Page 1 User Manual Combination Generator Control Module Catalog Numbers 1407-CGCM...
Page 2 Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE). Allen-Bradley, Rockwell Software, Rockwell Automation, ControlLogix, Logix5000, and RSLogix are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.
Page 3 This manual contains new and updated information. Changes throughout this revision are marked by change bars, as shown to the right of this paragraph. This table contains the changes made to this revision. Updated the dimension diagrams Updated the Configuration Messaging section Added information for the Network status indicator Added information for the Module status indicator Updated the Get Attributes All (service code 0x01) table for Identity...
Page 4: Rockwell Automation Publication 1407-Um001H-En-P - November
Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 5: Table Of Contents
Additional Resources ..........7 Introduction .
Page 6 Introduction ........... . 189 Synchronous Machine Terminal Voltage Transducer and Load Compensator Model.
Page 7 The information in this manual applies to the 1407-CGCM module, Series D, Revision A, with host firmware revision 4.25 and ControlNet firmware revision 1.07. The manual notes differences with earlier versions of the product where they occur. These documents contain additional information concerning related products from Rockwell Automation.
Page 8 Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 9: Functions
The Combination Generator Control Module (CGCM unit) is a microprocessor-based control and protection device. The CGCM unit is designed to integrate with a Logix family programmable controller to provide generator control, protection and synchronization functions. Programmability of system parameters, regulation settings, and protective functions enable the CGCM unit to be used in a wide range of applications.
Page 10 General Information This list contains the generator protection functions: • Loss of excitation current (40) • Over-excitation voltage (59F) • Generator over-voltage (59) • Generator under-voltage (27) • Loss of sensing (60FL) • Loss of permanent magnet generator (PMG/Excitation power) (27) •...
Page 11 • Pulse-width modulated output power stage rated at 15 A • Discrete redundancy relay output • Discrete fault output driver • Load sharing connection for use with the Allen-Bradley Line Synchronization Module (1402-LSM) or compatible hardware The CGCM unit has these three communication ports: •...
Page 12 General Information Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 13 This equipment is intended for use in a Pollution Degree 2 Industrial Environment, in over-voltage Category II applications (as defined by IEC publication 60664-1). Because the units contain a heat sink, they must be mounted vertically. Any other mounting angle reduces the heat dissipation capabilities of the units, possibly leading to premature failure of critical components.
Page 14 Installation Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 15 Installation The CGCM unit’s connections are dependent on the application and excitation scheme. All inputs or outputs cannot be used in a given installation. Incorrect wiring can result in damage to the unit. Connect the CGCM unit’s terminals with copper wire rated for a minimum of °...
Page 16 Installation ID(+)1 A 1 A cross-current compensation CT input 2.6…2.1 mm (10…12 AWG) ID(+)5 A 5 A cross-current compensation CT input ID(-) Cross-current compensation CT common input I3(+)1 A 1 A phase C CT input I3(+)5 A 5 A phase C CT input I3(-) Phase C CT common input I2(+)1 A...
Page 17 Installation Excitation power is wired to the PMG terminals, whether connected to the generator output (Shunt Excited) or to a PMG. Connect shunt excited inputs with a voltage transformer (VT). PMG inputs are on TB1 and are labeled PMG A, PMG B, and PMG C, illustrating their respective phase relationships.
Page 18 Installation This diagram is based on a Leroy Somer 300 kW AREP (auxiliary winding regulation excitation principle) machine. Details can differ on other machines. Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 19 Installation The excitation outputs are on TB2 and are labeled EXC(+) and EXC(-). Twisted, shielded cabling is required for the excitation outputs. When the redundancy function is used, three or four external flyback diodes in series must be placed across the generator field winding. Refer to the redundancy wiring diagrams on pages 31…32.
Page 20 Installation The terminal labeled CH GND, on TB4, is the chassis ground. Ground studs are also provided on the lower part of the mounting flanges and are internally connected to the CH GND terminal. Connect chassis ground to earth ground with minimum 2.6 mm (10 AWG) copper wire attached to either stud on the lower part of either side of the unit and to the CH GND terminal with 1.6 mm...
Page 21 Installation CGCM units provide 3-phase AC current sensing with provisions for 1 A and 5 A nominal sensing ranges. The inputs for 3-phase current sensing are on TB3. The ID (+) and ID (-) terminals are used for systems connected in a cross-current compensation system.
Page 22 Installation L1 L2 L3 Fuse Optional Ground Fuse VBus A VBus B VBus C Use of a third potential Fuse VBus N transformer is optional. The CGCM unit can be connected TB 6 in either open or closed delta. Fuse Optional Ground VGen A...
Page 23 Installation Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 24 Installation L2 L3 Fuse VB u s A VB u s B VB u s C Fu se VB u s N TB 6 Fuse Optional Ground Fuse VGe n A VGe n B VGe n C VGe n N Use of a third potential Fu se transformer is optional.
Page 25 Installation L2 L3 Fu se Optional Ground VB us A Fu se us B VB us C VB us N TB 6 Fuse Use of a third potential transformer is optional. The CGCM unit can be connected in either open or closed delta. Fuse Fuse V Gen A...
Page 26 Installation Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 27 Installation L1 A L 2A L 3 A L1 B L 2B L 3 B Fus e VB us A VB us B Fu se VB us C us N TB 6 Fuse Optional Ground VGen A VGen B Fuse VGen C VGen N TB 5...
Page 28 Installation Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 29 Installation Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 30 Installation The connections shown in this diagram can be used if only two CTs are available in the generator circuit. Two CTs can be used only with a three-wire delta generator. The circuit shown in this diagram can be substituted for the CT connections shown in Figures 9, 11, 14, and 16.
Page 31 Installation The fault relay output is an open-collector sinking output. The fault relay output terminals are on TB4 and are labeled FLT. The following illustration shows a typical connection. The redundancy relay output is an open-collector sinking output. The redundancy relay output terminals are on TB4 and are labeled RD RLY. The following figures illustrate typical redundancy connections.
Page 32 Installation Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 33 Installation The load sharing terminals connect to a 0…5V DC, internally powered circuit. The load sharing terminals are on TB7 and are labeled LS(+) and LS(-). Terminal SHLD4 is provided to land the cable shield. Twisted, shielded cabling is required for the load sharing connections.
Page 34 Installation L 1 L2 Cross- ID (+ ) 1A current CT ID (+ ) 5A (typical) ID (-) TB 3 Customer Supplied CT Shorting Switch or Test Block (typical) ID (+ ) 1 A ID (+ ) 5 A ID ( -) TB 3 ID (+ ) 1 A ID (+ ) 5 A...
Page 35 Installation There are three ports on the unit: the factory calibration port, the redundancy port (COM1), and the ControlNet network port. The factory calibration port is not intended for use by anyone other than qualified factory representatives. The DB-9 female connector on the bottom side of the CGCM unit is used for communication with another CGCM unit when operating in a redundant system configuration.
Page 36 Installation Two ControlNet tap cables and channel labels are included with the 1407-CGCM unit. If redundancy is desired, use both connectors. Otherwise, you can use either connector. You can use the mounting fasteners provided on the right-hand side of the unit chassis to fasten the tap cables.
Page 37: Inputs And Outputs
This section provides a operational description of the CGCM unit’s functions. The CGCM unit incorporates hardware inputs and outputs, software inputs and outputs to a Logix family programmable controller, configuration settings, and its internal control algorithms to provide the regulation, synchronizing, and protection functions described in this section.
Page 38 CGCM Unit Operation The figure below shows the front panel layout of the CGCM unit. Input and output connections are made through the terminal blocks TB1…TB7. The CGCM unit provides a number of analog inputs for use in the regulation and control of stand-alone and paralleled generator systems.
Page 39 CGCM Unit Operation The CGCM unit uses voltages measured through the generator voltage sensing inputs for generator voltage, VAR and/or power factor regulation, kW and kVAR load sharing, synchronization, metering, and protection. The inputs accept signals with up to 40% Total Harmonic Distortion (THD) and are connected for single-phase and 3-phase applications.
Page 40 CGCM Unit Operation This input is an analog voltage (-10…10V DC), and provides a means to remotely adjust the regulation point of the generator. Resistive isolation is provided through the use of differential amplifiers. The auxiliary input terminals are labeled VREF(+) and VREF(-). The unit has two types of power inputs: control power inputs and excitation power inputs.
Page 41: Communication
CGCM Unit Operation The unit has two types of analog outputs: excitation output and real power load sharing. The CGCM unit Pulse Width Modulated (PWM) power stage provides DC generator exciter field current. The excitation power stage is designed to accommodate up to 125V DC (nominal) field voltages.
Page 42 CGCM Unit Operation The CGCM unit provides two discrete open collector outputs, the fault output and the redundancy relay output. These are sinking type outputs internally connected to the control power BAT(-) supply. They are intended to drive a user-supplied relay connected between the control power BAT(+) supply and the applicable discrete output terminal.
Page 43: Operational Functions
CGCM Unit Operation Your Logix family host programmable controller must include the hardware and communication interfaces with the generator, prime mover, power system, and balance of plant that are not specifically included in the CGCM unit module. The software interface between the CGCM unit and its host controller is made via the ControlNet software interface.
Page 44 CGCM Unit Operation The CGCM unit controls the DC excitation current of the generator exciter based on a number of factors, including the following: • The selected control mode • The configuration of the CGCM unit including gains • Measured generator voltage and current •...
Page 45 CGCM Unit Operation FCR mode provides manual control of the excitation current. In FCR mode, the CGCM unit measures and controls its field excitation current output to maintain the commanded field current setpoint. The FCR feedback loop includes adjustable proportional, integral, and derivative gains. In FCR mode, automatic voltage control, reactive power control, power factor control, over-excitation limiting, and under-excitation limiting are disabled.
Page 46 CGCM Unit Operation To activate droop: • the metering CTs and generator VTs must be properly connected and configured. • the desired droop setpoint must be written to the V_DroopSetpt tag. • excitation enabled (tag SoftwareExcEn = 1). • remote Excitation Enable On (discrete input). •...
Page 47 CGCM Unit Operation The auxiliary input provides a means to remotely adjust the regulation point of the generator. This analog voltage (-10…10V DC) input signal changes the setpoint of the selected operating mode by one percent of the applicable rated value for each volt applied (positive or negative), multiplied by the auxiliary gain setting for AVR/FCR or VAR/PF.
Page 48 CGCM Unit Operation In VAR mode, the CGCM unit controls field excitation current output to maintain the commanded reactive power setpoint. The CGCM unit uses the measured generator voltages and currents to calculate reactive power. The VAR feedback loop includes adjustable proportional and integral gains. To activate VAR mode: •...
Page 49 CGCM Unit Operation If the generator is not up to speed when the soft start begins, the voltage increases but only to the level determined by Volts/Hz limiting. When the unit is operating in FCR mode, soft start operates as it does in the AVR mode, with the field current, rather than the generator voltage, being the controlled parameter.
Page 50 CGCM Unit Operation The tag SetptTraverseActive = 1 when the CGCM unit is traversing between the internal tracking setpoint and the new operating mode's setpoint. The tag = 0 when the operating point has completed traversing to the new mode's setpoint. This tag is used by the host Logix controller to determine when the new mode has taken control.
Page 51 CGCM Unit Operation Volts/Hertz limiting acts to reduce the generator output voltage by an amount proportional to generator frequency. This is done to protect the generator from overheating and reduce the impact on the prime mover when adding a large load. When the generator frequency drops, the voltage setpoint is automatically adjusted by the CGCM unit so that generator voltage follows the under-frequency slope.
Page 52 CGCM Unit Operation Over-excitation limiting (OEL) operates in all modes except FCR. The CGCM unit senses and limits the field current to prevent field overheating. When the limit is reached, the limiter function overrides AVR, VAR, or Power Factor modes to limit field current to the preset level. OEL operates in the area above the Field Winding Heating Limitation curve in the generator capability curve.
Page 53 CGCM Unit Operation The CGCM unit also uses two counters, the reset counter and the time limit counter. The counters are used to prevent excessive heating of the exciter field that can be a result of repeated over-excitation. The time limit counter monitors the duration of an over-excitation condition.
Page 54 CGCM Unit Operation The CGCM unit detects the fault conditions listed and described below. Faults detected by the CGCM unit are communicated to the host Logix programmable controller. Fault flags are communicated in the Scheduled Read table. A fault flag is latched until the host controller resets it.
Page 55 CGCM Unit Operation The CGCM unit can be used as primary protection in applications not requiring utility grade protection or in utility applications where the authority having jurisdiction has approved the CGCM unit for use as primary protection. In applications requiring utility grade protection, where the local authority has not evaluated or approved the CGCM unit, the CGCM unit can be used for secondary protection in conjunction with a primary protection system.
Page 56 CGCM Unit Operation For three-wire and four-wire sensing, Loss of Sensing detection is based on the logical combination of several conditions. They include these conditions: 1. The average positive sequence voltage is greater than 8.8% of the AVR setpoint. 2. The negative sequence voltage is greater than 25% of the positive sequence voltage.
Page 57 CGCM Unit Operation If voltage to the PMG excitation power inputs falls below 10V AC for approximately 400 ms or more, a Loss of Excitation power fault occurs. When single phase PMG is selected, the CGCM unit senses phases A and C for this function.
Page 58 CGCM Unit Operation When generator frequency exceeds the over-frequency setpoint for a specified amount of time, a definite time over-frequency fault occurs. Once the frequency drops below the threshold, the over-frequency fault timer is reset. If this fault occurs, tag OvrFreqFlt = 1 in the Scheduled Read table. When generator frequency drops below the under-frequency setpoint for a specified amount of time, a definite time under-frequency fault occurs.
Page 59 CGCM Unit Operation The Rotating Diode fault is inhibited if the field current is less than 1.5 A DC or if the generator frequency is outside the range of 45…70 Hz. The CGCM unit calculates the negative sequence voltage of the 3-phase generator voltage sensing input.
Page 60 CGCM Unit Operation The CGCM unit provides information that its host Logix controller uses to synchronize the generator output voltage, frequency, and phase to a reference power system, or bus. 3-phase, dual bus, and single-phase connection schemes are described below. •...
Page 61 CGCM Unit Operation To enable single-phase synchronizing, select the Generator VT Configuration as Single-phase. The CGCM unit provides a number of configurable settings to facilitate synchronizing between systems with different voltages and metering configurations. Please refer to Chapter 4 for more information. Prior to performing synchronization, the host controller must initialize tags in the Output table to their appropriate values as described below.
Page 62 CGCM Unit Operation • Check Synchronization The host controller sets the CheckSyncEn tag to enable Check Synchronization mode. This mode is the same as the Automatic Synchronization mode except the CGCM unit does not set a close breaker tag. This mode is useful for testing the system. •...
Page 63 CGCM Unit Operation When synchronization is active, the CGCM unit adjusts the values of the Scheduled Read table tags as described below. • Voltage Match Error as computed above • Frequency Match Error as computed above • Phase Match Error as computed above •...
Page 64 CGCM Unit Operation Limit defines the maximum per unit load share error reported to the host controller. Rate defines the maximum change in the load share error per CGCM unit update cycle, expressed in percent of rated kilowatts per second. For example, if a change of load of 50% is required and the rate set for 10% per second, the change takes 5 seconds to complete.
Page 65 CGCM Unit Operation Gen Voltages, 3, L-L AB, BC, CA AB, BC, CA AB, BC, CA Gen Voltage, avg, L-L Yes (=CA) Gen Voltages, 3, L-N A, B, C Gen Voltage, avg, L-N Gen Currents, 3 A, B, C A, B, C A, B, C A, B, C Gen Current, avg...
Page 66 CGCM Unit Operation The CGCM unit is capable of being used in a Redundant mode that provides automatic transfer of control to a second CGCM unit. In a redundant configuration, the host Logix programmable controller is primarily responsible for sensing power system conditions that require a transfer of control. The CGCM unit also can initiate a transfer of control in case of certain CGCM unit failures.
Page 67 CGCM Unit Operation If a loss of communication between redundant CGCM units occurs, the primary CGCM unit remains primary and the secondary CGCM unit switches to primary also. Because in this state both units are supplying current to the field, the host Logix programmable controller must be programmed to take corrective action (for example disable excitation to one CGCM unit) when this condition occurs.
Page 68 CGCM Unit Operation Once the primary and secondary CGCM unit roles have been established by the host controller, they remain in their respective modes indefinitely. You can force a transfer by disabling excitation on the primary unit. This causes the secondary unit to sense a loss of tracking information, switch to Primary mode, and take over-excitation control.
Page 69 CGCM Unit Operation The redundant tracking delay setting adjusts the delay of the tracking function to prevent the secondary CGCM unit output from being adjusted into an undesirable condition. For example, with AVR mode active in the primary CGCM unit, if the generator sensing VT fails open the excitation output goes to a full-on state.
Page 70 CGCM Unit Operation Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 71 This section provides a generic set-up and verification procedure for power generation systems by using the CGCM unit and RSLogix 5000 software. The various configuration parameters required to customize the device to a specific application are presented. Because every application is unique, read this section carefully and make sure that the configuration entries are appropriate for the system being implemented.
Page 72: Create A New Module In The Controllogix Controller
CGCM Unit Configuration • Generator capability curve • Generator decrement curve Consult with the generator manufacturer to be sure that you have the correct data. Verify and record system information and generator information required for configuration of the CGCM unit. Typically this information can be obtained from the generator nameplate, manufacturer’s data sheets, and system electrical drawings.
Page 73 CGCM Unit Configuration 2. Select 1407-CGCM, click Create, and then in the Select Major Revision dialog box, enter the Major Revision of the host firmware (for example 4 where the host firmware revision is 4.x or 2 where the host firmware is revision 2.x).
Page 74 CGCM Unit Configuration 5. Select an Electronic Keying mode to suit your application needs and click Finish. Alternately, you can click Next to begin configuring the CGCM unit at this point. Refer to the configuration tabs description below. Once you have added the module, you must schedule the connection to the CGCM unit with RSNetWorx for ControlNet software.
Page 75 CGCM Unit Configuration • Compatible module - a unit with host firmware major revision 3 or 4 functions as a unit with host firmware major revision 2 if so configured when the new module is created • Disable keying - the inserted module does not reject a connection to the controller An I/O module that is connected in a ControlLogix system compares the following information for itself to that of the original configuration:...
Page 76 CGCM Unit Configuration The Unscheduled Write data tag must be written to the CGCM unit by using a message instruction in the controller program. Refer to Chapter 6 for more information on the program interface for CGCM unit configuration. Input the initial settings (parameters) to match your system application for each of the configuration tabs as shown in the following paragraphs.
Page 77 CGCM Unit Configuration The Generator tab is used to configure the unit to the design ratings of the generator. Enter the generator’s nameplate ratings in the appropriate fields of the Generator tab. Rated Frequency - Sets the generator's rated frequency in Hz. Sets the value of tag GenRatedFreq in the Configuration table.
Page 78 CGCM Unit Configuration The Transformers tab is used to match the unit with the configuration of the generator voltage and current sensing transformers. To configure the Transformer tab, you must know the system wiring configuration. The settings entered in the Transformers tab must correspond to the actual wiring configuration.
Page 79 CGCM Unit Configuration • Bus VT Configuration - The bus VT configuration selections are (1) single-phase, (2) two-transformer open delta, (3) three-wire wye, (4) four-wire wye, and (5) dual breaker. This parameter is stored in the tag BusVT_Config in the configuration table. For applications that require synchronizing to one of two busses, dual breaker must be selected.
Page 80 CGCM Unit Configuration The Excitation tab is used to configure the unit’s settings related to operation and protection of the exciter. • Soft Start Initial Voltage - The generator voltage setpoint that is applied immediately after enabling the CGCM unit excitation output. This parameter is stored in tag SoftStart_InitLevel in the Configuration table.
Page 81 CGCM Unit Configuration • Loss of Excitation Current Setpoint - Establishes the level of excitation current that is considered to be a minimum needed to maintain generator synchronization when in parallel with other power sources such as a utility grid. This setpoint is stored in tag LossExc_I_Setpt in the configuration table and scaled in amperes.
Page 82 CGCM Unit Configuration • Rotating Diode Fault Delay - Establishes the time duration that the ripple current must be at or above the fault level before the CGCM unit annunciates a rotating diode fault. Tag DiodeMonitorTimeDelay in the configuration table stores this value, expressed in seconds. Refer to Chapter 5 for more information on configuring rotating...
Page 83 CGCM Unit Configuration The Volts/Hz tab is used to configure the unit’s settings related to operation of the Volts/Hz compensation function. The parameters define a curve, which determines the Volts/Hz response. • Volts per Hertz Upper Knee Frequency - Establishes the frequency at which the V/Hz characteristic starts to reduce the generator voltage as a function of generator frequency.
Page 84 CGCM Unit Configuration • The Validate and graph button becomes active when a parameter has been changed. When clicked, the V/Hz curve established by the knee and slope values is plotted in the Volts/Hz tab. Related Parameters: • GenRated_V • GenRatedFreq The OEL tab is used to configure the unit’s settings related to operation of the Over-excitation Limiting (OEL) function.
Page 85 CGCM Unit Configuration High Current Level Medium 0.0…30 A dc Current Medium Level Current Current CONTINUOUS 0.0… 20 A dc Current Time Time Level 0…120 seconds 0…10 seconds 0.0…15 A dc TIME IN SECONDS – Point A is defined by tags OEL_OnlineHiSetpt and OEL_OnlineHiTimeDly –...
Page 86 CGCM Unit Configuration The UEL tab is used to configure the unit’s settings related to operation of the Under-excitation Limiting (UEL) function. The values entered in this tab establish break points in a piecewise linear curve that defines the characteristic curve for this function.
Page 87 CGCM Unit Configuration • The tags listed below determine the points shown in the UEL configuration diagrams below. These tags are in the configuration table and are set by the like-named fields in the UEL tab. VAR values are actually negative, indicating leading.
Page 88 CGCM Unit Configuration The Gain tab is used to configure the unit’s gain parameters necessary for the operation of the excitation control. Except as otherwise noted, gain parameters are unitless. Appendix B provides additional information regarding the mathematical models used in the unit. The parameters in the Gain tab are stored in the Unscheduled Write table and are not automatically written to the unit.
Page 89 CGCM Unit Configuration • Proportional Gain Kp - Sets the proportional gain, which determines the characteristic of the dynamic response to changes in generator voltage. If the transient response has too much overshoot, decrease Kp. If the transient response is too slow, with little or no overshoot, then increase Kp. The tag AVR_FCR_Kp in the Unscheduled Write table stores this parameter.
Page 90 CGCM Unit Configuration Power Factor Control The Power Factor Control gains determine the response of the power factor control loop for the voltage regulation function when in PF mode. These settings can be adjusted during system startup. Please refer to Chapter 5 for more information on tuning the power factor control gains.
Page 91 CGCM Unit Configuration Under-excitation Limiting The UEL gains determine the response of the UEL control loop for the voltage regulation function when UEL is active. These settings can be adjusted during system startup. Please refer to Chapter 5 for more information on tuning the UEL control gains. •...
Page 92 CGCM Unit Configuration The Tracking tab is used to configure the unit’s internal and redundant tracking parameters. Enter the internal tracking, redundant tracking, and traverse rates in the appropriate fields of the Tracking tab. Internal Tracking • Enable internal tracking - This checkbox sets the Boolean tag Internal_Tracking_En in the Configuration data table.
Page 93 CGCM Unit Configuration An example of how these parameters affect tracking is shown in the Internal Tracking graph. In this example, a loss of sensing causes a full-scale regulator output. The internal tracking delay permits FCR mode to begin operation at the output level prior to the loss of sensing.
Page 94 CGCM Unit Configuration • Redundant Tracking Delay - This setting adjusts the delay in the redundant tracking function. This sets the value of the RedndtTrackDelay tag in the Configuration table, expressed in seconds. Its purpose is to reduce the likelihood that the short-term response of the active CGCM unit’s Regulating mode to an upset will be transferred to the back-up CGCM unit when it becomes primary.
Page 95 CGCM Unit Configuration The following diagram shows the function of internal tracking and traverse rates on a switch from VAR to PF operating modes. Generator Voltage PF Mode Internal PF Mode Traverse Rate Tracking Setpoint = Determines Transition to New Measured PF Mode's Operating Point PF is New...
Page 96 CGCM Unit Configuration The Synch tab is used to configure the unit’s parameters related to the synchronizing function of the CGCM unit. Synchronization Limits • Frequency Match - Establishes the acceptance window for frequency matching, defined by Configuration table tags SyncFreqLoLimit and SyncFreqHiLimit.
Page 97 CGCM Unit Configuration Bus A Offsets • Voltage multiplier - Establishes a factor by which the Bus A voltage is scaled during synchronization. It can be used to compensate for transformer ratio differences between the generator and bus voltages. For example, if the generator nominal voltage is 4160V and the nominal Bus A voltage is 12,480V (each measured line-to-line), a voltage multiplier value of 0.333 permits voltage matching during synchronization.
Page 98 CGCM Unit Configuration Single phase (line-to-line) Dual breaker (line-to-neutral) Single phase (line-to-line) Four-wire wye Open delta Dual breaker (line-to-neutral) Open delta Four-wire wye Three-wire wye Dual breaker (line-to-line) Three-wire wye Dual breaker (line-to-neutral) Three-wire wye Four-wire wye Four-wire wye Dual breaker (line-to-line) Four-wire wye Single (connected line-to-line) Four-wire wye...
Page 99 CGCM Unit Configuration The Load Share tab is used to configure the unit’s parameters related to the real power load sharing function of the unit. • Full Scale Voltage - Sets the load share output voltage when the generator is producing rated real power.
Page 100 CGCM Unit Configuration The Voltage tab is used to configure the unit’s parameters related to the voltage protection and compensation functions. Over-voltage • Setpoint - Establishes the over-voltage setpoint used by the CGCM unit. This setpoint is stored in tag Ovr_V_Setpt in the configuration table and scaled in per cent rated generator volts.
Page 101 CGCM Unit Configuration Under-voltage • Setpoint - Establishes the under-voltage setpoint used by the CGCM unit. This setpoint is stored in tag Undr_V_Setpt in the configuration table and scaled in per cent rated generator volts. • Delay - Establishes the time the generator voltage must be below the under-voltage setpoint before the CGCM unit annunciates an under-voltage fault.
Page 102 CGCM Unit Configuration The Current tab is used to configure the CGCM unit parameters related to the over-current protection function. Refer to Appendix A for more information on setting the parameters in the Current tab as well as the available time over-current characteristic curves. Over-current •...
Page 103 CGCM Unit Configuration • Validate and graph button – Updates the graph shown on the Current tab to display the selected over-current characteristic curve. The specific curve selected by the over-current time dial setting is displayed in black. Related Parameters •...
Page 104 CGCM Unit Configuration The Power tab is used to configure the unit’s parameters related to reverse power and reverse reactive power protection. A higher setpoint value corresponds to larger reverse power or VAR flow before a fault is declared. • Reverse kW Setpoint - Establishes the generator reverse kW setpoint in percent of rated VA.
Page 105 CGCM Unit Configuration The Fault Relay tab is used to configure the unit’s parameters related to the fault relay output. Checking the box enables the fault output for that particular fault. The fault output relay operates when a selected fault occurs if the fault output is enabled, and the corresponding fault tag in the Output (Scheduled Write) Data table is set.
Page 106 CGCM Unit Configuration Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 107: Safety
This chapter provides a suggested set of steps that the user can follow in commissioning a CGCM system. This assumes that you have: • evaluated the system design needs. • selected a suitable instrument wiring arrangement. • followed recommended installation procedures. •...
Page 108 CGCM Unit Startup Electrostatic discharge can damage integrated circuits or semiconductors. Follow these guidelines when you handle the module. Touch a grounded object to discharge static potential. • Wear an approved wrist strap-grounding device. • Do not open the module or attempt to service internal components. •...
Page 109: Recommended Start-Up Procedure
CGCM Unit Startup An appropriately calibrated 3-phase voltage and 3-phase current source is recommended to simulate generator and system power conditions at known operating points of interest. These can be connected to the CGCM VT and CT input terminals in place of system VT and CT instruments. Never open a current transformer (CT) secondary circuit with primary current applied.
Page 110 CGCM Unit Startup Follow these steps to verify the ControlNet network connection. 1. Use the RSWho function of RSLinx software to browse and confirm the CGCM unit is on the ControlNet network. 2. Verify the CGCM unit’s firmware revision is the same or later than indicated on the firmware revision label.
Page 111 CGCM Unit Startup Follow these steps to simulate the AC Gen and Bus inputs and verify the metered parameters. 1. Disconnect Generator VT and CT inputs, and Bus VT inputs, in a manner that lets you verify as much of the system wiring as practical. Ideally, this is done at the VTs for voltage inputs and at the CT shorting blocks for the CT inputs (after suitably shorting the CTs).
Page 112 CGCM Unit Startup Follow these steps to test that the Over-excitation voltage function is working properly. 1. Connect a suitable load to the excitation output terminals of the CGCM unit. 2. Decrease the field over-excitation voltage setpoint to a level that causes an alarm.
Page 113 CGCM Unit Startup 7. Verify that a generator under-voltage alarm is annunciated following the expected delay. 8. Reset the generator under-voltage setpoint to the desired level. Follow these steps to test that the Loss of Sensing function is working properly. 1.
Page 114 CGCM Unit Startup This fault is enabled only when PMG excitation is selected and excitation is enabled. If shunt excitation is selected, skip these steps. Follow these steps to test that the Loss of Permanent Magnet Generator function is working properly. 1.
Page 115 CGCM Unit Startup Follow these steps to test that the Under-frequency function is working properly. 1. Connect a suitable load to the excitation output terminals of the CGCM unit. 2. Enable excitation in FCR mode. 3. Clear the EngineIdle tag in the controller tag database. 4.
Page 116 CGCM Unit Startup Follow these steps to test that the Phase Rotation Error function is working properly. 1. Apply simulated generator voltage signals by using the test voltage source, opposite to the configured phase rotation. 2. Adjust the simulated generator voltage to the rated generator voltage. 3.
Page 117 CGCM Unit Startup During the following tests, the response of the AVR or FCR modes of operation can be determined by creating a step change in the voltage setpoint. Increasing and decreasing the voltage setpoint creates the step change. The typical change in setpoint is between 1% and 10%.
Page 118 CGCM Unit Startup 5. Verify that the configured soft start occurs and the generator voltage increases to near the specified rated output voltage. 6. Adjust the FCR setpoint and verify that the metered field current responds as desired. 7. Adjust gains as required to achieve the desired result. Follow these steps to verify metered voltages and phase rotation.
Page 119 CGCM Unit Startup Follow these steps to verify the CGCM unit’s redundancy operation. 1. Determine which CGCM unit is the primary of the redundant pair by monitoring the Spare1 tag in the Input table. 2. Disable excitation on the primary CGCM unit by removing the hardware excitation enable input, or clearing the software excitation enable tag, or removing the ControlNet connections, or removing 24V DC control power from the primary CGCM unit.
Page 120 CGCM Unit Startup 5. Confirm that the CGCM unit reports appropriate error signals and issues a close command when appropriate. The CGCM unit has these automatic operating modes: • Droop (reactive current compensation) Operation • Cross Current (reactive differential compensation) Operation •...
Page 121 CGCM Unit Startup 3. Change the mode of operation to cross-current compensation. 4. Adjust the voltage setpoint. 5. Monitor the reactive power and verify that the measured reactive power changes by the expected amount. For example, if the cross-current compensation gain is 5%, and the voltage setpoint is changed by 1%, the expected change in reactive power is 20% of rated kVA.
Page 122 CGCM Unit Startup Perform this test with the generator operating in parallel with a large power source that is maintaining constant voltage. Follow these steps to test the PF control operation. 1. Place the voltage control in Droop mode. 2. Adjust the prime mover to produce a constant power of approximately 25% of rated output.
Page 123 CGCM Unit Startup Perform the following tests to verify Limiter Functions and Diode Monitor operation. Perform this test with the generator operating unloaded in Constant Speed mode and constant voltage AVR mode. Follow these steps to test the Volts/Hz operation. 1.
Page 124 CGCM Unit Startup Perform this test with the generator operating unloaded in Constant Speed mode and constant voltage AVR mode. Follow these steps to test the OEL operation. 1. Enable the OEL function. 2. Determine the field current required to reach 105% of the rated generator voltage.
Page 125 CGCM Unit Startup 5. Set the Shorted Diode Level to a value that is 50 times the highest normal percent ripple found above. The multiplier can be varied from 40…70 to adjust the trip margin. Regardless of the calculated value, the level has a maximum value of 70. Reducing the multiplier could result in nuisance EDM shorted diode indications.
Page 126 CGCM Unit Startup Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 127 This chapter provides information on communicating with the CGCM unit by using the ControlNet network. It discusses scheduled and unscheduled messaging between the ControlLogix controller and the CGCM unit and touches briefly on the user program communication interface. Summary of Data Tables page 128 provides an overview of the module-defined Data Types that are created in the ControlLogix controller when...
Page 128 CGCM Unit Software Interface This table summarizes what information the data tables provide. Input (Scheduled AB:1407_CGCM:I:0 Read) Output (Scheduled AB:1407_CGCM:O:0 Write) 3. /4. AB:1407_CGCM:O:1 Unscheduled Read AB:1407_CGCM: Unscheduled_Read 3. /4. AB:1407_CGCM: Unscheduled_Read3 Unscheduled Write AB:1407_CGCM: Unscheduled_Write 3. /4. AB:1407_CGCM: Unscheduled_Write3 Configuration AB:1407_CGCM:C:0 S (W)
Page 129 CGCM Unit Software Interface In addition to the module configuration interface, the data in the Configuration and Unscheduled Write tags can be accessed by reading and writing elements of the tags in the user program. RSLogix 5000 software performs data range checks on configuration data entered into the module configuration screens.
Page 130 Unscheduled Write data table to the CGCM unit. Simplified logic rung to send the Unscheduled Write message from the controller to the 1407-CGCM after the Configuration write has been accepted. Enable_UW is a user-defined permissive interlock. CGCM:I.ConfigRcvd asserted indicates that the CGCM has accepted the scheduled Configuration write.
Page 131 CGCM Unit Software Interface Two types of connection-related services are involved in the configuration of the CGCM unit: • Forward Open - When a connection is first established, for instance when the module profile is first configured or the CGCM unit is powered on, a Forward Open service is executed.
Page 132: Cgcm Unit Data Tables
CGCM Unit Software Interface In normal operation, the ControlLogix controller and the CGCM unit share operating data through scheduled and unscheduled ControlNet network messaging. The overall functions and detailed content of the CGCM unit data tables are described in the next section. The tables in this section show the content and organization of the CGCM Unit data tables.
Page 133: Rockwell Automation Publication 1407-Um001H-En-P - November
CGCM Unit Software Interface The standard abbreviations shown below are used in the data table names for the assembly object table data names. Acknowledge Auxiliary Load Share Average Maximum Automatic Voltage Medium Regulator Brkr Breaker Minimum Cross Current Over-excitation Limiting Compensation CCCT Cross Current...
Page 134 CGCM Unit Software Interface The Input data table contains time-critical status data read from the CGCM unit by the ControlLogix controller. Data in this Controller Tag is automatically read by the host controller from the unit at the scheduled update rate whenever a connection between the two exists. This occurs independently of the user program.
Page 135 CGCM Unit Software Interface Bool CGCM_Flt CGCM Internal Fault 0=Inactive, 1=Active Bool LossExcFlt Loss of Excitation Current Fault Bool OEL_Active Over-excitation Limiting Active Bool UEL_Active Under-excitation Limiting Active Bool LossSensingFlt VT Sensing Loss Bool LossPMGFlt PMG Loss Bool RotDiodeFlt Rotating Diode Fault Bool PhRotFlt Phase Rotation Fault...
Page 136 CGCM Unit Software Interface Bool AutoSync Auto Synchronization Enabled 0=Disabled, 1=Enabled Bool CheckSync Check Synchronization Enabled Bool PermissiveSync Permissive Synchronization Enabled Bool UndefinedSyncMode Undefined Synchronization Mode 0=No, 1=Yes Bool SyncModeConflict Synchronization Mode Conflict Bool SyncDeadBus Dead Bus Synchronization Bool CloseBusA_Brkr Close Bus A Breaker 0=Don’t Close, 1=Close...
Page 137 CGCM Unit Software Interface Real V_MatchErr Voltage Match Error -100…100 Real FreqMatchErr Frequency Match Error -90…90 Real PhMatchErr Phase Match Error -180…180 Real GenFreq Generator Frequency 10…90 Real BusFreq Active Bus Frequency 10…90 Real Spare10 Real Spare11 The Output data table contains time-critical command and setpoint data written to the CGCM unit by the ControlLogix controller.
Page 138 CGCM Unit Software Interface Data UINT See Output (scheduled write) Data Table, Assembly Instance 1 Set Attribute Single is supported for this instance only when there is no scheduled connection to it. Otherwise it returns the error CI_GRC_BAD_OBJ_MODE. No range checking is performed on the Output data table. Bool RevVARFltOutEn Reverse VAR Fault Output Enable...
Page 139: Voltage Regulator
CGCM Unit Software Interface Bool Spare2 Bool Spare3 Bool EngineIdle Engine Idle 0=False, 1=True Bool Spare4 Bool PF_VAR_Select Power Factor/VAR Select 0=PF, 1=VAR Bool PF_VAR_En Power Factor/VAR Enable 0=Disabled, 1=Enabled Bool AVR_FCR_Select Automatic Voltage 0=AVR, 1=FCR Regulator/Field Current Regulator Select Bool FltReset Fault Reset...
Page 140 CGCM Unit Software Interface Bool Spare9 Bool Spare10 Bool Spare11 Bool Spare12 Bool kVAR_LS_BridgeEn kVAR Load Share Bridge Enable 0=Disabled, 1=Enabled Bool kVAR_LS_En kVAR Load Share Enable Bool kW_LS_BridgeEn kW Load Share Bridge Enable Bool kW_LS_En kW Load Share Enable Bool 0…7 Spare13_20...
Page 141 When the energy tag value exceeds 8,338,600, rounding of the value begins to occur. The energy values are not retentive. When the 1407-CGCM unit powers up or re-establishes a connection with the controller, the energy presets in the Unscheduled Write table are written to the energy metering values.
Page 142 CGCM Unit Software Interface Real AvgPF Average Power Factor -1…1 Real PhA_PF Phase A Power Factor Real PhB_PF Phase B Power Factor Real PhC_PF Phase C Power Factor Real Total_kVA Total kVA 0…3E+09 Real PhA_kVA Phase A kVA Real PhB_kVA Phase B kVA Real PhC_kVA...
Page 143 CGCM Unit Software Interface Real Exc_I Excitation Current Amps Real ExcRipple_I (Rev.2.x) Excitation Ripple Current Amps/% ExcRipple (Rev. 3.x) Real kW_Hrs kW Hours -3.04 * 10 3.04 * 10 Real kVAR_Hrs kVAR Hours kVARh -3.04 * 10 3.04 * 10 Real kVA_Hrs kVA Hours...
Page 144 CGCM Unit Software Interface Data UINT See Unscheduled Write Data Table, Assembly Instance 6 When an unscheduled write is received, the CGCM unit verifies that individual parameters are within the range indicated in the table below (for example, perform range checking). If an out-of-range parameter is detected, the CGCM unit ignores all data in the unscheduled write in the message instruction.
Page 145 CGCM Unit Software Interface Real kWHoursPreset kW Hours Preset -1 x 10 …1 x 10 Real kVARHoursPreset kVAR Hours Preset -1 x 10 …1 x 10 Real kVAHoursPreset kVA Hours Preset 0…1 x 10 Message size depends on the unit’s firmware revision. 64 (FRN 2.x) or 76 (FRN 3.x or later) byte Message size from CNET to CGCM (Written to the CGCM unit).
Page 146 CGCM Unit Software Interface Writing the CGCM unit’s configuration with unscheduled messaging is not recommended. We recommend using only scheduled configuration messaging sent when the connection is opened or the module configuration is edited in RSLogix 5000 software. The Get Attributes Single service for instance 4 of the Assembly Object can access the following information.
Page 147 CGCM Unit Software Interface SINT Space Reserved for Logix controller Revision Configuration Number SINT Pad Bytes Reserved for Logix controller Usage Bool RevVARFltOutEn Reverse VAR Fault Output 0=Disabled, Enable 1=Enabled Bool RevPwrFltOutEn Reverse Power Fault Output Enable Bool OvrExcFltOutEn Over-excitation Fault Output Enable Bool Ovr_I_FltOutEn...
Page 148 CGCM Unit Software Interface Bool 0…7 Spare5_12 Real GenVT_Pri_V Generator Voltage 1…30,000 Transformer Primary Voltage Real GenVT_Sec_V Generator Voltage 1…240 Transformer Secondary Voltage Real BusA_VT_Pri_V Bus A Voltage Transformer 1…30,000 Primary Voltage Real BusA_VT_Sec_V Bus A Voltage Transformer 1…240 Secondary Voltage Real BusB_VT_Pri_V Bus B Voltage Transformer...
Page 149 CGCM Unit Software Interface Real SyncV_HiLim Synchronization Voltage -25…25 High Limit Real SyncV_LoLim Synchronization Voltage -25…25 Low Limit Real SyncPhHiLim Synchronization Phase High -45…45 Limit Real SyncPhLoLim Synchronization Phase Low -45…45 Limit Real SyncAcceptDly Synchronization Accept 0…10 Delay Real DeadbusGenFreqLoLim Deadbus Generator 40…70 Frequency Low Limit...
Page 150 CGCM Unit Software Interface ExciterPole Exciter Pole Poles 2…24 Rev_kW_Setpt Reverse kW Setpoint %/100 100…10,000 Rev_kW_TimeDly Reverse kW Time Delay s/100 10…30,000 Rev_kVAR_Setpt Reverse kVAR Setpoint %/100 100…10,000 Rev_kVAR_TimeDly Reverse kVAR Time Delay s/100 10…3000 OvrFreqSetpt Over-frequency Setpoint Hz/100 3000…7000 OvrFreqTimeDly Over-frequency Delay s/100...
Page 151 CGCM Unit Software Interface Real OEL_OnlineHiTimeDly Over-excitation Online High 0…60 Time Delay Real OEL_OnlineMedSetpt Over-excitation Online 0…9999 Medium Setpoint Real OEL_OnlineMedTimeDly Over-excitation Online 0…120 Medium Time Delay Real OEL_OnlineLoSetpt Over-excitation Online Low 0…9999 Real OEL_OfflineHiSetpt Over-excitation Offline High 0…9999 Setpoint Real OEL_OfflineHiTimeDly Over-excitation Offline High...
Page 152 CGCM Unit Software Interface Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 153 This chapter lists suggested diagnostic and corrective action procedures for a variety of common generator system malfunctions. If the suggested actions do not resolve the anomaly, please contact Rockwell Automation technical support. Information on Rockwell Automation support can be found on the back cover. This chapter does not include procedures to diagnose or correct issues related to the basic communication between the CGCM unit and its host Logix controller.
Page 154 Troubleshooting Excitation output is greater than FCR not selected/enabled Check excitation FCR select Correct Logix controller logic or I/O setpoint as required Wiring error Check wiring for excitation current Correct wiring as required output, fuses open, grounding, and PMG/supply Gain mis-adjusted Check gains entered into CGCM unit Calculate/adjust as required configuration...
Page 155 Troubleshooting Voltage output is less than setpoint AVR not selected/enabled Check excitation enable (hardware Correct Logix controller logic or I/O and software) and AVR select as required Wiring error Check wiring for excitation enable, Correct wiring as required excitation current output, VT inputs, fuses open, grounding, and PMG/supply Insufficient supply power...
Page 156 Troubleshooting Voltage output is greater than AVR not selected / enabled Check excitation AVR select Correct Logix controller logic or I/O setpoint as required Wiring error Check wiring for excitation current Correct wiring as required output, VT inputs, fuses open, grounding, and PMG/supply Gain mis-adjusted Check gains entered into CGCM unit...
Page 157 Troubleshooting Power Factor not at PF setpoint PF not enabled Check input tag If not enabled, select appropriate modes of operation to enable PF mode Gain misadjusted Observe response of PF to changes If a response is slow, increase gain in PF setpoint Diode failure Use diode monitor if previously...
Page 158 Troubleshooting Voltage does not change with Droop not selected/active Check tag If not active, check/correct logic for changes in reactive load while not mode selection connected to the grid Cross current mode is Check If active, check/correct logic for enabled/selected mode selection Metering error See Metering troubleshooting...
Page 159 Troubleshooting VARs do not share at all and when a Cross current mode is not Check If not active, check/correct logic for voltage adjust is made, reactive enabled/selected mode selection power transfers to/ from the machine Wiring error Measure voltage at ID+/- terminal Correct wiring as required if voltage and adjust reactive power/voltage signal from CCCT circuit is not...
Page 160 Troubleshooting Excitation Current exceeds the OEL not enabled Check tag and configuration Correct logic or configuration programmed OEL limit (OEL does not as required limit/activate) OEL Gain misadjusted Force into OEL Adjust gains as required OEL not configured Check OEL settings against generator Correct as required excitation requirements / limits Metering error...
Page 161 Troubleshooting Units do not share load equally: units Series 2 CGCM unit on network is Verify CGCM unit is firmware Replace with Series 3. CGCM unit both change together powered down and load share lines revision earlier than 3.3 when available connected Add relay to disconnect load share lines on power down...
Page 162 Troubleshooting No close indication from CGCM unit Voltage not matched Observe voltage match tag during If voltage match indicated, check (cont.) synchronization close command tag. If no voltage match indicated, check voltage match error Observe voltage error, generator If no voltage error is reported by voltage, and selected bus voltage CGCM unit correct wiring and verify reported by CGCM unit during...
Page 163 Troubleshooting Current does not read correctly Configuration errors Observe CT configuration Correct configuration to match parameters and to verify they reflect expected CT wiring desired/ expected CT ratios Wiring errors Observe each phase, and average Correct phase rotation, polarity, or current indication.
Page 164 Troubleshooting The ControlNet Network Status indicators indicate the state of the ControlNet network connected to the BNC connectors. If more than one state is present, the status indicators always reflect the highest priority status present on the network. The following tables describe the status indicator states and the priority of each status indicator.
Page 165 Troubleshooting No power Green Operating in normal condition, controlled by a scanner in Run state Flashing Green (1 Hz) The module is not configured, or the scanner in idle state Unrecoverable faults, EXCEPTION, or Fatal event Flashing Red (1 Hz) Recoverable faults, MAC ID has been changed after initialization Both CGCM units operate as primary Serial cable not properly connected...
Page 166 Troubleshooting Loss of excitation current (40) Wiring error Check excitation output wiring Correct wiring as required Gains mis-adjusted Check AVR gains Calculate/adjust gains as required Over-excitation voltage (59F) Wiring error Check excitation output wiring Correct wiring as required Gains mis-adjusted Check AVR gains Calculate/adjust gains as required OEL limit exceeded...
Page 167 Troubleshooting Rotating diode monitor Failed diode Remove and test diodes Replace diode Incorrect configuration Confirm test / set up of diode Correct as required monitor parameters with active parameters Insufficient number of fly back Check number of external flyback Install as required diodes installed diodes installed at CGCM excitation output if required...
Page 168 Troubleshooting Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 169 The CGCM unit time over-current protection function provides time/current characteristic curves that closely emulate most of the common electromechanical, induction disk relays manufactured in North America. To further improve relay coordination, selection of integrated reset or instantaneous reset characteristics is also provided.
Page 170 Time Over-current Characteristic Curves S, Short Inverse 0.2663 0.03393 1.000 1.2969 0.028 0.5000 S2, Short Inverse 0.0286 0.02080 1.000 0.9844 0.028 0.0940 L1, Long Inverse 5.6143 2.18592 1.000 1.000 0.028 15.750 L2, Long Inverse 2.3955 0.00000 1.000 0.3125 0.028 7.8001 D, Definite Time 0.4797 0.21359...
Page 171 Time Over-current Characteristic Curves S, Short Inverse ABB CO-2 S2, Short Inverse GE IAC-55 L, L1, Long Inverse ABB CO-5 L2, Long Inverse GE IAC-66 D, Definite Time ABB CO-6 M, Moderately Inverse ABB CO-7 I, I1 Inverse Time ABB CO-8 I2 Inverse Time GE IAC-51 V, V1 Very Inverse...
Page 172 Time Over-current Characteristic Curves The CGCM unit has a maximum time dial setting of 9.9. The CGCM unit’s equivalent time dial setting for the electromechanical maximum setting is provided in the cross reference table even if it exceeds 9.9. This allows interpolation as noted above.
Page 173 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 174 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 175 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 176 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 177 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 178 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 179 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 180 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 181 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 182 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 183 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 184 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 185 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 186 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 187 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 188 Time Over-current Characteristic Curves Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 189 This appendix contains the mathematical model of the CGCM unit’s excitation systems. The rotating rectifier model is based on the type AC8B model available in the reference Computer Models for Representation of Digital-Based Excitation Systems in the IEEE Transactions on Energy Conversion September, 1996, Vol.
Page 190 CGCM Unit Math Models Per-unit Block Diagram for Rotating Rectifier Excitation System shows the model of the CGCM excitation system used with a brush-type rotating exciter. The rotating exciter parameters are not included in this discussion because they are the responsibility of the exciter manufacturer. V is the input from the power source for the excitation system.
Page 191 CGCM Unit Math Models The VAR/PF controller is a summing point type controller and makes up the outside loop of a two-loop system. This controller is implemented as a slow PI type controller. The voltage regulator forms the inner loop and is implemented as a fast PID controller.
Page 192 CGCM Unit Math Models The operating characteristics are designed to mimic the characteristics of the limiter on the P-Q plane. The desired UEL curve is generated based on the user input points. Typical UEL reference is illustrated in Under-excitation Limiter Reference.
Page 193: V/Hz Limiter
CGCM Unit Math Models Reference Field Current (I OEL_REF Count Down For Reset Time (s) V/Hz limiter is designed to protect the generator and step-up transformer from damage due to excessive magnetic flux resulting from low frequency operation and/or over-voltage. V/Hz limiter has been designed with an adjustable slope (K ) from flat to V/HZ...
Page 194: Soft Start Control
CGCM Unit Math Models The soft start control function is provided to cause orderly build-up of terminal voltage from the residual voltage to the rated voltage in desired time with minimal overshoot. In CGCM units, the fast dynamic response is used while the voltage reference is adjusted based on the elapsed time.
Page 195: Field Current Regulator
CGCM Unit Math Models Per-unit Block Diagram for Rotating Rectifier Excitation System shows the model of the CGCM field current regulator used with a brush-type rotating exciter. V is the input from the power source for the excitation system. Typical value for T is 0.
Page 196 CGCM Unit Math Models Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 197 In addition to the standard adapter class ControlNet core objects, the CGCM unit also supports these application specific objects: • Identity Object • Assembly Object The ControlNet and Logix controller data types used by the CGCM unit assembly objects are shown in the table below. BOOL Boolean SINT...
Page 198 Major, Minor (example 4, 25) Status WORD See Table 41 Device Status Serial Number UDINT Unique device serial number-factory assigned Product Name CHAR[] CGCM Host - Series C and earlier units 1407-CGCM - Series D units Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 199 Major, Minor (example 1,11) Status WORD See Table 41 Device Status Serial Number UDINT Unique device serial number Product Name CHAR[] ’1407-CGCM-DC’ - Series C or earlier ControlNet - Series D Module Owned (reserved) Configured (reserved) 4... 7 Extended Device Status: Value:...
Page 200 Additional ControlNet Network Information The Reset service for instance 1 of the Identity Object requests that a CGCM unit’s communication reset be performed. If excitation is enabled, the request is denied. If excitation is not enabled, the request is accepted. If a reset is accepted, the CGCM unit resets the entire CGCM unit and communication with the Logix controller is lost.
Page 201 The CGCM unit’s electrical and physical characteristics are listed in the following tables. 18…32V DC (24V DC nom) 30 W (The device is to be powered by a 24V Nominal Battery or 24V DC Power Supply with ATEX certification.) AC ripple, max 50%, 50…120 Hz Single-phase PMG-A and PMG-C...
Page 202 Specifications Single- V Gen A and Min 57 Vrms Min 20 Hz phase V Gen C Max 150 Vrms Max 90 Hz Three- Floating wye Min 99 Vrms L-L Min 20 Hz phase Max 208 Vrms L-L Max 90 Hz Three- Grounded wye Min 99 Vrms L-L...
Page 203 Specifications Single- V Bus A and Min 57 Vrms Min 20 Hz phase V Bus C Max 150 Vrms Max 90 Hz Three- Floating wye Min 99 Vrms L-L Min 20 Hz phase Max 208 Vrms L-L Max 90 Hz Three- Grounded wye Min 99 Vrms L-L...
Page 204 Specifications Voltage rating 24V DC nom Input impedance 5.6K Logical high voltage, min 18V DC Logical low voltage, max 5V DC Voltage rating 24V DC nom Voltage range 18…30V DC Rated current, max 500 mA Continuous voltage 32, 63, 125V DC Continuous current 15 A DC 10-second forcing voltage...
Page 205 Specifications The following modes are used to regulate the CGCM unit. • Accuracy: ±0.25% over the load range at rated power factor and constant generator frequency. • Steady State Stability: ±0.1% at constant load and generator frequency. • Temperature Drift: The maximum error due to temperature drift will be 0.005% of full scale per degrees Celsius for voltage and current measurements and 0.010% of full scale per degree Celsius for watt and VAR measurements.
Page 206 Specifications Pickup 1…200V DC 1V DC Time delay 0.1…30 s 0.1 s Pickup 10…320% of rated ±2% rated current generator current Time delay Characteristic inverse 0.1 s per ANSI C50.13 configurable Pickup 60…100% of rated ±2% rated voltage generator voltage Time delay 0.1…300 s ±0.1 s...
Page 207 Specifications Pickup < 10V AC single-phase, < 50V AC 3-phase or an imbalance greater than 20% Response time < 400 ms Time delay 0.10…300 s 0.10 s ±0.1 s Pickup 30…70 Hz 0.01 Hz ±2% Hz Time delay 0.10…300 s 0.10 s ±0.1 s Pickup...
Page 208 Specifications Field current < 1.5 A DC Generator frequency < 45 Hz Generator frequency >70 Hz Pickup 67% of rated voltage ±2% of rated voltage Time delay ±0.1 s Soft start initial voltage 0…90% of rated voltage in 1% increments Soft start time 1…7200 s in 1 s increments Accuracy...
Page 209 Specifications Pickup 0…15 A DC 0.1 A DC Time delay 0…10 s Real power 0…100% kW for each of 5 points Reactive power 0…100% kvar for each of 5 points Range 0…15.0 A DC Increment 0.1 A DC Generator voltage 57…208V AC 0.2% (50/60 Hz) Generator current...
Page 210 Specifications Temperature, operating -20…70 °C (-4…158 °F) Temperature, storage -40…85 °C (-40…185 °F) Humidity, operating 5…95% (noncondensing) Shock, operating 30 g Shock, nonoperating 50 g in 3 perpendicular planes Vibration, operating 10 … 500 Hz, 5.0 g / 0.015 in. max (p-p) 2 hours each axis Dielectric strength Tested per IEEE 421.3...
Page 211 Specifications Width 247.7 mm (9.75 in.) Height 355.6 mm (14.00 in.) Depth 209.6 mm (8.25 in.) Weight 7.7 kg (17 lb) Heat dissipation 3.1 kW max Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 212 Specifications Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 213: Generator Parameters And Configuration Status
This section describes the generator parameters and configuration status input and output tags for the CGCM unit. • GenVT_Pri_V – This tag defines the rated primary voltage for the Generator potential transformers. • GenVT_Sec_V – This tag defines the rated secondary voltage for the Generator potential transformers.
Page 214: Avr Mode
Detailed CGCM Unit Tag Descriptions • PMG_Shunt_Select - This tag selects whether the CGCM unit receives power-input voltages from the generator’s terminals (shunt) or from a permanent magnet generator (PMG). If PMG is selected, then the information for the PMG Phase Select parameter must be provided. •...
Page 215 Detailed CGCM Unit Tag Descriptions • HardwareExcEned – This tag reports the state of the Excitation Input [EX-D(+), EX-D(-) terminals on Terminal Block TB7]. Field excitation is disabled when this bit is in a 0 state. • SoftwareExcEned – This tag reports the state of the SoftwareExcEn tag. •...
Page 216: Fcr Mode
Detailed CGCM Unit Tag Descriptions The AVR mode has one output. • AVR_FCR_Selection – This tag reports the selection of AVR or FCR control (see AVR_FCR_Select). This section describes the FCR mode inputs and outputs for the CGCM unit. The FCR mode has these inputs: •...
Page 217: Power Factor Mode
Detailed CGCM Unit Tag Descriptions This section describes the Power Factor mode inputs and outputs for the CGCM unit. The Power Factor mode has these inputs: • PF_VAR_Select – This tag lets you select PF or VAR control. • PF_VAR_En – When this tag is set to 1, the CGCM unit uses the PF_VAR_Select tag to determine its control mode.
Page 218: Var Mode
Detailed CGCM Unit Tag Descriptions This section describes the VAR mode inputs and outputs for the CGCM unit. The VAR mode has these inputs. • PF_VAR_Select – This tag lets you select PF or VAR control. • PF_VAR_En - When this tag is set to 1, the CGCM unit uses the PF_VAR_Select tag to determine its control mode.
Page 219: Excitation Control Features
Detailed CGCM Unit Tag Descriptions This section describes the excitation control features. • SoftStart_InitLevel - This tag configures the generator voltage that is generated immediately after enabling the CGCM unit. This parameter is based on a percentage of the nominal generator voltage. •...
Page 220 Detailed CGCM Unit Tag Descriptions • OEL_En – Setting this tag enables the Over-excitation Limiting function. • OEL_Kg - This tag lets you adjust the proportional gain of the Over-excitation limiter. It also determines the response of the limiter to an Over-excitation event.
Page 221 Detailed CGCM Unit Tag Descriptions • LineDropComp - This tag configures the amount of voltage droop that is experienced during paralleling generator applications. • UEL_En - Setting this tag enables the Under-excitation Limiting function. • UEL_Kg - This tag lets you adjust the proportional gain of the Under-excitation limiter.
Page 222: Protection
Detailed CGCM Unit Tag Descriptions • UEL_Curve_VAR_Pt4 - This tag is used as the VAR coordinate in the fourth Watt, VAR coordinate pair, that, in combination with four other Watt, VAR coordinate pairs, lets you enter an Under-excitation Limiting curve. •...
Page 223 Detailed CGCM Unit Tag Descriptions • LossExcFlt - This tag is used to communicate the occurrence of a Loss of Excitation Fault to the host Logix controller. When this tag is a 1, it indicates that a fault has occurred. The tag is latched until the host Logix controller resets it by setting the FltReset tag.
Page 224 Detailed CGCM Unit Tag Descriptions • Ovr_V_Flt – This tag is used to communicate the occurrence of an Over-voltage Fault to the host Logix controller. When this tag is a 1, it indicates that a fault has occurred. The tag is latched until the host Logix controller resets it by setting the FltReset tag.
Page 225 Detailed CGCM Unit Tag Descriptions • LossPMGFltOutEn - When this tag is a 1 in the configuration, and a Loss of PMG Fault occurs the Fault Relay is energized. When this tag is a 0 in the configuration, a Loss of PMG Condition has no effect on the Fault Relay.
Page 226 Detailed CGCM Unit Tag Descriptions • OvrFreqFlt - This tag is used to communicate the occurrence of an Over-frequency Fault to the host Logix controller. When this tag is a 1, it indicates that a fault has occurred. The tag is latched until the host Logix controller resets it by setting the FltReset tag.
Page 227 Detailed CGCM Unit Tag Descriptions • RevPwrFlt - This tag is used to communicate the occurrence of a Reverse Power Fault to the host Logix controller. When this tag is a 1, it indicates that a fault has occurred. The tag is latched until the host Logix controller resets it by setting the FltReset tag.
Page 228: Synchronizing
Detailed CGCM Unit Tag Descriptions • PhRotFlt - This tag is used to communicate the occurrence of a Phase Rotation Fault to the host Logix controller. When this tag is a 1, it indicates that a fault has occurred. The tag is latched until the host Logix controller resets it by setting the FltReset tag.
Page 229: Table
Detailed CGCM Unit Tag Descriptions • CheckSyncEn – This tag is used to configure the CGCM unit to perform Check Synchronization. This is one of three synchronization modes, each selected by their respective tag. Only one can be active (1) or the SyncModeConflict tag is activated and the synchronization fails (indicated by SyncFailure tag).
Page 230: Table
Detailed CGCM Unit Tag Descriptions • BusA_PhOffset - This tag configures a phase angle added to the measured bus A phase angle. It is used to compensate for phase shift across sensing transformers. • BusA_V_Scaler - This tag configures a multiplier by which the measured bus A voltage is multiplied.
Page 231: Load Sharing
Detailed CGCM Unit Tag Descriptions • PhMatch - This tag reports that the phase difference between the two busses is within the configured acceptable range. • V_MatchErr – This tag reports the percentage difference in voltage between the two busses to be synchronized. •...
Page 232 Detailed CGCM Unit Tag Descriptions • kW_LS_OutV – This tag sets the voltage that the CGCM unit attempts to output from the load-sharing terminals. • kVAR_LS_OutV – This tag is reserved for future use. • LS_FS_V - This tag sets the voltage the load share output reaches when the generator is producing 1 p.u.
Page 233: Metering
Detailed CGCM Unit Tag Descriptions This section describes the metering inputs and outputs for the CGCM unit. • Set_kW_Hrs – When this tag is set to a 1, the kW_Hrs counter is set to 0 in versions 2.x. In host firmware revision 3.x and later, the value of the tag kWHoursPreset is loaded into the counter.
Page 234 Detailed CGCM Unit Tag Descriptions • Total_kVAR - This tag reports the Total kVARs being produced by the active phases of the generator. • PhA_kVAR - This tag reports the kVARs being produced by Generator Phase A. • PhB_kVAR - This tag reports the kVARs being produced by Generator Phase B.
Page 235: Redundancy
Detailed CGCM Unit Tag Descriptions • Exc_V- This tag reports the Excitation Voltage. • Exc_I – This tag reports the Excitation Current. • ExcRipple – This tag reports the Ripple Current component of the Excitation Current. • kW_Hrs – This tag reports the cumulative kWHours produced by the Generator.
Page 236: Rockwell Automation Publication 1407-Um001H-En-P - November
Detailed CGCM Unit Tag Descriptions • CGCM_Flt - This tag indicates, if the CGCM unit is still capable, that the CGCM unit has a detected an internal failure. • CGCMInControl - This tag indicates that the CGCM unit has hardware and software excitation enabled.
Page 237 We suggest you use these charts to record the initial configuration settings of the CGCM unit for each generator. Please make a copy of this appendix for each generator to be controlled. After entering the data and settings, keep this information for future reference.
Page 238 Configuration Record Worksheet Rated frequency Rated voltage V AC Rated current A AC Rated power Rated field voltage V DC Rated field current A DC Generator VT configuration Generator VT primary voltage V AC Generator VT secondary voltage V AC Bus VT configuration Bus A VT primary voltage V AC...
Page 239 Configuration Record Worksheet Soft start initial voltage Soft start time Excitation select PMG or shunt PMG phase select Single or three Loss of excitation current setpoint A DC Loss of excitation current delay Rotating diode fault open diode level % ripple Rotating diode fault delay Rotating diode fault shorted diode level % ripple...
Page 240 Configuration Record Worksheet Online high-level setpoint A DC Online high-level time delay Online medium-level setpoint A DC Online medium-level time delay Online low-level setpoint A DC Offline high-level setpoint A DC Offline high-level time delay Offline low-level setpoint A DC High Current Level...
Page 241 Configuration Record Worksheet UEL Curve kW point #1 UEL Curve kW point #2 UEL Curve kW point #3 UEL Curve kW point #4 UEL Curve kW point #5 UEL Curve kvar point #1 kvar UEL Curve kvar point #2 UEL Curve kvar point #3 UEL Curve kvar point #4 UEL Curve kvar point #5 Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 242 Configuration Record Worksheet Power factor integral gain Ki Power factor overall gain Kg Var integral gain Ki Var overall gain Kg OEL integral gain Ki OEL proportional gain Kg UEL integral gain Ki UEL proportional gain Kg AVR control proportional gain Kp AVR control integral gain Ki.
Page 243 Configuration Record Worksheet Frequency match lower limit Frequency match upper limit Voltage match lower limit Voltage match upper limit Phase match lower limit Phase match upper limit Acceptance delay Bus A voltage multiplier Bus A offsets phase Bus B voltage multiplier Bus B offsets phase Dead bus minimum frequency Dead bus maximum frequency...
Page 244 Configuration Record Worksheet Over-voltage Setpoint (percent of rated) Over-voltage Time Delay Under-voltage Setpoint (percent of rated) Under-voltage Time Delay Over-excitation Voltage Setpoint V DC Over-excitation Time Delay Droop Percentage Line Drop Voltage Compensation Over-current Setpoint. Over-current Curve Over-current Time Dial Over-current Voltage Restraint Setpoint Over-frequency Setpoint Over-frequency Delay...
Page 245: Table
OEL 84 power tab 104 synch 96 generator and bus voltage 20 tracking 92 generator current 21 transformers 78 UEL 86 voltage 100 volts hertz 83 auxiliary 40 bus voltage sensing 39 crosscurrent 39 generator line currents 39 generator voltage sensing 38 creating new module 72 electronic keying 74 excitation 41...
Page 246 AC voltage sensing 20 auxiliary input 30 chassis ground 20 AVR FCR control 88 communication connectors and settings 35 other gains 91 control power 19 over-excitation limiting 90 cross current compensation 33 power factor control 90 current sensing 20 under-excitation limiting 91 discrete outputs 30 VAR control 90 excitation output 19...
Page 247 inputs 221 inputs 231 outputs 232 inputs 227 outputs 228 current 55 inputs 222 outputs 223 inputs 217 power 57 outputs 217 inputs 225 outputs 225 control power 40 excitation power 40 inputs 224 outputs 224 equipment required 72 record system parameters 72 definite time over-frequency 225 functions 10 definite time overfrequency 226...
Page 248 under-excitation limiting 209 under-voltage protection 206 inputs 235 voltage matching 208 operation 67 outputs 236 relay outputs 67 tracking 68 recommended equipment 108 initial checkout 109 operational test functions 116 power up 109 test current and voltage source 109 simulate AC gen and bus inputs 111 test protective functions 111 inputs 226 test redundancy operation 110...
Page 249 breaker test position 119 inputs 218 time dial setting cross ref 171 outputs 218 voltage restraint 172 internal tracking 92 redundant tracking 93 diode monitor 124 traverse rates 94 OEL 124 UEL 123 volts Hz 123 communication 164 metering 162 compensation settings 101 protection 166 over-voltage 100...
Page 250 Rockwell Automation Publication 1407-UM001H-EN-P - November 2014...
Page 252 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. http://www.rockwellautomation.com/support you can find technical and application notes, sample code, and links to software service packs. You can also visit our Support Center at https://rockwellautomation.custhelp.com/ for software updates, support chats and forums, technical information, FAQs, and to sign up for product notification updates.

Allen-Bradley 1407-CGCM User Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Allen-Bradley 1407-CGCM

Summary of Contents for Allen-Bradley 1407-CGCM

Table of Contents