Engineering and Commissioning Guideline
AVR Unitrol 1020
PowerES
070.020
Project: Standard
KKS Code: xxMKA01
Revision: A
Issued by: PPPEA
T. Herzog, 04.01.2021
MAN Energy Solutions - Stadtbachstr. 1 / D-86224 Augsburg / Germany
AVR Unitrol 1020 EngineeringCommissioning Guideline_Rev.A.xlsm 1 / 19
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translation thereof.
I Revision History
Rev. Written Checked Released Release date Status/Edition Issued for Remark
A. Piranishvili / Changes highlighted
A T. Herzog J. Rabe 04.01.2021 AFC Application yellow
B. Mennen
A. Piranishvili /
0 T. Herzog J. Rabe 05.10.2018 AFC Application
B. Mennen
AVR Unitrol 1020 EngineeringCommissioning Guideline_Rev.A.xlsm 2 / 19
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translation thereof.
II Table of Contents
I Revision History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
II Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
III Principle Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
III.1 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
III.2 Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IV Reference Documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
V Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
V.1 System Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
V.2 Soft Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
V.3 Field Flashing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
V.4 Limiter Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
V.4.1 Limiter Functions - V/Hz Limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
V.4.2 Limiter Functions - Max. Ie Limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
V.4.3 Limiter Functions - Max UM Limiter & Min UM Limiter. . . . . . . . . . . . . . . . . . . 8
V.4.4 Limiter Functions - Max IM Limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
V.4.5 Limiter Functions - Min Ie Limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
V.4.6 Limiter Functions - Min Q Limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
V.4.7 Limiter Functions - Boost and FRT detection. . . . . . . . . . . . . . . . . . . . . . . . 10
V.4.8 Limiter Functions - Limiters Temperature Influence. . . . . . . . . . . . . . . . . . . . . 10
V.5 Setpoints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
V.6 Voltage Droop Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
V.7 Digital I/Os. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
V.8 Analog Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
V.9 Analog Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
V.10 Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
V.11 Diode Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
V.12 Monitor and Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
V.13 Tune. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
V.14 AVR Ethernet Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
V.15 Excitation Current Limiter ECL-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
VI Remarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
AVR Unitrol 1020 EngineeringCommissioning Guideline_Rev.A.xlsm 3 / 19
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III Principle Description
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III.1 Purpose
This Engineering and Commissioning Guideline shall support during the engineering phase and is part
of the specification for alternator commissioning to ensure proper settings for safe and reliable operation
of the alternator.
This guideline is valid for all projects where MAN ES supplies alternator with AVR ABB Unitrol 1020 1CH and
control system GCP (Genset Control Panel).
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III.2 Properties
The AVR is one of the major components in the Genset control system.
The main functions of the AVR utilized by MAN are:
- Excitation system
- Regulator control modes, for example Automatic voltage regulator (AVR) and Power factor regulator (PF)
- Automatic synchronization
- Limiters to keep the alternator in a safe and stable operation area (e.g. V/Hz limiter, PQ Min limiter,
Max Ie limiter, Machine Voltage limiter)
- Soft Start
- Rotating Diode Monitoring
- Modbus TCP interface to MAN's control system for signal exchange, switchover between control modes
and setpoint setting for AVR and PF mode
- Hardware interface to the generator protection relay for intertripping
Generally the settings are based on MAN ES standard, alternator data sheet, alternator FAT test report, VT
and CT ratings in alternator as well as MV switchgear.
Most of the settings are determined during engineering phase by MAN ES.
The setting file (*.ini) for alternator commissioning is handed over by MAN ES with complete project
specific settings including latest PID parameters from alternator FAT.
During alternator commissioning the commissioning engineer shall cross-check the settings to the
relevant documents, e.g. alternator data sheet, MV switchgear drawings and further relevant documents.
Additionally PID settings for the regulations modes shall be optimized for best regulation behavior.
In case of doubt for certain AVR settings MAN engineering team shall be contacted.
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translation thereof.
IV Reference Documents
- UNITROL® 1020 User Manual (3BHS335648 E82)
- ABB AVR Unitrol 1020 1CH Mounting Plate Drawing 3BHS581347E20)
- ABB AVR Unitrol 1020 1CH System Description (3BHS581347 E41)
- ABB AVR Unitrol 1020 1CH Dimensional Drawing (3BHS581347_E01)
- Project Specific Genset Control Panel (GCP) Documentation
- Project Specific Alternator Manual (incl. FAT Test Report)
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translation thereof.
V Settings
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V.1 System Data
The system data is determined project specific based on alternator data and CT/VT ratings of the alternator
and MV switchgear. The values shall be cross-checked during commissioning.
The following values are only for example:
Most of the values mentioned above are taken directly from the alternator data sheet, except for "Kceiling"
and "Ie No Load", which are determined by the alternator manufacturer and are part of the FAT test report
of the alternator.
Remark:
According to MAN's standard configuration for GCP, the Machine Potential Transformer and Network
Potential Transformer are located in the MV switchgear.
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V.2 Soft Start
The soft start values are standard values, which have been determined in coordination with ABB.
The values usually don't need to be adapted project specifically.
The standard soft start settings can be found in below picture:
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V.3 Field Flashing
Due to remanent magnetism of the alternator, field flashing is not required, therefore no settings to be done.
For the theoretical case, of alternator having lost ist remanent magnetism, field flashing may be utilized
temporary.
V.4 Limiter Functions
V.4.1 Limiter Functions - V/Hz Limiter
The V/Hz limiter shall be activated below the normal frequency operating range
The values usually don't need to be adapted project specifically.
The standard setting for 50Hz application is 47,0Hz.
The standard setting for 60Hz application is 56,5Hz.
The standard setting for Slope is 100%/fknee
AUTO SP adjustment by frequency drop settings doesn't need to be changed.
This function might only be required in island operation for heavy load applications.
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V.4.2 Limiter Functions - Max. Ie Limiter
The Ie Limiter are standard values, which have been determined in coordination with ABB.
The values usually don't need to be adapted project specifically.
The standard Max. Ie Limiter settings can be found in below picture:
V.4.3 Limiter Functions - Max UM Limiter & Min UM Limiter
The standard setting for Max UM Limiter is 110,0%.
The standard setting for Min UM Limiter is 90,0%.
The values usually don't need to be adapted project specifically.
V.4.4 Limiter Functions - Max IM Limiter
The Max IM Limiter should be deactivated, as this function is already covered by the control system (GCP).
Furthermore, the alternator can be operated with overcurrent for a limited time (standard 110% for 1 hour).
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V.4.5 Limiter Functions - Min Ie Limiter
The Min Ie Limiter shall be deactivated, as this function is covered by the Min Q Limiter.
V.4.6 Limiter Functions - Min Q Limiter
The Min Q Limiter (PQ Limiter) shall be active and needs to be set project specifically based on the required
and permissible underexcitation area. The settings shall be done according to the PQ-diagram of the
alternator and in coordination with the underexcitation protection settings.
Generally, the limiter shall operate before protection relay trips.
The following values are only for example:
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V.4.7 Limiter Functions - Boost and FRT detection
If Permanent Magnet Generator (PMG) is utilized, the Boost function is not required. However the settings
for Boost function shall remain as indicated below. Only the digital output DIO6 shall be set to "None", in
case PMG is utilized.
The values usually don't need to be adapted project specifically.
The function "FRT detection" is not utilized and not required.
The standard boost settings can be found in below picture:
V.4.8 Limiter Functions - Limiters Temperature Influence
The cooling media temperature is not connected to the AVR. Therefore this limiter function is not utilized.
The winding temperature sensors and bearing temperature sensors of the alternator are connected to
and monitored by the control system.
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V.5 Setpoints
The range of the AUTO setpoint (voltage setpoint) is adjustable between 90%...110%. The Initial setpoint is
100%. For smooth voltage adjustments a ramp rate of 0,3%/sec is adjusted.
The range of the PF setpoint (voltage setpoint) is needs to be adapted project specifically, based on
the specified range. The standard range is between -0,95(lead)…0,8(lagg).
The Initial setpoint is PF 1,00. For smooth PF adjustments a ramp rate of 0,005%/sec is adjusted.
The manual setpoint is only required during commissioning and can be determined by alternator
commissioning engineer.
V.6 Voltage Droop Compensation
The function voltage droop compensation for sharing the reactive power between the gensets equally
by using RS485 connection between the AVRs is not utilzed. The reactive power sharing is done by
the CCP (Common Control Panel).
Furthermore the function is be only used for island operation.
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V.7 Digital I/Os
The digital I/Os for the AVR have been determined by ABB and MAN ES based on the design of the
mounting plate, in order the ensure the correct function of the AVR.
Changes are only required, if PMG system is used (DIO6).
Digital I/O settings for voltage transformer supply Digital I/O settings for PMG system:
with AC boost:
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V.8 Analog Inputs
Analog inputs are not required. All analog setpoints signals (voltage or power factor) are transferred via
MODBUS interface from control system (GCP) to the AVR.
V.9 Analog Outputs
The Fbias signal for synchronization is given on analog output AO2 and given to the GCP.
However, in control system (GCP) the MODBUS signal of Fbias is utilized.
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V.10 Synchronization
The alternator frequency should always be slightly higher than the grid frequency to avoid reverse power.
Practical recommendation values for synchronization are as follows:
∆U = 5%
∆f = 0,7%
Angle = 7%
The standard synchronization settings can be found in below picture:
Remark:
In case of synchronization over a block transformer the related angle offset needs to be considered.
Examples:
Block transformer with vector group Ynd11 (11 x 30° = 330°): angle offset = +30°
Block transformer with vector group Dyn5 or Yd5 (5 x 30° = 150°): angle offset = +30° and additionally the
wiring for UNET at the terminals on the AVR mounting plate need to to be exchanged.
V.11 Diode Monitoring
The Diode Monitoring shall be always activated. It serves for the detection the following faults:
- Opened Diode - Opened Diode will cause an alarm (alarm level 5%, delay 10 sec)
- Shorted Diode - Shorted Diode will cause trip of the AVR and Generator Circuit Breaker (trip level
20%, delay 0,3 sec)
The alarm&trip level as well as delay time are standard values, which usually are not to be changed.
The settings for the Nominal Exciter Frequency and Exciter Time Constant have been determined by the
alternator supplier and shall be indicated in the alternator manual / FAT test report.
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V.12 Monitor and Protection
The following monitoring and protection functions have been defined between ABB and MAN ES, the
settings need not to be changed.
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V.13 Tune
The settings for Tune Auto (PID settings), Tune Pf/Var/PQ Limiter and Manual/Ie Limiter are determined
during alternator FAT and are indicated in the FAT test report of the alternator.
The following values are for example only:
The PID settings of the AVR shall be optimized during commissioning by the alternator commissioning.
engineer.
Optimized tuning will be achieved if the step response of the machine voltage (Um) shows following graph:
V.14 AVR Ethernet Settings
For Modbus communication between control system (GCP) and AVR, the following IPs need to be
set:
IP address to be set to 192.168.201.135.
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V.15 Excitation Current Limiter ECL-10
The ECL-10 excitation current limiter is only relevant, if AC Boost system is utilized. For
If Permanent Magnet Generator (PMG) is utilized, the ECL-10 is not relevant.
The ECL-10 is intended to limit excitation current in case of a short circuit at the output of the synchronous
generator. It is mounted on a AVR mounting plate. The setting is done by means of jumpers on the
terminals (terminal numbers 4-13).
Before commissioning of the AVR the alternator commissioning engineer has to crosscheck with the
alternator FAT test report whether the trigger settings (jumpers) of ECL-10 are done properly.
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VI Remarks
- PSS (Power System Stabilizer) settings are not mentioned in this guideline, as for PSS a separate project setting
report needs to be carried out.
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translation thereof.
