Abb, Unitrol 1020

Excitation Systems, DMPC-PE, Rudolf Moeckli / 7 January 2016
UNITROL® 1010, UNITROL® 1020

Benchmark digital voltage regulators
for brushless generators & motors
© ABB Group
April 13, 2018 | Slide 1
Doc no. 3BHS666181 E01 Rev. C
ABB Global Product Line Excitation Systems
Products, systems and applications
Industries
Power; Chemical, Oil Power; Marine; Power; Chemical, Oil Power Marine
& Gas; Pulp & Paper; & Gas; Minerals &
Traction; Wind
Sugar Mining; Metals
Power Applications
xx Power xx
§ Generator synchronization § Synchronous generators § Synchronous generators § Gas turbine starter § Onboard DC-grid systems
§ Paralleling of lines and motors and motors § Generator excitation
§ Rotating compensators and § Synchronous compensators
converters
SYNCHROTACT® UNITROL® 1000 UNITROL® 6000 MEGATROL UNIREC
© ABB Group
§ SYNCHROTACT 5 § UNITROL 1005 (AVR) § UNITROL 6000 Light § MEGATROL Light § UNIREC Basic
§ UNITROL 6000 Medium
§ SYNCHROTACT CSS § UNITROL 1010 (AVR) § MEGATROL Medium § UNIREC GENREC
§ UNITROL 6000 Power
§ SYNCHROTACT MSP § UNITROL 1020 (AVR) § MEGATROL Power § UNIREC EXC
§ UNITROL 6000 X-power
§ UNITROL 6000 Nuclear
§© ABB Group
§April 13, 2018 | Slide 2
UNITROL 1000 family
Applications
Power Marine
Wind Traction
© ABB Group
UNITROL 1000 history and references
Main customer
§ Engine manufacturer (power plant / marines)

è UNITROL 1000 used as standard
§ ABB Marines
§ Wärtsilä (Diesel)
§ Siemens (Gas Turbine)
§ Rolls Royce (Diesel)
§ GE Jenbacher
§ Generator manufacturer
§ ABB Machines
§ Cummins AVK
§ Leroy Somer
§ Retrofit / engineered projects
© ABB Group
Diesel applications, land based power plants
Diesel engines up
to 15 MW Benefits and used functions
§ Reactive load sharing via RS485
§ Paralleling up to 31 machines for reactive
load sharing
§ Power plant up to 400 MW
§ Synchronization
CMT1000
§ Very fast
Synchroscope
§ Self synchronization after start up
§ PSS
§ IEEE compliant PSS
§ Certified by 3rd parties companies for
§ Russian / USA
© ABB Group
Diesel applications, Marines
Diesel engines up
to 15 MW Benefits and used functions
§ Reactive load sharing via RS485 (VDC)
§ Support for ring bus structure
§ Accurate load sharing over time and
temperature range
§ Synchronization
CMT1000
§ Very fast
Synchroscope
§ Self synchronization after start up
§ Enhanced monitoring functions
§ Event and data logging
§ GL / DNV class approval
© ABB Group
Gas turbine applications
Gas turbine up to
50 MW Benefits and used functions
§ Dual channel systems
§ Increased availability
§ Various monitoring functions like PT/CT
failures
§ Temperature influence limiters

CMT1000 dual
§ Adjusted Limits according measured
channel cooling media temperature
configuration
§ Remote Control (Modbus)

§ Extend digital IO over fieldbus
© ABB Group
ABB Global Product Line Excitation Systems
Most common types today
Field circuit supply:

- PMG
- shunt transformer
- auxiliary power
AVR
AVR
SM E SM
Rotating exciter: 1 – 400 A Static excitation: 100 – 12,000 A

+ brushless (mostly) + fast response
- slow response for transients - brushes
© ABB Group
UNITROL 1000 family
Automatic voltage regulator (AVR)
System duties
§ Supply variable DC current to the field
winding of exciter machine
§ Control of generator terminal voltage
with specified accuracy
§ Keep machine within permissible
operating range
§ Ensure a stable operation with other
E AVR machines and network
§ Contribute to transient stability at a
grid fault by field forcing
§ Communicate with the power plant
control
© ABB Group
UNITROL 1000 portfolio in 2016
Device overview
UNITROL 1005
UNITROL 1010
UNITROL 1020
© ABB Group
UNITROL 1000 portfolio 2016
Hardware overview
*) at 70°C ambient
temperature
8A at 55°C
UNITROL UNITROL UNITROL
**) Ie > 15 A requires
1005 1010 1020
external capacitor
Excitation current 5 A cont. * 10 A cont. 20 A cont. **
at 55 °C 10 A ceiling 20 A ceiling 38 A ceiling
Separate terminals for

NO YES YES
aux power supply
HMI NO NO YES
4 digital outputs 8 digital I/Os 8 digital I/Os
8 digital input 4 digital input 4 digital input
I/Os 2 analog inputs 3 analog inputs 3 analog inputs
2 analog outputs 2 analog outputs
USB USB USB

Ethernet RS485 RS485
Interfaces Ethernet Ethernet
(CAN) (CAN)
IP20 IP20 IP20

Mechanicals Suitable for machine Suitable for machine Suitable for machine
mounting mounting mounting
CE, (DNV/GL), CE, cUL, DNV, GL, CE, cUL, DNV, GL,
Certificates (cUL), Traction CCS, Traction CCS, Traction
© ABB Group
UNITROL 1000 portfolio 2016
Software overview
UNITROL UNITROL UNITROL

Software functions 1005 1010 1020
AVR/FCR/PF/VAR
Limiters
Protection / Monitoring
ECO
Soft start
LIGHT Voltage matching
LIGHT
LIGHT
History logger
Modbus TCP
Rotating diode monitoring
BASIC
BASIC
Reactive load sharing via RS485
BASIC
Dual channel
Auto-synchronization (SYNC)
FULL + PSS
Event logger
FULL
FULL Data logger
Real-time clock
Time synchronization by SNTP
Option Power System Stabilizer (PSS)
© ABB Group
Technical data UNITROL 1010 /20
Device overview
§ Robust mechanical design

§ Spring tension terminals for power and
measurement
§ Plug-in type terminal blocks for digital and
analog I/O’s
§ Status information by 3 LED’s
§ Equipped with industrial USB
§ Ethernet, CAN and RS485 ports
§ Human Machine Interface, HMI
(model UNITROL 1020)
© ABB Group
Connection overview
External capacitor if
Ie > 15 A
© ABB Group
Technical data
§ Control supply voltage rage

9 – 300 VAC 3-phase (min. to max. )
16 – 300 VAC 1-phase (min. to max. )
18 – 420 VDC (min. to max. )
è Nominal voltage must not exceed 250 VAC
§ Power electronics supply 0 – 300 VAC or 0 – 420 VDC
è Nominal voltage must not exceed 250 VAC m
è Max filed forcing voltage 350Vdc (depending on input voltage)
§ Excitation output 20 ADC cont. 38 ADC 10 sec
è Excitation current above 15 A requires external capacitor
§ 3-phase or single phase stator voltage measurement up 500 VAC
è earthed at secondary side of PT
§ Single phase current measurement (1 to 5 A)
§ Single phase measurement of line voltage for synchronization
up 500 VAC
§ Measurement accuracy 0.1%
§ Control accuracy typically < 0.5% (depending on Vp)
§ AVR response time < 20 ms with 3 phase measurement
< 50 ms with 1 phase measurement
© ABB Group
Supply modes
®
UNITROL 1000, most
flexible AVR
© ABB Group
Supply modes
Permanent Magnet Generator (PMG)
AVR
UNITROL 1000
AVR System
PMG SM E
§ 3 phase PMG è Most save supply mode for extended operational life
time
§ Easy to simulate
© ABB Group
Supply modes
Auxiliary winding
AVR
UNITROL 1000
AVR System
SM E
§ Attention must be paid to none sinusoidal voltage

è Peak level must never exceed 420Vp
§ Difficult to simulate, voltage dependent on machine load
© ABB Group
Supply modes
Axillary power, e.g. UPS
DC AC
AVR
UNITROL 1000
SM E
§ Attention must be paid to max inrush current

è Max 200A for 10ms, limit current by resistor
§ Easy to simulate
© ABB Group
Supply modes
Shunt supplied
AVR
UNITROL 1000
SM E
§ No support for short circuit at grid connection point

§ Easy to simulate
© ABB Group
Supply modes
Shunt supplied with DC or AC boost at AVR input
AVR
Station
battery UNITROL 1000
Voltage
relay
SM E
§ Attention must be paid to max inrush current

è Max 200A for 10ms, limit current by resistor
© ABB Group
§ Easy to simulate
Supply modes
Shunt with AC boosting for field forcing
AVR
Boost for short
circuit support
UNITROL 1000
boost
SM E
§ Machine short circuit capability defined by CT’s
© ABB Group
§ Difficult to engineer and simulate
Supply modes
Calculating kceiling for UNITROL 1000
3 phase PMG Internal DC voltage:
UPMG= (UDC + 8) /1.35 UDC = Ue max.
UPMG= 127 VAC = kceiling * Ue no load
AVR
= 10 * 16.4 V = 164 VDC
UNITROL 1000
AVR System
PMG SM E
Excitation voltage:
Ue no load = 16.4 V
kceiling = Ue max. / Ue no load
© ABB Group
kceiling= 5…10… 15
SW Functions
®
UNITROL 1000 provides
widest range of integrated
SW functions
© ABB Group
Software functions
ECO package (1/4)
§ Start up functions
§ Soft start
§ Field flashing off / voltage relay function
§ Fast line voltage matching
§ Regulator modes
§ Voltage control mode with PID control algorithm
§ Power factor controller with PID control algorithm
§ Reactive power (VAR) controller with PID control
algorithm
§ Super imposed PF/VAR controller
§ Excitation current controller (manual control) with PID
control algorithm
© ABB Group
Software functions
ECO package (2/4)
§ Limiters
§ V/Hz limiter
§ Minimum excitation current limiter
§ Underexcited reactive current limiter as a function of
active power (P/Q)
§ Three step delayed maximum excitation current limiter,
generator cooling media temperature depending
§ Stator current limiter, generator cooling media
temperature dependent
§ Machine voltage min. / max. limiters
(Only used in PF/VAR mode)
Power chart
© ABB Group
Power chart with operational limits
max. field current

limiter
P
min. field current

limiter
underexcitation
P,Q limiter
max. stator
current limiter
-Q 1/Xd +Q
UNITROL 1020 will keep
operation point inside
permissible range
© ABB Group
UNITROL 1000 family
Power Chart and operational limits
Under-excited Over-excited
(leading) +P (lagging) Limiter:
1 Rotor current limiter
Stability limit Driving limit P/Q limiter
Generator Minimum field current limiter
Stator current limiter
§IGn The excitation system keeps the

generator within thermal and stability
limits
§j
§d Protection:
-Q -1 1 1 +Q Excitation over current
xd
UNITROL 1020 will keep

Motor
operation point inside
permissible range
-1
1 p.u. = nominal
-P
© ABB Group
Software functions
ECO package (3/4)
§ Monitoring / protection functions

§ Device supervision functions grouped to 2 supervision
alarm signals /1 trip output
§ Watchdog / communication / PT / CT
§ PWM (excessive excitation / loss of excitation)
§ DSP temperature / control supply voltage / digital
output
§ External monitoring functions grouped to 3 monitor
alarm signals
§ Rotating diode monitoring RDM
§ Generator voltage (min. / max.)
§ Excitation current (max.)
© ABB Group
Software functions
ECO package (4/4)
§ Network short circuit support functions

§ Boost function
§ Fault ride-through (FRT) detection
§ Voltage SP reduction at load application
§ High Initial Response controller to improve performance
with high ceiling factor
§ AVR Gain dependency on frequency and power input
to improve stability over wide range of operations
conditions
§ Commissioning
§ Open loop control of output voltage for test purposes
§ Built-in step test function for regulator tuning, together
with CMT1000
© ABB Group
Software functions
LIGHT package (includes all function of ECO)
§ History Logger
§ Records last 2 hour of operation for claim investigation
§ Modbus TCP (Ethernet) / RTU (RS485)
§ Access to all measurement status information and
parameters
§ Remote control, alternative for digital I/Os
§ Easy extension of I/Os
§ Rotating diode monitoring
§ Supervision of rotating diode on the exciter machine to
prevent damage on the machine
© ABB Group
Software functions
BASIC package (1/2)
§ Voltage droop compensation (VDC) mode for island

operation è See more information
§ Reactive load sharing at constant bus bar voltage
§ Up to 31 machines
§ Support for 2 tie breaker or ring structure
§ Analog input from superimposed regulator to summing
point of voltage regulator
© ABB Group
Voltage droop compensation (VDC)
VDC principles
Load A Load B
U = 100 %
RS-485
AVR 1 AVR 2 AVR 3 AVR 4

SM SM SM SM
§ Reactive load sharing at constant bus bar voltage

§ Fix to 100% in range of min. / max. VAR set point
§ Outside min. / max. VAR set point in static droop mode
§ Interaction between units based on digital serial bus
communication RS485
§ Up to 31 machines
§ Only for island operation
© ABB Group
VDC for bus bar with 2 tie breaker
§ Support for 4 Net ID’s

§ Status of generator breaker defines whether
AVR is joining load sharing
§ Tie breaker status is routed to every AVR to
define load sharing groups (Sec. Net 1 & 2
inputs)
© ABB Group
VDC for bus bar with 2 tie breaker
§ Baud rate 59.9 kBaud / 56.7 kBaud (standard baud rate à

standard repeater can be used)
§ Bus length
§ Mixed installations with UNITROL 1000-15 à 250m
§ Only UNITROL1020 à 500m
§ Max. devices on bus 31 machines
© ABB Group
VDC for ring structure
§ Based on segments, max 6 segments

§ Tie breaker status only wired inside segment
§ Status of local tie breaker is send over RS485 to
other AVR’s
§ Algorithm defines which AVR’s are on the same bus
§ Algorithm defines which AVR’s are on same bus
§ Define numbers of segments
§ Define in segment AVR is
© ABB Group
VDC for ring structure
§ Based on sections with 2 breakers

§ Sec.Net 1 & 2
© ABB Group
Software functions
BASIC package (2/2)
§ Dual channel functions

§ Setpoint follow up of second channel over CAN
§ Blocking of channel switch over in case of redundant
channel failure
§ Configurable switch over logic
§ Internal trip logic and forcing logic
§ Configurable forcing excitation off (trip) or to Manual
mode depending on monitor status
§ Automatic synchronizing
§ Generating close command for GCB (breaker closing
time as parameter)
§ Analog output or higher / lower pulses to governor
§ Dead bus synchronizing
© ABB Group
Software functions
FULL package (1/1)
§ Real time clock, time synchronizing over SNTP server

§ Event logging, up to 500 events
§ Time stamped with 1ms time resolution
§ Export to text file
§ Readout via Modbus
§ Data logger
§ Up to 10 data logs, each containing 12 signals with
2,000 samples (5 signals free configurable)
§ Sampling time between 10ms and 500ms
§ Configurable triggering (event)
§ Export to text file or as COMTRADE format
§ Read out via Modbus
© ABB Group
Software functions
Options and further developments
§ Power system stabilizer (IEEE PSS2A/2B/2C, optional)

§ Injection points for frequency, active power and input of
lead lag filter
§ 2 configurable test points for CMT1000 and external
measurement devices
§ Configurable damping of engine firing frequncy to
reduce noise at AVR output
§ Future development (Rel 6.4 not yet scheduled)
§ Supprot for IEC61850
§ CAN 1939 fieldbus
© ABB Group
Commissioning &
maintenance tool CMT100
Best of class operating tool
© ABB Group
Commissioning & Maintenance Tool CMT1000
Benefits
User-friendly
tool for all
UNITROL 1000
products
§ Intuitive commissioning and maintenance tool

è Easy to learn how to operate
§ Build-in step and real time recording functions
è No additional measuring devices needed
§ Extended debug functions
è Fast commissioning and trouble shooting
è Enables precise and focused remote support
© ABB Group
Quick start
§ Main Window
§ OFFLINE Not connected
§ MONITROR Read only
§ CONTROL Read / Write
§ EEPROM Green indicates
parameter saved into
Flash
§ Help è About CMT1000…
§ Revision of CMT
§ Serial number of device
§ Target SW release
© ABB Group
Intuitive I/O setup windows
§ Digital I/O
§ Input / output
§ Select signal with drop down menu
§ Select polarity
§ Green LED è terminal voltage is high
§ Analog input
§ Select signal with drop down menu
§ Select scaling
§ Terminal voltage directly shown
© ABB Group
Step function and real time recording
§ Step function
§ All regulator modes
§ Define step size
§ Down or up (10 sec)
§ Real time recording

§ Simultaneously 16 signals recorded
(50ms)
§ Additional status information like
modes, I/Os, limiters
§ Save waveform to PC
© ABB Group
Required data for remote support
§ Single line diagram

§ Parameter file
§ Waveform file of oscilloscope
Analyzing of waveform files, CMT in offline

§ Load parameter file and open waveform file
§ All other CMT windows are following cursor A
§ Measuring window
§ PQ-diagram
§ Adjust setpoint window
§ I/O setup windows
© ABB Group
Scope of supply
List of items coming with every unit on a CD - free
§ CMT1000
§ Easy to use commissioning tool
§ PID tuning tool

§ Calculation and verification of optimized PID
setting for stable and reliable operation
§ E-learning
§ Interactive learning of
§ Excitation basics
§ UNITROL 1010 / 1020 functions and features
§ Module interfaces
§ Manuals
§ Presently available in English, French, Spanish
and German
© ABB Group
Components around the
AVR
Systems designed by ABB
is based on over 100 years
of experience
© ABB Group
New Hardware Features
n Design based on UNITROL 1000-7
n Power input voltage to 300V ac max.
n Exciter current up to 20A (max. 40A)
n Remote access over integrated Ethernet controller
n USB for local connection of CMT (serial port removed)
n Power up via USB port in case of no power supply available (easy
parameters downloading for spare AVR’s)
n Removable local panel for accessing AVR settings &
measurements (stores also AVR settings)
n Additional 4 digital I/O’s
n Easy wiring due to removable connectors (spring loaded
terminals for control wires)
n Natural cooling with heat sink
n Max operating temp 70ºC
Compatible with
n Plastic housing, IP20 existing hardware
n UL / DNV certified UN1000-15
n Wärtsilä mounting plate design with UL-components è same
footprint with exisiting UNITROL 1000-15 plate
© ABB Group
New SW Features
n MODBUS / TCP interface

n Up to 10 connections
n Up to 60 free configurable signals
n Event logger
n Storage of up to 500 events, 1 ms time resolution
n Data recorder for 12 signals
n Sample rate between 2 and 100 Samples/sec
n Recording time between 2 and 100 seconds
n Configurable Triggers
n Time synchronization with SNTP server
n USB interface, shows up on PC as standard COM port
n Prepared for integrated Web server
n Reactive load sharing with ring bus support
© ABB Group
UNITROL 1020 Prototype
© ABB Group
UNITROL 1020 Front Side
© ABB Group
UNITROL 1020 Wärtsilä Plate
© ABB Group
UNITROL 1020 Plate Circuit Diagram
© ABB Group
Components around the AVR
UNITROL 1020, 1 channel system
© ABB Group
© ABB Group
© ABB Group
Configuration
© ABB Group
Configuration
© ABB Group
Configuration
Main features:
automatic change over to Redundant-AVR, but
manual resetting back to Main.
Þ MAIN AVR must detect the failure and
activate transfer
Monitoring conditions for change-over to redundant:

Potential Transformer Monitor (wire break, MCB trip)
Current Transformer Monitor (wire break)
Loss of Excitation (PWM high, but field current is low)
Loss of Control (control transistor short-circuit)
Loss of Auxiliary Supply (DC-supply lost)
Design considerations:
Generator should be equipped with:

• Own CT secondary's for both AVR’s current measuring
• Own VT secondary's + MCB’s for both AVR’s voltage measuring MAIN-AVR: REDUNDANT-AVR:
[SOFTSTART] [SOFTSTART]
Starting Level=25.0% Starting Level=25.0%
Notice! Hold Time=1.0s Hold Time=2.0s
Master & Redundant AVR parameters are NOT identical! Ramp Time=5.0s Ramp Time=8.0s
[DIGITAL I/O 3] [DIGITAL I/O 3]

Input=Standby Input=None
Polarity=Inverted Polarity=Normal
Main differences are listed here Output=System_OK
Direction=Out
Output=None
Direction=Out
[DIGITAL INPUT 5] [DIGITAL INPUT 5]

Input=None Input=Standby
Polarity=Normal Polarity=Normal
© ABB Group
Configuration
UNITROL 1020, 2 channel system VT’s
Generator measuring transformer configuration

for 2-channel AVR
Own secondary's for both

Voltage Transformers AVR’s
CT’s
Current Transformer, x/1A
© ABB Group
Synchronizing Function
n Voltage matching
n Speed control, analogue bias signal
n Breaker close command
n Synchrocheck UNET UNITROL 1000
Setpoint fSP = fNom
Command
CB
Fbias Sync
Speed Controller
Setpoint
UM
Regulator
T SM E
© ABB Group

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Excitation Systems, DMPC-PE, Rudolf Moeckli / 7 January 2016

UNITROL® 1010, UNITROL® 1020

SYNCHROTACT® UNITROL® 1000 UNITROL® 6000 MEGATROL UNIREC

§ Engine manufacturer (power plant / marines)

§ Temperature influence limiters

§ Remote Control (Modbus)

Field circuit supply:

Rotating exciter: 1 – 400 A Static excitation: 100 – 12,000 A

Separate terminals for

USB USB USB

IP20 IP20 IP20

UNITROL UNITROL UNITROL

Option Power System Stabilizer (PSS)

§ Robust mechanical design

§ Control supply voltage rage

§ Attention must be paid to none sinusoidal voltage

§ Attention must be paid to max inrush current

§ No support for short circuit at grid connection point

§ Attention must be paid to max inrush current

§ Machine short circuit capability defined by CT’s

max. field current

min. field current

Generator Minimum field current limiter

Stator current limiter

§IGn The excitation system keeps the

UNITROL 1020 will keep

§ Monitoring / protection functions

§ Network short circuit support functions

§ Voltage droop compensation (VDC) mode for island

AVR 1 AVR 2 AVR 3 AVR 4

§ Reactive load sharing at constant bus bar voltage

§ Support for 4 Net ID’s

§ Baud rate 59.9 kBaud / 56.7 kBaud (standard baud rate à

§ Based on segments, max 6 segments

§ Based on sections with 2 breakers

§ Dual channel functions

§ Real time clock, time synchronizing over SNTP server

§ Power system stabilizer (IEEE PSS2A/2B/2C, optional)

§ Intuitive commissioning and maintenance tool

§ Real time recording

§ Single line diagram

Analyzing of waveform files, CMT in offline

§ PID tuning tool

n MODBUS / TCP interface

Monitoring conditions for change-over to redundant:

Generator should be equipped with:

[DIGITAL I/O 3] [DIGITAL I/O 3]

[DIGITAL INPUT 5] [DIGITAL INPUT 5]

Generator measuring transformer configuration

Own secondary's for both

Current Transformer, x/1A

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