INTRODUCTION TO SYNCHRONIZING

AUTOMATIC SYNCHRONIZING
CONSIDERATIONS AND APPLICATIONS

I. INTRODUCTION
A. Definition
B. Necessity for Synchronizing

II. TYPES OF SYNCHRONIZING

A. Manual
B. Manual with Permissive Relay
C. Fully Automatic

III. TYPES OF AUTOMATIC SYNCHRONIZERS

A. Phase Lock Type Automatic Synchronizer
a. Frequency/Phase Correction Option
b. Voltage Correction Option
c. Dead Bus Option
B. Anticipatory Type Automatic Synchronizer
a. Frequency Matching
b. Boost Pulsing
c. Voltage Matching

IV. SYNCHRONIZING CONSIDERATIONS

A. Generator Size
a. Small Machines
b. Large Machines

V. SUMMARY

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 INTRODUCTION TO SYNCHRONIZING

AUTOMATIC SYNCHRONIZING
CONSIDERATIONS AND APPLICATIONS

INTRODUCTION
It is the intention of this presentation to provide an explanation of the automatic synchroniz-
ing process, to explore the considerations involved and to look at some synchronizing
applications, as well as to provide a guide for selection of the proper synchronizer for the
application.

Definition
Synchronizing, in its simplest form, is the process of electrically connecting additional
generators to an existing bus or on-line generator(s).

Necessity for Synchronizing

The necessity for synchronizing and parallel generator operation is predicated on several
factors that must be considered. They are:

1) When the rated generating capacity of an existing system has been exceeded
by new load demands.
2) When enhanced reliability (multiple generating vs. single unit generating) is to
be considered.
3) When operating efficiency of generator sets is a valid concern (i.e., the ability to
add or remove generating sets as necessary) synchronizing will be required.
4) When the economics of cogeneration and/or peak load shaving is to be
considered.

These additional generators will be connected to operate in parallel to each other and
supply power to the same load. The additional oncoming generators must be paralleled
properly to ensure:

1) The generators supply the proper power to the load.

2) Power transients are minimized.
3) System stability is maintained.

These factors of consideration, along with many others, have increased the utilization of
synchronizing and parallel generator operation. They have also led to the need for more
flexible and sophisticated synchronizing equipment.

The level of synchronizing sophistication is largely attributable to the particular application

in which the equipment is intended to function.

To better understand the synchronizing process, let’s examine an analogy of a typical

facility with on-site power generation shown in the example of Figure 1.

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 Figure 1: Typical industrial facility with its own on-site generators

Let’s assume that this facility has a critical manufacturing process that cannot tolerate a
power failure, or the consequence would be an expensive and lengthy clean-up process.
Due to an open circuit breaker as a result of a fault on Utility Feed B, the plant manager has
decided to start the facility’s own generators and supply the majority of its own power
demands in the event that Utility Feed A also trips and would cause their facility to become
islanded.

The loads connected to the Station Bus (the common power conductors for the facility)
are increasing beyond the capacity of Generators #1 and #2 that are already on-line, so it
is necessary to parallel another generator to provide the power for the increased load. See
Figure 2 for an expanded view of the generator to be synchronized.

Figure 2: Expanded view of the oncoming generator

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The Oncoming Generator (the generator to be put on line) needs to have its Prime Mover
(an internal combustion engine or turbine that turns the generator shaft) started. Once the
prime mover is up to rated speed and the generator is producing voltage at nominal fre-
quency, the operator will need to interpret monitoring devices that help make decisions in
the synchronizing process.

Figure 3: Photo of typical generator control panel

Figure 4: Photo of typical synchronizing meter panel

As seen in Figure 4, synchronizing meter panels are used to provide information to opera-
tors for manual synchronization. The metering devices typically include individual bus and
generator frequency meters for matching frequency, individual bus and generator a-c

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voltmeters for matching voltage, a synchroscope, and two indicating lamps. A voltage
sine wave typically provided from step-down potential transformers (in high voltage appli-
cations) provides the input signal to these devices. Note that single phase, line to line
voltages from the same phases on either side of the generator circuit breaker are used. In
most cases, single phase sensing for synchronizing equipment is adequate, because the
mechanical design of the generator dictates that the three phases of the generator are
displaced 120 electrical degrees apart. Before the generator is synchronized the first time,
it must be confirmed that the phase rotation (a.k.a. phase sequence) of the generator
matches the same sequence as the station bus. Matching the phase sequence can be
accomplished by the appropriate physical connections at the generator terminals or other
suitable locations.

The synchroscope is a multiple parameter information source. It tells you if there is a slip
rate (a frequency difference between generator and bus) and if the generator frequency is
running slower or faster than the bus frequency by causing the pointer to rotate in a coun-
terclockwise or clockwise direction. As seen in Figure 5, the twelve o’clock position indi-
cates 0 degrees phase angle difference. Any instantaneous position of the pointer indicates
the phase angle difference between the bus and generator voltage. Of course, the object of
the synchronizing process is to close the generator breaker at a 0 degree phase angle to
minimize power flow transients when the breaker is closed. Figure 6 illustrates phase angle
displacements of the voltage sine wave.

Figure 5: Synchroscope

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 Figure 6: Phase angle displacements
The most primitive devices used for synchronizing are a pair of incandescent lamps con-
nected to the same phases on either side of the generator breaker as shown in Figure 7.
This demonstrates that if both the generator and bus voltages are “in phase”, there is 0
volts potential difference; therefore, the lamps will not be illuminated, hence, the term “dark
lamp method of synchronizing”. Although simplistic in design, this is a reliable method of
phase angle verification when used in conjunction with a synchroscope to verify there is no
malfunction of either the lamps or synchroscope.

Figure 7: Dark lamp method of synchronizing

In practice, for manual synchronization, an operator will preferably create a very slow slip
rate by adjusting the prime mover speed slightly faster than the bus frequency. This allows
the generator to pick up kW load immediately rather than have the gen-set operate in a
motoring condition when the breaker is closed. Generators typically aren’t operated in the
underexcited condition so as not to risk having the generator pull out of synchronism.
Therefore, it is preferred that an operator adjust the generator voltage slightly greater than
the bus voltage before closing the breaker, so that a small amount of reactive power will be
exported out of the generator when the breaker is closed.
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TYPES OF SYNCHRONIZING
For the purpose of this presentation, we will consider that there are three basic levels of
synchronizing sophistication: 1) Manual , 2) Manual with permissive relay or supervision of
some sort, and 3) Fully automatic synchronizing.

Manual Synchronizing
Manual synchronizing is widely used on a variety of machines. The basic manual synchro-
nizing system includes synchronizing lights, a synchroscope, some means to monitor the
system parameters, and a breaker control device.

With manual synchronizing as described in the analogy above, the operator controls the
speed and voltage of the oncoming generator as well as the closure of the breaker device.

The chief advantages of manual synchronizing are system simplicity and low cost. The
major drawback is that it requires a disciplined operator with enough knowledge to avoid
damage to the machinery.

Figure 8: Manual synchronizing

Manual With Permissive Relay

This level of synchronizing sophistication is identical to that described previously, with the
exception of the addition of a sync-check or sync-verification device (ANSI/IEEE Device 25).
The sync-check device is provided to back up the operator’s decision to close the genera-
tor breaker. In other words, the sync-check device only allows breaker closure to occur
when the phase angle, frequency and voltage are within predetermined limits. Although not
recommended, operators have been known to hold the breaker control switch closed until
the sync-check device permits the circuit breaker close circuit to be energized.

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 Figure 9: Manual synchronizing with permissive relay

Fully Automatic Synchronizing

With fully automatic synchronizing, as its name implies, all functions are provided automati-
cally. The automatic synchronizer (ANSI/IEEE Device 25A) monitors frequency, voltage and
phase angle and provides correction signals for voltage matching and frequency matching
and also provides the breaker closing output contact.

Figure 10: Automatic Synchronizing

TYPES OF AUTOMATIC SYNCHRONIZERS

Fully automatic synchronizers may be either the phase lock type or may be of the anticipa-
tory type.

Phase Lock Type Automatic Synchronizers

The phase lock or phase matching type synchronizer establishes a window of operation as
a result of predetermined set in values for breaker closing angle and voltage acceptance.
When the oncoming generator is within this window of operation (i.e., matched to the bus)
the synchronizer energizes an isolated output contact to initiate breaker closing.

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The phase lock type synchronizer operates on the principle of providing correction signals
to the governor and voltage regulator until the two waveforms are matched in phase and
magnitude and then initiating breaker closure. Until recently this type of synchronizer was
capable of operating only with electronic governors. Today, it is also compatible with other
types of governors that require contact inputs.

Phase lock type synchronizers are intended primarily to be used on a per machine basis.

As the prime mover brings the oncoming generator up to speed, the generated voltage is
applied to the synchronizer. When the voltage reaches 85 Vac, the synchronizer begins to
sense both the oncoming generator and the existing bus for frequency, phase angle and
voltage. Figure 11 shows a block diagram for a phase lock type synchronizer.

Figure 11: Phase-Lock Synchronizer Block Diagram

At this point, the synchronizer senses a rather large difference between the sources for
frequency/phase angle and voltage and begins to give corrective signals to the oncoming
generator in an attempt to match it with the bus.

Frequency/Phase Correction Option (See Figure 12)

When the synchronizer output is a summing point type, bi-polar d-c correction output
signals to the governor are at maximum until the generator frequency is corrected to within
±3 Hz of the station bus frequency. Once the ±3 Hz difference is reached, the output signal
becomes proportional to the difference frequency. In other words, the output correction
signal for a 3 Hz difference is larger than the output signal for a 1 Hz difference.

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When the synchronizer has contact output correction signals, the output contact is closed
for any phase angle greater than the front panel setting. The contact will open when the
phase angle is less than the front panel setting.

Figure 12: Frequency/phase matching with bipolar output

Voltage Correction Option

Operation of the voltage matching option is similar to that of frequency/phase angle match-
ing, except that the correction signal controls the regulation set point of the voltage regula-
tor. When the synchronizer has the summing point output, the synchronizer outputs a
bipolar corrective signal that is proportional to the voltage difference between the genera-
tor and the bus. If the reset jumper is installed, the synchronizer stops sending correction
signals when the generator voltage is within the front panel setting. If external reset con-
tacts are utilized (i.e., auxiliary contact from the breaker), the corrective signals continue
until the external reset contact closes.

When the synchronizer has contact output voltage matching, the contact remains closed
until the voltage difference between the generator and the bus is within the preset limit.
When the voltage difference is within the setting, the contact opens.

Dead Bus Option

The synchronizer may also have the dead bus option included. This option allows the
generator to be connected to the bus even though the bus may be dead or extremely low
(i.e., 10 to 50 Vac) by permitting the breaker to close. This feature is very attractive for
emergency standby systems that require the first generator up to close onto the de-ener-
gized bus.

Anticipatory Type Automatic Synchronizer

The anticipatory type automatic synchronizer monitors the frequency, phase angle and
voltage on both sides of the controlled breaker much the same as any other synchronizer.
However, it also has the added capability to give the breaker close command in advance of
phase coincidence such that the breaker blades close at minimal phase difference. This
capability minimizes system transients.

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The breaker blades cannot close instantaneously; therefore, the synchronizer must have a
way to compensate for the actual breaker closing time as well as for the time spent in
moving the armature of the output relay (0.018 seconds). In order to close the breaker
blades at or close to zero degrees, the synchronizer must, therefore, initiate the breaker
close signal in advance of the synchronism point. In other words, “anticipate” the actual
point of synchronism, hence its name.

The anticipatory type synchronizer calculates the advanced angle that is required to com-
pensate for the breaker closure time by monitoring the slip frequency (frequency difference
between the oncoming generator and the bus) and the set in value for breaker closing. It
additionally factors in the constant of the armature movement (0.018 seconds) to complete
the calculation. The calculation relationship is:

A= 360 (TB+ T R) FS

where

A
= the advance angle, which is the electrical phase angle of the generator with
respect to the system bus when the synchronizer initiates closure of the
controlled circuit breaker.
TB = the circuit breaker closing time. This is the time between the initial application of
the electrical stimulus to the closing circuitry and the actual contact of the
breaker poles. This is considered to be a constant by the automatic synchronizer.
TR = the response time of the output relay, which is approximately 0.018 seconds.
FS = the slip frequency - i.e., the difference between the oncoming generator fre-
quency and the system bus frequency.

Anticipatory Type Synchronizer System Operation

In the synchronizing process, the machine is started and the synchronizer initiated as the
machine comes up to speed. The slip frequency is initially greater than that allowable by
the slip frequency control setting. But as the machine accelerates and approaches the
system frequency, an automatic synchronizing system with speed and voltage matching
capabilities will make the adjustments required to match the machine’s speed to the sys-
tem frequency by stimulating the governor controls. The voltage monitoring portion of the
automatic synchronizer system will attempt to adjust the voltage regulator to bring the
machine’s terminal voltage within the tolerances set on to the synchronizer’s front panel
controls. When the voltage difference between the machine terminals and the system bus
is within the limits established on the automatic synchronizer and the slip frequency is
within the predetermined limits, corrections made by the synchronizing system will cease.
The synchronizer will then calculate the advance angle required to close the breaker
blades for a zero degree phase difference based on the programmed breaker closure time
and the actual slip frequency existing at that point in time. Note that in order for the syn-
chronizer to function properly, there must be a small slip frequency existing between the
system and the generator in order to make the proper calculation.

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 Figure 13: Slip Frequency Advance Angle Characteristic
Figure 13 illustrates the relationship between slip frequency, breaker closure time and the
advance angle required prior to initiation of closure for a zero phase difference across the
blades at the instant of contact.

Modern synchronizers have the capability to precisely match or control both speed and
voltage as well as operate for very slow slip rates.

Units furnished with voltage matching and frequency or speed matching circuits will auto-
matically adjust the voltage and frequency to within limits acceptable to the synchronizer.
Both voltage matching and frequency matching corrections are through relay contacts.

Frequency Matching
The frequency of the machine relative to the bus is important because if the machine fre-
quency is significantly less than the bus, the system must supply the power necessary to
accelerate the machine to synchronous speed. This power flow may result in tripping by
the reverse power relay or damage to the machine itself. On the other hand, if the machine
is rotating faster than the system, the machine will attempt to supply the power required to
accelerate the system. If the frequency difference (FS) is too great, the transient power flow
is reflected into the prime mover shaft, which may result in excessive shaft or coupling
stress.

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 Figure 14: Proportional frequency matching
A significant advancement has been made regarding the problem of hypersensitive gover-
nor control on generators by utilizing proportional speed matching correction pulses.
Several factors inherent to hydro generators such as length of penstock and machine
inertia can cause a synchronizer with fixed correction pulses to repeatedly overshoot
targeted slip frequencies.

A proportional speed matching function such as the F5 option in the BE1-25A will allow
maximum correction pulse width trains at large slip frequencies. Correction pulse width is
then proportionally decreased when slip frequencies become smaller. It eliminates over-
shoots and hunting by responding instantaneously to changes in slip frequency.

In the event that the generator speed is very closely matched but the phase angle between
the generator and bus voltages is excessive, a bump pulse can gently increase the genera-
tor speed and reduce the phase angle.

Boost Pulsing (Refer to Figure 15)

Modern day synchronizers will apply a boost to the governor control circuitry to increase
the machine speed, if the slip frequency falls below the minimum slip frequency capability
of the synchronizer and the relative phase angle is greater than that allowable to close
the particular controlled breaker in a relatively short time. Typically, this boost pulse is
applied when the phase angle between the voltages is 180 degrees. This will increase the
machine speed and slip frequency slightly, thereby decreasing the relative phase angle and
also enabling faster synchronization of the machine.

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 Figure 15: Anticipatory Autosynchronizer Block Diagram
The boost pulse circuitry is a part of the speed matching capability of the synchronizer. The
speed matching feature should be capable of locking onto the generator voltage signal
when the generator frequency is within ±10 percent of the system frequency, at which time
it begins the appropriate corrections.

Voltage Matching
Another consideration in the synchronizing process is the terminal voltage of the machine.
If not matched to the bus voltage, reactive power will flow either into or out of the system at
the instant of breaker closure. If the machine voltage is less than the bus voltage, reactive
power will be drawn by the machine from the system and excite the generator to the volt-
age level of the system. Similarly, if the machine voltage is higher than the bus voltage,
reactive power will flow from the machine into the system. If this voltage difference is too
great, the reactive power flow may result in high transient stresses which could damage the
windings of the machine. Various voltage matching options are available such as continu-
ous contact closure, fixed pulse and proportional pulse contact closure.

SYNCHRONIZING CONSIDERATIONS

Generator Size
For power to flow out of the machine and into the system at the time the breaker contacts
close, it is desirable for larger machines that their speed be slightly greater than the system
prior to synchronizing. Therefore, the synchronizer must be capable of determining that the
machine frequency is greater than the system frequency (i.e., that the slip rate is positive).
However, with small machines, it may be acceptable to initiate closure of the generator
breaker while the machine is slightly slower than the system, providing that the synchro-
nizer parameters are within the preset limits and the machine is accelerating and capable of
accepting load.
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For the intent of this paper, we will refer to small machines as meaning those machines
used for emergency and standby operations and to large machines as those used solely
for power generation.

Small Machines
The need for generator sets as standby power is crucial for the operation of many facilities.
For example, an airport facility would require several engine generator sets to maintain
continuity of service during emergency conditions or supply specific load requirements
during peak demand periods. The load demands as expected at an airport complex would
exceed the generating capability of one generator and would require additional generators
to be connected to the station bus.

Manual synchronizing could be performed by power plant operating personnel. The oper-
ating personnel would manually adjust the frequency and voltage of the generator to be
paralleled and would ultimately close the circuit breaker to tie the generator to the load
bus. This type of synchronizing scheme is quite simple and most economical. However, the
one drawback is that it requires skilled operators at the controls to avoid costly damage to
equipment due to improper synchronizing.

The addition of a supervisory relay to the manual synchronization process can eliminate
improper synchronization. Manual synchronization with a supervisory relay still requires the
operator to manually control voltage and frequency, but the supervisory relay sets up an
operating tolerance that must be equaled before the circuit breaker can be closed to paral-
lel the alternator.

The supervisory relay would compare the slip frequency, phase angle and voltage differ-
ences between the oncoming generator and the station bus. These parameters and some
typical ranges are listed below. The supervisory relay would not close its output contacts
until all system parameters are satisfied.

Parameters Range
Slip Frequency + 0.1 Hertz
Note: Time Delay setting will define maximum slip.
Fs = 2 x Phase Angle Setting
360 x time
Phase Angle 0° to + 30° (adjustment)
Voltage + 4 volts

The relay’s output contacts would be placed in series with the operator’s control switch.
Closure of the circuit breaker would only occur when 1) the operator manually attempts to
close the circuit breaker, and 2) the supervisory relay contacts are closed. This is illustrated
in Figure 16.

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 Figure 16: Breaker Closure with Supervisory Control
A function could be included for the supervisory relay to bypass the sync check function and
close its output contact when it is desirable to close a breaker during a dead bus condition.
A functional block diagram of the supervisory type relay is illustrated in Figure 17.

Figure 17: Sync-Check Block Diagram

Some loads within the airport complex require immediate attention from the standby emer-
gency generator sets. This demand for immediate attention rules out the use of operating
personnel and manual synchronizing.

Because of the importance of restoring electrical power following an emergency outage, a

dedicated synchronizer is desired for each machine. This allows the machines to parallel to
each other as quickly as possible. If the automatic synchronizing equipment includes a dead
bus provision, it will allow one of the machines to pick up the dead bus and start the syn-
chronizing process for the remaining machines.

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For this application, we could use the anticipatory type synchronizer discussed earlier.
However, this type of device is expensive to apply on a dedicated basis to a number of
machines. A sequencing circuit could be used to switch the anticipatory device from one
machine to another, but this adds time to the restoration of system power and complexity
to the overall control circuitry which might not be desirable in this application. So for this
particular job, we would use the phase lock type automatic synchronizer.

By applying the phase lock type synchronizer on a per machine basis, the need for se-
quencing logic is eliminated and each synchronizer/governor/engine combination, together
with the voltage regulating equipment, can be optimized for performance and synchroniz-
ing speed.

Figure 18: Typical Autosynchronizer Interconnect

Up to now, we have seen the need for synchronizing equipment as applied to engine gen-
erator sets for emergency load conditions or peak demand conditions. A majority of these
generators fall within the lower generating capacity levels. For installations with greater
generating capacities, what type of synchronizing equipment is required? What are some
typical applications of these generators and what features are requested with the synchro-
nizer?

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Large Machines
Some typical applications where the larger generators are used are hydroelectric and
industrial cogeneration power facilities. These facilities usually provide power for sale to the
utility. Typical facilities consist of multi-generators operated in parallel.

In these applications, a single automatic synchronizer can be used and shared by all ma-
chines within the installation (See Figure 18).

Some auto synchronizers can be used on multiple-generator systems by switching the

generator sensing voltage and the breaker closing circuit simultaneously from one genera-
tor to the next. The closing time of each breaker of each generator is entered into the
memory of the synchronizer and is recalled by positioning the ganged switch accordingly.

In a hydro installation, the time for the generator to respond to a speed change signal
depends on several factors, including 1) the inertia of the machine, 2) the type of turbine, 3)
the head, 4) length of penstock, and 5) location of the gates. These installations, therefore,
require precise control and typically are synchronized by an anticipating device that pre-
dicts when actual phase coincidences will occur. In installations, it is desirable that the
prime mover is accelerating so that the generator can pick up and supply the load immedi-
ately, In other words, a slip frequency is desired.

In restored hydro installations, it is conceivable that rebuilt circuit breakers may be used
and that each breaker within the installation may have a different operating time. The syn-
chronizer must, therefore, be capable of compensation for these times. Modules are avail-
able in today’s synchronizer to provide this compensation.

Because of the time and precise control requirements of the larger generating systems,
more control adjustment capability is required within the synchronizer.

In critical installations where precise speed matching is required, there are several factors
to be considered in applying an anticipatory type of synchronizer.

First, because of the precise speed matching requirement, very low slip frequencies will be
encountered. The synchronizer must be capable of measuring these small frequency differ-
ences and calculating the required advance angle. This type of synchronizer is also desir-
able from the point of view that it is also recommended that the generator be running
slightly faster than the system to allow the generator to pick up load quickly.

Another part of the synchronizing problem is the precise control of the generator’s speed.
This is accomplished by supplying a correction pulse once per slip cycle. As the slip fre-
quency decreases, the interval between correction pulses increases.

Therefore, by being able to adjust the duration of the correction pulse, extremely sensitive
speed control can be achieved.

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SUMMARY
We have looked at the automatic synchronizing process and explored some of the consid-
erations involved. We have additionally evaluated some applications for automatic syn-
chronizing and seen that there are many different factors that make up the application.
Through all of this, we have tried to establish some kind of guidelines for the selection of
the proper synchronizing system for the application.

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