ABB SAM600 Series Operating instructions

Grid Automation Products

SAM600 Process Bus I/O System

Version 1.2

Operation Manual

Document ID: 1MRK 511 434-UEN

Issued: May 2019

Revision: B

Product version: 1.2

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 511 437-

BEN SAM600 Product Guide.

Warranty

Please inquire about the terms of warranty from your nearest ABB representative.

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.

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 60255-26 for the EMC directive,

and with the product standard EN 60255-27 for the low voltage directive. The product is

designed in accordance with the international standards of the IEC 60255 series.

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.

Table of contents

Section 1 Introduction.........................................................................................................3

1.1 This manual......................................................................................................................................... 3

1.2 Intended audience............................................................................................................................. 3

1.3 Document revision history............................................................................................................... 3

1.4 Related documents............................................................................................................................3

1.5 Symbols and conventions................................................................................................................ 4

1.5.1 Symbols........................................................................................................................................... 4

1.5.2 Document conventions................................................................................................................ 4

Section 2 SAM600 Process Bus I/O System..................................................................... 5

2.1 System overview................................................................................................................................ 5

2.1.1 SAM600 common design features ............................................................................................5

2.1.2 SAM600-CT for conventional current measurements ...........................................................6

2.1.3 SAM600-VT for conventional voltage measurements............................................................7

2.1.4 SAM600-TS for time synchronization and IEC 61850 gateway............................................ 8

2.1.5 System functionality..................................................................................................................... 9

2.2 Installing SAM600.............................................................................................................................11

2.3 Functional description.................................................................................................................... 13

2.3.1 Distributed analog sampling .................................................................................................... 13

2.3.2 Communication ports and available services........................................................................ 14

2.3.3 Bridging of sampled values streams ...................................................................................... 15

2.3.4 Quality information in sampled values streams....................................................................16

2.3.5 Merging and bridging of SV streams in a SAM600 system.................................................16

2.3.6 Simulation of sampled values................................................................................................... 18

2.3.7 Digital inputs ............................................................................................................................... 19

2.3.8 Configuration of time synchronization...................................................................................19

2.3.9 SAM600 module and system supervision...............................................................................23

2.3.10 System error announcement ....................................................................................................24

2.3.11 Watchdog functionality..............................................................................................................25

2.3.12 SAM600 system configuration mismatch ............................................................................. 26

Section 3 PCM600 Device Configuration Tool............................................................... 27

3.1 Connectivity packages.................................................................................................................... 27

Section 4 Commissioning SAM600..................................................................................29

4.1 Safety instructions ......................................................................................................................... 29

4.2 Unpacking..........................................................................................................................................29

4.3 Mounting and earthing connection..............................................................................................29

4.4 Electrical wiring ............................................................................................................................... 29

4.5 Communication wiring................................................................................................................... 30

4.6 Storing, mounting and disposal................................................................................................... 33

Table of contents

SAM600 Process Bus I/O System 1

Operation Manual

Section 5 SAM600 System Startup..................................................................................35

5.1 Start-up behavior ............................................................................................................................ 35

Section 6 Diagnostics and Maintenance......................................................................... 37

6.1 Maintenance instructions ..............................................................................................................37

Section 7 Technical Data...................................................................................................39

7.1 Module dimensions and mounting distances............................................................................39

7.2 Labels, connectors and indications of SAM600 modules....................................................... 40

7.2.1 SAM600 module identification.................................................................................................40

7.2.2 Connector diagrams...................................................................................................................40

7.2.2.1 SAM600-CT............................................................................................................................... 40

7.2.2.2 SAM600-VT................................................................................................................................ 42

7.2.2.3 SAM600-TS................................................................................................................................44

7.2.3 LED indications for all SAM600 modules............................................................................... 46

7.2.3.1 Description of LED HMI functionality...................................................................................47

Section 8 System Log Events........................................................................................... 49

Section 9 Glossary............................................................................................................. 53

Table of contents

2 SAM600 Process Bus I/O System

Operation Manual

Section 1 Introduction

1.1 This manual

GUID-37808C73-5FF6-4D6D-A413-95F2E720BD05 v1

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

GUID-0FD08E01-B107-4F8F-8C3D-FDBE9CAF9293 v1

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 Document revision history

GUID-DF73222C-C15C-4961-B89A-0C30B78C8D12 v1

Document

revision

Date Product revision History

A 2017-06 1.2.0 First release for product version 1.2

B 2019-04 1.2.1 Document enhancement and corrections

1.4 Related documents

GUID-8348908E-52BA-4728-8044-B005FBC79560 v1

The following product documentation is available for the SAM600.

SAM600 Product documentation Document number

SAM600 Product Guide 1MRK 511 437-BEN

SAM600 Engineering Manual 1MRK 511 433-UEN

SAM600 Operation Manual 1MRK 511 434-UEN

SAM600 Cyber Security Deployment Guideline 1MRK 511 435-UEN

SAM600 Accessory List 1MRK 511 436-BEN

SAM600 Safety Leaflet 1KHL511872-UEN

SAM600-TS Wiring Diagram 1KHL511910

SAM600-VT Wiring Diagram 1KHL511911

SAM600-CT Wiring Diagram 1KHL511912

SAM600 1.2 PICS and PIXIT (IEC61580 Ed1) 1KHL516076

SAM600 1.2 MICS (IEC61850 Ed2) 1KHL516090

SAM600 1.2 IEC/IEEE 61850-9-3 PICS 1KHL516091

SAM600 1.2 TICS (IEC61850 Ed2) 1KHL516092

1MRK 511 434-UEN B Section 1

Introduction

SAM600 Process Bus I/O System 3

Operation Manual

1.5 Symbols and conventions

1.5.1 Symbols

GUID-02020343-B7F4-47D8-BBBE-142E9E53CE2D v1

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.

1.5.2 Document conventions

GUID-0F467E9F-DAFE-489F-A3C4-6D2591965E86 v1

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.

• Parameter names are shown in italics.

For example, the function can be enabled and disabled with the

Operation

setting.

Section 1 1MRK 511 434-UEN B

Introduction

4 SAM600 Process Bus I/O System

Operation Manual

Section 2 SAM600 Process Bus I/O System

2.1 System overview

GUID-300360E0-8897-4ACA-A73C-3BF75903163E v1

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 61850 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.

2.1.1 SAM600 common design features

GUID-CAA48BE0-4015-44EB-9499-ABDCC68ADBC6 v1

IEC18000512 V1 EN-US

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.

• A SAM600 module per primary apparatus interfaces conventional current or voltage

transformers and provides standalone merging unit (SAMU) functionality according to the

IEC 61850-9-2 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.

1MRK 511 434-UEN B Section 2

SAM600 Process Bus I/O System

SAM600 Process Bus I/O System 5

Operation Manual

• 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 61850-9-2 traffic by simplifying integration with non-

conventional instrument transformers.

• A SAM600 system can externally synchronize to IEEE 1588 (according to profile IEC/IEEE

61850-9-3). 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 62439-3:2016).

2.1.2 SAM600-CT for conventional current measurements

GUID-A4683182-2819-443C-B675-C06E565834AC v1

IEC18000513 V1 EN-US

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 61850-9-2LE 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 61850-9-2LE 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.

A SAM600-CT module can be configured to provide IEC 61850 access points on each physical

port that is not used for SAM600 system bus connection. An IEC61850 access point can

subscribe or publish IEC/UCA 61850-9-2LE streams.

A SAM600-CT module supports IEEE 1588 access point in a standalone configuration or as an

edge module in a daisy chain system bus.

Section 2 1MRK 511 434-UEN B

SAM600 Process Bus I/O System

6 SAM600 Process Bus I/O System

Operation Manual

2.1.3 SAM600-VT for conventional voltage measurements

GUID-C6B69804-9F14-4DC3-987F-54CD16F41C09 v1

IEC18000514 V1 EN-US

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 61850-9-2LE 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

61850-9-2LE 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.

A SAM600-VT module can be configured to provide IEC 61850 access points on each physical

port that is not used for SAM600 system bus connection. An IEC61850 access point can

subscribe or publish IEC/UCA 61850-9-2LE streams.

A SAM600-VT module supports IEEE 1588 access point in a standalone configuration or as an

edge module in a daisy chain system bus.

1MRK 511 434-UEN B Section 2

SAM600 Process Bus I/O System

SAM600 Process Bus I/O System 7

Operation Manual

2.1.4 SAM600-TS for time synchronization and IEC 61850 gateway

GUID-A3F698B4-86EA-40E7-AC3E-5D7816A8CEF1 v1

IEC18000515 V1 EN-US

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 61850-9-3) 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 61850 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 access points.

• 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 access points.

• 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 access points.

Access points of SAM600-TS modules can (externally) receive and publish IEC/UCA

61850-9-2LE 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 61850 access points.

Section 2 1MRK 511 434-UEN B

SAM600 Process Bus I/O System

8 SAM600 Process Bus I/O System

Operation Manual

2.1.5 System functionality

GUID-1B23DA9A-4759-4F1D-B469-5F38E78ED30B v1

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 61850 process bus architectures. On SAM600-CT and

SAM600-VT modules up to three independent IEC 61850 access points are available to publish

analog measurements according to IEC/UCA 61850-9-2LE. 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 61850 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 61850-9-2LE streams

With a SAM600 system, IEC/UCA 61850-9-2LE based streams that consist of information

provided by individual SAM600 modules can be configured and published on all IEC 61850

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 "bridged" through a

SAM600 system to several IEC 61850 access points. External streams cannot be merged with

SAM600 internal streams.

Each SAM600 module provides its measurements as IEC/UCA 61850-9-2LE 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 61850 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.

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 61850-9-2LE 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.

1MRK 511 434-UEN B Section 2

SAM600 Process Bus I/O System

SAM600 Process Bus I/O System 9

Operation Manual

Neutral behavior

The IEC/UCA 61850-9-2LE 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 61850-9-2LE stream will reflect the setting.

Time synchronization

Analog samples are time synchronized in order to provide the phase accuracy required by IEC

61869-9. Synchronization of a SAM600 system with IEDs is achieved by IEEE 1588 (profile IEC

61580-9-3) or through a 1PPS signal. Internally, a SAM600 system always synchronizes using

IEEE 1588.

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 2.3.8.

On each SAM600-TS module only one single link access point or the redundant

PRP/HSR access point can be configured as IEEE 1588 access point. 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 61850 access points and relevant IEC/UCA 61850-9-2LE 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 61850 configuration of a SAM600 system can also be exported

and used in IEC 61850 system engineering tools.

Watchdog

The SAM600-TS module provides watchdog functionality. The watchdog is activated during

critical system states. For more details, refer

Section 2.3.11.

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.

Section 2 1MRK 511 434-UEN B

SAM600 Process Bus I/O System

10 SAM600 Process Bus I/O System

Operation Manual

For more information refer to 1MRK 511 435-UEN SAM600 Cyber Security Deployment

Guideline document.

2.2 Installing SAM600

GUID-D48A191F-DF8E-4B2C-8131-44BA1D25716F v1

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 61850 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).

1MRK 511 434-UEN B Section 2

SAM600 Process Bus I/O System

SAM600 Process Bus I/O System 11

Operation Manual

IED

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IEC18000516 V1 EN-US

Figure 5: Installation options of SAM600 process bus I/O system

Section 2 1MRK 511 434-UEN B

SAM600 Process Bus I/O System

12 SAM600 Process Bus I/O System

Operation Manual

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