for two
predefined temperature’s thresholds, for alarm and trip purposes.

4.9.2 Other monitoring and protection functions
Control Electronics Cards
Self-test functions of the electronics cards include program sequence monitoring ("watch
dog"). The particular faults are displayed on the seven-segment display of the Control Board
(COB). Further, the input voltages to the power packs and their stabilized values are
supervised.
Thyristor converter
The following functions for monitoring of the thyristor converter operation are available:
• Micro switches for indication of melted semiconductors' fuses.
• Current conduction monitoring.
• Cooling air flow and fan supervision.
• Converter temperature supervision.
• Converter cubicle locked door detection.
• Micro switches for indication of blown AC over voltage fuses
AC over-voltage protection
An AC over-voltage protection circuit placed at the AC input of each converter bridge

absorbs the voltage spikes caused by the thyristor commutation. The AC over-voltage
protection consists basically of a three-phase diode bridge and a capacitor connected on its
DC side. The capacitor represents a low impedance for the high frequency spikes and acts
as a filter. In parallel with the capacitor there is a discharge resistor which absorbs the
energy when the capacitor is discharged. The capacitor for this application shall be able to
support high di/dt. The AC side of the diode bridge is protected by fuses, which are
supervised by micro switches.
DC Over Voltage Protection:
Faults on the machine terminals such as short-circuits, false synchronization and/or

asynchronous operation cause induced negative field currents, which can produce high
voltages in the field circuit. Such over-voltages must be limited to a level with sufficient safety
margin for the insulation voltage of the field winding (test voltage) and also below the PIV
value (peak inverse voltage) of the converter thyristors. The so-called CROWBAR circuit is
usually applied for this purpose.
The CROWBAR circuit employs break-over diodes to detect positive and negative over-
voltages in the field circuit. Whenever they respond, the associated thyristor is fired,
connecting immediately the field suppression resistor in parallel to the field. Simultaneously,
an excitation trip is initiated, causing an immediate opening of the field circuit breaker.

Earth Fault Protection:
The purpose of the earth fault protection is to monitor the isolation level of the field winding
with respect to the earth. If this function is requested to be included within the excitation
system equipment, ABB provides an Earth Fault Relay Type UNS 3020. The measuring
principle is based on the Whetstone’s Bridge, in which the balance of the measuring bridge
is established by two capacitors; one connected between the positive lead and the earth and
another one connected between the negative lead and the earth. With this relay, not only the
isolation level of the field winding is detected but also the isolation level of all power
equipment including secondary winding of the excitation transformer. It comprises two
stages or two different levels, both individually adjustable regarding the fault resistance and
time delay. Whenever an alarm for earth fault is given, it is stored in the relay and can be
acknowledged using the RESET button on the front of the module. This relay may be tested
while the excitation is switched on. More information can be taken from a separate brochure.

5. Thyristor Converter
The thyristor converter and other power equipment of a static excitation system are carefully
designed taking into consideration the following requirements:
- The thyristor converter should continuously provide 10% more field current than
required by the synchronous machine under rated working conditions.
- The thyristor converter should supply a so-called field ceiling, e.g. 1.6 times of rated
field voltage, for a short period of time (usually 10 sec.). In case of disturbances in the
power network the field ceiling capability contributes to a shorter settling time of the
main machine terminal voltage, reactive and active power, load angle and network
parameters.
- The thyristor converter should withstand the induced field current due to a 3 phase
short circuit on the machine terminals or on the high voltage side of the block
transformer.
- The repetitive peak reverse voltage as well as the repetitive peak off-state voltage of
the applied thyristors should satisfy the voltage security factor of at least 2.7.This is
referred to the maximum value of the excitation transformer secondary voltage.
- According to the system requirements on redundancy the thyristor converter can be

configured as one thyristor converter (economy design - without redundancy), as two
thyristor’s converters (each allowing 100% of operation conditions - twin design) or as
several thyristor converters connected in parallel. The last configuration allows all
operation conditions with one thyristor converter out of operation (so called n-1 design).
Each thyristor converter is a self-standing unit with its modularized parts, that are particularly
described in item 5.1. No part is commonly used between the thyristor converters connected
in parallel. Thus a fault in one thyristor converter does not influence the operation of other
thyristor converters working in parallel.
5.1 Power Electronics
(Valid also for Economy Design)
Each thyristor converter consists of one full wave thyristor bridge module, equipped with 6
double side-cooled thyristors. An ultra speed fuse is connected in series to each thyristor. Its
main purpose is to isolate a branch with faulty thyristor, thus protecting other thyristors and
their fuses from damage. On melting, a microswitch, forming part of the fuse, is actuated by
a spring for control and annunciation purpose.
In order to reduce the voltage spikes during commutation a RC – Snubber circuit is

employed. A resistor/capacitor circuit is connected on the AC-side of the bridge. Moreover,
this circuit absorbs the over-voltages from the network, when these appear on the secondary
side of the thyristor bridge. (N.B. the capacitive voltages induced by the lightening are
damped by the excitation transformer earthing screen winding.)

Pulse transformers are provided for reason of galvanic separation between power and
control circuits and are parts of the Gate Driver Interface (GDI).
The thyristor heatsinks are forced cooled by AC-motor driven centrifugal fan(s). The fan’s
fault is indirectly monitored by the measuring of the thyristor converter temperature, which is
a function within the Converter Interface (CIN). A redundant forced cooling is provided as an
option. The AC-motor driven centrifugal fan with other associated components are installed
in a fan box, which is easy removable.
Natural cooling, if required, is mainly applicable for the Mechanical Protection Class IP20.
However, if a higher Mechanical Protection Class is specified, requiring also the filter mats at
air inlets and outlets, the door fan is needed. Its main role is to establish an airflow through
the cubicle.
The equal current division between the thyristor converters working in parallel is assured by
the dynamic current distribution mechanism, which is a software function within the
Converter Interface (CIN). For this purpose and for the purpose of the conduction monitoring
the Hall-Sensors are employed for the current measuring.
Optionally, a 5 - pole isolator may be integrated per each thyristor converter. This is used for
repairing a faulty thyristor converter, while the others are under load. However, ABB
standard solution is with an additional thyristor converter (n-2 design) instead of 5 – pole
isolator.
Two level adjustable thermal-sensor is employed for monitoring of the thyristor converter
temperature.
5.2 Twin Configuration

A twin configuration is consisted of two independent thyristor converters, each designed to
satisfy all required working conditions. Accordingly, a 100% redundancy is ensured. Only
one thyristor converter is in operation (on line converter) at the time, while the control pulses
of the other thyristor converter (stand-by converter) are blocked. The latter comes into
operation upon failure of the on line thyristor converter. The switching-over is performed by
the AVR control. Upon detection by the Converter Interface (CIN) that the main thyristor
converter (on line converter) fails, its pulses are blocked. Simultaneously, the pulses of the
stand-by converter are released and it takes over the field current.
5.3 N - 1 Configuration
N -1 configuration is designed by three or more thyristor converters working in parallel
simultaneously. With one thyristor bridge out of operation, all required working conditions are
possible without restrictions.
The conduction monitoring function within the Converter Interface (CIN) monitors the
operation of the thyristor converter and takes care of the fault evaluation. E.g. if two
thyristors in separate thyristor converters but if different branches fail, the excitation system
will still remain in operation. Only in the case when two or more thyristors in the same
branches fail, the trip will be initiated. With this function a higher availability of the excitation
system is achieved.

5.4 Converter Interface (CIN)
The Converter Interface (CIN) is a decentralized control and regulating device and is
together with the Gate Driver Interface (GID), Current Sensor (CUS) and Converter Display
(CDP) a consisted part of each thyristor converter cabinet. Its main function is to generate
the chain of the triggering pulses to the Gate Driver Interface (GDI) for the 3-phase full wave
thyristor bridge operation. In addition, this device includes the following functions:
• Provides a galvanic isolation of the triggering pulses and control signals between the
Control Board (COB) and the Gate Driver Interface (GID).
• Measures the branches’ currents and accordingly perform the conduction monitoring
of each particular thyristor. The same signals are used for the local Converter
Display (CDP).
• Enable the ARCnet field bus connection and thus serve the control and status
signals transmitted between the Control Board (COB) and itself.
• Monitors the status of thyristor converter components such as fuses, temperature, 5-
pole insulator (if provided) etc. These signals are serially sent to the Control Board
over the ARCnet field bus.
• Transmits the commands from the Control Board (COB) such as pulse blocking / de-
blocking and the fan switch-on.
• Regulates and optimizes the current distribution between the thyristors’ bridges
working in parallel, so called dynamic current distribution.
5.5 Gate Driver Interface (GDI)

Gate Driver Interface (GDI) serves for the pulse amplification and matching to the level
necessary for the triggering of thyristors. The pulse transformers are parts of this device.
However, for the isolation level more than 5 kV special type pulse transformers are
separately provided and installed into the thyristor bridge itself.
5.6 Current Sensor (CUS)

Current Sensor (CUS) is employed for the measuring of the branch currents of the thyristor
bridge. The output signals are directly connected to the Converter Interface (CIN).
5.7 Converter Display (CDP)

Converter Display (CDP) is placed on the cabinet's door and serves a visible annunciation of
the converter operation. It is convenient for rapid inspection of the status of the thyristor
converter. It provides the following facilities:
• Status indication of the conducting of each thyristor’s branch with LEDs. A faulty
branch is shown on its dedicated LED.
• Converter Interface (CIN) status indication with LEDs, blocked / de-blocked, CIN
fault.
• LCD display of the thyristor converter output current measured on the CIN.

6. Field suppression
ABB’s standard solution to the field suppression is based on the control of the field circuit
breaker on ac side of the thyristor bridge, CROWBAR thyristor and pulse blocking. Although
the same field circuit breaker may be set on the DC-Side of the thyristor bridge, if required,
ABB has left this concept because of some practical reasons. At first, it provides a reliable
disconnection of the thyristor converter from the supply source in the case of an internal
short circuit. Therefore, the possible damages, this may happen within the thyristor converter
and other power parts, are considerably reduced. Moreover, a reliable disconnection from
the supply source is usually useful for the testing and maintenance purposes providing also
a higher security for the operation staff. The concept with a field breaker on the ac side of the
thyristor bridge is however restricted to the field current up to 4500 A. For the higher current
demand a so called High-Speed DC Circuit Breaker is employed.
A field suppression starts upon receiving a trip command, either from the generator
protection system or from the internal excitation system protection. The sequential control
sends the simultaneous commands for: AC-Field breaker OFF, pulse blocking and for the
triggering of the CROWBAR thyristor. The later command enables the commutation of the
field current to the field suppression resistor. Since the pulse blocking is also applied, the
available negative wave of the ac-supply voltage is added to the arcing voltage of the field
breaker and the field suppression time is reduced.
The field suppression with the field circuit breaker on dc side of the thyristor converter is
applied if requested. The sequential control is similar to the above described but the inverter
operation of the thyristor converter is introduced instead of the is pulse blocking.
The rate of the field discharge resistor is sized and coordinated with the field breaker arching
voltage and the maximum admissible voltage across the field winding. It is also sized to
absorb the suppressing energy, accumulated in the field winding, due to an induced field
current from a three-phase short circuit on generator terminals and / or from the ceiling field
current in no-load operation.

7. Field flashing
UNITROL 5000 is normally capable for start up from the residual machine voltage. At the
beginning of the starting sequence only 10 to 20 V at the input of the thyristor converter are
necessary for the normal operation of the control electronics. If it is not the case, the thyristor
converter is continuously fired (diode mode of operation) to reach this value and to switch
over to the normal converter operation. If this, however, doesn’t take place within several
seconds (e.g. after a long stand still period), the back-up field flashing is activated (-R03, -
V03, -Q03). This back-up circuit is designed to reach the necessary 10 to 20 V. At 10% of
the generator voltage the converter has taken over and therefore the field flashing can be
deactivated. At this point the soft-start function takes place to build up the voltage to the
required pre-set level. The whole start up sequence is controlled and monitored with AVR
software.
Since only a small current is supplied from the back-up field flashing circuit, a battery can
always be used for large excitation systems. This means that with a relatively high ohmic
resistor in the field flashing circuit the field time constant (L/R) is also considerably reduced.

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UNITROL 5000

for Excitation Systems

1. Overall system description..................................................................................... 2

2. Mechanical Design .................................................................................................. 5

3. UNITROL 5000 Control Electronics..................................................................... 9

4. Voltage Regulation, Monitoring and Protection Functions................................ 23

5. Thyristor Converter ............................................................................................... 43

7. Field flashing ......................................................................................................... 47

3BHS 110 389 E Page1/47

1. Overall system description

• Excitation transformer -T02

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23.04.02\Functional Description \11:42

-T05 AC AUX. BUS

Figure 1: Block diagram of a typical UNITROL 5000 Excitation System

DII ROI LBI AIO PTI OBI

Mechanical Protection Degree:

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• Pre-treatment including de-greasing, purging, galvanizing and a high pressure

• Control circuits: 1.0 mm2

• Auxiliary supply: 2.5 mm2

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PT's & CT's

3.2 Configuration and mechanical design

AVR – Automatic Voltage Regulator

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Figure 4: Type D5T – Single

BLOC EGC In D5S configuration all

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Figure 6: Type A5E – Full

Figure 7: Type A5T – Full redundant COB 1 THYRISTOR CONVERTER

Figure 8: Type A5S – Full Redundant

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3.3 Main control boards

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Figure 10: Typical configuration of the double channel system

EGC (Extended Gate Controller)

• Extended Gate Controller (EGC)

• Power Signal Interface (PSI)

• Power Supply of the Control Electronics

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3.5 Human-Machine Interface

3.5.1 Service Panel (SPA)

Figure 11: Service Panel (SPA)

The Service Panel (SPA) in a multi-purpose

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Figure 12: Local Control Panel (LCP) in a typical operation

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• Indication of the selected mode

• Local operation control

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Figure 13: CMT-Tools, display on the PC Screen

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Order Commands Status and Alarm Signals

- Excitation Start - Excitation On

Table 1: List of standard remote control, status and alarm signals.

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