.

Wiring modifications for Automation

Modifications in sequencer

Sequencer out put Q45-Q59 to be assigned to the following sequencer states. This requires software
modification as shown

Sequence Status Out put relay

Unit at rest available for Start Q45
Unit start in progress( this includes a speed bar gragh) Q46
Unit Isolated Q47
Unit start up Auxiliaries(this includes a speed bar graph) Q48
Unit Start up to speed-no load Q49
Commissioning in progress -Do not Operate Q50-N/A
Unit at speed no load Q51
Unit Synchronising sequence Q52
Turbine to governor power setting-generator ready to load vars. Q53
Unit Stop in progress( Includes speed bar graph) Q54
Turbine at rest Q55
Speed signal fault (Q56) Q61
Caution Test mode Enabled Q57
Battery Faulty Q58 Q62
Self test Q59
Field switch Closed Q61 Q56
Excitation-Build Up failure Q62 Q58

Note that N/O contacts of the relays RL45 –RL59 & RL61-RL62 are already wire to TB2 terminal
45T&B – 59T&B

To generate the following indications wire the Extra N/O contact of the following relays to TB2 the
sequencer failure alarm still has to be engineered

Designation Relay Wire No Terminal

Sequencer failure Q60?? Ax11 Tb2/70T
Ax12 Tb2/70B
Incomplete sequence Q33 Ax13 Tb2/71T
Ax14 Tb2/71B
Auto sync on RL65B Ax15 TB2/72T
Ax16 TB2/72B
Ready to sync RL21 Ax17 TB2/75T
Ax18 TB2/75B
Unit in operation RL41 Ax19 TB2/110T
Ax20 TB2/110B
Acitation In AUTO RL42 Ax21 To be unidentified
Ax22 And recorded
Excitation In RL43 Ax23
Manual/S/ByMan Ax24

On the circuit Breaker control supply cct change the ferrule L200 (TB2 /112T+TB2/113B) and Link
terminal (LK17) to L210 and L201 (TB2/ 94b +TB2/24B) and fuse terminal (FS17) to L211. This is

Automation Wiring ModificationsPage 1 of 11 revised 28/01/02

because L200 and L201 are used in the Unit TX supply available indication circuit advice P2 to
modify drawing as well

Modifications in the Governor

To generate signals for Governor fail and governor fault
Loop L1 in Gov. Panel to terminal 9 on R5&R6 (in governor) and connect L5 to terminals 11 on R5&R6 (in
governor) this will generate the governor fault t signal
Connect L5 to terminal 95 on B50X1.
Connect spare core No 5 in cable 1G006 to L5 and connect the other end onto TB1 in the turbine panel
No the Core No 6 in 1G006 is wired to B50x1:116 is labelled L26 mistakenly, change ferrule to L4 and
connect the other end onto TB1 in the turbine panel

R5 B50X1. Turbine panel

9 11 B50X1.95 L5

R6
9 11 To New relay panel

R7 B50X1.116 L4

R8
To New relay panel

L1 B50X1.118

Automation Wiring ModificationsPage 2 of 11 revised 28/01/02

 Analogue signals- Transducer connections

Single pair twisted screened cables to be used for the transducer out puts the cable s to run
from the transducers to the S800 remote I/O box

Voltage transducer connections

Out put
E51a`` Voltage 4-20mA
TB2 Transducer
110 V from VT
TB2 E11a

Temperature Indications

Check the indicator manual for terminal Numbers for the analogue outputs

Temperature Indicator

4-20 ma analogue output

Temperature sensor

Pressure indications

The pressure traducers available are the Two wire transducers rated for 24 V input and 4-20
ma output connections as shown below.

Transducer connection for Two wire transducers for measuring pressure

+24V Trans
ducer
-VE Bn 4-20mA signal
4-20mA
S800
analogue
Input An
Channel-n
n

Automation Wiring ModificationsPage 3 of 11 revised 28/01/02

Modifications in the Annunciator

For the following signals going to the control room loop from the terminals indicated to the
spare cores in the 37 core linking the remote control junction box to the Annanciator
terminate the spare cores on free terminal on the Annanciator

Wire No Loop to core Designation

in 37 core
cable to
Annanciator
Unit Tx C02 Isolated
X60 Unit Tx C02 released
X56 Unit Tx 380V earth
fault
Common

For the Alarm supply fail alarm wire the N/O contact on the DCF (terminal 9&11) relay
wire No’s Ax7 & Ax8
For the Emergency drain pump Running Alarm supply fail alarm wire the N/O contact on
the EDPRR(terminal 9&11) wire No’s ax9 & ax10
For the SDR operated alarm use the spare contacts on the SDR wire No Z79 and Z100

Top cover High water Level Alarm

Use one N/O contact on the TCHWL relay or wire another relay of there is no volt free
contact available .Use wire No’s Ax5 & Ax6

Auto/Manual Indication

Use free N/O contact on 43A wire No’s Ax1& Ax2 to be wired to TB1on turbine panel

Remote Local indication

Use free N/C contact on 43B wire No’s Ax3& Ax4 to be wired to TB1on turbine panel

Modify the wiring for the sequence input I03 so as to introduce a relay contact in serIes as
shown below to facilitate reset of the auto-synch from remote

43B
W1143

Seq input I03

TB2 W1145

W1145A -Tb1 TB1

Auto sycnh Reset Relay

Automation Wiring ModificationsPage 4 of 11 revised 28/01/02

 Water Flow Metering.

The output of the water flow transmitter is to be connected in series with one analogue input
channel ch14 as shown below

Protronic
Display Unit

Water 1
flow
transmit 2 3
ter

S800
Terminal 2 &3 to remain Analogue
Bridged until S800 is powered input
channel

Lake Level and Tail Race level Measuring Equipment

The signal for the lake level and the Tailrace level to be connected to the S800 on Unit one.
AI channels 15 & 16. These are two wire transducers to be connected the same way as the
pressure transducers show above.

Automation Wiring ModificationsPage 5 of 11 revised 28/01/02

 Installation of Tail water level measuring Transducer

Road

Existing Holes

Tail race 1 Tailrace 3 Tail race 5

Tail Water level transducer to be installed in pipe to be installed in this hole

Weather proof connection box

Supporting Flange for

Shielding Pipe
No 1 tail race opening

Tail Water level variation: appr (379.40m- 385m)-nominal

Up to 392 with 2flood gates open & Up to 401.9m at full flood

- - - - - - - - -
- - - - - - -
Water in Tail Race
- - - - - - - - -
- - - - - -

- - - - - - -
- - - - - -
Level sensor Shielding Pipe

Automation Wiring ModificationsPage 6 of 11 revised 28/01/02

 Installation of Lake Level Measuring Transducer at
Intakes -Option 1

Weather-Proof connection box

Supporting Bracket for

Shielding Pipe

Top of dam wall

- - - - - - -
- - - - - -
Water At intakes
- - - - - - -
- - - - - -

- - - - - - -
- - - - - -
Level sensor Shielding Pipe

Lake Water Level Variation: Approximate (475.5m- 485m)-nominal

& Up to 487.m at full holding capacity.

Automation Wiring ModificationsPage 7 of 11 revised 28/01/02

 Installation of Lake Level Measuring Transducer at
Intakes -Option 2
Connection box

Water level Stop Log Slot

1.25 Intake platform

1.0

------------ - - - - - - - - - - - - - - -
- - - - - - - - - - - -- -- -- ---
-- - ----- -- --- - - sensor cable

Sensor

Pipe to protect sensor to be gouted to the cencrete

Intake tunnel

Intake rake

Automation Wiring ModificationsPage 8 of 11 revised 28/01/02

Automation Wiring ModificationsPage 9 of 11 revised 28/01/02
 Wiring and hardware modifications to be implemented 11/04/02

Original
DI Description ca Alarm Name in Dbase Dbase Channel Relay Test Points Test Points S800
No ble /indic No Relay coil Relay coil ccabl
ation e
termi
nal
14 Trip CCT fail Alarm 2 Alarm G5A51-PROT6 DI800_51.14 R14 U1007 U1008 566 569 566 569
19 Excitation Build up failure 3 Alarm G5AG6-EX1 DI800_52.3 31TX N/A N/A 1721 1722 572 586
26 Air flow failure 3 Alarm G5AG6-EX8 DI800_52.10 44AAF& N/A N/A U1021 U1022 579 586
44BAF
37 Field contactor closed 3 Ind G5AG6- DI800_53.5 41X & N/A N/A 1723 1724 591 603
EXFCC Q61
38 POWER SYSTEM Stabiliser 3 Alar G5AG6- DI800_53.6 98F N/A N/A U1051 U1052 592 603
failed EXFCO
39 Standby control/ manual 3 Ind G5AG6-EX19 DI800_53.7 43SXE N/A N/A Ax23 Ax24 593 603
control
56 Speed signal fault 4 Ind G5A32-SEQ17 DI800_54.8 Q56 N/A N/A 1711 1712 611 620
58 Battery Faulty 4 Ind G5A32-SEQ19 DI800_54.10 Q58 N/A N/A 1715 1716 613 620
97 Alarm supply fail 6 Alar G5A14-COM7 DI800_57.1 DCFFl Ax7 Ax8 650 654
m
93 Unit Txco2 isolated 6 Ind G5A51- DI800_56.13 R49
PROT12

Automation Wiring ModificationsPage 10 of 11 revised 28/01/02

 Proposed Modifications
DI Description ca Alarm Name in Dbase Dbase Channel Relay Test Points Test Points S800
No ble /indic No Relay coil Relay coil ccabl
ation e
termi
nal
14 Trip CCT fail Alarm VT 2 Alarm G5A51-PROT6 DI800_51.14 R14 U1007 U1008 566 569 566 569
fail/ Exciter Trip to
man
19 Excitation Build up failure 3 Alarm G5AG6-EX1 DI800_52.3 31TX N/A N/A 1721 1722 572 586
(Q58) 1715 1716
26 Air flow failure Thyristor 3 Alarm G5AG6-EX8 DI800_52.10 44AAF& N/A N/A U1021 U1022 579 586
cooling failure 44BAF
37 Field contactor closed 3 Ind G5AG6- DI800_53.5 41X & N/A N/A 1723 1724 591 603
EXFCC Q61 1711 1712
Q56
38 Field Contactor Open- 3 Alar G5AG6- DI800_53.6 98F N/A N/A U1051 U1052 592 603
POWER SYSTEM Stabiliser EXFCO
failed
39 Standby control- Standby 3 Ind G5AG6-EX19 DI800_53.7 43SXE N/A N/A Ax23 Ax24 593 603
control / manual control
56 Speed signal fault 4 Ind G5A32-SEQ17 DI800_54.8 Q56 N/A N/A 1711 1712 611 620
Q61 1723 1724

58 Battery Faulty 4 Ind G5A32-SEQ19 DI800_54.10 Q58 N/A N/A 1715 1716 613 620
Q62 1721 1722
93 Alarm supply fail- Unit 6 Alar G5A51- DI800_56.13 DI800_57.1 R49
97 Txco2 isolated m PROT12
G5A14-COM7
97 Unit Txco2 isolated Alarm 6 Ind G5A14-COM7 DI800_57.1 DI800_56.13 DCFFl Ax7 Ax8 650 654
93 supply fail- G5A51-
PROT12

Automation Wiring ModificationsPage 11 of 11 revised 28/01/02