Generator Condition Monitor (GCM-X) ATEX

Transcription

1 UTILITY SYSTEMS Generator Condition Monitor (GCM-X) ATEX Installation and Operation Manual GA0456P01 Rev. A

2 Contents Generator Condition Monitor (GCM-X)... 5 Safety Consideration... 5 Specifications... 6 Application... 7 Principle of Operation... 7 System Description... 9 System Electronics... 9 Control/Display Panel... 9 Customer Interface Installation Mounting Lifting Piping Electrical Connections Contacts Signals Circuit Protection System Operation GCM-X Initialization GCM-X Menu Displays Navigating the LCD Display LCD Display Menu Two Modes of Operation Menu Profile Menu Navigation Tutorial Activating the Menu Navigating the Menu in Scrolling Mode (GCM-X default) Disabling Scrolling Mode Navigating the Menu in Non-Scrolling Mode Function (FN) Menu Setup Menu Test Menu View Menu Log Menu Procedures Calibrating the Ion Chamber GA0456P01 Rev. A

3 Setting the Sampler Interval Setting the Warning Level Setting the Low Flow Limit Setting the High Flow Limit About the Faults Log About the Power Log Modes of Operation Startup Startup Problems Suspended Operation Normal Operation Troubleshooting Maintenance Periodic Maintenance Daily Weekly Monthly Annually When the Generator is Down Tubing and Fitting Replacement Component Replacement Instructions ICD, Filter Solenoid and Sampling System Solenoid Processor Assembly I/O Assembly (Located in the System Electronics Enclosure) Display Assembly Fuses GCM-X Remote Panel GCM-X in Local Mode GCM-X in Remote Mode (Optional)...33 Transferring Control from the GCM-X Remote Panel (Optional) Removing the GCM-X Remote Panel s Display Assembly (Optional) Appendix A Generator Condition Monitor Output Traces GCM-X - Parts List GA0456P01 Rev. A 2

4 Figures Table 1 - Customer Contacts Table 2 - Display Indicators Table 3 - Display Keys Table 4 - GCM-X Status Table 5 - Relay Problems Figure 1 - System Overview Figure 2 - Piping Schematic Figure 3 - GCM-X Outline Figure 4 - Customer Interface Wiring Figure 5 - ICD Current and Flow Figure 6 - GCM-X Remote Panel (Optional) Figure A1 - Front View, GCM-X Figure A2 - Back View, GCM-X Figure A3 - GCM-X Display, Front View Figure A4 - GCM-X Display - Backside of Door, Cold Start Button Access GA0456P01 Rev. A

5 GA0456P01 Rev. A 4

6 GENERATOR CONDITION MONITOR (GCM-X) IMPORTANT INFORMATION! THIS EQUIPMENT OPERATES AT VOLTAGE LEVELS THAT CAN BE HAZARDOUS TO PERSONNEL. THE SECTION ABOUT SAFETY CONSIDERATIONS SHOULD BE READ BEFORE INSTALLING OR SERVICING. THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED, OR SHOULD PARTICULAR PROBLEMS ARISE THAT ARE NOT COVERED SUFFICIENTLY FOR THE PURCHASER S PURPOSES, THE MATTER SHOULD BE REFERRED TO ENVIRONMENT ONE CORPORATION. GENERATOR CONDITION MONITOR (GCM-X) SAFETY CONSIDERATION THE SYSTEM ELECTRONICS ENCLOSURE, CUSTOMER INTERFACE ENCLOSURE, SOLENOID VALVES AND HEATER CONTAIN 115 AND/OR 230 VOLTS AC. THIS VOLTAGE APPEARS AT THE AC POWER STRIP AND VARIOUS OTHER POINTS. EQUIPMENT OPERATION INVOLVES A FLAMMABLE GAS (HYDROGEN) UNDER PRESSURE. APPROPRIATE MEASURES MUST BE TAKEN TO PREVENT LEAKS AND AVOID SOURCES OF IGNITION. ALL ELECTRICAL CONNECTIONS TO THE SYSTEM ELECTRONICS, CUSTOMER INTERFACE AND CONTROL/DISPLAY PANEL SHOULD BE TESTED AND VERIFIED TO BE CORRECT. ALL WIRING MUST BE IN ACCORDANCE WITH CENELEC STANDARD EN USE OF THIS EQUIPMENT IN A MANNER NOT SPECIFIED BY ENVIRONMENT ONE CORPORATION IS STRICTLY PROHIBITED. IT IS NECESSARY TO ENSURE THAT ALL SEALING FITTINGS ARE FILLED WITH AN APPROVED COMPOUND. THIS IS A CENELEC REQUIREMENT FOR ZONE 2, GROUP II H2 ENVIRONMENTS. ALL GAS CONNECTIONS TO THE GCM-X MUST BE LEAK CHECKED PRIOR TO APPLYING AC POWER. CHECK FOR LEAKS AT ALL TUBING AND MECHANICAL CONNECTIONS INSIDE THE GCM-X ENCLOSURE. IF LEAKS ARE FOUND, DETERMINE THE CAUSE AND REPAIR. REPEATING THE LEAK CHECK UNTIL THE GCM-X ENCLOSURE IS DETERMINED TO BE LEAK TIGHT IS NECESSARY. 5 GA0456P01 Rev. A

7 Specifications Measurement Characteristics Detection principle Hydrogen Flow Rate Differential Pressure Ionization chamber Adjusted by internal valve 4 to 5 (102 mm to 127 mm) min. Readout (bar graph) Normal Operation 80% of scale, typical Alarm Condition 50% of scale, typical Flow 1.5 Electrical Characteristics Power Input Voltage Input Frequency Input Power Inrush Current 85 VAC to 250 VAC 47 Hz to 63 Hz 100W 2A Outputs, Relays Contact Rating 250 VAC Resistive Alarm Warning 30 VDC Resistive Trouble VDC Resistive Outputs, Signal (Caution: Do not externally excite output signals) Output 4-20 ma current output (transmitter) 4-20 ma = 0-100% Flow 4-20 ma current output (transmitter) 4-20 ma = 0-3 H2O Mechanical Characteristics Dimensions, overall 30.8 H x 21.8 W x 23.6 D (782mm x 553mm x 600mm) Temperature F (0-52 C) Area Classification Hydrogen Pressure Connections, gas inlet Zone 2, Ex II H2, CE 100 psi maximum 150 lb., ½ pipe flanges, standard GA0456P01 Rev. A 6

8 Application The Generator Condition Monitor (GCM) is a sensitive real-time instrument designed to provide immediate indication of overheating in hydrogen-cooled generators before extensive damage can occur. Tests conducted on operating hydrogen-cooled generators have shown that the GCM can detect thermal decomposition of small amounts of insulating materials. Thermal decomposition of organic materials such as epoxy paint, core lamination enamel or other insulating materials used in the generator results in the production of a large number of small particles. The onset of particle production, as the material is heated, occurs at a temperature characteristic of the material and its surrounding atmosphere. Below this temperature, no particles are created, yet once the critical temperature is reached, millions of submicron particles are generated each second for every square centimeter of surface. GCM-X represents the next generation in condition monitoring incorporating microprocessorbased electronics, flameproof, intrinsically safe design features (Ex II H2, CE) and self diagnostics. E/One has taken the field-proven system that has served the worldwide power generation community for decades and improved upon it in the form of increased safety, performance and reliability. GCM-X features: Microprocessor-based electronics Flameproof, intrinsically safe design (Ex II H2, CE) Self diagnostics Flow indication Trouble indication Separate enclosure for system electronics and customer interface Allowance for remote control/display and communication Integral auto/manual sampling system Automatic alarm verification Simple installation Maintenance-free operation Principle of Operation A basic understanding of the GCM is necessary in order to properly utilize the information it provides. Particle detection occurs by means of an ionization chamber through which the hydrogen cooling gas is continuously circulated by the pressure produced by the generator fan. The Ion Chamber Detector (ICD) consists of an ionizing section and ion collecting chamber contained in a 7 GA0456P01 Rev. A

9 (Principle of Operation cont d) pressure housing. The hydrogen first passes through the ionizing section, which contains a low level alpha source (Thorium 232). The resulting ions then pass with the hydrogen to the ion collecting chamber in which there is an electrode maintained at -10 VDC. Because the ions are extremely small, they have a high ratio of charge to mass, giving them a high mobility when placed in an electric field. The -10 VDC potential is sufficient to cause most of the ions to be attracted to a collecting electrode, where they produce the output current. High concentrations of submicron particles (pyrolysis products) are produced whenever any material within the generator is heated sufficiently to produce thermal decomposition. These hot spots can lead to catastrophic failure if not caught in time. When particles are present in the hydrogen, some of the ions will become attached to them. Therefore, the charge to mass ratio of the particle-ion combination is very much reduced (by a factor of a thousand or so), and the mobility is very low. This means that only a very few are now attracted to the collecting electrode, resulting in a reduced output current. Upon detection, the microprocessor initiates and monitors an alarm verification sequence. If the alarm is confirmed, a verified alarm indication is given, alarm contacts are switched and a portion of the hydrogen flow automatically passes through the sampling system where these particles are collected for laboratory analysis. The sampling system can be set to auto or manual. Alarm confirmation is made quickly by the automatic alarm verification circuit that activates the solenoid valve in the filter/solenoid valve assembly. Normally bypassed, all the hydrogen then passes through the filter, which removes the particles. If the alarm is valid and thermally produced particles are present, their removal in this manner will cause the collector current to return to its normal level, confirming their presence and overheating. Figure 1 shows a typical GCM. In this arrangement a differential pressure transmitter that monitors the pressure drop across the ion chamber indicates flow. Ion chamber output current is amplified by an electrometer. The amplified current and flow are displayed on bar graphs. The usual operating procedure is to adjust the flow to a given differential pressure indication and calibrate the electrometer gain to produce an output of 80 percent. Refer to Appendix A, Generator Condition Monitor Output Traces. GA0456P01 Rev. A 8

10 System Description The GCM-X is designed for use on hydrogen-cooled generators. It is designed to operate in Zone 1, IIC hazardous areas (Zone 2, Group II H2). GCM-X s main purpose is to detect overheating in hydrogen cooled generators. The major components of the GCM-X include the System Electronics, Control/Display Panel, Customer Interface, Ion Chamber Detector (ICD) and Transmitter (Figures A1, A2 and A3). System Electronics The System Electronics consist of one Processor Board, one Input/Output Board, one Power Supply, one RFI filter and three Isolation Barriers (Figure A1). All are mounted in a flameproof enclosure. Electrical connections are made through three cable glands (optional conduit sealers). The System Electronics provide calibration, mode selection, alarm contacts, data logging, system inputs/outputs and diagnostics. Fail-safe operation of the GCM-X is assured by: 1. On power-up the GCM-X must execute and pass qualifying self tests. Failure in any test results in the termination of operation and the annunciation of the condition causing the failure. 2. Following power-up and/or system reset, the GCM-X is continuously supervised by an independent watchdog monitor that serves to reset it should its operation become erratic. 3. The GCM-X is completely self-supervised and continuously checks itself for legal processor functioning, internal voltages, analog-to-digital conversion accuracy, integrity of cabling and relay operation. Any faults are immediately annunciated. Control/Display Panel The Control/Display Panel provides control of all functions of the GCM-X as well as complete annunciation of GCM-X s status (Figure A3). Functions are accessed by means of a four-button membrane-switch keypad and 16-character Liquid Crystal Display (LCD). Generally, pressing the Fn (Function) key causes the LCD to continuously scroll the names of the available functions. A function may then be accessed by pressing the Enter key when the function name appears. See Menu Navigation Tutorial for more information. After the GCM-X has been installed and commissioned, individuals performing service work on the Display Panel must wear an electrostatic wriststrap. The Display Panel provides Light Emitting Diodes (LED s) to annunciate GCM-X status; they indicate Warning, Alarm and Trouble conditions. In addition, they display Sampler and Reset mode, and the status of the sampler and verification filter. A green LED indicates AC Power. To permit a system level initialization ( cold start ) a momentary push-button located behind the Display Panel (at the upper edge of the board) may be pressed. Since all calibration constants are stored in non-volatile memory, these values will not be lost should the system be initialized or should it lose, then regain, AC power. 9 GA0456P01 Rev. A

11 (Control/Display Panel cont d) The cold start button should be pressed via a nonconductive tool. Depending on the GCM-X configuration, the Cold Start button may be accessed by reaching behind the Display Assembly from the front, or by way of a small access hole located on the back side of the GCM-X front door (Figure A3). Customer Interface The Customer Interface/System Electronics enclosure contains one RFI filter and circuit board assemblies (Figure A1). The I/O circuit board assembly has terminal strips where all customer connections (relay outputs, signal output and power) are made. Electrical connections are made through three cable glands (optional conduit sealers) provided at the side of the enclosure. GA0456P01 Rev. A 10

12 Installation These instructions provide details to facilitate the equipment installation. The exact location of the Generator Condition Monitor, Explosion-Proof Design (GCM-X) should be in accordance with recommendations made by the generator manufacturer or its authorized representative. Prior to applying power to the GCM-X System, ensure that the local power source used matches the power rating on the GCM-X nameplate. All Gas lines must be connected to the GCM-X and leak tested before continuing. CAUTION! Care must be taken when opening the covers on the flameproof enclosure to avoid damage (scratches, etc.) to the sealing surfaces of the cover and enclosure. Do not remove the cover from the enclosure unless power is removed from the System Electronics and the system is free of hydrogen. Individuals involved in opening the flameproof enclosure covers must be trained in the use of such equipment and should adhere to ATEX, Cenelec or NEC standards, local codes and generally accepted professional practices. Mounting The GCM-X should be installed indoors, or at least under a roof that extends far enough to protect it from the elements. If outdoor installation is necessary, a protective enclosure must be used, located out of direct sunlight to prevent the interior ambient temperature from exceeding 52 C (125 F). The protective enclosure should also be ventilated to prevent the accumulation of hydrogen in the event of a leak. Lifting The GCM-X should be lifted from the bottom of the cabinet whenever possible. It should never be lifted from the flanges. If the unit is being lifted without the assistance of a mechanical lift, the upper portion of the cabinet is recessed, allowing for a manual grip (Figure 3). In any and all instances, the cabinet should be supported to prevent tipping. Piping Figure 2 shows the locations of gas connections. The cabinet should be located close to the generator so that the inlet gas line will be 30 meters (100 feet) or shorter in order to minimize loss of signal. The ambient temperature should not exceed 52 C (125 F). Gas dryers, or other devices that would filter out particles, should not be installed in series in the signal line ahead of the GCM-X (Figure 2). The gas connections are standard pipe flanges modified to use O-rings. The outlet and inlet connections at the generator must be located so as to produce adequate pressure differential in order to provide sufficient flow (DP of 4 to 5 min.). If a dryer is connected in parallel with the GCM-X, its effect on the pressure drops in the piping should be checked so that flow changes through the dryer (as when it is being reactivated) will not adversely affect the flow through the GCM-X. Care should be taken also in location of the generator outlet connection so that the hydrogen stream will not be contaminated by oil vapor from the bearings. The high and low pressure taps preferably should be located as high as possible on the generator casing in order to prevent the entry of liquids into the lines. Generators with two fans should have an outlet tap at 11 GA0456P01 Rev. A

13 (Piping cont d) each end connected to a manifold so a composite hydrogen sample is supplied to the GCM-X. To prevent the accumulation of liquids in the lines, horizontal runs should slope down in the direction of flow, with a drip leg installed at all low points. At each drip leg the succeeding length of pipe should start with a vertical tap at the top of the preceding section. This applies also to the lines from the GCM-X back to the generator, to prevent liquids from draining back to the GCM-X, particularly after shutdown. It is recommended that an oil moisture trap, such as Environment One Part No. GA0174P02, with grounding kit GB0084G02, be installed at the inlet of the GCM-X (Figure 2). CAUTION: SOME OIL-MOISTURE TRAPS CAN REMOVE THE OVERHEATING PARTICU- LATE SENSED BY THE GCM-X. CONSULT ENVIRONMENT ONE BEFORE USING ANY TRAP OTHER THAN THAT SUPPLIED BY ENVIRONMENT ONE. A line must be connected to the vent outlet at the right side of the cabinet (Figure 2). This line should not contain valves, and must provide low restriction to the flow of hydrogen so that it can be safely vented to atmospheric pressure. Electrical Connections Electrical connections are made through three male conduit unions provided at the back of the GCM-X cabinet (Figures 3 and A2). System power requirement is 115/230 VAC, 50/60 Hz. The source of AC power should be reliable and not subject to severe transients. To gain access to the inside of the System Electronics enclosure for electrical connections, remove the threaded cover. Take care that the threads of the enclosure are not damaged during the removal process. Wiring and wire routing should be in accordance with Figure 4 so that noise generated from the AC power and contacts does not interfere with the signals. If a circuit breaker is used, it should be 10 amps. The ground wire should be 12 AWG with 25-amp capacity. ALL WIRING MUST BE IN ACCORDANCE WITH CENELEC STANDARD EN Contacts As shown in Figure 4, the GCM-X provides these relay contacts: Warning Relay Both a normally open and a normally closed contact (single pole, double throw configuration) is provided and a warning is signaled by an energized relay. Alarm Relay Both a normally open and a normally closed contact (single pole, double throw configuration) is provided and an alarm is signaled by an energized relay. Trouble Relay Both a normally open and a normally closed contact (single pole, double throw configuration) is provided and Trouble is signaled by a de-energized relay. Signals Output Signal 4-20 ma signal (transmitter) Flow 4-20 ma signal (transmitter) The 4-20 ma signals are self-powered. Do NOT excite the 4-20 ma signals. GA0456P01 Rev. A 12

14 Circuit Protection The 2-amp slo-blo fuse (F1) provides circuit protection for 115/230 VAC. 13 GA0456P01 Rev. A

15 System Operation GCM-X Initialization With system power on, press the RESET push-button on the backside of the DISPLAY PANEL (Figure A3). The GCM-X DISPLAY PANEL will respond with (a) all discrete LED s lit; (b) all segments of the FLOWSET and OUTPUT bar graphs lit; and (c) all pixels of the LCD display on. Once communication has been established with the rest of the system, (a) all discrete LED s, except the AC POWER, LOCAL, GCM FAULT and FLOW LED s, will turn off; (b) all segments of the FLOWSET and OUTPUT displays will turn off; and (c) the display will echo the results of cold start initialization: GCM-X Ver 2.0E-7 CHECKSUM OK POWER OK RELAY TEST PASSED ICD=N.NpA DP=N.N INCHES NORMAL OPERATION will flash for two seconds; the GCM-X will begin normal operation and the display will read GCM-X by E/One. For a first-time installation, it is essential that a calibration be performed on the GCM-X system; also, the faults log should be cleared. See CALIBRATION under the SETUP MENU and CLEAR FAULTS LOG under LOG MENU for specific instructions. GA0456P01 Rev. A 14

16 GCM-X Menu Displays The following sections provide definitions and user information regarding the various menus that are accessible via the GCM-X s LCD display. It is strongly recommended that users familiarize themselves with this section. Additional questions can be forwarded to Environment One. Navigating the LCD Display Four keys are used to control menu operation. The keys are FN, ENTER, UP ARROW and DOWN ARROW. The FN key activates the menu and exits the menu. The ENTER key selects an item from the menu. The UP ARROW and DOWN ARROW keys change the selection displayed. LCD Display Menu Two Modes of Operation The menu has two modes of operation. The modes are scrolling and non-scrolling. In scrolling mode the selection shown on the LCD changes automatically every two seconds. In non-scrolling mode the UP ARROW and DOWN ARROW keys must be used to change the selection. Scrolling is the default mode. Users can change modes by reviewing the SETUP MENU section in the following pages. Menu Profile Five menus are available: they are the Function menu, the Log menu, the Setup menu, the View menu and the Test menu. The Function menu is the top-level menu; all of the other menus are accessed through this menu. Function Log Setup View Test 15 GA0456P01 Rev. A

17 Menu Navigation Tutorial Activating the Menu Press FN to start the menu. The LCD should display the prompt <FUNCTION MENU>. Press FN again to turn it off. Navigating the Menu in Scrolling Mode (GCM-X default) Press FN to start the menu. The LCD should display the prompt <FUNCTION MENU>. After two seconds the prompt should change to GO REMOTE. Wait until the prompt is GO TO VIEW MENU and press the ENTER key. The LCD should display the prompt <VIEW MENU>. Wait until the prompt is SHOW ICD CURRENT and press the ENTER key. The display should show ICD=N.NpA where N.N is the present value of the ICD current. Press the FN key. The prompt will be restored to SHOW ICD CURRENT. Press FN again. The prompt will be restored to GO TO VIEW MENU. Press FN a third time. The LCD will display GCM-X by E/One as the menu is deactivated. Disabling Scrolling Mode Press FN to start the menu. Wait until the prompt is GO TO SETUP MENU and press ENTER. Wait until the prompt is SET SCROLL OFF and press ENTER. The prompt will flash SET SCROLL OFF. Press FN to return to the beginning of the menu. Navigating the Menu in Non-Scrolling Mode The LCD should display the prompt <FUNCTION MENU>. Press the DOWN ARROW key until the prompt is GO TO VIEW MENU and press the ENTER key. The LCD should display the prompt <VIEW MENU>. Press the DOWN ARROW key until the prompt is SHOW ICD CURRENT and press the ENTER key. The display should show ICD=N.NpA where N.N is the present value of the ICD current. Press the FN key. The prompt will be restored to SHOW ICD CURRENT. Press FN again. The prompt will be restored to GO TO VIEW MENU. Press FN a third time. The LCD will display GCM-X by E/One. GA0456P01 Rev. A 16

18 Function (FN) Menu GO REMOTE Select this item to transfer control to the optional, remotely located display panel. The GO REMOTE prompt will flash for two seconds after it is selected. If the FN key is pressed while GO REMOTE is still flashing, transfer will be canceled. If the GCM-X cannot detect a remote panel, the transfer will be canceled and the GCM-X will remain in local mode. GO LOCAL Select this item to transfer control to the display panel located on the front of the GCM-X cabinet (only if the optional GCM-X Remote Panel installed). The GO LOCAL prompt will flash for two seconds after it is selected. If the FN key is pressed while GO LOCAL is still flashing, transfer will be canceled. GO TO LOG MENU Select this item to enter the LOG MENU. The log menu contains selections to view and clear the fault and power logs. The log menu also includes a selection to view the software version number. GO TO SETUP MENU Select this item to enter the SETUP MENU. The setup menu includes selections for calibration and configuration. Items that can be configured include the sampler interval, the operating mode and the menu scroll rate. The setup menu also includes a selection to calibrate the ion chamber detector. GO TO TEST MENU Select this item to enter the TEST MENU. The test menu contains selections to test the power supplies, the keypad, the relays, the solenoids, the bar graphs and the four- to 20-milliamp (4-20 ma) outputs. GO TO VIEW MENU Select this item to enter the VIEW MENU. The view menu contains selections to view the ion chamber electrical output, the differential pressure across the ion chamber and the four software variables associated with the ion chamber amplifier. Setup Menu CALIBRATION Select this item to calibrate the ion chamber output. When selected the CALIBRATION prompt will flash for two seconds before entering the calibration procedure. If the FN key is pressed while it is still flashing the procedure will be canceled. See Calibrating the Ion Chamber for more information. SAMPLER INTERVAL Select this item to change the sampler interval. See Setting the Sampler Interval for more information. WARNING LEVEL Select this item to change the warning level. See Setting the Warning Level for more information. LOW FLOW LIMIT Select this item to change the low flow limit. See Setting the Low Flow Limit for more information. HIGH FLOW LIMIT Select this item to change the high flow limit. See Setting the High Flow Limit for more information. STOP MONITORING This item is to be used for troubleshooting and is displayed when the monitoring is currently turned on. Select it to turn monitoring off. When selected the STOP MONITORING prompt will flash STOPPING for two seconds before monitoring is suspended. If the FN key is pressed while it is still flashing, the command will be canceled. See Suspended Operation for more information. 17 GA0456P01 Rev. A

19 (Setup Menu cont d) START MONITORING This item is displayed when the monitoring is currently turned off. Select it to turn monitoring on. When selected the START MONITORING prompt will flash STARTING for two seconds before monitoring begins. If the FN key is pressed while it is still flashing, the command will be canceled. See Normal Operation for more information. SET SCROLL OFF This item is displayed when the scrolling is currently turned on. Select it to turn scrolling off. When scrolling is inactive the displayed menu items will not change until a menu key (UP ARROW, DOWN ARROW, FN or ENTER) is pressed. SET SCROLL ON This item is displayed when the scrolling is currently turned off. Select it to turn scrolling on. When scrolling is active, the displayed menu items will change once every two seconds. Test Menu CONTACT TEST Select this item to start an interactive test of the relay contacts. The GCM- X will place all relays except one in a de-energized condition. The LCD will display the name of the single relay that is still energized. Use the arrow keys to change which relay is energized. Press the FN or ENTER keys to terminate the test. KEYPAD TEST Select this item to start an interactive test of the keypad. The LCD will display the prompt PRESS ANY KEY at the start of the test. Test the keypad by pressing, one at a time, all of the keys on the keypad, reserving the FN key for last. The LCD will echo the name of each key as it is pressed. The test will terminate when the FN key is pressed. OUTPUT TEST Select this item to start an interactive test of the bar graphs and four- to 20- milliamp (4-20 ma) outputs. The GCM-X will clear the bar graphs, set the four- to 20-milliamp outputs to four milliamps and display CURRENT=4mA on the LCD display at the start of the test. Use the arrow keys to increase or decrease the current in one milliamp steps. The bar graphs will track the current outputs with four milliamps equal to zero percent and 20 milliamps equal to 100 percent. Press FN or ENTER to terminate the test. POWER TEST Select this item to test the power supplies. When POWER TEST is selected, the GCM-X will display the voltage for each power supply in the format <nominal value>=<present value>. An example for the 12-volt power supply would be +12 VOLTS =12.1. The GCM-X will scroll through all five power supply voltages. The voltages are displayed for two seconds apiece. RELAY TEST Select this item to test all of the relays. The LCD will display RELAY TEST The system will cause each relay to be energized. If no errors are detected, the LCD will display RELAYS PASS. If an error is detected, the LCD will display the failure mode and then list the names of the malfunctioning relays. The failure modes are STUCK ON, STUCK OFF and NOT TESTED. Refer to Table 5 for a list of the probable cause(s) of these errors. View Menu SHOW ICD CURRENT Select this item to display the ICD s electrical output in pico amps. SHOW DP INCHES Select this item to display the differential pressure across the ion chamber in inches of water. SHOW AMPLIFIER Select this item to view the four software variables associated with the GA0456P01 Rev. A 18

20 ion chamber amplifier. The variables are displayed as four pairs of hexadecimal digits. This is an advanced diagnostic intended for factory use only. Log Menu (View Menu cont d) SHOW FAULTS LOG Select this item to view the faults log. See About the Fault Log for more information. CLEAR FAULTS LOG Select this item to clear the faults log. When selected the CLEAR FAULTS LOG prompt will flash for two seconds before clearing the faults log. If the FN key is pressed while it is still flashing clearing of the log will be canceled. See About the Fault Log for more information. SHOW POWER LOG Select this item to view the power log. See About the Power Log for more information. CLEAR POWER LOG Select this item to clear the power log. When selected the CLEAR POWER LOG prompt will flash for two seconds before clearing the power log. If the FN key is pressed while it is still flashing clearing of the log will be canceled. See About the Power Log for more information. SHOW PROGRAM ID Select this item to display the program identification and revision level in the format GCM-X Rev X.X. This manual was written for software version 2.0E GA0456P01 Rev. A

21 Procedures Calibrating the Ion Chamber Alarms and warnings are detected by comparing the electrical output of the ion chamber detector against a reference level. The calibration process sets this reference level. The calibration procedure takes about 25 seconds to run. Once started the calibration procedure can be canceled by pressing the FN key. The GCM-X requires that the differential pressure across the ion chamber detector be between 1.4 and 1.6 inches of water during the calibration procedure. The GCM-X will halt calibration and prompt the operator to adjust the FLOWSET valve if the pressure is outside of this range. Calibration will resume when the differential pressure enters the required range and remains there for at least five seconds. If insufficient differential pressure is available to meet this requirement it can be bypassed by pressing the FN key. However, operating the GCM-X with insufficient differential pressure will reduce response time. The GCM-X engages the verification filter to remove any particulate from the gas stream during the calibration process. It waits at least 15 seconds for the filtered gas to flush any particulate out of the ion chamber. It considers the ion chamber flushed when its output current varies by less than ±4 percent over a five-second period. If the output current is not stable at the end of the 15-second waiting period the GCM-X will wait until it becomes stable. The GCM-X displays the output as a percentage of the initial reference level at the end of the initial 15-second waiting period. Once the output stabilizes, the GCM-X calculates a new value for the reference level and displays the output as a percentage of this new reference level. The new reference level will be 1.25 times the average electrical output level of the ion chamber detector during the last five seconds of the calibration procedure. Setting the Sampler Interval The sampler interval is the length of time that the GCM-X routes hydrogen through the collector in response to a verified alarm or the operator pressing the SAMPLER START/ STOP key. The sampler interval can be changed by selecting SAMPLER INTERVAL from the SETUP MENU. When SAMPLER INTERVAL is selected the sampler interval will be displayed on the LCD display. Press the UP ARROW key to increase it. Press the DOWN ARROW key to decrease it. It cannot be increased beyond 30 minutes or decreased below 10 minutes. Press the ENTER key to save your changes and return to the SETUP MENU. Press the FN key to discard the changes and return to the SETUP MENU. Setting the Warning Level The warning level determines what electrical output from the ion chamber detector will trigger a WARNING indication The warning level is expressed as a percentage of the reference level set by the calibration procedure. A WARNING indication is given when the ratio of the electrical output to the reference level is less than the value of warning level. The factory default GA0456P01 Rev. A 20

22 value for the warning level is 70 percent. The warning level can be changed by selecting WARNING LEVEL from the SETUP MENU. When WARNING LEVEL is selected, the warning level will be displayed on the LCD display. Press the UP ARROW key to increase it. Press the DOWN ARROW key to decrease it. It cannot be increased beyond 80 percent or decreased below 50 percent. Press the ENTER key to save your changes and return to the SETUP MENU. Press the FN key to discard the changes and return to the SETUP MENU. Setting the Low Flow Limit The low flow limit determines what differential pressure, across the ion chamber detector, will cause a FLOW TROUBLE indication. The low flow limit is expressed in inches of water. A FLOW TROUBLE indication is given when the differential pressure drops below the low flow limit. The factory default value for the low flow limit is 1.1 inches of water. The low flow limit can be changed by selecting LOW FLOW LIMIT from the SETUP MENU. When LOW FLOW LIMIT is selected the low flow limit will be displayed on the LCD display. Press the UP ARROW key to increase it. Press the DOWN ARROW key to decrease it. It cannot be increased beyond 2.5 inches of water or decreased below 0.5 inches of water. Press the ENTER key to save your changes and return to the SETUP MENU. Press the FN key to discard the changes and return to the SETUP MENU. Setting the High Flow Limit The high flow limit determines what differential pressure, across the ion chamber detector, will cause a FLOW TROUBLE indication. The high flow limit is expressed in inches of water. A FLOW TROUBLE indication is given when the differential pressure rises above the high flow limit. The factory default value for the high flow limit is 1.9 inches of water. The high flow limit can be changed by selecting HIGH FLOW LIMIT from the SETUP MENU. When HIGH FLOW LIMIT is selected the high flow limit will be displayed on the LCD display. Press the UP ARROW key to increase it and press the DOWN ARROW key to decrease it. It cannot be increased beyond 2.5 inches of water or decreased below 0.5 inches of water. Press the ENTER key to save your changes and return to the SETUP MENU. Press the FN key to discard the changes and return to the SETUP MENU. About the Faults Log (Warning Level cont d) The Faults log traps these error conditions: I/O Read Error, I/O Write Error, Unverified Alarm, Flow Fault and Power Fault. An I/O Read Error is logged when a read error is detected in the communication channel that connects the processor and I/O board. An I/O Write Error is logged when a write error is detected in the communication channel that connects the processor and I/O board. An Unverified Alarm is logged when the GCM-X starts an alarm verification sequence but cannot verify the alarm. A Flow Fault is logged when the differential pressure across the ion chamber detector falls below the low flow limit or climbs above the high flow limit. 21 GA0456P01 Rev. A

23 (Faults Log cont d) A Power Fault is logged when the measured voltage of one or more of the power supplies is out of specification. About the Power Log The Power log records the minimum and maximum voltage of each power supply. The voltage is sampled once every two seconds. When SHOW POWER LOG is selected, the GCM-X will display the minimum and maximum for each power supply in the format <nominal value>=<minimum value>,<maximum value>. An example for the 12-volt power supply is +12V=11.8,12.1. Use the UP ARROW key or DOWN ARROW key to scroll through the five power supply voltages. Press the FN key to return to the LOG MENU. GA0456P01 Rev. A 22

24 Modes of Operation Startup The GCM-X initializes the display mode to local and all relays to the de-energized position. The GCM-X executes a power on self test (POST) to verify its proper operation. It verifies its software by checksum testing the contents of its read-only memory (ROM). It tests all of its power supplies and all of its relays and solenoids. It checks the differential pressure across the ion chamber detector and if it is out of spec prompts for its adjustment. It checks the output level of the ICD and prompts for calibration if required. The POST will take about 20 seconds to complete if no errors are encountered. At the conclusion of the POST the GCM-X display panel will flash NORMAL OPERATION for two seconds before beginning normal operation. If the FN key is pressed while it is still flashing, normal operation will be canceled and the GCM-X will enter suspended operation instead. Startup Problems Immediately after power up the GCM-X begins searching for displays. If the local display is present and functioning properly, the search will complete in less than one tenth of a second. If the GCM-X cannot communicate with the local display, LINKING may appear on the LCD. The GCM-X stops trying to communicate with the local display after four seconds and starts trying to communicate with a remote display. If it finds a remote display, the GCM-X will start in remote mode rather than local mode. If the GCM-X cannot find a local or a remote display within six seconds, it will assume local mode and proceed with the power on self test (POST). The GCM-X verifies its software by checksum testing the contents of its read only memory (ROM). If it finds a problem it will stop the POST process and flash BAD CHECKSUM on the LCD. The FN key may be pressed to allow the GCM-X to continue the POST process. However, proper operation cannot be guaranteed if this error is present. The GCM-X will annunciate any problems it finds with the power supplies, relays or solenoids. The presence of one or more of these faults will not stop the POST process. However, they should be corrected as soon as possible because they indicate a hardware problem. The GCM-X requires the differential pressure across the ion chamber detector to be between 1.4 and 1.6 inches of water. The POST will be halted and the operator prompted to adjust the FLOWSET valve if the pressure is outside of this range. The POST will resume once the differential pressure enters the required range and remains there for at least five seconds. The test can be bypassed by pressing the FN key. The GCM-X expects the electrical output of the Ion Chamber Detector to fall between the warning level and 95 percent of the reference level. The POST is halted and the operator prompted to calibrate the GCM-X if the output is outside of this range. The POST resumes once the FN key is pressed. The GCM FAULT LED will remain illuminated after startup in normal mode if the output bar graph is not between the warning level and 95 percent. This problem can be caused by the GCM-X being out of calibration or by the presence of particulate in the hydrogen gas. 23 GA0456P01 Rev. A

25 Suspended Operation When the GCM-X is in suspended operation it will monitor the flow rate and particulate level of the hydrogen but it will not generate any alarms or warnings. The GCM FAULT LED will be illuminated and the SAFE LED will be darkened whenever the GCM-X is in this mode of operation. The GCM-X monitors the flow rate with a differential pressure gauge and a calibrated orifice. It monitors the particulate level with an ion chamber detector. The GCM-X will display the differential pressure and the ICD output current on the LED bar graphs. The differential pressure and ICD output current are also available through two fourto 20-milliamp (4-20 ma) outputs. The ICD output current is updated once every one to three seconds and the differential pressure is updated 10 times per second. Normal Operation When the GCM-X is in normal operation it will monitor the flow rate and particulate level of the hydrogen. It will indicate a warning or alarm condition if it is out of specification. The GCM-X monitors the flow rate with a differential pressure gauge and a calibrated orifice. It monitors the particulate level with an ion chamber detector. The GCM-X will display the differential pressure and the ICD output current on the LED bar graphs. The differential pressure and ICD output current are also available through two fourto 20-milliamp (4-20 ma) outputs. The ICD output current is updated once every one to three seconds and the differential pressure is updated 10 times per second. The GCM-X will display a flow warning if the differential pressure drops below the low flow limit or climbs above the high flow limit. The GCM-X will display a warning if the ICD output current drops below the warning level or climbs above 95 percent and remains there for at least four seconds. It will also display a warning during the alarm verification sequence. The GCM-X will initiate an alarm verification sequence if the output current of the ICD drops below 50 percent and remains there for at least four seconds. GA0456P01 Rev. A 24

26 Troubleshooting Table 1 - Customer Contacts Contact Status Ref. 1 ALARM General Purpose WARNING General Purpose TROUBLE General Purpose Energized when a verified alarm occurs Energized when the output level is out of specification De-energized when the GCM-X detects an abnormal condition 1 2 3, 4, 5, 6, 7, 9 1 Applicable line in Table 4 - GCM-X Status 4 Check the fault log to distinguish between items 4, 5, 6 and 7 5 Run a power test to identify power supply problems 25 GA0456P01 Rev. A

27 Table 2 - Display Indicators Indicator Status Ref. 2 LOCAL Lit when the local display has the focus REMOTE Lit when the remote display has the focus POWER SAFE ALARM Lit whenever the display panel is powered and functioning properly Lit when the GCM-X is not in trouble and not in warning or alarm Lit when a verified alarm occurs WARNING Lit when the output level is out of specification 2 Auto Alarm Reset Reset Mode Manual Verification Filter Indicates that a verified alarm condition will be reset automatically upon return to normal Indicates a verified alarm condition can only be cleared by pressing RESET Lit when hydrogen gas passes through the verification filter Trouble GCM Fault Lit when the GCM-X detects an abnormal condition 4, 5, 6, 7 Trouble Flow Lit when the differential pressure is out of specification 3 Trouble Sampler On Sampler Mode Auto Sampler Mode Manual Sampler Start/ Stop Lit when hydrogen gas passes through the collector Indicates that the sampler will engage automatically with a verified alarm Indicates that the sampler must be engaged manually Same as Sampler On Applicable line in Table 4 - GCM-X Status GA0456P01 Rev. A 26

28 Table 3 - Display Keys Key Function Ref. 3 Reset Clear a verified alarm 1 Reset Mode Verification Filter Sampler Mode Sampler Start/ Stop Toggle automatically reset alarm upon return to normal conditions on and off Manually activate the verification filter Toggle automatically start collecting a sample for analysis on and off Manually start collecting a sample for analysis Applicable line in Table 4 - GCM-X Status 27 GA0456P01 Rev. A

29 Table 4 - GCM-X Status Condition Typical Cause Indicators Affected 1 Verified Alarm High concentration of submicron particles are present in the gas stream 2 Warning 3 Gas Flow Problem ICD current is not between warning level and 90 percent of the reference value (see page 21) Differential pressure across the ICD is less than 1.1 inch of water or greater than 2.0 inches of water (see page 21) 4 Unverified Alarm 4 The GCM-X started an alarm verification sequence but was unable to verify the alarm Alarm Relay Verified Alarm LED Warning Relay Warning LED Trouble Relay Trouble Flow LED Trouble Relay Trouble GCM Fault LED 5 Solenoid or Relay Problem 4 A missing or defective relay or solenoid Trouble Relay Trouble GCM Fault LED 6 Power Supply Problem 4,5 One or more power supplies are not within tolerance Trouble Relay Trouble GCM Fault LED 7 I/O Error 4 The GCM-X is detecting a communication error while trying to talk to the I/O board or display Trouble Relay Trouble GCM Fault LED 8 Verifying presence of particles in the gas stream User activation or as part of the alarm verification sequence Verification Filter LED 9 Collecting a sample for analysis User verification or in response to a verified alarm with Sampler Mode Auto enabled Trouble Relay Trouble Sampler On LED Sampler Start/Stop LED Table 5 - Relay Problems Item Stuck On Stuck Off Not Tested Solenoids Open coil, not installed properly or an electronics failure Electronics failure N/A General Purpose Relays Electronics failure Defective relay or an electronics failure GA0456P01 Rev. A 28

30 Maintenance Periodic Maintenance The Generator Condition Monitor is designed for reliable, trouble-free operation and ease of periodic checks and maintenance. Daily Check GCM-X hydrogen flow and adjust if necessary. The output should be at 80 percent. POWER and SAFE indicators should be on. Weekly Push the VERIFICATION FILTER button at the GCM-X display panel. The indicator light should illuminate. There should be little or no change in flow or output. If the flow indication drops more than 20 percent, the filter may be restricted. If the output increases significantly, particulate may be present in the hydrogen. Monthly Perform RELAY TEST check (see SYSTEM description for instructions). Annually Check tubing connections annually, or whenever they have been disturbed. Use leak check solution on joints, fittings and valve packing. Activate MANUAL sampler to obtain a background sample at intervals recommended by the generator manufacturer. When the Generator is Down During periods where the generator is shut down, it is recommended that power be maintained to the GCM-X, particularly during periods of high humidity, in order to maintain an elevated temperature within the ion chamber. This will serve to eliminate the possibility of condensation buildup within the ion chamber. If power plant personnel wish to isolate the GCM-X while power is applied and relieve hydrogen pressure from the instrument, close isolation valves A and B (see Figure 2 - Piping Schematic) and place the auto sampler in manual mode by pressing the sampler mode button (see Figure A3). If power plant personnel wish to isolate the GCM-X and relieve hydrogen pressure from the instrument when power has been removed, close isolation valves A and B (see Figure 2 - Piping Schematic) and open isolation valves C and D. Please note that approximately 1 liter of hydrogen will be released through isolation valves C and D. Tubing and Fitting Replacement The differential pressure measured by the flow gauge includes the drop in some of the internal tubing and fittings. If replacing tubing or fittings is necessary, replacements should be the same size as the original in order to avoid changing the flow calibration. Environment One should be notified of instances where site personnel are performing such replacements. Plant management must assure that individuals performing such work are acting in accordance with Cenelec guidelines, local codes and generally accepted professional practice. Perform a leak check whenever any tubing connections are disturbed. 29 GA0456P01 Rev. A

31 Component Replacement Instructions The GCM-X was designed to facilitate component replacement, when and if it becomes necessary in the field. Several GCM-X components/assemblies may be removed by site personnel and forwarded to Environment One for evaluation repair/replacement, as noted below. In all other instances, the GCM-X will need to be returned to Environment One for servicing, or an Environment One technician will be required on site. Plant management is to assure that individuals performing work on the GCM-X are adequately trained to do so and that they work in accordance with Cenelec requirements, local codes and generally accepted professional practice. If oil contamination is suspected, Environment One recommends that the GCM-X be returned for comprehensive evaluation, cleaning and repair. After the GCM-X has been installed and commissioned, individuals performing service work on the electronics must wear an electrostatic wriststrap. ICD, Filter Solenoid and Sampling System Solenoid The Ion Chamber Detector (ICD) (GD0013G04), Filter Solenoid Assembly, Sampling System Solenoid Assembly and GCM-X Heater (GA0363P01) are mounted on the GCM-X mounting plate, which is an aluminum plate attached to the GCM-X frame by four 3/8-inch nuts. Removal of any of the mounted components is best accomplished by removing the back plate first and then removing the individual assembly. To remove the mounting plate: Disconnect power from the GCM-X. Detach the heater from the mounting plate by removing the four screws on the heater s mounting bracket. Detach grounding wire and other cables from the four wire ties. Detach solenoid coils from the two solenoid valves. Detach tubing connections from assemblies mounted to the mounting plate. Remove the four 3/8-inch bolts that secure the mounting plate to the GCM-X frame. Each of the respective components mounted on the GCM-X back plate can then be removed for service, replacement or return to Environment One. To re-install the assemblies, reverse the process above. Processor Assembly The Processor Assembly (GA0449G01) (GD0082G02+GA0396P03) is located in the flameproof enclosure, which is referred to as the System Electronics. To remove the Controller Assembly: 1. Disconnect power from the GCM-X. GA0456P01 Rev. A 30