Auto Synchronizer Device

ZX400 SERIES
MICROPROCESSOR-BASED
ACCURATE SYNCHRONIZER
USER MANUAL
GORI AUTOMATION ENGINEERING LTD.
PDF "pdfFactory Pro" www.fineprint.cn
ZX400 SERIES
MICROPROCESSOR-BASED
ACCURATE SYNCHRONIZER
USER MANUAL
VER. 11.1W
MANUAL SERIAL NO GR-200-019W
CONTENTS
Chapter 1
Overview of the device..................................................... 1
1. Features ......................................................................................... 1
2. Technical Specification .........................................................................................................3
3. Classification and naming .....................................................................................................4
Chapter 2
Hardware Specification .................................................... 4
1. Appearance and Signals Definition .......................................................................................4

2. Connection ............................................................................................................................9
3. SYN parameters setting and modifying ..............................................................................17
4. Notes for using the device ...................................................................................................18
Chapter 3
Software Specification ................................................... 20
1. Overview .............................................................................................................................20
2. System Requirements ..........................................................................................................21
3. Operation.............................................................................................................................21
Chapter 4
Device Test ....................................................................... 27
1. Calibration test ....................................................................................................................27

2. Loading Parameter test ........................................................................................................27
3. Function test ........................................................................................................................28
ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL
Chapter 1
Overview of the device
ZX400 series microprocessor-based automatic accurate synchronization control device

is used for connecting to grid in power plant or busbar to power line in substation. The
device is safety, reliable, fast, stability and of high precision. In the process of
synchronization, the device also has the function of protection for the over or lower
voltage and frequency of the system or the generator and the PT secondary cycle
broken and over-excitation, etc.
1. Features
l High safety and reliability
Equipped with state-of-art 16 bit single-chip microprocessor, ZX400 is of dual CPU and
redundant structure. Its major switch-in output consists of two series-connected sub
output unit. So the device has very high safety and reliability.
l Quick synchronization speed and high precision
Using the modern control theories and the artificial intelligence concepts, ZX400 can
accurately estimate the switch-in angle. Using the PID regulation, it can accurately track
the voltage and the frequency of power system, insuring complete switch-in at the first
synchro point.
l High stability and strong ability in anti-interference
Built with low power-consumption electronic parts and high-quality switch power supply
as well as advanced multi-layer printed circuit, ZX400 is of characteristic of heat-stable,
well adoptive to voltage change. All input/output and power supply circuits are designed
as anti-wave with various reliable isolation measure deployed. It has passed through the
test of the electromagnetism compatibility and radiation, electrical fast pulse crowd
meeting to the national standards.
l The PT secondary cycle broken and lower voltage protection
The syn. voltage will drop in the cases of the broken PT circuit or the excitation loop
abnormity. In this situation ZX400 will alarm and refuse to send out synchronization
signal. It will display the lower voltage of the system or the generator on the screen.
Criteria of lower voltage value can be set up respectively.
l Over-voltage and over-excitation protection

The over voltage of the generator will easily bring over excitation to the generator (also
the transformer for generator-transformer unit) in synchronization process. ZX400 has
ability of over-voltage and over-excitation protection, criteria of generator over-high
voltage value and system voltage value can be set up respectively.
l Over-frequency and lower frequency protection
To guarantee the generator connect to grid safely, ZX400 provides the protection for
both over-frequency and lower-frequency. The upper limit and lower limit can be set up
respectively.
l
Supporting line voltage and phase voltage synchronization.
ZX400 can automatically compensate the difference of phase angle and the
difference of voltage caused by the main transformer /Y wiring, thus it is not
necessary to use phase angle transformer.
l Recording the actual time spent in switch-in process

Each actual switch-in time can be monitored on the screen.
l Easy Operation
ZX400 can be started manually or automatically one-time or multi-times, through the
different combination of input terminal connection. So it is ease to cooperate with manual
control or DCS system.
l Equipped with communication interfaces
ZX400 can be connected to a back-end PC computer and display graphically the
syn.-meter and the real-time parameters of the synchronization process on computer
screen.
l Cooperating with intelligent operating box and the selector of line
This makes the switch-over between various voltage loops more reliable, and also
simplified the design of multi-object syn. switch-in logic and the cooperation with the
DCS system.
l
Data is displayed in Chinese or English.
Easy test and maintenance.
2. Technical Specification
2.1 Power Supply:
AC85~260V or DC110~370V,
Power consumption: <50W.
2.2 Input Signals:
Secondary Voltages of voltage transformer (TV) on both sides of the synchronization
point.
Voltage:
AC50~140V,
Frequency:
44Hz~56Hz,
Power consumption: <1VA.
2.3 On-off Signal Input:
All are passive empty contacts.
2.4 On-off Signal Output:
Relay empty contact.
Contact capacity: DC220V/5A.
2.5 Synchronization Object: 14 / 8 / 4
2.6 Set-up range of frequency difference:
-0.30Hz~+0.30Hz, calibration: 0.01Hz.
2.7 Set-up range of voltage difference:
-10V~+10V, calibration: 0.1V
2.8 Set-up range of Lead-time:
10ms~990ms, Calibration: 10ms.
2.9 Working temperature:
-10C~50C
2.10 Working humidity:
5%~80%, no coagulation
2.11 Dimension:
483322133mm
3
3. Classification and naming

3.1 ZX400 is Microprocessor-based automatic accurate synchronization control device
3.2 The name definition is as follows:
ZX400
Design sequence (F,F/8,F/4,e.g.)
Model
3.3 The Function of Each Installation

Max.
Model
CPU
Object
Object
Voltage
No-voltage
Test
Switch-in
Switch-in
M0dule
LCD
No.
ZX400F
Gen / Line
14
* *
ZX400F/8
Gen / Line
* *
ZX400F/4
Gen / Line
* *
ZX400G/X
Gen / Line
* *
ZX400F(T)
Gen / Line
16
* *
Notice:
*: The function of speed and voltage regulation is only for generator object.
**: The function of no-voltage Switch-in can just take effect only when the object type is the
line,generator and it need no-voltage function only.
3.4 This User Manual only applies to the types of ZX400, ZX400/8 and ZX400/4
microprocessor-based automatic accurate synchronization control devices.
Chapter 2
Hardware Specification
1. Appearance and Signals Definition

The obverse appearance of the device is shown in Fig 2.1. Each district definition as
follow:
ZX400
RUN
SYNCHRONIZER
NONV
SYN
f+
U+
ORDER
f-
U-
ERROR
GORI
2
Fig 2.1
The obverse appearance of the device
1----Electronic type Syn.-meter

2----LCD screen:
Display the syn. parameters and real-time parameters.
3----RS-232C:
Serial port. 9 needle sockets of D model, used in modifying parameters.
4----State indication lamps indicating follows if light:
Increase Speed Lamp - Send out the pulse of Increasing Speed.
Decrease Speed Lamp - Send out the pulse of Decreasing Speed.
Increase Voltage Lamp - Send out the pulse of Increasing voltage.
Decrease Voltage Lamp - Send out the pulse of Decreasing voltage.
Switch-in Lamp - Send out the pulse of switch-in.
Alarm Lamp - Prohibit switch-in or internal fault.
5----Film Button:
Used in checking data and inputting command.
6----Running Lamp :
Astigmatic frequency is 1 Hz after switch-on and astigmatic frequency is 2 Hz in running,
indicating the device works well.
The rear appearance of the device is shown in Fig 2.2.
Fig 2.2
The rear appearance of the device
7----Earth terminal connecting to the earth.

8~10----Input and output terminals X1, X2 and X3. The definitions are shown in table 2.1,
2.2 and 2.3.
11----The screw hole (M4) for installation.
Table 2.1:
Terminal X1
No.
Definition
Remark
In/Output
1
2
3
4
5
6
L220V(+)/110V(+)
AC/DC power+
AC/DC power-
NOOP
NOOP
* System side voltage
System side voltage
Input
Input
/
/
Input
Input
7
8
9
TVG
TVG
* Generator side voltage

Generator side voltage
Input
Input
Inc. f
Output
10
COM
Speed regulation common

terminal
Output
11
12
Dec. f
Output
V+
Inc. V
Output
13
VCOM
Voltage regulation
common terminal
Output
14
15
16
V-
Dec. V
Output
CL
Switch-in
Switch-in
Output
N220V(-)/110V(-)
NC
NC
TVS
TVS
CL
Output
Note: There will be no output from 9~14 terminals when the SYN. objects are set be LINE.
Table 2.2:
Terminal X2
No.
Definition
.f
1
.f
2
FLT
3
FLT
4
NC
5
TXD
6
RXD
7
Remark
In/Output
SYN check-up
Output
SYN check-up
Output
Output terminal of alarm
Output
Output terminal of alarm
Output
Empty
Communication interface
Output
Output
8
9
10
11
12
13
14
15
16
Table 2.3:
GND
Output
QF1
#1 Object chosen
Input
QF2
#2 Object chosen
Input
QF3
#3 Object chosen
Input
QF4
#4 Object chosen
Input
QF5
#5 Object chosen
Input
QF6
#6 Object chosen
Input
QF7
#7 Object chosen
Input
QF8
#8 Object chosen
Input
Remark
In/Output
QF9
#9 Object chosen
Input
QF10
#10 Object chosen
Input
QF11
#11 Object chosen
Input
QF12
#12 Object chosen
Input
QF13
#13 Object chosen
Input
QF14
#14 Object chosen
Input
NO-U
NU
Input
TR-M
QF time
Input
NC
Empty
NC
Empty
TRIPS
SYN starting
Input
TRPS-COT
Times control of SYN starting
Input
24VGND
Inner 24V GND
Input
24VGND
Inner 24V GND
Input
24VGND
Inner 24V GND
Input
24VGND
Inner 24V GND
Input
Terminal X3
No.
Definition
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Fig 2.3
The Wiring diagram of the terminal X1, X2 and X3
2. Connection
can be operated both manually or through automatic control order from DCS system.
Matched GR-3 circuit selector (or YAC-2000 intelligent operating case), it can make the
circuit design of multi-object SYN switch-in controlled by DCS system simple and the
voltage switch more safe and reliable.
2.1 The exemplar of ZX400 multi object circuit wiring for manual control
Manually controlled ZX400 device means it can be put into operation through DTK
switch. The circuit switching of object selecting and speed regulation and voltage
regulation through TK SYN switch The Wiring is shown in Fig 2.4 and Fig 2.5.
Notes:
1. Objects #1, #2 and #3 are generators. Other objects are lines in Fig. 2.4
2. The SYN voltages of each object can be connected to the SYN voltage buses by the
SYN switches of each object.
3. The speed or voltage regulation of objects #1, #2 and #3 can be output through
middle relay 1-4zzJ and also be output directly form the device while the middle
relay 1-4zzJ is not needed. If the output of speed regulation need to suit with DEH, it
can concatenate the empty contact from DEH to the circuit of corresponding public
terminal of speed regulation output.
4. X3-8 should be disconnected from X3-14 when not to measure the switch-in time of
breaker.
5. The way of starting the device is as follows:
A) When DTK is in test position (short circuit X3-11, X3-12 and X3-16), The device can
repeat started by itself and send out switch-in pulse if the SYN condition is satisfied.
B) When DTK is in ON position (short circuit X3-11 and X3-16 only). The device can
started by itself once and send out switch-in pulse only one time. Thus can prevent the
accident because of sending out repeatedly switch-in pulses when the breaker is fault.
6. The device can start once at pressing one time when the DTK contacts 30 and 32 are
canceled (X3-12 is empty) and connect a starting button between X3-11 AND X3-16.
7. The no-voltage permission contact UN connected between X3-7 and X3-16. It can
not make no-voltage switch-in when the contacts is break and It can make no-voltage
switch-in when the contacts is connected. If the object is line and the corresponding
SYN switch contacts replace the UN contacts, it also can achieve no-voltage
switch-in.
8. If the phase angle difference of two SYN voltage is not 0 because of the influence of
the Y/ wiring transformer, so the contacts of the SYN checking relay JJ should be
canceled in corresponding circuit of switch-in output.
9
Fig.2.4 SYN circuit wiring 1 for multi object and manual control
2THM
3THM
TEST
1TK
2TK
29
OFF
ON
31
14TK
1TK
Object 1 switching-in
2TK
14TK
1TK
Object 1 +
1TK
Object 1 -
2TK
Object 2 +
2TK
Object 2 -
3TK
Object 3 +
3TK
Object 3 -
1TK
Object 1 V+
1TK
Object 1 V-
2TK
Object 2 V+
2TK
Object 2 V-
3TK
Object 3 V+
3TK
Object 3 V-
1TK
com
2TK
3TK
1TK
V com
2TK
3TK
Fig.2.5 SYN circuit wiring 2 for multi object and manual control
10
2.2 The exemplar of ZX400 multi objects circuit wiring matched GR-3
2.2.1 The circuit wiring of power supply and SYN voltages is shown in Fig 2.6.
Notes:
1. The power supplies of ZX400 and GR-3 are controlled by DTK at the manual / DCS
positions.
2. The circuits of I / II / III / IV are SYN voltages of object 1 / 2 / 3 / 4.
11
220V(+)
220V(-)
KK
KK
GR-3
DTK
OFF DCS
M
1
A1-1
DTK
OFF DCS
A1-2
ZX400FZX400F/8ZX400F/4
X1-1
X1-2
GR-3
ZX400FZX400F/8ZX400F/4
A3-1
I
II
A3-2
A2-3
A3-3
A3-4
A2-4
A3-13
A2-5
A3-14
A3-15
A2-6
X1-5
X1-6
X1-7
X1-8
A3-16
A4-1
III
A4-2
A4-3
A4-4
A4-13
A4-14
IV
A4-15
A4-16
Fig.2.6
The circuit wiring of power supply and SYN voltages matched GR-3
2.2.2 The circuit wiring of choosing objects and SYN starting is shown in Fig 2.7.
Notes:
12
1. After the power supplies and SYN voltages are switched in, the SYN object will be
chosen by DCS1-1~DCS1-4 at remote mode or by 1TK~4TK at manual mode. Then
the SYN operating will start and send out the switching-in order at the adequate SYN
conditions.
2. No-V switching-in permission will be controlled by NU at remote mode or by WK at
manual mode when the adequate No-V switching-in conditions no matter the type of
SYN objects.
3. The contacts above should be retentive. If the remote signals are short pulses,
DTK-14 to GR-3:A1-9 must be shorted and the signal for remote reset must be
effective.
4. If the phase angle difference of two SYN voltage is not 0 because of the influence of
the Y/ wiring transformer, so the contacts of the SYN checking relay JJ should be
canceled in corresponding circuit of switch-in output.
GR-3
DCS1-1
1TK
2
ZX400F
A1-3
A2-17
X2-9
A1-4
A2-18
X2-10
A1-5
A2-19
X2-11
A1-6
A2-20
X2-12
A1-7
A2-22
X3-7
DCS1-2
2TK
2
DCS1-3
3TK
2
DCS1-4
4TK
2
NU
WK
2
R-RESET
DTK
OFF
A1-10 A2-21
X3-11
A2-24
X3-13
DCS
13
14
A1-9
10
A1-12
11
12
Fig.2.7 The circuit wiring of choosing objects and SYN starting

2.2.3 The circuit wiring of switching-in, +/- and V+/- is shown in Fig 2.8
Notes:
1. The signals for switching-in and SYN check of ZX400 must be connected to GR-3
13
first. Then the final signal for switching-in will be outputted by GR-3 at the SYN
conditions passing master.
2. The signals for +/- and V+/- will be effective only when the object type is generator.
3. The circuits for+/- and V+/- need not be connected when the object type is line.
ZX400F
GR-3
A3-5
X1-9
A2-7
A3-6
A3-7
X1-10
com
X1-11
X1-12
V+
A2-10
A3-11
X1-13
Vcom
A2-11
A3-12
X1-14
V-
A2-12
X2-1
X2-2
X1-15
A2-8
A2-9
A3-8
A3-9
A3-10
SYN check
SYN check
I ~ IV
A4-17
A2-13
A4-18
A4-19
A2-14
A4-20
A4-21
A4-22
A4-23
Alarming
X2-4
X3-9
X3-10
Fig.2.8
} V+ output
} V- output
A2-16
Switching-in
X2-3
} + output
} - output
A2-15
Switching-in
X1-16
}Switching-in output
A4-24
}Switching-in output
} + output
} - output
} V+ output
} V- output
}No power supply

The circuit wiring of switching-in, +/- and V+/-
2.2.4 The other circuit wirings

1. The circuit wiring of switching-in time measure is shown in Fig 2.9. 1DL~4DLare the
N.O. auxiliary contacts of breakers. The measured time will be shown on the screen
of ZX400 to check the setting values.
14
Fig.2.9
The circuit wiring of switching-in time measure
2. The circuit wiring of communication for devices is shown in Fig 2.10. The real SYN
messages can be shown on the background computer from the RS-485/232
interface.
Fig.2.10
The circuit wiring of communication for devices
2.2.5 The notes for operation sequences

1. Remote operation (SYN-V switching-in )Set DTK to DCS position DCS be
connected to supply power DCS1-1~DCS1-4 be connected and holding (Choose
SYN object) Automatically start by device, +/- and V+/- (Generator type)
Send switching-in order from ZX400 to GR-3 at the SYN conditions Output the
switching-in order from GR-3 Complete the SYN operation DCS1-1~DCS1-4
15
be released.
2. Remote operation (NO-V switching-in )Set DTK to DCS position DCS be
connected to supply power NU be connected and holding (Choose NO-V SYN)
DCS1-1~DCS1-4 be connected and holding (Choose SYN object)
Automatically start by device Send switching-in order from ZX400 to GR-3 at the
SYN conditions Output the switching-in order from GR-3 Complete the SYN
operation DCS1-1~DCS1-4 be released.
(If the remote signals are short pulses, DTK-14 to GR-3:A1-9 must be shorted and the
signal for remote reset must be effective.)
3. Local operationSet DTK to M position, the switches and buttons will instead of the
DCSs contacts. The operation sequences will be similar to the sequences above.
2.3 The exemplar of ZX400 multi objects circuit wiring matched YAC-2000
YAC-2000 Synchronization Intelligent Operator will be matched with ZX400 when the
objects number is more than four to simplify further the connection and to reduce the
middle relay in periphery circuit and then reduce fault because of bad contact.
A single YAC-2000 may be used for eight SYN-objects, NO.1~NO.3 are used for
generator, the others NO.4~NO.8 all for power line. Two YAC-2000 operators may be
used for sixteen SYN-objects and so on.
Notes:
1. All input control signals of YAC-2000 are dead contacts without electricity. Except the
P.S. of the synchronizer all output control signals of YAC-2000 are also dead
contacts without electricity. Thus the security and reliability of the equipment work are
guaranteed. By means of control signals, YAC-2000 control ZX400 to complete
synchronizing paralleling work of generator or power line. The speed and voltage
adjustment and the switch-in output all by means of YAC-2000 without transfer relays.
Thus predigest connection greatly if more SYN-objects.
2. Without manual operation in such hardware control work, if completed by DCS or
ECS system automatically. And each operating result may be back-checked in
control process.
3. Such hardware control mode is also applicable for manual local operation.
4. On background computer with menu display By means of RS485 interface to control
YAC-2000 operation to realize synchronizing paralleling of generator or power line.
Each operation step all get back-check signals in operation process. To permit next
step operation after affirm this operation step success. Thus the operation is very
security.
16
YAC-2000
ZX400F
SYN voltages
Choose object
Operating control
Power supply
Background computer
RS-232
RS-232
RS-485
+/- output
V+/- output
Switching-in output
Alarm signal
Re-check signal
Fig.2.11
The circuit wiring of multi-objects SYN operation matched YAC-2000
3. SYN parameters setting and modifying

can be connected to the portable back-end computer through the RS-232C and a special
connection cable (provided with the device) as shown in Fig.2.12.
The setup and modification of all SYN parameters can be finished in the back-end
computer. The parameters cannot be changed from within the device, thus avoiding the
possibility of parameters mess up and mistake in operation.
17
Fig.2.11
The connection to computer for setting and modifying
4. Notes for using the device

4.1.
The device should be tested according to the requirement of chapter 4 before

being put into operation for the first time.
4.2. When the device is used for multi objects, carefully check related wiring to avoid
accidental operation.
4.3. The device has been calibrated before leaving factory. If it needed to calibrate
again, it should be carried out according to the correct method described in
Chapter 4, otherwise the mistake will be shown.
4.4. The setting and modification of synchro parameters can be finished on the
back-end computer using GrsynF software (refer to Chapter 3).
4.5. The operating sequence for different wiring (see circuit wiring section in this
Chapter). It does not necessarily mean that the device has problems when the
device sends out the alarm in the process of working (the alarm reason is shown
on the screen). The device allowed to operate again at this point and neednt to
be reset.
4.6. The device is equipped with a LCD screen to display the information such as SYN
objects and its parameters, and monitor the real-time SYN process as well. Its
main function menu interface is shown as Fig.2.12.
Description of each function menu item is as follows:
(1) Display synchro fixed value: Including object number, lead-time, the allowed
difference of the voltage and frequency of switch-in; the value of upper limit and
lower limit of the voltage and frequency of the system and generator; voltage and
frequency regulation cycle and corresponding voltage and frequency regulation
factors, phase angle compensation of the SYN objects.
18
Main menu interface

1.SETTING
2.REALTIME
3.MESSAGE
4.CALIBRATION
5.SELECTED
6.DEVICE
Fig.2.12
The device main function menu interface
(2) Display real time data: The value of the voltage and frequency, the difference of
voltage, the difference of frequency and the difference of phase in the system and
generator in the process of switch-in.
(3) Display data log: It will show lead-time, the value of voltage and frequency, the
difference of phase angle in the system and generator; the actual switch-in time of
the breaker when switch-in succeed. If switch-in fails user can check out the audit
trail and message.
(4) Calibrating: When calibrated according to the correct method, it will show
calibrating succeed, otherwise it will show calibrating error. Calibration should
be done by connecting the device with special telecommunication cable.
(5) Display the object to be switched in, it shows the number of object and the
objects equipment number.
(6) Display the setting of the device:
It shows baud rate, voltage compensation factor and phase angle of the SYN
voltage in the device.
4.7. Voltage difference setting
As show in Attached Fig.13, QF is the SYN breaker, T is the voltage-raising transformer.
.
If
II
is the rating voltage (Ex. 220KV, 110KV etc.) and T is the voltage-raising
.
transformer and the voltage of generator terminal is at its rating value
GN
, the voltage
.
of high voltage side of transformer is greater than the rating voltage of system U II
(If the voltage of high voltage side of transformer is 242KV, K%10. If 236kV
K
236 220
220
7.3. If 121kV
121110
110
10.)
If the voltage of system
II
is at rating value,
U II 100V to make
19
.
I
equal toU II

.
.
U GN
100
corresponding to U G
When the
1+K%
1+K%
voltage compensate factor of generator side is 1.1 (see the parameter 12 in Chapter 3),
for switch-inthere we set
UG
in fact in device the generator voltage is used in comparison is
110
U G 1+K% . Obviously when K10,
U G' 1.100
U G' 100v. This means that if the
voltage compensate factor of generator side is 1.1, the voltage difference setting is the
same as the one without voltage-raising transformer. For instance -3VU3V.
If K10that is K10take KK-10. If 12then 2. Here we only need
to subtract from the upper limit and lower limit of voltage difference. For above
example it is 5VU1V.
If K10 (that is K<10)take KK-10. If 7.5then 2.5The setting
is just like above. For above example, it is 0.55.5V.
Fig.2.13
The phase compensation for SYN voltage
Chapter 3
Software Specification
1. Overview
The parameters configuration software of ZX400 series microprocessor-based automatic
20
accurate synchronization control device is based on platforms such as WINDOWS9X,

2000, XP, NT. It provides the functions of creating, modifying, saving, loading and
printing of the SYN parameters.
User can run this program (GrsynF.exe) and create a configuration file for the device.
Each device needs a configuration file.
2. System Requirements
Hardware Requirement:
Main Computer:
Main frequency: more than P100,

Memory:
more than 16M,
Hard disc:
more than 1G,
CD-ROM
Keyboard: Standard Keyboard
Mouse:
Serial port mouse or bus line mouse
Display:
VGA Pattern, resolution: 800*600
Software Requirement:
Chinese/English WINDOWS9X, 2000, XP or WINDOWS NT.
3. Operation
GRsynF program is used specially in ZX400 for setting up 14 objects parameters. Each
object has 25 parameters.
3.1
Startup
Fig.3.1 shows the user interface after GRsynF startup. Each object parameters are
initially set to default value. User can modify all these parameters.
21
3.2
Fig.3.1
User Interface after start up
Fig.3.2
User Interface for selecting object
Object Selection
22
The user interface for selecting object is shown in Fig.3.2. User can select different
objects by clicking the object in the menu.
3.3 Parameter Modification
After selecting the object, user can modify its parameters. The definition of parameters is
as follows:
Parameter 1: Unit Name
Unit name is the number that identifies a specific object. It consists of 11 ASCII
characters.
Parameter 2: Type
It is the object type and can be set as Generator or Line.
Parameter 3: Tpre
It is the time period from the point that the switch-in order is sent out to the point that the
breakers main contact closes. This parameter should be measured at real time. The
value scope of the parameter is 10ms~990ms with the calibration of 10 ms. The device
can only be used when this parameter is properly set.
Parameter 4: Difference allowed voltage difference
It is the allowed maximum voltage difference (as input to ZX400 device) between two
sides of the undergoing synchro switch-in connection. It can be positive or negative, and
the positive value needs not to be equal to the negative value. The less this parameter is,
the less the reactive power impact is in switch-in process, but the switch-in time may be
lengthened accordingly. The value scope of the parameter is -10V~+10V with the
calibration of 0.1V. The typical value of voltages difference is -3V~+3V. This parameter
needs not to be modified unless for some special situation.
Parameter 5: Difference - allowed frequency difference
It is the allowed maximum frequency difference (as input to ZX400G/X device) between
the two sides of the breaker of the undergoing switch-in. It may be positive or negative
and the positive value needs not to be equal to the negative value. The less this
parameter is, the more time of speed regulation the switch-in process may take. The
value scope of the parameter is -0.3Hz~+0.3Hz with the calibration of 0.01Hz. The
typical value of frequency difference is -0.2Hz ~+0.2Hz. The parameters value needs not
to be modified unless for some special situation.
Parameter 6: Dfai allowed phase angle difference in ring grid connection
This parameter is invalid when the object type is generator unit.
Parameter 7: Coefficient kU - Voltage compensation factor in system
It is the factor used to compensate the amplitude change which is aroused by the
transform of Y/. The value can be set to 1.0, 1.1 or 1.732. The typical value is 1.0. The
value needs not to be modified if no transformer wiring of /Y or Y/.
Parameter 8, 9: Umin / Umax - Voltage upper and lower limit in system
When the voltage in system is over the setting value, the device will send out alarm.
23
Parameter 10, 11: fmin / fmax - Frequency upper and lower limit in system
When the frequency in system is over the setting value, the device will send out alarm.
Parameter 12: Line Voltage Coefficient KU - compensation factor at switched-in
side
It is the factor used to compensate the voltage amplitude change at switched-in side
which is aroused by the transform of Y/ and the ratio of the voltage-raising transformer.
The values can be set to 1.0, 1.1 or 1.732. The typical value is 1.0.
Parameter 13, 14: Umin / Umax - Voltage upper and lower limit values at
switched-in side
They are similar to parameter 8 and 9.
Parameter 15, 16: fmin / fmax - Frequency upper and lower limit values at
switched-in side
They are similar to parameter 10 and 11.
Parameter 17: Phase-Shift Angle/dfal Phase angle compensation
There is a difference of phase angle between synchro voltage which is aroused because
of the presence of Y/ wiring transformer. The device can automatically compensate the
difference of phase without using a phase angle transformer. The value scope of the
parameter is 180~+180 degree with the calibration of 30 degree (Note: It will be
negative for leading voltage and positive for lag voltage). The typical value is 0 degree.
The parameter values needs not to be modified if no change to the transformers /Y or
Y/ wiring.
Note: Phase compensation applied to both CPU should be kept equally. So a CPU is
achieved by needle plug according to the real value of another one.
Parameter 18: period / TV - The cycle of voltage regulation
The scope of the value is from 1000 ms to 15000 ms.
Parameter 19-21: PID Coefficient / Kpv / Kiv / Kdv - PID parameter of voltage
regulation
It can be obtained from experiment. The scope of each parameter is from 0 to 100.
Parameter 22: period / Tf - The period of speed regulation
The scope of the value is from 1000ms to 15000ms.
Parameter 23-25: PID Coefficient / Kpf / Kif / Kdf - PID parameter of frequency
regulation
It can be obtained from experiment. The scope of each parameter is from 0 to 100.
Press SAVE key (or click the menu item shown in Fig 3.3) to save the change to the
parameters.
24
Fig.3.3
Interface of file save
3.4. Loading object parameters

Loading object parameters can be completed through function in SETTING menu as
shown in Fig 3.4.
Clicking Current CB menu item to load the chosen objects parameters
Clicking All CBs menu item to load 14 objects parameters.
3.5. Print
The operation of printing is shown in Fig.3.5.
25
Fig.3.4
Fig.3.5
Interface of communication
Interface of printing operation
26
Chapter 4
Device Test
1. Calibration test
1.1 Connect AC100V/50Hz standard signal source to the input terminal Us and Ug of
the device. Switch on the device.
1.2 Press Calibrate button to start the calibration (Note: The special communication
cable should be connected).
1.3 The screen will show the message of Calibration successful in
about 5 seconds.
1.4 Filling out the test result in Table 4.1.
2. Loading Parameter test

2.1. Connecting ZX400 to the back-end computer via serial port with a special
communication cable.
2.2. Switching on the ZX400.
2.3. Starting GRsynF program on the back-end computer.
2.4. Setting the parameters for each SYN object.
For example: The settings of SYN parameter for object 1 may be as follows.
Equipment numbers: 1234
l Lead-time: 200ms
l The allowed difference of voltage in switch-in: -4VU+4V
l The allowed difference of frequency in switch-in: -0.2Hzf0.2Hz
l Voltage compensation factor of system side: 1.0
l Voltage lower limit value of system side: 80V
l Voltage upper limit value of system side: 115V
l Frequency lower limit value of system side: 48.5Hz
l Frequency upper limit value of system side: 51Hz
27
l
l
l
l
l
l
l
l
l
l
Voltage compensation factor of switched-in side: 1

Voltage lower limit value of switched-in side: 80V
Voltage upper limit value of switched-in side: 115V
Frequency lower limit value of switched-in side: 48.5Hz
Frequency upper limit value of switched-in side: 51Hz
Phase compensation: 0
The cycle of voltage regulation: 6000ms
PID parameters of voltage regulation: P=15, I=0, D=10
The cycle of frequency regulation: 2000ms
PID parameters of frequency regulation: P=15, I=0, D=10
Other objects can be set similarly.

2.5. Loading the parameters for a single object or all objects to ZX400
2.6. Checking whether the loaded parameters value is consistent with the Loading
parameters value.
2.7 Filling out the test result in Table 4.2.
3. Function test
3.1 For Generator Object
The parameters of object 1 are as above example . Test wiring is shown as Fig4.1
28
Fig 4-1 Function testing wiring

3.1.1. Disconnect NU. If it is not necessary to measure the real switch-in time of the SYN
breaker, disconnect X3-8 with X3-14.
3.1.2. Make the output ZX400G/X as generator frequency 49.9Hz, generator voltage
106V or 94V. Switch on ZX400 and start ZX400.
3.1.3. When sending out reducing voltage pulse, the reduce voltage lamp lights, X1-13
and X1-14 are connected (X1-12 and X1-13 are not connected). When sending out
raising voltage pulse, the raise voltage lamp lights, X1-12 and X1-13 are connected
(X1-13 and X1-14 are not connected). The cycle of voltage regulation pulse is about 6
seconds. The indicator lights on the back-end computer screen will show the same
condition.
3.1.4. When sending out acceleration pulse, the increase speed lamp lights, X1-9 and
X1-10 are connected (X1-10 and X1-11 are not connected). When sending out
deceleration pulse, the deceleration lamp lights, X1-10 and X1-11 are connected (X1-9
and X1-10 are not connected). The cycle of the speed regulation pulse is about 2
seconds. The indicator lights on the back-end computer screen will show the same
condition.
3.1.5. When the requirements of differences of voltage and frequency are satisfied,
ZX400 send out switch-in pulses. At that point switch-in lamp flashes and X1-15, X1-16
switches on one time.
3.1.6. Real time SYN information in SYN process can be shown on the device screen in
the process of test. Meanwhile the functions of device panel button are also tested. Real
time SYN information in SYN process will also be displayed on the back-end computer.
3.1.7. If the accessorial contact of the breaker is connected to X3-8 and X3-14, the real
switch-in time can be recorded and shown.
29
3.1.8. If alarm pops up during working process, the full content of alarm can be shown
on the screen in Chinese and English. Meanwhile the alarm lamp light and empty
contact output.
3.2 For Generator Object
The parameters of object 1 are as above example. Test wiring is shown as Fig4.1
3.2.1. Synchronization switch-in
3.2.1.1. Disconnect NU
3.2.1.2. Switch on ZX400. Make the difference of voltage and frequency be in the setting
scope by adjusting the button of speed and voltage regulation. Thus the device can
automatically send out switch-in pulse. It can be monitored if is consistent with the actual
switch-in time. There are no speed and voltage regulation output in the whole process of
testing.
3.2.2. Ring grid connection under the same frequency.
3.2.2.1. Disconnect NU
3.2.2.2. Make the frequency of the two SYN voltage the same.
3.2.2.3. Adjusting the phase angle regulation button to make the difference of phase
angle of the two SYN voltage fall into the setting range, start ZX400G/X and it will send
out switch-in pulse.
3.2.3.
Switch-in under condition of no-voltage
3.2.3.1. Disconnect the input signal to X1-5, X1-6 and connect X1-5, X1-6.
3.2.3.2. Switch on NU.
3.2.3.3. Switch-on ZX400 and start it, will send out switch-in pulse.
3.2.3.4. Switch-in for no-voltage of TVG+ and TVG- or both synchro sides is the same as
above.
3.2.3.5. If NU is disconnected, no switch-in pulse is sent out in the above tests.
Appendix 1
Outline of ZX400
30
Appendix 2
Installation holes size of ZX400
Appendix 3
Installation screw size of backboard
Appendix 4
Installation holes size of GR-3
31
GORI AUTOMATION ENGINEERING LTD.
All right reserved
ADDROOM 201, CHANGJIANG SCIENCE PARK, NO.97, LUXIYING, NANJING, CHINA

POSTCODE210037
TEL025-8364121183323057
FAX025-83353991
MKT025-83551973
WEBwww.jsgori.com
E-MAILjsgori@163.com

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ZX400 SERIES

GORI AUTOMATION ENGINEERING LTD.

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Overview of the device..................................................... 1

Hardware Specification .................................................... 4

1. Appearance and Signals Definition .......................................................................................4

Software Specification ................................................... 20

Device Test ....................................................................... 27

1. Calibration test ....................................................................................................................27

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ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL

Overview of the device

ZX400 series microprocessor-based automatic accurate synchronization control device

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ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL

l Over-voltage and over-excitation protection

Supporting line voltage and phase voltage synchronization.

l Recording the actual time spent in switch-in process

Data is displayed in Chinese or English.

Easy test and maintenance.

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ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL

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ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL

3. Classification and naming

3.3 The Function of Each Installation

1. Appearance and Signals Definition

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ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL

The obverse appearance of the device

1----Electronic type Syn.-meter

The rear appearance of the device

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ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL

7----Earth terminal connecting to the earth.

* Generator side voltage

Speed regulation common

Output terminal of alarm

Output terminal of alarm

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ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL

#10 Object chosen

#11 Object chosen

#12 Object chosen

#13 Object chosen

#14 Object chosen

Times control of SYN starting

Inner 24V GND

Inner 24V GND

Inner 24V GND

Inner 24V GND

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ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL

The Wiring diagram of the terminal X1, X2 and X3

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ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL

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ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL

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ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL

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ZX400 SERIES MICROPROCESSOR-BASED SYNCHRONIZER USER MANUAL

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