Instruction manual

Synchronisation unit
CO3212-6V
 Instruction manual
Synchronisation unit
CO3212-6V
 Instruction manual
Synchronisation unit
CO3212-6V

1. Preface ............................................................................................................................................... 1
2. Legal information ............................................................................................................................... 2
2.1. Liability limitations ....................................................................................................................................... 2
2.2. Copyright/authorisation............................................................................................................................... 2
2.3. Name and address of manufacturer ............................................................................................................ 2
3. Target groups ..................................................................................................................................... 3
4. Basic safety instructions ..................................................................................................................... 4
4.1. Symbols used ............................................................................................................................................... 4
4.2. Safety information ....................................................................................................................................... 4
5. Description of module ...................................................................................................................... 10
5.1. Product brand and model .......................................................................................................................... 10
5.2. Applications and stipulated use ................................................................................................................. 10
5.3. Technical data ............................................................................................................................................ 11
5.3.1. CO3212-6V (3 x 400 V/50 Hz) ..................................................................................................................... 11
5.3.2. CO3212-6V2 (3 x 220 V/60 Hz) ................................................................................................................... 11
5.3.3. CO3212-6V6 (3 x 400 V/60 Hz) ................................................................................................................... 11
5.3.4. Environmental conditions .......................................................................................................................... 11
6. Terminals and controls ..................................................................................................................... 12
7. Commissioning ................................................................................................................................. 13
7.1. Wiring examples......................................................................................................................................... 13
7.1.1. The synchronising light method ................................................................................................................. 14
7.1.2. The synchronising dark method ................................................................................................................. 15
7.1.3. Three-lamp circuit ...................................................................................................................................... 16
8. Maintenance and cleaning ................................................................................................................ 17
8.1. Maintenance and customer service ........................................................................................................... 17
9.1. Spare parts ................................................................................................................................................. 17
9. Disassembly and disposal ................................................................................................................. 18
9.2. Decommissioning ....................................................................................................................................... 18
9.3. Disassembly and disposal ........................................................................................................................... 18
10. Copyright.......................................................................................................................................... 19
 Instruction manual
Synchronisation unit
CO3212-6V
 Instruction manual
Synchronisation unit
CO3212-6V

1. Preface
This instruction manual is written to be read, understood and complied with in every respect by persons intending
to use the training system.

It contains basic tips and instructions to be observed during assembly, operation, maintenance, disassembly and
disposal involving the training system.

For that reason, this manual must be read through carefully before assembly by any teaching staff, students or
other users. Only the information in this manual can prevent errors and ensure faultless operation.

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2. Legal information

2.1. Liability limitations

LUCAS-NÜLLE GmbH accepts no liability for any damage occurring due to the following:

 Inappropriate or incompetent use

 Irresponsible or incorrect assembly and/or commissioning by operators or third parties
 Subsequent modifications by operators or third parties
 Natural wear and tear
 Negligent or incorrect handling, servicing or maintenance
 Actions not in keeping with the instruction manual
 Use of inappropriate materials

2.2. Copyright/authorisation

This instruction manual is authorised for the use of teaching staff and students.

The instruction manual contains specifications and drawings of a technical nature. These may not be reproduced
distributed, utilised without permission for competitive advantage or passed on to others either in part or in full.

The making of copies, including extracts, is expressly permitted to users of the training system, but only for
internal use in connection with the operation of the equipment.

2.3. Name and address of manufacturer

LUCAS-NÜLLE GmbH
Siemensstr. 2
D-50170 Kerpen

Tel.: +49 (0) 22 73 5 67-0

Fax: +49 (0) 22 73 5 67-30

E-Mail: info@lucas-nuelle.com
www.lucas-nuelle.com

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3. Target groups
Those groups at whom this instruction manual is targeted are described as listed in the following:

Target groups - Tasks - Qualification

Target group 1 Tasks Qualification

Training staff  Supervision of students  Electrician

 Teachers
 Trainers
 Educational assistants
 Laboratory supervisors
 Set-up of training system
 Providing students with an initial
introduction to the training systems
 Providing safety instructions for
students
 Enabling power supplies
 Rectification of minor faults
 Observation of procedures
 Recognition of faults and safety
problems and guaranteeing correct
functioning of processes related to
the training system

Target group 2 Tasks Qualification

Students  Set-up of training system  Must have had some electrical

 Modifications to training system set- instruction
 Trainees up  Person with specific previous
 Students  Switching training system on and off instruction and reading and writing
skills in the language of their country
 Work placement trainees  Rectification of minor faults
 Introduced to the training system by
 Observation of procedures
teaching staff
 Recognition of faults and safety
problems and guaranteeing correct
functioning of processes related to
the training system

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4. Basic safety instructions

4.1. Symbols used

Hazard symbols

Degree of risk Application

This symbol means there is a direct risk to life and health of people. Ignoring this
warning can result in a serious effect on the health of persons and may result in
life-threatening injuries.

This symbol means there is a direct risk to life and health of people. Ignoring this
warning can result in a serious effect on the health of persons and may result in
life-threatening injuries.

This symbol provides important advice on the proper and economic use of the
training system. Ignoring this warning can result in slight injuries or adverse
effects on health or may result in damage to the training system or its
environment.

4.2. Safety information

The training system is designed and constructed with the latest technology and according to recognised safety guidelines.
Nevertheless, incompetent or unauthorised use of the equipment may result in risks to life and limb of users or third parties
or to damage to the training system itself or to other equipment.
The training system may only be used if it is in technically perfect operating condition and following specified procedures with
attention paid to aspects of safety and risk. Any faults which may adversely affect safety must be rectified immediately.

This instruction manual must be stored close to the training system itself and be accessible by anyone at any time.

Validity

Apart from definitive laws of the user's respective land, and the safety guidelines applicable for operation,
maintenance and assembly of equipment as set forth by the educational establishment or company involved, the
following instructions must be observed.

Any person given responsibility for the operation, set-up, maintenance or repair of the training system must have
read and understood the relevant instruction manual and any experiment instructions.

The valid regulations for prevention of accidents should be stored within view in the vicinity of the training system
and should be accessible to anyone there. Regular instruction of users must be undertaken by those responsible
for the equipment.

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Modifications

Reconfiguration and/or modification of the training system by users may only be undertaken with the consent of
the supplier. The supplier assumes no liability for any measures taken without that consent or for any damage
resulting therefrom. This includes any use of the training system that contravenes the instruction manual (during
assembly/set-up modifications and conduct of experiments using the training system).

Prevention of accidents during operation

The training system is safe to use if the instructions are adhered to correctly and the equipment uses the latest
technology. Danger may only occur under the following circumstances:

 Use of the training system by persons with no electrical instruction

 Incorrect operation of the training system
 Use of the training system that contravenes the instructions

Operators

All the safety features and operating instructions provided by the manufacturer are to be regarded as prerequisites for the
safe operation of the training system and for avoiding accidents.
The operator and teaching staff are responsible for the prevention of accidents when using the equipment. Staff should be
fully conversant with their tasks relating to use of the training system.

The operator must guarantee the following:

 Training staff are sufficiently trained for their specific task in relation to safety regulations
 Safety regulations for the workplace are made known to training staff and students and this action is
documented
 Safety regulations are available for inspection at any time
 Safety regulations are obeyed

Electrical installations must meet the valid local standards. In particular, suitable earthing connections must be provided for
the training system.

Legal regulations for the prevention of accidents

Apart from the regulations specified here and all the contents of this instruction manual, as signified by hazard
symbols, the following general guidelines are also binding for the use of the training system:

 Safety regulations for EU member states

 Relevant safety regulations in countries outside the EU

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Training system users

The training system is manufactured using the latest technology. It is safe to use and should be operated
appropriately by persons who have received electrical instruction under supervision of qualified teaching staff.

Non-compliance may result in risk to life and limb for the operator or for third parties, damage to the training system or other
equipment and may endanger the efficient use of the training system.

Function checks, maintenance work

Regular function checks and maintenance work advance safety.

Training staff should check the training system before use for any visible damage or shortcomings. Any changes
which may affect safety should be rectified at once.

The training staff is responsible for maintaining the training system in perfect condition at all times.

Maintenance and cleaning work are not permitted when the training system is in operation.

Protective systems

Existing protection may only be removed during the course of setting up an experiment with the power supply
turned off and must be properly replaced after the work is completed.

Ensuring safety of the workplace

During upkeep, cleaning and reconfiguration of the training system, the workplace should be protected
appropriate to the circumstances.

Power should be turned off and protection provided to stop it being turned back on.

Electrical components that cannot be turned off must be protected from being turned on by removal of fuses.

The housing and rear of the devices may not be covered since this may lead to impermissible heating of the
equipment and to the possible failure of the training system.

Fuses may only be removed and replaced by authorised personnel!

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Safety equipment

Safety equipment may not be modified, removed or rendered inoperable. Unprotected elements may cause life-
endangering injuries.

All safety equipment, such as safety switches, covers and barriers must always be functional. The operation of the
training system is not permitted if the safety equipment is faulty or missing. Correct functioning of the necessary
safety equipment must be checked before starting the training system.

Personal safety

For your own safety, the necessary protective clothing and equipment must be worn.
It is not permissible to wear loose clothing or jewellery that become trapped within the training system. Long hair should be
bound with a hair net.
Prohibition of gloves: when working next to moving or rotating pieces of equipment, gloves may not be worn.

Persons under the influence of drugs, alcohol or medication capable of affecting reactions are prohibited from operating,
maintaining or repairing the training system.

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Protection of the feet

Danger of crushing!

Panels have sharp edges and could fall on people's feet if not correctly handled.
Always wear appropriate, safe footwear.

Specific safety instructions

Danger due to electric current

Incorrect earthing of the training system may lead to life-endangering current flows.
The training system must be earthed as stipulated
Devices with a plug-in mains power supply will be earthed via the power supply itself. Devices not powered by such
equipment must be connected to an earth conductor via the green/yellow sockets.

Danger due to electric current

It should be observed that the plugs for the training system (cables and sockets) are always connected to the correct, identical
colours and patterns.
Use the green/yellow sockets exclusively for earth connections.
Only use green/yellow cables for the earth connection

Danger due to electric current

Incorrect use of the supplied power cable can lead to life-endangering flows of current.
The training system may only be used with the supplied cabling.
Always use safety cabling and safety plugs.
Make sure that the measuring cables are in perfect condition.
All experiment cables must have continuous double insulation throughout their length.

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Danger due to electric current

The training system may only be used in circuits protected by fuses or circuit breakers with a maximum rating of 16 A.

Danger due to electric current

Use the equipment in the training system only at the specified operating voltages.

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5. Description of module

5.1. Product brand and model

The synchronisation unit training panel comprises 5 independent displays (double voltage meter, zero voltage
meter, synchronoscope, double frequency meter and 3 lamps) for determining suitable times for synchronisation,
in order to switch a synchronous generator into an existing power network, for example. The built-in four-pole
power switch allows three phases and a control voltage to be switched on.

The following experiments can be conducted:

• Determining a suitable time for synchronisation using the synchronising light method and the
synchronising dark method or a three-lamp switching circuit at known frequencies and voltages for the
mains and the generator

• Determining a suitable time for synchronisation using a double voltage meter, a zero voltage meter or a
synchronoscope

5.2. Applications and stipulated use

The synchronisation unit described in the instruction manual is a training system exclusively designed for
educational purposes to be used solely in schools, universities, training establishments and other educational
institutes for the teaching of electrical engineering and power engineering (see Section "5.1. Product brand and
model").

The training system is only authorised to be used in rooms that fulfil the local regulations for education and
training.

The training system can only be operated within the bounds as stated in the technical data.
Any other use or any use which exceeds the specifications is in contravention of regulations.
LUCAS-NÜLLE GmbH assumes no liability for any damage resulting from such use. The user alone is liable for all risks.
Use of the equipment as per regulations involves constant observation of the specifications in the supplied instruction
manual.

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5.3. Technical data

5.3.1. CO3212-6V (3 x 400 V/50 Hz)
Nominal voltage: 3 x 400 V
Current: 10 A
Frequency: [47, …, 53] Hz
Dimensions: (297 x 452 x 125) mm (HxWxD)
Weight: 2 kg

5.3.2. CO3212-6V2 (3 x 220 V/60 Hz)

Nominal voltage: 3 x 220 V
Current: 10 A
Frequency: [57, …, 63] Hz
Dimensions: (297 x 452 x 125) mm (HxWxD)
Weight: 2 kg

5.3.3. CO3212-6V6 (3 x 400 V/60 Hz)

Nominal voltage: 3 x 400 V
Current: 10 A
Frequency: [57, …, 63] Hz
Dimensions: (297 x 452 x 125) mm (HxWxD)
Weight: 2 kg

5.3.4. Environmental conditions

Max. relative humidity: 60%, without condensation
Max. ambient temperature: 35°C
Orientation when in use: Vertical (wiring cover facing the rear)

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6. Terminals and controls

1. Double voltage meter: Left-hand side VMains, right-hand side VGenerator (phase-to-phase/line-to-line
voltage). Before synchronisation, both values need to be nearly identical.
The needles can be recalibrated by means of the white plastic screws on the front.
2. Zero voltage meter: This measures the difference between VMains and VGenerator for a single phase. Before
synchronisation, this value should be close to 0 V.
The needle can be recalibrated by means of the white plastic screw on the front.
3. Digital synchronoscope: The display shows the phase angle between VMains and VGenerator. When the display
is rotating clockwise, the generator frequency is higher (more positive) than the mains frequency. Before
synchronisation, the green LEDs at the top of the circle need to be almost permanently lit.
4. Double frequency meter: fMains (I) and fGenerator (II) can be read off from the most active oscillating
measuring bar. Before synchronisation, both frequencies need to be almost identical.
5. By means of the three lamps, it is possible to construct circuits for determining the correct time for
synchronisation. Circuits most worthy of mention in this regard include the light method, dark method
and three-lamp circuits. The sockets for the three live conductors provide the power for the lamps (see
example in Section “7.1. Product brand and model")
6. Power switch: Connects the three live conductors and the control contact Sync. The neutral conductor is
permanently connected.
7. Network terminals: 4-mm safety sockets for (from top to bottom) L1, L2, L3, N and PE.
8. Generator terminals: 4-mm safety sockets for (from top to bottom) L1, L2, L3, N and PE.

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7. Commissioning

It is essential to take note of Section 4.2 “Safety information”

Before it is put into operation, the laboratory set-up should be fully connected and ready to run.

 Wire the synchronisation unit as in the following examples.

 Determine before switching on the maximum values for current and voltage.
 Make sure the wiring is correct when you are connecting it up.

7.1. Wiring examples

This section includes wiring examples for connecting up the synchronisation unit. All that ever changes is the way
the lamps are connected. The four other meters are permanently connected and need to be taken into account in
addition to the lamps.

If the three lamps do not behave as described, the directions of rotation of VMains and VGenerator are probably the
wrong way round. If this happens, you should first check whether VMains and VGenerator are actually rotating in the
same direction.

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7.1.1. The synchronising light method

When the synchronising light method is used, the correct time for
synchronisation is determined when all three lamps are lit to their
brightest extent. Between phase angles of 0° and 360° (between VMains
and VGenerator) all the lamps grow lighter and darker simultaneously.

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7.1.2. The synchronising dark method

When the synchronising dark method is used, the correct time for
synchronisation is determined when all three lamps are completely off.
Between phase angles of 0° and 360° (between VMains and VGenerator) all the
lamps grow lighter and darker simultaneously.

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7.1.3. Three-lamp circuit

A three-lamp circuit is slightly different from the other two circuits.

Between phase angles of 0° and 360° (between VMains and VGenerator), a
light “pointer” rotates in a circle. In the set-up illustrated at the bottom
below, the correct time for synchronisation is given when the lamp at the
bottom is not lit and the ones at the top are.

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8. Maintenance and cleaning

8.1. Maintenance and customer service

9.

It is essential to take note of Section 4.2 “Safety information”.

The address for customer service can be obtained from your local dealer.

The address of the manufacturer is found in Section 2.3.”Name and address of manufacturer”.

9.1. Spare parts

LUCAS-NÜLLE GmbH assumes no liability whatever for any damage caused by the use of spare parts or accessories not
supplied by us and any guarantee is thereby invalidated.
See the Section 4.2 “Safety information”.

Ordering spares from LUCAS-NÜLLE GmbH

When ordering spares, please provide the following data:

 Article number
 Order number/delivery date
 Name of the spare part
 Number of spare parts required

The address for our spare parts sales department can be found in Section 2.3.”Name and address of
manufacturer”.

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9. Disassembly and disposal

9.2. Decommissioning

The specifications under “Section 4 “Basic safety instructions” must be obeyed at all costs.
Non-compliance may result in:
Risks to life and limb of the operator or third parties
Depreciation of the training system, of individual products or other equipment
Risk to the efficient operation of the training system

9.3. Disassembly and disposal

Disassembly

The equipment may only be disassembled by qualified personnel!

Disposal

Components must be disposed of according to the regulations stipulated by the responsible legal authority.

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10. Copyright

1 st edition

Copyright © 2013 LUCAS-NÜLLE GmbH.

All rights reserved.

This instruction manual is protected by copyright and may not be reproduced in any form, as a photocopy, on
microfilm or by any other method or copied to a format readable by machines, in particular computers, without
the specific written permission of LUCAS-NÜLLE GmbH. Any changes made without the consent of LUCAS-NÜLLE
GmbH or its authorised agents invalidate all liabilities of the manufacturer and any guarantee claims.

Made in Germany

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Lucas-Nülle GmbH
Siemensstraße 2 · D-50170 Kerpen-Sindorf
Telefon +49 2273 567-0 · Fax +49 2273 567-30

www.lucas-nuelle.com