Opal Generator Annunciator - Turbine V1 - Rev C

8/12/2019 Opal Generator Annunciator - Turbine V1 - Rev C

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OPAL ANNUNCIATORTurbine - Generator

(Si-TEC Xtend remote display panel with monitoring)


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________________________

Please send your queries and feedback on our publications to:

Dawson Technology Pty Limited231 Holt StreetEagle Farm, QLD 4009AUSTRALIATel: (07) 38684777 {International: (61)-7-38684777}Fax:(07) 38684666 {International: (61)-7-38684666}E-mail: [email protected] web site: http://www.dawsontec.com

________________________


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WARNING

Please read this entire manual and all other publications pertaining to the work to be performedbefore 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 (overtemperature, or overpressure, where applicable) shutdown device(s) that operates totallyindependently 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 mechanicalhydraulic 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 damagesby over current, voltage differences or reverse power.

PLEASE NOTE

This manual has attempted to provide instructions on the techniques of electronic governing and theuse 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 shouldnot be used in any particular application without independent testing and verification by the partyperforming the application.

Independent testing and verification are critical in any application, particularly where malfunction ofthe equipment may result in personal injury and/or property damage.

For these reasons Dawson Technology provides no warranty of any kind, either expressed orimplied, with respect to the contents of this manual, that the examples and data used are consistentwith industry standard and that they meet the requirements of any particular application.


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INDEX

Installation Section

1.0 Overview of the OPAL Generator Annunciator ..........................................2

2.0 Features of the OPAL Generator Annunciator ...........................................3

3.0 Input / Output Description............................................................................4

4.0 Turbine Board Hardware Description .........................................................54.1 Logic Inputs ............................................................................................................................5

4.1.1 Logic 6 / Remote reset switch ........................................................................................54.2 Relay Outputs ........................................................................................................................5

4.2.1 Shutdown Relay..............................................................................................................54.2.2 Prewarn Relay ................................................................................................................54.2.3 Audio Alarm Relay..........................................................................................................54.2.4 Visual Alarm Relay .........................................................................................................54.2.5 Opal Typical Connections...............................................................................................6

4.3 Analog Inputs .........................................................................................................................74.3.1 Inlet pressure Input .........................................................................................................84.3.2 Exhaust pressure Input...................................................................................................84.3.3 Analog 3 Input.................................................................................................................8

4.3.4 Lube Oil Pressure ..........................................................................................................8

5.0 OPAL Hardware Summary ...........................................................................9

Set up & Operation Section

1.0 Key Funct ions .............................................................................................13

1.1 COMMON ............................................................................................................................131.1.1 Silent keypad & lamp test .............................................................................................131.1.2 Scroll Up .......................................................................................................................131.1.3 Scroll Down...................................................................................................................131.1.4 Select ............................................................................................................................131.1.5 Mute ..............................................................................................................................13

1 2 TURBINE 14


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1.3.7 view alarms...................................................................................................................151.3.8 reset alarms ..................................................................................................................15

2.0 Overspeed Protection.................................................................................16

3.0 Menu Structures..........................................................................................173.1 Introductory Menus ..............................................................................................................173.2 Analog input setup menus ...................................................................................................183.4 Logic Switch Input Menus ....................................................................................................19

3.4.1 Logic Input User Settable Text .....................................................................................203.6 Opal Configuration Menus ...................................................................................................21

3.6.1 Alarm Monitoring Speed & Turbine Board Monitoring..................................................213.6.2 MPU Gear Teeth & Module Address ............................................................................21

3.7 Logic Input / Output Monitoring Menus................................................................................223.7.1 Turbine Protection Status Outputs (from power supply board) ....................................223.7.2 Turbine Board logic inputs............................................................................................223.7.3 Turbine Board Relay Output Status..............................................................................23

3.8 Alarm Menus ........................................................................................................................243.8.1 Pre-warn level alarm screen.........................................................................................243.8.2 Shutdown level alarm ...................................................................................................243.8.3 First Up & End of alarms...............................................................................................24

3.9 General Warning Menus ......................................................................................................25

4.0 Special Settings ..........................................................................................264.1 Remote Reset Button...........................................................................................................26

5.0 Opal Module Address Data Reference (read only)...................................27

Appendix 1 Cal ibration Mode........................................................................28


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Installation

Section


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1.0 OVERVIEW OF THE OPAL GENERATOR ANNUNCIATOR

The Si-TEC Xtend series Opal Generator Annunciatorcomprises various features including remotedisplay of Si-TEC Xtend CGC control LCD, metering display of critical governor and generatorparameters, alarms, trip causes and running hours, as well as turbine monitoring and over-speedprotection, all integrated within a single module.

The Opal Generator Annunciator is used in conjunction with the Si-TEC Xtend CGC control module

for generator applications involving steam turbines. These may be used in a wide range ofapplications including power stations, sugar mills, mining, government and commercial buildings,hospitals, defence and telecommunications facilities, marine & shipping, as well as the oil & gasindustry.

In addition to the Opal Generator Annunciator, the Opal Turbine Annunciator is used in conjunctionwith the Si-TEC Xtend ADG control module for display and monitoring of mechanical drive steamturbine applications, including mills, shredders, pumps, compressors, fans, etc.

NOTE: This Opal Generator Annunciator module may only be used with Si-TEC Xtend CGC versionBA_1.XXand BX_1.XXonwards. Earlier Si-TEC Xtend control versions would require firmwareupgrade to allow for interface with the Opal module. Consult Dawson Technology for further details.


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2. FEATURES OF THE OPAL GENERATOR ANNUNCIATOR

Remote displayof the Si-TEC Xtend control (via CAN BUS interface), and designed for mounting onsystem control panel. A 4-line LCD screen allows operators to view actual and reference values ofthe Si-TEC Xtend control. Also includes specific menu keys on the Generator keypad.

Metering of essential generator parameters that include generator Voltage, Frequency, RealPower (kWatts) and Power Factor (lag and lead) This reduces the need for using conventionalmeters and transducers.

Overspeed Protectionability. This feature is designed and built as hardware function independent ofthe main processor. A dedicated speed sensor (MPU) input is available and is required for thisfunction.

Turbine monitoring capability including measuring Inlet Pressure, Exhaust Pressure, Lube OilPressure, Control Supply Voltage, and a user select input (eg. Control Oil Pressure).Alarmfunctionsare available via logic inputs (status) and relay outputs (eg. Pre-Warn, Audible and Visual). Typically,these inputs are configured and set up to receive 4-20mA signal from an external transmitter. Asthese are loop signals that are not fully-isolated from each other, it is recommended that a signalisolator be used for each input. The monitoring also includes specific menu keys on the Turbine keypad.

Turbine protection capability including, Overspeed, Inlet Pressure, Exhaust Pressure, Lube OilPressure, etc. The Shutdown functions are available through logic inputs (status) and relay outputs(Overspeed and Shutdown).

Multiple Opal units may be connected to the Si-TEC Xtend control module via the CAN BUSinterface. These include 1 x primary Opal module (for remote display, Turbine monitoring and Turbineprotection) and up to 2 x secondary Opal modules (for remote display only).


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3. INPUT / OUTPUT DESCRIPTION

3.1 Introduct ion

The Opal Generator Annunciator is a remote display module of a Si-TEC Xtend CGC turbine-generator control, and also includes generator metering, overspeed protection, as well as turbinemonitoring and protection. The Opal Annunciator may also be used for turbine-alternator or for non-generator applications. Chapter 4 through 5provide details of the various logic inputs, relay outputs,analog inputs and analog outputs. This provides information for the relevant application

documentation and drawings, together with details of the input and output hardware specifications ofthe Opal Generator Annunciator module. Accordingly, it is necessary to check all preset values priorto the commissioning of the turbine control system.

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 finalapplication settings.


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4.0 Turbine Board Hardware Description

4.1 Logic Inputs

There are 6 logic inputs on the Opal turbine board.

The logic inputs are isolated and require a 24VDC power source and then they must be switched tothe source 0VDC.

These logic inputs can be programmed to be active on or active off in the Opal configuration.

4.1.1 Logic 6 / Remote reset switch

Logic input 6 can be used as the remote alarm reset.See section 4.1 for details.When this input is set to be remote reset, then the normal timed monitoring on this input is ignored.

4.2 Relay Outputs

4.2.1 Shutdown Relay

The shutdown relay is activated due to any shutdown alarms on the Opal.The shutdown relay is fail-safe, therefore it is on even when there are no alarms.

4.2.2 Prewarn Relay

The prewarn relay is not fail-safe.The prewarn relay is active only when there is prewarn alarms.

4.2.3 Audio Alarm Relay

The audio alarm relay is active when there are any alarms that the Opal is aware of.The audio alarm relay will be active at the same time the piezo sounder is sounding an alarm.When the Mute Siren button is pressed the audio alarm turns off

4.2.4 Visual A larm Relay

The visual alarm relay is active when there are any alarms that the Opal knows about.

Pressing the Mute Siren button has no effect on the visual alarm relay


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6

24 V DC

Use duringcommissioning

only

Magnetic

Pick UpStop Turbine

if circuit iso en

FromBattery *

State of the contactswhen the Opal

is switch off

State of the contactswhen the Opal

is switch off

Start Alarm ifcircuit is open

24 V DC

CAN BusCable to Xtend

24 V DC

Internal resistance6.8k each in ut

Refer to Analog Inputs Section for connection examples

Note: The shieldshould be earth at

one point only

Not Used

Monitoringthe battery

4.2.5 Opal Typical Connections


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4.3 Analog Inputs

All inputs can be calibrated in the Opal Configuration.All Inputs can have their units set in the Opal Configuration.

How to connect the Analog Inputs

-

-+

+

TXTransmitter

Shield

OPAL

Terminal39

Analog Input 1

-

Connection Example

OPAL

+

_

+

_

+

_

+

_

-+

+

TXTransmitter

+

24 Vdc

_

+

24 Vdc

_

51

52

47

48

44

40

43

2000.25W

2000.25W

2000.25W

2000.25W

Shield

Analog Input 2

OPALAnalog Input 3

OPALAnalog Input 4


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Digital

Open /Closed input

Inlet Pressure Open / closed oilpressure sensor

input

Switch to BAT (2mAdrive)

Open /Closed input

ExhaustPressure

Open / closed oiltemperature input


Open /Closed input

Lube OilPressure

Open / closed watertemperature input


Open /Closed input

Configurablelogic 4

Open / closed switch Switch to BAT (2mAdrive)

Open /Closed input

Configurablelogic 5


Open /Closed input

Configurablelogic 6


OutputsRelay Over speed Over speed relay Change over relay

8A contacts

(see note 1)Relay Prewarn Prewarn relay NO contacts

5A contacts(see note 2)

Relay Shutdown System shutdownrelay

NO contacts5A contacts(see note 2)

Relay Audible alarm Audible alarm relay NO contacts5A contacts

(see note 2)

Relay Visual alarm Visual alarm relay NO contacts5A contacts(see note 2)

MiscellaneousSwitch Input Over speed

ResetA remote switch(normally Opencontact), can beplaced this input and

common to reset theoverspeed relay

Common Common

Voltagemeasurement

Speed Gives a voltagewhile the engine isrunning at nominal


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Note 1: The complete Contact Ratings for this relay are:

Rated Load 10A at 120 VAC; 8 A at 30 VDC, resistive load (cos=1)

Rated carry current 10AMax. switching voltage 250 VAC, 30 VDC (UL/CSA standard)

Max. switching current AC: 10 A; DC: 8 A

Max. switching power 1,200 VA, 240W

Failure rate (reference value) 10 mA at 5 VDC

Endurance Mechanical: 10,000,000 operations min. (at 18,000 operations/hr)Electrical: 100,000 operations min. (at 1,800 operations/hrs)

36,000 operations min. (10 A at 250 VAC)

Note 2: The complete Contact Ratings for this relay are:

Rated Load 5A at 250 VAC, 5 A at 30 VDC, resistive load (cos=1)

Rated carry current 5 A

Max. switching voltage 250 VAC, 30 VDC

Max. switching current 5 A

Max. switching power 1,250 VA, 150W

Failure rate (reference value) 10 mA at 5 VDC

Endurance Mechanical: 20,000,000 operations min. (at 18,000 operations/hr)Electrical: 100,000 operations min. (5 A at 250 VAC/30 VDC, resistive load)

300,000 operations min. (2 A at 250 VAC/30 VDC, resistive load)


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Set up &Operation


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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 onthe second and third Opal units if the keys on the primary Opal unit have not been pressed in the last30 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 theOpal.

1.2.3 Store

Stores the altered variable value. (Only while in factory configuration mode)

1.2.4 Sign

Decrements a variable. (Only while in factory configuration mode)

1.2.5 + Sign

Increments a variable. (Only while in factory configuration mode)

1.2.6. view alarmsReturns the display to the TURBINE mode.Shows the alarms that are present for the Turbine

1.2.7 reset alarms

Wh i TURBINE di l d l l th t b t


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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 30seconds.

1.3.1 Generator Home

Returns the display to the Si-TEC Xtend modeTakes the display to the default Home Si-TEC Xtend menu.

1.3.2 Contro lReturns the display to the Si-TEC Xtend modeTakes the display to the Si-TEC Xtend Control Information menu

1.3.3 Trip cause

Returns the display to the Si-TEC Xtend modeTakes the display to the Si-TEC Xtend Trip Cause Information menu

1.3.4 Hours

Returns the display to the Si-TEC Xtend modeTakes 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 modeTakes 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


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2.0 Overspeed Protection

The Opal comes with an in-built & dedicated turbine overspeed protection functions:

This function requires an MPU for speed monitoring & triggering of Overspeed Relay upondetection.

The function of the hardware protection is not controlled by the software, although it is monitored bythe software.

The overspeed protection is custome set to be a speed level at typically 10% above the normal

running speed of the turbine.

The overspeed limit is set by adjusting the Pot P2 on the back of the Opal. Pot P3 is not applicable.

When the turbine speed has exceded the overspeed set point, the overspeed relay latches on.

The overspeed relay is intended to go in line with the turbine protection equipment (eg. SD Solenoid).

The overspeed relay can be reset by pressing the RESET ALARMS button on the Turbine side ofthe Opal. Another way to reset the overspeed relay is by pulling the Overspeed Reset pin low (pin16 on the rear of the Opal). Note that Overspeed Relay cannot be rest while condition is still present.

TURBINEPotentiometers


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3.0 Menu Structures

3.1 Introductory Menus

CONT VOLTS 00. 0 VTURBI NE RPM 0rpm

I NLET SP 0kPaEXHAUST SP 0kPa

LUBE OI L P 0kPaANALOG 3 0kPa

These 2 menus show the present status of the analog inputs.

To navigate through the menus in the factory configuration mode (See Appendix 3), the Selectbutton gives access to the options included in the menu. Once the changes have made and store, theSelect button will also exit from that menu when pressed.


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3.3 Logic Switch Input Menus

I NLET SP SWI TCHAl ar m i f : Cl osedAl ar m i s: Shut downDel ay: Tr i g 15 Al m 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 turbineis 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 themessage Never Monitor.

Then delay on refers to the time that the condition must be present for the alarm to occur. This is onlymonitored after the idle time has expired.

The delay on is limited to 0 to 60 seconds.

There are three dedicated logic inputs:Inlet Pressure SwitchExhaust Pressure SwitchLube Oil Pressure Switch

The description of the dedicated logic inputs is fixed


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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 besaved. Note: In order to store the new description the 10 characteres must be stored (this mean thatalso the blank spaces should be entered)


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3.5 Logic Input / Output Monitoring Menus

3.5.1 Turbine Protection Status Outputs (from power supply board)

The protection logic display shows the current state of the protection logic on the Opal power supplyboard.

The state of each inpt is listed as (O)pen or (C)losed.

The logic assignments are:O overspeed conditionC reservedM MPU condition

3.5.2 Turbine Board logic inputs

The turbine monitor logic display shows the current state of the logic on the Opal turbine board.


The logic assignments are:E Exhaust pressure sensor switchL Lube Oil Pressure sensor switch4 logic input 45 logic input 56 logic input 6I Inlet Pressure sensor switch

PROTECTI ON LOGI C- - - OCM- -CCCOCCCC

TURBI NE MONI TOR LOGI C- EL456- ICOOOOOCO


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3.5.3 Turbine Board Relay Output Status

TURBI NE MONI TOR RELAYSVASP- - - -OOOOOOOO

The monitor relays display shows the current state of the Opal turbine board. relays


The logic assignments are:V Visual alarm relayA Audible alarm relayS Shutdown alarm relayP Prewarn alarm relay

If the Opal is in factory configuration mode then by using the + or - buttons toggles the subsequentrelay from off to on.


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3.6 Alarm Menus

Alarms and warnings will only be shown if they are present.

If the alarms are being shown and the turbine home key is pressed, then the alarms will be hiddenso that the operator can view how the monitoring has been set up.

Using the scroll up and down goes through the list of all the alarms that have occurred.

3.6.1 Pre-warn level alarm screen

If only prewarning alarms are present then the PRE WARNING message will appear.

3.6.2 Shutdown level 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. Anyprewarning messages will also be shown while scrolling.

Oi l Pr essure Pr ewar n- * PREWARNI NG *-

- * ALARM *-

Oi l Pressure Shut down- * ALARM *-

- * ALARM *-


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3.7 General Warning Menus

When the Sitec Xtend keypad has been used it locks out the Opal generator key functions for 30seconds.

When the Opal generator keys are pressed during this time the Xtend keys in use warning appearsfor a few seconds.

Engi ne i s Shut DownENABLE RUN I NPUT #1LOW. START I NHI BI TED*- Xt end key i n use- *

I NLET 0kPaEXHAUST 0 oC

LUBE OI L 0 oc>No Moni t or i ng Uni t

Documents

Opal Generator Annunciator - Turbine V1 - Rev C