Grid Automation Products. SAM600 Process Bus I/O System Operation Manual

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1 b Grid Automation Products SAM600 Process Bus I/O System

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3 Document ID: 1MRK UEN Issued: June 2017 Revision: A Product version: 1.2 Copyright ABB. All rights reserved

4 Copyright This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party, nor used for any unauthorized purpose. The software and hardware described in this document is furnished under a license and may be used or disclosed only in accordance with the terms of such license. Trademarks ABB and SAM600 are registered trademarks of the ABB Group. All other brand or product names mentioned in this document may be trademarks or registered trademarks of their respective holders. Open Source License Acknowledgements This product incorporates open source software components covered by the terms of third party copyright notices and license agreements. For more information, refer to 1MRK BEN SAM600 Product Guide. Warranty Please inquire about the terms of warranty from your nearest ABB representative.

5 Disclaimer The data, examples and diagrams in this manual are included solely for the concept or product description and are not to be deemed as a statement of guaranteed properties. All persons responsible for applying the equipment addressed in this manual must satisfy themselves that each intended application is suitable and acceptable, including that any applicable safety or other operational requirements are complied with. In particular, any risks in applications where a system failure and /or product failure would create a risk for harm to property or persons (including but not limited to personal injuries or death) shall be the sole responsibility of the person or entity applying the equipment, and those so responsible are hereby requested to ensure that all measures are taken to exclude or mitigate such risks. This document has been carefully checked by ABB but deviations cannot be completely ruled out. In case any errors are detected, the reader is kindly requested to notify the manufacturer. Other than under explicit contractual commitments, in no event shall ABB be responsible or liable for any loss or damage resulting from the use of this manual or the application of the equipment.

6 Conformity This product complies with the directive of the Council of the European Communities on the approximation of the laws of the Member States relating to electromagnetic compatibility (EMC directive 2014/30/EU) and concerning electrical equipment for use within specified voltage limits (Low-voltage directive 2014/35/EU). This conformity is the result of tests conducted by ABB in accordance with the product standard EN for the EMC directive, and with the product standard EN for the low voltage directive. The product is designed in accordance with the international standards of the IEC series.

7 Safety Information Observe the following safety instructions when using the product. Before first usage, read the product documentation in order to ensure safe and reliable operation of SAM600 products. Dangerous voltages can occur on the connectors, even though auxiliary voltages are disconnected. Each SAM600 product must be safely connected to ground using the ground strap. Only a competent electrician is allowed to carry out the electrical installation. Always follow national and local electrical safety regulations. Non-observance of the safety information can result in death, personal injury or substantial property damage. Whenever changes in parameter settings are applied to SAM600 modules, take measures to avoid inadvertent tripping or malfunction of connected protection and control devices.

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9 Table of contents Table of contents Section 1 Introduction This manual Intended audience Related documents Symbols and conventions Symbols Document conventions... 4 Section 2 SAM600 Process Bus I/O System System overview SAM600 common design features SAM600-CT for conventional current measurements SAM600-VT for conventional voltage measurements SAM600-TS for time synchronization and IEC gateway System functionality Installing SAM Functional description Distributed analog sampling Communication ports and available services Bridging of sampled values streams Quality information in sampled values streams Merging and bridging of SV streams in a SAM600 system Simulation of sampled values Digital inputs Configuration of time synchronization SAM600 module and system supervision System error announcement Watchdog functionality SAM600 system configuration mismatch Section 3 PCM600 Tool Connectivity packages Section 4 Commissioning SAM Safety instructions SAM600 Process Bus I/O System 1

10 Table of contents 4.2 Unpacking Mounting and earthing connection Electrical wiring Communication wiring Storing, mounting and disposal Section 5 SAM600 System Startup Start-up behavior Section 6 Diagnostics and Maintenance Maintenance instructions Section 7 Technical Data Module dimensions and mounting distances Labels, connectors and indications of SAM600 modules SAM600 module identification Connector diagrams LED indications for all SAM600 modules Appendix A System Log Events Appendix B Glossary SAM600 Process Bus I/O System

11 1MRK UEN A Section 1 Introduction Section 1 Introduction 1.1 This manual The SAM600 operation manual provides information about the usage of a SAM600. The manual contains instructions on how to configure, install and commission a SAM600 system and on how to operate the system once it has been commissioned. 1.2 Intended audience This manual addresses engineers and operators who configure, install, commission and operate a SAM600 system. The user must be trained in and have a basic knowledge of how to operate substation automation secondary system equipment. The manual contains terms and expressions commonly used to describe this kind of equipment. 1.3 Related documents The following product documentation is available for the SAM600. Table 1: SAM600 product documentation SAM600 Product documentation SAM600 Product Guide SAM600 Engineering Manual SAM600 SAM600 Cyber Security Deployment Guideline SAM600 Accessory List SAM600 Safety Leaflet SAM600-TS Wiring Diagram SAM600-VT Wiring Diagram SAM600-CT Wiring Diagram SAM PICS and PIXIT (IEC61580 Ed1) SAM MICS (IEC61850 Ed2) SAM IEC/IEEE PICS SAM TICS (IEC61850 Ed2) Document numbers 1MRK BEN 1MRK UEN 1MRK UEN 1MRK UEN 1MRK UEN 1KHL UEN 1KHL KHL KHL KHL KHL KHL KHL SAM600 Process Bus I/O System 3

12 Section 1 Introduction 1MRK UEN A 1.4 Symbols and conventions Symbols The electrical warning icon indicates the presence of a hazard which could result in electrical shock. The warning icon indicates the presence of a hazard which could result in personal injury. The caution icon indicates important information or warning related to the concept discussed in the text. It might indicate the presence of a hazard which could result in corruption of software or damage to equipment or property. The information icon alerts the reader of important facts and conditions. The tip icon indicates advice on, for example, how to design your project or how to use a certain function. Although warning hazards are related to personal injury, it is necessary to understand that under certain operational conditions the operation of damaged equipment may result in degraded process performance leading to personal injury or death. Therefore, it is recommended to comply fully with all warning and caution notices Document conventions A particular convention may not be used in this manual. Abbreviations and acronyms in this manual are spelled out in the glossary. The glossary also contains definitions of important terms. HMI menu paths are presented in bold. For example, select Main menu or Settings. Parameter names are shown in italics. For example, the function can be enabled and disabled with the Operation setting. 4 SAM600 Process Bus I/O System

13 1MRK UEN A Section 2 SAM600 Process Bus I/O System Section 2 SAM600 Process Bus I/O System 2.1 System overview SAM600 process bus I/O system is a modular, extensible, and customizable product solution that converts signals from the primary analog process to its digital counterpart according to the IEC standard. The product is designed for both AIS and GIS applications. It can be beneficially applied to secondary system upgrades as well as new substation installations, thus integrating seamlessly with modern sensor technology. SAM600 optimally tailors to different applications, is prepared for placement in harsh outdoor setups and can be deployed in a stepwise manner in marshalling kiosks close to primary apparatus, or in existing secondary system protection and control panels SAM600 common design features Figure 1: SAM600 module SAM600 process bus I/O system provides unique features with focus on adaptability to different application types, easy installation and maintenance for integration into existing secondary systems or for new installations. SAM600 Process Bus I/O System 5

14 Section 2 SAM600 Process Bus I/O System 1MRK UEN A A SAM600 module per primary apparatus interfaces conventional current or voltage transformers and provides standalone merging unit (SAMU) functionality according to the IEC standard. DIN-rail mountable SAM600 modules with a compact form factor can be placed close to the primary apparatus. SAM600 modules support operating temperature ranges between -40 C to +70 C. Each SAM600 module terminates main signals from the process (for example, voltages and currents), as well as auxiliary signals (fuse failure and test switch indication), thus avoiding cross-wiring and simplifying replacement and maintenance activities. SAM600 modules can be combined into a SAM600 system that scales to the specific needs of the installation in terms of analog interfaces, communication ports, and time synchronization capabilities needed. A SAM600 system can be assembled by connecting the individual modules in a daisy chain or in a High-availability Seamless Redundancy ring for added reliability. A SAM600 system can bridge IEC traffic by simplifying integration with non-conventional instrument transformers. A SAM600 system can externally synchronize to IEEE 1588 (according to profile IEC/IEEE ). In addition, SAM600-TS can synchronize to a 1PPS source, as well as it provides 1PPS outputs for synchronizing other devices. SAM600-TS modules provide redundant process bus connectivity according to the Parallel Redundancy Protocol (PRP) and High-availability Seamless Redundancy (HSR) protocol (IEC :2016).. 6 SAM600 Process Bus I/O System

15 1MRK UEN A Section 2 SAM600 Process Bus I/O System SAM600-CT for conventional current measurements Figure 2: SAM600-CT module A SAM600-CT module has four analog input measurement channels and interfaces conventional current transformers with a 1A or 5A secondary interface (order variant). The measurement chain is calibrated and temperature compensated. Interposing CTs are not required and different ratios can be set as settings in PCM600. The neutral current as provided in the IEC/UCA LE stream can either be measured or calculated as sum of the three phase values. A pre-assigned binary input can be directly wired to a test switch. The input signals a test condition in the IEC/UCA LE stream through a corresponding quality bit in order to allow for blocking conditions in the IEDs receiving the data stream. The polarity of the binary input is configurable. SAM600-CT provides two IEC access points which can be assigned for configured for incoming (bridging) and outgoing IEC LE traffic. SAM600 Process Bus I/O System 7

16 Section 2 SAM600 Process Bus I/O System 1MRK UEN A SAM600-VT for conventional voltage measurements Figure 3: SAM600-VT module A SAM600-VT module has four analog input measurement channels and interfaces conventional voltage transformers with a configurable input voltage between 100V 125V AC (phase-phase) on the secondary interface. The measurement chain is calibrated and temperature compensated. The neutral voltage as provided in the IEC/UCA LE stream can either be measured or calculated as sum of the three phase values. Binary inputs are provided to signal fuse failure and test conditions in the IEC/UCA LE stream through a corresponding quality bit in order to allow for blocking conditions in the IEDs receiving the data stream. Three inputs which can be wired to the secondary contacts of MCBs are pre-assigned to signal a fuse failure per phase. A fourth input is provided to signal a test condition in the stream. The polarities of the binary inputs are configurable. SAM600-VT provides two IEC access points which can be assigned for configured for incoming (bridging) and outgoing IEC LE traffic. 8 SAM600 Process Bus I/O System

17 1MRK UEN A Section 2 SAM600 Process Bus I/O System SAM600-TS for time synchronization and IEC gateway Figure 4: SAM600-TS module A SAM600-TS module provides communication redundancy and time synchronization. The module also has a hardware watchdog functionality. A SAM600 system can run in a free-running mode or synchronize with IEEE 1588 (profile IEC/IEEE ) or 1PPS signal. Conversely, SAM600 can synchronize through SAM600-TS other merging units or IED devices through the five 1PPS outputs available or through the module s connection to the process bus. A SAM600-TS module can be configured to provide IEC access points on each physical port that is not used for SAM600 system bus connection. Access points can be redundant or single link in the following combinations: Up to five single link access points; one of them can support IEEE 1588 time synchronization. One PRP redundant access point and up to 3 single link access points. Either the PRP access point or one of the single link access points can support IEEE 1588 time synchronization. One HSR redundant access point and up to 3 single link access points. Either the HSR access point or one of the single link access points can support IEEE 1588 time synchronization. SAM600 Process Bus I/O System 9

18 Section 2 SAM600 Process Bus I/O System 1MRK UEN A All access points can (externally) receive and publish IEC/UCA LE streams from and to the SAM600 system to bay level protection and control devices. A SAM600-TS module is optional in a SAM600 system. Up to three SAM600- TS modules can be chained into a SAM600 system. Connectors X106 and X107 on the SAM600-TS module can not be used for SAM600 system bus connection. These two connectors can only be configured as IEC access points. 10 SAM600 Process Bus I/O System

19 1MRK UEN A Section 2 SAM600 Process Bus I/O System System functionality Scalable SAM600 system Each SAM600 module with analog inputs (SAM600-VT and SAM600-CT) is a self-contained SAMU and can be used in different IEC process bus architectures. On SAM600-CT and SAM600-VT modules two independent IEC access points are available in order to publish analog measurements according to IEC/UCA LE. On SAM600-TS modules up to five independent access points can be configured, and also in redundant configuration. A SAM600 system can synchronize to external clocks by means of IEEE 1588 Precision Time Synchronization Protocol (see Section 2.1.4), or by the use of a SAM600-TS modules, to 1PPS.. A SAM600 system can be built by chaining up to 10 SAM600 modules through a SAM600 system bus. Alternatively, the modules can be connected as a HSR ring for added communication reliability. A SAM600 system bus ring can use optical and electrical ports on the SAM600 modules. The connected SAM600 modules act as a single SAMU with scalable and configurable IEC access points. A SAM600-TS module is optional in a SAM600 system. A SAM600 system can contain a combined total of seven SAM600- CT and SAM600-VT modules. Up to three SAM600-TS modules can be added to a SAM600 system. Merging and bridging of IEC/UCA LE streams With a SAM600 system, IEC/UCA LE based streams that consists of information provided by individual SAM600 modules can be configured and published on all IEC access points of the SAM600 system. This allows to adapt to various communication architectures and performance requirements of client devices such as IEDs. Sampled value streams from external sources (e.g. optical sensors) can be brdiged through a SAM600 system to several IEC access points. External streams cannot be merged with SAM600 internal streams. Each SAM600 module provides its measurements as IEC/UCA LE compatible stream on the SAM600 system bus. With PCM600, streams can be created with the SV Configurator Tool and are assigned to the available IEC access points of a SAM600 system. Usage of electrical or optical communication ports SAM600 modules can be placed in a single marshaling kiosk or in separate housings in order to achieve close proximity to primary equipment (see Figure 5) and minimize cabling to primary apparatus. SAM600 Process Bus I/O System 11

20 Section 2 SAM600 Process Bus I/O System 1MRK UEN A When installed in the same kiosk, a SAM600 system bus is typically realized through 100BASE-TX ports. When installed in different compartments in the field, the system bus through which SAM600 modules communicate with each other must be realized by 100BASE-FX ports. Binary inputs for process supervision Binary inputs on SAM600 modules are used for secondary system supervision. The inputs are pre-assigned with test switch indication (SAM600-VT and SAM600-CT) and fuse failure indication (SAM600-VT only). Information acquired through these inputs is reflected in the quality information in the IEC/UCA LE streams. The polarity and the input level of the binary inputs are configurable. If the binary inputs of a SAM600 module are not connected, their input processing can be disabled in the Parameter Setting Tool of PCM600. Neutral behavior The IEC/UCA LE telegram definition contains a fourth measurement for both currents and voltages. Depending on the primary equipment and user requirements, SAM600 modules can be configured individually on how the fourth measurement is acquired. Both, measurements of the primary value and summation of measured phases are available. The quality information in the IEC/UCA LE stream will reflect the setting. Time synchronization Analog samples are time synchronized in order to provide the phase accuracy required by IEC Synchronization of a SAM600 system with IEDs is achieved by IEEE 1588 (profile IEC ) or through a 1PPS signal. Internally, a SAM600 system always synchronizes using IEEE The following synchronization methods are supported: Synchronization by IEEE 1588 Access points of a SAM600 system can synchronize against an external IEEE 1588 master clock with an accuracy of 1μs in order to ensure synchronous sampling. Free-running A SAM600 system can operate in a free-running mode with no external time synchronization. The SAM600 system itself synchronizes internally by means of IEEE 1588 in order to ensure synchronous sampling of the analog data. Synchronization by 1PPS A pulse per second (1PPS) from an external clock is used to synchronize a SAM600 system through SAM600-TS module with an accuracy of 1μs in order to ensure synchronous sampling. For details about supported time synchronization configurations, see Section SAM600 Process Bus I/O System

21 1MRK UEN A Section 2 SAM600 Process Bus I/O System On each SAM600-TS module only one single link access point or the redundant PRP/HSR access point can be configured for time synchronization. A bridging-through of time synchronization can be achieved by placing two SAM600-TS modules in a SAM600 system. SAM600 configuration with PCM600 PCM600 Protection and Control IED Manager Software is used for configuring SAM600 modules and SAM600 systems. A SAM600 Connectivity Package provides the user with a wizard-based configuration approach for SAM600 system setup, such as SAM600 module types and topology configuration. IEC access points and relevant IEC/UCA LE stream configurations, as well as specific SAM600 module and system settings are configurable by the user. PCM600 generates a SAM600 system configuration which is downloaded to a SAM600 system by connecting to any SAM600 module through USB and then replicated to the other SAM600 modules in the system. The IEC configuration of a SAM600 system can also be exported and used in IEC system engineering tools. Watchdog The SAM600-TS module provides watchdog functionality. The watchdog is activated during critical system states. For more details, refer Section Cyber security SAM600 modules provide means for minimizing the impact of cyber security attacks such as denial of service or network flooding. By default all unused physical ports and services are disabled in a SAM600 system configuration. For more information refer to 1MRK UEN SAM600 Cyber Security Deployment Guideline document. SAM600 Process Bus I/O System 13

22 Section 2 SAM600 Process Bus I/O System 1MRK UEN A 2.2 Installing SAM600 As depicted in Figure 5 and Figure 6, SAM600 modules can be deployed in a variety of scenarios which optimally suit different installation types. Physical deployment SAM600 modules installed in a single marshalling kiosk in the field (Figure 5a) - All SAM600 modules are installed in a marshalling kiosk which is placed in the field close to the primary apparatus. Cabling from the instrument transformers is terminated at the kiosk and fiber optic is used for communication to protection and control equipment. The kiosk requires station battery supply for powering the SAM600 modules. SAM600 modules installed in several marshalling kiosks (Figure 5b and Figure 5c) - SAM600 modules can be deployed in a physically distributed setup and exchange information over fiber optic communication according to IEC standard. This deployment optimizes proximity to primary apparatus. SAM600 modules installed in secondary system control and protection panels (Figure 5d) - The existing copper cables from primary apparatus can be terminated directly at SAM600 modules mounted in the station panels. This deployment option is ideal for retrofit projects where copper cabling already exists and is not exchanged in a retrofit project. Communication architectures A SAM600-TS module is optional in a SAM600 system setup, but is necessary for 1PPS synchronization requirements (Figure 6a, Figure 6b). The SAM600 system bus can be formed as HSR ring. It is possible to use electrical and optical connections within one ring if the modules are not located in one marshalling kiosk (Figure 6b, Figure 6c). SAM600-TS modules can be configured to join two physical ports into a redundant access point according to the PRP or HSR standard (Figure 6b, Figure 6c). 14 SAM600 Process Bus I/O System

23 1MRK UEN A Section 2 SAM600 Process Bus I/O System (a) (b) 1PPS IED Ctrl 9-2LE 1PPS IED Ctrl 9-2LE 1PPS IED Prot 9-2LE 1PPS IED Prot Station house 1PPS source 1PPS 9-2LE IED Busbar Station house SAM600 TS 9-2LE 1PPS IED Busbar 1PPS 9-2LE SAM600 Process Bus SAM600 TS SAM600 CT SAM600 VT Kiosk SAM600 CT SAM600 VT Kiosk Analog current Analog current Analog voltage Analog voltage (c) (d) IED Ctrl 9-2LE 1PPS IED Ctrl 9-2LE 1PPS IED Prot 9-2LE 1PPS IED Prot Station house 9-2LE 1PPS 9-2LE 1PPS IED Busbar Station house SAM600 TS 9-2LE 1PPS SAM600 CT IED Busbar SAM600 VT SAM600 CT SAM600 TS Kiosk SAM600 Process Bus Analog current Analog current SAM600 VT Kiosk Analog voltage Analog voltage Figure 5: Installation options of SAM600 process bus I/O system SAM600 Process Bus I/O System 15

24 Section 2 SAM600 Process Bus I/O System 1MRK UEN A Figure 6: Communication architectures for SAM600 process bus I/O system 16 SAM600 Process Bus I/O System

25 1MRK UEN A Section 2 SAM600 Process Bus I/O System 2.3 Functional description Distributed analog sampling SAM600-CT and SAM600-VT modules convert analog input values from secondary protection or measurement cores (1A/5A order variant, or 100V-125V AC, settable, respectively) to a digital format transmitted over Ethernet according to IEC , following the UCA implementation guideline Inputs are converted following the IEC standard for protection and operational metering applications. The amplitude accuracy and phase displacements for the analog input channels for both SAM600-CT and SAM600-VT are specified in the SAM600 product guide (1MRK BEN) Communication ports and available services SAM600-CT and SAM600-VT modules have four communication ports (X101 X104). SAM600-TS modules have two additional communication ports (X106 and X107). These ports are used as SAM600 system bus ports for SAM600 system internal communication or as uplink ports for external communication. Table 2 indicates the various services available on different ports. A combination of services can be applied to one physical port, except the SAM600 system bus communication which is exclusive. Table 2: Available services on different ports Service Available ports Comment IEC/IEEE (SAM600-TS only) X101, X102, X103, X104, X106, X107 One single link access point or the redundant (PRP or HSR) access point on a SAM600-TS module can be used for external time synchronization according to IEEE LE publisher or subscriber X101, X102, X103, X104, X106, X107 Available on all ports on all modules of each SAM600 system not used for SAM600 system bus. On SAM600-TS modules two of the available ports can be combined to a redundant access point according to the PRP or HSR standard. SAM600 system bus X101, X102, X103, X104 Modules can be connected in a daisy chain or HSR ring. On each module physical ports can be arbitrarily combined as SAM600 system bus connection. SAM600 Process Bus I/O System 17

26 Section 2 SAM600 Process Bus I/O System 1MRK UEN A Figure 7. shows an example configuration. The SAM600 system consists of four SAM600 modules. Based on the configuration applied, the necessary services are enabled on the related ports. Not configured ports are automatically closed by the configuration. Figure 7: Example configuration Depending on the position of the SAM600 module in the SAM600 system, each SAM600 module is assigned with one or two ports to the SAM600 system bus communication. This also applies when the SAM600 system consists of only one SAM600 module. Kiosk Process Bus to PRP LAN-A X104 X103 X104 X106 (optional with IEEE 1588 time synchronization) SAM600 TS SAM600 TS Process Bus HSR (optional with IEEE time synchronization) Process Bus to PRP LAN-B X101 X102 X101 X107 Kiosk X101 SAM600 CT Redundant SAM600 System Bus X102 SAM600 VT 9-2LE bridge through X104 X103 X104 X LE bridgie through Process Bus (single link, electrical) Process Bus (single link, optical) Figure 8: SAM600 System configured for redundant communication 18 SAM600 Process Bus I/O System

27 1MRK UEN A Section 2 SAM600 Process Bus I/O System Figure 8 depicts a SAM600 system configured for increased communication reliability. The SAM600 system bus is set-up as HSR ring. Note that the ring can span optical and electrical links as it connects SAM600 modules in two different marshalling kiosks. Access points on SAM600-TS modules can be configured as redundant communication links according to the PRP or HSR standard. A combination of optical and electrical links can be used as necessary. Note that each SAM600-TS module supports one redundant access point. Two (three, in case of a SAM600 system bus daisy chain) additional single link access points can be configured on the SAM600-TS module Bridging of sampled values streams Access points in a SAM600 system can be configured for bridging incoming IEC/UCA LE traffic into a SAM600 system to outgoing IEC access points in the SAM600 system, thus acting as switching functionality for IEC/UCA LE traffic. A SAM600 system does not influence nor manipulate any bridged messages. Each SAM600 module can receive a maximum of 8 bridged streams on all its uplink ports. On a SAM600 module up to three IEC access points can be configured for receiving bridged streams. SAM600 Process Bus I/O System 19

28 Section 2 SAM600 Process Bus I/O System 1MRK UEN A Quality information in sampled values streams Sample quality codes Sampled values streams contain a Health information according to IEC in order to indicate the validity of the transmitted information. The quality information contains several attributes: a general validity code (2 bit), a detail quality code/source and a test (14 bit). SAM600 uses the quality attributes as described in Table 3. Table 3: Usage of IEC quality codes in SAM600 Quality attribute Validity Detail Quality Source Test Used value Good (0x0000) Invalid (0x0001) Bad Reference (0x0010) Failure (0x0040) Inconsistent (0x0100) Derived (0x2000) Substituted (0x0400) Test (0x0800) The resulting quality of a measured quantity in an IEC/UCA LE is one out of the two possible validity values. The other quality attributes can be a combination of the possible values. Sample quality indications If a SAM600 module is configured for sending unmerged sampled value streams to its uplinks, then the sample quality of the not contained quantity is set to Invalid (quality code 0x0001) and the sample quality of the contained quantity is set to Good (0x0000). Detail quality values for various conditions are listed in Table 4. Table 4: Quality indications used by SAM600 modules Quality Set under the following conditions Invalid Bad Reference Invalid Failure Invalid Inconsistent Good Substituted Good Test Good Derived Startup sequence of SAM600 module or source stream of quantity for merging not in synch SAM600 is not set to simulation mode and (A/D converter not calibrated or SAM600-VT fuse failure input is active ) Source stream of quantity for merging not detected or sample count not matching SAM600 is set to simulation mode SAM600 is not set to simulation mode and Test switch indication is active SAM600-VT neutral phase and SAM600-CT neutral phase only; if SAM600 module is in simulation mode or neutral phase is set to Calculated 20 SAM600 Process Bus I/O System

29 1KHL UEN Section 2 SAM600 Process Bus I/O System Merging and bridging of SV streams in a SAM600 system The configuration of the SAM600 system regarding assignment of streams to access points is performed with the SV Stream and Port Configuration tool in PCM600 (see Section 3). On each SAM600 module, one or two ports are reserved for SAM600 system bus communication depending on the SAM600 module position within the SAM600 system. The other ports can be used as uplink ports. Each SAM600 module can be configured to send a total of 10 IEC/UCA LE streams to its uplink access points. This may be any combination of merged and bridged streams. The combination of a specific SAM600-CT and a specific SAM600-VT source stream can be sent to multiple uplink ports in parallel, if each of the streams has its own unique Sample Value Identifier (svid) assigned. Each SAM600 module can receive up to 8 bridged streams. These 8 streams can be freely distributed to all uplink ports in a SAM600 system. Forwarding on the SAM600 system bus is not affected by this limitation as a SAM600 module is capable of forwarding any number of IEC/UCA LE streams between its SAM600 system bus ports as long as the bandwidth limitation is not exceeded. A SAM600 module can register up to 8 unique source streams for sending to its uplink ports. These sources can consist of bridged streams taken in on this SAM600 module, bridged streams received on the SAM600 system bus, sampled value stream generated by the SAM600 module itself (SAM600-CT or SAM600- VT), or sampled value streams received on the SAM600 system bus that were generated by SAM600 other modules in the system. Table 5 summarizes the stream number limits on SAM600 modules. The SV Stream and Port Configuration tool in PCM600 enforces these limits. Table 5: Stream configuration limits Stream configuration Maximum quantity Maximum forwarding between SAM600 system bus ports 90 Mbit/s Maximum number of published 9-2LE streams 10 Maximum number of 9-2LE streams received from external publisher 8 Maximum number of unique source streams for merging and/or 8 passing to the uplink ports SAM600 Process Bus I/O System 21

30 Section 2 SAM600 Process Bus I/O System 1KHL UEN Figure 9 shows an example of a SAM600 SV configuration. The SAM600 system consists of four SAM600 modules, three of them generate IEC/UCA LE streams on the SAM600 system bus. Also, the bridged streams Bridged1 and Bridged2 are available on the SAM600 system bus. In this example, the SAM600- TS module has registered five unique streams: the streams generated by SAM600- CT (1), SAM600-CT (2) and SAM600-VT; as well as the bridged streams Bridged1 and Bridged2. It sends five streams to its uplink ports and receives one stream (Bridged1) from an external 9-2LE publisher. Figure 9: Example SAM600 SV configuration 22 SAM600 Process Bus I/O System

31 1KHL UEN Section 2 SAM600 Process Bus I/O System Simulation of sampled values SAM600-VT and SAM600-CT modules support a simulation mode. An individual SAM600 module or all SAM600-VT and SAM600-CT modules of a SAM600 system can be set to simulation mode by selecting the SAM600 Command Simulation Mode in the PCM600 navigation tree on the appropriate level. The simulation mode is not persistent and will revert back to its default value (Simulation Mode off) upon the next restart of a SAM600 module. The simulated values with the quality information Substituted will be processed as valid values by any subscriber. This has to be considered for systems in operation. Sine waves with nominal values and frequency will substitute the measured values. The frequency of the generated sine wave is according to the configuration parameter Power system frequency. The resulting sine wave nominal amplitude is scaled according to the configuration parameter Transducer value on primary. Phase A has a zero-crossing at the full second. Simulated values are merged according to the same rules as measured values (see conditions in Table 4). The values are provided on the IEC61850 access points. The detail quality information of the samples in the IEC/UCA LE stream for simulated data is set to Substituted (see Table 4) Digital inputs SAM600 modules have four digital input channels. These digital inputs have preassigned process supervision functionality as described in Table 6. Table 6: Application usage of digital input channels SAM600 module type SAM600-CT SAM600-VT Digital input 1 Digital input 2 Digital input 3 Digital input 4 Test switch activation level Test switch activation level Not used Not used Not used Fuse failure phase A indication Fuse failure phase B indication Fuse failure phase C indication SAM600-TS Not used Not used Not used Not used The voltage level of the high potential (channel is active) for all channels can be set to different values (24V, 48V, 110V, 125V, 220V DC). The voltage level of the low potential (channel is off) is 0V. SAM600 Process Bus I/O System 23

32 Section 2 SAM600 Process Bus I/O System 1KHL UEN The voltage level can be set as a configuration parameter on SAM600 system level and on the individual SAM600 modules Digital inputs rated voltage in the PCM600 Parameter Setting Tool. The high potential is detected after exceeding 80% of the selected voltage level. The low potential is detected after falling below 20% of the selected voltage level. Configuration parameters Test switch activation level (SAM600-CT and SAM600- VT) and Fuse failure activation level (SAM600-VT only) can configure the polarity for the fuse failure and the test switch indication inputs. Besides the selection of the polarity (active on high potential, active on low potential) with which test switch and fuse failure are detected as active, the input detection can also be disabled by selecting the parameter value Input disabled. In this case, the SAM600 module does not report any indication irrespective of the potential detected on its digital inputs. The default value for the Test switch activation level is High potential. The default value for the Fuse failure activation level is Low potential. The polarity can be configured on SAM600 system level and on the individual SAM600 modules in the PCM600 Parameter Setting Tool. If the digital inputs are not disabled, then their status can influence the quality information of the related samples in the IEC/UCA LE stream (see Section 2.3.6). 24 SAM600 Process Bus I/O System

33 1KHL UEN Section 2 SAM600 Process Bus I/O System Configuration of time synchronization Time synchronization options The time synchronization methods of a SAM600 system are: Synchronization by IEEE 1588 (IEC profile) Free-running Synchronization by 1PPS The sample synchronization field (SmpSync) of the generated SV streams depends on the configured synchronization method and the current state of the system. The SAM600 modules of a system are synchronized to each other always according to IEC/IEEE , which is a profile of IEEE 1588 v2 (PTP). One of the SAM600 modules is PTP Master and all others are PTP slaves, or all of the modules in the system are PTP slaves to an external PTP Master depending on the configured synchronization method. IEC/IEEE (PTP) A SAM600 system can be synchronized to an external time master via PTP by configuring the IEC/IEEE (PTP) time synchronization method. IEC/IEEE time synchronization method has two modes: GrandMaster clock with GPS Master clock In the setting GrandMaster clock with GPS, a SAM600 system expects to receive IEC/IEEE from a time master that has GPS connection. Unavailability of a time master with GPS connection will be indicated by SmpSync field of sampled value streams provided. An example for a GPS synchronized SAM600 system is shown in Figure 10. The 1PPS output from SAM600-TS module can be used for synchronizing client devices such as IEDs that are not directly synchronized by IEE SAM600 Process Bus I/O System 25

34 Section 2 SAM600 Process Bus I/O System 1KHL UEN Use the GrandMaster clock with GPS setup if absolute time synchronization is necessary, or if a SAM600 system needs to be insync with another sample value sources. GPS GM Clock Time Master IED IED IED IEEE PPS 1PPS SAM600 TS SAM600 CT SAM600 VT Figure 10: SAM600 system synchronized to GPS time master via IEC/IEEE In Master clock configuration, a SAM600 system synchronizes freely to the best time master available (selected according to the IEE 1588 best master clock algorithm). SmpSync field of sampled value streams indicate the unavailability of a PTP time master connection. An example of this configuration is shown in Figure 11. The 1PPS output from SAM600-TS module can be used for synchronizing client devices such as IEDs that are not directly synchronized by IEE Use the Master clock setup when the SAM600 system need to be insync with another sample value source but no absolute time synchronization is required. In this configuration, different sample value sources which are synchronized to different time masters and different time domains can cause error condition for the system setup. If sampled value streams from different sources must be in synch then it is recommended to use GrandMaster clock with GPS method, whenever possible. A SAM600 system has configurable PTP Domain Number with range and default value 0. When IEC/IEEE (PTP) time synchronization method is selected, it is recommended that only one domain number is active. Therefore, PTP messages from multiple Domain Numbers should not be received in the SAM600 system. 26 SAM600 Process Bus I/O System

35 1KHL UEN Section 2 SAM600 Process Bus I/O System IED Time Master IED IED 1PPS 1PPS IEEE 1588 SAM600 TS SAM600 CT SAM600 VT SAM600 TS SAM600 CT SAM600 VT Figure 11: Any Master Clock capable device is the Time Master of the whole PTP system via IEC/IEEE (PTP) -Master clock Free-running If IEC/IEEE (PTP) option is selected, all the devices that interconnect the time master with the PTP slaves must support the PTP standard (i.e transparent or boundary clocks). Therefore, in IEC/IEEE (PTP) mode, switches that are used for interconnections must support the corresponding IEEE 1588 v2 features according to IEC/IEEE All SAM600 System bus connections have transparent clock functionality enabled (regardless which of the physical ports X101.. X104 of a module are assigned as system bus ports). Thus, SAM600-TS, SAM600-CT and SAM600-VT modules synchronize to other modules on the SAM600 system bus by IEEE Local Synchronization is the default time synchronization method of a SAM600 system. Based on the IEE 1588 best master clock algorithm one SAM600 module will take the role for the time master of the SAM600 system. A locally synchronized SAM600 system in which a SAM600-TS module takes the role of the time master is shown in Figure 12.. The SAM600 system is free running and not externally synchronized. Prefer this time synchronization option if there is no absolute time synchronization necessary or the SAM600 system does not need to be in-sync with another sample value sources. Sampled value streams which are not synchronized provided by the same SAM600 system (during start-up or error condition) will be indicated by SmpSync field of sampled value streams provided. SAM600 Process Bus I/O System 27

36 Section 2 SAM600 Process Bus I/O System 1KHL UEN IED IED IED 1PPS SAM600 TS Time Master 1PPS 1PPS SAM600 CT SAM600 VT Figure 12: SAM600 IO System synchronized to a SAM600 module Pulse per second (1PPS) synchronization A SAM600 system can be configured to require a 1PPS input as synchronization source. SmpSync field of sampled value streams indicate the unavailability of a 1PPS signal on SAM600-TS PPS input. An example of this configuration is shown in Figure 13. GM Clock IED 1PPS 1PPS SAM600 TS SAM600 CT SAM600 VT Figure 13: SAM600 IO System synchronized to a 1PPS source The 1PPS input of SAM600-TS modules is activated only in this configuration. A loss of 1PPS synchronization source will block the 1PPS outputs of the SAM600-TS modules. 28 SAM600 Process Bus I/O System

37 1MRK UEN A Section 2 SAM600 Process Bus I/O System Handling of sample synchronization in a SAM600 system The SmpSync field denotes the synchronization status of the sampled value stream. According to IEC the possible values of SmpSync are: 0 sampled value stream is not synchronized by an external clock signal 1 sampled value streams is synchronized by a clock signal from an unspecified local area clock 2 sampled value stream is synchronized by a global area clock signal (time traceable, GPS) The sample synchronization value of a sampled value stream that is provided by a SAM600 system depends on the configured time synchronization method and the current synchronization status of the SAM600 system. Table 7 presents the corresponding sampled value stream synchronization options. Table 7: Sample synchronization value based on the SAM600 s configuration and state Time synchronization configuration Sample synchronization value (SmpSync) Health state Fault state IEC/IEEE (PTP) (GPS) (2) (0) IEC/IEEE (PTP) (no GPS (2) or (1) 1 (1) or (0) 2 required) Free running (1) (0) Synchronization by 1PPS (2) (0) 1 The SmpSync value depends on the quality of the current time master. If it has a GPS reception then SmpSync will be (2). Otherwise, it will be (1). 2 The SmpSync value depends on the location where the time synchronization fault occurred. A time synchronization error within a SAM600 system will result in sample synchronization as (0), as shown in Table 7. However, a time synchronization error outside of the SAM600 will not be detected. Therefore, the Sample synchronization value will be (1). IEC/IEEE (PTP) - No GPS required is an advanced configuration. If IEDs compare sampled value streams that originate from different SAM600 systems it is recommended to use GrandMaster clock with GPS setting whenever possible. The other alternative is to synchronize the different SAM600 systems from the same 1PPS source. SAM600 Process Bus I/O System 29

38 Section 2 SAM600 Process Bus I/O System 1MRK UEN A SAM600 module and system supervision Each SAM600 module regularly checks various aspects of its health status. If an issue is detected, a log entry is recorded (see Appendix A). Certain issues are also indicated by the HMI (see Section 7.2.3). Board temperature: The board temperature of the SAM600 modules is supervised. In case a board temperature of 80 C or above is detected, a hightemperature alarm is reported. If the SAM600 module detects board temperature below 80 C, the SAM600 module returns back to normal operating state. Board Calibration: SAM600-CT and SAM600-VT modules check at startup the integrity of A/D calibration. If the check fails a log is created and the condition is reflected in a corresponding status LED (see Section 7.2.3). In addition, the quality information of the IEC/UCA LE stream will indicate this by raising the failure bit (see Section 2.3.4). Digital input voltage detection: If the SAM600 module fails to detect the input voltage on its digital input channels, it reports a hardware error. Sample synchronization status: If the expected synchronization is not achieved (for example, Grandmaster clock with GPS configured and no time master with GPS connection available), the SAM600 module reports a mismatch in its synchronization state. Input stream missing: If the SAM600 module does not detect a stream which the module is configured to receive on the SAM600 system bus, a stream missing condition is reported. Note that Input stream supervision is limited to IEC/UCA LE streams generated by the SAM600 modules in the system. Bridgedtrough streams are not supervised. Link state of network interfaces: The link state (link up/link down) of all network ports is constantly monitored. The detected link state is reflected in a corresponding status LED (see Section 7.2.3). Upon detecting a change in the link state of a port a log entry is recorded. SAM600 system bus link supervision: In addition to link up/link down supervision of physical ports the connection of the SAM600 module to the SAM600 system bus is constantly monitored. In case the SAM600 system bus is configured as HSR ring, a single link failure in the ring is logged and indicated by the neighboring modules. A double link failure in the HSR ring (or a single link failure in a daisy chain SAM600 system bus) will be indicated by all modules in the SAM600 system. IEEE 1588 time synchronization on network interface: Each SAM600 module constantly monitors the exchange of IEEE 1588 time synchronization messages with its device neighbors on the SAM600 system bus and also, if configured, on its 30 SAM600 Process Bus I/O System

39 1MRK UEN A Section 2 SAM600 Process Bus I/O System uplink port. If a message loss is detected, the SAM600 module reports this condition as Peer Delay Error and records a log accordingly. Mismatch of neighboring SAM600 module: Each SAM600 module constantly monitors the communication with its device neighbors on the SAM600 system bus. In each of the following situations the SAM600 module reports a topology error: No neighbor is detected on a SAM600 system bus port that should connect to a neighboring SAM600 module. A neighboring SAM600 module is detected, but its SAM600 module identifier or type is not matching with the system configuration. A neighboring SAM600 module is detected on a port, but according to the system configuration no SAM600 module should be connected. A topology error is indicated by steady light on the HMI (see Section 7.2.3). In addition, a log is recorded. SAM600 Process Bus I/O System 31

40 Section 2 1MRK UEN - SAM600 Process Bus I/O System System error announcement A SAM600 module announces the following locally detected error conditions to all modules in the SAM600 system: System topology error Loss of synchronization to an external clock Time synchronization state not as configured Digital input voltage error (SAM600-CT and SAM600-VT only) SAM600 system bus link error Fatal module failure All modules in the SAM600 system will react to an error condition (locally detected or announced by another module): If a topology error is announced, the SAM600 module will set the red LED to steady ON. If a topology error is announced and the SAM600 module s time synchronization mode is Local, the sample synchronization field value of all sampled value streams (except bridged streams) on all uplink ports of the SAM600 module is set to (0). If a topology error or peer delay error is announced and the SAM600 module s time synchronization mode is Master Clock and the SAM600 module is currently not synchronized to an absolute time source, then the sample synchronization field value of all sampled value streams (except bridged streams) on all uplink ports of the SAM600 module is set to (0). If the sample synchronization field value is set to (0) due to either of the above conditions, then the SAM600-TS module disables all of its PPS output connectors. All SAM600 modules in the SAM600 system return to their normal behavior when the error condition is cleared on the announcing SAM600 module. 32 SAM600 Process Bus I/O System

41 1MRK UEN A Section 2 SAM600 Process Bus I/O System Watchdog functionality A watchdog functionality is available on SAM600-TS. The watchdog is activated in case of a device error on SAM600-TS or a severe error condition announced by any module in the SAM600 system. Error conditions announced in the SAM600 system are listed in Section The SAM600-TS module will operate the watchdog if any one of these conditions is announced in the system or detected locally. Once the error condition is cleared, the SAM600-TS module will automatically reset the watchdog. The watchdog error indication is not sticky. Once the error condition is cleared the SAM600-TS module will reset the watchdog automatically after ca. 20 seconds. In case the SAM600 system bus is configured as HSR ring the behaviour of the watchdog regarding SAM600 system bus link errors is configurable. The parameter Open IRF contact on system bus single redundancy error controls whether the watchdog is operated on a single link error or double link error. Default value of the parameter is FALSE, which means the watchdog is not operated in case of a single link failure in the SAM600 system bus. Due to the communication redundancy of the HSR ring such a single link error has no impact on the system functionality. Nevertheless, the user can set the parameter value to TRUE, in which case a single link failure in the SAM600 system bus will trigger the watchdog. Double link failures, i.e. a module has no connection to the SAM600 system bus on either of its two ports, will always trigger the watchdog. The parameter Open IRF contact on system bus single redundancy error can be configured in the Parameter Setting Tool of PCM600. The parameter is systemwide, i.e. all SAM600-TS modules will operate their watchdog in the same way. SAM600 Process Bus I/O System 33

42 Section 2 1MRK UEN - SAM600 Process Bus I/O System SAM600 system configuration mismatch When configuring a SAM600 system, PCM600 verifies that the configured SAM600 module system matches the detected physical SAM600 module system. The equivalency check requires that the SAM600 module type and SAM600 module identifier match at each position in the SAM600 module system and each SAM600 module is connected to its neighboring SAM600 modules by the same ports as defined in the configuration. If the user attempts to write a configuration to the SAM600 system that is not matching the physical SAM600 module system, then PCM600 issues a warning. The user may still choose to write the configuration. SAM600 modules verify their configuration against the SAM600 neighbors detected on the SAM600 system bus. If a SAM600 module receives a new configuration and the configured SAM600 neighbors cannot be detected within two minutes after startup, then the configuration is discarded and the module reverts back to the Wait for Configuration state. The purpose of this behavior is to reopen all communication ports that may be closed according to the configuration and keep the whole SAM600 module chain reachable for PCM600. The two minute time frame allows all SAM600 modules in the chain to start up and verify their neighboring devices. Once a SAM600 module has verified its neighboring devices, the configuration is accepted as valid. If the SAM600 module detects a mismatch between configured and detected SAM600 neighbors, it announces a topology error. See Section for details on SAM600 supervision and Section for system error announcement. 34 SAM600 Process Bus I/O System

43 1MRK UEN A Section 3 PCM600 Device Configuration Tool Section 3 PCM600 Device Configuration Tool Protection and Control IED Manager PCM600 offers all the necessary functionality to work throughout all stages of the SAM600 life cycle. Planning Engineering Commissioning Operation Functional analysis Specific tool components in PCM600 enable to perform different tasks and functions, and control the whole substation. For more information, see PCM600 documentation. For more information on engineering SAM600 using various tools available within PCM600, see SAM600 Engineering Manual (1MRK UEN). 3.1 Connectivity packages A Connectivity package is a software component that consists of executable code and dta which enables IEC system tools to communicate with a SAM600 system. Connectivity packages are used to create configuration structures in PCM600. A connectivity package includes all the data which is used to describe the IED. For example, it contains a list of the existing parameters, data format used, as well as units and visibility settings of the parameter. In addition, it contains code which allows software packages that consume the connectivity package to properly communicate with the SAM600 system. Update Manager is a tool that helps in selecting the right connectivity package versions for different system products and tools. Update Manager include products that use connectivity packages. Update Manager is a part of the PCM600 installation. SAM600 Process Bus I/O System 35

44 36

45 1MRK UEN A Section 4 Commissioning SAM600 Section 4 Commissioning SAM Safety instructions Safety instructions must be followed as described in this operation manual and as described in document 1KHL UEN. 4.2 Unpacking Upon receiving of the SAM600 modules check for any physical damage sustained during the transport. 4.3 Mounting and earthing connection SAM600 modules are DIN-rail mounted and can be installed horizontally or vertically in a rack or marshalling kiosk. Preferred mounting position is horizontal mounting. The minimum spacing between SAM600 modules, and between SAM600 modules and cable ducts as described in Section 7.1 must be observed. The DIN rails onto which SAM600 modules are mounted must be properly connected to the station earthing system. Use a conductor with a core cross section area of at least 4mm 2 (AWG12). Each SAM600-CT and SAM600-VT module must be connected to protective ground in the cubicle using a ground strap with the protective earthing screw (Section 1.1). 4.4 Electrical wiring Connecting the power supply SAM600 modules are powered with 24V DC voltage. Use only approved DC/DC converters or power supplies. Approved power supplies are listed in SAM600 accessory list (1MRK UEN). SAM600 Process Bus I/O System 37

46 Section 4 Commissioning SAM600 1MRK UEN A The wiring from the cubicle terminal block (station battery) to the DC/DC converter must be made in accordance with established standards for this type of equipment. Wiring from the DC/DC converter to the SAM600 module uses a 3-pin connector. For details on wiring diagrams, see Table 1. Power supply connectors Each SAM600 module has two power supply connectors (X1 and X2). This allows to connect the SAM600 modules to individual power supply units. The two connections X1 and X2 are module internally decoupled to support power supply redundancy. The connectors accept conductors with a cross section area of mm2 (AWG 24-14, Section 7.2.2). The conductors can be of rigid type (solid, stranded) or of flexible type. The fastening screw shall be tightened with a torque of 0.4 Nm. The wires shall be connected to the connector before it is plugged into the SAM600 module, where the connector is then securely tightened with the two screws on each side of the connector. 4.5 Communication wiring SAM600 modules exchange information through the SAM600 system bus and provide IEC/UCA LE process bus traffic through their IEC access points. Synchronization to external source can be achieved by 1PPS or IEC/IEEE (PTP). For details on wiring diagrams, see Table 1. Setting up electrical communication Use Category 5 SFTP cable for electrical communication wiring inside the cubicle. Electrical Ethernet cabling is only allowed inside the boundaries of an individual electrical cubicle or kiosk. It is not allowed to interconnect SAM600 modules between different cubicles using electrical Ethernet cable. Setting up optical communication modules (SFP) Use below recommended fiber optical cables for SAM600 system installations and communication wiring: Glass fibers with gradient index and LC connector (for 62.5/50 µm optical fibers) Diameter of core 62.5/50 µm, sheath 125 µm Maximum permissible attenuation 8 db/6db Rodent protected and longitudinally waterproof if in cable ducts 38 SAM600 Process Bus I/O System

47 1MRK UEN A Section 4 Commissioning SAM600 When laying the fiber optic cables, make sure to observe the permissible bending radius and follow the manufacturer s recommendations. Each SAM600 module has two SFP (small form factor pluggable) cages, which can be equipped with optical SFP modules. Only use the approved SFP modules in order to avoid malfunctioning. Use approved SFP modules listed in Accessory list (1MRK UEN). Depending on the number of IEC access points required for the application and for connecting the SAM600 system bus, insert the required number of SFP modules in the SFP cages of a SAM600 module. When inserting, ensure that the SFP modules are locked with the cage in order to ensure proper functioning. SAM600-TS modules have two additional LC connections (X106, X107) which can be used as additional IEC access points. Do not use Ethernet ports X106 and X107 of a SAM600-TS module as SAM600 system bus ports. This is a configuration setting which is prevented by PCM600. SFP modules meet Class I Laser safety requirements per IEC standard. Do not stare into the beam or view the beam directly with optical instruments. Failure to observe this warning could result in an eye injury or blindness. Connecting 1PPS time sync interface Depending on the application, a SAM600 system can be setup to run as a freerunning system or require an external 1PPS signal from a time master or another merging unit. If an external 1PPS synchronization is required, use port X300 on SAM600-TS to connect a 1PPS signal. SAM600-TS provides five 1PPS outputs, which can be used to synchronize bay level protection and control devices, or 3 rd party merging units, such as the ABB FOCS. The connectors X301-X305 on SAM600-TS provide a synchronized 1PPS output signal. PPS output connectors X301-X305 meet Class I Laser safety requirements per IEC standard. Do not stare into the beam or view the beam directly with optical instruments. Failure to observe this warning could result in an eye injury or blindness. SAM600 Process Bus I/O System 39

48 Section 4 Commissioning SAM600 1MRK UEN A Connecting the configuration interface Use a USBA-A cable on port X105 in order to establish a communication to a PC with PCM600. For setting up PCM600 and appropriate drivers for communicating with SAM600 modules, see SAM600 engineering manual (1MRK UEN). Connecting the SAM600 system bus SAM600 modules can be combined into a SAM600 system by connecting the modules in a daisy chain or ring. The communication link between SAM600 modules is called SAM600 system bus. Each SAM600 module has two pairs of electrical and optical communication ports (X103/X104 and X101/X102 if equipped with LC SFP modules). A SAM600 module can interface to the SAM600 system bus with any two of these communication ports. Edge modules in a daisy chain SAM600 System bus can use one more port as access point to the process bus. It is recommended to use an electrical communication port for connecting to a neighboring SAM600 module deployed in the same marshalling kiosk. For a communication connection that leaves the kiosk an optical communication port should be selected. The ports X106 and X107 on SAM600-TS modules cannot interface to the SAM600 system bus. These two ports can only interface to the process bus. Connecting process bus communication interfaces Optical communication is typically used for IEC process bus communication. For a SAM600 system, ports for IEC communication are defined in PCM600. Depending on the layout and deployment of SAM600 modules, the number of SAM600 modules in a system results in a scalable number of communication ports that are available and can be used for IEC process bus communication. On SAM600-TS modules two communication ports can be joined into an access point with communication redundancy according to PRP or HSR standard (IEC :2016). It is allowed to combine any two of the SAM600-TS module s communication ports into a redundant access point. Configuration of access points is done in the System Configuration Tool in PCM SAM600 Process Bus I/O System

49 1MRK UEN A Section 4 Commissioning SAM600 Use the approved SFP module and fiber optic cables with LC connectors in order to establish a communication connection with bay level protection and control devices. If SAM600 modules are deployed in marshalling kiosks close to the primary equipment in the field, fiber optic patch panels are recommended to terminate the rugged outdoor cable at the entry of the marshalling kiosk and use more flexible optical cable for internal connections. Verify electrical and communication connections After installation, verify that SAM600 modules are correctly connected to the other parts of the protection system. This is done with SAM600 modules and all connected circuits de-energized. Verifying VT circuits Check that the wiring is in strict accordance with the supplied connection diagram. Correct possible errors before continuing to the test circuitry. Execute the following steps for testing the circuitry: Polarity check VT circuit voltage measurement (primary injection test) Earthing check Phase relationship Insulation resistance check The polarity check verifies the integrity of circuits and phase relationships. The check must be performed as close to the SAM600 module as possible. The primary injection test verifies the VT ratio and the wiring all the way from the primary system to the SAM600 module. Injection must be performed for each phase-to-neutral circuit and each phase-to-phase pair. In each case, voltages in all phases and neutral are measured. Verifying CT circuits Check that the wiring is in strict accordance with the supplied connection diagram. Correct possible errors before continuing to the test circuitry. The CTs must be connected in accordance with the circuit diagram provided with SAM600-CT, both with regards to phases and polarity. The following tests shall be performed on every primary CT connected to SAM600-CT: SAM600 Process Bus I/O System 41

50 Section 4 Commissioning SAM600 1MRK UEN A Primary injection test to verify the current ratio of the CT, the correct wiring up to SAM600-CT and correct phase sequence connection (L1, L2, L3, and L4). Polarity check to prove that the predicted direction of secondary current flow is correct for a given direction of primary current flow. CT secondary loop resistance measurement to confirm that the current transformer secondary loop DC resistance is within specification and that there are no high resistance joints in the CT winding or wiring. CT excitation test in order to confirm that the current transformer is of the correct accuracy rating and that there are no shorted turns in the transformer windings. Manufacturer s design curves must be available for the current transformer to compare the actual results. Earthing check of the individual CT secondary circuits to verify that each three-phase set of main CTs is properly connected to the station earth and only at one electrical point. Insulation resistance check. Phase identification of the CT shall be made. Both the primary and secondary sides must be disconnected from the line and the SAM600-CT when plotting excitation characteristics. If the CT secondary circuit earth connection is removed without the current transformer primary being de-energized, dangerous voltages may result in the secondary CT circuits. Verifying the power supply Check that the auxiliary supply voltage from the DC/DC converter remains within permissible input range under all operating conditions. Check that the polarity is correct before powering on a SAM600 system. Verifying binary inputs Check all connected signals and auxiliary supply voltage so that both input level and polarity are in accordance with the SAM600 module specifications. Verifying communication connections Check that SFP modules are plugged in correctly in the SFP cages and are locked. Check that Tx and Rx optical connections on ST connectors (towards bay level protection and control devices) are correct. Check that the minimum bending radius for optical fibers is in accordance with the cable manufacturer s specifications. 42 SAM600 Process Bus I/O System

51 1MRK UEN A Section 4 Commissioning SAM Storing, mounting and disposal Storing SAM600 modules SAM600 modules not immediately installed should be stored in a dry and clean place. It is recommended to avoid extreme temperature fluctuations. Do not remove the module from shipping boxes and do not remove wrapping material. Dismounting SAM600 modules Before carrying out any work on the equipment make sure you are familiar with the electrical safety regulations. De-energize the measurement equipment connected to the analog input connectors of the SAM600 module Remove the SAM600 module s power supply Unplug the digital inputs Remove the wiring from measurement equipment to the terminal blocks of the SAM600 module Remove the network cables from the SAM600 module On the SAM600-TS module remove all 1PPS and 1PPS out connections Remove the SAM600 module from its rail mounting Disposing of SAM600 modules SAM600 modules are electronic devices. While the modules are not hazardous, many countries environmental laws require special handling of old electronic appliances. SAM600 modules can be returned to the vendor, who will properly handle the disposal. The return address can be found in the documents accompanying the SAM600 module. SAM600 Process Bus I/O System 43

52 44

53 1MRK UEN A Section 5 SAM600 System Startup Section 5 SAM600 System Startup 5.1 Start-up behavior SAM600 modules ship with factory default settings. All settings are at their default values (see table Parameter settings in the SAM600 engineering manual for default value of each settable parameter). In factory default settings, SAM600 modules do not send any sampled value streams to any port. The HMI flashes to indicate the Wait for Configuration state. The user has to create a configuration for the SAM600 system, and write the configuration to the SAM600 modules in order to switch on their sampling and merging functionality. The process for creating and downloading a configuration is described in the SAM600 Engineering Manual (1MRK UEN). In factory default settings, SAM600 modules do not publish sampled value streams. Inappropriate settings on the SAM600 modules may lead to misbehavior in protection and control applications due to wrong information transmitted in the IEC/UCA LE sampled value streams. Before powering on a SAM600 module, check the firm wiring of analog and digital inputs. Verify firm grounding of SAM600 modules. SAM600 modules will restart once the configuration is applied, activate all parameter settings, port configurations and SV configurations which are contained in the configuration and then start-up the SAM600 sampling and merging functionality. Steady light of the HMI indicates the Normal Operation state. A new configuration is subject to verification against the physical SAM600 system topology, see Section If a configuration has been downloaded to a SAM600 module, the same configuration is applied each time the SAM600 module starts up. If the command Reset to factory default is applied then the SAM600 module will be reset to its factory defaults and it will restart into the Wait for Configuration state as described above. SAM600 Process Bus I/O System 45

54 Section 5 SAM600 System Startup 1MRK UEN A The SAM600 modules in a SAM600 system can be powered on in arbitrary order. The SAM600 modules will synchronize and automatically detect IEC/UCA LE sampled value streams on the SAM600 system bus. If a valid configuration is available, the SAM600 module starts sampling the analog input values and publishes IEC/UCA LE sampled value streams according to its configuration. During 60 seconds after initialization the sample quality of the locally measured quantity (current or voltage) is forced to Invalid (0x0001). 46 SAM600 Process Bus I/O System

55 1MRK UEN A Section 6 Diagnostics and Maintenance Section 6 Diagnostics and Maintenance 6.1 Maintenance instructions SAM600 modules are self-supervising. If a SAM600 module experiences a problem it will store the information in the event log. It is advisable to read the contents of the SAM600 module s event log during regular intervals and to backup the information in case a later analysis should be necessary. In case of a serious malfunction, the SAM600 module tries to clear the problem by restarting and re-initializing itself several times until it waits in startup mode. Information about clearing attempts is also logged as system events. If the situation cannot be cleared the SAM600 module will block its operation and indicate the error by steady light on the HMI (see Section 7.2.3). The cause of the error is described in a SAM600 event log. Servicing of SAM600 module In case of SAM600 module maintenance, ensure that safety instructions and cabling verification according to Section 4.5 are followed. SAM600 modules in operation can heat up to the ambient temperature in the mounted kiosk. Ensure that the surface of SAM600 module has cooled down to room temperatures. Before servicing a SAM600 module, visually inspect that no wires connecting to SAM600 modules have loosened. Replacing a SAM600 module In case a SAM600 module is damaged it must be replaced. Follow the steps for dismounting the SAM600 module as described in Section 4.6. Contact an ABB representative for replacement or repair handling instructions. Before dismounting a SAM600 module make sure to de-energize all equipment connected to the SAM600 module s analog connectors. Make sure that the SAM600 module s power supply and digital input connection are removed and the module is electrically isolated. SAM600 Process Bus I/O System 47

56 Section 6 Diagnostics and Maintenance 1MRK UEN A The SAM600 replacement module must be mounted according to the installation instructions in Section 4.6. PCM600 can be used to restore the configuration from a backup. After restoring, the SAM600 replacement module will integrate seamlessly into the SAM600 system. 48 SAM600 Process Bus I/O System

57 1MRK UEN A Section 7 Technical Data Section 7 Technical Data 7.1 Module dimensions and mounting distances SAM600 modules come with a compact form factor and are mounted on standard DIN-rails (see Figure 14). SAM600 modules can be mounted both in horizontal or vertical orientation. All SAM600 modules are equipped with a marked safety GND connection point on the left side of the module. Figure 14: SAM600 module (SAM600-VT) Table 8 provides an overview of the dimensions and weights of the SAM600 modules. Table 8: Dimensions and weights of SAM600 modules Dimensions and weights SAM600-CT SAM600-VT SAM600-TS Length (mm) Width (mm) (with/without connectors) 157/ / /132 Height (mm) (with DIN-rail clamp) Weight (kg) < 1.30 < 1.00 < 1.30 Minimum horizontal space (mm) 20 (between modules or cable duct) Minimum vertical space (mm) 50 (between modules or cable duct) SAM600 Process Bus I/O System 49

58 Section 7 Technical Data 1MRK UEN A 7.2 Labels, connectors and indications of SAM600 modules SAM600 module identification All SAM600 modules carry a device label as depicted in Figure 15 allowing to identify a SAM600 module and its basic properties. Figure 15: SAM600-CT device label Table 9 lists the details of the information printed on SAM600 labels. Table 9: SAM600 device label properties Label (Example) SAM TS-DA-P2 O/N 1KHL150031R0110 S/N PP A/N: 1KHL160060R1002D Description SAM600 module order code. See SAM600 product guide for more details SAM600 module order number For internal ABB use only SAM600 module serial number SAM600 module article number For internal ABB use only 50 SAM600 Process Bus I/O System

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