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Summary of Contents for EONE GCM-X
- Page 1 UTILITY SYSTEMS Generator Condition Monitor (GCM-X) Installation and Operation Manual GA0353P02 Rev. B...
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Page 2: Table Of Contents
Contents Specifications ............................5 Application ............................6 Principle of Operation ........................6 System Description ..........................7 System Electronics .......................... 7 Display Panel ..........................7 Input/Output Board ......................... 7 Installation ............................8 Mounting ............................8 System Design Considerations ......................9 Transit Time Calculations ........................ 10 Sampling System Components ...................... - Page 3 Log Menu ............................22 Procedures ............................23 Draining the Humidifier ....................... 23 Adjusting the Ambient Airflow ...................... 23 Adjusting the Generator Airflow ....................24 Adjusting the Cloud Chamber Airflow ..................25 Setting the Ambient Gain ......................25 Setting the Ambient Warning Level ....................25 Setting the Ambient Alarm Level ....................
- Page 4 Figures Figure 1 - System Overview ..........................39 Figure 2 - GCM-A Outline ..........................40 Figure 3 - GCM-A Mounting ..........................41 Figure 4 - Customer Interface Wiring ....................... 42 Figure 5 - Closed Circuit “H” Probe ......................... 43 Figure 6 - Closed Circuit “U” Probe ......................... 44 Figure 7 - Open Circuit “Sample Heads”...
- Page 5 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 AT +1 518 346 6161 OR WWW.EONE.COM/ DETECTION. SITE MANAGEMENT IS RESPONSIBLE FOR ASSURING THAT ALL PERSONNEL...
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Page 6: Specifications
Specifications Measurement Characteristics Detection principle Submicron particle detector Air Flow Rate Adjusted by Zone Manifold, nominal 14 LPM Readout (bar graph) Ambient Air 0% to 100% of scale Generator Air 0% to 100% of scale Electrical Characteristics Power Input, grounded power cable 115/230 VAC, 50/60 Hz Output Relays, general purpose Ambient Alarm, Generator Alarm,... -
Page 7: Application
Application The Generator Condition Monitor for air-cooled machines (GCM-A) is a sensitive real-time instrument designed to provide early warning indication of overheating (or arcing) in air- cooled generators before extensive damage can occur. Tests conducted on operating air- cooled generators have shown that the GCM-A can detect thermal decomposition of small amounts of insulating materials. -
Page 8: System Description
System Description The GCM-A is primarily designed for use on air-cooled generators, although application to other air-cooled machines is possible. Its main purpose is to provide early warning and detection of overheating (or arcing) in these machines. The major components of the GCM-A are the System Electronics and the sampling system. System Electronics The System Electronics consist of one display board, one controller board, one input/output board, two airflow metering boards, one power supply, one vacuum pump, one cloud... -
Page 9: Installation
Installation These instructions provide details to facilitate the equipment installation. Mounting The GCM-A (GD0080G01) should be installed indoors. If outdoor installation is necessary, a protective enclosure should be considered and discussed with Environment One. Locate the GCM-A out of direct sunlight to prevent the interior ambient temperature from exceeding 50 C (122 F). -
Page 10: System Design Considerations
System Design Considerations The GCM-A system consists of the detector unit (the GCM-A itself) and an associated air sampling system. When designing a system for a particular application, one needs to consider: a) The configuration of the generator’s cooling system. In particular, it is important to know whether the application is a single pass (open) or enclosed (closed) cooling circuit. -
Page 11: Transit Time Calculations
Transit Time Calculations Environment One will utilize information from the customer to develop a sampling system transit time calculation. The main purpose for this analysis is to verify that the sampling system will meet minimum system requirements for air flow through the sampling system and to establish an expectation for the amount of time an overheat signal generated from within the generator will take to reach the detector unit. -
Page 12: Sampling System Components
Sampling System Components As noted, the GCM-A’s sampling system is composed of a pipe network that delivers an air sample to the GCM-A. The individual components of a GCM-A sampling system may differ from installation to installation (see isometric views Figures 5 though 8 of an open and closed circuit application). -
Page 13: Electrical Connections
Electrical Connections Electrical connections are made through three knockouts provided at the top and bottom of the GCM-A cabinet (Figure 4). The system power requirement is 115/230 VAC (+/- 10%), 50/60 Hz. The source of AC power should be reliable and not subject to severe transients. 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. -
Page 14: System Operation
System Operation GCM-A Initial Startup The GCM-A leaves the factory without any water in the water bottle or in the humidifier to prevent damage during shipping. Before starting the GCM-A, fill the water bottle with distilled water. (WARNING: The use of anything other than distilled water will damage the GCM-A and will void the warranty.) To fill the GCM-A water bottle: •... -
Page 15: Typical Responses To Gcm-A Warning & Alarm Indications
Typical Responses to GCM-A Warning & Alarm Indications This section addresses what a power plant may consider as reasonable actions in response to particular GCM-A indications. It does not purport to cover all instances. The GCM-A provides information for plant personnel to use in making operational decisions. The information provided is often validated by other I&CS. - Page 16 (Typical Responses, cont’d) the generator cooling circuit. In this instance, other site instrumentation should be reviewed for corroborating indications of generator overheating. Differential Warning and Alarm — A Differential Warning or Alarm occurs as a result of a difference existing between Ambient and Generator particle levels. It is an expression of “Generator less Ambient”...
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Page 17: Gcm-A Initialization
GCM-A Initialization Apply system power to the GCM-A. The GCM-A DISPLAY PANEL will respond with (a) all discrete LED’s lit; (b) all segments of the AMBIENT and GENERATOR bar graphs lit; and (c) all pixels of the LCD display on. After a delay of two seconds, (a) all discrete LED’s, except the AC POWER, SYSTEM TROUBLE and FLOW LED’s, will turn off;... -
Page 18: Gcm-A Menu Displays
GCM-A’s LCD display. It is strongly recommended that users familiarize themselves with this section. Additional questions can be forwarded to Environment One at +1 518 346-6161 or www.eone.com/detection. Navigating the LCD Display Four keys are used to control menu operation. The keys are FN, ENTER, UP ARROW and DOWN ARROW. -
Page 19: Menu Navigation Tutorial
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-A default) 1. Press FN to start the menu. The LCD should display the prompt <FUNCTION MENU>. After two seconds the prompt should change to GO REMOTE. -
Page 20: Function (Fn) Menu
Function (FN) Menu · GO REMOTE Select this item to transfer control to an active remote control software session. 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-A cannot detect an active remote control software session, the transfer will be canceled and the GCM-A will remain in local mode. -
Page 21: Test Menu
(Setup Menu, cont’d) · AMBIENT ALARM Select this item to change the ambient alarm level. See Setting the Ambient Alarm Level for more information. · GENERATOR ALARM Select this item to change the generator alarm level. See Setting the Generator Alarm Level for more information. ·... -
Page 22: View Menu
(Test Menu, cont’d) 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-A will display the voltage for each power supply in the format <nominal value>=<present value>. -
Page 23: Log Menu
(View Menu, cont’d) · VIEW FLOW Select this item to display the ambient or generator airflow in liters per minute. Press the up or down arrow keys to toggle between the ambient airflow and the generator airflow. Log Menu · SHOW FAULTS LOG Select this item to view the faults log. -
Page 24: Procedures
DP Gauge. So long as the difference is minor, the end-user need not be concerned. Should the difference between the GCM-A’s internal indicator and the GP Gauge exceed 25 percent, contact Environment One at +1 518 346-6161 or www.eone.com/ detection, for technical support. -
Page 25: Adjusting The Generator Airflow
DP Gage. So long as the difference is minor, the end-user need not be concerned. Should the difference between the GCM-A’s internal indicator and the GP Gage exceed 25 percent, contact Environment One at +1 518 346-6161 or www.eone.com/ detection, for technical support. -
Page 26: Adjusting The Cloud Chamber Airflow
(Adjusting the Generator Airflow, cont’d) Disconnect the differential pressure gauge and replace the sealing caps on the zone manifold taps. Adjusting the Cloud Chamber Airflow When CHAMBER FLOW ADJ is selected, the GCM-A will stop monitoring particulate levels and the SYSTEM TROUBLE LED will illuminate. The prompt CONNECT FLOWMETER will be displayed on the LCD display for reference. -
Page 27: Setting The Generator Gain
(Setting the Ambient Alarm Level, cont’d) When AMBIENT ALARM is selected, the ambient alarm 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 decreased below the ambient warning level or increased beyond 99 percent. -
Page 28: Setting The Differential Alarm Level
(Setting the Differential Warning Level, cont’d) beyond the differential alarm level. Press the ENTER key to save your changes and return to the SETUP MENU. Press the FN key to discard changes and return to the SETUP MENU. Setting the Differential Alarm Level The differential alarm level determines what electrical output from the cloud chamber detector will trigger an ALARM indication. -
Page 29: About The Power Log
(About the Faults Log, cont’d) · An AMBIENT FLOW FAULT is logged when flow rate through the ambient air intake falls below the ambient low flow limit or climbs above the ambient high flow limit. · A GENERATOR FLOW FAULT is logged when flow rate through the generator air intake falls below the generator low flow limit or climbs above the generator high flow limit. -
Page 30: Modes Of Operation
Modes of Operation Startup The GCM-A initializes the display mode to local and all relays to the de-energized position. The GCM-A 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. -
Page 31: Alternating Operation
(Startup Problems, Cont’d.) ambient low flow limit or greater than ambient high flow limit. This error indicates that the airflow needs to be adjusted according to the procedure “Adjusting the Ambient Airflow.” · GEN FLO=N.N LPM a flashing airflow indicates that the airflow indicated is less than the generator low flow limit or greater than generator high flow limit. -
Page 32: Generator Only Operation
(Ambient Only Operation, cont’d) available through two four- to 20-milliamp (4-20mA) outputs. · The particulate level of the generator and ambient air is updated every second. Generator Only Operation • When the GCM-A is in suspended operation, it will monitor the generator particulate level, but it will not generate any alarms or warnings. -
Page 33: Troubleshooting
Troubleshooting Table 1 (Customer Contacts) Status Contact ref. Energized when an ambient alarm occurs, can only be cleared by Ambient Alarm pressing reset. Energized when a generator alarm occurs, can only be cleared by Generator Alarm pressing reset. Energized when a difference alarm occurs, can only be cleared by 3,4,5, Difference Alarm pressing reset. - Page 34 Table 3 (Display Keys) Function ref. Reset 1,2,3 Clear all alarms. Applicable line in Table 4 (GCM-A Status) Table 4 (GCM-A Status) Condition Typical Cause Indicators Affected High concentration of submicron particles are Ambient Alarm Relay 1 Ambient Alarm present in the gas stream. Ambient Alarm LED The ambient output level is above its Warning Relay...
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Page 35: Remote Access
Remote Access Requirements · A null modem cable for a direct connection or an external modem capable of 9600 baud or greater for a dial-up connection (a U.S. Robotics Sportster modem is suggested.). · A copy of GCM-NET for GCM-A version 2.0 or newer. ·... -
Page 36: Changing The Modem String
(Using a Custom Modem String, cont’d) · &R1 — ignore RTS (disable hardware flow control) · &H2 — use XON/XOFF for flow control · &I2 — XON/XOFF to your modem only (not “and remote system”) Changing the Modem String Start the GCM-A Net communication software. Connect to the GCM-A. Select the “SETUP” page. -
Page 37: Establishing A Dialup Connection
Establishing a Dialup Connection 1. Start the GCM-A remote control software. 2. Across the bottom left hand side of the computer screen are four tabs. The tabs are labeled DISPLAY, HISTORY, SETUP and CONNECT. Choose the tab labeled CONNECT. 3. In the upper left hand corner of the setup page is a combo box labeled “Select Communication Port.”... - Page 38 (Configuring the GCM-A for Historical Data Collection, cont’d) 3. Select “Alarm Recording Rate.” Choose the new recording rate from the drop down combo box located beneath the configuration tree. Press the “SAVE” button to update the GCM-A. If this is the first time you are configuring the alarm history recorder, or if you would like to discard all of the previously recorded alarm history, press the “Clear Alarm Log”...
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Page 39: Maintenance
Maintenance Periodic Maintenance The Generator Condition Monitor is designed for reliable, trouble-free operation and ease of periodic checks and maintenance. Daily Check that power is on and that no system troubles are identified. Weekly Check that power is on and that no system troubles are identified. Monthly Perform RELAY TEST check (see SYSTEM description for instructions). -
Page 40: Figure 1 - System Overview
Figure 1 - System Overview GA0383P02 Rev. C... -
Page 41: Figure 2 - Gcm-A Outline
Figure 2 - GCM-A Outline GA0383P02 Rev. C... -
Page 42: Figure 3 - Gcm-A Mounting
Figure 3 - GCM-A Mounting GA0383P02 Rev. C... -
Page 43: Figure 4 - Customer Interface Wiring
Figure 4 - Customer Interface Wiring POWER SUPPLY LINE NEUT POWER IN I/O BOARD GENERATOR 4-20 mA AMBIENT DIFFERENTIAL ALARM n.o. GENERATOR ALARM n.o. AMBIENT ALARM n.o. GP RELAYS COMMON FLOW TROUBLE n.o. SYSTEM TROUBLE n.c. COMMON WARNING n.o. CONTROLLER DB-9 RS232 MODEM... -
Page 44: Figure 5 - Closed Circuit "H" Probe
Figure 5 - Closed Circuit “H” Probe GA0383P02 Rev. C... -
Page 45: Figure 6 - Closed Circuit "U" Probe
Figure 6 - Closed Circuit “U” Probe GA0383P02 Rev. C... -
Page 46: Figure 7 - Open Circuit "Sample Heads
Figure 7 - Open Circuit “Sample Heads” GA0383P02 Rev. C... -
Page 47: Figure 8 - Open Circuit "Probes
Figure 8 - Open Circuit “Probes” GA0383P02 Rev. C... -
Page 48: Figure 9 - Sampling System, 3/8" Typical (Pvc)
Figure 9 - Sampling System, 3/8” Typical (PVC) GA0383P02 Rev. C... -
Page 49: Figure 10 - Sampling System, 1/2" Typical (Pvc)
Figure 10 - Sampling system, 1/2” Typical (PVC) GA0383P02 Rev. C... -
Page 50: Figure 11 - Sampling System, 1/2" Flange Configuration
Figure 11 - Sampling System, 1/2” Flange Configuration GA0383P02 Rev. C... -
Page 51: Figure 12 - Zone Manifold
Figure 12 - Zone Manifold 3/8 NPT TYPICAL BOTH ENDS INLET FROM SAMPLE HEAD 3/16 DIA MTG HOLE THUMB SCREWS TYPICAL FILTER FILTER FLOW D P FLOW ADJUST OUTLET TO DECTECTOR GA0383P02 Rev. C... -
Page 52: Figure 13 - Sample Head
Figure 13 - Sample Head 3/8 NPT 1.25 IN 32 MM SAMPLING HEAD HOUSING SECTION AA 1.50 IN 38 MM SCREEN RETAINING RING DO NOT PAINT GA0383P02 Rev. C... -
Page 53: Figure 14 - Sample Probe
Figure 14 - Sample Probe GA0383P02 Rev. C... -
Page 54: Figure 15 - Zone Manifold Flow, Dp Mm Water
Figure 15 - Zone Manifold Flow, ∆ ∆ ∆ ∆ ∆ P mm Water .6 .7 .8 .9 1.0 8 9 10 ZONE MANIFOLD FLOW P mm WATER GA0383P02 Rev. C... -
Page 55: Figure 16 - Particle Concentration
Figure 16 - Particle Concentration Particle Concentration vs. GCM-A Output GCM-A Output @ Unity Gain GA0383P02 Rev. C... -
Page 56: Figure 17 - Control Panel Detail
Figure 17 - Control Panel Detail GA0383P02 Rev. C... -
Page 57: Figure 18 - Manifold Dp Gage
Figure 18 - Manifold DP Gage Instruction Procedure: 1. Place gage on a level surface and check zero. Adjust if necessary, using the adjustment on the front of the gage. 2. To check flow, remove the caps from the flow differential pressure taps on the manifold. Connect the + tube (high side) to the + flow differential pressure tap, and the –... - Page 58 A PCC Flow Technologies, Inc. Company Environment One Corporation 2773 Balltown Road Niskayuna, New York USA 12309–1090 Tel: (01) 518.346.6161 FAX: 518.346.6188 www.eone.com...
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