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Copyright 2007 by Dawson Technology Pty Limited. All rights reserved. This document may not be reproduced or distributed to a third party without prior approval.
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WARNING Please read this entire manual and all other publications pertaining to the work to be performed before installing, operating or servicing this equipment. Practise all plant and safety instructions and precautions. Failure to follow instructions may result in personal injury and/or damage to property.
WARNING The engine, turbine or other type of prime mover must be equipped with an overspeed (over temperature, or overpressure, where applicable) shutdown device(s) that operates totally independently of the prime mover control device(s) to protect against runaway or damage to the prime mover and to protect against possible personal injury or loss of life, should the mechanical hydraulic governor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), or the controlled device(s) fail. In the case of generator sets, an effective monitoring system must be available to prevent damages by over current, voltage differences or reverse power.
PLEASE NOTE This manual has attempted to provide instructions on the techniques of electronic governing and the use of accessories, using examples and data that are believed to be accurate. However, the examples, data and other information are intended solely as a training aid and should not be used in any particular application without independent testing and verification by the party performing the application. Independent testing and verification are critical in any application, particularly where malfunction of the equipment may result in personal injury and/or property damage. For these reasons Dawson Technology provides no warranty of any kind, either expressed or implied, with respect to the contents of this manual, that the examples and data used are consistent with industry standard and that they meet the requirements of any particular application. Dawson Technology disclaims any implied warranties for the manuals quality, performance, merchantability or fitness for any particular purpose. Dawson Technology also disclaims all liability for direct, indirect, incidental or consequential damages that result from any use of the examples, data or other information in this manual.
IMPORTANT Correct set points must be entered into the Opal Annunciator module for each specific application prior to starting the Turbine. Particular care should be taken with regard to cable shielding and power supply connections to ensure the equipment meets all requirements specified by Dawson Technology concerning EMI.
5.0 Opal Module Address Data Reference (read only)...................................27 Appendix 1 Calibration Mode........................................................................28
Installation Section
3.2 Terminology
The following is a list of common terms used in this manual: Analog Input: 4-20mA input signals. Logic Input: a switched input voltage (nominally 24Vdc). Relay Output: voltage free contacts for providing output control, status or alarm. High Input: when 24Vdc is applied to a logic input. Low Input: when the logic input has no input voltage. Preset Value: pre-shipped set point value of an internal control function that is adjustable for final application settings.
24 V DC
24 V DC
Not Used State of the contacts when the Opal is switch off
From Battery *
Magnetic Pick Up
TX Transmitter
Shield
Terminal 39 40
200 0.25W
+ _
43 44
200 0.25W
+ _
+ 24 Vdc _
47 TX Transmitter 48
200 0.25W
+ _
Shield
51 52
200 0.25W
+ _
Caution: The negative inputs (-) of the Op-amps are connected internally, (Common reference)
4.3.1 Inlet pressure Input The Inlet pressure input is a 4-20mA input.
4.3.2 Exhaust pressure Input The Exhaust pressure input is a 4-20mA input.
4.3.4 Lube Oil Pressure The Lube Oil Pressure input is a 4-20mA input. Note: It is recommended that signal isolators be used for each individual analog input, to minimise any signal measurement discrepancy due to external noise.
General
Supply Voltage Supply Voltage Power Opal 14-32 V DC Max Current @ 24V - 600 mA Max Current @ 14V - 1 Amp -
Display
LCD 3 x 7 seg LED LED 3 x 7 seg LED LED 3 x 7 seg LED 3 x 7 seg LED LED LED LED LED Main display Volts KV Power MW Hz PF Lag Lead Turbine Generator 4 x 20 LCD display for text messages 9.5mm high Generator voltage Kilovolts indicator for display Generator Power Megawatt indicator for display Generator frequency Generator power factor PF Lag indicator PF Lead indicator Indicator that LCD is displaying Turbine parameters Indicator that LCD is displaying Generator (Si-TEC Xtend) parameters
0 999 kV 0kW 999 MWatt 0.0 99.9 Hz 1.00 0.00 lead or lag
Inputs
Analog Sensor input Inlet Pressure Pressure analog input Pressure analog input Pressure analog input User analog input From 0.2 to 4.8V or From 4 to 20mA according to the sensor. From 0.2 to 4.8V or From 4 to 20mA according to the sensor. From 0.2 to 4.8V or From 4 to 20mA according to the sensor. From 0.2 to 4.8V or From 4 to 20mA according to the sensor. 20Hz - 20Khz
Sensor input
Sensor input
Sensor input
MPU
Magnetic Pick Up
Digital Open / Closed input Open / Closed input Open / Closed input Open / Closed input Open / Closed input Open / Closed input
Inlet Pressure Exhaust Pressure Lube Oil Pressure Configurable logic 4 Configurable logic 5 Configurable logic 6
Open / closed oil pressure sensor input Open / closed oil temperature input Open / closed water temperature input Open / closed switch Open / closed switch Open / closed switch
Switch to BAT (2mA drive) Switch to BAT (2mA drive) Switch to BAT (2mA drive) Switch to BAT (2mA drive) Switch to BAT (2mA drive) Switch to BAT (2mA drive)
Outputs
Relay Relay Relay Relay Relay Over speed Prewarn Shutdown Audible alarm Visual alarm Over speed relay Prewarn relay System shutdown relay Audible alarm relay Visual alarm relay Change over relay 8A contacts (see note 1) NO contacts 5A contacts (see note 2) NO contacts 5A contacts (see note 2) NO contacts 5A contacts (see note 2) NO contacts 5A contacts (see note 2)
Miscellaneous
Switch Input Over speed Reset A remote switch (normally Open contact), can be placed this input and common to reset the overspeed relay Gives a voltage while the engine is running at nominal speed. Check Overspeed protection section. Set the voltage reference to trigger the overspeed protection by adjusting the pot P2. Check Overspeed protection section.
Common Speed
Voltage measurement
Reference
10
11
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1.1 COMMON
1.1.1 Silent keypad & lamp test When a key is normally pressed a tactile beep is sounded to indicate that key has been pressed. Pressing the silent keypad & lamp test toggles that tactile sound on or off. At the same time all of the segments on the LED displays will light for approximately 1 second.
1.1.2 Scroll Up Scrolls up through the different menus, while the LCD is in the TURBINE or the GENERATOR modes
1.1.3 Scroll Down Scrolls down through the different menus, while the LCD is in the TURBINE or the GENERATOR modes
1.1.4 Select Selects the menu option, while the LCD is in the TURBINE or the GENERATOR modes
1.1.5 Siren Mute Silences the audio piezo alarm when present, and also turns off the audio alarm relay
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1.2 TURBINE
Note: In the case there are two or three Opal units working together, the turbine keys only work on the second and third Opal units if the keys on the primary Opal unit have not been pressed in the last 30 seconds.
1.2.1 Turbine Home Returns the display to the TURBINE mode, and puts the menu at the top level. Also restricts the menu selection to just the introductory menus. If there are turbine alarms present, then the alarm display is masked and the normal display is allowed.
1.2.2 Turbine config Returns the display to the TURBINE mode. Also allows access to menus other than the introductory menus To set the unit into calibration mode the user should press 5 consecutive times Turbine config button on the Turbine side. In previous units this button must be pressed while turning off and on the Opal.
1.2.3 Store Stores the altered variable value. (Only while in factory configuration mode)
1.2.6. view alarms Returns the display to the TURBINE mode. Shows the alarms that are present for the Turbine
1.2.7 reset alarms When in TURBINE display mode, clears any alarms that may be present.
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1.3 GENERATOR
These keys are only active if the keys on the Si-TEC Xtend have not been pressed in the last 30 seconds.
1.3.1 Generator Home Returns the display to the Si-TEC Xtend mode Takes the display to the default Home Si-TEC Xtend menu.
1.3.2 Control Returns the display to the Si-TEC Xtend mode Takes the display to the Si-TEC Xtend Control Information menu
1.3.3 Trip cause Returns the display to the Si-TEC Xtend mode Takes the display to the Si-TEC Xtend Trip Cause Information menu
1.3.4 Hours Returns the display to the Si-TEC Xtend mode Takes the display to the Si-TEC Xtend Operating Hours Information menu
1.3.5 3 phase Returns the display to the Si-TEC Xtend mode Takes the display to the Si-TEC Xtend Three Phase AC Information menu
1.3.6 peak hold Returns the display to the Si-TEC Xtend mode Takes the display to the Si-TEC Xtend Peak Hold Information menu
1.3.7 view alarms Returns the display to the Si-TEC Xtend mode. Takes the display to the Si-TEC Xtend Alarm Information menu
1.3.8 reset alarms Returns the display to the Si-TEC Xtend mode. Resets the Si-TEC Xtend Alarm Conditions & History menu
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-*
ALARM
*-
16
To navigate through the menus in the factory configuration mode (See Appendix 3), the Select button gives access to the options included in the menu. Once the changes have made and store, the Select button will also exit from that menu when pressed.
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INLET SP ALARM Low Pre High 0 120 200 kPa Delay: Trig 59 Alm 5
These menus show how each of the analog inputs have been set up. The parameters can be altered only when the Opal is factory configuration mode (See Appendix 3). To change the parameters , press Select, navigate using the up & down arrow keys, use + and - to alter a value. Finally press store to save the new value.
Each analog input is monitored for a too low and a too high condition. If either of these occur then an alarm will occur and the shutdown relay will activate.
The pre-warning alarms work as follows: INLET PRESSURE prewarn works on a falling value EXHAUST PRESSURE prewarn works on a rising value LUBE OIL PRESSURE prewarn works on a falling value USER ANALOG 3 prewarn works on a rising value CONTROL VOLTAGE prewarn works on a falling value If a prewarn alarm occurs, then a prewarn relay will activate.
The monitoring of each of these inputs is controlled by the delay times. If the idle delay is set to 0 seconds, then the input will be monitored at all times whether the turbine is running or not. This is shown by the message Always. If the idle delay is set to 61 seconds then the input is not monitored at all. This is shown by the message Never Monitor. Then delay on refers to the time that the condition must be present for the alarm to occur. This is only monitored after the idle time has expired. The delay on is limited from 1 to 60 seconds.
The units for each of the analog inputs can also be set to be one of the following options: (none), kPa, psi, bar, oC, oF, sec, rpm, ppr, V, %.
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INLET SP SWITCH Alarm if: Closed Alarm is: Shutdown Delay: Trig 15 Alm 5
These are the menus showing the monitoring of the logic inputs. The parameters can be altered only when the Opal is in factory configuration mode (See Appendix 3). To change the parameters , press Select, navigate using the up & down arrow keys, use + and - to alter a value. Finally press store to save the new value.
Each of the inputs can be configured to be active open or active closed. (Alarm if)
Each of the inputs can be set to operate the prewarn or the shutdown relay. (Alarm is)
The monitoring of each of these inputs is controlled by the delay times. If the idle delay is set to 0 seconds, then the input will be monitored at all times whether the turbine is running or not. This is shown by the message Always Monitor. If the idle delay is set to 61 seconds then the input is not monitored at all. This is shown by the message Never Monitor. Then delay on refers to the time that the condition must be present for the alarm to occur. This is only monitored after the idle time has expired. The delay on is limited to 0 to 60 seconds.
There are three dedicated logic inputs: Inlet Pressure Switch Exhaust Pressure Switch Lube Oil Pressure Switch The description of the dedicated logic inputs is fixed. The are three definable logic inputs Logic 4 Logic 5 Logic 6 The three definable inputs have a 10 character text string that can be set to describe the sensor input. The connections are clearly define by the labels at the rear of the unit, as shown in the following page:
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3.3.1 Logic Input User Settable Text For the logic inputs 4, 5 and 6 there is a 10 character settable description of the input. The parameters can be altered only when the Opal is factory configuration mode. To change the parameters , press Select, navigate using the up & down arrow keys. When the user text menu is showing then the description can be changed. Use + and - to alter a character value. The character being changed will flash. Use store to save the changed character and move to the next character. When the last character has been changed and the store is pressed , then the new decription will be saved. Note: In order to store the new description the 10 characteres must be stored (this mean that also the blank spaces should be entered)
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TURBINE MONITOR Speed 0rpm Trig Speed @ 3000rpm MPU gear teeth 60
The Speed shows the current calculated speed of the turbine. This value cannot be edited. n.b. The Opal must have an MPU attached to the turbine for this function to work. The Trig Speed @ is the speed at which the monitoring of analog input sensors or logic input switches (where applicable) if there is a value entered for Trig Speed. n.b. The Opal must have a dedicatec MPU sensor input from the turbine for the Trig. Function to enable the turbine monitoring. The MPU gear teeth is the number MPU pulses per turbine revolution.
Off 0
The Monitoring enables or disables all of the turbine board monitoring. If the turbine board is not installed then this option should be set to Off The Module Addr is the module number. Up to 3 Opal modules can be connected to the one Sitec Xtend. Only module 0 will monitor any alarms, modules 1 & 2 are only slaves to module 0.
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The turbine monitor logic display shows the current state of the logic on the Opal turbine board. The state of each inpt is listed as (O)pen or (C)losed. The logic assignments are: E Exhaust pressure sensor switch L Lube Oil Pressure sensor switch 4 logic input 4 5 logic input 5 6 logic input 6 I Inlet Pressure sensor switch
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The monitor relays display shows the current state of the Opal turbine board. relays The state of each inpt is listed as (O)pen or (C)losed. The logic assignments are: V Visual alarm relay A Audible alarm relay S Shutdown alarm relay P Prewarn alarm relay If the Opal is in factory configuration mode then by using the + or - buttons toggles the subsequent relay from off to on.
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Oil Pressure Prewarn -* PREWARNING *If only prewarning alarms are present then the PRE WARNING message will appear.
-*
ALARM
*-
Oil Pressure Shutdown -* ALARM *When a shutdown alarm occurs the display shows the ALARM message.
3.6.3 First Up & End of alarms Using the scroll up and down goes through the list of all the alarms that have occurred. Any prewarning messages will also be shown while scrolling.
-* ALARM *-* FIRST ALARM *Oil Pressure Shutdown -* END OF ALARMS *When the last alarm has been shown the END OF ALARMS message is shown, and the first alarm that occurred is also shown at the same time.
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Engine is Shut Down ENABLE RUN INPUT #1 LOW. START INHIBITED *-Xtend key in use-*
When the Sitec Xtend keypad has been used it locks out the Opal generator key functions for 30 seconds. When the Opal generator keys are pressed during this time the Xtend keys in use warning appears for a few seconds.
When the Monitoring is turned off (i.e. when the board is not installed) and the Opal Turbine keys are used, the display shows the turbine status and the No Monitoring Unit warning for a few seconds and the display is returned to the Sitec Xtend mode.
25
26
byte 0 - Digital inputs (high byte of unit) bit 0 - Inlet Pressure Switch bit 1 - Status of Opal Local LED bit 2 - Logic Input 6 switch bit 3 - Logic Input 5 switch bit 4 - Logic Input 4 switch bit 5 Lube Oil Pressure switch bit 6 Exhaust Pressure switch bit 7 - MPU status (on / off) byte 1 - Alarm Status (from analog inputs) High / Over (low byte of unit) bit 0 - Oil Pressure bit 1 - Oil Temperature bit 2 - Water Temperature bit 3 - battery bit 4 - analog 3 bit 5 - not used ( = 0) bit 6 - not used ( = 0) bit 7 - not used ( = 0)
2066
Logic Status 2
byte 2 - Alarm Status (from analog inputs) Under / Low (high byte of unit) bit 0 - Inlet Pressure bit 1 - Exhaust Pressure bit 2 - Lube Oil Pressure bit 3 - battery bit 4 - analog 3 bit 5 - not used ( = 0) bit 6 - not used ( = 0) bit 7 - not used ( = 0) byte 3 - Alarm Status (from analog inputs) Pre-Warn (low byte of unit) bit 0 - Inlet Pressure bit 1 - Exhaust Pressure bit 2 - Lube Oil Pressure bit 3 - battery bit 4 - analog 3 bit 5 - not used ( = 0) bit 6 - not used ( = 0) bit 7 - not used ( = 0)
2067
Logic Status 3
byte 4 - Shutdown Alarm Status (from digital inputs) bit 0 - Inlet Pressure Switch bit 1 - Exhaust Pressure Switch bit 2 - Lube Oil Pressure switch bit 3 - Logic 4 bit 4 - Logic 5 bit 5 - Logic 6 bit 6 - Overspeed Relay Alarm Active bit 7 - MPU Open Alarm Active byte 5 - Prewarn Alarm Status (from digital inputs) bit 0 - Inlet Pressure Switch bit 1 - Exhaust Pressure Switch bit 2 - Lube Oil Pressure switch bit 3 - Logic 4 bit 4 - Logic 5 bit 5 - Logic 6 bit 6 - not used ( = 0) bit 7 - not used ( = 0)
2068
Turbine Speed
27
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Dawson Technology
Designed and Manufactured in Australia
Generator Annunciator
tend series
kV
MW
MENU
LED Display Values: RMS
TURBINE
home
flashes on alarm
flashes on alarm
GENERATOR
home control
m ute
select
store
engine config
siren
view alarms
view alarms
trip cause
hours
Parameters
reset alarms
reset alarms
3 phase
peak hold
PN122-125
Front View
(Cut Out is 254 x 254 mm)
Side View