We reserve all rights in this document and in the information contained therein.

Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Copyright 2008 ABB. All rights reserved

Procedure and Report for

Test and Commissioning
of Excitation System
UNITROL 6800
Plant: P.H. SOGAMOSO
Type: A6T-O/U5H1-F2500
Unit: 2
ABB Order No.: 600182
ID No.: 3BBR520311D0042
Serial No.: P15392Z

Approval signatures YES NO

The test procedure and report have been examined. The functions and performance of the tested
object are according to its specifications with exceptions according to the exception list and the
review comments.
The object has been tested in accordance with the conditions stipulated in the contract and observing
relevant safety rules.
No findings were recorded
The following findings were recorded Exception List sheet no:
Follow up inspection: Not needed Needed Date/Place:

FAT: <Customer/Name/Date> FAT: <ABB/Carlos Mello/20.01.2012>

Site: <Customer/Name/Date> Site: <ABB/Name/Date>

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Prep. Alisson Cruz 07-2011
Appr. Rodrigo Reis
Doc. kind Doc. Item

Title Test and Commissioning Report Des. Des.

UNITROL 6800 Resp. Dept. ATPE

Doc. no.
Lang. Rev. Ind. Page 1
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p. 30
 TABLE OF CONTENTS

1. GENERAL ............................................................................................................................................. 3
2. REFERENCE DOCUMENTS................................................................................................................. 6
3. MAIN SIGNAL DATA ............................................................................................................................ 7
3.1 General Data ............................................................................................................................. 7
3.2 Identification Plate of Excitation................................................................................................. 7
4. HARDWARE-SETTINGS ...................................................................................................................... 8
4.1 Non Linear Resistors ................................................................................................................. 8
4.2 Linear Resistors, Type: GINO (-R02) ........................................................................................ 8
4.3 Overvoltage Protection / Crowbar: Firing Print UNS 0017a-P, Var. 1 (-A02) ............................. 8
4.4 Advanced Power Distribution (APD).......................................................................................... 8
4.5 Settings for Converter Fans....................................................................................................... 9
4.6 Settings for AVR Cubicle Fans ................................................................................................ 10
4.7 Transducer Settings ................................................................................................................ 10
4.8 Rotor Earth Fault Relay UNS 3020a-Z (-F40).......................................................................... 11
4.9 Additional Hardware Modifications .......................................................................................... 11
5. FACTORY TESTS AND PRECOMMISSIONING ................................................................................ 12
5.1 Visual and Mechanical Checks................................................................................................ 12
5.2 High Voltage Test (See Additional Report) .............................................................................. 12
5.3 Check of Supplies.................................................................................................................... 13
5.4 Adjust Device and IP Addresses ............................................................................................. 14
5.5 Converter Control Panel (CCP) AF D242 ................................................................................ 15
5.6 Excitation Control Terminal (ECT) ........................................................................................... 15
5.7 Device firmware download and project-specific programming................................................. 15
5.8 Downloading Application ......................................................................................................... 16
5.9 Field Flashing (-A03) ............................................................................................................... 16
5.10 Function Test of Protection Devices ........................................................................................ 17
5.11 Analog Signals 17
5.12 Control Functions Test ............................................................................................................ 17
5.13 Function Tests of the Regulator............................................................................................... 18
5.14 Excitation Monitoring and Protection (Standard-SW, Option for FAT) ..................................... 18
5.15 Water Circuit Tests .................................................................................................................. 18
5.16 Final Works 19
6. TESTS DURING COMMISSIONING ................................................................................................... 20
6.1 Pre-Tests (Standing Machine) ................................................................................................. 20
6.2 No Load Tests (Machine at Rated Speed)............................................................................... 22
6.3 On Line Functions (Machine Synchronized) ............................................................................ 24
6.4 Final Works.............................................................................................................................. 26
7. USED INSTRUMENTS ........................................................................................................................ 27
7.1 Factoy Test.............................................................................................................................. 27
7.2 Commissioning ........................................................................................................................ 27
8. APPENDIX........................................................................................................................................... 28
9. OPEN ISSUES..................................................................................................................................... 29
10. MODIFICATIONS AFTER COMMISSIONING..................................................................................... 30

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 2
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
1. GENERAL
The test sections refer to the Test Instructions (TI) 3BHS210837 E31:
Example: TI Chapter 5.8

Test Specification: see Chapter 5ff.

20.01.2012
Date of the factory test:
< Date >

DMSESS / Carlos Mello

Factory test carried out by:
< Dept./initials of first name, family name >

Date of the site test:

< Date >

Site test carried out by:

< Dept./initials of first name, family name >

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 3
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
Abbreviations used in this document

Abbreviation Signal
UT2o Secondary no-load voltage of excitation transformer
Usyn Synchronous voltage
UC Control voltage
UTestmax Test voltage
Upower Converter supply during the test
ICT1 Current transformer primary current (CT)
IfDC Current Field current measurement
IDC Current Excitation current measurement
RL Load of the excitation systems during the test

Abbreviation Signal
AC Alternating Current
AI Analog Input
AO Analog Output
APD Advanced Power Distributor
AVR Automatic Voltage Regulation
BOD Break-over Diode
BU Backup Channel
CB Control Builder
CCI Converter Control Interface
CCM Communication Control Measurement Device
CCM BU Communication Control Measurement Device (Backup Channel, BU)
CCP Converter Control Panel
CH1 Channel 1 of the Automatic Voltage Regulator
CH2 Channel 2 of the Automatic Voltage Regulator (Dual channel system)
CIO Combined Input/Output Device
COMM. Commissioning
CT Current Transformer
CtrlBuilder Internal Software for PEC80-devices
DC Direct Current
ECT Excitation Control Terminal
EDS Ethernet Device Switch
EMC Electromagnetic Compatibility
FAT Factory Acceptance Test
FW Firmware
HW Hardware
ICU Input Coupling Unit
IP International Protection
MCB Miniature Circuit Breaker
OPC OLE for Process Control
PC Personal Computer
PI Proportional Integral
PID Proportional Integral Differential
PQ Power and Reactive Power
PSS Power System Stabilizer
PT Potential Transformer
RTM Rotor Temperature Measurement
SW Software
TI Test Instruction
TL Test Lab
USB Universal Serial Bus

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 4
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
 V/Hz Volt per Hertz

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 5
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
2. REFERENCE DOCUMENTS
The following documents are related to the item and to this document.
Identity Document kind Title
3BBR520311D0002 HW-Schematic
3BBR520311D0004 Layout Drawing
3BBR520311S0007 Test Instructions (TI)

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 6
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
3. MAIN SIGNAL DATA

3.1 General Data

Generator Nominal Value Transducer Remarks
Apparent Power SN [MVA] 324 --
Rated machine voltage U [V ac] 16500 16500 / 120
Rated machine current I [A ac] 11337
Rated machine frequency f [Hz] 60 --
Synchronous d-axis reactance Xd [p.u.] 0.953 --
Synchronous q-axis reactance Xq [p.u.] 0.675 --
No-load field current Ifo [A dc] 1030 -- For systems with rotating exciter, the
values are valid for exciter field
Rated field current IfN [A dc] 1830
Ceiling current Ip [A dc]
No-load field voltage Ufo [V dc] -- For systems with rotating exciter, the
values are valid for exciter field
Rated field voltage UfN [V dc] 356.1
Ceiling voltage Up [V dc]
Excitation System
Supply mode Shunt Supply -- Auxiliary only temporarily for test
Excitation transformer U1 / U2 [V ac] 16500 / 899
Converter supply voltage [V ac] (*) 899 -- Phase to phase
Converter supply frequency [Hz] 60 --
Excitation system rated current IEN [A dc] 2112
Auxiliaries
Auxiliary Supply Uaux [V ac / Hz] 120 / 480 / 60 --
Battery Supply 1 Ubatt [V dc] 125 --
Battery Supply 2 Ubatt [V dc] 125
(*) No load, Excitation transformer secondary [Volt]

3.2 Identification Plate of Excitation

Description Nominal Value
TYPE: A6T-O/U5H1-F2500 Language: English
ABB ORDER NO.: 3BBR520311D0005
SERIAL NO. P15392Z
YEAR OF DELIVERY: 2011
RATED CONT. DC-CURRENT: 2112 A
CEILING VOLTAGE:
CONVERTER SUPPLY: 900 V
SUPPLY FREQUENCY: 60 Hz
PROTECTION DEGREE: IP54
MAX. AMBIENT TEMPERATURE: 40C
DIAGRAM: 3BBR520311D0002
OPERATION INSTRUCTION:

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 7
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
4. HARDWARE-SETTINGS

4.1 Non Linear Resistors

TI Chapter 5.8
Doc. Ref.: HIER 466876 / 466877 / 464797

ABB-Order-No. Pos. [kWs] Project Manufacturer Label Test Comm. Rem.

HIER 466876 P... 550
HIER 466877 P... 800
HIER 464797 P0002 1100
...
4.2 Linear Resistors, Type: GINO (-R02)
TI Chapter 5.8

ABB-Order-No. Rubr. Type Resistor value No. of Project Tester Comm. Rem.
]
R20C [ elements in
series
3BHE025009 R2315 690.0 0.02 15

4.3 Overvoltage Protection / Crowbar: Firing Print UNS 0017a-P, Var. 1 (-A02)
Doc. Ref.: HIEE 422032 Datasheet

Name Function Default Project Test Comm. Rem

Voltage 24V 110V 125V 220V 250V 110 V 125V
1001 K1-Coil IN OUT IN OUT IN OUT IN
1002 K1-Coil IN IN OUT OUT OUT IN OUT
1003 K1-Coil IN IN IN IN OUT IN IN
1004 K2-Coil IN OUT IN OUT IN OUT IN
1005 K2-Coil IN IN OUT OUT OUT IN OUT
1006 K2-Coil IN IN IN IN OUT IN IN
R1001 K3-Coil 4.7k
0 /3W 5.6k /3W 10k /6W /7W
12k OUT OUT -- --
K3 Free wheeling relay (IN for 2 ch. type A5T) OUT OUT -- --
1007 Free wheeling function (closed for 2 ch. type A5T) OUT OUT -- --
1011 Closed for non redundant de-excitation OUT OUT
(UNS 4017/4023 Var. 612, 622, 632, xx)
V1000 Break over diode OUT 2400V

4.4 Advanced Power Distribution (APD)

Doc. Ref: 1333787 ZAE 000 Datasheet
Name Current Setting Project Test Comm. Rem.
APD #1 CH #1 (+ER-Q801) 2A 2A
APD #1 CH #2 2A 2A
APD #1 CH #3 2A 2A
APD #1 CH #4 6A 6A

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 8
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
APD #2 CH #1 (+ER-Q802) 1A 1A
APD #2 CH #2 1A 1A
APD #2 CH #3 1A 1A
APD #2 CH #4 1A 1A
APD #1 CH #1 (+ER-Q811) 2A 2A
APD #1 CH #2 2A 2A
APD #1 CH #3 2A 2A
APD #1 CH #4 6A 6A
APD #2 CH #1 (+ER-Q812) 1A 1A
APD #2 CH #2 1A 1A
APD #2 CH #3 1A 1A
APD #2 CH #4 1A 1A

Name Current Setting Project Tester Comm. Rem.

APD #1 CH #1 (+EE-Q801) 1A 1A
APD #1 CH #2 2A 2A
APD #1 CH #3 1A 1A
APD #1 CH #4 1A 2A
APD #2 CH #1 (+EE-Q802) 1A 2A
APD #2 CH #2 1A 2A
APD #2 CH #3 1A 1A
APD #2 CH #4 1A 1A
APD #1 CH #1 (+EE-Q811) 1A 1A
APD #1 CH #2 2A 2A
APD #1 CH #3 1A 1A
APD #1 CH #4 1A 2A
APD #2 CH #1 (+EE-Q812) 1A 2A
APD #2 CH #2 1A 2A
APD #2 CH #3 1A 1A
APD #2 CH #4 1A 1A

4.5 Settings for Converter Fans

Fan M.C.B. for UNL 14300-Converter
(n) = number of converter 1 to 8
M.C.B. Project Tester Witness Comm. Rem.
+EG.1 -Q10, -Q20 2.0A
+EG.2 -Q10, -Q20 2.0A

Pressure Measuring Value Tester Witness Comm. Rem.

+EG.1 Pressure Measuring 450Pa
+EG.2 Pressure Measuring 450Pa

Notice: The test report of the single converter module UNL14300 is not part of this
document. Please refer to the test report of the individual converter.

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 9
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
4.6 Settings for AVR Cubicle Fans

Thermostat for AVR Cubicle Fan

Thermostat Project Tester Witness Comm. Rem.
+ER -F96 30C

4.7 Transducer Settings

TI Chapter 5.12
PHOENIX-CONTACT: 3 way isolation amplifier, configurable, type MINI MCR-SL-UI-UI
Combination table for In- and Output signals and settings with DIP-switch S1 and S2
(see Phoenix-Contact User Manual)

Output Transducer connected to CCM:

-U501 (AO) Setting Project Test Comm. Signal Range
[Field Current] Range (o: open / C: closed)
Input 0...10 V S1 o o 2...10 V
Output 020 mA S2 o o o o o c 420 mA (Measuring range)

-U502 (AO) Setting Project Test Comm. Signal Range

[] Range (o: open / C: closed)
Input 0...10 V S1 o o 2...10 V
Output 020 mA S2 o o o o o c 420 mA (Measuring range)

Output Transducer connected to CIO:

-U534 (AO) Setting Project Test Comm. Signal Range
[] Range (o: open / C: closed)
Input 0...10 V S1 o o 2...10 V
Output 020 mA S2 o o o o o c 420 mA (Measuring range)

-U535 (AO) Setting Project Test Comm. Signal Range

[] Range (o: open / C: closed)
Input 0...10 V S1 o o 2...10 V
Output 020 mA S2 o o o o o c 420 mA (Measuring range)

-U536 (AO) Setting Project Test Comm. Signal Range

[] Range (o: open / C: closed)
Input 0...10 V S1 o o 2...10 V
Output 020 mA S2 o o o o o c 420 mA (Measuring range)

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 10
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
4.8 Rotor Earth Fault Relay UNS 3020a-Z (-F40)
TI Chapter 5.9
Name Function Default Project Test Comm. Remarks
S1 Measuring bridge to shaft earth (terminal 1-01) IN IN
S2 Measuring bridge to coupling cap.(terminal 1-02) IN IN
S3 24 V DC-supply to earth (terminal 3-12) OUT OUT
S103 Operation frequency selection 50 Hz 60 Hz
S104 Operation frequency selection 50 Hz 60 Hz
S1201 Output relays active during test OUT OUT
S1202 Output relays not active during test IN IN
R1101 Matching resistor for shaft voltage filter * 120 1k
R1401 Setting range stage 1 820 820
R1402 stage 2 820 820
C1101 Compensation capacitor 1 F 1 F F
C1102 Compensation capacitor 1 F 1 F F
C1103 Compensation capacitor -- -- -- F
C1104 Compensation capacitor -- -- -- F
* Without shaft filter 120, with shaft filter 1k

4.9 Additional Hardware Modifications

Device Element Value Modification Descriptions

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 11
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
5. FACTORY TESTS AND PRECOMMISSIONING

5.1 Visual and Mechanical Checks

Action Test Witness Remarks
Ensure checklist 3BHS298272_D03 is filled out completely
Arrange components, quality and safety
Affix identification and name of the cubicles, components and
system cables
Affix identification plate sticker, according to the data in chapter 3.2
Affix 24h Hotline sticker beside the plant name plate
Ground the devices and components, interface boards, doors,
ground bars etc.
Check power cables and bus bars according to schematic diagram
Check according to Manufacturing Guideline
Fill out correct SW-Release on relevant sticker at panel door
Put the documents in the document case

5.2 High Voltage Test (See Additional Report)

TI Chapter 5.5

Action Project Max Values Test Remark

Power Circuits 3500 V, 60 Hz; 1 Min. < 20 mA
Auxiliary Circuits 230 V ac 1500 V; 60 Hz; 1 Min.
2500 V; 60 Hz; 1 Min. < 20 mA
Auxiliary Circuits 400 V ac
2500 V; 60 Hz; 1 Min.
Auxiliary Circuits 1 DC
2000 V; 60 Hz; 1 Min. < 10 mA
Auxiliary Circuits 2 DC
PT 1
2000 V; 60 Hz; 1 Min. < 10 mA
CT 1
PT 2
2000 V; 60 Hz; 1 Min. < 10 mA
CT 2
Fan and Heaters circuits
2000 V; 60 Hz; 1 Min. < 10 mA

Fans, UNL14300 2500 V; 60 Hz; 1 Min.

Measuring transducers
500 V; 60 Hz; 1 Min. < 10 mA
(analog signals)

Converter Type Test Voltage power circuits

D5 converter, Type UNS7915 Var. V5, 2500 V; 50 Hz; 1 Min.
D5 converter, Type UNS7915 Var. V7, 3500 V; 50 Hz; 1 Min.
UNL13300 converter, 5000 V; 50 Hz; 1 Min.
UNL14300 conv., Input Volt. between 460V and 1340V acc. to appl. 5000 V; 50 Hz; 1 Min.
UNL14300 conv., Input Volt. between 1080V and 1500V acc. to appl. 7500 V; 50 Hz; 1 Min.

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 12
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
 Notice The high voltage test must not be repeated on the plant with the values
specified above.

5.3 Check of Supplies

TI Chapter 5.6
Action Test Comm. Remarks
Auxiliary supply AC (light, heating, fans)
AC shunt supply (fans, converter supply, AC supply transformer)
Auxiliary supply DC (Battery 1 and 2)
Control voltage 24 V dc

5.3.1 DC/DC Supply (-G80)

TI Chapter 5.6
Function Test Comm. Remarks
Input voltage to the supply unit 124,8 V dc . V dc
Adjust output voltage to 25 VDC 25,00 V dc .... V dc
Vdc
5.3.2 DC/DC Supply (-G81)
TI Chapter 5.6
Function Test Comm. Remarks
Input voltage to the supply unit 124,8 V dc . V dc
Adjust output voltage to 25 VDC 25,00 V dc .... V dc
Vdc
5.3.3 DC/DC Supply (-G100)
TI Chapter 5.6
Function Test Comm. Remarks
Input voltage to the supply unit 124,8 V dc . V dc
Adjust output voltage to 25 VDC 25,00 V dc .... V dc
Vdc

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 13
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
5.4 Adjust Device and IP Addresses
TI Chapter 5.8
Adjustment of IP Addresses is only necessary with PC D232. The PC D235 does not feature any Ethernet
connections.

Name Device Addresses IP Addresses Project Test Comm. Remarks

S 200 Code Switch Subnet Mask
CIO #1 (-A51) Device Address 1
PC D235
CIO #2 (-A52) Device Address 2
PC D235
CIO #3 (-A53) Device Address 3
PC D235
CIO #4 (-A54) Device Address 4
PC D235
CIO #5 (-A55) Device Address 5
PC D235
CIO #6 (-A56) Device Address 6
PC D235
ECT Not Available 172.16.0.61
(-H100) 255.255.0.0
Comm. PC Not Available 172.16.0.63
255.255.0.0
CCM #CH1 Device Address 1 172.16.0.21
(-A11) 255.255.0.0
CCM #CH2 Device Address 2 172.16.0.22
(-A21) 255.255.0.0
CCI #1 pos Device Address 1 172.16.0.31
Converter 1 255.255.0.0
CCI #2 pos Device Address 2 172.16.0.32
Converter 2 255.255.0.0

Configuration Positive Bridge Negative Bridge Remarks

Converter #8
DI Input 12 on CCI: Link between -
No Yes
X300:23 and X300:24
Project No
Tester
Comm.

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 14
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
5.5 Converter Control Panel (CCP) AF D242
Doc. Ref.: 3BHS233287 E80 Operating Instructions

Name Project Tester Comm. Rem.

CCP Converter #1 connected to -X66
CCP Converter #2 connected to -X66

5.6 Excitation Control Terminal (ECT)

Doc. Ref.: 3BHS233935 E80 Operating Instructions

Function Default Project Tester Comm. Rem.

Supply ECT 24VDC 24VDC
EDS (Ethernet Device Switch) U100 USED USED
USB-Dongle installed YES

5.7 Device firmware download and project-specific programming

TI Chapter 5.7

Check the firmware ident-Nr. and download the specified version if necessary.
Check conformity of the serial numbers of the following converters against the delivered converter test reports
and add these reports to the test and commissioning report.
Project Test Comm.
El. SW Release
Project Desig.
Firmware
Version.

Compare the enlisted installer software to Release Track

v.3.0.00
List 3BHS261662 E01
All Software Tools must be up to date and be checked
before testing or commissioning by means of the
database (Softw. General)
AC 800 PEC Main Controller v.3.0.01
Compare Serial-No. with
CH #1 -A10
test report SG1290772019
AC 800 PEC Main Controller v.3.0.01
Compare Serial-No. with
CH #2 -A20
test report SG1591011018
PC D230 CCM CH #1 Compare Serial-No. with -A11 v.1.5.09
test report
113230S0005
PC D230 CCM CH #2 Compare Serial-No. with -A21 v.1.5.09
test report
113230S0047
PC D235 CIO #1 Compare Serial-No. with -A51 v.1.1.06
test report
110235S0063

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 15
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
 PC D235 CIO #2 Compare Serial-No. with -A52 v.1.1.06
test report
110235S0032
PC D235 CIO #3 Compare Serial-No. with -A53 v.1.1.06
test report
110235S0066
PC D235 CIO #4 Compare Serial-No. with -A54 v.1.1.06
test report
110235S0065
PC D235 CIO #5 Compare Serial-No. with -A55 v.1.1.06
test report
110235S0107
PC D235 CIO #6 Compare Serial-No. with -A56 v.1.1.06
test report
110235S0060
PC D231 CCI #1 Compare Serial-No. with -A01 v.1.5.05
test report
134231S0010
PC D231 CCI #2 Compare Serial-No. with -A02 v.1.5.05
test report
111231S0017
Converter Control Panel Compare Serial-No. with -H101 v.1.1.02
CCP #1 test report

Converter Control Panel Compare Serial-No. with -H101 v.1.1.02

CCP #2 test report

Excitation Control Terminal Compare Serial-No. with -H100 1.4.0.15986

ECT test report
Check: All boards of the same type inside an excitation
--
unit must have the identical firmware release.

5.8 Downloading Application

Action Project Tester Comm. Rem.
Configure IP of used downloading PC to: 172.16.0.63
Download software package - -
Application software (.zip file) - -
Set IP-Addresses to devices - -
Set time synchronizing - -

5.9 Field Flashing (-A03)

TI Chapter 5.10
Check the appropriate field flashing assembly

AC or DC M.C.B -Q03 Transformer Field Flashing Control voltage Tester

Field Flashing [A] -T03 Assembly [V]
Supply [V] [20A, 40A, 60A, 80A]
AC 16 --- 20A 125Vdc

Action Tester Comm. Rem.

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 16
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
Check field-flashing current 20A

5.10 Function Test of Protection Devices

Action Test Witness Remarks
Function of the transformer overtemperature protection
Function of the overvoltage protection / Crowbar
Function of the rotor earth fault relay (Option)
Additional protective relay (Option)

5.11 Analog Signals

Action Test Witness Remarks
Check the local measuring devices and indications (CCP/ECT)
Check the measuring of the actual value for the excitation
Check analog signals for external indications

5.12 Control Functions Test

5.12.1 Local and Remote Operation

TI Chapter 5.14
Action Test Witness Remarks
Changeover between remote and local operation
Field Breaker ON/OFF, status indication
Excitation ON/OFF orders, status indication
Setpoint RAISE / LOWER orders, MIN / MAX position indication
Transfer between AUTO and MAN operation modes, status
indication
Transfer between channels 1 and 2, status indication
Transfer between channels 1, 2 and Back-up channel, status
indication (for T6x systems)
Check additional application programming

5.12.2 Self Acting Control Functions

TI Chapter 5.9
Action Test Witness Remarks
Control of the field-flashing
Protective transfer to alternate channel (only applicable for two
channel systems)
Protective transfer to manual operation
Protective blocking of thyristor bridges (only applicable with N-1
redundancy of the converter bridges)
Protective transfer to the stand-by converter bridge (only
applicable for TWIN converter arrangement)

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 17
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
5.12.3 Converter Control
TI Chapter 5.11
Action Test Witness Remarks
Test of the converter with temporary supply and base load
Check firing orders
Check the converter and inverter end position
Shape of the converter output voltage over the full range of control

5.13 Function Tests of the Regulator

TI Chapter 5.13

5.13.1 Tests in Open Loop Mode

Tests with simulated actual values and regulators in open loop condition
Action Test Witness Remarks
Variation of setpoints
Measurement of actual values

5.14 Excitation Monitoring and Protection (Standard-SW, Option for FAT)

TI Chapter 5.17

5.14.1 Excitation Monitoring

Action Test Witness Remarks
Monitoring of the actual values
Rectifier Monitoring

5.14.2 Protection Functions

Action Test Witness Remarks
Overcurrent Protection
P/Q- protection --
V/Hz-protection --

5.14.3 Alarms and Trips

Action Test Witness Remarks
Hardware Trips and Alarms
Software Trips and Alarms

5.14.4 Software Compliance

Action Tester Witness Remarks
With closed field breaker download the application software in
each channel, no trip allowed

5.15 Water Circuit Tests

Action Test Witness Remarks

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 18
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
 Apply water to the system and check for leakage (Pressure 6 bar)
Verify Pressure switch indication (P> tags: F10 / F20)
Verify Leakage detector (PDIT tags: U10 / U20)
Verify Pressure indicator transmitters (Pit tags: U01 / U03)
Verify Flow Indicator (Fit tag: U02)
Verify temperature sensor (Te tag R02)
Verify temperature indicator (TI tag: P02)
Check Valve position indications (Y01, Y02, Y21, Y22, Y11, Y12)

5.16 Final Works

Action Test Witness Remarks

Thermo strip necessary according to 3BHS288505 E01 yes/no
Disconnect system and prepare for delivery
Disconnect connections between transportation units
Plug protection covers on optical transmitters/receivers

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 19
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
6. TESTS DURING COMMISSIONING

6.1 Pre-Tests (Standing Machine)

6.1.1 Visual Checks

Action Result Remarks
Cubicles mounted properly, no visible damages
External wiring, bus bar connections, external grounding
Field breaker, field-flashing and de-excitation circuits
Remove protection covers on optical receivers/transmitters and connect
optical fibers

6.1.2 Field Resistance

Action Result Remarks
Field resistance including cables at 20 C

6.1.3 InsulationTest
Action Result Remarks
Insulation test of main circuit

6.1.4 Supplies
Action Result Remarks
AC main supply for converter and supply transformer V
AC supply for light and heating V
DC supply for electronic circuits V
Second DC supply (option) V
Field flashing supply
24V supply V
Function of electronic devices okay / Internal power supplies okay

6.1.5 Field Flashing

Action Comm. Remarks
Measured field flashing supply voltage V

6.1.6 Software
Action Result Remarks
Make sure that the tools on the comm. PC are up-to-date
Download the most recent project software to the PC (to both channels of a 2
or 3 channel system) if there were changes in the TL after testing.
Firmware-Version updated and added to the list in case of changes
Adjustment of project-specific parameters

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 20
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
6.1.7 Transducer
Action Result Remarks
Programming of the transducer
Definition setpoint range and Pre-sel for the manual channel
Definition setpoint range and Pre-sel for the auto channel

6.1.8 Control Circuits

Action Result Remarks
Check all command inputs
Check all signalization outputs
Check alarm circuits
Check trip circuits
Field breaker control circuits
Field-flashing control circuits
Check fan control circuits
Check PTs and CTs
Check analog inputs and outputs

6.1.9 Protection Devices

Action Result Remarks
Adjustment of rotor ground fault relay
Test temperature supervision of excitation transformer
Visual inspection of crowbar (correct BOD-elements)

6.1.10 Converter Test with Base Load

Action Result Remarks
All firing pulses present
Characteristic UE = f(UC) with base load, polarity of voltage
Check limits of firing angle

6.1.11 Current Tests on Standing Machine

Action Result Remarks
Optimization of manual channel with ref. value jumps

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 21
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
6.2 No Load Tests (Machine at Rated Speed)

6.2.1 Manual Channel

Action Result Remarks
Field-flashing with blocked converter, measuring of Ug %
Check actual value measuring (U, Usyn, If, Uf), adapt resp rescale if
necessary
Define limits of reference value and preset-value
Adaptation of PI-Filter in MAN (with reference value jumps)
Converter supply voltage at rated voltage / phases correct V
Check of de-excitation with field breaker off (de-excitation via resistance)
Deexcitation with inverter operation (Field breaker remains closed)
Check of de-excitation without field breaker off (de-excitation via converter)
Adjustment Diode monitoring at IEmin
Setpoint adjustment with +/-buttons
Setpoint adjustment via analog input

6.2.2 Automatic channel

Action Result Remarks
Field-flashing and Softstart
Define limits of reference value and preset-value
Optimization of PID-Filter
Settings and check of V/Hz-limiter
Check de-excitation circuits (normal de-excitation and trip field breaker)
Definition of P/Q-droop resp. P/Q-compensation
Setpoint adjustment with +/-buttons
Setpoint adjustment via analog input

6.2.3 Channel Changeover

Action Result Remarks
Check changeover from CH1, CH2 and Backup-channel; smooth
changeover
Check changeover from AUTO MAN and vice versa; smooth changeover

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 22
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
6.2.4 Monitoring / Protection
Action Result Remarks
Check emergency changeover AUTO MAN with missing U-measuring
Check emergency changeover CH1 CH2 CH3
(only A6x or T6x systems)
Adjust and check rotor ground fault relay
Bridge voltage after calibration u+(no load) Veff
Desired resistor for alarm level Rf1 . k
Stage 1: u+ (=Uref1) V
Delay time s
Desired resistor for trip level Rf2
Stage 2: u+ (Uref2) V
Delay time s

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 23
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
6.3 On Line Functions (Machine Synchronized)

6.3.1 General Tests after Synchronization

Action Result Remarks
Adjust generator current measurement / check P- and Q-measuring
Auto channel setpoint step on the grid to optimize the dynamic behavior
Manual channel setpoint step on the grid to optimize the dynamic behavior
Load rejections with P 0; Q positive
Load rejections with P 0; Q negative
Adjust diode monitoring at IEN
Adjust manual restrict
Trip of the generator breaker through the excitation

6.3.2 IE- Limiter

Action Result Remarks
Define and check IE-limitation overexcited
Jump into limitation to optimize dynamic behavior

6.3.3 I- Limiter
Action Result Remarks
Define and check I-limitation over- and underexcited
Jump into limitation to optimize dynamic behavior

6.3.4 P/Q Limiter

Action Result Remarks
Define P/Q-characteristic
Check P/Q-limitation underexcited
Jump into limitation to optimize dynamic behavior

6.3.5 IEmin Limiter

Test No./ Test description Result Remarks
Define and check IEmin-limitation underexcited
Jump into limitation to optimize dynamic behavior

6.3.6 Superimposed cos phi-Regulator

Action Result Remarks
Check stability and dynamic behavior of cos phi-regulator
Check limits of cos phi-reference value
Check reference value settings by +/-buttons
Check reference value setting by analog input
Check follow up between analog reference value and +/-reference

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 24
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
6.3.7 Superimposed Q-Regulator
Action Result Remarks
Check stability and dynamic behavior of Q-regulator
Check limits of Q-reference value
Check reference value settings by +/-buttons
Check reference value setting by analog input
Check follow up between analog reference value and +/-reference

6.3.8 Rotor Temperature Measurement (Optional)

Action Result Remarks
Setting of RTM-parameters
Measurement of rotor temperature Deg.

6.3.9 Excitation Transformer Measurement

Action Result Remarks
Setting of excitation transformer parameters
Measurement of transformer temperature Deg.

6.3.10 Power System Stabilizer

Action Result Remarks
Define parameters of PSS (K1 and K2)
Verification of correct behavior of PSS

6.3.11 Special Tests

Action Result Remarks
Time synchronization with ECT
Time synchronization with Time Server

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 25
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
6.4 Final Works
Action Result Remarks
All screws fixed
Clear fault logger
Reset all temporary parameter settings
Save parameters in both channels
Save the following files to a CD for the customer and make a copy for ABB
home documentation:
Project archive: - Installer Archive files, *.zip from all channels
- Snapshot files from all channels
- CIT Software, *.zip

ECT archive: - OPC files, *.*Xml (if no ECT present, copy from PC)
- ECT configuration files, *.xml
- ECT database file, *.fdb
- ECT single line diagram, *.dll (if applicable)
- Trendings (not on customer CD)
Hand over the CD called "as Commissioned" with the above files to the
customer
(Use and complete the labeling of the ABB pre-labeled CD)
All modifications must be registered in a schematic diagram and a
commissioning protocol
Client signature must be marked in commissioning protocol
Provisional acceptance report filled out and signed
Restart Data Logger
Temperature registration according to 3BHS288505 E01 and values in excel
file (3BHSxxxxxx E02). Only when 5.13 temperature strip present and
already powered
Check and correct (if necessary) SW-Release on sticker at panel door

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 26
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
7. USED INSTRUMENTS

7.1 Factoy Test

Name / Type Identification Last Calibration

7.2 Commissioning
Name / Type Identification Last Calibration

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 27
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
8. APPENDIX

Upower

CONTROLS CONVERTER
V/A
V

Digital output

Digital input

Generator U
Model
I

If

Uc

Uaux Ubatt RL

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 28
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
9. OPEN ISSUES
Rem. Remarks Date/ Decision/Action Cleared:
No. Signature (Date)

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 29
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30
10. MODIFICATIONS AFTER COMMISSIONING

*) Rev. Ind. A B C D E F
Based on 3BHS223093 E31 Rev. D Project P.H. SOGAMOSO
Title Test and Commissioning Report
UNITROL 6800
Document no.
Lang. Rev. ind. Pages 30
ABB Switzerland Ltd 3BBR520311D0042 en 1 No. of p.
30