000-1533A OM3 User Guide PDF

On-Line Circuit Breaker Performance
and SF6 Gas Density Monitor

User’s Guide
©FFS 000-1533 Rev A

LIABILITY DISCLAIMER
INCON™ (Intelligent Controls) reserves the right to change this document and specifications at any time without notice.
INCON™ makes no express or implied warranty with regard to the content of this User’s Guide. INCON™ assumes no
liability for errors or omissions, or for any damages, direct or consequential, that may result from the use of this document
or the equipment it describes. This User’s Guide is written for the OPTIMIZER3 with firmware version 1.1.
INTELLECTUAL PROPERTY
This document contains proprietary information and is protected by copyright. All rights reserved. This document may
be reproduced so long as it remains in the custody of the original purchaser, and is used only by the original purchaser’s
personnel for informational purposes. OPTIMIZER3 is a registered trademark of Intelligent Controls.
Only qualified personnel should undertake application, installation, and use of the
Warning
OPTIMIZER3 on any power system. While applying this device on a power system, there
is always the possibility of faulty equipment operation and electric shock. Any of these
situations may result in injury or death.
RETURN SHIPPING CHARGES

INCON™ will not accept shipments of returned products without a Return Goods Authorization (RGA) number. RGAs are
obtained by contacting Technical Support. No RGAs will be given without the serial number. Return material remains the
property of the buyer until replaced or repaired.
UNDER WARRANTY: INCON™ will pay all freight and insurance charges for RGAs.
NON-WARRANTY: It is the buyer’s responsibility to prepay all freight and insurance charges for RGAs.
Refer to Warranty policy document #000-1397.
CONTACT INFORMATION: INCON Technical Service

24/7 207-571-1180
FAX 207-283-0158
General Inquiries 800-872-3455
www.incon.com/contact.aspx

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Contents
LIABILITY DISCLAIMER.......................................................................................................... 2
INTELLECTUAL PROPERTY.................................................................................................. 2
RETURN SHIPPING CHARGES............................................................................................. 2
1.0 INTRODUCTION..........................................................................................................4
1.1 Overview............................................................................................................................ 4
1.3 CT Inputs........................................................................................................................... 5
1.4 Control Inputs.................................................................................................................... 6
1.5 Input Power........................................................................................................................ 6
1.6 Communication Ports........................................................................................................ 6
1.7 Communications Software................................................................................................. 7
1.8 Self-Diagnostics................................................................................................................. 7
1.9 Specifications..................................................................................................................... 7
2.0 INSTALLATION............................................................................................................8
2.1 Mounting............................................................................................................................ 8
2.2 Current Pickup Coils.......................................................................................................... 9
2.3 SF6 Sensor Mounting...................................................................................................... 10
Mounting Location........................................................................................................................ 10
TEE Adapters................................................................................................................................11
LenSense Active Lens for SF6 Gauge......................................................................................... 12
2.4 SF6 Gas Monitoring......................................................................................................... 12
SF6 Parameter Set Up................................................................................................................. 13
SF6 Alarm Settings...................................................................................................................... 14
SF6 GIL (Gas Insulated Transmission Line) Application.............................................................. 15
2.5 Pressure or Density Trend Alarm..................................................................................... 17
2.6 Temperature Monitoring................................................................................................... 17
2.7 Voltage Monitoring........................................................................................................... 18
2.8 Current Monitoring........................................................................................................... 18
2.9 Heater Monitoring Using UPSM (Universal Power System Monitor)............................... 19
2.10 Circuit Breaker Monitor Function................................................................................... 20
2.11 Navigation...................................................................................................................... 21
2.12 Location- Where to install the OPTIMIZER3.................................................................. 23
3.0 SETUP & CONFIGURATION.....................................................................................24
3.1 Purpose of Circuit Breaker Monitoring............................................................................. 24
3.2 Choosing the Desired Operating Mode........................................................................... 24
Mode 1......................................................................................................................................... 24
Mode 2......................................................................................................................................... 26
Mode 3......................................................................................................................................... 27
Mode 4......................................................................................................................................... 29
Mode 5......................................................................................................................................... 31
Mode 6......................................................................................................................................... 34
Mode 7......................................................................................................................................... 36
3.3 Application Concept......................................................................................................... 39
3.4 Circuit Breaker Open Operation- Monitoring Example.................................................... 40
3.5 Circuit Breaker Close Operation- Monitoring Example.................................................... 41
3.6 Wiring Connections to circuit breaker control circuits...................................................... 42
Circuit Breaker Control Signals- Polarity Settings........................................................................ 43
3.7 Sensors............................................................................................................................ 46
4.0 Export Reports, Action, Active Events, Reset.......................................................46
5.0 Firmware Upgrade Process.....................................................................................48
6.0 DNP Setup and Navigation......................................................................................49
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1.0 INTRODUCTION
1.1 Overview
The OPTIMIZER3 is an on-line continuous performance monitor for high voltage circuit breakers. It provides information
for the process of Condition-Based Maintenance (CBM). OPTIMIZER3 is designed to be installed inside the circuit breaker
control cabinet, CT marshalling box, or other location where necessary access to the required circuits are conveniently
available. These include control and secondary CT circuits, and SF6 gas plumbing.
OPTIMIZER3 performs four main functions:
1. Mechanism Timing
2. Estimation of interrupter condition as degraded by internal arcing effects
3. Measurement of SF6 gas attributes
4. Auxiliary systems
OPTIMIZER3 measures and logs the following information:
• Breaker status OPEN/CLOSE • Restrike Occurrence
• SF6 Density • Contact Life; cumulative I2T or IT
• SF6 Temperature • Last Trip Coil Energized (TC1 / TC2)
• SF6 Liquefaction Occurrence • Close Latch Time
• SF6 Dew Point • Open Average Velocity
• Motor Run Time • Close Average Velocity
• Motor Runs per Day • Open Operation Arcing Time
• Motor I2T • Clearing Time
• Motor Total Run Time • Travel Time
• Heater Status On/Off • Closing Time
• Heater Current • Total Operation Count
• OM3 Line Voltage • Total Operation Count
• Ambient Cabinet Temperature • Switching Operation Count
• Control cabinet door status open/closed • Fault Operations Count
• Total Days since Last Operation • Sensor Malfunction
The OM3 continuously monitors the SF6 attributes according to what sensors are used. Available sensors include:
• Temperature-Compensated Pressure analog sensor (plumbed into gas piping)
• Temperature-Compensated Pressure analog sensor (Lensense or Hybrid SF6 Controller)
• SF6 Temperature (model DSDP digital true density sensor)
• SF6 Density analog
• SF6 Dew Point
The OM3 uses these measured attributes to calculate other user-defined properties in desired units. OM3 calculates
density, pressure, trends, trend rates, changes in mass, changes in dew point, etc. Most attributes can be compared to
static alarm settings for assertion when they go out-of-tolerance. OM3 issues alarms via contacts, through DNP3.0 points,
and via HTTPS web service, locally or remotely.
The OM3 Installation has been kept simple, with few connections required to the circuit breaker control circuits. Simple
electrical connections are made to trip and close circuits. Open-core CTs are attached to bushing CT circuits and SF6 gas
sensors may be installed on the gas plumbing in a number of ways.
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The OM3 can be applied to any type of circuit breaker- vacuum, bulk oil, minimum oil, air blast, SF6, live tank or dead
tank. OM3 is useful on small sub-transmission circuit breakers to large EHV circuit breakers. Contact wear models vary
slightly by manufacturer and technology used. During set up, the manufacturer’s limits for contact wear and timing should
be used. If this information is not available, then IEEE C37.06-1989 standard should be used as a guide.
All wiring diagrams are shown with circuit breaker in the OPEN position with no gas.
1.2 Sensor Inputs

The OM3 includes eight inputs for sensors and five inputs for control signals.
Loop-powered (2-wire) digital or analog sensor inputs.

Supports 4-20 mA sensors or digital sensors with up to 12
volt compliance voltage. Twisted-pair wiring recommended.
Loop-powered (2-wire) analog sensor inputs. Supports

4-20 mA sensors with up to 20 volt compliance voltage.
Twisted-pair wiring recommended.
Sensor inputs A, B, and C are dual function. They accept either 2-wire 4-20ma analog sensors or digital 2-wire protocol
used by DSDP digital density sensor. Sensor inputs 1-5 are 4-20ma analog only and do not accept the digital protocol. For
each 4-20ma analog sensor, there is a corresponding setup area in the CONFIGURATION web pages where the scaling
of the input is done. The digital inputs require no scaling and the OM3 scales those signals automatically.
12 VDC sensor power is provided for sensors A, B, and C. 20 VDC sensor power is provided for Sensors 1-5.
1.3 CT Inputs
The OM3 measures the current flowing through the bushing CT secondaries of the circuit breaker. These measurements
are used in the contact wear calculations, arc time, and determination of load versus fault Opening characterization. Line
current is also logged. During installation, small split-core CTs are attached to the relevant bushing CT circuits, noting the
bushing turn ratio. Depending upon the maximum current expected in the bushing CT circuits, an optimal split-core CT is
selected. INCON offers split-core CTs with the following full-scale ratings:
INCON Part Number CT-20 CT-30 CT-50 CT-100 CT-160 CT-250 CT-400 CT-800
Full Scale Rating (amps) 20 30 50 100 160 250 400 800
Range (amps) 1.4-10 2.1-30 3.5-50 7-100 11.2-160 17.5-250 28-400 56-800
Each Part Number includes a set of three CTs. One CT is attached to each phase. The CTs are compatible with 50 or 60
Hertz power systems. The CTs snap on over existing insulated bushing CT circuits without tools are rated 1.0 % accuracy
and 0.05VA burden at 5 amps. Removal or disruption of bushing CT circuits is not necessary.
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1.4 Control Inputs
The five control inputs are each fused on both legs. The use of the inputs is determined by the circuit breaker application. Each
control input is multi-function and is defined in the system CONFIGURATION. The control inputs are continuously interrogated
to detect when the control circuit nodes are at active or inactive state. Each AUX input presents 540kΩ input impedance.
1.5 Input Power

The OM3 operates from station battery or AC station service. Input voltage range is 110-250 VDC or 90-264 VAC. Power
consumption is 40 VA maximum. The power input automatically accepts either AC or DC, no manual.
Both power supply legs are fused. If external fuses are used, 3.15 amp slow-blow are recommended. Power input leads
are isolated from chassis and are floating, not referenced to ground.
Ground connection is internally connected to metal chassis. It is recommended that the ground be connected to the station
ground or ground bar inside the circuit breaker cabinet. Follow the electrical grounding standard in effect at your utility.
The OPTIMIZER3 is connectorized and all wiring connections are made to removable connectors. The OM3 may be completely
isolated by pulling out all the connectors from the chassis. Follow the electrical isolation standard in effect at your utility. If
fused-cutouts are desired, locate them physically near the OM3 with 3.15 Amp Slow-Blow fuses for all input and control wiring.
1.6 Communication Ports

Communication ports re used for Configuration of alarms and settings, history data retrieval, resets, data viewing, and
data transfer using DNP3.0 protocol.
RS-485 is half duplex. If the OM3 is the last device in the network, a wire jumper is needed between terminals marked
Term Jump. This jumper places an internal 120Ω resistor into the circuit for termination. Factory defaults are Data bits: 8,
Stop bits: 1, Parity: 1, Baud Rate: 9600 bps, flow control: none.
Ethernet is used with DNP 3.0 and TCP/IP protocols. OM3 is multi-session so both can be run simultaneously. When
connected to a secure local area network, OM3 can be accessed remotely with a web browser by using its unique IP
address. Firmware upgrades can be performed (locally or remotely) via this port using the INCON upgrade tool. The
default IP address from the factory is https://192.168.171.171.
USB Port is used for manual data dumping (using BIN files and ASCII text files). A USB memory stick with special
software is necessary to perform specific operations, each operation requires a different software program.
Mini USB Port is the recommended local connection to the device for setup changes and data downloading. Its default
IP address from the factory is https://192.168.171.171 but may be changed and must be different than the Ethernet
port IP address. Drivers may be required. It is recommended that the PC or laptop be connected to a network upon first
connection to the OM3 using the Mini USB. The PC or laptop will better be able to find the necessary driver files for the
device. If this is not possible or does not work, a Mini USB driver file is included on the USB memory stick which was
included with the OM3. It also contains the OM3 User’s Guide and other information.
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1.7 Communications Software
The OM3 is a web server. Only a web browser is required to communicate with it using the TCP/IP protocol. If DNP 3.0
protocol is used, the DNP master device will have software for network communication. OM3 will respond to validated
DNP commands.
1.8 Self-Diagnostics
A blinking green LED “Flashing OK” indicates normal operation of the microprocessor system.
1.9 Specifications
Size: 11.125W X 5.625H X 2.625D, Inches Nominal, Weight: 6 Lbs.
Data Storage: Data is stored in non-volatile memory. The OM3 saves the most recent:
• 10,000 Application Events
• 10,000 Alarm Events
• 5000 Circuit Breaker Monitoring Events
• 5000 SF6 Gas Parameter data points
• 750 Daily Summary logs
• 5000 3 phase Line Current (through circuit breaker main contacts) data points
• 1000 Line Voltage (as measured at power input) data points (AC rms or DC)
• 5000 Ambient Temperature Measurements (as measured at the monitor)
The OM3 is tested to rigorous international standards. Standard tests include:
• CISPR 16-2-1 (Conducted Emissions)
• CISPR 16-2-3 (Radiated Emissions)
• IEC61000-4-2 (ESD)
• IEC61000-4-3 (Radiated RF)
• IEC61000-4-4 (EFT)
• IEC61000-4-5 (Surge)
• IEC61000-4-6 (Conducted RF)
• IEC 61000-4-11 (Voltage Dips & Interrupts)
• IEC 61000-4-12 (Damped oscillatory wave- Power Ports)
• FCC Part 15, Subpart B; ICES-003 (Emissions)
Specification Table
Communication: RS-485 Full / Half Duplex
Electrical:
RS-232
Power Supply Input 110-250 VDC / 90-264 VAC, 50 / 60 USB Master
Voltage Hz
Ethernet
Power Supply Input
Fuses 1.6 A Slow-Blow User Interface: 19 LED’s
Current rating of the
0.5A Immunity and Emissions Certification:
OM3 unit.
Aux A & B Input CISPR 16-2-
0 to 48 - 250 VDC IEC61000-4-5 (Surge)
Voltage 1 (Conducted
Aux A & B Input Fuses ¼ A Fast-Blow Emissions) IEC61000-4-6 (Conducted RF)
CT (Pickup Coil) Input CISPR 16-2-3 IEC 61000-4-11 (Voltage Dips &
0 to 5 VAC
Signal
(Radiated Emissions) Interrupts)
Input Sampling Rate 32 Samples per line cycle
Analog: 4 to 20 mA IEC61000-4-2 (ESD) IEC 61000-4-12 (Damped Osc. Wave,
SF6 Input Signal Digital: Frequency & Pulse-Width Power Ports)
IEC61000-4-3
Modulated
(Radiated RF) FCC Part 15, Subpart B; ICES-003
SF6 Sensor Power 20 VDC @ 25mA Max (Emissions)
Dry Contact; 2 ea. Form C, 1 ea. IEC61000-4-4 (EFT)
Relay Outputs Form A Physical:
2 Amps @ 250 VAC or 3 Amps @ 30
Relay Contact Rating VDC 184 L x 146 W x 76 H Millimeters
Relay Contact Fuses 3.15 A Slow-Blow Dimensions
7.25 L x 5.75 W x 3.00 H Inches
Environmental:
Shipping Weight 5 lbs. (2.25Kg)
Operating
-40 to 65° C
Temperature
Storage Temperature -40 to 65° C
Humidity 0 to 95% Non-condensing
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2.0 INSTALLATION
2.1 Mounting
Figure 2.2 OM3 Mounting Dimensions (Not Actual Size)

OPTIMIZER3 may be mounted to the circuit breaker cabinet on side walls, on swing panels, or any other convenient
location within the control cabinet. It must be mounted horizontally so that the air vent holes on the bottom and top can
provide cooling by convection air flow. If OM3 cannot be mounted horizontally, the ambient temperature measured by the
sensor may read slightly higher than expected.
There are two rows of pluggable connectors on the left side and one row on the right side. In the event that isolation
is required or replacement is necessary, the connector plugs are unscrewed at the ends and unplugged. Each plug is
fastened by two screws, one on each end of each connector. These must be tightened to assure the plugs stay engaged
and do not come loose from normal shock and vibration of the circuit breaker.
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Figure 2.3 OM3 General Dimensions
2.2 Current Pickup Coils

The OM3 should be installed so the current pick up coil leads are as short as possible; they should be cut to length and
neatly run in Panduit or secured with wire ties. The connections are not polarity sensitive even though they are colored
black and white.
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Figure 2.1 OPTIMIZER3 Wiring of Current Transducers/Typical Installations
2.3 SF6 Sensor Mounting

NOTICE: If any part of the SF6 plumbing system is adjusted or modified as part of this installation, it is necessary to
test for any leaks before circuit breaker equipment is returned to service. If any leaks are found, they must be
repaired and their tightness verified by test before returning the equipment to service.
Pipe Thread Details
The standard SF6 density sensor is P/N DSDP. The DSDP has a threaded male connection. The threads are 3/8 inch
British Standard Parallel Pipe (BSPP) with an O-ring seal. There are many types of adaptors to mate the DSDP to the
plumbing found on a circuit breaker. If the DSDP is not used with a female threaded coupling or into a manifold with a flat
surface for the O-ring to seat against, it is recommended that pipe dope compound be used liberally on the threads and
allowed to set before assembly to assure a gas-tight seal.
Mounting Location
The DSDP is a true-density sensor and will give accurate readings regardless of the ambient temperature of the sensor.
For the best representative density measurement of the SF6 in the interrupters, the DSDP sensor should be plumbed into
the gas system as close as possible to the interrupters. In this case, close means the shortest length of piping or tubing
between the sensor and the interrupter. The DSDP may be mounted outside without any weather protection; it has an
IP65 environmental rating. A variety of SF6 plumbing adaptor kits that are pre-engineered to fit common styles of circuit
breakers are available. Universal adaptors to install the DSDP directly at the DN8, DN20, or Malmkvist filling port are also
available. Consult the factory for more information.
It is inevitable that a very small amount of air will be in the sensor and nearby in the adaptor when installed. Any trapped
air will delay the accurate response of the DSDP density measurement. Air is far less dense than SF6 so if there is air,
the beginning density reading will be lower than expected. Until the trapped air is dispersed into the SF6, the reading will
be low. Gradually, due to convection and gas movement caused by circuit breaker operation, the air will dissipate and the
density reading will stabilize and read accurately. Depending on the circumstances, this can take from 2 to 14 days.
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Figure 2.4 DSDP SF6 Gas Density Sensor Details
The recommended site for the DSDP is at the lowest physical point in the SF6 plumbing system. This is where the SF6 is
most dense. Many circuit breaker manufacturers have their own pre-engineered systems for installing the DSDP. When
the OPTIMIZER3 is specified on a new circuit breaker, the sensor will arrive on the circuit breaker, already plumbed-in.
If the DSDP is to be installed on an existing circuit breaker in the field, there are a number of options available to limit the
amount of custom field work and reduce the possibility for SF6 leaks in the added plumbing.
TEE Adapters
OM-DN8TV
OM-DN20TV
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LenSense Active Lens for SF6 Gauge
Adding the OPTIMIZER3 to existing circuit breakers in the field is the easiest when no SF6 plumbing for sensors is
required.
This is an attractive choice because no SF6 escapes and no moisture is introduced to the circuit breaker SF6 system.
For circuit breakers that have a compatible gauge in place, installation is simple.
Route the wiring by tie-wrapping it to the existing gauge control wiring and through the bulkhead fitting into the cabinet.
2.4 SF6 Gas Monitoring

SF6 density is measured with the digital density sensor. SF6 temperature-compensated-pressure is measured with
LenSense. OPTIMIZER3 can measure density but present pressure. It can also measure pressure and present density.
OPTIMIZER3 receives the density measurement (in grams/liter) from the DSDP sensor and calculates the equivalent
pressure (in PSIG). Pressure calculations are based on entered SF6 mass or weight values and the nameplate fill
pressure. A daily density or pressure trend is calculated from nameplate fill pressure, total weight of SF6, and temperature
using gas law equations. The daily trend is the decrease or increase per day in density or pressure, whichever is desired.
When using LenSense as the pressure transducer, it is simply reading the gauge. The gauge is presenting temperature-
compensated-pressure. LenSense interprets the gauge and produces a proportional 4-20ma signal that OPTIMIZER3
reads as pressure. This value is displayed and logged as pressure, equal to the reading of the gauge by a technician, or it
can be converted to an equivalent density value, given in grams/liter units.
A major benefit of LenSense is that it forces the local pressure shown by the gauge to be equal to the monitored pressure.
This happens because the measurement system is common to both. A technician standing at the circuit breaker will read
the same pressure from the gauge as the dispatcher reading SCADA will see on his screen with no discrepancy.
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SF6 Parameter Set Up
The parameters and alarm settings for SF6 are set in the Gas Monitor section of Configuration Page.
The first setting is what SF6 measurement type is to be displayed. Pressure is the default choice. The System
measurement units are given according to the selection made in on the Preferences Page.
To ensure the user always sees measurements in some preferred chosen units, the preferred units of measure can be
entered into the Preferences Page. There are known as “Personal Preferences” and override the System Preferences in
terms of what is seen on screens served from the OPTIMIZER3.
Internally, the OPTIMIZER3 works in System Preferred units. What is seen externally can be controlled by what is entered
in the “Personal” Preferences Page.
The “Personal” Preferences override the System Preferences if they are not the same.
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SF6 Alarm Settings
OPTIMIZER3 continuously records SF6 density and SF6 pressure. This is done separately for every SF6 sensor that is used.
The Fill Pressure, Warning, and Danger alarm pressures should always correspond to what is written on the circuit
breaker nameplate. Here, the Operating Pressure is the Fill Pressure and is 87 PSIG, the Alarm Pressure is 75 PSIG, and
the Minimum/Cutout Pressure is 72 PSIG. The Gas Fill Weight is 128 lbs.
Here, the Normal Operating Pressure is the Fill Pressure and is 66.7 PSIG, the Low Pressure Alarm is 52.2 PSIG, and the
Minimum Pressure is 47.9 PSIG. The Gas Fill Weight is 26 lbs.
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The two examples on the previous page apply to circuit breakers with one common SF6 system, using one density sensor.
For circuit breakers having three independent SF6 systems (one for each pole), the settings are slightly different.
The Fill, Warning, and Danger alarm pressures will be the same for each pole. For this type of circuit breaker with separate
SF6 systems for each pole, one SF6 density sensor must be installed on each pole. Each SF6 density sensor works
independently and leak calculations for each pole assumes the fill weight is for each system the sensor is attached to.
Therefore, in the case of three SF6 density sensors used on three separate poles, the Total Weight of SF6 Gas given on
the nameplate must be divided by three. 360 ÷ 3 = 120 lbs.
SF6 GIL (Gas Insulated Transmission Line) Application

OPTIMIZER3 is a useful SF6 gas monitoring system for GIL. There are 8 sensor inputs which all may be used for SF6
density or pressure measurement.
In this example, a three-pole GIL was monitored. Each pole was made up of two SF6 gas zones. An SF6 gas density
sensor is installed on each riser, making up a total of 6 gas zones. The GIL manufacturer supplies the following
information:
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Fill Pressure is 55 PSIG, Warning Alarm is 50 PSIG, and Danger Alarm is 43.5 PSIG.
The Fill Weight is the average of all six compartments since they are all slightly different.
Fill Weight = (701.79 + 677.14 + 652.49 + 701.79 + 726.44 + 751.09) ÷ 6 = (4211 ÷ 6) = 702lbs
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2.5 Pressure or Density Trend Alarm
Each SF6 gas density sensor provides information to OPTIMIZER3 to calculate the SF6 pressure. If an SF6 leak is
detected in any of the SF6 zones and it exceeds the Pressure Trend Alarm Limit, the alarm contact or DNP SCADA point
can be asserted, if desired.
Low Gas Alarm Forecast & Forecast Planning Alarm

The Low Gas Alarm Forecast reports how many days until the Danger Alarm pressure will be reached. Based on this SF6
leak trend, the number of days until this alarm is asserted is given on the Sensors Page and available via DNP.
The maximum reading is 999 days.
(Shown on the Sensors Page)

The Forecast Planning Alarm adds a user-defined number of days to the Low Gas Alarm Forecast to allow for planning,
equipment preparation, and outage scheduling. When the SF6 gas pressure decreases so that the predicted number of
days until the Danger Alarm is asserted is equal to or less than the Forecast Planning Alarm, the alarm contact or DNP
SCADA point can be asserted, if desired.
2.6 Temperature Monitoring

OPTIMIZER3 monitors temperature with external loop-powered 4-20 mA temperature transducers.
The sensors can be used to monitor cabinet temperature, interrupter heater blankets, etc. When Temperature is selected,
scaling for the mA current range and temperature range appear.
High and Low Temperature Alarm Limits appear. If either Alarm Limit is set to -40, the alarm is disabled.
The Low Temperature Alarm Limit is asserted if the measured temperature is less than or equal to the setting.
The High Temperature Alarm Limit is asserted if the measured temperature is greater than or equal to the setting.
A hysteresis of 3 degrees is applied to the measurement to reduce nuisance toggling of the alarm. The alarm is non-
latching and clears itself when the measured temperature inside the alarm limits.
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2.7 Voltage Monitoring
OPTIMIZER3 monitors Voltage with external loop-powered 4-20 mA Voltage transducers.

The sensors can be used to monitor DC station battery voltage at the circuit breaker, AC station service voltage at the
circuit breaker, or motor activity. When Voltage is selected, scaling for the mA current range and voltage range appear.
High and Low Voltage Alarm Limits appear. If either Alarm Limit is set to 0 (zero), the alarm is disabled.
The Low Voltage Alarm Limit is asserted if the measured voltage is less than or equal to the setting.
The High Voltage Alarm Limit is asserted if the measured voltage is greater than or equal to the setting.
A hysteresis of 3 volts is applied to the measurement to reduce nuisance toggling of the alarm. The alarm is non-latching
and clears itself when the measured voltage inside the alarm limits.
If Yes is selected for Run-Time Metrics, it is assumed the voltage sensor input is connected in parallel to a spring charging
motor, air compressor motor, or hydraulic pump motor. The cumulative run time, the number of runs per day, and average
run duration are reported. If Yes is selected for Monitor Continuous Voltage, the daily average, minimum, maximum, and
sample count are reported.
2.8 Current Monitoring
OPTIMIZER3 monitors Current with external loop-powered 4-20 mA current transducers.

The sensors can be used to monitor motor current, heater current, or the current of other accessory equipment. When
Current is selected, scaling for the mA current range and measured current range appear.
High and Low Current Alarm Limits appear. If either Alarm Limit is set to 0 (zero), the alarm is disabled.
The Low Current Alarm Limit is asserted if the measured current is less than or equal to the setting.
The High Current Alarm Limit is asserted if the measured current is greater than or equal to the setting.
A hysteresis of 1 (one) amp is applied to the measurement to reduce nuisance toggling of the alarm. The alarm is non-
latching and clears itself when the measured current inside the alarm limits.
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If Yes is selected for Run-Time Metrics, it is assumed the current sensor input is connected around the input conductor to
a spring charging motor, air compressor motor, or hydraulic pump motor. The cumulative run time, the number of runs per
day, and average run duration are reported. If Yes is selected for Monitor Load Metrics, the maximum current per run, run
time, and I2T for the run is reported. Load Metrics are useful for spring charging motors and Run Time Metrics are useful
for air compressors or hydraulic pumps.
2.9 Heater Monitoring Using UPSM (Universal Power System Monitor)

The UPSM accessory detects when the thermostat is calling for heat and measures the current in the main heater circuit.
The design assumes that all failures of electric heating elements are caused by open circuits. If the measured heater
current is too low the alarm contact or DNP SCADA point can be asserted, if desired.
In this example of an IPO circuit breaker with separate mechanism cabinets, there is a 1500 watt heater for each
interrupter tank running at 240 VAC. There is a 42 watt heater running at 240 VAC in each cabinet. The total current is
18.6 amps. The loss of one cabinet heater is the lowest reduction that could occur. This would reduce total current to 18.4
amps. For this example, the Low Current Alarm Limit should be set to 18.4 amps.
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2.10 Circuit Breaker Monitor Function
The OM3 has five inputs which are connected to specific combinations of open coils, close coils, auxiliary switches, red
light bulbs, green light bulbs, and other control circuit inputs as appropriate for a particular circuit breaker. The DC voltage
levels (states) of these circuit nodes are interpreted by the OM3 to produce operating times, main contact state (OPEN/
CLOSE), and many other analysis functions.
Mode 1 Mode 2 Mode 3 Mode 4

Continuous A & B Pulse Open Coil Continuous A Pulse Open Coil
No B No B Continuous B
Aux 1 Red Light or 52a Switch Open Coil Red Light or 52a Switch Open Coil
Input Channels
Aux 2 Green Light or 52b Switch Green Light or 52b Switch

Aux 3
Aux 4
Aux 5
Open Time Start N/A Open Coil Active Edge N/A Open Coil Active Edge
Open Time Stop N/A Open Coil Deactive Edge + AD N/A Open Coil Deactive Edge + AD
Interrupting Time Start Ø N/A Open Coil Active Edge N/A Open Coil Active Edge
Timing Measurements
Arcing Time Start Ø Aux A Active Edge + AD Open Coil Deactive Edge + AD Aux A Active Edge + AD Open Coil Deactive Edge + AD
Arcing Time End Ø <7% Amplitude <7% Amplitude <7% Amplitude <7% Amplitude
Interrupting Time End Ø N/A <7% Amplitude N/A <7% Amplitude
Travel Time Start Aux A Active Edge N/A N/A Open Coil Deactive Edge
Travel Time Stop Aux B Active Edge N/A N/A Aux B Active Edge
Close Trip Start N/A N/A N/A N/A
Close Trip Stop N/A N/A N/A N/A
Closing Time Start Aux B Deactive Edge N/A N/A N/A
Closing Time Stop Aux A Deactive Edge N/A N/A N/A
A-B Input Logic Failure 52a and 52b inputs are Open coil input is active N/A Open Coil input is active
Modes active at the same time continuously continuously
Note: Modes 1 thru 4 are identical to OPTImizer2

Note: AD represents “A Input Delay” the time skew between 52A switch and main breaker contact action.
OPTIMIZER2 monitors use AD, OPTIMIZER3 uses A Input Delay. They are the same parameter.
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Mode 5 Mode 6 Mode 7
Pulse Open Coil & Close Coil Two Open Coils, No Close Coil Two Open Coils, One Close Coil
52a and 52b Input 52a and 52b Input 52a and 52b Input
Aux 1 Open Coil Open Coil 1 Open Coil 1
Input Channels
Aux 2 Close Coil Open Coil 2 Open Coil 2

Aux 3 Red Light or 52a Switch Red Light or 52a Switch Close Coil
Aux 4 Green Light or 52b Switch Green Light or 52b Switch Red Light or 52a Switch
Aux 5 Green Light or 52b Switch
Open Time Start Open Coil Active Edge 1st Open Coil Active Edge 1st Open Coil Active Edge
Open Time Stop Open Coil Deactive Edge + AD Open Coil Deactive Edge + AD Last Open Coil Deactive Edge + AD
Interrupting Time Start Ø Open Coil Active Edge 1st Open Coil Active Edge 1st Open Coil Active Edge
Arcing Time Start Ø Open Coil Deactive Edge + AD Open Coil Deactive Edge + AD Open Coil Deactive Edge + AD
Timing Measurements
Arcing Time End Ø <7% Amplitude <7% Amplitude <7% Amplitude

Interrupting Time End Ø <7% Amplitude <7% Amplitude <7% Amplitude
Travel Time Start TC Deactive Edge Last Open Coil Deactive Edge or Last Open Coil Deactive Edge or
Aux A Active Edge Aux A Active Edge
Travel Time Stop 52b Active Edge Aux B Active Edge Aux B Active Edge
Close coil time start CC Active Edge N/A Close Coil Active Edge
Close coil time stop CC Deactive Edge N/A Close Coil Deactive Edge
Closing Time Start 52b Deactive Edge Aux B Deactive Edge Aux B Deactive Edge
Closing Time Stop 52a Deactive Edge Aux A Deactive Edge Aux A Deactive Edge
Velocity Time Duration between 52a & 52b Time Duration between 52a & 52b Time Duration between 52a & 52b
A-B Input Logic Failure Open Coil or Close Coil input is Open coil or Close coil input is Open coil 1, Open coil 2, or Close
Modes active continuously or both 52a active continuously or 52a and coil input is active continuously,
and 52b inputs are active at the 52b inputs are active at same time or 52a and 52b inputs are active at
same time same time
OPTIMIZER3 Operating Modes, Measurements Made, Required Wiring Connections
2.11 Navigation
OPTIMIZER3 functions as a web server so the only required software is a web browser. Using the browser and the mini
USB cable supplied with the unit, log into the unit. Enter the IP address into the address bar and connect to the unit. The
IP address must be compatible with the PC Local Area Network settings otherwise communication cannot be established.
By default the Mini USB IP address is 192.168.171.171. See appendix for more information.
The first login attempt will require a new admin password. The password is blank from view but if it needs to be seen to
ensure accuracy, clicking holding the left mouse button on the eyeball icon in the entry box will reveal what has been
typed.
To set the time zone, use the Date/Time section from the Configuration menu.
Local date and time is set from the Date/Time pull-down menu.
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If a new time zone is selected after the time has been set from the main menu, the time will be adjusted to the new time
zone. It is best to select the Time Zone first, then set the local time after that.
The landing page after login is the CBM page which shows the present status of the circuit breaker.
Click on Configuration to begin setting up the monitor. Each category can be individually expanded by clicking on the cell.
The entire page may be expanded by clicking on Expand. The details and choices for each parameter are shown by
clicking on the cell for the desired parameter to be edited. When setup is complete, click Save to keep the changes.
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2.12 Location- Where to install the OPTIMIZER3
The OPTIMIZER3 is designed to be installed in the circuit breaker control cabinet. Usually this is the most convenient
place because there is easy access to SF6 plumbing for the density sensors, bushing CT circuits, and control circuits.
Often the O&M technicians have no access to the control building where the protective relays are located. If it is not
possible to locate the OPTIMIZER3 in the control cabinet, then it may be installed in the control building. Most often this
decision is based on access to communication links or SCADA RTU access.
For use as a SF6-only monitor, such as for monitoring compartments of GIS or SF6 insulated bus, the OM3 may be
located up to 2000 feet from the digital SF6 density sensors (OM-DSDP) if AWG 14 wire is used. This makes it feasible to
locate the OM3 in a control building, near communications access points.
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3.0 SETUP & CONFIGURATION
3.1 Purpose of Circuit Breaker Monitoring
Circuit breakers are complex mechanical and electrical systems which require periodic maintenance. The need for
maintenance is affected by
• Number of fault operations
• Number of total operations
• SF6 sealing system integrity
• Environmental conditions
• Time since last operation
• Time since installation (equipment age)
There are symptoms associated with the maintenance needs which the OPTIMIZER3 detects.
• Longer-than-normal arcing times
• Occurrence of restrikes
• Longer-than-normal OPEN time
• Large standard deviation of OPEN times
• Spring-Charging motor high peak current
• Trip Coil or Close Coil exhibiting high forward voltage drop
Longer-than-normal OPEN time is equivalent to slower-than-normal average velocity. In most cases, long measured
OPEN times are caused by poor lubrication or bearings that have seized with grease where liquids have evaporated and
only the clay or other thickener remain.
Extended arcing time can result from blast nozzles on puffer circuit breakers that have a high accumulated arcing duty.
The exposure to hot arcs causes ablation of the Teflon nozzle material so the nozzle diameter gets larger and the velocity
of the SF6 blasted into the arc is reduced, with reduced effectiveness to extinguish the arc. For Oil Circuit Breakers,
extended arcing times may be the symptom of contaminated oil or fault currents in excess of its rating.
OPTIMIZER3 will detect fugitive emission (leaks) of SF6 far earlier than the 63X pressure switch or SF6 controller.
Leaks are not only detected, but the day on which the low-gas alarm will assert is determined and made known to the
maintenance planner. Beyond this, OPTIMIZER3 calculates how much SF6 has leaked and when the circuit breaker is re-
filled and with how much SF6 gas. Circuit breakers that have had leak problems over their life are likely to also have high
moisture content in the SF6 gas. These circuit breakers are good candidates for SF6 Dew Point monitoring with an added
OM-DPS sensor.
OPTIMIZER3 monitors the phase currents and calculates the I2T during the arcing portion of the circuit interruption.
I2T is an abbreviation for ∫I2 dt from contact part until the time when the arc is extinguished. This is done for each phase
separately. By keeping track of the cumulative duty for each pole separately, a pole replacement might be justified in
certain circumstances compared with a full circuit breaker replacement, thereby reducing O&M expense.
3.2 Choosing the Desired Operating Mode

For circuit breaker characteristic monitoring, there are eight operating modes to select from.
Mode 1
This choice monitors the state of the 52a and 52b auxiliary switches for the circuit breaker. When the 52a changes state,
the monitor registers an Open operation and records the time duration until the 52b changes state. This time duration is
called Open Travel Time, given in milliseconds. This time is the actual measurement and is not modified by the A Input
Delay.
When the 52b changes state, the monitor registers a Close operation and records the time duration until the 52a changes
state. This time duration is called Close Travel Time, given in milliseconds.
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OM3 assigns the control inputs as a default, but they can be changed if desired. The AUX 1 input is assigned to the 52a
switch and the AUX 2 input is assigned to 52b auxiliary switch. The recommended connection is to spare 52a and 52b
switches that are wetted by the station battery voltage. An equivalent timing signal is to connect in parallel with the Red
Light and Green light. In both cases, the Input Polarity for AUX 1 is Negative because the voltage level transitions from
high to low on the Open operation. Similarly, the Input Polarity for AUX 2 is Positive because the voltage level transitions
from low to high on the Close operation.

Recommended Connection Alternate Connection Alternate Connection
AUX 1 Input Polarity = Negative AUX 1 Input Polarity = Positive AUX 1 Input Polarity = Negative

AUX 2 Input Polarity = Positive AUX 2 Input Polarity = Negative AUX 2 Input Polarity = Positive
Mode 1 Configuration
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Mode 1 Mechanical Data Export
Report ID Date/Time Type Operation Number Open Travel Time Close Travel Time
76 Jul 23, 2015, 9:32:54 AM Close 55
75 Jul 23, 2015, 9:20:41 AM Trip 47 18
74 Jul 23, 2015, 9:20:41 AM Close 55
73 Jul 23, 2015, 9:19:24 AM Trip 46 17
72 Jul 23, 2015, 9:18:31 AM Close 53
71 Jul 23, 2015, 9:18:31 AM Trip 45 18
70 Jul 23, 2015, 9:00:20 AM Close 56
69 Jul 23, 2015, 8:53:07 AM Trip 44 16
68 Jul 23, 2015, 8:53:07 AM Close 56
67 Jul 23, 2015, 8:51:30 AM Trip 43 17
66 Jul 23, 2015, 8:50:34 AM Close 53
65 Jul 23, 2015, 8:50:33 AM Trip 42 16
64 Jul 23, 2015, 8:48:44 AM Close 56
63 Jul 23, 2015, 8:44:57 AM Trip 41 16
62 Jul 23, 2015, 8:44:57 AM Close 57
61 Jul 23, 2015, 8:44:42 AM Trip 40 18
60 Jul 23, 2015, 8:44:42 AM Close 56
59 Jul 23, 2015, 8:44:07 AM Trip 39 17
58 Jul 23, 2015, 8:26:18 AM Close 55
57 Jul 23, 2015, 8:26:11 AM Trip 38 17
56 Jul 23, 2015, 8:25:43 AM Close 56
55 Jul 23, 2015, 8:25:27 AM Trip 37 17
54 Jul 23, 2015, 8:25:11 AM Close 56
53 Jul 23, 2015, 8:25:04 AM Trip 36 18
52 Jul 23, 2015, 8:19:50 AM Close 56
51 Jul 23, 2015, 8:19:40 AM Trip 35 17
Mode 2
This choice monitors the state of the Open coil only. When the Open coil changes state, the monitor registers an Open
operation and records the time duration from Open coil energization to 52a open. This time duration is called Open Time,
given in milliseconds. This time is the actual measurement and is not modified by the A Input Delay.
Mode 2 is used on older field retrofits when there is no opportunity for connecting to 52b auxiliary switches. OM3 does not
provide any Close operation data in Mode 2.
Assign the Open Coil connection to AUX 1.
The Polarity set to Positive because the Open coil energization is a positive-going pulse.
AUX 1 Input Polarity = Positive
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Report ID Date/Time Type Operation Number Open Time
75 Jul 23, 2015, 9:20:41 AM Trip 47 26
73 Jul 23, 2015, 9:19:24 AM Trip 46 27
71 Jul 23, 2015, 9:18:31 AM Trip 45 26
69 Jul 23, 2015, 8:53:07 AM Trip 44 27
67 Jul 23, 2015, 8:51:30 AM Trip 43 27
65 Jul 23, 2015, 8:50:33 AM Trip 42 28
63 Jul 23, 2015, 8:44:57 AM Trip 41 28
61 Jul 23, 2015, 8:44:42 AM Trip 40 28
59 Jul 23, 2015, 8:44:07 AM Trip 39 27
57 Jul 23, 2015, 8:26:11 AM Trip 38 27
55 Jul 23, 2015, 8:25:27 AM Trip 37 26
Mode 3
This choice monitors the state of the 52a auxiliary switch only. When the 52a changes state, the monitor registers an
Open operation, modifies it by the A Input Delay setting, and calculates contact duty. Mode 3 is used on older field retrofits
when the only connection that can be made is to the 52a auxiliary switch.
Assign the 52a auxiliary switch connection to AUX 1.
The recommended connection is in series with a wetted spare 52a auxiliary switch. Alternate connection may be made in
parallel to an in-service 52a auxiliary switch or in parallel with the red light bulb.
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Report ID Date/Time Type Operation Number
75 Jul 23, 2015, 9:20:41 AM Trip 47
73 Jul 23, 2015, 9:19:24 AM Trip 46
71 Jul 23, 2015, 9:18:31 AM Trip 45
69 Jul 23, 2015, 8:53:07 AM Trip 44
67 Jul 23, 2015, 8:51:30 AM Trip 43
65 Jul 23, 2015, 8:50:33 AM Trip 42
63 Jul 23, 2015, 8:44:57 AM Trip 41
61 Jul 23, 2015, 8:44:42 AM Trip 40
59 Jul 23, 2015, 8:44:07 AM Trip 39
57 Jul 23, 2015, 8:26:11 AM Trip 38
55 Jul 23, 2015, 8:25:27 AM Trip 37
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Mode 4
When the Open coil is energized, the monitor registers an Open operation and records the time duration from Open coil
energization to 52a auxiliary switch opening. This time duration is named Open Time, given in milliseconds. This time is
the actual Open time measurement and is not modified by the A Input Delay.
In addition, the time duration from 52a auxiliary switch opening to 52b auxiliary switch closing is recorded and reported as
Open Travel Time.
Circuit breaker Close operations are detected from the 52b auxiliary switch transitioning from close to open. No
mechanical information is recorded for the Close operation other than a time stamp for when it closed.
OM3 assigns the control inputs as a default, but they can be changed if desired. The AUX 1 input is assigned to the Open
coil and the AUX 2 input is assigned to 52b auxiliary switch.
The recommended AUX 2 connection is to a spare 52b switch that is wetted by the station battery voltage. There are other
wiring connections which give an equivalent timing signal for AUX 2- in parallel to an in service 52b auxiliary switch or
connection in parallel with the green light bulb. The AUX 2 Polarity setting is specific to the connection location.
AUX 2 Input Wiring Connection AUX 2 Polarity setting

In series with wetted spare 52b auxiliary switch Positive
In parallel with in service 52b auxiliary switch Negative
In parallel with green light bulb Positive
Recommended connection diagrams are shown below:

AUX 2 Input Polarity Positive AUX2 Input Polarity Negative AUX 2 Input Polarity Positive
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Mode 4 Example Configuration

Report ID Date/Time Type Operation Number Open Time Open Travel Time
76 Jul 23, 2015, 9:32:54 AM Close
75 Jul 23, 2015, 9:20:41 AM Trip 47 28 18
74 Jul 23, 2015, 9:20:41 AM Close
73 Jul 23, 2015, 9:19:24 AM Trip 46 27 17
72 Jul 23, 2015, 9:18:31 AM Close
71 Jul 23, 2015, 9:18:31 AM Trip 45 26 18
70 Jul 23, 2015, 9:00:20 AM Close
69 Jul 23, 2015, 8:53:07 AM Trip 44 27 16
68 Jul 23, 2015, 8:53:07 AM Close
67 Jul 23, 2015, 8:51:30 AM Trip 43 27 17
66 Jul 23, 2015, 8:50:34 AM Close
65 Jul 23, 2015, 8:50:33 AM Trip 42 28 16
64 Jul 23, 2015, 8:48:44 AM Close
63 Jul 23, 2015, 8:44:57 AM Trip 41 27 16
62 Jul 23, 2015, 8:44:57 AM Close
61 Jul 23, 2015, 8:44:42 AM Trip 40 26 18
60 Jul 23, 2015, 8:44:42 AM Close
59 Jul 23, 2015, 8:44:07 AM Trip 39 27 17
58 Jul 23, 2015, 8:26:18 AM Close
57 Jul 23, 2015, 8:26:11 AM Trip 38 27 17
56 Jul 23, 2015, 8:25:43 AM Close
55 Jul 23, 2015, 8:25:27 AM Trip 37 26 17
54 Jul 23, 2015, 8:25:11 AM Close
53 Jul 23, 2015, 8:25:04 AM Trip 36 26 18
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Mode 5
When the Open coil is energized, the monitor registers an Open operation and records the time duration from Open coil
energization to 52a auxiliary switch opening. This time duration is named Open Time, reported in milliseconds. This time is
the actual Open time measurement and is not modified by the A Input Delay.
The time duration from 52a auxiliary switch opening to 52b auxiliary switch closing is reported as Open Travel Time.
When the Close coil is energized, the monitor registers a Close operation and records the time duration from Close coil
energization to 52b auxiliary switch opening. The time duration from 52b auxiliary switch opening to 52a auxiliary switch
closing is reported as Close Travel Time.
OM3 assigns default control inputs, but they can be changed if desired:
AUX 1 input is assigned to the Open coil
AUX 2 input is assigned to the Close coil.
AUX 3 input is assigned to the 52a auxiliary switch
AUX 4 input is assigned to the 52b auxiliary switch
The recommended AUX 3 connection is to a spare 52a auxiliary switch that is wetted by the station battery voltage. There
are alternate wiring connections which give an equivalent timing signal for AUX 3- connection in parallel to an in service 52a
auxiliary switch or connection in parallel with the red light bulb. The AUX 3 Polarity setting is specific to the connection type.
AUX 3 Input Wiring Connection AUX 3 Polarity setting Type

In series with wetted spare 52a auxiliary switch Negative Recommended
In parallel with in service 52a auxiliary switch Positive Alternate
In parallel with red light bulb Negative Alternate
The recommended AUX 4 connection is to a spare 52b auxiliary switch that is wetted by the station battery voltage. There are
other wiring connections which give an equivalent timing signal for AUX 4- connection in parallel to an in service 52b auxiliary
switch or connection in parallel with the green light bulb. The AUX 4 Polarity setting is specific to the connection location.
AUX 4 Input Wiring Connection AUX 4 Polarity setting Type

In series with wetted spare 52b auxiliary switch Positive Recommended
In parallel with in service 52b auxiliary switch Negative Alternate
In parallel with green light bulb Positive Alternate
Wiring connection diagrams are shown below and on the next page:

31


32

Report ID Date/Time Type Operation Number Trip Type Open Time Open Travel Time Close Time Close Travel Time Total Close Time Open Velocity Close Velocity
76 Jul 23, 2015, 9:32:54 AM Close 0 55 55 1.33
75 Jul 23, 2015, 9:20:41 AM Trip 47 Fault Open 26 18 4.12
74 Jul 23, 2015, 9:20:41 AM Close 41 55 96 1.33
73 Jul 23, 2015, 9:19:24 AM Trip 46 Non Fault Open 27 17 4.25
72 Jul 23, 2015, 9:18:31 AM Close 16 53 69 1.37
71 Jul 23, 2015, 9:18:31 AM Trip 45 Non Fault Open 26 18 4
70 Jul 23, 2015, 9:00:20 AM Close 0 56 56 1.31
68 Jul 23, 2015, 8:53:07 AM Close 41 56 97 1.31
66 Jul 23, 2015, 8:50:34 AM Close 15 53 68 1.39
64 Jul 23, 2015, 8:48:44 AM Close 41 56 97 1.31
62 Jul 23, 2015, 8:44:57 AM Close 39 57 96 1.29
61 Jul 23, 2015, 8:44:42 AM Trip 40 Non Fault Open 28 18 4.12
60 Jul 23, 2015, 8:44:42 AM Close 40 56 96 1.31
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Mode 6
Mode 6 assumes that no connection to the Close coil is possible. Because of this, Close Time is not measured.
Two Open coils are monitored. The first Open coil to be energized is identified and an Open operation is reported.
The time duration from Open coil energization to 52a auxiliary switch opening is reported as Open Time, given in
milliseconds. The reported Open time measurement is not modified by the A Input Delay.
The time duration from 52b auxiliary switch opening to 52a auxiliary switch closing is reported as Close Travel Time.

34


35
Report ID Date/Time Type Operation Number Open Coil Trip Type Open Time Open Travel Time Close Travel Time Open Velocity Close Velocity
76 Jul 23, 2015, 9:32:54 AM Close 55 1.33
75 Jul 23, 2015, 9:20:41 AM Trip 47 Redundant Open Coil Fault Open 62 18 4.12
74 Jul 23, 2015, 9:20:41 AM Close 55 1.33
73 Jul 23, 2015, 9:19:24 AM Trip 46 Redundant Open Coil Non Fault Open 27 17 4.25
72 Jul 23, 2015, 9:18:31 AM Close 53 1.37
71 Jul 23, 2015, 9:18:31 AM Trip 45 Redundant Open Coil Fault Open 26 18 4
70 Jul 23, 2015, 9:00:20 AM Close 56 1.31
69 Jul 23, 2015, 8:53:07 AM Trip 44 Primary Open Coil Fault Open 65 16 4.52
68 Jul 23, 2015, 8:53:07 AM Close 56 1.31
66 Jul 23, 2015, 8:50:34 AM Close 53 1.39
65 Jul 23, 2015, 8:50:33 AM Trip 42 Primary Open Coil Non Fault Open 28 16 4.52
64 Jul 23, 2015, 8:48:44 AM Close 56 1.31
62 Jul 23, 2015, 8:44:57 AM Close 57 1.29
60 Jul 23, 2015, 8:44:42 AM Close 56 1.31
58 Jul 23, 2015, 8:26:18 AM Close 55 1.32
56 Jul 23, 2015, 8:25:43 AM Close 56 1.3
Mode 7
Two Open coils are monitored. The first Open coil to be energized is identified and an Open operation is reported.
The time duration from Open coil energization to 52a auxiliary switch opening is reported as Open Time, given in
milliseconds. The reported Open time measurement is not modified by the A Input Delay.
When the Close coil is energized, the monitor registers a Close operation and records the time duration from Close coil
energization to 52b auxiliary switch opening. The time duration from 52b auxiliary switch opening to 52a auxiliary switch
closing is reported as Close Travel Time.

36

Aux 4 Input Polarity = Negative Aux 4 Input Polarity = Positive Aux 4 Input Polarity = Negative

Aux 5 Input Polarity = Positive Aux 5 Input Polarity = Negative Aux 5 Input Polarity = Positive
37
Report ID Date/Time Type Operation Number Open Coil Trip Type Open Time Open Travel Time Close Time Close Travel Time Total Close Time Open Velocity Close Velocity
76 Jul 23, 2015, 9:32:54 AM Close 0 55 55 1.33
74 Jul 23, 2015, 9:20:41 AM Close 41 55 96 1.33
72 Jul 23, 2015, 9:18:31 AM Close 16 53 69 1.37
71 Jul 23, 2015, 9:18:31 AM Trip 45 Redundant Open Coil Fault Open 26 18 4
70 Jul 23, 2015, 9:00:20 AM Close 0 56 56 1.31
68 Jul 23, 2015, 8:53:07 AM Close 41 56 97 1.31
66 Jul 23, 2015, 8:50:34 AM Close 15 53 68 1.39
65 Jul 23, 2015, 8:50:33 AM Trip 42 Primary Open Coil Non Fault Open 28 16 4.52
64 Jul 23, 2015, 8:48:44 AM Close 41 56 97 1.31
62 Jul 23, 2015, 8:44:57 AM Close 39 57 96 1.29
60 Jul 23, 2015, 8:44:42 AM Close 40 56 96 1.31
58 Jul 23, 2015, 8:26:18 AM Close 40 55 95 1.32
56 Jul 23, 2015, 8:25:43 AM Close 40 56 96 1.3
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3.3 Application Concept
The concept of on-line circuit breaker monitoring can be compared to the activity of a nurse in a hospital. The nurse
does rounds with patients. The nurse makes observations, takes blood pressure, takes patient temperature and makes
other tests and asks the patient questions about how they feel. When the nurse discovers trends that indicate worsening
condition, the doctor is called in to investigate the symptoms and order treatment.
The OPTIMIZER3 records the performance characteristics for every circuit breaker operation. It continually monitors the
SF6 pressure, station battery voltage, AC voltage, spring-charging current, and air compressor or hydraulic pump run times
and current draw. It also measures the fault magnitude for every open operation as an indicator of main contact condition.
The goal of on-line circuit breaker monitoring is to improve maintenance planning by alerting personnel to measured
trends that could indicate a future failure of the asset. Maintenance activity can be made more effective by directing
resources to assets that need attention and with enough advance warning to plan it into the regular work day.
OPTIMIZER3 focuses on four functional areas:
1. Mechanism Function (timing, open coil and close coil function, velocity of main contacts, motor current)
• Inefficient Open coil action due to high impedance, loose connections, or shorted turns
• Binding of bearings in the trip latch mechanism caused by degraded lubrication
• Misalignment of levers, links, or bearings
• Bearing seizure
• Inefficient stored-energy system including springs, hydraulics, compressed air
2. Insulating Gas (density, pressure, temperature, water dew point)
• Gas leaks from corroded connections, O-ring seals, defects in castings
• Liquefaction of SF6 due to pressure and/or temperature out of effective range
• Re-strike occurrence due to low SF6 pressure
• Logging of SF6 refills
• Days until low pressure warning level is reached, due to leakage
3. Main contact arcing duty (fault vs: switching, peak current, arcing time, ∫I2 dt, ∫I dt)
• Contact wear due to arcing
• Extended arc duration due to blast nozzle ablation (caused by heat)
• Justification of single-pole replacement rather than full circuit breaker replacement
4. Auxiliary systems (tank & cabinet heating, ambient temperature, audible sound emission, cabinet door status)
• Tank heater effectiveness by heating element current measurement or measured tank temperature
• Cabinet temperature measurement- heating element effectiveness
• Station security- Monitored status of control cabinet door switch
• Electrical connection integrity- Station battery DC voltage monitored/logged at control cabinet
• Electrical connection integrity- Station service AC voltage monitored/logged at control cabinet
• Overall system “finger print”- Sound Capture Technology (recording of audible sound emitted during operation)
39
3.4 Circuit Breaker Open Operation- Monitoring Example
In this Open test, C1 indicates the opening of the 52a auxiliary switch. C2 indicates the closing of the 52b auxiliary switch.
C1 and C2 bracket the travel of the circuit breaker operating rod and they also bracket the time duration for the travel.
Velocity is calculated from the distance divided by the time.
The Travel Stroke is entered as part of the Configuration and is rounded to the nearest 10 mm.
Travel Time = 44.7ms – 24.7ms = 20 ms
Stroke = 80mm - 13mm = 67mm → 70mm
Velocity = 70 ÷ 20 = 3.5 meters/Second
The main contacts 1, 2, and 3 part at 28.2ms. The 52a auxiliary switch C1 opens at 24.7ms. The timing skew between
the main contacts and 52a auxiliary switch is 3.5ms. This value is entered as part of the Configuration as A Input Delay.
Because this skew is constant, it is used to determine when the main contacts part.
Main contact part = 24.7ms + 3.5ms = 28.2ms
If current is measured on any of the three phases after 28.2 ms, then this is assumed to be arcing, because the main
contacts have physically parted. The time duration of the arcing is reported and logged for each phase.
If the arcing (indicated by measured current) ceases for at least 4ms but re-establishes (re-ignites) for any phase, then a
Re-Strike is assumed to have occurred and is reported and logged for each affected phase.
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3.5 Circuit Breaker Close Operation- Monitoring Example
In this Close test, C2 indicates the opening of the 52b auxiliary switch. C1 indicates the closing of the 52a auxiliary switch.
C1 and C2 bracket the travel of the circuit breaker operating rod and they also bracket the time duration for the travel.
Velocity is calculated from the distance divided by the time.
The Travel Stroke is entered as part of the Configuration and is rounded to the nearest 10 mm.
Travel Time = 92.7ms – 37.3ms = 55.4 ms
Stroke = 80mm - 13mm = 67mm → 70mm
Velocity = 70mm ÷ 55.4ms = 1.26 meters/Second
OPTIMIZER3 measures the time from close coil energization to 52b auxiliary switch opening as Close Time. From this
timing chart, 37.3ms is shown, the energization ceases when the 52b auxiliary switch opens.
The main contacts 1, 2, and 3 make at 97.8ms as shown in the timing plot. OPTIMIZER3 determines main contact make
by detecting and time-stamping the 52a auxiliary switch closure then subtracting the 3.5ms timing skew.
OPTIMIZER3 reports and logs the Close operation in two segments- Close Time and Close Travel Time. The sum of these
two segments is the reported as Total Close Time.
41
3.6 Wiring Connections to circuit breaker control circuits
There are five inputs on the left-hand side of the OPTIMIZER3 labelled AUX 1 thru AUX 5. Each input pair is fused on
each let, optically isolated, and high impedance (500kΩ). These AUX inputs are connected to certain wiring points in
a circuit breaker control circuit to determine the circuit breaker state (open/close) and also for voltage state change
transitions used for timing and verification.
OPTIMIZER3 interprets different combinations of five wiring connections depending on which operating mode is chosen.
1. Parallel connection to primary Open coil
2. Parallel connection to secondary Open coil
3. Parallel connection to Close coil
4. Connection to 52a auxiliary switch
5. Connection to 52b auxiliary switch
Connections 1-3 are specific and required for the most useful monitoring information.
Connections 4 and 5 can each be done in three ways.
52a auxiliary switch 1. Connection in series with a spare 52a switch and station battery
2. Connection in parallel with an in service 52a switch
3. Connection in parallel with the red light bulb
52b auxiliary switch 1. Connection in series with a spare 52b switch and station battery
2. Connection in parallel with an in service 52b switch
3. Connection in parallel with the green light bulb

It is recommended that spare 52a and 52b auxiliary switches be used, especially for monitors installed by the circuit
breaker manufacturer. Very often the red and green light bulbs are remotely located at the end-user substation; in the
relay control building. Because of this, these remote circuits would need to be temporarily installed for the circuit breaker
manufacturer to completely test the system.
42
Circuit Breaker Control Signals- Polarity Settings
Input signal connections can be made to a number of control circuit nodes. The signal edge may be a positive-going
transition or a negative transition. OPTIMIZER3 must be configured to correctly interpret the transitions.
To program the Red Light/52A Input Polarity, the entry is the answer to the question-
What does the signal do when the circuit breaker transitions from Close to Open?
To program the Green Light/52B Input Polarity, the entry is the answer to the question-
What does the signal do when the circuit breaker transitions from Open to Close?
Circuit breaker interrupter duty
OPTIMIZER3 uses either I2t (∫ I2 dt) or IT (∫ I dt) as a model for heat energy released by the arc just after main contact part.
There is not always an arc and not always on all phases. The time duration of arcing is reported and logged as Arctime for
each phase. The line currents for each pole of the circuit breaker are measured by the clip-on pickup coils attached to the
bushing CT secondary circuits. The measurements are sampled at 2 kHz, each sample is squared, then multiplied by the
sample width. This process ends at the cessation of current flow.
During the process, the results are continually added together to form the cumulative duty the interrupter has endured.
The wear model is chosen from a pull-down menu on Circuit Breaker Monitor section of the Configuration Page
Consider I X T for circuit breakers with vacuum interrupters; live tank or dead tank. I2T is generally used with all other
types including bulk oil, minimum oil, SF6 puffer, SF6 self-blast, and air blast circuit breakers; live tank or dead tank.
OPTIMIZER3 compares the cumulative duty of the circuit breaker pole with the highest total to the Contact Life Danger
Limit. The limit may be entered as an integer or in scientific notation (shown). This cumulative duty represents the end-of-
life for the interrupter, which is made up of main contacts, arcing contacts, blast nozzles, etc. It is a lumped parameter and
is approximate. When this limit is reached by any pole of the circuit breaker, the alarm contact or DNP SCADA point can
be asserted, if desired.
The Contact Life Warning Limit is set as a percentage of the Danger Limit and is expressed as percentage life remaining.
A Contact Life Warning Limit set to 25% for this example means the total I2T of 3e8 will have been reached and 1e8 of
available interrupter duty is available. When the Contact Life Warning Limit is reached, an alarm contact or DNP SCADA
point can be asserted, if desired.
OPTIMIZER3 registers arcing during a circuit breaker Open operation when there is current flow in any pole after the 52a
auxiliary switch opens, as modified by the A Input Delay setting. This is the moment of main contact parting.
Guidance for what the upper limit of arcing time should be is provided by the circuit breaker manufacturer. In practice, arc
times often occur in multiples of a half-cycle, extinguishing at voltage zero crossings. Depending on breaker interrupter
design, arc times are sometimes higher for small fault current values and lower for large fault current values.
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Arcing detected which lasts in excess of the Arc Time Limit can assert the alarm contact and DNP points, as desired.
Clearing Time is equivalent to interrupting time. This time is the sum of the Opening Time and Arcing Time. Clearing Time
which exceeds the Clearing Time Limit can assert the alarm contact and DNP points, as desired.
Opencoil Time is equivalent to opening time. It is the time duration from energization of an open coil to the opening of the
52a auxiliary switch
Closecoil Time is the duration of the closing coil energization, beginning at the instant of voltage applied to the closing coil
to the opening of the 52b auxiliary switch.
Open travel Time is the duration of time from the opening of the 52a auxiliary switch to the closing of the 52b auxiliary
switch. This is the segment of circuit breaker motion during which OPTIMIZER3 calculates open velocity.
Close travel time is the duration of time from the opening of the 52b auxiliary switch to the closing of the 52a auxiliary
switch. This is the segment of circuit breaker motion during which OPTIMIZER3 calculates close velocity.
The Operations Count is the total number of operations that the circuit breaker performs. An operation is considered an
Open and Close. The counter is incremented with each Open operation. When the count reaches the limit, the alarm relay
can be asserted or DNP point set. The Operations Count is similar to a trip odometer on a car; it may be reset at any time
and set to a limit that initiates some maintenance activity such as an inspection.
When the Operations Count Alarm Limit is set to zero, the alarm is disabled.
The Fault Operations Count Alarm Limit is the cumulative total of all Open operations with recorded maximum phase
current equal to or greater than the Fault Detect Threshold. The Fault Detect Threshold is given in amps as measured
in the bushing CT secondary circuit. The Non-Fault Operations Count is the cumulative total of all Open operations with
recorded maximum phase current less than the Fault Detect Threshold.
The No Operations Alarm Limit is the total number of days elapsed since the most recent circuit breaker Open operation.
When the number of days elapsed is equal to the Alarm Limit, an alarm contact and DNP points can be asserted, as
desired.
44
OPTIMIZER3 detects restrikes (re-ignitions) using the ANSI definition C37.10. For any pole of the circuit breaker, if the
measured phase current goes to zero but re-establishes after ¼ of a cycle, the restrike alarm is asserted. If the current re-
establishes sooner than ¼ of a cycle, this is not a restrike but considered to be a continuation of the original arc and the
total time elapsed is given as the Arcing time even if part of the time there is no measured current.
The Restrike Alarm may be Enabled or Disabled, as desired. If enabled, a detected restrike will assert the alarm contact
and DNP points can be asserted, as desired.
Open and close operations are separately logged and timing information is recorded for the discrete segments of each
operation. Open operations are segmented into Opening Time, Open Travel Time, Arcing Time, and Interrupting Time.
Close operations are segmented into Close Time and Close Travel Time.
The average velocity is calculated and given for each circuit breaker operation. The average velocity is calculated and is
given by the quotient of the Stroke Length divided by the Travel Time for each Open and Close operation.
The stroke length is taken from the time/travel test done by the manufacturer or from a field test using equipment which
includes a motion sensor and inputs for 52a and 52b auxiliary switches. From the test plot, the distance travelled is
calculated with 52a and 52b transitions as distance endpoints. The distance travelled is the same for either the Close or
Open operation. From the Close plot below, the 52b auxiliary switch opens at 80mm and the 52a auxiliary switch closes at
13mm. The stroke is 80-13=67. The entry is rounded to the nearest 10 mm, therefore 70mm is entered for Stroke Length.
The Close travel time begins when the 52b auxiliary

switch opens and ends when the 52a auxiliary
switch closes.
In this example 92.7 – 37.3 = 55.4 ms
Close Travel Time = 55.4 ms
The Average Velocity for this Close operation is then
70mm ÷ 55.4 ms = 1.26 m/S.
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3.7 Sensors
There are 8 sensor inputs.
Sensor A, B, and C are dual-use. They are compatible with 4-20 milliamp 2-wire sensors or sensors using the digital
protocol.
The INCON OM-DSDP Digital Density Sensor must be connected to Sensor A, B, or C inputs.
Sensors 1-5 are compatible only with 4-20 milliamp 2-wire sensors and can be scaled to represent many parameters.
4.0 Export Reports, Action, Active Events, Reset

OPTIMIZER3 stores history of circuit breaker monitoring data and associated sensor data. Reports may be downloaded
directly from the monitor by clicking on EXPORT. From the EXPORT page, specific sensor inputs or report types may be
defined for any date range.
This default export screen will give the last 30 days of data given by Sensor 1, generally a DSDP sensor which gives both
temperature and SF6 density. The report is generated in CSV and will be put in the download folder and appear at the
bottom of the screen as an MS EXCEL file. A typical download with the above choices is shown to the right.
Alarm resets, counter presets, and circuit breaker contact life presets are all done from the ACTION page.
46
Counts may be reset. If the OPTMIZER3 is installed on a circuit breaker with a known history record or the history can
be estimated, this information may be entered for fault, non-fault, and operation number which is usually synchronized
with the mechanical counter on the circuit breaker mechanism. Note that the increment of the mechanical counter may
be on either the OPEN operation or the CLOSE operation. Either may be accommodated and is selected from the
CONFIGURATION page. The setting for Remaining Contact Life is useful when the monitor is installed on a legacy
breaker whose contacts are not new but remaining service life can be estimated. It is also used when one interrupter is
serviced or otherwise when each interrupter has a different service history. Each may be reconciled on this page.
The ACTIVE EVENTS page gives a recent history of all the inputs with respect to their boundary conditions. It gives
record keeping of all settings changes, communications access, circuit breaker status changes, etc. As the history builds,
multiple pages are available for review.
Resetting the OPTIMIZER3 is done from the RESET page.
From here, a reboot can be initiated or the system can be reset so all defaults are restored and the monitor is as it was
when it left the factory, with default settings and default IP addresses. All data will be wiped.
47
5.0 Firmware Upgrade Process
When new functionality is available, the OM3 may be upgraded to the new level by updating its firmware.
Firmware may be uploaded to the OM3 locally with a laptop PC or remotely through a network from a PC.
Firmware is usually provided as a .BIN file and normally 65mB in size.
At this writing, the firmware is this:

To upload the new firmware, the .bin file must reside on the computer that is connected to the OM3.
Select Upgrade from the menu and then find the .bin file you want to use, at the prompt.
Immediately on selection the file, the upgrade process will begin and the progress is shown. During the process, the OM3
Mini USB connection will disconnect then re-connect, the PC may make a sound when these events occur.
To continue working with the OM3 after the upgrade, login is required.
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6.0 DNP Setup and Navigation
Distributed Network Protocol 3.0 is supported. The method of developing the DNP point index is new with OPTIMIZER3.
The Process has three parts:
1. Select Sensors to be used in the installation
2. Select Operating Mode
3. Develop Point Index by assigning points to measured attributes, as defined by the Mode and Sensors Used
In this way, the DNP point list is said to be dynamic. After the sensors and Mode are defined, the OM3 then knows what
measurements and data will be available to put into a DNP point index. When a DNP configuration is complete, it can be
saved and re-used by uploading it to other OM3 units as required.
Step 1- Select the sensors for an installation
For this example, the circuit breaker has one SF6 system where all three interrupters are manifolded together so only one
SF6 density sensor used. The circuit breaker has a spring-spring mechanism. The spring charging motor is run from AC
so that will be monitored with an AC current sensor. Load metrics will be provided, yes is entered for that selection.
Step 2- Select the Mode of operation
The circuit breaker has two Open coils, one Close coil, one 52A auxiliary switch, and one 52b auxiliary switch. The best
choice for these available connections is Mode 7.
The DNP setup is located at the bottom of the Configuration page.
Select the DNP mode whether TCP/IP or RS485. Select ports and addresses as required for your SCADA system.
Select how many measurements to poll from the Number of Measurements menu.
If unsolicited messages are desired, YES is selected from the pull-down menu. With unsolicited messages, the selections
are further expanded to include settings for deadbands. Deadbands may be changed as necessary by clicking on the
default value.
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Binary input data is useful to monitor two-state devices. This include alarm assertions on/off, circuit breaker open or close,
pressure below or above alarm settings. Based on the sensors and Mode chosen, each binary point will have a Source
menu that lists all the available parameters that are binary. In this example, the number of measurements has been
chosen as 4.
If the DNP configuration requires more than 4, then more can be added at any time by changing the number, then saving.
Static Variation, Event Variation and Event Class are configured from separate pull-down menus:
Analog input data conveys voltages, currents, power, pressures, and temperatures.
50
As with the binary inputs, the analog variations are configured with separate pull-down menus.
If the dead band requires adjustment for any source, it may be edited to suit.
51
PO Box 638 • 34 Spring Hill Road • Saco, ME 04072 U.S.A.
Tel: +1 207 283 0156 Fax: +1 207 283 0158
©2015 FFS 000-1533 Rev A Tel: USA & Canada 1 800 872 3455

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On-Line Circuit Breaker Performance

and SF6 Gas Density Monitor

©FFS 000-1533 Rev A

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CONTACT INFORMATION: INCON Technical Service

1.2 Sensor Inputs

Loop-powered (2-wire) digital or analog sensor inputs.

Loop-powered (2-wire) analog sensor inputs. Supports

1.5 Input Power

1.6 Communication Ports

Figure 2.2 OM3 Mounting Dimensions (Not Actual Size)

2.2 Current Pickup Coils

2.3 SF6 Sensor Mounting

2.4 SF6 Gas Monitoring

SF6 GIL (Gas Insulated Transmission Line) Application

Low Gas Alarm Forecast & Forecast Planning Alarm

(Shown on the Sensors Page)

2.6 Temperature Monitoring

OPTIMIZER3 monitors Voltage with external loop-powered 4-20 mA Voltage transducers.

2.8 Current Monitoring

OPTIMIZER3 monitors Current with external loop-powered 4-20 mA current transducers.

2.9 Heater Monitoring Using UPSM (Universal Power System Monitor)

Mode 1 Mode 2 Mode 3 Mode 4

Aux 2 Green Light or 52b Switch Green Light or 52b Switch

Note: Modes 1 thru 4 are identical to OPTImizer2

Aux 2 Close Coil Open Coil 2 Open Coil 2

Arcing Time End Ø <7% Amplitude <7% Amplitude <7% Amplitude

OPTIMIZER3 Operating Modes, Measurements Made, Required Wiring Connections

3.2 Choosing the Desired Operating Mode

AUX 1 Input Polarity = Positive

Mode 3 Mechanical Data Export

AUX 2 Input Wiring Connection AUX 2 Polarity setting

AUX 1 Input Polarity = Positive

Mode 4 Mechanical Data Export

AUX 3 Input Wiring Connection AUX 3 Polarity setting Type

AUX 4 Input Wiring Connection AUX 4 Polarity setting Type

Mode 5 Mechanical Data Export

AUX 2 Input Polarity = Positive

Mode 6 Example Configuration

AUX 3 Input Polarity = Positive

Recommended Connection Alternate Connection Alternate Connection

Recommended Connection Alternate Connection Alternate Connection

Mode 7 Mechanical Data Export

Main contact part = 24.7ms + 3.5ms = 28.2ms

The Close travel time begins when the 52b auxiliary

4.0 Export Reports, Action, Active Events, Reset

Resetting the OPTIMIZER3 is done from the RESET page.

At this writing, the firmware is this:

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