CH10003 - Operating & Maintenance Manual PDF

Jebsen & Jessen Technology (M) Sdn Bhd
16 Jalan 51A/225,
46100 Petaling Jaya,
Selangor, Malaysia
Documentation:
Operations and
Maintenance Manual
Order number CH10003
Customer JC Chang (Pte) Ltd.
Location Lahad Datu – Melewar Properties
Turbine Model NG DME-700 8’/16’ MVA-III
Gearbox Model Triveni HSG-360
Generator Model TDPS TD110
Year 2010
The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization
is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or
ornamental design registration
Operation and Maintenance Manual
Master Table of Contents
Contents: Master Table of Contents
Section 1: Equipment Manuals

1.1 Turbine
1.1.1 Turbine Specifications
1.1.2 General Data
1.1.3 Steam Curve
1.1.4 General Description of Equipments
1.1.5 Construction Details
1.1.6 Operation and Maintenance
1.1.7 Disassembly and Inspection
1.1.8 Installation
1.1.9 Irregularities and Possible Causes
1.1.10 General Information
1.1.11 Cleanliness of the Lube and Control Oil System
1.1.12 Safety Instruction
1.1.13 Steam Purity
1.1.14 Cleaning of Steam Lines and Checking of Cleanliness
1.1.15 Enclosure Drawings
1.1.16 Turbine Dimensional Drawing
1.1.17 Recommended Spares for Turbine
1.2 Gearbox
1.2.1 Gearbox Operations and Maintenance Manual
1.2.2 Technical Data
1.2.3 Rust Preservation Procedure
1.2.4 Lubrication Chart
1.2.5 Main Oil Pump Operation and Maintenance Manual
1.2.6 General Arrangement Drawing
1.2.7 Sectional Arrangement Drawing
1.2.8 Recommended Spares for Gearbox
1.3 Generator
1.3.1 Generator Operations and Maintenance Manual
1.3.2 Generator Technical Specifications
1.3.3 Capability Curves
1.3.5 Terminal Box Drawing
1.3.6 Generator and Auxiliary Parameters Final Setting
1.3.7 Generator Current Transformer (CT) Drawing
1.3.8 Recommended Spares for Generator
1.4 Oil Cooler
1.4.1 Oil Cooler Operation and Maintenance Manual
1.4.2 Oil Cooler Specifications Sheet
1.4.3 Oil Cooler General Arrangement Drawing
1.4.4 DOSH Approval - JKKP 127
Section 2: Auxiliary Equipment

2.1 Auxiliary Oil Pump
2.2 High Speed Coupling
2.3 Low Speed Coupling
2.4 Lubrication & Control Oil Filter
2.5 Pressure Control Valve
2
2.6 Adjustable Orifice

2.7 Speed Governor Woodward 2301D-ST
2.8 Current to Pressure Converter - Woodward CPC-I
2.9 Magnetic Speed Pickup
2.10 Speed Indicator
2.11 Accumulator
2.12 Ball Valve
2.13 Check Valve
2.14 Pump Bypass Valve & Accumulator Drain Valve
2.15 Solenoid Valve
2.16 Air Breather
2.17 Pressure Indicator
2.18 Pressure Transmitter
2.19 Pressure Switch
2.20 Temperature Indicator
2.21 Temperature Transmitter
2.22 Temperature Element
2.23 Level Indicator
Generator Control Panel Components
2.24 Unitrol 1000 Automatic Voltage Regulator
2.25 GE489 Generator Management Relay
2.26 PQM-II Power Quality Meter
2.27 Master Trip Relay
2.28 Trip circuit supervision relays
2.29 Instantaneous Voltage Relay
2.30 Alarm Annunciator System
2.31 Synchroscope
2.32 Woodward SPM-D10 Synchronizing Unit
2.33 Electronic Timer
2.34 Diode Failure Relay
2.35 Woodward XUA1 – AC Voltage and phase balance relay
2.36 Power Supply Unit – 24VDC
2.37 LASCPT Operation and Maintenance Manual
2.38 NGR Operation and Maintenance Manual
Turbine Control Panel Components
2.39 3-Phase Supply Control Relays
2.40 Power Supply Unit - 24VDC
2.41 Control Relays
2.42 Ethernet Switch
2.43 Radiant Heater
2.44 Human Machine Interface (HMI) – PanelView Plus 6
2.45 Circuit Breakers
2.46 Motor Circuit Breakers
2.47 Motor Contactor
2.48 PLC Relay
2.49 PLC System – CompactLogix
2.50 Signal Isolator
2.51 Thermostat
2.52 Timer
3
Section 3: Contract Documents

3.1 General Arrangement Drawing DR-10003-001
3.2 Foundation Drawing DR-10003-002
3.3 Piping & Instrumentation Diagram DR-10003-004
3.4 Turbine Control Panel DR-10003-007A
3.5 Turbine Control Panel – Cable Schedule DR-10003-007B
3.6 Turbine Control Panel – Junction Box Wiring DR-10003-007C
3.7 Turbine Nameplate DR-10003-008
3.8 Turbine Sectional Drawing DR-10003-009
3.9 Steam Piping Layout DR-10003-010
3.10 Steam Piping Isometrics DR-10003-011
3.11 Oil Piping Layout DR-10003-013
3.12 Oil Piping Isometrics DR-10003-014
3.13 Instruments Interconnection Piping DR-10003-017
3.14 Alignment of Turbine, Gearbox, and Generator DR-10003-024
3.15 Single Line Diagram (SLD) DR-10003-030
3.16 Generator Control Panel (GCP) DR-10003-031
3.17 Lightning Arrestor, Surge Capacitor, Potential Transformer Panel (LASCPT) DR-10003-032
3.18 Neutral Ground Resistor (NGR) DR-10003-033
3.19 Generator Cabling List and Interconnection Details DR-10003-034
3.20 Technical Installation Datasheet DS-10003-001
3.21 Utility List LI-10003-002
Section 4: Databook
4.1 Turbine Databook
4.2 Gearbox Databook
4.3 Generator Test Report
4.4 Generator Databook
4.5 Generator GCP Test Certificates
4.6 Generator LASCPT Test Certificates
4.7 Generator NGR Test Certificates
4.8 Oil Cooler Databook
4
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
Section 1:
Equipment Manual
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1 Turbine
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.1 Turbine Specifications
1 2 3 4
COPYING OF THIS DOCUMENT GIVING IT TO OTHERS, USE OR COMMUNICATION OF THE
CÓPIA DESTE DOCUMENTO, FORNECIMENTO A OUTROS, USO OU DIVULGAÇÃO DE SEU
FOR INFORMATION
CONTENT THEREOF ARE FORBIDDEN WITHOUT EXPRESS AUTHORIZATION.
A
CONTEÚDO SÃO PROIBIDOS SEM EXPRESSA AUTORIZAÇA.
PROJECT NAME: MELEWAR PROPERTIES
PROJECT NUMBER: CH10003

D
CUSTOMER: JC CHANG
APPROVED SCALE DIMENSION

- : (mm)
E
CHECKED
- - - - ELABORATED
. -
DESCRIPTION ELABORATED APPROVED DATE REV.
TÍTULO
TITLE
TURBINE SPECIFICATIONS
JC CHANG CUSTOMER
CUSTOMER
DWG.
.
ORDER N° CH10003 FUNC.DWG. SEQUEN. 1 / 3 DWG. CH10003-TS-001 REV. 0
STEAM TURBINE FOR GENERATOR DRIVER
1. Operating conditions:
Driven equipment ........................................................................Generator driver
Output at Generator Terminals ............................................................... 3500 kW
Normal turbine speed .............................................................................5000 rpm
Steam Conditions Normal UNITS

Inlet pressure 30.0 bara
Inlet temperature 293 ºC
Exhaust pressure 4.1 bara
2. Turbine Characteristics:
Model .....................................................................................................DME 700
Type ............................................................................Multi-stages/Backpressure
Nominal diameter .....................................................................................680 mm
Number of stages................................................................................... 3 Rateau
Stage type ................................................................................................ Impulse
Nº of emergency valves ......................................................................................1
Nº of automatic control valves.............................................................................2
Inlet branch diameter ....................................................................... ∅8” 600# RF
Exhaust branch diameter ............................................................... ∅16” 150# RF
Casing limits:
Maximum allowable inlet pressure..................................................... 43 bara
Maximum allowable inlet temperature..................................................400 ºC
Maximum allowable exhaust pressure................................................. 5 bara
3. Turbine materials:
Upper casing ........................................................................... ASTM A 217 WC1
Bottom casing ......................................................................... ASTM A 217 WC1
Rotor shaft............................................................................................. AISI 4140
Wheel.................................................................................................... AISI 4340
Blades ..................................................................................................... AISI 410
Nozzles ............................................................................................... ASTM A36
Diaphragms seals-labyrinth..................................................................... AISI 410
Journal Bearings ................................................................................White Metal
NG reserves the right of change any of the above materials, during the project
development, for other equivalent material without to affect the quality of final
product.
4. Control system:
Electronic type governing system, with the following components:
Manufacturer................................................................................ Woodward
Model ....................................................................................... 2301 D-ST
Type ....................................................................................... Electronic
Adjustment class.......................................................................... Nema D
Electric/hydraulic converser model CPC manufactured by Woodward.
Actuator hydraulic (165/60 model) manufactured by NG.
5. Forced feed lubrication oil system for turbine, gearbox and generator. The
steam turbine will need an oil flow of 90 l/min @ 1.5 kgf/cm²g for bearing
lubrication and 50 l/min @ 15 kgf/cm²g for the actuator control. The lubrication and
control oil should be according to ISO VG 68.
6. Turbine performance:
Steam Conditions Normal UNITS

Inlet pressure 30.0 bara
Inlet temperature 293 ºC
Exhaust pressure 4.1 bara
Output at Generator Terminals 3500 kWe
Steam Flow 50500 kg/h
Steam Rate 14.42 kg/kWh
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.2 General Data
GENERAL DATA
NG Reference 4.1.4853
Driven equipment Generator
Turbine type DME – 700
Reducer type -
Power (Normal) (kW) 3500
Speed (Normal) (rpm) 5000
Output speed – reducer (rpm) -
Rotation Counterclockwise
Trip speed (rpm) 5500
Steam conditions NORMAL
Inlet pressure (bara) 30
Inlet temperature (°C) 293
Exhaust pressure (bara) 4,1
Steam rate (Normal) (kg/kW.h) 14,42
Steam consumption (Normal) (kg/kW.h) 50.500
Note: Values for steam rate and steam consumption in table above, are evaluated for
normal steam conditions only.
DME-700 01
Page 1 /2
CONTROL SYSTEM
SPEED CONTROL
Model 2301 D-ST
Supplier Woodward
Speed Adjustment Eletrônico
Converter
Model CPC
Supplier Woodward
Atuactor
Model 165/60
Supplier NG
DME-700 01
Page 2 /2
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.3 Steam Curve
1 2 3 4
FOR INFORMATION
A

D
CUSTOMER: JC CHANG

- : (mm)
E
CHECKED
- - - - ELABORATED
. -
TÍTULO
TITLE
PERFORMANCE CURVE
JC CHANG CUSTOMER
CUSTOMER
DWG.
.
ORDER N° CH10003 FUNC.DWG. SEQUEN. 1 / 6 DWG. CH10003-PC-001 REV. 0
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.4 General Description of Equipments
GENERAL DESCRIPTION OF EQUIPMENTS
GENERAL REMARKS
This instruction manual describes the construction of the turbine and contains operation
and maintenance methods.
The manual is not designed to cover details of the equipment, not to provide solutions to
all problems that may occur. Still, it is suggested that it be read very carefully. Additional
information or solutions to specific problems should be requested directly from NG
Metalúrgica Ltda.
In order to avoid difficulties during the operation of the turbine, special attention should
be given to the following:
• Lubrication oil in sufficient quantities should be applied to all bearings whenever the
turbine is rotating (in operation) so as to avoid damage to them.
• All drain valves should be opened at start-up of the turbine or when in low-rotation
operation.
• When the main shutdown valve is kept in the same position for an extended period
of time, the stem may become stuck; hence the valve handwheel should be turned
slowly at least once a day.
• Check and note readings of gauges, thermometers and other instruments at regular
intervals.
• When an extended shutdown of the turbine is planned, all valves on the steam
piping, with the exception of drain valves, must be kept totally closed, to protect the
turbine from rust (oxidation).
GENERAL ARRANGEMENT
The unit supplied by NG Metalúrgica Ltda. is composed of a turbine mounted on an
independent baseplate, with auxiliary equipments as follows:
Back-pressure turbine, equipped with 3 Rateau stages.
Hydraulic/mechanical governor type.
Trip shutdown device for event of turbine’s runaway speed.
DME-700 02
Page 1 / 5
CHARACTERISTICS OF THE UNIT
Turbine (Drawing 1)
Type: Action (impelled by 3 Rateau stages)
Operation: with back-pressure
Form of Construction: horizontal shaft, with split casing
Forced-Lubrication System for NG Hydraulic Governor

The turbine-forced lubrication system consists of a high-pressure line (170 psig) and
a low-pressure line (15 to 20 psig)
Oil is drawn by suction from the storage tank by the lubrication pump and conveyed to
the parts that use it through a cooler, a filter and a pressure reducer.
High-pressure oil activates the hydraulic speed governor of the turbine and feeds the oil
impeller pump, while the low-pressure oil system feeds the bearings of the turbine and,
when required, the bearings of the driven equipment, such as the reducer, hydraulic
pump, exhaustor, generator, etc.
The forced lubrication system is composed of the following parts:
Main Oil Pump (Not supplied by NG)

As the application of NG turbines usually involves the use of a gearbox, the main oil
pump is driven by the low speed shaft of gearbox.
Lubrication auxiliary pump (Not supplied by NG)

The auxiliary pump is a gear type pump attached to an electrical motor.
The pump is utilized in the start-up of the turbine and when it should work, for a short
period of time, with very low rotation.
The motor can be started manually or automatically with the installation of a pressure
switch in the oil system.
Oil filter (Not supplied by NG)

Depending on the turbine and equipment to be installed, the oil filter should be with its
filtering part made of special cloth or screen.
Oil pressure reducer

The oil pressure governor is a adjustable hole type, installed in the lubrication system
after the filter and cooler, and is utilized to reduce the oil pressure from 170 psig to 15 to
20 psig.
Relief valve (Not supplied by NG)

Installed in the high pressure line, it is utilized to return the oil excess from the pumps,
to the reservoir. At the same time it is utilized to keep the oil high pressure to the
constant value of 12.0 kgf/cm2g.
DME-700 02
Page 2 / 5
Oil reservoir (Not supplied by NG)
Steel-plate built with proper finishing and sized to assure the oil retention during, at
least, 3 minutes.
General description of lubricating oil

The turbine oil must meet several very important requirements. Among these the
following should be emphasized:
• Reduce friction to a minimum.
• Absorb heat generated by friction.
• Prevent corrosion.
• Under pressure, facilitate operation of hydraulic governor (regulator).
To satisfy these requirements for long periods with adequate safety, the turbine oil must
have the following characteristics:
• High anti-oxidation stability
• Application for long periods of time
• Adequate viscosity (low viscosity variations under variable temperatures)
• Capacity to impede the waste of the metal
• Non-foaming properties
• Purity and uniformity.
Characteristics of Turbine oil (DIN 51515, equivalent to classification ISO VG 68)
Kinetic viscosity at 50oC 44 ± 4cSt

o
Kinetic viscosity at 20 C (maximum) 200 cSt
Flash (ignition) point 210 oC
Density at 15oC (maximum) 0.900 g/ml
Pour Point (maximum) - 6 oC
Corrosive action on steel in distilled water anticorrosive
Aging behavior (increase of neutralization
index after 1,000 hrs) - maximum
2.0 mg KOH/g oil
Reference oil Suplier
Some oils that meet the above conditions are listed below. These oils present
satisfactory results, previously used in NG Metalúrgica turbines:
Petrobrás - Marbrax TR 52
Esso - Turbine Oil 68
Mobil - Mobil Oite Heavy Medium
DME-700 02
Page 3 / 5
Shell - Turbo 68
Texaco - Regal Oil PC 68
Castrol - Perfecto T68
Maintenance of turbine oil

Safe and economical maintenance of the turbine cannot be expected without perfect
maintenance of the oil in use, even when oil used is of top quality.
It should be borne in mind that the majority of problems with lubricating oils is due to
unsatisfactory conservation of oils.
Replacement oil must always be of the same type.
When storing, drawing off or transfering oil used in the turbine, adequate and clean
vessels and receptacles should be used to prevent foreign substances and bodies from
lodging in the oil.
The maintenance and conservation of oil for the turbine should be regarded as
important as the quality of the oil itself.
Oil inspection during operation

Inspections and tests during operation must be conducted by the following methods:
• Pay special attention to changes in level of oil in tank.
• Periodically inspect the system’s filters to maintain purity of oil.
• Check residuals filtered out: any white metallic particles may indicate possible faults
in bearings.
• Constantly check oil gaskets and oil cooler to locate and avoid possible leakages of
oil and water.
• Carefully check cooling water temperature, both at inlet and outlet of oil cooler.
• Temperature of oil and bearings should be periodically adjusted by increasing or
decreasing quantity of cooling water, so as to keep oil temperatures as follows:
• At turbine inlet: 110 – 150°F
• At bearing outlets: Under 150°F
Criteria for oil changes

Generally the periodicity of oil changes is defined by the increase in the oil
neutralization index.
However, this index varies with the type of oil, and hence there is no decision uniformity.
Special attention must be paid to a drop in the quality of oil, and the supplier should be
consulted as to recommended oil change intervals.
When any operational irregularities are found in the turbine, the oil should be analysed
and tested.
DME-700 02
Page 4 / 5
When a change occurs in sources or suppliers of oil, periodic tests should be carried out
for purposes of quality control.
In the case of foam formation, emulsion or sludge at excessive levels, consult oil
supplier and correct or change the oil.
Control and periodic inspection of oil system
During overhauls, special care must be taken to avoid entry of particles into the oil
circulation system.
Depending on inspection results, if there should be found some damages in the
bearings or scales of film of anti-rust paint or dregs in the oil circulation system,
corrective steps must be taken.
The oil in the storage tank should be transferred to a clean vessel; the tank must then
be cleaned, removing all dregs and particles. This cleanup must be conducted with
material that does not leave threads (do not use cotton waste cleaning rags).
Once purifield and treated, the oil can be placed back in the reservoir, passing it through
a filter.
DME-700 02
Page 5 / 5
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.5 Construction Details
CONSTRUCTION DETAILS
TURBINE
Casing
The turbine casing is made of two parts: upper and lower. These are firmly joined
together by screws in the horizontal flange.
The high-pressure steam chamber is cast at the side of the lower casing and features
flanges for the mounting of the body valves.
The turbine’s lower casing is fastened to the bearing supports by means of screws on
the four side shoes (brackets) while allowing some clearance for thermic dilation. Two
central guide shoes (brackets) serve to align the turbine between bearings.
Nozzles and Diaphragms

The turbine includes the 1st stage nozzle plus two diaphragms for the following stages.
Fixed blades of nozzles and diaphragms are directly mechanical on the internal ring and
then assembled to the external ring by an interference fit, being finally welded together.
First stage nozzle is welded to the turbine casing, while the diaphragms are mounted
directly at the casing.
Shaft sealing (Drawings nbrs. 4, 5, 6 and 7)

The turbine is equipped with a sealing system of the “labyrinth” type in order to keep
steam leakages to a minimum.
The “Labyrinths” consist of a certain number of thin circular strip-ribbons fixed to the
casing and to the shaft so that the clearance between the shaft and the edge of the
strips is kept small.
In addition, a gland steam sealing system including a steam ejector is provided.
Due to this type of mounting, steam escape is kept to a minimum, due to the constant
drop in pressure to which it is submitted in sequentially traversing the several labyrinths.
Bearings
Turbine’s bearings are split and offer good stability at high rotation speeds.
Bearing is composed of a carbon steel gland housing, on which the patent metal is cast.
Lubricating oil is pumped to the bearing through two side cavities and discharged on
both sides inside the bearing support.
The two halves are aligned by means of conical pins, and are affixed by means of a
brace on the upper part.
Provision is made for split type seal rings at each bearing end, to avoid oil leakage.
Front bearing support has a groove, which permits its displacement in the case of
dilations.
DME-700RC 03
Page 1 / 4
Rotor (Drawing nbr. 2)
Turbine’s rotor is composed of three Rateau stages coupled together by keys. Both
shaft and wheel are made of forged alloy steel. At one of the extremities of the shaft, the
excess-speed emergency system is mounted, and at the other end, the coupling.
Blades
Both the moving and stationary (fixed) blades are manufactured of stainless steel.
Moving blades are mounted in the machined grooves on the outer edge of the wheel
(disc), held firmly in place with the help of cleats and wedges. The shrouds are mounted
at the tips of the blades for more efficient use of steam and to decrease vibration
frequency of each blade, thus reducing fatigue stress and increasing life spans.
Automatic overload valves (Drawing nbr. 8)

These are mounted in the admission valves unit, and operated by the valve stem which,
through the correct position of the valves in the stem, determines the optimum opening
sequence for the turbine operation in partial charges.
GOVERNOR SYSTEM
Speed Regulator and Hydraulic Actuator (Drawing nbr. 11)

The turbine speed regulating system is composed of: A Woodward electronic regulator
model 2301 Woodward electro-hydraulic converter (CPC), NG hydraulic actuator model
165/60 (mounted on the turbine valve body) and Woodward magnetic sensor (mounted
on the steam inlet bearing housing).
The electronic regulator receiving the speed signal from the turbine, by means of a
magnetic sensor, sends an electrical signal to the electro-hydraulic converter, the
intensity of which depends on the correction to be made in the turbine speed.The
converter modulates the oil pressure that feeds the hydraulic actuator pilot piston
chamber (control oil), thus causing the main piston to move, which is connected to the
control valve lever system. The high pressure oil (12,0 kgf/cm2) (170 psi), applied on
the head of the actuator force piston, generates the force necessary to move the control
valve.
In case of failure in the oil feed, the hydraulic actuator will move in the direction of
closing the control valve, interrupting the flow of steam to the turbine.
DME-700RC 03
Page 2 / 4
Control valve (Drawing nbr. 8)
The control valve is located before the steam chest, and its actuation is controlled
automatically by the governor.
The control valve stem is coupled to the servo-motor’s stem, which transmits the
movement to the valve, thus making it open or close the two existing openings, which in
turn varies the steam flow.
EMERGENCY SYSTEM
General
The turbine is equipped with an over speed trip safety device, which is activated in
emergency cases, closing the trip valve.
System is activated automatically in situations where turbine speed exceeds the
maximum limit, or manually by means of a switch lever.
Basically the system consists of the following:
- safety device
- shutdown trip device
Trip valve (Drawing nbr. 8)

Trip valve is joined in a horizontal position to control valve body by flanges with screws,
and thus, when open, allows steam to flow in order to get a softer operation.
The valve is composed of two valves activated by the same stem.
Both large and small valves, as well as seats, are made of stainless steel.
Trip valve operation
Start-up
By turning the handwheel fully, in clockwise direction, the threaded sleeve moves
backwards, until it reaches the position where it is locked by the blockade shaft. The
sleeve is locked by pulling the button of the shutdown trip device.
Next, by turning the handwheel counter clockwise, steam will begin to flow into the
turbine, increasing rotation.
DME-700RC 03
Page 3 / 4
In operation
Under normal operating conditions, the valve is kept in full-open position.
When turbine rotation exceeds upper limit, the emergency device is activated, allowing
valve to shut down.
Emergency
In the case of any system failure which calls for turbine stop, the operator pushes button
that prompts trip shutdown, thus releasing threaded gland, which due to action of
helicoidal spring closes down steam flow, stopping turbine.
Safety device (Drawing nbr. 3)

Basically the system consists of a pin moved by centrifugal force, which after
overcoming the tension of a spring, activates a trigger that releases the shutdown trip
device.
Trip speed adjustment done is by use of a wedge.
Shutdown trip device (Drawing nbr. 9)

The shutdown trip device is designed to supply a motion capable of being transmitted to
the shutdown valve’s blockade shaft.
The device is designed to supply this movement when one of these situations occurs:
- Activation of the safety system.
In this case, the lever is operated to release the stem which moves by its spring
action. In this movement, the stem carries along the action lever coupled to it.
- Activation of the emergency system
In this case, the device button is depressed, activating the internal stem which in
turn activates the lever that releases the holed stem, starting up the system, as
above.
DME-700RC 03
Page 4 / 4
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.6 Operation and Maintenance
OPERATION AND MAINTENANCE
OPERATION
How to start-up turbine

Checking and preparing before start-up
- Steam source must be ready for operation.
- All measuring instruments must indicate zero (except those measuring temperature).
- Oil level in tank must stand at normal.
- Trip valve must be closed.
- Note if the governor speed was previously adjusted.
- Start-up auxiliary oil pump.
- Check oil pressure in bearings.
- If using manual pump, pump oil for 2 minutes and check bearings pressure.
- Open water in-and-out valves of cooler.
- Check water supply.
- Do not supply cooling water when oil temperature at cooler outlet is lower than or at
85°F; however, check continuously the temperature.
- Open drain valves of shutdown valve casing in the piping system (inlet and exhaust)
and expanders chamber.
- Proceed carefully with draining operation, not allowing humidity to enter turbine.
- Open exhaust gate valve.
- All valves mounted on the steam piping system should be open so as to permit slow
warming up of all pipes.
- Slowly open live steam valve, so that piping up to turbine’s trip valve is placed under
pressure .
- Check steam pressure before trip valve
- Do not proceed with start-up if steam pressure is below normal.
- Make ready shutdown trip device
- Slowly open trip valve (By opening of this valve, turbine will start to turn).
- Increase rotation up to about 500 r.p.m. and keep turbine at this speed during 15
minutes for warming-up purposes; then raise rotation to 3,000 r.p.m., during about 10
minutes, then raise to normal operating speed. If vibrations or abnormal noises occur,
stop turbine and check for cause.
- Check the discharge pressure of main oil pump which should increase by increasing
the rpm of turbine.
- Check pressures and temperatures at all points: should be at normal levels
DME-700 04
Page 1 / 4
- Switch off auxiliary oil pump
- Shut drain of live steam pipe and of valves
- Slowly place load in turbine
In Operation
- If any abnormal event is observed, check cause and shut down turbine if necessary.
- If emergency device automatically stops turbine, the auxiliary lubricating pump should
be activated manually or automatically. Check cause carefully before readying system
for new start-up.
- Emergency device should be tested at every opportunity (at 1- to 2 - week intervals).
- Turn hadwheel of trip valve at least once a day to avoid becoming stuck.
- If temperature of bearings reaches 165°F, check oil. If temperature raises abruptly,
stop turbine and check cause.
- Check oil level in tank.
- Check for oil, water and steam leakages throughout the entire unit, particularly
loosening of screws in flanges.
- Make sure there are no vibrations or abnormal noises in unit.
- We recommend checking, about once every two weeks, for oil contamination by water,
by drawing off a sample through oil tank drain valve.
- Take special care in draining inlet steam piping to avoid entry of humidity into turbine,
which would damage it.
- Check and note down all readings on gauges, thermometers, and other instruments at
regular intervals.
DME-700 04
Page 2 / 4
How to stop turbine (manually)
- Start auxiliary oil pump
- Close trip valve by handwheel or emergency device
- Open inlet steam piping drain valve
- Open drain valve trip valve body
- Close escape valve and open corresponding drain valve
- Allow the auxiliary oil pump to continue operating up to cooling of turbine
- Shut off auxiliary oil pump
- Shut off cooler water supply
- Close all drain valves.
MAINTENANCE
General
Turbine unit is built to run under uninterrupted service, and when for any reason it has
to be kept inactive for a long period of time, a number of steps must be taken to keep
unit in perfect operating condition.
Turbine maintenance
- It is necessary to remove humidity from body of turbine to keep its inside dry.
- Clean oil filter or parts where sludge and sediments can collect.
- Spin turbine rotor ¼ turn once a day.
- Every 2 or 3 days, convey oil to all bearings.
- Check functioning of all valves and registers at least once a week.
- Close escape valve and corresponding drain valve.
Start up after long shutdown period

- Check for oxidation on inside of turbine and other parts.
- Check piping and sealing systems.
DME-700 04
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CHECKING THE FUNCTIONING OF SAFETY DEVICE IN CASE OF OVER SPEED
Mechanical-type safety device
Test procedure
- Start-up turbine and maintain normal rotation (turbine loadless).
- Check functioning of manual emergency device.
- Slowly increase turbine rotation until emergency system is activated.
Make sure maximum rotation (r.p.m.) is within range of 9% to 11% of normal rotation.
- Repeat test a second time.
IMPORTANT:
- This test should be conducted in presence of technician responsible for maintenance.
- In case rpm surpasses 13% of normal rotation, manual device should be activated
immediately.
Inspection of over speed safety device

(Ref.: Drawing nbr. 4.080.03067.9)
If safety device does not activate within range of 13% above normal rotation, test should
be interrupted for inspection of device.
For inspection of this device, first remove the lid of the support of front bearing, as
follows:
1. Remove threaded pin (1)
2. Loosen nut (2)
3. Remove safety pin (3), support wedge rings (4) and spring (6)
4. Check entire system for possible accumulation of oil sludge impeding the
functioning of device.
5. Clean all pieces and parts, lubricate, install again, following reverse order.
NOTE: Ring (4) has the function of setting the moment of action of trigger activator of
turbine shutdown.
This setting is obtained by means of varying this ring’s thickness.
DME-700 04
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16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.7 Disassembly and Inspection
DISASSEMBLY AND INSPECTION
GENERAL GUIDELINES
We recommend that at least once a year, all parts of turbine be inspected to ascertain
the machine’s condition and to correct possible faults.
Unprogrammed revisions and overhauls should be carried out immediately after finding
abnormal occurrences during turbine operation.
During disassembly, assembly and inspection, special attention should be paid to:
- Gain sufficient understanding of unit’s construction details.
- Use appropriate tools for every type of servicing, taking into account unit’s weight and
location.
- Keep unit’s inside clean, taking care never to damage its parts and keeping them
protected after disassembly.
- Mount checked and revised parts into original position, not leaving any objects behind
(example: screws, nuts, lint & cotton waste rags, etc.) inside unit.
- Note down results of inspection, filing away document for later reference.
- Thermometers and tachometers should be removed before revision & overhaul work.
DISASSEMBLING TURBINE
Turbine disassembly should only be carried out when cold.
Casing disassembly
- Remove all accessories, piping systems and instruments.
- Remove or disconnect all parts that hinder revision of casing.
- Remove screws of horizontal flange.
- Install lift hook.
- Remove both conical pins.
- Raise upper casing about 3 mm by means of 2 release screws.
- Carefully raise upper casing by lift hook with help of lifting equipment.
- Upper halves of the shaft sealing casings must be raised together with main body.
- Assembly should be carried out in reverse order of above.
Body screws must be tightened evenly after the flanges and contact surfaces of the 2
half casing have been coated with loctite - LQ 1014 or similar.
DME-700 05
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Rotor disassembly
- Remove main pump unit.
- Uncouple turbine from driven equipment.
- Remove lid of bearing support, bearing lids and seals.
- Remove rotor.
Bearing disassembly
- Remove lid of bearing supports.
- Remove bearing lid.
- Remove upper half of bearing.
- Apply pressure to lower half of bearing on one side, causing it to slide on its seat.
In this manner, bearing can be removed without need to remove rotor, which will remain
in place supported by seals.
Turbine inspection
- All clearances between nozzles and blades, seals and the rotor, extremities of blades
and body etc., must be measured and checked against original numerical
specifications.
- Check for corrosion, wear and incrustations on nozzles, blades, body etc., measuring
and checking against original specifications.
If any indications of rust or incrustations are observed on nozzles surfaces, remove
them with steel brush, then clean with compressed air jet.
- Check inside of turbine for dirt, rust or fractures.
- Check for looseness at fixation parts of blades and rotor.
- Check for clogging of drain holes by foreign substances, sludge, sediments etc..
- Check and clean the over speed safety device.
- After assembling turbine, test over speed safey device.
- Inspection of bearings:
- Check surface contact, scratches and wear.
- Bearing wear can be measured with help of a micrometer.
NOTE: Check numerical results of measurements in three different positions against
original specifications, replacing bearing when wear exceeds 0.1 mm. (See clearances
specifications in Drawing n° 4.083.02938.0).
DME-700 05
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DISASSEMBLY AND INSPECTION OF SAFETY AND SHUTDOWN TRIP DEVICE (Drawings nbrs.
4.080.03067.9 and 3.080.01640.1)
Disassembly of safety device (Drawing nbr. 4.080.03067.9)

See Chapter 3: Inspection of over speed safety device.
Inspection
- Check system for dirt that may hinder movement of pin.
Disassembly of shutdown trip device (Drawing nbr. 3.080.01640.1)

- Loosen lock screw (19) and screw (9).
- Remove conical pins (17) and nuts (18).
- Remove whole unit.
- Once unit is removed, by releasing the brace pin (14), ring (4) and inside lock screw
(19), disassembly of whole unit becomes possible.
Inspection of shutdown trip device

- Carefully clean whole unit to avoid obstructions that may hinder movement of stem.
Assembly
Follow reverse order of disassembly.
TRIP VALVE (Drawing nbr. 3.080.01644.9)
Disassembly
- Loosen coupling (14).
- Loosen screws (28) and remove unit from valve body (1).
- Remove lock screw (26), key and handwheel (22).
- Remove lid (17), gland (18) and spring (25).
- Loosen nut (2) and remove piston (16).
- Loosen screws and remove stem guide sleeve and valves.
DME-700 05
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Inspection
- Check seat of large valve (7) and small valve (8) for wear and contact.
- Check stem (5), shaft (4) and their sleeves for contact, distortion and wear.
- Check spring (25).
- Clean all parts.
CONTROL VALVE UNIT WITH AUTOMATIC OVERLOAD VALVE (DRAWING NBR. 4.080.04598.1)
(It substitutes the control valve unit)
Disassembly
- Uncouple the governor of the control valve
- Remove the stem guide of valve (1).
- Remove the stem with the governor cone (2 and 6) and the overload valve (multivalve)
(11).
- Remove the unit from stem extremity guide (8).
Inspection
- Check governor cone seats against body of valve and the wear of overload valve
sleeve (multivalve).
- Check valve stem and respective sleeves for contact, distortion and wear.
- Clean all parts.
DME-700 05
Page 4 / 4
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.8 Installation
INSTALLATION
INTRODUCTION
Turbine installation must be rightly made to ensure satisfactory operation.
FOUNDATION
The foundation should support the loads specified in drawing “Foundation Plant”, and
be isolated for not transmitting vibrations of the adjacent areas of the turbine.
ALIGNMENT
A perfect alignment of shafts is essential for the correct operation of turbines.
Experience shows that, most of the time, the excess of vibration is caused by the
misalignment of shaft. Frequently worn bearings and couplings result from shaft
misalignment. In extreme cases, a misalignment may cause the breakage of coupling or
shaft.
If the furnishment consists of a turbine and reducer being mounted on a soleplate, these
equipments are factory-aligned and fixed; however, this alignment should be checked
and, if necessary, be remade; in this case, the hole for guide pins of base reducer shall
also be remade.
This check shall be accomplished before aligning driven equipment.
We must define two basic types of misalignment to be detected and corrected within
certain tolerances:
1) Angular misalignment (Figure A)
It is a form of misalignment where the shaft centerlines intersect.
2) Parallel Misalignment (Figure C)
It is a kind of misalignment that occurs when the shaft centerlines are parallel.
DME-700 06
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TYPES OF SHAFT MISALIGNMENT:
A - Angular Misalignment
B - Colinear Alignment
C - Parallel Misalignment
DME-700 06
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Before aligning the turbine or the turbo-reducer unit with the driven equipment, certify
that the turbo-reducer is nivelled and positioned in relation to the driven equipment (the
bases have jackscrew).
In the case of alignment between turbine-reducer mounted in a baseplate, the turbine
should keep fixed, while the reducer should be moved during alignment, since the
turbine cannot be shimmed in respect to the baseplate.
In the alignment between turbo-reducer and the driven equipment, one or the other can
be fixed or movable, as more convenient.
Initial alignment should be carried out with the turbine at room temperature and before
the finishing of concrete base. Checks of alignment should follow a logical sequence: if
an angular misalignment is noted, find it and correct it before correcting a parallel
misalignment.
Check of the angular misalignment

1. Place the shafts in the operation position
WARNING
Lubricate all bearings before trying to move or rotate the shafts
2. Use a sensoring caliber to determine the separation between the coupling faces in 4
positions that are 90° equidistant, as showed in figure D.
DIAL INDICATOR
SPACER BAR
D – Shaft alignment
3. Make all necessary adjustments for alignment moving the place and shimming the
equipment that shall be moved (as previous description) to make distances equal,
with a tolerance of up to 0.05 mm between the coupling faces in each 90° position.
Refer to the drawings or manufacturer’s specifications of coupling for the necessary
coupling spacing.
DME-700 06
Page 3 / 9
Measure in the two indicated planes (“x” and “y”)
∆ maximum for both planes:
(E2 - E1 ) = 0.05 mm (slope 1:4000).
The tolerance indicated in the previous figure does not take into account the machining
error of coupling flanges. To compensate for the possible machining errors of the
coupling face in relation to the shaft (perpendicularity), proceed as follows:
1) Measure E’2 and E’1
2) Rotate both shafts at 180º and carry out a new measurement of E”2 and E”1.
(E2 −E1 )real = (E2 − E1 )+(E2 − E1 )

' ' " "
2
“(E2 - E1) real” corresponds to the opening of the faces properly machined with relation
to the shaft.
DME-700 06
Page 4 / 9
Example I:
- Measurements in the position Oº
E’1 = 8.24 mm
E’1 = 8.12 mm
∆E’’1 = -0.12 mm
- Measurements in the position 180º
E’’1 = 8.36 mm
E’’1 = 8.12 mm
∆E’’1 = -0.24 mm
− 0,12 − 0,24
∴ ( E2 − E1 ) real = = − 0,18
2
The negative sign means that E2 < E1 and, therefore, the opening is bigger in the
upper part).
The opening of 0.18 mm is through the diameter (or 0.09 through the radius), therefore,
to align, lift one of the equipment in its extremity, to close the faces of 0.09 mm in the
upper part.
This example shows alignment only in the vertical plane; to obtain the correct alignment
in the horizontal plane, proceed in the same manner.
Check of the parallel misalignment

1. Mark with a punction the two halves of the coupling in order to make possible the
determination of the relative position of shaft, at any time during alignment.
2. Mount the comparison reader support on one of the coupling cubes. With the reader
stem touching the opposite cube, adjust its indicator to zero.
3. Simultaneously rotate both shafts and keep the marks together. Write down the
readings of hand in 90º, 180º, 270º and 360º. The indicator should indicate zero on
360º (start point).
Repeat this process several times to avoid errors.
Always rotate shafts in the same direction and against axial bearings, avoiding this way
errors in the measurements due to clearance of axial and journal bearings.
4. Loosen the fastener nuts of the movable equipment during the alignment and correct
the vertical parallel misalignment, by adding or removing the wedges previously
placed between the base and the support blocks.
5. Fasten the nuts and check again the vertical and horizontal parallel alignment.
6. Loosen the nuts and correct the horizontal parallel alignment, moving the equipment
on the sides.
7. Fasten the nuts and check once more the horizontal and vertical parallel alignment.
DME-700 06
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8. Once the parallel alignment is determined as satisfactory (maximum permissible
parallel misalignment: 0.05 mm LTI), check again the angular alignment.
NOTE:
• Support blocks of equipment should be concreted with special cement of minimum
contraction.
• Final alignment should only be carried out after drying of blocks.
• After the final tightening of the fasteners, level checking, alignment between
turbine/reducer, alignment between reducer/driven equipment and contact of
reducer teeth (see Manual of the Reducer) or alignment between turbine and driven
equipment, proceed to the finishing of foundations.
FINISHING OF FOUNDATIONS
Finishing of foundations provides a rigid connection between the irregular surface of
base and the equipment. It is important that the lining fills completely the space existing
between the foundation and the baseplate surfaces in order to maintain the alignment of
shafts. Pipings should be disconnected during the finishing operation.
PIPINGS
- Steam piping
The right project and proper installation of piping is an important part of turbine
installation.
For a correct installation of the turbine, some requirements must be fulfilled:
1. Transmission of tension by dilation and the own weight to the turbine casing must be
avoided, because it could affect the shaft alignment.
2. Drain any humidity accumulated in the steam admission piping and in the discharge
piping and, this way, assure the furnishment of dry stearn to the turbine. It is
recommended the installation of block valves in the steam pipings in order to allow
working in the turbine without shut off the boiler.
Valves should be placed in a place of easy access between the turbine and the main
piping.
It is recommended the installation of a steam filter or a humidity separator, with
integrated filter, between the block valve and the turbine.
DME-700 06
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Turbine casing should be protected against piping weight and dilation tensions. The
weight of piping should be supported in proper supports. Themal originated tensions in
pipings can be reduced to satisfactory levels, by using flexibility in the piping through
expansion curves or dilation joints. The cold connections between piping flanges and
turbine flanges should be made without forcing the piping to any direction, for it is the
only way to obtain a satisfactory connection. The piping flanges should be aligned with
the turbine flanges, with a tolerance of 0.25 mm (0.010 inches), without being placed
the flange screws. The next figure represents NG’s suggestion for a configuration of
admission and discharge steam pipings. Whenever using dilation joint at piping, utilize
articulated or self-compensated joints.
ATTENTION
Efforts in turbine flanges should not surpass the values as per forecast at NEMA-SM 23
standard
Suggestion for a disposition of steam pipings
DME-700 06
Page 7 / 9
- Safety valve (relief valve)
A safety valve shall be installed between the turbine discharge flange and the first block
valve of discharge piping (as previous figure).
The function of this safety valve is to protect the turbine against excess discharge
pressure.
The safety valve shall have a size that allows the discharge of the maximum steam flow,
that can circulate inside the turbine, avoiding this way that the turbine pressure
overcomes its project value. The installation of the relief valve in the piping is on the
client’s responsibility.
ATTENTION
Turbine shall not be operated unless the safety valve or any other device has been
installed before any block valve and is in conditions for operation.
The sentinel warning valve, placed in the turbine casing, does not work as a safety
valve. The sentinel warning valve is not able to discharge steam flow, so as to relief the
turbine casing from an excess escape pressure.
- Drainage pipings
Installation of drainage pipings must be made with attention and carefulness.
Drainage pipings should be directed to an open collector. The condensate from these
drains should not be reused. All valves should be grouped as close as possible to the
collector, and all pipings should be labelled for identification. The drainage pipings,
connected by valves, should have closed valves during operation. The drains connected
without the use of valves, should be cleaned and connected to an open drain.
ATTENTION
All drains must separately convey to the collector
The drain connections are identified (dimension and position) at turbine dimensional
drawing or at layout drawing.
DME-700 06
Page 8 / 9
- Cooling water piping
There are no conections for cooling water in the turbine.
The cooling of the oil is achieved through an oil cooler with flanged connections for
cooling water.
NOTE
Cooling water pressure should not surpass 55 psig, in order to avoid oil contaminations in
case of leakage. Cooling water temperature should not surpass 90oF.
- Oil piping
The oil piping is furnished by NG Metalúrgica, and should be interconnected according
to the specific drawing for furnishment.
The customer must foresee pipeline for oil tank drainage.
NOTE
Positioning and dimensions of several piping connections to be provided by the customer
are in the dimensional drawings specifically furnished for each equipment and/or in the
drawing “General Arrangement”, when requested.
DME-700 06
Page 9 / 9
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.9 Irregularities and Possible Causes
IRREGULARITIES AND POSSIBLE CAUSES
If an increase of noise or vibrations occurs during start-up or operation, stop turbine and
check causes.
VIBRATION
See table at next page.
DME-700 07
Page 1 / 4
SYMPTOM GENERAL CAUSE PROBABLE SPECIFIC CAUSE
Vibration or abnormal noise in Contact between (Some contacts can be recognized

given spot. Noise varies with moving and fixed by slowly turning rotor).
turbine rotation. parts. a) Moving blades are in contact with
fixed stationary parts.
b) Inadequate clearances in seals or
moving blades.
c)Damaged thrust bearing
Uniform vibration throughout Unbalancing of a)Inadequate balancing

machine. Constant frequency with moving parts. b)Bent shaft
rotation, probably diminishing as c)Broken or corroded blades
load increases. d)Deposits on blades
e)Uneven heating up often found due
to excessively fast start-up
Vibration with variable frequency, Unsatisfactory a) Coupling incorrectly mounted
probably increasing as load rises. alignment (assembled), or loose screws.
b) Bearing misalignment.
Vibration throughout all equipment Foundation a) Anchor bolts not firmly lodged in
and adjacent areas. concrete or loose screws.
Frequency remains constant with
varying loads.
Local (spot) vibration - Noise during Loose parts. a) Excess clearance or damaged
start-up and shutdown of turbine. bearings.
b) Parts of bearings loose
c) Parts of rotor loose
General, overall vibration Accumulation of a) Drain holes clogged
humidity in body of
turbine
Noise at turbine inlet. Variation in steam a) Water from boiler.
entry
b) Deposits (sediments) in steam
c) Rupture in steam filter
d) Governor not functioning
satisfactorily
Note: It is recommended that at all times normal noise and vibration level tables be kept
easily available, for reference use.
DME-700 07
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LUBRICATION
Noise in oil piping, and drop in Air in oil suction Oil pipe leakage
oil pressure. pipe
Low pressure in pressure gauge Pressure drop in oil a) Losses in oil suction pump
piping
b) Oil losses in oil tank
c) Filter clogged or other

obstructions in piping
d) Damage or obstruction in
pressure gauge or piping of
gauge
High temperature readings on Excessively high a) Oil losses for above

bearing thermometers temperature of oil in mentioned reasons
bearings
b) Impurities in lubricating oil
c) Lowered efficiency of oil

cooler, caused by: air in
system, dirt in pipes or loss
of cooling water.
d) Mechanical failures in
bearings
1) Patent metal in filter
2) Unsatisfactory alignment
3) Inadequate clearances
Note: It is recommended that at all times normal pressure and temperature tables of the
system be kept easily available, for reference use.
DME-700 07
Page 3 / 4
INSTABILITY / IRREGULARITIES OF NG HYDRAULIC GOVERNOR
- “Freezing” (becoming stuck) of - Pilot piston

governor’s moving parts
- Servo motor piston
- Balance pins
GOVERNOR INSTABILITY
- “Freezing” (becoming stuck) of - Valve stem - sleeve

control valve
- Inadequate adjustment of springs - Springs
- Unstable oil pressure - Oil characteristics
- Oil temperature too high or

too low
- Insufficient power in servo-motor - Discharge pressure of main

piston oil pump too low. “Freezing”
(becoming stuck) of piston or
control valve
- Instability in steam pressure - Main steam piping
DME-700 07
Page 4 / 4
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.10 General Information
GENERAL INFORMATION
UNPACKAGE
Take out package and check wether all items of the dispatch control list were furnished.
Chek if there is any damaged or missing part. Be careful when handling the parts. In
case of damage of the turbine during transportation, contact the transporter and
communicate such fact to NG Metalúrgica Ltda.. If any part be missing, contact NG
Metalúrgica Ltda.
HANDLING
ATTENTION
Do not try to lift the turbine by the eyehole existing at the top of the upper half of casing.
The eyehole only should be utilized to lift the upper half of casing (lid). It is extremely
dangerous to use such eyehole to lift the entire turbine.
It is advisable to use the lifting eyehole existing at the baseplate. When lifting the
turbine, protect the machined surfaces and keep it on level. In general, the customer
should program the movement of the turbine and its auxiliary equipment according to
the local availabilities for installation. The personnel in charge of the installation should
be responsible for the handling of equipment.
STORAGE
Before being packed, the turbine receives a treatment of an anti-rust product. Such
product has an average validity of three months if the turbine is kept indoors.
It is advisable that, if possible, the turbine be not stored outdoors. The adequate place
for storage of the turbine should be clean, dry and maintain an appropriate average
temperature.
While stored, the turbine should not be unlevelled. The anti-rust product will not be
enough to protect the turbine if it is stored outdoors. When keeping outdoors, the turbine
is exposed to temperature changes, humidity excess and, in some cases, corrosive sea
air. All these factors reduce effectiveness of product against rust, and for this reason
should be avoided.
In case the turbine is kept without operation for a long period, it is advised to
prepare its storage. The items listed below, if followed, should protect the turbine from
rust and corrosion.
1. Remove the lids of bearings and protect with an anti-rust product the bearing necks.
2. Put back the lids of bearings. Fasten the screws manually and mark the lids to
indicate that the screws are not loose.
3. Remove the upper part of turbine casing and protect the rotor assembly and casing
internal parts with an anti-rust product.
DME-700 08
Page 1 / 4
4. Put back the upper part of casing. Place a note to remember that joint faces of casing
horizontal flange should be cleaned and receive a coat of LOCTITE - LQ 1014, or
similar before the final closing, previous to the start-up (see chapter on
Maintenance).
5. Also cover the machined external parts with an anti-rust product.
6. In case the turbine is equipped with a WOODWARD governor, fill it with the turbine
oil. In case of NG governor, apply anti-rust product in the internal parts.
7. Cover the articulations, the pins and the machined external parts of the governor with
an anti-rust product.
8. Periodically inspect the turbine and, if necessary, apply again the anti-rust product.
Before to start-up the turbine, you should:
1. Remove completely the anti-rust protection using an appropriate solvent and clean
rags.
2. Inspect if turbine was damaged during the storage and handling periods.
3. Carefully clean the parts with small corrosion using a thin sandpaper. Substitute any
part which shows much corrosion.
4. Remake the horizontal flange joint of casing (as per the previous item 4).
ATTENTION
Machined internal parts should be clean, without grease and dry as far as possible before
the application of the anti-rust product.
The external parts, machined, protected with the anti-rust product, should still be covered
with oily paper.
ORDER FOR SPARE PARTS

When ordering a spare part or consulting about any part, always supply the following
information:
1. Order number of turbine
2. Number of drawing, item name & number of the part at drawing (consult enclosed
drawings).
3. Desired quantity.
4. Customer’s name
5. Complete address and instructions for transportation.
DME-700 08
Page 2 / 4
STORAGE OF SPARE PARTS
1. Inspect the parts and cover surfaces with an anti-rust product.
2. Label or mark the parts to be readily localized and identified.
3. Place the parts in a clean and dry local.
4. Dispose the parts on shelves or boxes to avoid deterioration.
5. Frequently inspect the parts. In case they show signs of rust or corrosion, apply more
anti-rust product.
SPECIFICATION OF THE RECOMMENDED ANTI-RUST PRODUCT
SPECIFICATION OF RECOMMENDED ANTI-RUST
PRODUCT: ANTI-CORROSION - ARTA 20
MANUFACTURER : IORGA PRODUTOS QUíMICOS LTDA.

(BRASIL)
COMPOSITION : Resins and anti-corrosive basis
APPLICATION : Arta 20 is recommended to protect parts that need an optimal
anti-rust protection.
The application mode can be pure, through brush or
immersion, or dissolving with any volatile petroleum-derived
solvent, (E.g. TOLUOL, XILOL, MINERAL TURPENTINE,
GASOLINE, etc.) through painting revolver.
Its anti-rust protection is sufficient to protect parts for
approximately one year, when stored indoors.
To remove ARTA 20, use any solvent.
DME-700 08
Page 3 / 4
CHARACTERISTICS:
Density 20/40oC : 0.865 ± 0.010 g/ml
Viscosity 37.8oC : 1,200 SSU
Flare point : 54oC
Inflammation point : 60oC
Protection “Salt Spray” : 1,440 hours
Toxidity index : negative (non-toxicant)
Corrosion copper blade : negative
Storage : ARTA 20 is chemically and physically stable, being able
to be stored for long periods of time.
Precautions : Keep the barrel closed, avoid heat and flame exposition.
DME-700 08
Page 4 / 4
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.11 Cleanliness of the Lube and Control Oil System
CLEANLINESS OF THE LUBE AND CONTROL OIL SYSTEM
(Low pressure system)
General
The cleanliness of the oil system is extremely important if the turboset are to operate
reliably and without interruption over long periods. Any contamination results in
premature wear in components and to sudden operational disturbances and failures.
The cleanliness must therefore be checked at specific intervals.
There are two major sources of contamination:
• that occurring during installation = Installation contamination
• that occurring during operation = Operational contamination
Installation contamination
Various types of contamination occur during the different manufacturing procedures of
components and systems: shavings, mould sand, cloth fibres, welding beads, rust,
scale, etc. Before the systems are commissioned, these mainly large contaminants
must be removed by washing or flushing. This is never completely successful despite
the strict regulations being adhered to.
During operation, particles are loosened due to vibrations, temperature change or fast
flowing liquids.
Installation contamination also includes the basic contamination contained in any liquids
supplied. In order to keep this contamination within limits supplies should only be
accepted which meet the required degree of cleanliness.
Operation contamination
During operation, fine contamination from the environment will be drawn into the
operating systems by the suction air via seals and moving parts. In addition, there is the
unavoidable abrasion of components and the basic contamination contained in refill
liquids.
Requirements
It is not economically viable to remove all contaminants from the systems using
extremely fine filters. However, before the oil system is used the cleanliness of the
working liquid must satisfy the following classifications:
• ISO 4406 or CETOP RP 70 20/17
• or
• NAS 1638, Class 11
The content of solid foreign bodies to DIN 51592 must not exceed 0.5% by weight.
DME-700 09
Page 1 / 3
Sampling
During operation it must be ensured that the specified degree of cleanliness and the
specified content of solid foreign bodies are not exceeded. For this purpose, samples
must be taken at regular intervals (yearly) and analyzed. The samples are always to be
taken at the same point in the liquid circuit.
For sampling purposes, we recommend special sampling flasks with ground glass
stoppers and a capacity of at least 200ml.
Before a sample is taken, 2 to 3 l of liquid must be drained from the extraction point; this
liquid can subsequently be returned to the tank. The sample is then to be taken without
the draining of the liquid being interrupted.
It must be ensured that the sample is not additionally contaminated. For this reason, the
flask must be covered as far as possible during sampling extraction and must be sealed
dust-tight immediately afterwards. Each sampling flask is to be labelled with the
following information:
• Sample number
• Sampling source
• Extraction method Date and time of extraction
• Type of liquid
• Remarks if necessary
• The operation is to be recorded in a Sample record.
Analysis
The procedure for determining the degree of cleanliness consists primarily in the
filtration and preparation of the typical liquid sample taken. Particles larger than the
pores on the filter paper used are retained on the filter surface and can be analyzed
using a micro-scope or a particle measuring unit.
In addition, the content of solid foreign bodies is to be determined in accordance with
DIN 51592. (Note: The solvent benzine, used in this standard, has been replaced by N-
heptane).
We recommend that the samples be analyzed by the laboratory services of a specialist
institute or a competent filter manufacturer. Within the Siemens Corporation, the
laboratory services of the Krafwerk Union (KWU), WiesenstraBe, D-4330 Mülheim/Ruhr
are available for this purpose.
The sampling results are to be recorded in the Sample record. This is important since
the recorded results permit an assessment of the plants operating reliability.
Action must be taken if the specified degree of cleanliness is exceeded over a certain
limit during continuous operation. The working liquid must the be cleaned, for example
by fine filters or separators in the bypass.
The permitted range in continuous operation for which action must be taken extends as
a maximum to the next highest group, in this case:
DME-700 09
Page 2 / 3
• ISO CETOP Code 21/18
• or
• NAS Class 12
However, appropriate action should be initiated as early as possible following detection
of an increase of contamination in order to protect the systems.
Number of particles per 100 milliliter

CÓDE more than 5µm more than 15µm
more than up to more than up to
21/18 1M 2M 130k 250K

21/17 1M 2M 64K 130K
21/16 1M 2M 32K 64K
21/15 1M 2M 16K 32K
20/17 500K 1M 64K 130K

20/16 500K 1M 32K 64K
20/15 500K 1M 16K 32K
20/14 500K 1M 8K 16K
19/16 250K 500K 32K 64K

19/15 250K 500K 16K 32K
19/14 250K 500K 8K 16K
19/13 250K 500K 4K 8K
Table 1: Cleanless code acc. to ISO 4406 (Abstract)
Particles size in µm, number of particles per 100 milliliter

CLASS 5 to 15 15 to 25 25 to 50 50 to 100 > 100
00 125 22 4 1 0
0 250 44 8 2 0
1 500 89 16 3 1
2 1000 178 32 6 1
3 2000 356 63 11 2
4 4000 712 126 22 4
5 8000 1425 253 45 8
6 16000 2850 508 90 16
7 32000 5700 1012 180 32
8 64000 11400 2025 360 64
9 128000 22800 4050 720 128
10 256000 45600 8100 1140 256
11 512000 91200 6200 2880 512
12 1024000 182000 32400 5760 1024
Table 2: Cleanless class acc. to NAS 1638
ISO = International Organization for Standardization

NAS = National Aerospace Standard
DME-700 09
Page 3 / 3
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.12 Safety Instruction
SAFETY INSTRUCTION
(Precautionary measures when handling liquid petroleum products and greases)
General Instructions
Experience in industrial medicine has shown that there sould be no health risk when
petroleum products are handled carefully and as prescribe.
We strongly recommend, however, that workers observe the following warnings,
instructions, and precautions to protect their health.
! WARNING
• Danger of fire!
Gasoline, diesel fuel, light heating oil, and thinners or solvents are inflammable and must
not be used for cleaning.
Petroleum products can pollute water. Hence, never pour any petroleum products on the
ground, in open waters, in drains, or in the sewer.
Violation of this are punishable by law!
• Store all used petroleum products carefully. Observe the valid regulations on the disposal of
used oil.
! CAUTION
• Some petroleum products contain substances which are poisonous or have been shown to
have carcinogenic properties in long-term animal experiments.
• Extended or repeated contact with liquid petroleum products or greases can also lead to
drying-out, irritation, or inflammation of the skin.
• Thus, avoid extended, excessive, or repeated skin contact with petroleum products and
breathing in of their vapors and fumes.
• Protect the skin with the appropriate protective clothing (e.g., working clothes, protective
goggles, or – when their use does not impair safety – protective gloves) or with suitable
protective agents.
DME-700 10
Page 1 / 2
NOTE:
• Wash skin thoroughly:

o Remove grime by washing thoroughly with soap and water
o For stubborn grime, use special hand cleaner.
• After washing, protect skin with appropriate cream.

• Change out of oil-soiled clothing and shoes.
• Never place oily rags in the pockets of clothing.
Cleaning of the lubricating oil system before the “start up”

As this phase is very important, it is recommended that is accompanied and
supervised by a technician NG.
After the welding of the piping and their components, should be dismounted and treated
chemically.
Piping supplied by NG welded in our factory are sent to field treated already chemically
treated.
Flushing of the lubrication system.
After every piping and their components internally clean and mounted. the "flushing" of
the lubrication system is executed
Before beginning the "flushing" the following precautions they should be taken:
- To isolate bearings of the turbine, gearbox and driven equipment
- To isolate the equipments of speed control turbine as : Hydraulic Actuator,
ConversorI/P
DME-700 10
Page 2 / 2
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.13 Steam Purity
STEAM PURITY
(minimum requirements)
Introduction
Steam quality is dependent on water quality, boiler design and operating procedures.
The build-up of deposits in turbines due to impurities in the steam can cause both
thermodynamic and mechanical problems which can develop into blade failure if
chlorides are present. This means that it is essential to eliminate chlorine and its
compounds, e.g., MgCl2, NaCl, from the steam. It has been shown beyond doubt that
even a quantity of 0.0025% Cl is dangerous for all the high-temperature steels used in
blade manufacture. The corrosion attack of the aggressive deposits primarily has a
negative impact on the fatigue strength of the blade materials in the dry/wet steam
transition zone.
See also the following operating instructions concerning turbine fouling and its possible
effects:
• NG11 Fouling of the Turbine
• NG12 Salt and Silica Deposits
Target Values
It is recommended that the following guidelines be followed as a basis for the
recommendations and target values associated with steam purity:
1. The VdTÜV-Richtlinien für Speisewasser, Kesselwasser und Dampf von
Dampferzeuger bis 68 bar zulässigem Betriebsüberdruck (April 1983 edition) and
2. The VGB-Richtinie für Kesselspeisewasser, Kesselwasser und Dampf von
Dampferzeuger über 68 bar zulässigem Betriebsüberdruck (1988 edition).
3. The guidelines of the NEMA (National Electrical Manufacturers Association)
“Steam Turbines for Mechanical Drive Service”, Standard Publication N° SM 23.
Although it is basically highly desirable for the target values to be complied with, it is not
always economically feasible to do so. This is especially true on initial start-up of new
plants and also during start-up and shutdown, as, among other things, major pressure
and/or load fluctuations, steam outputs exceeding the maximum level and operation at
pressures considerably below the allowable operating pressure have negative effects
on steam purity.
When assessing the cost of water treatment, however, the cost of possible turbine
outages and repairs resulting from steam-impurity demage should always be offset
against it.
In order to avoid any misunderstandings we should emphasize that the target values for
steam purity given in the following tables are only a starting point. Adherence to these
values does not rule out turbine deposits with absolute certainty.
DME-700 11
Page 1 / 2
If there is any possibility of improving the steam purity above the given target values we
strongly advise that is be taken. It is also advisable to provide a recording instrument to
continuously monitor of the water/steam cycle by measuring electrical conductivity of
the main steam and turbine condensate after a strongly acid cation exchanger.
In the evet of salt contamination, internal washing of the turbine with saturated steam is
to be performed immediately to remove any chlorides deposited on blades.
Target value or value in normal operation Target value 1) Normal operation

General requirements - clear and colorless
Total iron (Fe) mg/l < 0,020 0,005
Total copper (Cu) mg/l < 0,003 0,001
Silica (SiO2) mg/l < 0,020 0,005
Sodium (Na) mg/l < 0,010 0,002
Conductivity at 25°C µS/cm < 0,2 0,1

downstream of highly acidic cation exchanger
continuous measurement at sampling point
1)
To avoid decreases in efficiency, we recommend that the normal operating values be used instead of the target values.
Table 1
Target values for steam quality in continuously operating turbines.
DME-700 11
Page 2 / 2
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.14 Cleaning of Steam Lines and Checking of Cleanliness
CLEANING OF STEAM LINES AND CHECKING OF CLEANLINESS
Introduction
During installation and welding foreign matter inevitably finds its way into the piping
system and generator, in spite of all care taken.
Oxide layers form due to heat treating operations like annealing and pre-heating.
Corrosion products may also be present.
The turbine is protected against the ingress of larger foreign bodies and resulting major
damage by steam strainers upstream of the turbine stop valves.
Within the turbine solid particles which are smaller than the mesh openings cause
damage to the blades. This results in roughening of blades, trailing-edge damage,
plugged blade channels, material thinning, solid-particle erosion, etc. Seal strip damage
is also observed on occasion.
Plugging of these strainers must be avoided to prevent throttling losses. It is not
admissible to wrap fine-mesh fabric around these strainers during normal operation.
This is to rule out the associated risk of partial plugging of the fine-mesh material, its
tearing and subsequent ingress into the turbine.
To rule out plugging to the greatest possible extent, before start-up of the plant the
steam systems upstream of the turbine must be cleaned thoroughly. The inside surface
of the pipes is to be freed from loose rust, scale, coatings, dirt and foreign matter to
allow the connected components to be started up safely.
The text which follows covers the cleaning methods, the necessary boundary conditions
and the evaluation criteria from the point of view of the turbine manufacturer.
The steam generator and turbine manufacturers, piping systems suppliers, and the
operator must reach a joint decision on the type of cleaning method, the criteria for
evaluation of cleanliness and the required degree of cleanliness.
There are two proven methods:
• chemical cleaning and
• steam blowing
which can be used separately or in combination.
Chemical cleaning of piping systems

Products of oxidation and corrosion as well as welding residues can be dissolved by
chemically treating the inside surface of the piping and then flushing these out. This is
performed by specialized contractors and boiler or piping system suppliers.
It must be ensured that all initial steam and induction steam piping or sections of the
same are chemically cleaned. Piping or sections of this which cannot be blown are to be
flushed extra thoroughly.
Chemical residues from this type of cleaning are unavoidable and cannot be removed
adequately even with intensive flushing. Hence, following acid cleaning, flushing, and
DME-700 12
Page 1 / 8
passivation using high velocity steam or air, additional cleaning is necessary for
systems for which this is permissible.
Blowing of piping systems

Blowing of piping systems is normally performed with steam. In special cases,
compressed air is used for cleaning with a reservoir charged and relieved to
atmosphere abruptly through flap valves.
The high velocity of the cleaning medium is utilized in both cases. Flow velocities must
be achieved which are greater than those during full-load operation.
The piping is to be blown in such a way that contamination and residues are not able to
be deposited in the dead ends of the piping system.
Instrumentation and control equipment which could be damaged by blowing are to be
removed before hand. Internals which could hinder the removal of solid matter, such as
strainers, filters, orifices, steam traps and moisture separators, valves, check valves,
etc. are also to be removed before blowing. Where appropriate, equipment removed is
to be replaced by blanks, Appropriate inserts are to be installed to protect sensitive
equipment which cannot be removed.
Steam discharge
For steam blowing there are a number of possibilities for steam discharge. There are
three main types.
• Discharge to atmosphere
This method has a high noise impact. Silencers can be used to lower the noise levels
but this method should only be used where the resulting noise level will be low.
• Discharge of steam to a body of water
Noise impact can be considerably reduced by discharging the steam under water. It
must be ensured here that the allowable thermal impact on the natural or artificial
bodies of water is not exceeded and that pollution of these bodies with possibly
hazardous substances does not exceed admissible limits.
• Discharge of steam to condenser
This method is employed where other discharge modes are not possible or where other
reasons, e.g. operation of the boiler system, only allow this alternative.
This method has both advantages and disadvantages.
Advantages:
• low noise impact,
• low expenditure on temporary steam blow piping,
• recovery of condensate.
Disadvantages:
• the danger of damage to the valve seats and,
DME-700 12
Page 2 / 8
• restriction of steam blowing to piping through which there is flow during bypass
operation,
• possible damage to the condenser tubes by foreign objects,
• accumulation of foreign objects in the hotwell and
• possible contamination of the water-steam cycle.
For steam blowing with discharge to condenser, the following components or system
must be in operation in addition to the water treatment plant with the appropriate
feedwater tanks:
• the circulating water supply,
• the vacuum pumps,
• the condensate pumps,
• the seal steam system,
• the oil system and (where provided),
• the turning gear and
• the low vacuum trip.
All three methods require additional temporary steam blow piping to be installed. The
blow exhaust pipe is integrated into the main steam network for discharge to the
condenser. Additional blow exhausts are installed for blowing with discharge to the
atmosphere and bodies of water.
The blow exhaust pipes are to be designed to accommodate the blowing conditions.
The diameter of the blow exhaust pipes must be at least as large as that of the piping to
be blown. blowout lines and additionally installed auxiliary piping shall be fastened such
that no disturbances due to temperature changes or pipe thrust occur.
Clean piping sections are to be used to fabricate the temporary steam blow piping
system. These should be temporary steam blow piping system. These should be of the
same size or one size larger than the piping to be blown. The use of fittings is to be
avoided as far as possible so as to minimize the resulting pressure drop. Piping should
be equipped with flanged joints as far as possible so as to allow rapid installation.
Design-dependent water pockets in the blowout lines are to be adequately drained to
avoid water hammer.
All lines through which main and auxiliary turbine steam passes must be cleaned by the
blowing procedure. Steam blowing is to be based on blowing plans.
Blowing should always be performed through a main line to which auxiliary lines have
already been connected. When blowing subsystems, the remaining auxiliary piping
must be closed off by blind flanges.
Systems should not normally be blown via the turbine valves or the turbine stop valve
bodies. These are to be blanked off appropriately. Piping may remain connected during
blowout. In exceptional cases and only when no other possibility exists can blowing be
performed through the turbine casing. For this purpose, however, special blanks are to
be ordered to fit the turbine stop and bypass valves or the check valves. The special
DME-700 12
Page 3 / 8
blanks serve to prevent contamination from entering the turbine and damage to the
seating surfaces.
CAUTION!
The solid particles are blown out of the blow exhaust pipe at high velocities.
Appropriate measures are to be taken to avoid damage to persons or property.
Blowing is only effective when the cleaning media achieve flow velocities which are
greater than those in force during full-load operation. It is expedient to perform steam
blowing with reduced main steam parameters due to the high mass flows with nominal
main-steam parameters. All the more reason to do this is that the state of the boiler
plant at the steam blowing stage frequently does not allow the nominal values to be
attained. However, the main steam pressure during blowout should reach levels of
>50% normal steam pressure but must not exceed max. operating pressure in the
separate piping sections.
The steam must be superheated by at least 176° - 212°F to avoid erosion damage but
must not exceed max. admissible operating temperature.
The required mass flow is determined with the mass flow/volume ratio, also known as
the CRF or K factor.
This can also be used to determine velocities in tubes and steam generators.
m& B 2 . VB
K= ≥ 1,2 to 1,7
m& V 2 . VV
mB mass flow during steam blowing

mv mass flow at full load
VB specific vol. during steam blowing
Vv specific volume at full load
The mass flow during steam blowing is determined using the following equation:
VV
m& B ≥ m& V x
VB
DME-700 12
Page 4 / 8
The actual value of mB is set by the K factor defined beforehand. The thermodynamic
values are taken from steam tables (Mollier diagram, etc.).
Steam blowing is divided into several phases, between which the steam generator
should be allowed to cool.
The first blow is to be performed at only 15 to 20% of specified blowing pressure for
reasons of safety. Only for the subsequent blows is pressure to be increased up to the
full values, during which the piping and supports are to be checked.
In each of the following phases several blows at maximum velocity are to be performed.
The effectiveness of steam blowing is not dependent on the duration of a phase, but
rather on the number of blows during which the piping material is heated up as high as
possible and cooled down again to room temperature or at least to below 100°C. In this
way, adherent oxidation, corrosion, and welding residues are removed.
Checking of cleanliness
Good results can only be expected from steam blowing when the steam conditions and
velocities approximate those given above. During a steam blow pressures,
temperatures, and mass flow must be measured or good approximations derived to
allow velocities in the individual systems to be checked.
The results of steam blowing are checked with a target assembly installed as shown in
Fig. 1. This assembly consists essentially of a holder 4 on which polished steel, copper
or aluminium strips are mounted. Polished aluminium strips 40mm wide, more than
1mm thick and with a Brinell hardness of HB25-35 are preferred. Both sides of the strips
should be usable. The target strip is to be reversed or replaced as appropriate for each
blow.
The foreign matter entrained in the blowing steam leaves pits on the targets. The
number, size and edge form of such impacts are important for evaluation of the results.
It must be noted that the steam velocities vary as a function of the piping cross-section.
It can be assumed that velocities are higher in the middle of the pipe than along the
sides. Thus, in evaluation greater importance should be attached to pits at the target
edges than to pits at the center of the target.
The targets installed in the first phase of steam blowing would show a great number of
large pits so that comparison with targets from the final phase of steam blowing would
not allow conclusive evaluation. For this reason targets for evaluation of results are not
to be installed until after the 4th or 5th blowing phase, each consisting of 3 to 5 blows.
DME-700 12
Page 5 / 8
1 Blowing steam flow
2 Cover
3 Target
4 Double I-beam
Fig. 1
Target assembly
Evaluation of the results of steam blowing

The following two methods can be used for evaluating results of steam blowing:
• Evaluation of the number and size of the pits
The number of surface pits and the proportion of their surface area (count and measure
these) in the high-velocity zone of the target strips installed after 4 to 5 blowout phases
are weighted with 100%. In the subsequent phases the decline in the number and size
of pits on the target strips is evaluated. Steam blowing has been successfully completed
when the number of pits and their area fall to 10 to 15%. There should no longer be any
significant raised edges to pits and the number of pits should no longer change much on
subsequent blows.
• Evaluation of absolute number of impacts
Here it is assumed that steam blowing has been successfully completed when the
number of pits without raised edges does not exceed 5 in the high-velocity zone and
there are no pits in the target edge zones. There should be no essential change (max.
20%) in this during subsequent blows and blowing phases. Otherwise blowing must be
continued until target cleanliness reaches the above criteria and is maintained there.
• Evaluation against reference standards
The cleanliness of the piping sections can also be evaluated using reference standards
(see Fig. 2). The degree of cleanliness of the reference standards increases with
increasing standard number from 1 to 10. We recommend standard 7 for evaluating the
cleanliness of the main steam lines (see page 5).
Evaluation is based on the number and size of pits as described above.
Steam blowing is to continue so long as the metal strips show greater numbers of pits
larger than 1.5mm in diameter. The surface of the metal strips should not be evaluated
until after a minimum blowing duration of 10 minutes.
The targets must be assessed by the operator and representatives from the steam
generator, piping system and turbine suppliers. The decision regarding termination of
steam blowing is made easier if acceptance crit6eria are defined jointly beforehand. The
result of the evaluation is to be documented for the individual sections of piping.
DME-700 12
Page 6 / 8
After the cleaning process has been concluded all parts removed are to be reinstalled.
All blind flanges and blanks and temporary piping sections installed are to be removed
and the additional connections blanked off.
Note!
Particular care must be taken to ensure that parts such as nuts, bolts, seals and valves
are reinstalled at the correct location in accordance with the data on the type of pipe or
in the parts list or on the isometric drawings (for flow direction).
DME-700 12
Page 7 / 8
Fig. 2
Reference standards for evaluation of cleanliness of piping sections
DME-700 12
Page 8 / 8
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.15 Enclosure Drawings
ENCLOSURE
GENERAL COMPONENTS OF TURBINE
TO PLACE ORDERS FOR REPLACEMENT PARTS,

PLEASE SPECIFY:
• DRAWING NUMBER
• ITEM OF PART (PIECE) IN DRAWING
• NAME OF CLIENT
• NUMBER OF PURCHASE TURBINE ORDER

RELATION OF ENCLOSURE DRAWING
FIGURE 1 - Cross Section – Overall Turbine Components

FIGURE 2 - Rotor
FIGURE 3 - Device of Safety
FIGURE 4 - Labyrinth Gland
FIGURE 8 - Assembly of the main valve
FIGURE 9 - Device of Safety
FIGURE 11 - Hydraulic Actuator 165/60
FIGURE 12 - Specification for Bearings Clearances
FIGURE 13 - Rotor Clearances
FIGURE 1
CROSS SECTION – OVERALL TURBINE COMPONENTS

FIGURE 2
ROTOR
ITEM DENOMINATION
1 DISC WITH BLADES - 1° STAGE

2 DISC WITH BLADES – 2° STAGE
3 DISC WITH BLADES – 3° STAGE
4 SHAFT
5 DEVICE OF SAFETY
6 RING
7 SPACE RING
8 SPACE RING
9 SPACE RING
10 KEY
11 KEY
12 KEY
13 SEAL RING
14 ROTOR LOCK NUT
FIGURA 3
DEVICE OF SAFETY
ITEM DENOMINATION
1 SLEEVE
2 NUT
3 SAFETY PIN
4 WEDGE (SUPPORT) RING
5 CONTACT SLEEVE
6 SPRING
7 SCREW
8 SCREW
FIGURE 4
LABYRINTH GLAND
ITEM DENOMINATION
1 BUSH
2 SPACER
3 PLATE
4 SCREW
FIGURE 8
ASSEMBLY OF THE MAIN VALVE
ITEM DENOMINATION
1 BODY
4 VALVE Nº1
9 VALVE Nº2
12 SPRING Nº1
13 SPRING Nº2
1
FIGURE 9
TRIP DEVICE
ITEM DENOMINATION
1 BODY
2 SLEEVE
3 PIN
4 NUT
5 STEM (TOP)
6 PLATE
7 BUTTON (SWITCH)
8 FLAT SPRING
9 SLEEVE (SPACER)
10 HOLED STEM
11 SPRING
12 RING
13 SLEEVE (SPACER)
14 TRIP LEVER (TRIGGER)
15 SPRING
16 STEM
17 PIN
18 NUT
19 SCREW
20 SCREW
21 SCREW
FIGURE 11
ACTUATOR
ITEM DENOMINATION
1 BODY
2 SUPPORT
3 PISTON
4 HEX. NUT
5 STEM
6 FLANGE
7 BRIDA
8 SPRING
9 SPRING
10 STUD BOLT
11 STUD BOLT
12 STUD BOLT
13 STUD BOLT
14 HEX. NUT
15 CAPSCREW
16 CAPSCREW
17 CAPSCREW
18 GASKETS
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.16 Turbine Dimensional Drawing
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.1.17 Recommended Spares for Turbine
1 2 3 4
FOR INFORMATION
A

D
CUSTOMER: JC CHANG

- : (mm)
E
CHECKED
- - - - ELABORATED
. -
TÍTULO
TITLE
RECOMMENDED SPARES FOR TURBINE
JC CHANG CUSTOMER
CUSTOMER
DWG.
.
ORDER N° CH10003 FUNC.DWG. SEQUEN. 1 / 6 DWG. CH10003-TSP-001 REV. 0
INDEX
1. OBJECTIVE...................................................................................................... 1
2. CONTROL VALVE / CSEV ............................................................................... 2
3. SEALING AND BEARING ................................................................................ 4
Form.PS-75 Rev.00
1
1. OBJECTIVE
To indicate the spare parts for the maintenance of the NG turbine model DME-
700S, S/N 414852 and 414853, year of manufacture 2010.
Defined as priority #1, parts whose recommendation is the immediate acquisition
(in red) for strategy reasons and / or partial maintenance accomplished annually and
priority #2 the necessary parts for complete turbine maintenance, accomplished each
five years (in blue).
Form.PS-75 Rev.00
2
2. CONTROL VALVE / CSEV
ITEM QTDE DESCRIPTION NG CODE PRIORITY
1 01 pc CSEV SPINDLE GUIDE BUSH 3869080640 1
CONTROL VALVE Nº1 SPINDLE

2 01 pc 4083078961/TT1 1
GUIDE BUSH
CONTROL VALVE Nº2 SPINDLE
3 01 pc 4083078973/TT1 1
GUIDE BUSH
4 01 pc SPRING 3865200250 2
5 01 pc SPRING 3865200250 2
6 01 cj CONTROL VALVE Nº1 L3083057402 2
Form.PS-75 Rev.00
3
7 01 cj CONTROL VALVE Nº2 L3083057414 2
8 01 pc CONTROL VALVE Nº1 SEAT 4083078882 2
12 01 cj CSEV L3080019335/9 2
13 02 pc BUSH 3921030150 2
14 03 pc ROD END SCREW RIGHT 3180984541 2
15 03 pc ROD END SCREW LEFT 3180984550 2
16 01 pc CSEV SPRING SUPPORT 3869101361 2
17 02 pc CSEV SEAT SPHERICAL 4083078948 2
Form.PS-75 Rev.00
4
3. SEALING AND BEARING
ITEM QTDE DESCRIPTION NG CODE PRIORITY
1 01 pc AXIAL BEARING 3865003004 1
2 01 pc FRONT BEARING L1083022869 1
3 01 pc REAR BEARING L2083036501 1
4 01 pc OIL BAFFLE 3869084335 1
5 02 pc OIL BAFFLE L2083036585/100 1
6 02 pc STEAM BAFFLE 3869104344 1
7 22,5m LABYRINTH BAND 1081701501 2
8 01 pc STEAM SEALING 2083009636 2
9 01 pc STEAM SEALING 3083009584 2
10 01 pc OIL BAFFLE 3869102295 1
11 0,3kg WIRE 1610081181 2
Form.PS-75 Rev.00
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.2 Gearbox
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.2.1 Gearbox Operations and Maintenance Manual
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
GEARBOX MODEL : HSG-360
JEBSEN & JESSEN TECHNOLOGY

CUSTOMER :
(M) SDN
MALAYSIA
PURCHASE ORDER NO. : 597172 dated 05.05.2010
OUR WORK ORDER NO. : 6158
QUANTITY : 1 No.
No. 1,2,3 Belagola Industrial Area

K.R.S. Road, Metagalli Post,
MYSORE - 57016, INDIA
PDF created with pdfFactory Pro trial version www.pdffactory.com

HIGH SPEED GEARS
,16758&7,21MANUAL
TABLE OF CONTENTS
Page
Section - I GENERAL SPECIFICATIONS 3
1. Engineering 3
2. Application 3
3. Housings 3
4. Gears 3
5. Pinions 3
6. Bearings 3
7. Extreme High Speed Gear Units 3
Section-II INSTALLATION 4
1. Handling 4
2. Mounting of couplings 4
3. Foundation, Alignment & Tooth contact check 4
4. Shaft Axial Positioning 5
5. Anticipation of shaft operating positions 6
6. Tooth Contact check 6
Section-III LUBRICATION 7
1. General Information 7
2. Type and Grade 7
3. Main Oil Pump 8
4. Lubrication System 8
Section-IV NEW UNIT CHECK-OUT 9

1. Factory check-out 9
2. Customer Check Before Starting 9
3. Customer Check After Start-up 9
Section-V COMMON GEAR PROBLEMS, THEIR CAUSES AND CURES 10

1. Abnormally High Temperature 10
2. Unusual Noise 10
3. Low Oil Pressure 10
4. Excessive Vibrations 11
1
Section-VI MAINTENANCE 13
1. Preventive Maintenance 13
2. Corrosion Protection During Inoperative Periods 13
3. Recommended Spares 14
4. Trouble Shooting 15
Section-VII TECHNICAL DATA SHEET 16

1. Reference Data 16
2. Name Plate Data 16
3. Bearing Data 16
ENCLOSURES
1. Instruction Manuals for

a) Main Oil Pump
2. Drawings
a) General Arrangement
b) Sectional Arrangement
c) RTD Diagram
d) Thermal & Mechanical Movement Data
2
SECTION - I
GENERAL SPECIFICATIONS
1) ENGINEERING grinding machines. The gear teeth are ground
ensuring concentricity between pitch circle
Each design is evaluated for maximum and bearing journals. Tooth profile, spacing,
practical torque capacity based on the latest runout and lead are held to precise
applicable standards. In this analysis, tooth tolerances to assure quite, trouble-free
geometry is evaluated to give the user an operation. The gear and pinion teeth are
optimum balance between tooth beam carburised hardened & ground to 58 RC.
strength and maximum durability rating Gear assemblies are dynamically balanced
based on the physical dimension of the gear to precision machinery standards. All gear
set. blanks are made from high alloy, high tensile
steel.
2) APPLICATION :
5) PINIONS
These high speed gear units are used for
both speed reducing and speed increasing Except for very low ratios, which result in
service. These high speed units must be large pinion diameters, pinions are made
used when the pinion speed is higher than integral with their shafts. Material is high alloy,
3600 RPM or when the pitch line velocity is high tensile steel. Pinion shaft extensions
higher than 25 m/sec. are ground to nominal dimensions or as per
customer’s requirements.
3) HOUSINGS
6) BEARINGS
Housings are of controlled specification high
tensile gray iron or fabricated steel, carefully The slow speed and high-speed bearings are
stress-relieved before machining for centrifugally cast, white metal with a split
dimensional stability during machining and steel shell. In case of double helical gearing
operating life. Housings are of two piece a tilting pad thrust bearing is mounted on slow
construction with parting line between speed shaft non-driving end for axial
bottom & top casings accurately machined. alignment and for taking nominal amount of
Interior surfaces are thoroughly shot-blasted, coupling thrust. In case of single helical gears
cleaned, and painted to insure absolute flat faced / taperland thrust bearings integral
freedom from foreign particles. Housings with radial bearings or separate tilting pad
are designed for heavy-duty service to thrust bearings are used on each shaft
provide maximum rigidity, assuring precision depending upon the thrust loads.
gear alignment. All housings are precision
bored, and alignment is certified before 7) EXTREME HIGH SPEED GEAR UNITS :
assembly.
TRIVENI manufactures all type of high-speed
Housing design incorporates the necessary
gear units for special applications. These
oil piping for bearing and mesh lubrication.
units can be custom designed to the
specialized requirements of the customer.
4) GEARS
All custom built high-speed applications must
be submitted to TRIVENI for
These gear units utilize gearing of the single/
recommendations.
double helical design, ground on precision
3
SECTION-II
INSTALLATION
1) HANDLING Next, heat the coupling uniformly until there

is sufficient clearance to place it on the shaft.
The gear unit should always be moved by It is important that the coupling be heated
rolling on bars or skates, or lifting it with slings uniformly and that care is taken so that
through lifting lugs or eyebolts found on all localized spots are not overheated (max.
the gear units. Never lift or sharply pound 250°C). An ideal way to do this is by using a
on the shaft extension or lubrication piping heated oil bath. In placing the coupling on
as serious damage may result. the shaft, do not pound directly on coupling
with a steel hammer, but use lead or rawhide
Every TRIVENI gear is test run with a break mallets so as not to damage coupling or
in oil that contains rust preventive, which will shaft. A temporary spacer block is helpful in
protect the internal parts for atleast six preventing the coupling from sliding too far
months after it leaves Triveni. Do not store onto the shaft.
gear outdoors. If the inoperative period is
greater than six months, see section VI para, 3) FOUNDATION, ALIGNMENT & TOOTH
“corrosion protection during inoperative CONTACT CHECK :
periods. “
Securing proper shaft alignment is one of the
2) MOUNTING OF COUPLINGS: most important phases of setting up a
highspeed gear unit. Even though flexible
Before attempting to mount the coupling, couplings are used on the shaft extensions,
inspect coupling bore and shaft diameter any appreciable amount of misalignment can
with a micrometer to determine that there is cause a multitude of gear problems ranging
approximately .0005 mm per mm of from non uniform bearing and gear tooth wear
diameter interference. Also, inspect the key to vibration and coupling problems.
and key sits for proper fit, making certain that Therefore, it is essential that good alignment
the key sits at the bottom of the shaft keyway be maintained, and that thermal growth and
and there is clearance at the top of the key. bearing clearances be anticipated in shaft
If the keyway extends past the coupling, alignment. Allowable alignment error based
the key should be split on the protruding on hot alignment check in the radial and axial
end to fill only the keyway to maintain direction may be taken from the table below.
proper shaft balance.
Shaft Surface Outside Diameter Face, TIR

Velocity m/sec TIR (mm) (mm)
25 m/sec and up 0.05 0.0004 per mm of R

15 m/sec to 25 m/sec 0.10 0.0005 per mm of R
7.5 m/sec to 15 m/sec 0.15 0.0006 per mm of R
2.5 m/sec to 7.5 m/ sec 0.20 0.0008 per mm of R
2.5 m/sec and down 0.25 0.0010 per mm of R
TABLE-1: maximum allowable runout (TIR) in mm.
4
Where R is the distance between shaft “anticipation of shaft operating positions”)
centerline & Dial point. and final alignment established. Care should
be taken in joining the two coupling halves to
Obviously, to maintain alignment, the gear observe any coupling match marks, lubricate
unit should be securely mounted to a suitable the coupling and check for free axial
rigid foundation. Two of the more common movement of pinion and gear. Before
foundations are the concrete foundation and tightening the foundation bolts, be sure that
soleplate combination, and the common the base sets evenly on all shims so that
bedplate. there will be no distortion after tightening the
bolts. After tightening the bolts, check for
The concrete foundation and soleplate distortion by placing a dial indicator on
combination is semipermanent and allows the gear housing foot near the bolt to be
for the removal of the gear housing at a later checked. If the housing foot moves when
date without disturbing the permanent- that bolt is loosened, then distortion is
mounting pad. The elevation of the concrete present and the hosing needs more
foundation should allow for final grouting of shims around that bolt. Similarly, align the
the machinery once accurate alignment of third machine component to the gear and
shafts is complete. A minimum of 1.5 mm make tooth contact check (See Para “Tooth
of shims may be used between the gear and Contact Check”).
soleplate to allow for final alignment.
Before starting, check again for alignment
The common baseplate is rigid structural with all three units bolted down and the gear
steel foundation common to both the gear doweled at the high-speed end. At this time,
unit and either the prime mover or the driven a hot alignment check should be made by
equipment. In this case, final alignment is running the gear package until temperatures
necessary after the baseplate has been stabilize, shutting it down and taking indicator
grouted in. reading while the package is hot. After
compete hot alignment is obtained, the gear
Generally, alignment should start with unit should be redoweled to the foundation
securing the driving or drive machine or base while the unit is running and
(whichever is more permanently settled) and temperatures are stabilized. The base flange
alignment of the gear unit to it. Jacking screw of all gear units is drilled for dowel pins, but
holes are provided on the base flange for they must be reamed at assembly. After
bringing the gear unit to the same horizontal coupling alignment is established, place
plane as the connecting shaft. Once there, coupling guards in position. Failure to use
the gear unit should be supported on broad, coupling guards may result in serious
flat shims located adjacent to each side of injury to personnel.
the foundation bolt holes. Next, move the
unit on its shim until the gear shaft is in the 4. SHAFT AXIAL POSITIONING:
same vertical plane as the connecting shaft
with a correct spacing between coupling Normally, the gears are located axially in the
hubs. (See para, 4 “axial positioning”). At this gear housing by either plain or tapered land
point the running position of driven and driving white metal lined thrust bearings. These
shafts should be anticipated (See para, 5 thrust bearings are located on either side of
5
the slow speed gear in case of double helical 6. TOOTH CONTACT CHECK:
gearing and on each shaft in case of single
helical gearing. Sufficient clearance is After all aligning has been done and prior to
provided to allow for normal thermal start-up, the tooth contact pattern should be
expansion of both the high and slow speed checked. This may be done in two ways:
shafts. However, if axially rigid couplings or
excessive thermal expansion is anticipated, a) Clean the oil from several meshing teeth
additional clearance can be provided at the on both the gear and pinion, and apply a
factory. light coat of Prussian blue to the clean
pinion teeth. Apply a drag to the slow
Normally, the slow speed shaft should be speed shaft and mesh the blue teeth by
axially positioned as far towards its mating rotating the pinion back and forth several
shaft as possible before the coupling times through the blue area. Inspect the
clearance is obtained during alignment impressions of Prussian blue on both
procedures, However, if the prime mover is gear and pinion. The tooth contact on
an a electric motor that has a magnetic the loaded side of the tooth should be
centre the magnetic centre should be located evenly distributed across 80-85% of the
and the gear positioned so that there is equal face of both helixes. Vertically, the
clearance on either side of the magnetic contact should cover 70% of the area
center. Similarly, limited end float couplings from just above tooth to slightly below
are sometimes used to axially position the the tip.
driving shaft. Here the running position
should be determined and the clearance split b) Clean eight or ten pinion teeth and apply
on either side of that running position. a coat of layout blue. Operate the unit
for two hours under a light load, shut it
5. ANTICIPATION OF SHAFT OPERATING down and remove the inspection cover
POSITIONS: to observe the areas on the pinion teeth
where the blue has worn off.
As mentioned above, the final position of the
shaft, under operating load and temperature, If the contact is not satisfactory, the
will differ from its position under no load and problem is usually due to gear housing
ambient temperature. distortion caused by drawing the housing
down to base that is not square with the
This is due to thermal expansion of the gear housing. Be sure the gear housing sets
housing and the direction of the bearing evenly on all shims before tightening the
loading. The driven and driving machines foundation bolts.
also have thermal movement, which must
be either added or subtracted from the gear c) Large Gear unit may require correction
movement, depending upon the direction of to the face contact due to housing and
the movements. This expected anticipated support flexibility. When contact is not
shaft operating positions of gearbox are acceptable, when checked by the above
shown in the general arrangement/sectional methods, correct contact by shimming
arrangement drawings or included in this at the proper foundation bolt between the
manual. housing and support.
6
SECTION-III
LUBRICATION
1) GENERAL INFORMATION bearing, and minimizes wear by

separating the journal and bearing.
In most gear drives, lubrication serves three
basic functions: 2) TYPE AND GRADE
a) To separate tooth surface and prevent The lubricating oils used in gear units should
metal-to-metal contact, thereby reducing be high grade, high quality, well-refined
friction and wear. petroleum oils. It is essential that the oils be
clean and non-corrosive to gears and
The contact action between gear teeth bearings. They must be neutral in reaction
is a combination of rolling and sliding. If and possess good deforming properties.
an oil film does not prevent contact of the When operating temperature is high, the oil
mating surfaces, high spots of metal must have good resistance to oxidation.
touch each other due to surface
roughness of each tooth. This metal-to- Straight mineral type lubricants should be
metal contact develops high localized used under normal operating conditions. The
temperatures, and results in welding. nameplate found on gear unit specifies the
Surfaces pull apart, adhere to one viscosity of the oil to be used in that particular
surface, and eventually break loose. After gear unit. Generally, single reduction high
many cycles of the welding and fracture speed gear units will use AGMA No. 1
process, the surface is deteriorated and lubricant (46 CST at 40°C).
wear is accelerated.
In some applications a lighter oil will be
b) To remove heat losses at the gear mesh. specified, usually light turbine oil with a
midrange viscosity of 32 CST at 40°C. In
At high pitchline velocities, approximately addition to the unit nameplate, the general
80% of the oil applied to the gear mesh arrangement drawing will also show the
is used to remove heat from the teeth recommended lubricant.
while the remainder form an oil film NOTE=Do not change grades of oil
separating the tooth surfaces. In high- without approval by TRIVENI.
speed gear units, a pinion tooth may go
through mesh several hundred times a When a new gear unit is started in operation,
second and generate heat with each the oil should be drained at the end of two
meshing. The heat generated must be weeks and the casing and filter thoroughly
removed before it can sink into teeth or flushed. The original oil may be used for
cause thermal distortion of the gear. refilling only if it has been filtered. Under
ordinary operating conditions the oil should
c) To remove heat produced in the bearings.
be changed every 2500 hours of operation
or every six months, whichever occurs first.
The oil removes the heat generated by
If oil needs to be added between oil changes,
the shearing of the oil film in the journal
7
care should be taken to avoid mixing different gears engaged in a superior quality nylon
brands of oil. sleeve having good resistance to high
temperatures. It requires no lubrication or any
In some cases, the additives in the mixture sort of maintenance.
are not compatible and form sludge.
Refer installation, operating and maintenance
It is very important to the successful and instructions for further details of the pump.
satisfactory operation of a gear unit that care
be given to proper lubrication, and that the 4. LUBRICATION SYSTEM:
lubricant be kept clean. Every precaution
should be taken to prevent water and foreign A skid mounted lubrication system is
particles from entering the gear casing. In sometimes provided along with the gear unit.
unusually dusty atmospheres and where The details will be available in the Vendor’s
there is rapid rise and fall in temperatures manual enclosed. Care should be taken
causing excessive condensation inside the while inter connecting the lubrication system
casing, it will be necessary to change the oil with the gearbox. A minimum slope of 1 in
more frequently than specified above. The 10 shall be provided in the drain line and the
only sure way of determining the condition top of oil console shall be atleast 300 mm
of the oil is to have a sample of it checked at below the base of the gearbox to allow
a laboratory. Most oil suppliers furnish this gravity drain of oil from the gearbox.
service.
Care also should be taken to see that the
3. MAIN OIL PUMP lubrication system should be kept as close
to the gearbox as possible to avoid pressure
This units are sometimes supplied with a line losses.
shaft driven flange mounted gear / screw
type positive displacement main oil pump It is advisable to provide a temperature and
which is connected to the nondriven end of a pressure gauge on the inlet line as nearest
the output shaft through a flexible coupling. to the gearbox as possible when such long
The coupling consists of two high quality steel pressure lines are necessary.
8
SECTION-IV
NEW UNIT CHECK OUT
1) FACTORY CHECK OUT: g) Check for correct water flow and
temperature through the oil cooler.
Every high-speed gear unit is carefully
inspected and tested before it leaves the h) Check for foundation bolt tightness.
factory. Standard testing includes, running
the gear at operating speed with no load. i) Check tooth contact
During testing a check is made on housing
j) Coupling guards and inspection covers
vibration, bearing temperatures, seal and
should be secured BEFORE start-up.
lubrication piping leaks, lubrication system
operation and finally, tooth contact and
3) CUSTOMER CHECK AFTER START-UP:
backlash.
a) Run gear unit at light load and reduced
2) CUSTOMER CHECK BEFORE speed if possible while checking for
STARTING: proper lubrication. After the unit has been
running approximately 15 seconds, the
a) Check the lubrication system for the oil pressure should not be less than 1
correct type and quality of oil. (see kg/cm². If there is a noticeable drop in oil
LUBRICATION ) pressure after several hours of operation,
clean the oil filter. Occasionally, lint will
b) Check that pump is primed to minimize clog the filter after initial start-up.
the time necessary to build up a positive
oil pressure. (Pressure should build up b) Watch the bearings for a sudden high
in 10-15 seconds. If pressure does not temperature rise that could be an
develop, stop unit and determine the indication of a bearing problem. In
problem). When an electric drive oil general, the bearing temperature rise
pump or some other remote pump should be no more than 30°C above the
provides lubrication for the gear, it is a inlet oil temperature OR a maximum of
good idea to run that pump a few minutes 100°C as measured by Resistance
prior to start up to provide initial lubrication Temperature Detector.
during start-up.
c) Run gear under full load and speed and
c) Check rotation. Be sure that the gear check for unusual noise, vibration, oil
unit will rotate in the direction for which it temperature and bearing temperature.
is intended. The oil pump if mounted is Normal vibration limits are given in
unidirectional and must rotate in the technical data sheet section-IX. After
direction indicated by the arrow. temperature stabilization, the oil
temperature downstream from the oil
d) Check for free turning of the shafts. cooler should generally be not hotter than
80°C.
e) Check for correct coupling alignment
d) After unit has run several hours (6 or 8)
f) Check to see that all necessary piping under load, shut it down, check coupling
and accessory wiring are complete. alignment, tighten any bolts that may be
loose, and recheck tooth contact.
9
SECTION-V
COMMON GEAR PROBLEMS, THEIR CAUSES AND CURES
1. ABNORMALLY HIGH TEMPERATURE mesh is below normal (indicated by

below normal oil pressure), then the heat
a) High oil temperature can be caused by created by friction at the mesh and
an inadequate water flow through the bearings will cause abnormally high
heat exchanger, or by cooling water that temperatures. To correct this situation,
is too hot. Check the technical data check the lubrication system (see para
sheet or General Arrangement Drawing 3 below) for the problem. Maintaining
for water flow and temperature or proper oil flow will carry heat to the heat
operation manual of Lub oil system. exchanger where excess heat will be
removed from the system.
b) If the oil level in the gearbox is so high
that the gear runs in the oil, then the Coupling misalignment can cause high
resulting churning action will heat up the operating temperature by introducing
oil. Check the oil level in the sight gauge unnecessary friction to the gearbox. This
and remove oil if necessary. may be corrected by maintaining proper
coupling alignment.
c) Insufficient bearing clearance may cause
high temperature by restricting the oil flow 2) UNUSUAL NOISE
through the bearing. The possible
problem should be considered only with One common cause of unusual noise is
replacement bearings since the original worn parts. If a part wears enough to cause
bearings are carefully checked at the slack in the system, then the slack may be
factory. Check bearing clearance heard as a rattle or noise of some sort. A
(Section VI, para 3a) and compare with mechanic’s stethoscope may be used to
correct clearance in technical data pinpoint the worn part, which should be
sheet. replaced.
d) If the gear housing should get coated with A coupling that is out of alignment may also
a foreign material that will not permit cause noisy operation. The misaligned
natural heat removal by convection, then coupling causes misalignment in the gear
high temperature may result. To prevent train, which produces noise or vibrations.
this, the unit should be cleaned The coupling should be immediately
periodically. realigned before damaging wear occurs.
3) LOW OIL PRESSURE :
e) Obviously, a high ambient temperature
will cause abnormally high temperature. a) One possible cause of low oil pressure
To prevent this, allow for adequate is the use of a lubricant, which has a
ventilation around the gear. viscosity less than that for which the lube
system was designed. There are several
If the oil flow to the bearings and gear orifices in the lube system which are
10
sized for lubricants which a particular f) An incorrect relief value setting may also
viscosity. A lubricant with less than cause low oil pressure by venting the
normal viscosity will pass through the pump discharge line back to the sump
orifices without building up pressure. This before proper pressure is built up. The
situation can be prevented by using the relief valve may be reset by adjusting the
lubricant designated on the nameplate of spring adjusting screw under the cap.
the gear unit. Abnormally low viscosity
may also result from high lubricant 4) EXCESSIVE VIBRATIONS:
temperatures.
a) Loose foundation bolts may cause the
b) A clogged oil fitter will also cause low oil gear unit to vibrate. This may be
pressure. Cleaning the fitter will allow prevented by checking the tightness of
more oil flow through, thus bringing the the bolts periodically.
oil pressure back to normal.
b) Any unbalanced rotating part may also
c) Another cause of low oil pressure is cause excessive vibrations, in this case,
pump cavitation. Should the oil level in the amplitude and frequency of vibration
the sump get so low that the pump is directly proportional to the rotational
suction line sucks both air and oil, then speed of the unbalanced part. In
the oil pressure will drop off. This checking for unbalanced parts, make
problem may be cured by maintaining certain that full length half-keys are used
proper oil level in the sump (wet sump in all exposed keyways, and that the
units). correct type of coupling is used (check
with coupling manufacturer).
d) Yet another cause of low oil pressure is
an air leak in the suction line to the pump. c) A foundation that is not sufficiently rigid
This situation is similar to pump cavitation may also cause vibration problems. To
in that air gets in the oil and results in low correct this, reinforce the foundation.
oil pressure. To remedy this problem,
check and tighten all pipe fittings in the d) At certain speeds a rotating shaft will
suction. become dynamically unstable, and the
resulting vibrations and deflections that
e) Worn bearing may also cause low oil occur may cause damage to the gear
pressure. In effect, the bearings, are unit. The speeds at which the shaft
orifices which, if enlarged by wear, will becomes unstable are called the critical
pass more oil than the lube system was speeds. They are a function of the shaft
designed for, thus creating low oil geometry and the type and spacing of the
pressure. If low oil pressure caused by supporting bearings.
worn bearing is suspected, check
bearing clearances and replace any worn TRIVENI Engineers analyse high-speed
bearings. shafting to assure that the operating
speed of the gear unit is at least 20%
away from the lateral critical speed of the
11
shaft. From the above discussion, it is e) Torsional vibrations may be caused by
obvious that if vibrations due to lateral operating the gear unit with a driver to
critical speeds are to be avoided, then driven machine which is not torsionally
care must be taken to avoid running the compatible; that is, a system in which the
shafts over the speed for which they were inherent torsional vibrations do not
designed. Also TRIVENI should be dampen out, but build to damaging
consulted if the coupling type is changed, proportions.
as the coupling weight is inversely
proportional to the critical speed of the A mass elastic drawing may be made
shaft. available on request. The customer is
responsible for analysing the complete
system for torsional problems.
12
SECTION-VI
MAINTENANCE
1) PREVENTIVE MAINTENANCE: d) Semi-Annual Maintenance ;
Good preventive maintenance habits will 1) Check gear tooth wear.

prolong the life of the gear unit and possibly 2) Check coupling alignment.
help in detecting trouble spots before they
3) Check zinc pencils in heat exchanger.
cause serious damage and long down time.
e) Annual Maintenance ;
When working near rotating elements, be
certain that the prime mover is turned off and 1) Check heat exchanger for erosion,
locked. The following schedule is corrosion, or foreign material.
recommended for most operating
2) Check bearing clearance and end
conditions:
play.
a) Daily Maintenance ; 3) Check Tooth pattern.

1) Check the oil level. 4) Check condition of oil and change, if
2) Check the oil temperature and necessary.
pressure against previously
established norms. 2. CORROSION PROTECTION DURING
3) Check for unusual vibration and INOPERATIVE PERIODS
noise.
a) The oil with which the gear box is trial
4) Check for oil leaks.
run is generally sufficient for protecting
the bearings and gearing from rust for
b) Weekly Maintenance ;
one month. The gear internals and
1) Inspect filter for possible flow bearings are smeared with grease or
obstructions. applied with rust preventives before
dispatch from the work for prolonged
c) Monthly Maintenance ; storage upto six months.
1) Check operation of auxiliary b) When the user adds the recommended

equipment and/or alarms. lubricating oil and the reducer is operated
for a period of time, the oil should protect
CAUTION: Do not operate auxiliary
interior for inoperative periods up to 30
oil pump and shaft driven pump at the
days.
same time for an extended period of
time.
c) If additional down times is needed, the
2) Clean air breather. customer should run the gearbox every
3) Check tightness of foundation bolts. 30 days to redistribute the oil to the non-
submerged parts and gain another 30
4) Clean filter. days protection.
13
d) If extended down time is expected and it 2. RECOMMENDED SPARES:
is impractical to spin the reducer, rust
preventive type oil should be brushed or It is recommended that a set of following
sprayed on the gear teeth and bearings. spares may be kept in stock for meeting any
Any openings such as breathers or emergency.
labyrinth seals should be sealed with,
masking tape. A quality rust preventive i) One complete set of bearings.
oil should give 12 months protection
against corrosion. This oil should be ii) Main Oil Pump & MOP Coupling
compatible with the operating oil, and it
iii) One set of Oil Seals, Oil Baffles, ‘O’Rings
should be unnecessary to remove the
& Gaskets, RTDs
rust preventive oil when the reducer is
started again.
iv) One set bearing pads in case of tilting
pad thrust bearings.
e) For adverse conditions or long term
storage, seal all openings and fill unit
Whenever spare parts are required/ordered
completely full of oil. The oil can be the
the nameplate details shall be mentioned in
normal operating lubricant. When the
the enquiry / order. Please also mention the
equipment is to be used, the seals must
part no. in accordance with sectional
be removed and oil drained off completely
arrangement drawing.
from the unit.
Spare parts are to be stored in their original
f) A second method for long term storage packing until they are used. If stored
is to disassemble the unit and coat each unpacked care should be taken to inspect
part with special rust preventives. Before them periodically to ensure the working
unit can be placed in service, special condition. TRIVENI will not be responsible for
cleaning with solvents will be necessary the safe working of the gearbox should spare
to remove all preservatives from unit parts from sources other then TRIVENI are
parts. NOTE : Options (a) through (d) procured.
assume normal atmospheric conditions.
14
4) TROUBLE SHOOTING
Possible Source &

Problem Where What To Inspect
Corrective Action
Irregularities in tooth flank Intermittent or metallic
GEARS such as, damages cracks, noise is not healthy.
breakage, wear loss of Corrective action to be taken
profile & increase in backlash. based on observation.
NOISE
BEARINGS Bearing clearances and Inspect bearings. Replace
condition of bearings. if damaged or worn-out
ANY OTHER Slackness of the part Check and tighten if found
PARTS slack
Condition of Gear tooth profile, Isolate the vibration frequency
unbalance in gears. & analyse the cause of vibration
GEARS at that frequency. Take corrective
actions accordingly in consul-
VIBRATION -tation with the supplier.
BEARINGS Clearances in bearing Replace bearings if clearances
found excessive.
GEAR CASING Foundation bolts Check slackness and tighten if
necessary.
Bearings Check clearance, Wear Shaft
runout, Misalignment,
Lubricating Oil
GEAR Shaft Check oil seal lubrciation
CASING & bearing
HIGH
TEMPER- Gear Mesh Check temperature of oil at
inlet. Check backlash, oil viscosity.
ATURE
Oil Pump Check pump is running hot
LUBE OIL Oil Viscosity Check correctness of oil being
used.
Oil Cooler Check cooling effectiveness
of oil cooler
Tooth Mesh Decouple Gearbox from driver
& driven machine and check
tooth mesh
PITTING Misalignment, Check alignment of Gear unit
TOOTH with driver and driven machine
FLANKS and correct if required.
Oil Viscosity Check correctness & choose
one grade higher if necessary.
15
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.2.2 Technical Data
GEAR BOX SPECIFICATION
MODEL - HSG-360
JEBSEN & JESSEN TECHNOLOGY (M)

Customer
SDN, MALAYSIA
Customer Order Number 597172 dated 05.05.2010
Gear Box Serial Number 0360X 00 00 150 HSGH

TEIL Reference Number 6158
1. Power Rating 3700 KW
2. Input Speed- NOMINAL/ACTUAL 5000 / 5017 RPM
3. Output Speed 1500 RPM
4. Service Factor 1.50
5. Ratio 3.345
6. Oil Quantity 70 LPM
7. Oil Viscosity 68 CST AT 40˚C
8. Oil Pressure 1.5 - 2.0 kg/cm2
General Arrangement Drg. No. TM2M8224 R6
Sectional Arrangement Drg. No. TM1M9791
TECHNICAL DATA SHEET
BEARING DATA
A. Radial Clearance (mm)
DESCRIPTION TYPE Min Max
HSS Bearing Hydrodynamic Journal 0.24 0.29
LSS Bearing Hydrodynamic Journal 0.16 0.21
B. Thrust Clearance (mm)
DESCRIPTION TYPE Min Max
HSS Bearing Hydrodynamic Journal cum thrust NA NA
LSS Bearing Hydrodynamic Journal cum thrust 0.40 0.65
ALIGNMENT DATA
REFER GENERAL ARRANGEMENT DRAWING NO. TM2M8224 R6
TEMPERATURE LIMIT SET POINTS
DESCRIPTION ALARM SHUTDOWN

Bearing Temperature (RTD) in ˚C 100 110
VIBRATION LIMIT SET POINTS

** Estimates Only. Site Conditions will decide final values.
TURNING GEAR DRIVE DATA
Power Input RPM Output RPM Worm Reducer Ratio
N.A.
Triveni Gears

16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.2.3 Rust Preservation Procedure
RUST PREVENTION PROCEDURE FOR STORAGE FOR MORE THAN
12 MONTHS AT SITE
The gear & Pinion teeth is smeared with grease before dispatch which should
generally protect the surfaces for a period of six months. The outer extended
surfaces of shaft are applied with a quality rust preventive which can protect the
surface upto 3 months. The bearings contain test run oil, which should be good
enough for 3 months.
If the gearbox is kept inoperative for more than the above period, it is necessary
that all the above rust & corrosion preventives should be reapplied every 3
months after cleaning off the previous application.
However, if the gearbox is trial run before this period and then kept inoperative
for more periods, procedure mentioned in the Operation & Maintenance Manual
shall be used to keep the items free from rust.
Alternatively for long time storage fill the gearbox with lubricating oil as
recommended in the O&M Manual/ Name plate upto gearbox joint line by adding
protective concentrate called Cortec VpCI 329 as an additive ( add Cortec VpCI
329 @10% to the lubrication oil). Pinion shaft to be rotated so that gear wheel
completes one full rotation.
This solution offers a tenacious film which clings to metal surfaces. This also
releases vapour phase inhibitors into the air over oil. These vapours condense
and form a protective vapour barrier. This will protect the surface upto 24
months. However periodic inspection once in every six months is recommended.
If the storage period is more than 24 months old mixture to be drained and fresh
oil with additive to be filled and above procedure to be repeated.
For any additional details regarding protective coatings, the supplier may be
contacted. This product is marketed by
M/s. Advance Engineering Corporation,

No. 75, Ranoji Rao Road,
Mohammeden Block,
Basavanagudi, BANGALORE – 560 004.
Ph: 080-41325090 email:murtaza@advance-engg.com

16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.2.4 Lubrication Chart
7_LUB_CHART
LUBRICATION CHART
LIGHT
AGMA NO. 1 AGMA NO. 2 AGMA NO. 3 EP AGMA NO. 4 EP AGMA NO.5 EP AGMA NO.6 EP AGMA NO. 7 EP AGMA NO. 8 EP BEARING
MAKE TURBINE
ISO VG 46 ISO VG 68 ISO VG 100 ISO VG 150 ISO VG 220 ISO VG 320 ISO VG 460 ISO VG 680 GREASE
ISO VG 32
SERVOMESH SERVOMESH SERVOMESH SERVOMESH SERVOMESH SERVOMESH

INDIAN OIL SERVOPRIME 32 SERVOPRIME 46 SERVOPRIME 68 SERVOGEM-2
SP100 SP150 SP220 SP320 SP460 SP680
HINDUSTAN PARTHAN EP-

TURBINOL 32 SERVOPRIME 47 TURBINOL 68 PARTHAN EP-100 PARTHAN EP-150 PARTHAN EP-220 PARTHAN EP-460 PARTHAN EP-680 LITHON-2
PETROLEUM 320
BHARATH BHARATH OIL BHARATH OIL BHARATH BHARATH BHARATH BHARATH BHARATH BHARATH BHARATH MP
SERVOPRIME 48
PETROLEUM 32 68 AMOCAM 100 AMOCAM 150 AMOCAM 220 AMOCAM 320 AMOCAM 460 AMOCAM 680 GREASE 2
CASTROL PERFECTO T32 HYSPIN AWS46 ALPHA ZN-68 ALPHA SP-100 ALPHA SP-150 ALPHA SP-220 ALPHA SP-320 ALPHA SP-460 ALPHA SP-680 GREASE AP-2
Y:\Gear_BOX_Manual\7471\7_LUB_CHART

16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.2.5 Main Oil Pump Operation and Maintenance Manual
D A T A S H E E T Page : 1
DESCRIPTION : GEAR PUMP

D.S. NO. : 106787 REF. : A2006849
ITEM-NO. : 333777-1 PROJECT :
REV.-DATE : PRINT DATE : 26.05.10
QUOTATION NO. : 2006849 CUSTOMER-NO. : 107208
CUSTOMER : Triveni Engineering & Industries
Ltd.
. .
gearpump R65/200 FL-Z-W-SAE3-L

acc. drawing MZ 330000-1//1
complete assembled and tested
suction connection acc. SAE3 (without counterflange)
pressure connection acc. SAE3 (without counterflange)
pump data:
pumping medium mineral oil ISO VG 68
fluid temperature in deg. C +50 (+20...+80)
kin. viscosity in mm²/s 43 (max. 215)
flow discharge (approx.) in dm³/min 287
inlet pressure in bar 0 (-0,4...+0,4)
outlet pressure in bar 15
design pressure in bar 15
test pressure in bar 25
speed in rpm 1500
sense of rotation (seen on shaft end) ccw
requested driving power in kW 11,6 (15 bar, 100 mm²/s)
kind of shaft sealing rubber radial shaft sealing
pressure relief valve without
pump materials:
casing EN-GJL-250 (GG-25)
gearshafts 16MnCr5
elastomere NBR
further data
coating 1-component alkyd resin enamel
RAL 6011 (reseda-green)
thickness of the coat approx. 40 µm
internal pump preservation (pump) by test fluid
approx. net weight gearpump in kg 37
A.m. product is not conform to

the ATEX rules.
BA2.QNNN~112
Operating and Maintenance Instructions for Gear Pumps and Units AN-ZU: 02
Series R25, R35, R45, R65, R95 Beam.: WebI27.09.07
Gepr.: LuI10.10.07
English name/date
page 1 (11)
Contents Page Contents Page
Important General Infonnation 2 5.3 Reversing the sense of rotation 7
1 Using gear pumps 3 6 Commissioning 7
2 Flow medium 3 7 Operation/F unction 8
3 Operating dangers 3 7.1 Pressure relief valve 8
3.1 Safety-conscious working 3 7.2 Dry running 8
procedure 7.3 Environmental protection 9
3.2 Dangers in case of failure to 3 8 Dismantling 9
observe safety precautions 9 Maintenance/Service 9
3.3 USing pressure relief valve 4 9.1 Gear pump 9
R25,R35 9.2 Pump unit 9
4 Transport and storage 4 10 Conversion/Changes to 10
4.1 Storage 4 gear pump

4.2 Lifting pump/pump unit 5 11 Decommissioning 10
5 Setupllnstallation/Mounting 5 12 Malfunctions/Causes/ 10
5.1 Suction pipe design, NPSHR value 6 Troubleshooting Measures

5.2 Sense of rotation and . 6
direction of flow i,J. .
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PUMPENTECHNOLOGIE
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Series R25, R35, R45, R65, R95 Bearb.: Web/27.09.07
Gepr.: L0I10.10.07
English name/date
page 2 (11)
Important General Information
•
In additiori1 to the information provided in these operating instructions, the
following documents must also always be observed:
1. The order data sheet from RICKMEIER GmbH shipped with the product.
2. In case of a planned deviation from the operating conditions in the order data sheet. please
observe the operating instructions and limits for use in the applicable RICKMEIER GmbH
pump catalog.
3. Other instructions (for pump units, e.g. the operating instructions 'of the drive motor).
4. When using in a potentially explosive environment. the ATEX operating instructions
BA2-0NNN-113 from RICKMEIER GmbH must also be observed. The information provided
there on the use of the pump have priority over the corresponding information of these
operating and maintenance instructions.
This documentation must alWays be .available at the operating location of the machine so that
dangers or injuries and damage can be prevented to the greatest extent possible. For storage,
transport, commissioning, operation, maintenance/service or decommissioning, the
respectively applicable national, local and system-specific regulations must be observed.
Special designs and design variants may differ in their technical details I In case of unclear
points, it is urgently recommended that RICKMEIER be consulted with specification of the
rating plate data from the pump/pump unit.
Basic Safety Rules
Installation, commissioning, operation, maintenance and decommissioning may only be carried
out by persons, who
1. have carefully read and understood the operatinglinstallation instructions
2. have received special training for the planned work and are authorized by your company to
perform such work
3. comply with the EC Directive 89/655/EEC Minimum Safety and Health Requirements for
the Use of Work Equipment by Workers at Work.
Information attached directly to the pump, such as the rotating direction arrow or markings
of the fluid connections must always be observed. These must always be kept in completely
legible condition.
Following operating instructions apply additionally with pump units:
1. without motor : operating instruction clutch
2 with motor : operating instruction motor.
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BA2..oNNN-112
Gepr.: L0I10.10.07
English name/date
page 3 (11)
1 Using gear pumps
RICKMEIER gear pumps may only be used to feed lubricating media.
The data relevant for operation will be specified in the RICKMEIER order data sheet, if
necessary with separate data sheets, drawings or similar documents. Should the stipulated
conditions be deviated from during later operation, then this must be coordinated with
RICKMEIER, as otherwise the any and all warranty claims shall be voided. Use in a potentially
explosive environment is only permissible when the pump/pump unit is marked accordingly!
2 Flow medium
As a condition for a longer service life and maximum operating safety, the flow medium is to
have lubricating properties (kinematic viscosity of the flow medium under all occurring
operating conditions always> 5 mm 2/s). The soiling of the flow medium should not be greater
than the Purity Class 21/19/17 according to ISO 4406:1999. The flow medium must always be
free of hard solid particles. The percentage of undissolved gases (bubbles) in the feed stream
should not exceed 10 % by volume. Otherwise increased noise emissions can result.
3 Operating dangers
3.1 Safety-conscious working procedure
The safety precautions listed in these operating instructions, the existing national regulations
for accident prevention and internal working, operating and safety regulations of the operator
must be observed.
3.2 Dangers in case of failure to observe safety precautions
Failure to observe the safety precautions can result in hazards to persons, the environment
and machines. Failure to observe the safety precautions can lead to the loss of any and all
warranty claims and claims to damages.
In particular, failure to observe the precautions can, for example, result in the following
hazards:
1. Endangering of persons, e.g. due to a danger of bums and poisoning
2. Leaks (e.g. of the shaft seal) of dangerous flow mediums (e.g. explosive, toxic, hot) must
be discharged so that no hazard to persons and the environment results. Legal regulations
must always be complied with.
3. If hot or cold machine parts lead to dangers, then these parts must be secured by the
customer against touching.
4. Failure of important functions of the machine/system
5. Shortening of the expected service life of the machine/system
6. Failure of specified maintenance and service methods
Never remove safety equipment or deactivate it by making modifications to the machinel
..,........GmbH
PUMPENTECHNOLOGIE
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BA2.oNNN·112
Series R25, R35, R45, R65, R95 Beam.: Web/27.09.07
Gepr.: LUl10.10.07
English name/date
page 4 (11)
3.3 Using pressure relief valve R25, R35
The pressure relief valve is used to protect the pump against impermissible loads. It is set to
the required opening presst:ire at the factory and should only react occasionally and briefly
during operation.
R25 IR35
1Tightening torque [Nm] 70 1100
Table 1: Tightening torques
Fig. 1: Pressure relief valve ~5, R35
In the case of later pressure adjustment. the following must be observed:
1. Remove cap nut Item 4 (32 mm).
2. Loosen hexagon nut Item 6 (32 mm).
3. Make pressure setting by adjusting the spindle (slot). Cautionl During the pressure
adjustment the spindle (Item 3) may only be screwed in clockwise (pressure increase), as
otherwise the dangers specified in 3.2 will occur.
The spindle is not secured against unscrewingl
4. Replace Cu sealing ring (2 each) Item 9 (DIN 7603-A21x26-Cu).
5. Tighten hexagon nut Item 6 according to Fig. 1, hold spindle at slot with screwdriver.
6. Mount cap nut Item 4 according to Fig. 1.
4 Transport and storage
Dispose of the packing material after unpacking according to the applicable legal regulations.
4.1 Storage
Always protect the pump against impairments due to moisture, dust, water and/or other
contami-nants. Store the pump in a clean, dry place (relative humidity ~ 70%) at temperatures
between - 25 °C and 40 °C; unpainted parts should stored with a relative humidity ~ 40%.
Pumps with a rotary shaft seal should be put into operation 6 months after shipping at the
latest. Storage conditions which differ from this must be agreed upon separately.
The top coating provided by RICKMEIER is a base coating which is only intended to protect
against corrosion during transport and storage. Do not damage the coating .
......... GMbH
PUMPENTECHNOLOGIE
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BA2..QNNN-112
Operating and Maintenance Instructions for Gear Pumps and Units
AN-ZU: 02
Series R25. R35, R45, R65, R95
Beam.: WebJ27.09.07
Gepr.: LUl10.10.07
English
nameJdate
page 5 (11)
4.2 Lifting pump/pump unit
The pump must be lifted with securely attached lifting belts. The center of gravity must lie
between the belts to prevent the pump from tipping (see Fig. 2).
A suitable hoist must be used!
Rg. 2: Transport/lifting
5 Setupilnstaliation/Mounting
The pump must be set up as stipulated when ordering. The drive of the gear pumps must be
adjusted to their power input.
The piping must be installed with as little tension as possible. For the suction and pressure
connections of the series with an inside thread, only screw-in parts with an exactly matching,
cylindrical thread may be used. When screwing in, make sure that the pump is not twisted. The
connections must be sealed in accordance with the operati'ng conditions (medium. pressure,
temperature). The connection flange surfaces of the pump and the corresponding mating
surfaces may not be damaged and must be free of paint residues and other soiling.
Drive elements such as clutches and gearwheels must be fit on the pump shaft with
ISO fitting H7. These parts may not be driven on with hammer blows. as the pump can be
damaged in the process.
When aligning the pump shaft to the drive machine. the permiSSible differences of the clutch
may not be exceeded (see related clutch operating instructions).
Ensure even contact, good base or flange mounting and exact alignment!
For pump series without factory clutch protection, corresponding touch protection must be
provided by the customer (for example, see the Machinery Directive 9BI37/EC
Paragraph 1.3.B).
Suitable precautions must be taken against the long-term effects of dust, water and exposure
to the direct sunlight {e.g. large-area protection}.
All parts which come into contact with the flow medium must be free of impurities. With hot
bent pipes or pipes belt by welding, it is particularly important to ensure that no residues are
present in the pipes during commissioning.
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AN-ZU:02
Series R25, R35, R45, R65, R95
Bearb.: Web/27.09.07
Gepr.: Lij,l10.10.07
English
name/date
page 6 {11>
5.1 Suction pipe design, NPSHR value
For proper operation, it is necessary that the static pressure directly at the entrance into the
pump is never less than -0.4 bar (equivalent to 0.6 bar absolute) under any operating
conditions. Deviations from this must be expressly agreed upon with RICKMEIER when placing
the order.
It is therefore advisable to calculate or measure the lowest possible static pressure at the
pump entrance during operation. When doing so, all hydraulic resistances in the planned
suction pipe must be taken into account. This is especially important when a filter is provided in
the suction pipe which can become clogged in the course of time. In this case, it is
recommended that the pump inlet pressure be monitored with a pressure measuring device as
close to the pump as possible and that regular filter maintenance be conducted.
If no measuring connection is available in the 11
suction pipe, the pressure gauge connection 'O~:---+---I-----I---+---I
facing the suction side can also be used for ""'
this purpose for pumps with a pressure relief I 9,;--~,.,:.t-~---+----+---~---l
valve. Otherwise, the suction pipe must be ~6+ e---+- I
"'~-+----+---+----l
-..::
absolutely leak-tight so that no air can be ~ 7+---I---""4..............

-.:::!IIto,.±---+----l
aspirated. """--
The NPSHR value of the pumps frequently G-t-----t---+---+--~-~-==-____i
used for comparison with the NPSHA value " --....
of a system is provided in Fig. 3. 600 100 800 900 1000 1100
Fig. 3: NPSHR Density of flow medium [kg/m1
5.2 Sense of rotation and direction of flow

Before commissioning the pump, it must be ensured that the direction of drive rotation matches
the direction of pump rotation. To check the rotating direction of the drive machine, it is
practical to detach the clutch so that the pump is not driven. If this is not possible, then at least
the pipe connections must be removed so that the pump cannot be damaged by an incorrect
rotating direction.
When checking the direction of drive rotation, a pressure buildup in the suction pipe must be
prevented (e.g. caused by an integrated non-return valve). Otherwise the shaft seal may be
damaged in the case of an incorrect rotating direction.
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PUUPENTECHNOLOGIE
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BA2..QNNN-112
Series R25. R35. R45, R65. R95 Bearb.: Web/27.09.07
Gepr.: LUl10.10.07
English name/date
page 7 (11)
rechtsdrehend = dockwise linksdrehend = counter-dockwise
.~ Sense of rotation, identification arrow " Direction of delivery

L, R: Sense of rotation, view on shaft end: R =dockwise, L = counter-dockwise
Fig. 4: Sense of rotation and direction of flow
5.3 Reversing the sense of rotation
The pumps of the sizes R25 to R65 are designed so that the sense of rotation can be changed
later. The direction of flow is then also reversed. Prior to conversion to another sense of
rotation, and with it the reversal of the feed direction, the manufacturer must be consulted.
The direction of rotation cannot be altered late at pumps with mechanical sealing. The
rebuilding on another direction of rotation and so the revers,ion of the direction of flow must
occur by RICKMEIER.
6 Commissioning
Before starting up, the pump and the suction or supply pipe must be filled with the flow
medium. If the pump is installed so that the gear wheels lie above each other, a small quantity
of flow medium remains in the pump even at a standstill. As a result, the pump retains its
suction capacity for restarting even after longer standstills.
When operating two pumps in parallel which are secured against each other with non-return
valves, both pumps should be bled on the pressure side. The same applies to a pump working
against a'dosed system (loaded non-return valve etc.). Feeding against a dosed pressure pipe
is not permitted due to possible impermissible temperature increases in the pump.
With difficult suction conditions, the pump should be installed so that the driving gear shaft and
the gear shaft are located above each other. This installation position ensures a better priming
after longer standstills due to the residual oil quantity which remains in the pump. The gear
pump is prevented from running dry when a non-return valve is present in the suction pipe.
This can also be achieved by laying suction and pressure pipes on the pump in the form of a
siphon.
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BA2..oNNN-112
Gepr.: LUJ10.10.01
English name/date
page 8 (11)
7 Operation/Function
Gear pumps are rotary displacement pumps. When the gear wheels tum, the medium
enclosed in the space between the teeth is transported from the suction to the pressure side.
Then the displacement toward the pressure side is carried out by the intermeshing teeth
(see Fig. 5). The transport of the flow medium results in a pressure drop on the suction side of
the pump. The flow medium compensates this pressure drop by flowing in, maintaining the
feed process.
+ + • +
Suck Transport Displace

Fig. 5: Gear pump delivery principle
This process is the same for both gaseous and liquid media. As a result. the pump is capable
of bleeding the suction pipe itself until it is completely filled with liquid flow medium.
7.1 Pressure relief valve
The pressure relief valve integrated in the end cover of the pump as an option is designed as a
spring-loaded valve. It may only be used as an occasionally, briefly actuated valve for pressure
limitation. If a larger partial quantity of the flow must be drained off over larger periods, a
separate valve with a return pipe to the suction tank in the pipe (e.g. RICKMEIER valves of the
type RSn, DBV40, DBV80, DB9) or another form of pressure relief must be provided. This also
applies when the pressure pipe can become completely blocked 'during pump operation.
Special designs and variants may differ in their technical details.
7.2 Dry running
Dry running is always to be avoided, i.e. the pump must be filled with the flow medium before
being put into operation.
Exceptions: Dry running frequently occurs during start-up with unfilled suction pipe or during
operation when the supply of flow medium has been interrupted. Pumps wetted with flow
medium inside beforehand can be operated for up to 20 minutes under the following
conditions:
1. Pump driven via clutch, i.e. free of radial forces
2. Pressure at pump inlet and outlet approximately equal
On pumps driven via a pinion, chain or belt. dry running is not permissible and must be
avoided by the operator (fill pump with flow medium prior to start-up).
IIidomoie< GmbH PUMPENTECHNOLOGIE

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BA2.oNNN·112
Gepr.: LOJ10.10.07
English name/date
page 9 (11)
7.3 Environmental protection
During installation work with the pump not completely drained, flow medium can get onto the
floor under the pump. The shaft seals can also show signs of wear after longer operating
periods. If the seals are not replaced in the course of maintenance work performed on
schedule, drip leaks are also possible. To prevent any possible consequential damage by the
flow medium, appropriate measure should be provided for safety's sake, e.g. a catch pan etc.
under the pump.
8 Dismantling
Depending on the flow medium, the liquid escaping can present a hazard to people and the
environment. Therefore, the required measures must be carried out in accordance with the
safety data sheets of the flow liquids. In addition, the recommendations given in 7.3 must also
be observed.
9 Maintenance/Service
9.1 Gear pump
RICKMEIER gear pumps usually require little maintenance when operated within the
permissible operating limits. If a gear pump becomes unusable as the result of wear, it must be
replaced. The installation of replacement parts generally does not restore the original
performance.
The service life of the shaft seals is mainly dependent on the manner of operation of the pump
and the purity and quality of the flow medium. As a result, in many cases no reliable prediction
as to the time of failure can be made. For pumps with shaft seals, it is therefore recommended
that they be subjected to an external visual inspection for drip leaks at regular intervals
(recommendation: after 48 hrs, then every 4,000 operating hours). If a high danger potential
exists due to the flow medium, a check should be made at shorter intervals.
When using in a potentially explosive environment, the maintenance intervals of the related
ATEX operating instructions BA2-ONNN-113 apply.
9.2 Pump unit
The maintenance of pump units also requires compliance with the maintenance intervals and
work of the dutch and the motor (see table 2).
Product Type of dutch Information to the maintenance
Unit without motor Clutch RotexlSowex Pump: see 9.1
Clutch: maintenance-free
Other dutches Pump: see 9.1
Clutch: see separate operating instructions
Unit with motor Clutch RotexlSowex Pump: see 9.1
Motor: see separate operating instructions
Other dutches Pump: see 9.1
Table 2: Maintenance of pump units
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AN-ZU: 02
Series R25, R35, R45, R65, R95
Gepr.: LUl1 0.1 0.07
English
name/date
page 10 (11)
10 Conversion/Changes to gear pump
Conversion of or changes to the gear pump are only permitted after consulting with
RICKMEIER.Genuine spare parts and accessories authorized by RICKMEIER help ensure
safety. The use of other parts can result in the voiding of any liability for the resulting
consequences, When ordering spare parts, please always specify the data provided on the
rating plate,
11 Decommissioning
When decommissioning the pump, it must be ensured that no pressure greater than
atmospheriC pressure exists in the pump, and that the pump drive cannot start up aCcidentally.
In addition, the recommendations in section 7.3 must also be observed. For environmental
protection reasons, pumps/pump units may only be disposed of by licensed specialized
companies.
12 Malfunctions/CauseslTroubleshooting Measures
The following tabular overvie.w is to be regarded as instruction to the removal for eventual
occuring troubles and their possible causes. If faults occur which are not named here, we
recommend consulting RICKMEIER. If it is necessary to remove the pump for troubleshooting,
the recommendations given in the sections 7.3,8 and 11 must be observed.
Fault
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c.
Compare sense of rotation with identification arrow on pump;
reverse motor polarity if necessary.
-+ Check whether pump is filled with flow medium.

Connections may be leaky. Check suction pipe and shaft seal for
leaks. In case pressure relief valve existing: condition of the
sealing rinos checks, renews if necessary
Pressure drop in suction pipe too great; if possible, increase line
cross-section, shorten suction pipe or raise liquid level on intake
side - if filter is installed: clean and enlarge if necessary.
Does the set opening pressure match the order data sheet?
-+ If necessary, increase opening pressure by approx. 10 %,
PUMPENTECHNOLOGIE
RICKMEIER
BA2..QNNN-112
Gepr.: LCtl10.10.07
English
name/date
page 11 (11)
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...... ... ... Check whether the pressure relief valve is soiled or damaged;
does valve piston move smoothly?
Bleed pump pressure side.
.... i Check switching type, speed and current consumption of drive
motor. Compare voltage and frequency with motor rating plate.
I ... In case of pressureless feeding of thin media, charge pump with
1-2 bar.
... ... Has maximum permissible speed according to order data sheet
been exceeded?
... ... When feeding media with a high vapor pressure (gasoline,
solvent, paints etc.), the medium is to flow to pump.
... ... ... Avoid gas bubbles in flow media (e.g. have return pipes end
below oil level of tank).
...... Is motor output at least in accordance with order data sheet?
Check whether flow medium has lost lubricity due to excessively
... high temperature.

Check whether relief hole from sealing chamber to suction
chamber is dogged.
...... ... ... ...

Check whether viscosity of flow medium matches information on
order data sheet.
Too small a pump was chosen .
... Pump piping may not be tension-free. Remove pump and check
Ipiping.
Table 3: Troubleshooting
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PUMPENTECHNOLOGIE
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16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.2.7 Sectional Arrangement Drawing
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.2.8 Recommended Spares for Gearbox
1 2 3 4
FOR INFORMATION
A

D
CUSTOMER: JC CHANG

- : (mm)
E
CHECKED
- - - - ELABORATED
. -
TÍTULO
TITLE
RECOMMENDED SPARES FOR GEARBOX
JC CHANG CUSTOMER
CUSTOMER
DWG.
.
ORDER N° CH10003 FUNC.DWG. SEQUEN. 1 / 2 DWG. CH10003-GBSP-001 REV. 0
SPARES FOR HSG-360 GEARBOX
Gearbox SI. No. 0360x000150HSGH
0360x000151HSGH
Model HSG-360
Power Range 3,700 KW
Input Speed Range 5,017 KW
Output Speed 1,500
S.I No. ITEM QTY

1 Bearings – HS-CW 1
2 Bearings – HS-CCW 1
3 Bearings – LSS-CW 1
4 Bearings – LSS-CCW 1
5 Oil Baffle – HSS DE 1
6 Oil Baffle – Output 1
7 Main Oil Pump 1
8 MOP Coupling 1
9 Input Coupling 1
10 Thermometer 4
11 Air Breather 1
12 Resistance Temp. Detector 8
NOTES:
Whenever spare parts are required/ordered the nameplate details shall be mentioned in the
enquiry / order. Please also mention the part no. in accordance with sectional arrangement
drawing.
Spare parts are to be stored in their original packing until they are used. If stored unpacked
care should be taken to inspect them periodically to ensure the working condition. Jebsen &
Jessen Technology will not be responsible for the safe working of the gearbox should spare
parts from sources other then Jebsen & Jessen Technology are procured.
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.3 Generator
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.3.1 Generator Operations and Maintenance Manual
3500kW /4375kVA, 11000V, 50Hz, 1500rpm, TD110 FRAME
STEAM TURBINE DRIVEN A.C GENERATOR
A.C.GENERATOR
INSTRUCTION MANUAL
Rating: 3500kW / 4375kVA, 11kV, 4 POLE,

1500 rpm
Frame Type: TD110
STEAM TURBINE A.C GENERATOR
TD Power Systems Pvt. Ltd.,

# 27, 28 & 29, KIADB INDUSTRIAL AREA, NELAMANGALA TALUK, BANGALORE - 562 111,
TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
Page 1 of 35
CONTENTS
1. General.
1.1 Safety precautions.
1.2 Foreword.
2. Packing and Transport.
3. Technical specification.
3.1 Specification of Generator.
3.2 Specification of A.C. exciter.
3.3 Principle of operation
4. Constructional Details.
4.1 Stator of main machine.
4.2 Rotor of Main machine.
4.3 Stator of Exciter.
4.4 Rotor of Exciter
4.5 Construction of Bearing
4.6 Rotating Rectifier assembly.
4.7 Discharge of Resistor.
4.8 Anti Condensation Heaters.
5. Installation and Dismantling.

5.1 Lifting

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Page 2 of 35
5.2 Engine to Generator coupling assembly.

5.3 Earthing
5.4 Direction of Rotation
5.5 AVR settings
6. Running.
6.1 Inspection prior to test running.
6.2 Inspection prior to Load running.
6.3 Inspection table at running condition
7. Accessories.
8. Winding and insulation resistance.
8.1 Insulation Resistance
8.2 Measurement of Insulation resistance
8.3 Insulation Resistance (IR) Values required for
running
8.4 Prevention of IR drop
8.5 Cleaning method of Winding
8.6 Wiping with cloth.
8.7 Winding Condition.
8.8 Winding Condition assessment.
9. Inspection and Maintenance.
10. Annexure-1.

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Page 3 of 35
1. GENERAL
1.1 Safety precautions
Safe and efficient operation can only be achieved if the equipment is
correctly operated and maintained. Before operating the generating set, read
the generating set operation manual and become familiar with it and the
equipment.
Note:
Ensure installation meets all applicable safety and local electrical
codes. Have all installations performed by a qualified electrician.
Do not operate the generator with protective covers, access covers
or terminal box covers removed.
Disable engine-starting circuits before carrying out maintenance.
Disable closing circuits and/or place warning notices on any
circuit breakers normally used for connection to the mains or
other generators, to avoid accidental closure.
1.2 Foreword
This operation and maintenance manual provides user of this generator with
understanding of the principles of operation, the criteria for which the
generator has been designed, and the installation and maintenance
procedures. Specific areas where the lack of care or use of incorrect
procedures could lead equipment damage and/or personal injury are
highlighted, with Note and it is important that the contents of this book are
read and understood before proceeding to fit or use the Generator.
Note:
Incorrect installation, operation, servicing or replacement of parts can result
in severe personal injury or death, and/or equipment damage. Service
personnel must be qualified to perform electrical and mechanical service.

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Page 4 of 35
2. PACKING AND TRANSPORT

The generators are packed in wooden box and dispatched. The generator is
dispatched in fully assembled condition and caution required to be exercised
so that intensive shock is not imparted to the generator during transport.
Even though the generator is packed, the packed generator should not be
left outdoors and should be protected from moisture, alkali, oil, gas, dust,
dirt and other injurious substances and must be stored in an enclosed
building.
In the case of lifting, slowly lift the generator using lifting shackle and lugs.
While placing the generator temporarily for a while, lumbers should be
placed and the generator should be lowered on them in a horizontal position.
Acceptance and Protection:
Our generator is dispatched after conducting strict inspection and test.
At the time of accepting the generator, please confirm the following
points:
Is there any missing item? (Especially accessory and spare parts if any)
Is there any damage during transport?
If any damage is found, the carrier and the relevant TDPS
Office/insurance Company must be notified without delay.
In order to prevent intrusion of foreign matters such as dust, concrete etc.,
in the interior of the generator which was unpacked during the period of
erection work to avoid the drop of insulation resistance due to absorption of
moisture in the coils by rain and water drips, the complete protective
measures such as to cover the generator with canvas sheet etc, is required to
be taken.

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Page 5 of 35
3. TECHNICAL SPECIFICATIONS
3.1 Specification of generator
This generator is a Brush less AC generator with an AC exciter and rotating
rectifier mounted on a common shaft. The specification of the generator is as
follows:
AC GENERATOR Details
1 Make Toyo Denki Power Systems Pvt Ltd

2 Frame TD 110
3 Conforming standards. IS 4722 / IEC 34
4 Type Horizontal foot mounted
construction, self-excited, self-
regulated, air-cooled ac generator
with double Bearings and
cylindrical type of rotor
construction.
5 Type of excitation system Brushless
6 AVR ABB make UNITROL
7 Continuous rated output at site
kW / kVA 3500 / 4375
8 Speed in (rpm) 1500
9 Voltage (volts) 11000
10 Full load current (amps) 230
11 Voltage regulation < ±10%
12 Frequency (Hz) 50 Hz, ± 5%
13 No. Of phases / No of terminal 3 ph / 6 wire
14 Power factor 0.8 (Lag)
15 Electrical Design ambient 45 Deg. C
16 Short Circuit Ratio 0.5
17 No. Of poles 4
18 Insulation Class Class F
19 Temperature class limited to Class F
20 Enclosure IP 23

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Page 6 of 35
21 Cooling System IC01 - IC8A1W7
22 GD2 of ACG 750 Kg-m2

23 Direction of Rotation when ANTI CLOCK WISE.
viewed from the NDE of
Generator.
24 Guaranteed Efficiency at rated
p.f (Subjected to tolerance as per
standard)
95.5 %
100% load
95.6 %
75% load
95.1 %
50% load
92.6 %
25% load
25 Over speed 20 % for 2 minutes.
26 Overload Capacity - 50 % For 30 Sec.
- 10 % For 1 hour in every 12 hours.
27 Accessories PT 100 type RTDs, RTD type BTDs
And Space Heaters.
28 Reactances (p.u) and time
constants (seconds)
Xd: Direct axis synchronous 0.195
a.
reactance
Xd’: Direct axis transient 0.181
b.
reactance
Xd’’: Direct axis sub transient 0.141
c.
reactance
X2: Negative Sequence 0.191
d.
Reactance
e. Xo: Zero Sequence Reactance 0.112
Xq: Quadrature axis 1.89
f.
synchronous reactance
Xq’: Quadrature axis transient 1.89
g.
reactance
Xq”: Quadrature axis sub 0.129
h.
transient reactance
i. Ra: armature resistance/ ph @ 0.139 ohms/phase

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Page 7 of 35
25 Deg C
j. Rf : field resistance @ 25 Deg C 0.665 ohms
k. Td” 0.035
l. T’do 2.201
m. T’d 0.198
n. T”do 0.253
o. Inertia constant-H 0.5
29 No of Bearings Double bearings
30 Bearing type Anti friction
Bearing Lubrication SHELL ALVANIA EP (LF) No.2 OF
31 M/S SHELL.
32 Vibration limit As per IEC 60034-14

33 Noise limit As per IEC 60034-09
34 Approx. Total weight of ACG 12.65 T

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Page 8 of 35
3.2 Specification of A.C. exciter

The rotary rectifier with silicon rectifier rectifies AC electric source that
comes from three-phase AC exciter to DC. Then that DC electric source
excites the field coil of generator. Therefore the generator does not have
brush and slip ring.
1 Type of exciter GZA 84

2 Output 55 kVA
3 Voltage 159 V
4 Current 200 A
5 Frequency 150 Hz
6 Revolutions 1500 rpm
7 Excitation voltage 45 V
8 Excitation current 10.6 A
9 No. Of phases 3
10 No. Of poles 12
11 Power factor 0.95 (lag)
12 Insulation class F
13 Rating Continuous
14 Type of outer housing IP 23
15 Armature Revolving-armature type
16 Bearing None
17 Guaranteed over speed 20 % for 2 minutes
18 Applicable standard IS: 4722
19 Exciting system Stator side by AVR

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Page 9 of 35
3.3 Principle of operation

Self-Excited AVR Controlled Brushless A.C. Generators
The main stator provides power for excitation of the exciter field via the AVR
which is the controlling device governing the level of excitation provided to
the exciter field. The AVR responds to a voltage-sensing signal derived from
the main stator winding. By controlling the low power of the exciter field,
control of the high power requirement of the main field is achieved through
the rectified output of the exciter armature.
For More Information on AVR its Operation and Accessories Please
Refer AVR Manual

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Page 10 of 35
4. CONSTRUCTIONAL DETAILS
For major dimensions and mounting details of the A.C Generator, refer
drawing No. in Annexure-1.
4.1 Stator of the main machine
Outer frame is of steel plate welded Construction of high quality and is

offered for rigid design. At the inner side of outer frame, stator core is fitted
at ample pressure through the media of stator core clamps. Two rectangular
steel plates welded to the frame, forms the generator feet.
Laminating silicon steel sheets of high quality and of little iron loss forms
stator core. Radial Ventilation ducts are provided for each proper length in
axial direction for the purpose of effectively cooling the interior.
Stator coils are Resin Rich Impregnated windings, which are mainly made of
mica and coated with special finish coating, which possesses heat
resistance, humidity resistance and oil resistance along with sufficient
insulating intensity. End bent part of stator coils are rigidly supported by
fibre glass coil support rings on both ends to protect the coils against
mechanical force due to vibration and over current.

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Page 11 of 35
4.2 Rotor of the main machine
The rotor of the main machine is of cylindrical type. It comprises of the

shaft, the laminated rotor core, the rotor winding and damper winding. Laminating
steel sheets forms rotor core. At every suitable length in its axial direction, duct
pieces are welded forming radial ventilating ducts to effectively cool the interior.
Shaft is made of forged steel and manufacture of this rotor is conducted with
due attention given to inspection and machining of material as well as to
balance. For rotor arrangement of the A.C Generator, refer drawing No. In
Annexure-1.
4.3 Stator of Exciter
Laminating silicon steel sheets of high quality and of little iron loss forms
exciter stator core. Axial Ventilation ducts are provided for the purpose of
effectively cooling the interior. The wound exciter stator is pressed into the
main machine frame.
4.4 Rotor of Exciter
Located on the same shaft are the laminated rotor core of the exciter with
the three-phase winding, the radial ventilator fan, the rectifier assembly and
the discharge resistors. Axial Ventilation ducts are provided for the purpose
of effectively cooling the interior.

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Page 12 of 35
4.5 Construction Around Bearing
NDE BEARING ASSEMBLY-6232+NU232 DE BEARING ASSEMBLY-NU240
Antifriction bearings are provided in this machine.

Bearing fit to housing is transition fit. On delivery, the bearings are
lubricated with high grade, lithium-saponified grease of grade 3
consistencies. The factory uses Shell Alvania NO.2 for this purpose.
The grease channels and the channel between the nipple and bearings are
filled with anti-friction bearing grease before leaving the factory.
The following alternative types of lithium saponified anti-friction bearing
grease may be used:
Shell Alvania R3
Castrol spherol AP3
Or any other lithium-saponified brand-name grease of equivalent
specification, heat resistant up to at least 130°C and complying with
Industrial Standard.
Recommendation:
Always lubricate the bearing with same selected brand of grease.
Dismantling the bearings
During shaft production, the bearing seat and the bearing stop shoulder on
the shaft are subjected to high degree of quality control. This is essential to
maintain the accuracy needed to keep the bearings fully operational. When

TEL: ++91-80-7734432 To 38, FAX: ++91-80-7734438 And 40
Page 13 of 35
dismantling the bearings, it is therefore important to handle the bearings

and bearing rings with particular care, otherwise the bearing seats on the
shaft and bearing plate could become damaged. To simplify dismantling, the
parts can be heated uniformly all round to a temperature of apprx. 80°C. Do
not install bearings previously removed, but renew them.
Assembling the bearings:
Bearings must only be renewed by qualified personnel possessing the
necessary knowledge and experience and should be worked in a dust
free environment, on a clean surface and using suitable tools including
metric wrenches.
The grease and bearings must be kept free of impurities; otherwise they
will wear out faster and possibly even fail. The correct arrangement of
the bearing components must be retained: this applies particularly in
the event of repair work.
When renewing bearings, install original type approved bearings only,
and maintain the correct amount of bearing play. The grease-regulating
disc should be rigidly attached to the shaft. Do not remove new
bearings from their packs until just before they are installed. Do not
wash the bearings out, as the anti-corrosion agent applied to them is
compatible with most customary anti-friction bearing greases.
Clean the part of the bearing that is to be re-installed. Before fitting the
bearing, check for dimensional accuracy and lack of distortion at the
bearing seats on the shaft and in the housing.
When single-piece bearings (e.g. deep-groove ball bearing) are installed,
the force exerted to fit them must always be applied to the firmly
located race which has to be mounted first. Forces applied to the free-
moving race have to be transmitted through the balls or rollers, which
can damage them and their tracks.
Installation of separable bearings (e.g. roller bearings) is more
straightforward. The two races can be installed separately. A screwing
movement when assembling them helps to avoid rubs marks.
When fitting the bearing on the shaft, heat it to about 80°C in an oil
bath, oven or by a suitable inductive heating method. Make absolutely
sure that it is located centrally and in positive contact with the shaft
shoulder.
Once they have cooled down, pack the bearing fully with grease. The
inner and outer bearing covers must each be filled with grease to
approx. 50% of their full capacity. Relubrication quantity is 200 Gms
for every 1500Hrs.

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Page 14 of 35
Monitoring the bearings:

The first indication of the damaged bearings is usually a noticeable change
in temperature or running behavior, or noise and vibration if bearing
damage has reached an advanced stage.
Recommendation:
Monitor the bearings by measuring transmitted noise, temperature and
vibration at regular intervals, and compare the readings with those taken on
previous occasions.
Temperature detectors for bearings:
RTD type bearing temperature detectors are given. Maximum allowable
temperature for grease-lubricated bearings is 90°C. Refer section 7.1 for
further details
Temperature rise of ball bearing:
Carefully check that temperature rise of the ball bearing doesn’t exceed 50°C
above the ambient temperature. Should it be otherwise, it is necessary to
stop the machine and to proceed to a general inspection.
Abnormal noises:
The production of abnormal noises and vibrations may result from the wear
and tear of the ball bearing: it is better to proceed to their renewal, so as to
avoid any risk of seizure that could seriously damage the alternator.
However, before proceeding to this replacement, make sure that the
alignment of the engine alternator set is correct as also the tightening of
bearing caps and of the ventilating fan.
4.6 Rotating Rectifier Assembly
Construction
Fig 4.61 shows the arrangement and connection diagram of rotating
rectifier assembly. The rectifier assembly is split into two groups, the
positive and negative, and the main rotor is connected across these
groups. This group is formed through the connection bar shorting
between two diodes as shown in fig 4.61. Each group carries 3 diodes,
the negative group carrying negative biased diodes and the positive group
carrying positive biased diodes. Care must be taken to ensure that the
correct polarity.
Diodes are fitted to each respective group. When fitting the diodes to the
connecting bar they must be tight enough to ensure a good mechanical
and electrical contact, but should not be over tightened. The
recommended tightening torque is 4.06 -4.74Nm (36-42lb in).

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Page 15 of 35
Silicon diode specification shall be as below:

Model: SKN(R) 240/16
Rated amps: 240 A (Avg.)
Reverse voltage: 1600 V
Inspection and Cleaning
Investigate whether the bolts and nuts around the rotating rectifiers are
loose or not. The life of silicon diodes used is semi-permanent under
condition of normal use. Therefore, unless otherwise there is a problem,
inspection of individual diodes is not required. In case, the voltage is not
built-up or generated voltage is low, failure of diode/s is to be considered
as one of the probable causes. Therefore, remove the lead wires and
check the continuity using a tester/multi-meter.
Refer fig 4.62 for inspection of silicone diode. In case any diode is found
to be damage, replace that with an identical on
Fig: 4.61
Note:
Please note the following points while replacing the diodes.
(A) Since 2 types of diodes (forward polarity and reverse polarity are used,
confirm the polarity of the diode to be replaced).
Clean the tightening thread part of diode and coat electrically and
thermally conducting grease (CHEM MOSIL) to prevent electrical
corrosion of this part.
(C) Tighten the diode using torque wrench. Tightening torque should be
as per the specified value.

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Page 16 of 35
Judgement, whether the rectifier (diode) is good or not, should be done

resorting to the following table.
Resistance value
Defective device
Normal
Short circuit Open circuit
Over 100 k-
Forward Less than 10 ohms.
Less than 10
direction ohms
ohms Over 100 k-
Reverse Less than 10 ohms.
Over 100 k-ohms.
direction ohms
4.7 Discharge Resistor

The discharge resistor is a permanently connected resistor connected across
the two rectifier plates to prevent high transient reverse voltages in the field
winding from damaging the diodes. This device rating is as below. Two
devices connected in parallel. Replace if faulty.
Technical specifications:
Resistance value: 17 Ohms/circuit at 25ºC
Capacity: 2600W/circuit
Voltage: 210 V (D.C)
IR: Min >100M Ohm at 25ºC
4.8 Anti Condensation Heaters
Anti-condensation heaters are fitted in the machine to avoid condensation in
the event of long storage. Care should be taken to switch on these heaters at
site when the machine is not in operation and should be switched off before
the machine is started. For technical specifications and connection details
refer section 7.1.

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Page 17 of 35
5. INSTALLATION AND DISMANTLING

5.1 Lifting
Minimum Lifting Capacity Required Is 10 Tonnes.
While lifting ensure that the lift is vertical of suitable length and use suitable
lifting capacity. Lifting points are designed to position the cranage point as
close to the center of gravity of the generator as possible. Care is therefore
needed to avoid personal injury or equipment damage.
5.2 Engine to Generator Coupling Assembly
During the assembly of the Generator to the Engine it will be necessary to
firstly carefully align, then rotate, the combined Generator rotor - Engine
crankshaft assembly, as part of the construction process, to allow location,
insertion and tightening of the coupling bolts.
While fitting and tightening the coupling bolts it will be necessary to rotate
the Engine crankshaft - Generator rotor assembly. Care should be taken to
ensure that rotation is carried out in an approved manner that ensures safe
working practice when reaching inside the machine to insert or tighten
coupling bolts, and that no component of the assembly is damaged by non-
approved methods of assembly rotation.
Engine Manufacturers have available a proprietary tool designed to enable
manual rotation of the crankshaft assembly. This tool must always be used,
having been engineered as an approved method of assembly rotation, by
engaging the manually driven pinion with the engine flywheel starter ring-
gear.
A flexible coupling should be fitted and aligned in accordance with the
coupling manufacturer's instruction. If a close coupling adaptor is used the
alignment of machined faces must be checked by offering the generator up to
the engine. Shim the generator feet if necessary. Ensure adaptor guards are
fitted after generator/engine assembly is complete. Open coupled sets
require a suitable guard, to be provided by the set builder. Axial loading of
the generator bearings should be avoided. Should it be unavoidable contact
the factory for advice.
Note:
Incorrect guarding and/or generator alignment can result in personal injury
and/or equipment damage.
5.3 Earthing
The generator frame should be solidly bonded to the generating set bedplate.
It should be earthed through suitably rated earth conductor (normally one
half of the cross sectional area of the main line cables).

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Page 18 of 35
Note: Refer to local regulations to ensure that the correct earthing

procedure has been followed.
5.4 Direction of Rotation
Fan Types
This machine is designed with an improved cooling system fitted with a
radial bladed uni-directional fan. These machines are suitable only for
clockwise rotation, as viewed from the drive end.
Phase Sequence
Phase sequence of this machine is UVW corresponding to direction of
rotation clockwise form drive end.
5.5 AVR Settings
Most of the AVR adjustments are factory set in positions, which will give
satisfactory performance during initial running tests. Subsequent
adjustment may be required to achieve optimum performance of the set
under operating conditions. Refer AVR manual for details.
5.6 Terminal cables
Main lead cables are 70mm² silicone rubber insulated flexible cables routed
to terminal box through bushings suitable for 5500 volts. Ensure that all
external cabling is correct and that all the generating set manufacturer's
pre-running checks have been carried out before starting the set. The
generator AVR controls will have been adjusted during the generating set
manufacturer's tests and should normally not require further adjustment.
Should malfunction occur during commissioning refer to AVR manual.

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6. RUNNING
6.1 Inspection Prior to Test Running
Conduct the inspection as per the following table prior to test running.
INSPECTION ITEM CONTENT OF INSPECTION

• Is the foundation fully cured and
solidified?
• Isn’t there clearance between the base
and foundation?
Condition of erection
• Are the tightening bolts of respective
parts fully tightened?
• Are there pieces of paper and cloth lying
on the surroundings?
• Is the whole of lead wire secured?
• Are the bolts and nuts tightened?
Terminations
• Is the treatment of terminal (lug or
socket) secured?
• Is the insulation resistance sufficient?
(High voltage circuit is desired to be over
10mega ohms and low Voltage to be over
Insulation resistance 1mega ohms).
NOTE: Terminals of diodes to be shorted
for measurement of insulation resistance
of field winding.

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6.2 Inspection Prior to Load Running

In the case of running, after test running or stopover for a long period of
time, no load running should be done for about 30 minutes. Then conduct
the inspection in accordance with the following table and confirm the
absence of abnormality. Thereafter commence load running.
INSPECTION ITEM CONTENT OF INSPECTION

• Is the grease o.k.?
• Is there any abnormal noise and vibration?
Bearing parts • Is the temperature abnormally high?
• Is the current flowing from bearing housing to
earth?
• Is there any abnormal odor and smoke coming
out?
• Is there any abnormal vibration?
Generator and Exciter (Caution is required because the vibration from
prime mover is high).
• Are there any parts where temperature is
abnormally high?
• Are the voltages of three phases balanced?
• Do the meters indicate the approximate
Control panel values?
• Is the circuit breaker set at the running
position?
SL NO PERIOD OF INSPECTION AND
SYMBOL
MAINTENANCE
Routine inspection once a day at times of running
1 D
and stop
Weekly inspection and maintenance once a week at
2 W
times of stop
Monthly inspection and maintenance once a
3 M
month at times of stop.
Periodical dismantling, inspection and
4 6M
maintenance once in 6 months at times of stop.
Periodical dismantling, inspection and
5 Y
maintenance once in a year at times of stop.

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6.3 Inspection Table at Running Condition

Note: The above symbols are used for inspection periods in the
explanations.
P
E
INSPECTION R JUDGEMEN INSPECTION MEASURES AT T
ITEMS I T CRITERIA METHOD ABNORMALITY
O
D
If vibration
increases
gradually, stop at
Whether the
suitable time and
vibration is
conduct
abnormally
If abnormality is investigation.
Vibration of high or not
felt by hand If abnormal
Generator D compared to
those touch resort to vibration is
body
observed so vibration meter. sensed suddenly,
far. stop the
generator
immediately and
conduct
investigation.
Discriminating
There should mechanical noise,
be no ventilation noise
abnormal and magnetic
noise noise should
Abnormal compared to make judgment.
noise from the noise at Resort to sense of In the case of
body D normal time hearing and noise abnormal noise
including (noise at hearing rod like magnetic
bearing normal time noise
should be well accompanying
listened to vibration, precise
and investigation
confirmed) should be
conducted.

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P
E
INSPECTION R JUDGEMENT INSPECTION MEASURES AT T
ITEMS I CRITERIA METHOD ABNORMALITY
O
D
If standard limits
are exceeded the
Temperature Measure by the machine must be
rise limits must attached stopped
not be thermometers immediately and
exceeded. In and scanners at inspected.
Temperature case the regular times
of respective D temperature daily. Current, If there is a large
parts rises gradually power factor variation cause
despite running and room temp should be
at constant should be precisely
load, caution is recorded at the investigated and
required. same time. corrective
measures should
be taken.
If abnormal odor
is sensed
machine must be
stopped
immediately.
There should be Investigate
Abnormal no abnormal mainly around
Resort to sense
odor from D odor compared the winding.
of smelling.
body. to that at Megger test for
normal times. the windings
since abnormal
odor mainly
results from
failure of
insulation.

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P
E
O
D
There must be
no deposit of
foreign matter Remove foreign
at ventilation matter if it is
openings. deposited at the
Temperature ventilation
By sensing wind openings.
difference
Condition of D pressure by
between If air quantity
ventilation temperature
suction air sensed is lesser
observation.
and discharge stop the machine
air must not by checking
indicate large running condition
difference and investigate.
from that at
normal times.
• Bolts of
respective
parts must
Torque wrench
not have loose
should be used
fit.
After air blow and for tightening the
• There must cleaning using diodes and the
be no color compressed air, tightening must
Surroundings change by inspection must be conducted at
Y
of rectifiers over heat. be conducted by the prescribed
visual torque. For the
• There must
observation or others, take
be no
hand touch. appropriate
deformation
measures to the
and
extent required.
impairment of
respective
parts.
Loose fit of Increase the
bolts that Tighten the bolts tightening. (Do
Check if bolts
tighten M using spanner or not break the bolt
turn lightly.
respective screwdriver. by tightening too
parts much).

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P
E
O
D
Replace with new
Deterioration grease of
of lubricating specified brand
grease as per the
nameplate data.
Generator
Stator: 5.5kV
winding
greater than
5M-ohms
By megger
Rotor low
Note:
voltage Cleaning and
Insulation
M winding Megger should be drying should be
resistance
conducted after conducted.
Greater than
disconnecting
1 M ohm
control circuit.
Exciter
Over 1Mohm
for armature
and field

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P
E
O
D
• No plugging
of air duct.
• No loose fit
and
deformation of
wedge.
• No color After air blow and
change by cleaning by
over heat. compressed air,
conduct visual Take appropriate
Surroundings
• No inspection. measures as
of field coil
Y deformation required after
(including Observation or
and cleaning by air
exciter) hands touch for
impairment of blow.
respective the range
parts. possible for
inspection.
• There must
be no trace of
contact with
stator.• No
loose bolt of
respective
Parts.
• Antifriction
bearings have
no unilateral
Surrounding contact.
Y Refer section 4.5. Refer section 4.5.
of bearing • Prevention of
shaft current
must be
adequate.

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7. ACCESSORIES
7.1 Standard Accessories
Stator winding Resistance temperature detectors
Nine (6 Nos+3 no’s spare) resistance temperature detectors, PT100 type,
in the stator winding.
The auxiliary terminal box, which is at left hand side of the machine
looking from NDE, is housing above accessories terminals. For auxiliary
terminal box details, refer to drawing no. in Annexure-1. The resistance
temperature detectors are in compliance with IS: 2848:1986. For
terminal markings and connection details refer connection diagram
datasheet in Annexure-1.
Bearing temperature detectors
One RTD type temperature detector, PT100 type, in each bearing.
The auxiliary terminal box, which is at left hand side of the machine
looking from NDE, is housing above accessories terminals. For auxiliary
terminal box details, refer to drawing No. in Annexure-1. The resistance
temperature detectors are in compliance with IS: 2848:1986. For
terminal markings and connection details refer to connection diagram in
Annexure-1.
Anticondensation heaters
Two space heaters of capacity 2x500W, 240V, 1Phase, 50Hz is
fitted in the machine as shown in the A.C.Geneartor outline
drawing. The space heater terminal box is also provided at left side
of the generator looking from NDE. Refer to connections refer to
datasheet in Annexure-1 for connection of space heaters and
terminal details and also for supply lead details.
7.2 Parallel Operation
Understanding of the following notes on parallel operation is useful before
attempting the fitting or setting of the droop kit accessory. When operating
in parallel with other generators or the mains, it is essential that the phase
sequence of the incoming generator matches that of the bus bar and also
that all of the following Conditions are met before the circuit breaker of the
incoming generator is closed on to the bus bar (or operational generator).
1. Frequency must match within close limits.
2. Voltages must match within close limits.
3. Phase angle of voltages must match within close limits.
A variety of techniques, varying from simple synchronizing lamps to fully
automatic synchronizers, can be used to ensure these conditions are met.

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Once connected in parallel a minimum instrumentation level per generator

of voltmeter, ammeter, wattmeter (measuring total power per generator), and
frequency meter is required in order to adjust the engine and generator
controls to share kW in relation to engine ratings and kVAr in relation to
generator ratings.
It is important to recognize that
1. kW are derived from the engine, and speed governor characteristics
determine the kW sharing between sets and
2. kVAr are derived from the generator, and excitation control
characteristics determine the kVAr sharing.

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Page 28 of 35
8. WINDING AND INSULATION RESISTANCE

8.1 Insulation Resistance
Note:
Insulation tests should be carried out before running the generating set,
both after assembly and after installation on site. The windings have been
H.V. tested during manufacture and further H.V. testing may degrade the
insulation with consequent reduction in operating life. Should it be
necessary to demonstrate H.V. testing, for customer acceptance, the tests
must be carried out at reduced voltage levels i.e. Test Voltage= 0.8 (2 X
Rated Voltage + 1000)
Insulation resistance is the resistance against leakage current that flows in
the interior and on the surface of insulation when certain value of D.C.
voltage is imposed. In case the generator is installed at a place where high
humidity exists or when the generator is kept idle over a long period of time,
generally the insulation resistance drops due to deposit of moisture on the
insulation surface. Therefore insulation resistance should be measured prior
to running of the generator.
8.2 Measurement of Insulation Resistance
Measurement of insulation resistance indicates the insulated condition
of the equipment in a very simple way. However, the value of insulation
resistance measured indicates the condition of insulation deterioration.
Measurement is essential before running the generator. Although the
measured value indicates the absolute value corresponding to the
condition of insulation at the instant of measurement, a comparative
value has more significance. It is essential to measure periodically and
to check in comparison the condition of change with reference to earlier
measured values.
Although the insulation resistance increases with time after the
imposition of D.C.voltage the value that settles down to a constant
should be registered. In case the insulation resistance increases
gradually little by little this insulation resistance value is indicated by
30 seconds value or 1-minute value.
Since the insulation resistance has a close relationship with the
temperature of insulation, when measuring insulation resistance, it is
always required to measure temperature of insulation at that time and
record this temperature along with the insulation resistance. It serves
convenient for maintenance purposes if the relationship between the
insulation resistance value and winding temperature at clean and dry
condition of winding is available. Generally, the insulation resistance
value drops rapidly together with the rise of temperature and the
relationship between the logarithm of insulation resistance value and

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temperature changes as straight line approximately in the temperature

range of usage.
Initially the insulation resistance drops at once and then starts rising
as the drying effect progresses. This is most generally seen.
In the case of drying on site the equipment that has absorbed moisture
excessively and/or large size machines, this type of characteristic is
frequently experienced. In the case of equipment that has absorbed
moisture excessively, since the amount of moisture absorbed is large,
the insulation characteristic is to be absorbed before the drying effect
appears. In the case of large size machines a long time is required for
the temperature rise of equipment and the drop portion due to
insulation characteristic offsets the rise portion due to drying effect. In
both the above cases, a fairly low value for the measured insulation
resistance by megger should continue without change. About 3 full
days (days and nights) may be required to reach the rising point.
Note:
At the time of measuring insulation resistance, attention should be paid to
the following points:
If rotating type megger is used, rotating it for one-minute at least
should do measurement.
If battery driven megger is used, error increases as the battery voltage
drops.
Prior to measurement, residual electric charge of winding should be
removed.
To exclude the effect of connected auxiliary devices, other circuits
should be disconnected at an easy convenient part and then
measurement should be done.
After the measurement the residual charges should be discharged.
8.3 Insulation Resistance (IR) Values Required for Running
The minimum permissible insulation resistance value changes extensively by
the type, rating, dimension and insulation method of generator. A general
value cannot be determined. However, the following guideline can be
approximately used when the windings are at normal temperature, for
permitting normal running.
Greater than 1 Meg-Ohm for low voltage stator winding and the field
winding.
Greater than 5 Meg-Ohm for 3.3kV and 6.6kV stator windings.
Greater than 10 Meg-Ohm for 11kV stator windings.

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Alternatively, the following formula may be used for the minimum insulation
resistance value.
Rated Voltage (V)
=
Rated Output (kW or KVA + 1000)
Rated Voltage (V)+1/3(rpm)

=
Rated Output (kW or KVA)+2000+0.5M-ohm
8.4 Prevention of IR Drop

It is desirable to run the generator with its winding condition always set
clean and dry. Dust deposited on the winding surface prevents heat
dissipation and becomes the cause of deterioration dependent on its kind.
Also, the intrusion of moisture into the interior from the cracks on insulation
leads to the drop of insulation resistance. Therefore, daily attention to
cleaning and prevention against moisture absorption leads to prevention of
IR drop especially for exciter, which is open type. Although generator’s
interior presents dry condition during running, there may be moisture
absorption during stoppage of generator at times of high humidity such as
rainy season. To prevent such situations, it is required to put-on the space
heater immediately after stopping the generator and to raise the temperature
of generator interior higher than the ambient temperature.
8.5 Cleaning Method of Winding
Dust accumulated on the insulation reduces the ventilation area and the
cooling effect. This may result in over-heating of the generator. Even though
the accumulated dust is not conductive by itself, it absorbs moisture and
becomes conductive thereby causing short circuit of winding and ground
fault. Therefore, it is essential to keep the winding always in a clean
condition. The particular points that need to be paid consistent attention are
to the following: -
Isn’t there any abnormality of the respective parts of generator
itself?
Isn’t there any harmful matter in the surrounding atmosphere?
When abundant dust is in presence in the wind passage, such dust will stick
to coil and dust and the dust will lead to the cause of short-circuit failure
and grounding failure. When the generator is started after a long time, since

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Page 31 of 35
there may be chances of lowering the insulation resistance of coil, perform

the drying thoroughly.
As for drying there are methods like resorting to space heater and the
method of permitting the flow of current directly through the coils.
For either of the above two methods, please avoid over-heating locally as well
as raising the temperature above 80°C. Though inspection in detail of the
respective parts is carried out at the time of trimming the generator, during
daily inspection, please inspect the machine by your sense as whether any
abnormality compared to previous condition has arisen or not.
In other words, please pay due attention by comparing the temperature rise
and vibration through the feeling obtained by touching your hand on the
generator, and by sensing abnormal noise or odor.
As for the confirmation of abnormal odor, please confirm it by opening the
covers once in a while.
8.6 Wiping with Cloth
This method is especially effective for cleaning the local parts where the
contamination is severe. Dry and clean cloth from which thread pieces do
not come out should be used. Attention should be paid as not to impair the
insulation by rubbing strongly
As part of routine maintenance procedures, periodic attention to winding
condition (particularly when generators have been idle for a long period) and
bearings is recommended.

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9. INSPECTION AND MAINTENANCE

To avoid failure in advance, it is indispensable to watch and inspect the
generator at all times.
By preparing checklist, please perform the inspection and trimming
periodically. Hereunder, points that need to be paid attention especially date
of inspection and method of inspection is given.
Respective tightening bolts and connecting location
Inspection and maintenance within the extent considered possible must be
performed once a year without taking out the rotor. In particular, inspection
of stator winding and re tightening of respective bolts and nuts must be
carried out. Tightening of set bolts must be done once after half a month
from the date of commencing running and furthermore inspection and re
tightening of these bolts must be done at the rate over 3 times within one
year thereafter.
Bearing
After the starting if bearing is overheated considerably within a short time or
if abnormality of noise or odor is detected, there is the need of dismantling
and inspection.
The causes of overheating of bearing are given hereunder.
Lubricating grease is not adequate
Use of filthy grease
Deficient erection and coupling
Generation of rust or presence of scar in bearing during the time
generator is laid off.

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Major requirement of inspection and maintenance at respective

time is tabulated in the following table:
Control of Daily
I inspection Monthly
inspection
t place of inspection
(during Annual inspection
e inspection (during stop)
running)
m
1. Maintenance of
winding.
1.Noise 1.Insulation
2. Maintenance of
Static part 2.Temperatur Resistance. core Parts.
1
e 2.Air gap 3. Inspection of lead
3.Vibration wires.
3.Cleaning
4. Inspection of bolt
and Nuts.
1. Loosening of spigot
fitting part and
balance weight.
2. Contact with static
Rotating 1. Inspection part.
2 1.Noise
part resistance.
3. Inspection of lead
wires.
4. Retightening of
bolts and nuts.
1.Noise 1.Examination of
rolling elements
2.Temperatur
3 Bearing part 2.Cleaning
e 2. Pitting marks to be
checked
3.Vibration
1.Odour
4 Others 2.Abnormal
noise

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10. ANNEXURE
Following is the list of reference drawings and data sheets for erection and
commissioning of A.C Generator.
SL Drawing no
Description
NO /Data sheet
1. 16019710 Outline Drawing Of A.C. Generator.
2. 37418810 Terminal Arrangement Drawing (Main)
3. 37418910 Terminal Arrangement Drawing (Neutral)
4. 46035908 AUX TERMINAL BOX( PMG )
5. 31054010 AUX TERMINAL BOX( MAIN CT’S & SPACE HEATER)
6. 31053910 AUX TERMINAL BOX( NEUTRAL CT’S & EXC FLD)
7. 31063810 AUX TERMINAL BOX( WINDING RTD’S & BTD’S)
8. 31027710 COUPLING
9. TDM142565 OCC & SCC
10. TDM142566 POWER CAPABILITY CURVE
11. TDM142567 LOAD Vs EFFICIENCY CURVE

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16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.3.2 Generator Technical Specifications
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.3.3 Capability Curves
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.3.5 Terminal Box Drawing
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.3.6 Generator and Auxiliary Parameters Final Setting

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16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.3.7 Generator Current Transformer (CT) Drawing
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.3.8 Recommended Spares for Generator
1 2 3 4
FOR INFORMATION
A

D
CUSTOMER: JC CHANG

- : (mm)
E
CHECKED
- - - - ELABORATED
. -
TÍTULO
TITLE
RECOMMENDED SPARES FOR GENERATOR
JC CHANG CUSTOMER
CUSTOMER
DWG.
.
ORDER N° CH10003 FUNC.DWG. SEQUEN. 1 / 2 DWG. CH10003-GSP-001 REV. 0
SPARES FOR TD110 GENERATOR
Model TD110, 11Kv AC GENERATOR
Power Range 3.5 MW
S.I No. ITEM QTY

1 Discharge Resistor 1 Set
2 Silicon Diodes (Anode) 3 Nos
3 Silicon Diodes (Cathode) 3 Nos
4 Bearing Temperature Detector (Resistance Type) 2 Nos
5 Bearing Temperature Detector (Dial Type) 2 Nos
6 Rotating Rectifier Assembly 1 Set
7 Silver Graphite Shaft Earthing Brush 1 Nos
8 Shaft Earthing Brush Holder 1 Nos
9 PMG 1 Nos
10 NDE – Ball Bearing 1 Nos
11 DE – Roller Bearing 1 Nos
HRC Fuses – 10% of used minimum of one each type
Miniature CBs – 10% of used minimum of one each type
Indicating Lamps/Push Buttons – 10% of used minimum of one each
type
12 1 Set
Aux Contactors/Control Relay – 5% of used minimum of one each
type
Timers – 10% of used minimum of one each type
Panel Illumination Lamp – 10% of used minimum of one each type
NOTES:
Whenever spare parts are required/ordered the nameplate details shall be mentioned in the
enquiry / order. Please also mention the part no. in accordance with sectional arrangement
drawing.
Spare parts are to be stored in their original packing until they are used. If stored unpacked
care should be taken to inspect them periodically to ensure the working condition. Jebsen &
Jessen Technology will not be responsible for the safe working of the gearbox should spare
parts from sources other then Jebsen & Jessen Technology are procured.
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.4 Oil Cooler
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.4.1 Oil Cooler Operation and Maintenance Manual
Sheet No. Rev. No. Language code O & M Manual
MAZDA 1/6 0 en
OPERTATION AND MAINTENANCE MANUAL FOR HEAT

EXCHANGER:
INSTALLATION:
HEAT EXCHANGER
HEAT EXCHANGER SETTINGS

Clearance for Dismantling
For fixed tube sheet exchangers, provide sufficient clearance at one end to permit
withdrawal and replacement of the tubes and enough space beyond the head at the
opposite end, to permit removal of bonnet or channel cover.
Foundation
Foundation must be adequate so that exchanger will not settle and impose excessive
strains on the exchanger of associated base frame. Foundation bolts should be set to allow
for setting inaccuracies. In concrete footing, pipe sleeves at least one size larger than bolt
diameter slipped over the bolt and casts in place are best for this purpose, as they allow
the bolt center to be adjusted after the foundation has set.
Foundation Bolts
Foundation bolts should be loosened at one end of unit to allow free expansion of shells.
Slotted holes in supports are provided for this purpose.
Leveling
Exchangers must be set level and square so that pipe connections may be made without
forcing.
CLEANLINESS PROVISIONS
Connection Protectors
All openings should be inspected for foreign material. Protective plugs and covers should
not be removed until just prior to installation.
Dirt Removal
The entire system should be clean before starting operation. Under some conditions, the
use of strainers in the piping may be required.
Cleaning Facilities
Convenient means should be provided for cleaning the unit.
FITTING AND PIPING

By-passes valves
It may be desirable to provide valves and by-passes in the piping system to permit
inspection and repairs.
Test Connections
When not integral with the exchanger nozzles, thermometer well and pressure gauge
connections should be installed close to the exchanger in the inlet and outlet piping.
Vents
Vent valves should be provided so units can be purged to prevent vapour or gas binding.
Special consideration must be given to discharge of hazardous or toxic fluids.
MAZDA 1/6 0 en
Drains
Drains may discharge to atmosphere, if permissible or into vessel at lower pressure. They
should not be piped to a common closed manifold.
Pulsation and Vibration

In all installations, care should be taken to eliminate or minimize transmission of fluid
pulsation and mechanical vibrations to the heat exchangers.
OPERATION OF UNIT
OPERATION OF HEAT EXCHANGER

Design and operating conditions
Equipment must not be operated at conditions, which exceeds those specified in
final drawing or datasheet
Operating procedure.
Before placing any exchanger in operation, reference should be made to the
exchanger drawings, specification sheet(s) and nameplate for any special
instruction. Local safety and health regulations must be considered. Improper
start-up and
Shutdown sequences, particularly of fixed tube sheet units, may cause leaking of
tube-to-tube sheet and/or bolted flanged joints.
Start-up operation
Most exchanger placed in service by first establishing circulation of the cold
medium, followed by the gradual introduction of the hot medium. During start-
up all vent valves should be opened and left open until all passages (passes) have
been purged of air and are completely filled with fluid. Fluid must be introduced
in a manner to minimize differential expansion between the shell and tubes.
SHUT-DOWN OPERATION
The units may be shut down by first gradually stopping the flow of the hot
medium and then stopping the flow of the cold medium, the circulation of hot
medium through the exchanger should also be stopped. The unit must be
shutdown in a manner to minimize differential expansion between shell and
tubes. When shutting down the system, system should be drained completely
when there is the possibility of freezing or corrosion damage. To guard against
water hammer, condensate should be drained from steam heaters and similar
apparatus during start-up or shut down. To reduce water retention after drainage,
the tube side of exchanger should be blown out with air.
Temperature Shocks
Exchangers normally should not be subjected to abrupt temperature fluctuations.
Hot fluid must not be suddenly introduced when the unit is cold, nor cold fluid
suddenly introduced when the unit is hot.
Bolted Joints
Heat exchangers are pressure tested before leaving the Mazda’s shop in
accordance with ASME code requirements. However, normal relaxing of the
gasket joints may occur in the interval between testing in the Mazda’s shop and
installation at the jobsite. Therefore, all external bolted joints may require
retightening after installation and, if necessary, after the exchanger has reached
operating temperature.
MAZDA 1/6 0 en
MAINTENANCE
HEAT EXCHANGER
Inspection of unit
At regular intervals and as frequently as experience indicates, an examination should be
made of the interior and exterior condition of the unit. Neglect in keeping all tubes clean
may result in complete stoppage of flow through some tubes which could cause severe
thermal strains, leaking tube joints, or structural damage to other components. Sacrificial
anodes, when provided, should be inspected to determine whether they should be cleaned
or replaced.
Indication of fouling
Exchanger subject to fouling or scaling should be cleaned periodically. A light sludge or
scale coating on the tube greatly reduces it’s efficiently. A marked increase in pressure
drop and / or reduction in performance usually indicate cleaning is necessary. The unit
should first be checked for air or vapour binding to confirm that this is not the cause for
the reduction in performance. Since the difficulty of cleaning increases rapidly as the
scale thickness or deposit increases, the intervals between cleaning should not be
excessive.
Disassembly for inspection and cleaning
Before disassembly, the use must assure himself that the unit has been depressurized,
vented and drained, neutralized and /or purged of hazardous material.
Locating tube leaks

Units with removable channel cover: Remove channel covers and apply hydraulic
pressure in the shell
This procedure may be used to locate perforated or split tubes and leaking joints between
tubes and tube sheets. In most cases, the entire front face of each tube sheet will be
accessible for inspection. The point where water escapes indicates a defective tube or
tube-to-tube sheet joint.
Hydraulic test should be performed so that the temperature of the metal is over 60°F
unless the materials of construction have a lower nil-ductility transition temperature.
Cleaning tube bundles

Cleaning methods:
The heat transfer surfaces of the heat exchanger should be kept reasonably clean
to assure satisfactory performance. Convenient means for cleaning should be
made available. Heat exchangers may be cleaned by either chemical or
mechanical methods. The method selected must be the choice of the operator of
the plant and will depend on
The type of deposit and facilities available in the plant. Following are several
cleaning procedures that may be considered:
(1) Circulating hot wash oil or light distillate through tubes or shell at high velocity
may effectively remove sludge or similar soft deposits
(2) Some salt deposits may be washed out by circulating hot fresh water.
(3) Commercial cleaning compounds are available for removing sludge or scale
provided hot wash oil or eater is not available or does not give satisfactory
results.
(4) High pressure water jet cleaning.
(5) Scrapers, rotating wire brushes and other mechanical means for removing hard
scale, coke or other deposits.
(6) Employ services of a qualified organization that provides cleaning services.
MAZDA 1/6 0 en
Cleaning precautions
(1) Tubes should not be cleaned by blowing steam through individual tubes since this
heats the tube and result in severe expansion strain, deformation of the tube, or
loosening of the tube-to-tube sheet joint.
(2) When mechanically cleaning a tube bundle, care should be exercised to avoid
damaging the tubes.
(3) Cleaning compounds must be compatible with the metallurgy of the exchanger.
Tube expanding
A suitable tube expander should be used to tighten a leaking tube joint. Care
should be taken to insure that tubes are not over expanded.
Gasket replacement
Gasket and gasket surfaces should be thoroughly cleaned and should be free of
scratches and other defects. Gaskets should be properly positioned before
attempting to retighten bolts. It is recommended that when a heat exchanger is
dismantled for any cause, it be reassembled with new gaskets. This will tend to
prevent future leaks and/or damage to the gasket seating surfaces of the heat
exchanger. Composition gaskets become dried out and brittle so that they do not
always provide an effective seal contact surfaces. In so doing they are work
hardened and, if reused, may provide an imperfect seal or result in deformation
and damage to the gasket contact surfaces of the exchanger.
Bolted joints and flanges are designed for use with the particular type of gasket
specified. Substitution of a gasket of different construction or improper
dimensions may result in leakage and damage gasket surfaces. Therefore, any
gasket substitutions should be of compatible design.
Any leakage at a gasketed joint should be rectified and not permitted to persist as
it may result in damage to the gasket surfaces.
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.4.2 Oil Cooler Specifications Sheet
HEAT EXCHANGER SPECIFICATION SHEET Page 5
MKH Units
Job No.
Customer JEBSEN & JESSAN TECHNOLOGIES Reference No. CH10002/CH10003
Address MALAYSIA Proposal No. Q2360/1/9/OC
Plant Location JC CHANG : ASIA & MALAWA MILLS Date 7/26/2010 Rev 0
Service of Unit OIL COOLER Item No.
Size 387.000 x 2199.97 mm Type BEM Horz. Connected In 1 Parallel 1 Series
Surf/Unit (Gross/Eff) 22.91 / 22.38 m2 Shell/Unit 1 Surf/Shell (Gross/Eff) 22.91 / 22.38 m2
PERFORMANCE OF ONE UNIT
Fluid Allocation Shell Side Tube Side
Fluid Name ISO VG 68 COOLING WATER
Fluid Quantity, Total kg/hr 13556.0 19636.0
Vapor (In/Out)
Liquid 13556.0 13556.0 19636.0 19636.0
Steam
Water 19636.0 19636.0
Noncondensables
Temperature (In/Out) C 60.00 45.00 32.00 36.59
Specific Gravity 0.8694 0.8764 0.9956 0.9940
Viscosity cP 4.6922 5.7456 0.7644 0.6969
Molecular Weight, Vapor
Molecular Weight, Noncondensables
Specific Heat kcal/kg-C 0.4828 0.4661 0.9988 0.9986
Thermal Conductivity kcal/hr-m-C 0.1212 0.1229 0.5315 0.5369
Latent Heat kcal/kg
Inlet Pressure kgf/cm2A 15.000 3.000
Velocity m/s 0.15 0.57
Pressure Drop, Allow/Calc kgf/cm2 0.190 0.037 0.100 0.054
Fouling Resistance (min) m2-hr-C/kcal 0.000200 0.000400
Heat Exchanged kcal/hr 90010.3 MTD (Corrected) 16.8 C
Transfer Rate, Service 239.17 kcal/m2-hr-C Clean 334.18 kcal/m2-hr-C Actual 274.46 kcal/m2-hr-C
CONSTRUCTION OF ONE SHELL Sketch (Bundle/Nozzle Orientation)
Shell Side Tube Side
Design/Test Pressure kgf/cm2G 19.999 / 5.000 /
Design Temperature C 80.00 80.00 387
mm
No Passes per Shell 1 4

2200
Corrosion Allowance mm mm
Connections In mm/ Rating 1 @ 77.927/150# 1 @ 77.927/150#

Size & Out mm/ Rating 1 @ 77.927/150# 1 @ 77.927/150#
Rating Intermediate @ @
Tube No. 174 OD 19.050 mm Thk(Avg) 1.070 mm Length 2200. mm Pitch 23.810 mm Layout 30
Tube Type Plain Material SA -249 TP 304 (Welded)
Shelll-SA 516 -70 ID 387.000 mm OD mm Shell Cover-SA 106-B
Channel or Bonnet Channel Cover
Tubesheet-Stationary- SA 516 -70 Tubesheet-Floating
Floating Head Cover Impingement Plate None
Baffles-Cross- SA 516 -70 Type SINGLE-SEG. %Cut (Diam) 25.00 Spacing(c/c) 266.462 Inlet 275.210 mm
Baffles-Long- SA 5 Seal Type
Supports-Tube U-Bend Type
Bypass Seal Arrangement Tube-Tubesheet Joint EXPANDED
Expansion Joint Type
Rho-V2-Inlet Nozzle 717.28 kg/m-s2 Bundle Entrance 185.25 Bundle Exit 183.77 kg/m-s2
Gaskets-Shell Side Tube Side
-Floating Head
Code Requirements TEMA Class C
Weight/Shell 749.29 Filled with Water 1086.05 Bundle 231.36 kg
Remarks:
1) Design Code : ASME SEC. VIII-DIV. 1 ,no stamp & TEMA- C
2) NR 13, API 611, N-466 (PETROBRAS) standard are not considered.
Reprinted with Permission (v6 )
C:\Documents and Settings\admin\Desktop\kalpesh\NG OIL COOLER\NG OIL COOLER.-3.htri

16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.4.3 Oil Cooler General Arrangement Drawing
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
1.4.4 DOSH Approval - JKKP 127
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
Section 2:
Auxiliary Equipment
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.1 Auxiliary Oil Pump
D A T A S H E E T Page : 1
DESCRIPTION : GEAR PUMP

D.S. NO. : 107766 REF. : A2007420
ITEM-NO. : 330269-2 PROJECT :
REV.-DATE : PRINT DATE : 30.06.10
QUOTATION NO. : 2007420 CUSTOMER-NO. : 109226
CUSTOMER : Jebsen & Jessen
. .
gearpump R65/200 FL-Z-DB25-W-SAE3-R

acc. drawing MZ 330160-3//1
complete assembled and tested
suction connection acc. SAE3 (without counterflange)
pressure connection acc. SAE3 (without counterflange)
pump data:
pumping medium mineral oil ISO VG 68
fluid temperature in deg. C max. 80
kin. viscosity in mm²/s 68
flow discharge (approx.) in dm³/min 268
inlet pressure in bar 0 (-0,4...+0,4)
outlet pressure in bar < 18
speed in rpm 1460
sense of rotation (seen on shaft end) cw
requested driving power in kW 15 (18 bar, 500 mm²/s)
kind of shaft sealing rubber radial shaft sealing
pressure relief valve yes (with internal backflow)

opening pressure (valve) in bar 18
pressure range (valve) in bar 10...25
pump materials:
casing EN-GJL-250 (GG-25)
gearshafts 16MnCr5
elastomere NBR
further data
coating 1-component alkyd resin enamel
RAL 6011 (reseda-green)
thickness of the coat approx. 40 µm
internal pump preservation (pump) by test fluid
approx. net weight gearpump in kg 38
A.m. product is not conform to

the ATEX rules.
Technische Unterlagen PB 0-5360-433600
technical documents AN-ZU 00
Montageplattenanlage MP65.350-R65/200 FL-Z-DB-SO 26.10.2010 / DS

mounting plate unit englisch 1/1
Kunde Jebsen & Jessen

customer 16A Jalan 51A/225
46100 Petaling Jaya, Selangor
MALAYSIA
Bestellung Nr. 611850

order no.
Kennwort
code word
Auftrag Nr. 4001439/10

work no.
Inhalt:
content
Technisches Datenblatt TD 0-5360-433600

technical data sheet
Zeichnung FZ 0-5360-433600//2
drawing
Betriebs- und Wartungsanleitung Pumpe BA 2-0NNN-112
operating and maintenance instruction gear pump
Zeichnung Pumpe MZ 3-1003-330160-3//3
drawing gear pump
Kupplung KTR 40210
coupling
Betriebsanleitung Motor
operating instruction motor
Seite 1
Technical data sheet
cond. date/sign
TD 0-5360-433600 a 11.08.10/RG
order-no. : 4001439 offer 1001438 customer: Jebsen & Jessen

flow diagr.: subj.-no. :
drawing-no.: FZ 0-5360-433600//2 codeword: Auxiliary oil pump for VG-68
item piece designation type id-no. cond.
10 1 gear pump R65/200 FL-Z-DB-SO 332440-7 a

with mounted safety valve
(damped piston)
adjustment range 4…16bar
Q = 260 l/min
pö = 16 bar
n = 1465 /min, clockwise
Medium: ISO VG 68
starting viscosity: 300 mm²/s/ 15°C
20 1 flex. coupling KC080A40A42-21 262855-0
30 1 bracket PT350A160-204 439135
40 1 mounting plate MP 65.350 425356 a

41 1 seal I DP 65.350 262705-7
42 1 seal II (board) DA 350 NBR 258744-2
50 1 D.N.-motor 15 kW BG 160L-4 439793

415V AC +/- 10%, 50 Hz, IP55, Fabr. WEG
ISO Kl. F, EFF2 Improved Efficiency
standart insulation for the tropics
n = 1465 /min
type IM V1 without cover (B5)
51 1 sign for the sense of rotation 403419
52 1 name plate 281175-0
60 mechanical standards 440029 a
61 1 suction line with tube DIN 2440-DN80

diving depth: X = ca. 560 mm
62 1 pressure line (vertical) with Flange a

ANSI flange B16.5, 2/1/2", 300lbs
70 mounting for item 10-62
80 painting: 439769 a
upper- and underside priming with
SEEVENAX - Universal base 114, 30µm
finishing coat: outside incl. Motor manufacturer standard

2-K- Icosit EG 5 (SIKA)
basis polyurethane,
color RAL 5007,
thickness of layer: approx 30 µm
total thickness of layer: approx 60 µm
Rickmeier GmbH
Langenholthauser Str.20-22 . D-58802 Balve
Telefon: +49 (0)2375/927-0
Telefax: +49 (0)2375/927-26
E-mail: kontakt@rickmeier.de . www.rickmeier.de
Translation of the original mounting instructions BA2-0NNN-112
Assembly and maintenance instructions for gear pumps and units AN-ZU: 04
Series R25, R35, R45, R65, R95 Gepr.: Web/06.01.10
English name/date
Page 1 (11)
Contents Page Contents Page

Important General Information 2 5.3 Reversing the sense of rotation 7
1 Intended use 2 6 Commissioning 7
2 Flow medium 3 7 Operation / Function 8
3 Operating dangers 3 7.1 Pressure relief valve 8
3.1 Safety-conscious working 3 7.2 Dry running 8
procedure 7.3 Environmental protection 9
3.2 Dangers in case of failure to 3 8 Dismantling 9
observe safety precautions 9 Maintenance / Service 9
3.3 Using pressure relief valve 4 9.1 Gear pump 9
R25, R35 9.2 Pump unit 9
4 Transport and storage 4 10 Conversion / Changes to 10
4.1 Storage 4 gear pump
4.2 Lifting pump / pump unit 5 11 Decommissioning 10
5 Setup / Installation / Mounting 5 12 Malfunctions / Causes / 10
5.1 Suction pipe design, NPSHR value 6 Troubleshooting Measures
5.2 Sense of rotation and 6
direction of flow
Form 229589-7
English name/date
Page 2 (11)
Important General Information

In addition to the information given in these assembly instructions, the acceptance
of order and the technical documentation must also be strictly observed.
The following documents must also be strictly observed:

1. Pump unit without motor: operating instruction clutch.
2. Pump unit with motor: operating instruction motor.
3. Other instructions.
4. When using in a potentially explosive environment, the ATEX operating instructions
BA2-0NNN-113 from RICKMEIER GmbH must also be observed. The information given in
the BA2-0NNN-113 instructions regarding the use of gear pumps takes precedence over
the corresponding information in these assembly and maintenance instructions.
The documentation must always be available at the operating location of the machine so that
dangers or injuries and damage can be prevented to the greatest extent possible. For storage,
transport, commissioning, operation, maintenance / service or decommissioning, the
respectively applicable national, local and system-specific regulations must be observed.
Special designs and design variants may differ in their technical details! In case of unclear
points, it is urgently recommended that RICKMEIER be consulted with specification of the
rating plate data.
Basic Safety Rules
Installation, commissioning, operation, maintenance and decommissioning may only be carried
out by persons, who
1. have carefully read and understood the assembly and maintenance instructions.
2. have received special training for the planned work and are authorized by your company to
perform such work.
3. comply with the EC Directive 89/655/EEC Minimum Safety and Health Requirements for
the Use of Work Equipment by Workers at Work.
Information attached directly to the pump, such as the rotating direction arrow or markings
of the fluid connections must always be observed. These must always be kept in completely
legible condition.
1 Intended use
RICKMEIER gear pumps of the R25, R35, R45, R65, R95 model range must be used
exclusively for the supply lubricating media.
The gear pumps must be used exclusively within the framework of the operational limits agreed
by the contract. The data relevant for operation are fixed in the acceptance of order and/or in
the technical documentation.
Use in a potentially explosive environment is only permissible when the gear pump / pump unit
is marked accordingly!
Any use other than those agreed is regarded as being in breach of the intended use. Should
the stipulated conditions be deviated from during later operation, then this must be coordinated
with RICKMEIER, as otherwise the any and all warranty claims shall be voided.
Form 229589-7
English name/date
Page 3 (11)
2 Flow medium
As a condition for a longer service life and maximum operating safety, the flow medium is to
have lubricating properties (kinematic viscosity of the flow medium under all occurring operating
conditions always > 5 mm2/s). The soiling of the flow medium should not be greater than the
Purity Class 21/19/17 according to ISO 4406:1999. The flow medium must always be free of
hard solid particles. The percentage of undissolved gases (bubbles) in the feed stream should
not exceed 10 % by volume. Otherwise increased noise emissions can result.
3 Operating dangers
3.1 Safety-conscious working procedure
The safety instructions, the current national rules and regulations for accident prevention and
also internal working, operational and safety rules of the operator contained in these assembly
instructions must be strictly observed.
3.2 Dangers in case of failure to observe safety precautions
Failure to observe the safety precautions can result in hazards to persons, the environment and
machines. Failure to observe the safety precautions can lead to the loss of any and all warranty
claims and claims to damages.
In particular, failure to observe the precautions can, for example, result in the following hazards:
1. Endangering of persons, e.g. due to a danger of burns and poisoning
2. Leaks (e. g. of the shaft seal) of dangerous flow mediums (e. g. explosive, toxic, hot) must
be discharged so that no hazard to persons and the environment results.
Legal regulations must always be complied with.
3. If hot or cold machine parts lead to dangers, then these parts must be secured by the
customer against touching.
4. Failure of important functions of the machine / system
5. Shortening of the expected service life of the machine / system
6. Failure of specified maintenance and service methods
Never remove safety equipment or deactivate it by making modifications to the machine!
Form 229589-7
English name/date
Page 4 (11)
3.3 Using pressure relief valve R25, R35
The pressure relief valve is used to protect the pump against impermissible loads. It is set to
the required opening pressure at the factory and should only react occasionally and briefly
during operation.
R25 R35
Tightening torque [Nm] 70 100
Table 1: Tightening torques
Fig. 1: Pressure relief valve R25, R35

In the case of later pressure adjustment, the following must be observed:
1. Remove cap nut Item 4 (32 mm).
2. Loosen hexagon nut Item 6 (32 mm).
3. Make pressure setting by adjusting the spindle (slot). Caution! During the pressure
adjustment the spindle (Item 3) may only be screwed in clockwise (pressure increase), as
otherwise the dangers specified in 3.2 will occur.
The spindle is not secured against unscrewing!
4. Replace Cu sealing ring (2 each) Item 9 (DIN 7603-A21x26-Cu).
5. Tighten hexagon nut Item 6 according to Fig. 1, hold spindle at slot with screwdriver.
6. Mount cap nut Item 4 according to Fig. 1.
4 Transport and storage
Dispose of the packing material after unpacking according to the applicable legal regulations.
4.1 Storage
Always protect the pump against impairments due to moisture, dust, water and/or other
contami-nants. Store the pump in a clean, dry place (relative humidity < 70%) at temperatures
between – 25 °C and 40 °C; unpainted parts should stored with a relative humidity < 40%.
Pumps with a rotary shaft seal should be put into operation 24 months after shipping at the
latest. Storage conditions which differ from this must be agreed upon separately.
The top coating provided by RICKMEIER is a base coating which is only intended to protect
against corrosion during transport and storage. Do not damage the coating.
Form 229589-7
English name/date
Page 5 (11)
4.2 Lifting pump / pump unit
The pump must be lifted with securely attached lifting belts. The center of gravity must lie
between the belts to prevent the pump from tipping (see Fig. 2).
A suitable hoist must be used!
60° < α < 90°
Fig. 2: Transport / lifting

5 Setup / Installation / Mounting
The pump must be set up as stipulated when ordering. The drive of the gear pumps must be
adjusted to their power input.
The piping must be installed with as little tension as possible. For the suction and pressure
connections of the series with an inside thread, only screw-in parts with an exactly matching,
cylindrical thread may be used. When screwing in, make sure that the pump is not twisted. The
connections must be sealed in accordance with the operating conditions (medium, pressure,
temperature). The connection flange surfaces of the pump and the corresponding mating
surfaces may not be damaged and must be free of paint residues and other soiling.
Drive elements such as clutches and gearwheels must be fit on the pump shaft with
ISO fitting H7. These parts may not be driven on with hammer blows, as the pump can be
damaged in the process.
When aligning the pump shaft to the drive machine, the permissible differences of the clutch
may not be exceeded (see related clutch operating instructions).
Ensure even contact, good base or flange mounting and exact alignment!
For pump series without factory clutch protection, corresponding touch protection must be
provided by the customer (for example, see the Machinery Directive 2006/42/EC
Paragraph 1.3.8).
Suitable precautions must be taken against the long-term effects of dust, water and exposure to
the direct sunlight (e. g. large-area protection).
All parts which come into contact with the flow medium must be free of impurities. With hot-bent
pipes or pipes belt by welding, it is particularly important to ensure that no residues are present
in the pipes during commissioning.
Form 229589-7
English name/date
Page 6 (11)
5.1 Suction pipe design, NPSHR value
For proper operation, it is necessary that the static pressure directly at the entrance into the
pump is never less than -0.4 bar (equivalent to 0.6 bar absolute) under any operating
conditions. Deviations from this must be expressly agreed upon with RICKMEIER when placing
the order.
It is therefore advisable to calculate or measure the lowest possible static pressure at the pump
entrance during operation. When doing so, all hydraulic resistances in the planned suction pipe
must be taken into account. This is especially important when a filter is provided in the suction
pipe which can become clogged in the course of time. In this case, it is recommended that the
pump inlet pressure be monitored with a pressure measuring device as close to the pump as
possible and that regular filter maintenance is conducted.
If no measuring connection is available in the
suction pipe, the pressure gauge connection
facing the suction side can also be used for
this purpose for pumps with a pressure relief
valve. Otherwise, the suction pipe must be
absolutely leak-tight so that no air can be
aspirated.
The NPSHR value of the pumps frequently
used for comparison with the NPSHA value
of a system is provided in Fig. 3.
Fig. 3: NPSHR Density of flow medium [kg/m3]

5.2 Sense of rotation and direction of flow
Before commissioning the pump, it must be ensured that the direction of drive rotation matches
the direction of pump rotation. To check the rotating direction of the drive machine, it is practical
to detach the clutch so that the pump is not driven. If this is not possible, then at least the pipe
connections must be removed so that the pump cannot be damaged by an incorrect rotating
direction.
When checking the direction of drive rotation, a pressure buildup in the suction pipe must be
prevented (e. g. caused by an integrated non-return valve). Otherwise the shaft seal may be
damaged in the case of an incorrect rotating direction.
Form 229589-7
English name/date
Page 7 (11)
rechtsdrehend = clockwise linksdrehend = counter-clockwise
Sense of rotation, identification arrow Direction of delivery
L, R: Sense of rotation, view on shaft end: R = clockwise, L = counter-clockwise

Fig. 4: Sense of rotation and direction of flow
5.3 Reversing the sense of rotation
The pumps of the sizes R25 to R65 are designed so that the sense of rotation can be changed
later. The direction of flow is then also reversed. Prior to conversion to another sense of
rotation, and with it the reversal of the feed direction, the manufacturer must be consulted.
The direction of rotation cannot be altered late at pumps with mechanical sealing. The
rebuilding on another direction of rotation and so the reversion of the direction of flow must
occur by RICKMEIER.
6 Commissioning
Before starting up, the pump and the suction or supply pipe must be filled with the flow medium.
If the pump is installed so that the gear wheels lie above each other, a small quantity of flow
medium remains in the pump even at a standstill. As a result, the pump retains its suction
capacity for restarting even after longer standstills.
When operating two pumps in parallel which are secured against each other with non-return
valves, both pumps should be bled on the pressure side. The same applies to a pump working
against a closed system (loaded non-return valve etc.). Feeding against a closed pressure pipe
is not permitted due to possible impermissible temperature increases in the pump.
With difficult suction conditions, the pump should be installed so that the driving gear shaft and
the gear shaft are located above each other. This installation position ensures better priming
after longer standstills due to the residual oil quantity which remains in the pump. The gear
pump is prevented from running dry when a non-return valve is present in the suction pipe. This
can also be achieved by laying suction and pressure pipes on the pump in the form of a siphon.
Form 229589-7
English name/date
Page 8 (11)
7 Operation / Function
Gear pumps are rotary displacement pumps. When the gear wheels turn, the medium enclosed
in the space between the teeth is transported from the suction to the pressure side. Then the
displacement toward the pressure side is carried out by the intermeshing teeth
(see Fig. 5). The transport of the flow medium results in a pressure drop on the suction side of
the pump. The flow medium compensates this pressure drop by flowing in, maintaining the feed
process.
Suck Transport Displace

Fig. 5: Gear pump delivery principle
This process is the same for both gaseous and liquid media. As a result, the pump is capable of
bleeding the suction pipe itself until it is completely filled with liquid flow medium.
7.1 Pressure relief valve
The pressure relief valve integrated in the end cover of the pump as an option is designed as a
spring-loaded valve. It may only be used as an occasionally, briefly actuated valve for pressure
limitation. If a larger partial quantity of the flow must be drained off over larger periods, a
separate valve with a return pipe to the suction tank in the pipe (e. g. RICKMEIER valves of the
type RSn, DBV40, DBV80, DB9) or another form of pressure relief must be provided. This also
applies when the pressure pipe can become completely blocked during pump operation.
Special designs and variants may differ in their technical details.
7.2 Dry running
Dry running is always to be avoided, i. e. the pump must be filled with the flow medium before
being put into operation.
Exceptions: Dry running frequently occurs during start-up with unfilled suction pipe or during
operation when the supply of flow medium has been interrupted. Pumps wetted with flow
medium inside beforehand can be operated for up to 20 minutes under the following conditions:
1. Pump driven via clutch, i.e. free of radial forces
2. Pressure at pump inlet and outlet approximately equal
On pumps driven via a pinion, chain or belt, dry running is not permissible and must be avoided
by the operator (fill pump with flow medium prior to start-up).
Form 229589-7
English name/date
Page 9 (11)
7.3 Environmental protection
During installation work with the pump not completely drained, flow medium can get onto the
floor under the pump. The shaft seals can also show signs of wear after longer operating
periods. If the seals are not replaced in the course of maintenance work performed on
schedule, drip leaks are also possible. To prevent any possible consequential damage by the
flow medium, appropriate measure should be provided for safety's sake, e. g. a catch pan etc.
under the pump.
8 Dismantling
Depending on the flow medium, the liquid escaping can present a hazard to people and the
environment. Therefore, the required measures must be carried out in accordance with the
safety data sheets of the flow liquids. In addition, the recommendations given in 7.3 must also
be observed.
9 Maintenance / Service
9.1 Gear pump
RICKMEIER gear pumps usually require little maintenance when operated within the
permissible operating limits. If a gear pump becomes unusable as the result of wear, it must be
replaced. The installation of replacement parts generally does not restore the original
performance.
The service life of the shaft seals is mainly dependent on the manner of operation of the pump
and the purity and quality of the flow medium. As a result, in many cases no reliable prediction
as to the time of failure can be made. For pumps with shaft seals, it is therefore recommended
that they be subjected to an external visual inspection for drip leaks at regular intervals
(recommendation: after 48 hrs, then every 4,000 operating hours). If a high danger potential
exists due to the flow medium, a check should be made at shorter intervals.
When using in a potentially explosive environment, the maintenance intervals of the related
ATEX operating instructions BA2-0NNN-113 apply.
9.2 Pump unit
The maintenance of pump units also requires compliance with the maintenance intervals and
work of the clutch and the motor (see table 2).
Product Type of clutch Information to the maintenance
Unit without motor Clutch Rotex/Bowex Pump: see 9.1
Other clutches Pump: see 9.1
Unit with motor Clutch Rotex/Bowex Pump: see 9.1
Other clutches Pump: see 9.1
Table 2: Maintenance of pump units
Form 229589-7
English name/date
Page 10 (11)
10 Conversion / Changes to gear pump
Conversion of or changes to the gear pump are only permitted after consulting with
RICKMEIER. Genuine spare parts and accessories authorized by RICKMEIER help ensure
safety. The use of other parts can result in the voiding of any liability for the resulting
consequences. When ordering spare parts, please always specify the data provided on the
rating plate.
11 Decommissioning
When decommissioning the pump, it must be ensured that no pressure greater than
atmospheric pressure exists in the pump, and that the pump drive cannot start up accidentally.
In addition, the recommendations in section 7.3 must also be observed. For environmental
protection reasons, pumps/pump units may only be disposed of by licensed specialized
companies.
12 Malfunctions / Causes / Troubleshooting Measures
The following tabular overview is to be regarded as instruction to the removal for eventual
occuring troubles and their possible causes. If faults occur which are not named here, we
recommend consulting RICKMEIER. If it is necessary to remove the pump for troubleshooting,
the recommendations given in the sections 7.3, 8 and 11 must be observed.
Fault
Pressure relief valve causes noises
Insufficient feed quantity or exit
Pump does not start up, stops

Pump is loud during operation
Outlet pressure too high
Pump does not draw in
Pump does not bleed
abruptly of jams up
pressure too low
Measure
Compare sense of rotation with identification arrow on pump;

reverse motor polarity if necessary.
Check whether pump is filled with flow medium.
Connections may be leaky. Check suction pipe and shaft seal for
leaks. In case pressure relief valve existing: condition of the
sealing rings checks, renews if necessary
Pressure drop in suction pipe too great; if possible, increase line
cross-section, shorten suction pipe or raise liquid level on intake
side – if filter is installed: clean and enlarge if necessary.
Does the set opening pressure match the order data sheet?
If necessary, increase opening pressure by approx. 10 %.
Form 229589-7
English name/date
Page 11 (11)
Fault
Pressure relief valve causes noises

Insufficient feed quantity or exit
Pump does not start up, stops

Pump is loud during operation
Outlet pressure too high
Pump does not draw in
Pump does not bleed
abruptly of jams up
pressure too low
Measure
Check whether the pressure relief valve is soiled or damaged;

does valve piston move smoothly?
Bleed pump pressure side.
Check switching type, speed and current consumption of drive
motor. Compare voltage and frequency with motor rating plate.
In case of pressureless feeding of thin media, charge pump with
1-2 bar.
Has maximum permissible speed according to order data sheet
been exceeded?
When feeding media with a high vapor pressure (gasoline,
solvent, paints etc.), the medium is to flow to pump.
Avoid gas bubbles in flow media (e. g. have return pipes end
below oil level of tank).
Is motor output at least in accordance with order data sheet?
Check whether flow medium has lost lubricity due to excessively
high temperature.
Check whether relief hole from sealing chamber to suction
chamber is clogged.
Check whether viscosity of flow medium matches information on
order data sheet.
Too small a pump was chosen.
Pump piping may not be tension-free. Remove pump and check
piping.
Table 3: Troubleshooting
AN-ZU Änderungen Datum Bearb.

04 ÄM 09/014 01.12.2009 Web
Form 229589-7
KTR Kupplungstechnik KTR-N 40210 EN
ROTEX®
GmbH sheet: 1 of 21
D-48407 Rheine Operating-/Assembly instructions
edition: 16
ROTEX®
Torsionally flexible jaw-type
couplings types
No. 001 – shaft coupling,
No. 018 – DKM,
with taper clamping sleeve
and their combinations
according to Standard 94/9/EC

(ATEX 95) for finish bored, pilot
bored and unbored couplings design No. 001 – shaft coupling
design No. 018 – DKM

double-cardanic coupling
design with taper clamping sleeve
Schutzvermerk Gezeichnet: 21.05.10 Pz/Bru Ersatz für: KTR-N vom 13.10.09

ISO 16016 beachten. Geprüft: 25.05.10 Pz Ersetzt durch:
ROTEX®
GmbH sheet: 2 of 21
edition: 16
ROTEX® is a torsionally flexible jaw coupling. It is able to compensate for shaft displacement
caused by, as an example, inaccuracies in production, heat expansion, etc.
Table of Contents
1 Technical Data
2 Hints
2.1 Coupling Selection
2.2 General Hints
2.3 Safety and Advice Hints
2.4 General Hints to Danger
2.5 Proper Use
3 Storage
4 Assembly
4.1 Components of the Couplings
4.2 Hint Regarding the Finish Bore
4.3 Assembly of the Hubs
4.4 Assembly of the Taper Clamping Sleeve
4.5 Displacements - Alignment of the Couplings
4.6 Spares Inventory, Customer Service Addresses
5 Enclosure A
Hints and Instructions Regarding the Use in Hazardous Areas
5.1 Use in Hazardous Areas According to the Regulations
5.2 Control Intervals for Couplings in Hazardous Areas

5.3 Approximate Values of Wear
5.4 Permissible Coupling Materials in the Hazardous Area
5.5 Marking of Coupling for the Hazardous Area

5.6 Starting
5.7 Breakdowns, Causes and Elimination
5.8 EC Certificate of Conformity according to the EC Standards 94/9/EC
dated 23 March 1994

ROTEX®
GmbH sheet: 3 of 21
edition: 16
1 Technical Data
® ®
picture 1: ROTEX (material: Al-D) picture 2: ROTEX (material: EN-GJL-250/EN-GJS-400-15)
Table 1: material Al-D

1) 3)
Spider (component 2) Dimensions [mm]
Compo- rated torque [Nm] 2) General
Size Finish bore
nent 92 Sh A 98 Sh A 64 Sh D 4)
d (min-max) L l1; l2 E b s DH DZ DZ1 dH D;D1 N
(yellow) (red) (green)
14 1a 6 - 16 35 11 13 10 1,5 30 - - 10 30 -
1 6 - 19 32
19 10 17 - 66 25 16 12 2 41 - - 18 20
1a 19 - 24 41
1 9 - 24 40
24 35 60 - 78 30 18 14 2 56 - - 27 24
1a 22 - 28 56
1 10 - 28 48
28 95 160 - 90 35 20 15 2,5 67 - - 30 28
1a 28 - 38 67
Table 2: material EN-GJL-250 (GG 25)/EN-GJS-400-15 (GGG 40)

1) 3)
Size Finish bore
d (min-max) L l1; l2 E b s DH DZ DZ1 dH D;D1 N
Cast iron EN-GJL-250
1 12 - 40 66
114 45 37
38 1a 190 325 405 38 - 48 24 18 3 80 - - 38
78
1b 12 - 48 164 70 62
1 14 - 45 75
126 50 40
42 1a 265 450 560 42 - 55 26 20 3 95 - - 46
94
1b 14 - 55 176 75 65
1 15 - 52 85
140 56 45
48 1a 310 525 655 48 - 62 28 21 3,5 105 - - 51
104
1b 15 - 62 188 80 69
1 20 - 60 98
55 410 685 825 160 65 30 22 4 120 - - 60 52
1a 55 - 74 118
65 1 625 940 1175 22 - 70 185 75 35 26 4,5 135 - - 68 115 61
75 1 1280 1920 2400 30 - 80 210 85 40 30 5 160 - - 80 135 69
90 1 2400 3600 4500 40 - 97 245 100 45 34 5,5 200 218 230 100 160 81
Nodular iron EN-GJS-400-15
100 1 3300 4950 6185 50 - 115 270 110 50 38 6 225 246 260 113 180 89
110 1 4800 7200 9000 60 - 125 295 120 55 42 6,5 255 276 290 127 200 96
125 1 6650 10000 12500 60 - 145 340 140 60 46 7 290 315 330 147 230 112
140 1 8550 12800 16000 60 - 160 375 155 65 50 7,5 320 345 360 165 255 124
160 1 12800 19200 24000 80 - 185 425 175 75 57 9 370 400 415 190 290 140
180 1 18650 28000 35000 85 - 200 475 185 85 64 10,5 420 450 465 220 325 156
1) maximum torque of the coupling TKmax. = rated torque of the coupling TK Nenn. x 2
2) bore H7 keyway to DIN 6885 sheet 1 [JS9] with thread for setscrew
3) dimensions G and t see table 6; threads for set screws are opposite the keyway in case of material Al-D and on the keyway in case of
material EN-GJL-250/EN-GJS-400-15
4) DZ1 = internal diameter of housing

ROTEX®
GmbH sheet: 4 of 21
edition: 16
1 Technical Data
® ® 5)
picture 3: ROTEX (material: steel) picture 4: ROTEX , design DKM
Table 3: material steel

1) 3)
Size Finish bore
d (min-max) L l1; l2 E b s DH DZ DZ1 dH D N
1a 35 11
14 0 - 16 13 10 1,5 30 - - 10 30 -
1b 50 18,5
1a 66 25
19 10 17 21 0 - 25 16 12 2 40 - - 18 40 -
1b 90 37
1a 78 30
24 35 60 75 0 - 35 18 14 2 55 - - 27 55 -
1b 118 50
1a 90 35
28 95 160 200 0 - 40 20 15 2,5 65 - - 30 65 -
1b 140 60
1 114 45 70 27
38 190 325 405 0 - 48 24 18 3 80 - - 38
1b 164 70 80 -
1 126 50 85 28
42 265 450 560 0 - 55 26 20 3 95 - - 46
1b 176 75 95 -
1 140 56 95 32
48 310 525 655 0 - 62 28 21 3,5 105 - - 51
1b 188 80 105 -
1 160 65 110 37
55 410 685 825 0 - 74 30 22 4 120 - - 60
1b 210 90 120 -
1 185 75 115 47
65 625 940 1175 0 - 80 35 26 4,5 135 - - 68
1b 235 100 135 -
1 210 85 135 53
75 1280 1920 2400 0 - 95 40 30 5 160 - - 80
1b 260 110 160 -
1 245 100 160 62
90 2400 3600 4500 0 - 110 45 34 5,5 200 218 230 100
1b 295 125 200 -
Table 4: design DKM 5)

1) 3)
rated torque [Nm] General
Size Measure
92 Sh A 98 Sh A d, D, D1 LDKM l1; l2 E b s DH dH l11 l12
(yellow) (red)
19 10 17 92 25 16 12 2 40 18 10 42
24 35 60 112 30 18 14 2 55 27 16 52
28 95 160 128 35 20 15 2,5 65 30 18 58
see table 1 to 3
38 190 325 158 45 24 18 3 80 38 20 68

42 265 450 174 50 26 20 3 95 46 22 74
48 310 525 192 56 28 21 3,5 105 51 24 80
55 410 685 218 65 30 22 4 120 60 28 88
65 625 940 252 75 35 26 4,5 135 68 32 102
75 1280 1920 286 85 40 30 5 160 80 36 116
90 2400 3600 330 100 45 34 5,5 200 100 40 130
2) bore H7 keyway to DIN 6885 sheet 1 [JS9] with thread for setscrew
3) dimensions G and t see table 6; threads for set screws are opposite the keyway in case of material Al-D and on the keyway in case of
material EN-GJL-250/EN-GJS-400-15
5) Type DKM not available with DZ elements.

ROTEX®
GmbH sheet: 5 of 21
edition: 16
1 Technical Data
Coupling design:
TB1 Cam-sided screwing

TB2 Collar-sided screwing
Different combinations of types TB1 and TB2

are possible.
®
picture 5: ROTEX , design with taper clamping sleeve
Table 5: design with taper clamping sleeve

1)
Taper
Compo- rated torque [Nm] general
Size Finish bore clamping
nent 92 Sh A 98 Sh A 2)
d (min-max) L l1; l2 E b s DH DZ DZ1 dH D1 N sleeve
(yellow) (red)
24 1a 35 60 10 - 22 64 23 18 14 2 55 - - 27 - - 1008
28 1a 95 160 10 - 25 66 23 20 15 2,5 65 - - 30 - - 1108
38 1a 190 325 10 - 25 70 23 24 18 3 80 - - 38 78 15 1108
42 1a 265 450 14 - 40 78 26 26 20 3 95 - - 46 94 16 1610
48 1a 310 525 14 - 40 106 39 28 21 3,5 105 - - 51 104 28 1615
55 1a 410 685 14 - 50 96 33 30 22 4 120 - - 60 118 20 2012
65 1 625 940 14 - 50 101 33 35 26 4,5 135 - - 68 115 5 2012
75 1 1280 1920 16 - 60 130 52 40 30 5 160 - - 80 158 36 2517
90 1 2400 3600 25 - 75 149 52 45 34 5,5 200 218 230 100 160 14 3020
ROTEX® couplings with attached parts that can generate heat, sparks and static charging
(e. g. combinations with brake drums, brake disks, overload systems like torque limiters,
impellers etc.) are not allowed for the use in hazardous areas.
A separate checking must be made.

ROTEX®
GmbH sheet: 6 of 21
edition: 16
2 Hints
2.1 Coupling Selection
CAUTION!
! For a continuous and troublefree operation of the coupling it must be designed according to
the selection instructions (according to DIN 740 part 2) for the particular application
(see ROTEX® catalogue).
If the operating conditions (performance, speed, changes at engine and machine) change,
the coupling selection must be checked again.
Please make sure that the technical data regarding torque only refers to the spider. The
transmissible torque of the shaft/hub connection must be checked by the orderer, and he is
responsible for the same.
For drives with endangered torsional vibration (drives with periodical load on torsional vibration) it is necessary to
make a torsional vibration calculation to ensure a perfect selection. Typical drives with endangered torsional
vibration are e. g. drives with diesel engines, piston pumps, piston compressors etc. On request KTR makes the
coupling selection and the torsional vibration calculation.
2.2 General Hints
Please read through these mounting instructions carefully before you set the coupling into operation.
Please pay special attention to the safety instructions!
The ROTEX® coupling is suitable and approved for the use in hazardous areas. When using the
coupling in hazardous areas please observe the special hints and instructions regarding safety in
enclosure A.
The mounting instructions are part of your product. Please keep them carefully and close to the coupling.
The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH.
2.3 Safety and Advice Hints
STOP DANGER! Danger of injury to persons.
! CAUTION! Damages on the machine possible.
) ATTENTION! Pointing to important items.
PRECAUTION! Hints concerning explosion protection.

ROTEX®
GmbH sheet: 7 of 21
edition: 16
2 Hints
2.4 General Hints of Danger
DANGER!
STOP With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is protected against unintentional engagement. You can be seriously hurt
by rotating parts. Please make absolutely sure to read through and observe the following
safety instructions.
• All operations on and with the coupling have to be performed taking into account "safety first".
• Please make sure to disengage the power pack before you perform your work.
• Protect the power pack against unintentional engagement, e. g. by providing hints at the place of engagement
or removing the fuse for current supply.
• Do not touch the operation area of the coupling as long as it is in operation.
• Please protect the coupling against unintentional touch. Please provide for the necessary protection devices
and caps.
2.5 Proper Use
You may only assemble, operate and maintain the coupling if you
• carefully read through the mounting instructions and understood them
• had technical training
• are authorized to do so by your company
The coupling may only be used in accordance with the technical data (see table 1 to 5 in chapter 1).
Unauthorized modifications on the coupling design are not admissible. We do not take any warranty for resulting
damages. To further develop the product we reserve the right for technical modifications.
The ROTEX® described in here corresponds to the technical status at the time of printing of these mounting
instructions.
3 Storage
The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9
months.
The features of the coupling spiders (elastomers) remain unchanged for up to 5 years in case of favourable stock
conditions.
CAUTION!
! The storage rooms may not include any ozone-generating devices, like e. g. fluorescent
light sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Please make sure that there is no condensation. The best relative air humidity is under 65%.

ROTEX®
GmbH sheet: 8 of 21
edition: 16
4 Assembly
Basically the coupling is supplied in individual parts. Before assembly the coupling has to be controlled for
completeness.
4.1 Components of Couplings
Components of ROTEX®, shaft coupling design No. 001

Compo-
Quantity Designation
nent
1 2 hub
2 1 spider 1)
3 5 2) elements DZ 1)
setscrew
4 2
DIN EN ISO 4029
1) optionally spider or DZ elements
2) with size 180 quantity = 6
picture 6:
®
ROTEX
Components of ROTEX®, DKM 1)

Compo-
nent
1 2 hub
2 2 spider
3 1 DKM - spacer
setscrew
4 2
DIN EN ISO 4029
1) Type DKM not available with DZ elements.
®
picture 7: ROTEX DKM
Components of ROTEX®, design with taper clamping sleeve

Compo-
nent
hub for taper
TB1/TB2 2
clamping sleeve
taper clamping
1 2
sleeve
2 1 spider 1)
3 5 2) elements DZ 1) picture 8:
setscrew ROTEX
®
4 4
DIN EN ISO 4029 design with
taper
1) optionally spider or DZ elements clamping
2) with size 180 quantity = 6 sleeve
Features of the standard spiders

Spider hardness
Marking (colour)
(Shore)
92 Sh A yellow
95/98 Sh A red
natural white with green
64 Sh D-F
marking of teeth

ROTEX®
GmbH sheet: 9 of 21
edition: 16
4 Assembly
4.2 Hint Regarding the Finish Bore
DANGER!
STOP The maximum permissible bore diameters d (see
table 1 to 5 in chapter 1 - Technical Data) must not be
exceeded. If these figures are disregarded, the
coupling may tear. Rotating particles may cause
serious danger.
• Hub bores machined by the customer have to observe

concentric running or axial running, respectively (see
picture 9).
• Please make absolutely sure to observe the figures for
dmax.
• Carefully align the hubs when the finish bores are
brought in.
• Please use a setscrew according to DIN EN ISO 4029
picture 9: concentric running and axial running
with a cup point or an end plate to fasten the hubs
axially.
CAUTION!
! The orderer is responsible for all subsequently made machinings to unbored or pilot bored
and to finish machined coupling parts and spare parts. KTR does not assume any warranty
claims resulting from insufficient refinish.
PRECAUTION!
Any mechanical rework to couplings that are used in hazardous areas require an explicit
release by KTR.
The orderer must send a drawing to KTR acc. to which the manufacture must be made. KTR
checks this drawing and returns it to the orderer with approval.
KTR supplies unbored or pilot bored coupling parts and spare parts on explicit customer´s
request. These parts are additionally labelled with the symbol .
Table 6: setscrews DIN EN ISO 4029

Size 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180
Dimension G M4 M5 M5 M8 M8 M8 M8 M10 M10 M10 M12 M12 M16 M16 M20 M20 M20
Dimension t 5 10 10 15 15 20 20 20 20 25 30 30 35 40 45 50 50
Tightening
1,5 2 2 10 10 10 10 17 17 17 40 40 80 80 140 140 140
torque TA [Nm]
Table 7: Recommended combinations of fit acc. to DIN 748/1

Bore [mm]
Shaft tolerance Bore tolerance
above to
50 k6 H7
50 m6 (KTR-Standard)
If a feather key is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR-Standard)
with normal operating conditions or ISO P9 with heavy operating conditions (frequently alternating torsional
direction, shock loads, etc.). Preferably the keyway should be positioned between the cams. For the axial
fastening by set screws the tapping should be positioned on the keyway with the exception of Al-D which should
be positioned opposite to the keyway.
The transmissible torque of the shaft/hub connection must be checked by the orderer, and he is responsible for
the same.

ROTEX®
GmbH sheet: 10 of 21
edition: 16
4 Assembly
4.3 Assembly of the Hubs
)
ATTENTION!
We recommend to check bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the hubs slightly (approx. 80 °C) allows for an easier installation onto the shaft.
PRECAUTION!
Please pay attention to the danger of ignition in hazardous areas.
DANGER!
STOP Touching the heated hubs causes burns.
We would recommend to wear safety gloves.
CAUTION!
! For the assembly please make sure that the distance dimension E (see table 1 to 5) is kept
to ensure that the spider can be moved axially.
Disregarding this hint may cause damage on the coupling.
• Assemble the hubs onto the shaft of driving and driven side (see picture 10).
• Insert the spider or elements DZ into the cam section of the drive- or driven sided hub.
• Move the power packs in axial direction until the dimension E is achieved (see picture 11).
• If the power packs are already firmly assembled, axial movement of the hubs on the shafts allows for adjusting
the dimension E.
• Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with cup point (tightening torque see table 6).
)
ATTENTION!
If the shaft diameters with inserted feather key are smaller than the dimension dH (see
table 1 to 5) of the spider, one or two shaft ends may protude into the spider.
picture 10: assemby of the hubs picture 11: coupling assembly

ROTEX®
edition: 16
4 Assembly
4.4 Assembly of the Taper Clamping Sleeve
Assembly of the taper clamping sleeve:

The taper clamping sleeve has cylindrical and even pocket holes parallel to the axis. Only half to these holes are
in the material of the sleeve. The other half located at the hub has convolutions.
Push the coupling part and the taper clamping sleeve into each other, make holes onto the cover and tighten the
grub screws slightly. Push the coupling part with taper clamping sleeve onto the shaft and tighten the grub screws
until reaching the tightening torque indicated in table 8.
During the screwing process the hub is pushed onto the conical sleeve and thus the sleeve is pressed onto the
shaft. With light hammer strokes the taper clamping sleeve must be further pushed into the taper bore with a
suitable sleeve. Afterwards please tighten the grub screws again with the tightening torque indicated in table 8.
This must be made once at least.
After the drive has operated under load for a short time please check if the grub screws have untightened.
An axial fixing of the taper lock hub (coupling hub with taper clamping sleeve) is only possible by a correct
assembly.
CAUTION!
! If used in hazardous areas the grub screws must be additionally secured against self-
loosening to fix the taper clamping sleeves, e. g. glue with Loctite (medium strength).
The use of taper clamping sleeves without a feather key is not permitted in hazardous
areas.
®
picture 12: ROTEX design with taper clamping sleeve
Disassembly of the taper clamping sleeve:

By removing the grub screws you can detach the taper clamping sleeve. Afterwards, one of the grub screws is
screwed into the thread of the sleeve as forcing screw and tightened.
The detached coupling hub can be manually taken off the shaft with the taper clamping sleeve.
Table 8:
Taper Screw dimension
clamping G L SW TA Quantity Spanner
sleeve [inch] [inch] [mm] [Nm]
1008 1/4 1/2 3 5,7 2 SW 3
1108 1/4 1/2 3 5,7 2 SW 3
1610 3/8 5/8 5 20 2 SW 5
1615 3/8 5/8 5 20 2 SW 5
2012 7/16 7/8 6 31 2 SW 6
2517 1/2 7/8 6 49 2 SW 6
3020 5/8 1 1/4 8 92 2 SW 8 picture 13: withworth grub screw (BSW)

ROTEX®
edition: 16
4 Assembly
The displacement figures shown in tables 9 and 10 offer sufficient safety to compensate for environmental
influences like, for example, heat expansion or lowering of foundation.
CAUTION!
! In order to ensure a long lifetime of the coupling and to avoid dangers regarding the use in
hazardous areas, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures indicated (see tables 9 and 10). If the
figures are exceeded, the coupling is damaged.
The exacter the alignment of the coupling, the higher is its lifetime.
In case of a use in hazardous areas for the explosion group IIC (marking II 2GD c IIC T X),
only the half displacement figures (see tables 9 and 10) are permissible.
Please note:
• The displacement figures mentioned in tables 9 and 10 are maximum figures which must not arise in parallel.
If radial and angular displacement arises at the same time, the permissible displacement values may only be
used in part (see picture 15).
• Please check with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 9 and 10
can be observed.
angular displacements radial displacements axial displacements
ΔKw = L1max. - L1min. [mm] Lmax = L + ΔKa [mm]

picture 14: displacements
Example for the misalignment

picture 15:
combinations given in picture 15: combinations of
displacement
Example 1:
ΔKr = 30 %
ΔKw = 70 %
Example 2:
ΔKr = 60 %
ΔKw = 40 %
ΔKtotal = ΔKr + ΔKw ≤ 100 %

ROTEX®
edition: 16
4 Assembly
Table 9: displacement figures

ROTEX® size 14 19 24 28 38 42 48 55 65 75 90 100 110 125 140 160 180
Max. axial displacement -0,5 -0,5 -0,5 -0,7 -0,7 -1,0 -1,0 -1,0 -1,0 -1,5 -1,5 -1,5 -2,0 -2,0 -2,0 -2,5 -3,0
ΔKa [mm] +1,0 +1,2 +1,4 +1,5 +1,8 +2,0 +2,1 +2,2 +2,6 +3,0 +3,4 +3,8 +4,2 +4,6 +5,0 +5,7 +6,4
Max. radial 1500 1/min 0,17 0,20 0,22 0,25 0,28 0,32 0,36 0,38 0,42 0,48 0,50 0,52 0,55 0,60 0,62 0,64 0,68
displacement
ΔKr [mm] with 3000 1/min 0,11 0,13 0,15 0,17 0,19 0,21 0,25 0,26 0,28 0,32 0,34 0,36 0,38 - - - -
ΔKw [degree] 1,2 1,2 0,9 0,9 1,0 1,0 1,1 1,1 1,2 1,2 1,2 1,2 1,3 1,3 1,2 1,2 1,2
max. angular displacement
with n = 1500 1/min
0,67 0,82 0,85 1,05 1,35 1,70 2,00 2,30 2,70 3,30 4,30 4,80 5,60 6,50 6,60 7,60 9,00
ΔKw [mm]
ΔKw [degree] 1,1 1,1 0,8 0,8 0,8 0,8 0,9 1,0 1,0 1,0 1,1 1,1 1,1 - - - -
max. angular displacement
with n = 3000 1/min
0,62 0,70 0,75 0,84 1,10 1,40 1,60 2,00 2,30 2,90 3,80 4,20 5,00 - - - -
ΔKw [mm]
Table 10: displacement figures only for design DKM

ROTEX® size 19 24 28 38 42 48 55 65 75 90
+1,2 +1,4 +1,5 +1,8 +2,0 +2,1 +2,2 +2,6 +3,0 +3,4
Max. axial displacement ΔKa [mm]
-1,0 -1,0 -1,4 -1,4 -2,0 -2,0 -2,0 -2,0 -3,0 -3,0
Max. radial displacement 1500 1/min 0,54 0,53 0,60 0,77 0,84 1,00 1,11 1,40 1,59 1,78
ΔKr [mm] with n = 3000 1/min 0,50 0,47 0,53 0,61 0,67 0,82 1,01 1,17 1,33 1,63
ΔKw [degree] max. angular 1500 1/min 1,20 0,90 0,90 1,00 1,00 1,10 1,10 1,20 1,20 1,20
displacement with n = 3000 1/min 1,10 0,80 0,80 0,80 0,80 0,90 1,00 1,00 1,00 1,10
4.6 Spares Inventory, Customer Service Addresses
A basic requirement to guarantee the operational readiness of the coupling is a stock of the most important spare
parts on site.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage
under www.ktr.com.

ROTEX®
edition: 16
5 Enclosure A
design 001: hub / spider / hub or hub / elements DZ / hub

design 018: hub / spider / DKM spacer / spider / hub
design with taper clamping sleeve: hub / taper clamping sleeve / spider / taper clamping sleeve / hub or
hub / taper clamping sleeve / elements DZ / taper clamping sleeve / hub
(Use of taper clamping sleeve only in connetion with a feather key!)
ROTEX® DKM and ROTEX® ZS-DKM only with spacer from steel or aluminium semifinished-products with a yield
point of Rp0,2 ≥ 250 N/mm2.
5.1 Use in Hazardous Areas According to the Regulations
Conditions of operation in hazardous locations
ROTEX® couplings are suitable for the use according to EC standard 94/9/EC.
1. Industry (with the exception of mining)

• device class II of category 2 and 3 (coupling is not approved for device class 1)
• media class G (gases, fogs, steams), zone 1 and 2 (coupling is not approved for zone 0)
• media class D (dusts), zone 21 and 22 (coupling is not approved for zone 20)
• explosion class IIC (explosion class IIA and IIB are included in IIC)
Temperature class:
ambient or operating
Temperature class max. surface temperature
temperature Ta
T4, T3, T2, T1 - 30 °C to + 90 °C 1) 110 °C 2)
T5 - 30 °C to + 80 °C 100 °C
T6 - 30 °C to + 65 °C 85 °C
Explanation:
The maximum surface temperatures result from each the maximum permissible ambient or operating temperature Ta plus the
maximum temperature increase ΔT of 20 K which has to be taken into account.
1) The ambient or operating temperature Ta is limited to + 90 °C due to the permissible permanent operating temperature of
the elastomers used.
2) The maximum surface temperature of 110 °C applies for the use in locations which are potentially subject to dust
explosion, too.
2. Mining
Device class I of category M2 (coupling is not approved for device category M1).
Permissible ambient temperature - 30 °C to + 90 °C.

ROTEX®
edition: 16
5 Enclosure A
5.2 Control Intervals for Couplings in Hazardous Areas
explosion group control intervals

For couplings which are classified in category 3G or 3D the operating and assembly
instructions that are usual for standard operation apply. During the standard operation
3G which has to be subject to the analysis of danger of ignition the couplings are free from any
3D ignition source. Merely the temperature increase produced by proper heating and
depending on the coupling type has to be considered:
for ROTEX®: ΔT = 20 K
A checking of the circumferential backlash and a visual check of the flexible spider/
elements DZ must be effected after 3,000 operating hours for the first time, after 6 months
at the latest. Except for centered, stiff connecting flanges (e. g. bellhousings).
If you note an unconsiderable or no wear at the spider/elements DZ after this first
inspection, the further inspections can be effected, in case of the same operating
II 2GD c IIB
parameters, respectively after 6,000 operating hours or after 18 months at the latest.
T4, T5, T6
If you note a considerable wear during the first inspection, so that a change of the spider/
elements DZ would be recommended, please find out the cause according to the table
„Breakdowns“, as far as possible.
The maintenance intervals must be adjusted according to the changed operating
parameters.
A checking of the circumferential backlash and a visual check of the flexible spider/
elements DZ must be effected after 2,000 operating hours for the first time, after 3 months
at the latest. Except for centered, stiff connecting flanges (e. g. bellhousings).
If you note an unconsiderable or no wear at the spider/elements DZ after this first
inspection, the further inspections can be effected, in case of the same operating
II 2GD c IIC
parameters, respectively after 4,000 operating hours or after 12 months at the latest.
T4, T5, T6
If you note a considerable wear during the first inspection, so that a change of the spider/
elements DZ would be recommended, please find out the cause according to the table
„Breakdowns“, as far as possible.
The maintenance intervals must be adjusted according to the changed operating
parameters.
ROTEX® coupling
picture 17.1:
®
ROTEX
elements DZ
picture 17.2:
®
ROTEX
spider
®
picture 16: ROTEX coupling
Here the backlash between coupling cams and the flexible spider/element DZ must be checked by a feeler
gauge.
When reaching the limit of wear of max. friction, the spider/element DZ must be exchanged immediately,
independent of the inspection intervals.
ROTEX®
edition: 16
5 Enclosure A
5.3 Approximate Values of Wear
In case of a backlash of more than X mm, the flexible spider/elements DZ must be exchanged.
The reaching of the exchange values depends on the operating conditions and the existing operating parameters.
CAUTION!
! In order to ensure a long lifetime of the coupling and to avoid dangers regarding the use in
hazardous areas, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures indicated (see tables 9 and 10). If the
figures are exceeded, the coupling is damaged.
picture 18: checking of the limit of wear picture 19: wear of spider
Table 11:
ROTEX® limits of wear (friction) ROTEX® limits of wear (friction)
size Xmax. [mm] size Xmax. [mm]
9 2 65 5
14 2 75 6
19 3 90 8
24 3 100 9
28 3 110 9
38 3 125 10
42 4 140 12
48 4 160 14
55 5 180 14
5.4 Permissible Coupling Materials in the Hazardous Area
In the Explosion Groups IIA, IIB and IIC the following materials may be combined:
EN-GJL-250 (GG 25)
EN-GJS-400-15 (GGG 40)
steel
stainless steel
Semifinished products from aluminium with a magnesium part of up to 7,5 % and a yield point of
Rp0,2 ≥ 250 N/mm2 are permitted for the use in hazardous areas.
Aluminium diecast is generally excluded for hazardous areas.

ROTEX®
edition: 16
5 Enclosure A
5.5 Marking of Coupling for the Hazardous Area
Couplings for the use in hazardous areas are marked on at least one component completely and on the
remaining components at the outside diameter of the hub or on the front side with an label for the respectively
permitted conditions of use. The flexible spider or elements DZ is excluded.
For reason of the limited space only the symbol is stamped up to size 19.
Complete labelling: II 2G c IIC T6, T5 bzw. T4 - 30 °C ≤ Ta ≤ + 65°C, + 80 °C bzw. +90 °C

II 2D c T 110 °C/I M2 c - 30 °C ≤ Ta ≤ + 90 °C
Short labelling:
II 2GD c IIC T X/I M2 c X
The former marking II 2G c IIC T4/T5/T6 - 30 °C ≤ Ta ≤ + 80/60/45 °C

remains valid: II 2D c T 110 °C/I M2 c - 30 °C ≤ Ta ≤ + 80 °C
The labelling with Explosion Group llC includes the Explosion Groups llA and llB.
If the coupling part is labelled with in addition to , KTR supplied it unbored or pilot bored.
CAUTION!
! Any mechanical rework to couplings that are used in hazardous areas require an explicit
release by KTR.
The orderer must send a drawing to KTR acc. to which the manufacture must be made. KTR
checks this drawing and returns it to the orderer with approval.
5.6 Starting
Before putting the coupling into operation, check the tightness of the setscrews in the hubs, the alignment and the
distance dimension E and correct, if necessary, and also check all screw connections regarding the stipulated
tightening torques dependent on the type of coupling.
If used in hazardous areas the grub screws to fix the hub as well as all screw connections must be
additionally secured against self-loosening, e. g. glue with Loctite (medium strength).
Last but not least, the coupling protection against unintended contact must be fixed.
The cover must be electrically conductive and be included in the equipotential bonding. Bellhousings (magnesium
part below 7,5 %) made from aluminium and damping rings (NBR) can be used as connecting element between
pump and electro motor. The cover may only be taken off after having stopped the unit.
During operation, please pay attention to

• strange running noises
• occurring vibrations.
If the couplings are used in dust explosive areas and in mining the user must make sure that there is no
accumulation of dust in a critical quantity between the cover and the coupling. The coupling must no operate in
an accumulation of dust.

ROTEX®
edition: 16
5 Enclosure A
5.6 Starting
For covers with unlocked openings on the upper side no light metals may be used if the couplings are used as
appliances of appliance group ll (if possible, from stainless steel).
If the couplings are used in mining (appliance group l M2), the cover must not be made from light metal. In
addition, it must be resistant to higher mechanical loads than if it is used as appliance of appliance group ll.
The minimum distance „Sr“ between the protection device and the rotating parts must at least correspond to the
figures mentioned below.
If the protection device is used as cover, regular openings complying with the explosion protection demands can
be made that must not exceed the following dimensions:
Cover [mm]
Openings
Top side Lateral parts Distance „Sr“
Circular - max. diameter 4 8 ≥ 10
Rectangular - max. lateral length 4 8 ≥ 10
Straight or curved slot -
prohibited 8 ≥ 20
max. lateral length/height
CAUTION!
! If you note any irregularities at the coupling during operation, the drive unit must be turned
off immediately. The cause of the breakdown must be found out with the table
„Breakdowns“ and, if possible, be eliminated according to the proposals. The possible
breakdowns mentioned can be hints only. To find out the cause all operating factors and
machine components must be considered.
Coupling layer:
If coated (priming, painting etc.) couplings are used in hazardous areas, the requirements to
conductability and layer thickness must be considered. In case of paintings up to 200 µm no
electrostatic load can be expected. Multiple coatings that are thicker than 200 µm are prohibited
for explosion group llC.
The below-mentioned errors can lead to an incorrect use of the ROTEX® coupling. In addition to the stipulations
in these operating and mounting instructions please make sure to avoid these errors.
The errors listed can only be clues to search for the errors. When searching for the error the adjacent
components must be generally included.
Due to incorrect use the coupling can become a source of ignition.

EC Standard 94/9/EC requires a special care from the manufacturer and the user.
General errors incorrect use

• Important data for the coupling selection was not forwarded.
• The calculation of the shaft/hub connection was not considered.
• Coupling parts with damage occurred during transport are assembled.
• If the heated hubs are assembled, the permissible temperature is exceeded.
• The fits of the parts to be assembled are not coordinated with each other.
• Tightening torques are below/exceeded.
• Components are exchanged by mistake/put together incorrectly.
• A wrong or no spider/elements DZ is inserted into the coupling.

ROTEX®
edition: 16
5 Enclosure A
Continuation:
• No original KTR parts (purchased parts) are used.

• Old/already worn out spiders/elements DZ or spiders/elements DZ stored too long are used.
• The coupling used/the coupling protection used is not suitable for the operation in hazardous areas and does
not correspond to EC Standard 94/9/EC, respectively.
• Maintenance intervals are not observed.
danger hints for

breakdowns causes elimination
hazardous areas
1) put the unit out of operation
2) eliminate the reason for the
misalignment (e. g. loose foundation
increased temperature
bolts, break of the engine fixing, heat
the the spider surface;
misalignment expansion of unit components, change
danger of ignition by
of the assembly dimension E of the
hot surfaces
coupling)
3) checking of wear see under point
Control
change of the 1) put the unit out of operation
running noises 2) disassemble the coupling and remove
and/or occurring wear of spider,
rests of the spider
vibrations short-term torque danger of ignition due
3) check coupling parts and exchange
transmission due to to sparking
damaged coupling parts
metal contact
4) insert spider, assemble coupling parts
5) check alignment, correct if necessary
2) check alignment of coupling
loose screws for danger of ignition due
3) tighten the screws to secure the hubs
axial securement of to hot surfaces and
and secure against self-loosening
hubs sparking
Control
wear of spider, 1) put the unit out of operation
danger of ignition due
torque transmission 2) change complete coupling
to sparking
due to metal contact 3) check alignment
break of the cams
danger of ignition due 2) change complete coupling
due to high shock
to sparking 3) check alignment
energy/overload
4) find out the reason of overload
break of cam operating
2) check the operating parameters and
parameters do not
danger of ignition due select a larger coupling (consider
correspond to the
to sparking installation space)
performance of the
3) assemble new coupling size
coupling
4) check alignment
mistake in service of danger of ignition due 2) change complete coupling
the unit to sparking 3) check alignment
4) instruct and train the service staff

ROTEX®
edition: 16
5 Enclosure A
danger hints for

breakdowns causes elimination
hazardous areas
2) eliminate the reason for the
misalignment (e. g. loose foundation
increased temperature
bolts, break of the engine fixing, heat
the the spider surface;
misalignment expansion of unit components, change
danger of ignition by
of the assembly dimension E of the
hot surfaces
coupling)
Control
e. g. contact with
2) disassemble the coupling and remove
aggressive liquids/
rests of the spider
oils, ozone- danger of ignition due
3) check coupling parts and exchange
influence, too to sparking in case of
premature wear of damaged coupling parts
high/low ambient metallic contact of the
spider 4) insert spider, assemble coupling parts
temperatures etc. cams
5) check alignment, correct if necessary
effecting a physical
6) make sure that further physical changes
change of the spider
of the spider are excluded
ambient/contact rests of the spider
temperatures which 3) check coupling parts and exchange
danger of ignition due
are too high for the damaged coupling parts
to sparking in case of
spider, max. 4) insert spider, assemble coupling parts
metallic contact of the
permissible 5) check alignment, correct if necessary
cams
e. g. T4 = 6) check and regulate ambient/contact
- 30 °C/+ 90 °C temperature (eventually even
elimination by using other spider
materials)
rests of the spider
premature wear of danger of ignition due 3) check coupling parts and exchange
spider (liquefaction to sparking in case of damaged coupling parts
drive vibrations
of material inside metallic contact of the 4) insert spider, assemble coupling parts
the spider cam) cams 5) check alignment, correct if necessary
6) find out the reason for the vibrations
(eventually elimination by spider with
lower or higher shore hardness)
If you operate with a worn spider/elements DZ (see item 5.2) and the subsequent contact of metal
parts a due operation meeting the explosion protection requirements and acc. to Standard 94/9/EC
is not ensured.
)
ATTENTION!
KTR does not assume any liabilities or guarantees regarding the use of spare parts and
accessories which are not provided by KTR and for the damages resulting herefrom.

ROTEX®
edition: 16
5 Enclosure A
5.8 EC Certificate of Conformity
EC Certificate of Conformity
corresponding to EC Standard 94/9/EC dated 23 March 1994
and to the legal regulations
The manufacturer - KTR Kupplungstechnik GmbH, D-48432 Rheine - states that the
flexible ROTEX® couplings

described in these mounting instructions and explosion-proof designed correspond to Article 1 (3) b)
of Standard 94/9/EC and comply with the general Safety and Health Requirements according to
enclosure II of Standard 94/9/EC.
According to article 8 (1) of Standard 94/9/EC the technical documentation is deposited with the:
IBExU
Institut für Sicherheitstechnik GmbH
Fuchsmühlenweg 7
09599 Freiberg
Rheine, 30.09.08 i. V. i. V.
Date Reinhard Wibbeling Michael Brüning
Engineering Manager Product Manager

INSTALLATION, OPERATION AND MAINTENANCE
INSTRUCTION MANUAL FOR INDUCTION MOTORS ENGLISH
INSTRUCCIONES PARA LA INSTALACIÓN Y

MANTENIMIENTO DE MOTORES ELÉCTRICOS ESPAÑOL
BETRIEBS - UND WARTUNGSANLEITUNGEN FÜR

ELEKTROMOTOREN DEUTSCH
INSTRUCTIONS POUR INSTALLATION ET

MANUTENTION DE MOTEURS ÉLECTRIQUES FRANÇAIS
ISTRUZIONI D’USO E MANUTENZIONE

PER MOTORI ELETTRICI ITALIANO
INSTALLATIONS-OG VEDLIGEHOLDELSESVEJLEDNING
FOR ELEKTRISKE MOTORER DANSK
INSTALLATIONS- OCH UNDERHÅLLSINSTRUKTIONER

FÖR ELEKTRISKA MOTORER SVENSKA
ИНСТРУКЦИЯ ПО УСТАНОВКЕ И
ТЕХОБСЛУЖИВАНИЮ ЭЛЕКТРОМОТОРОВ PYCCKNÑ
INSTRUKCJA INSTALACJI, OBSŁUGI I EKSPLOATACJI

SILNIKÓW INDUKCYJNYCH POLSKI
MANUAL DE INSTALAÇÃO, OPERAÇÃO E MANUTENÇÃO

PARA MOTORES DE INDUÇÃO TRIFÁSICOS PORTUGUÊS
OIKOSULKUMOOTTORIEN ASENNUS-,
KÄYTTÖ- JA HUOLTO-OHJEET FINNISH
ENGLISH
INSTALLATION, OPERATION AND MAINTENANCE
INSTRUCTION MANUAL FOR INDUCTION MOTORS
04 - 15
ESPAÑOL
INSTRUCCIONES PARA LA INSTALACIÓN Y
MANTENIMIENTO DE MOTORES ELÉCTRICOS
16 - 28
ITALIANO FRANÇAIS DEUTSCH

BETRIEBS - UND WARTUNGSANLEITUNGEN FÜR
ELEKTROMOTOREN
29 - 41
INSTRUCTIONS POUR INSTALLATION ET MANUTENTION DE

MOTEURS ÉLECTRIQUES
42 - 54
ISTRUZIONI D’USO E MANUTENZIONE PER MOTORI

ELETTRICI
55 - 66
INSTALLATIONS-OG VEDLIGEHOLDELSESVEJLEDNING FOR
DANSK
ELEKTRISKE MOTORER
67 - 78
SVENSKA
INSTALLATIONS- OCH UNDERHÅLLSINSTRUKTIONER
FÖR ELEKTRISKA MOTORER
79 - 90
PYCCKNÑ
ИНСТРУКЦИЯ ПО УСТАНОВКЕ И ТЕХОБСЛУЖИВАНИЮ
ЭЛЕКТРОМОТОРОВ
91 - 104
INSTRUKCJA INSTALACJI, OBSŁUGI I EKSPLOATACJI

POLSKI
SILNIKÓW INDUKCYJNYCH
105 - 117
FINNISH PORTUGUÊS
MANUAL DE INSTALAÇÃO, OPERAÇÃO E MANUTENÇÃO

PARA MOTORES DE INDUÇÃO TRIFÁSICOS
118 - 130
OIKOSULKUMOOTTORIEN ASENNUS-, KÄYTTÖ- JA

HUOLTO-OHJEET
131 - 142

ENGLISH
INDEX
1. RECEIVING INSPECTION
2.HANDLING AND TRANSPORTATION
3. STORAGE
4. INSTALLATION
4.1 - Safety
4.2 - Operating Conditions
4.3 - Foundation
4.4 - Drain Holes
4.5 – Balance
4.6 – Alignment
4.7 - Couplings
4.8 – Electrical Connection
4.9 - Starting Methods
4.10 – Protection Device
4.11 - Start-Up
5 - MAINTENANCE
5.1 - Lubrication
5.1.1 - Machines without Grease Nipples
5.1.2 - Machines Fitted with Grease Fittings
5.1.3 - Compatibility of MOBIL Polirex EM grease with other types of grease
5.2 – Assembly and Disassembly
6 - SPARE PARTS
7 - VARIABLE FREQUENCY DRIVE MOTORS
7.1 - Standard Motors
7.2 - Inverter Duty Motors
7.3 – Bearing insulation
8 - ADDITIONAL INSTRUCTIONS
8.1 – Smoke Extraction Motors
8.2 – Hazardous Area Motors
8.2.1 General
8.2.2 Installation
8.2.3 Checking and Maintenance
8.2.4 Explosion Proof Motor Repairs
9. WARRANTY TERMS

This manual is intended to supply important topics that must be followed during
transportation, installation, operation and maintenance of WEG motors.
Therefore, we recommend reading carefully this manual before installing and
operating the motor.
To ensure physical integrity to the operation and material protection, all
ENGLISH
information included in this Manual must be strictly followed.
1. RECEIVING INSPECTION: This locking device must be

used on any further motor
When receiving the motor and anything has
transportation, even when this
been noticed, notify immediately the carrier,
means to uncouple the motor
the insurance company and WEG.
from the driven machine.
Failure in giving notice to the carrier, to the
insurance company and to WEG may result
in loosing product warranty. 3. STORAGE
If motors are not immediately installed, they
Do not remove the existing protecting must be stored in dry areas, free of dust,
grease from the shaft end, nor the stoppers vibrations, gases, corrosive smokes, under
or plugs that close the terminal box holes, constant temperature and in normal position
if any. These protection items must be kept free from other materials.
in place until the final installation has been
concluded. Motor storage temperature must remain
After being removed from the package, a between 5ºC to 60ºC, with relative humidity
complete visual inspection on the motor not exceeding 50%.
should be made:
If motors are stored for more than two years,
 Check if any damage has occurred during bearings must be replaced or the lubrication
transportation. grease must be totally removed after
 Check nameplate data. cleaning.
 Rotate the shaft by hand to make sure it is
turning freely. Single-phase motors when kept in stock for
 Make sure the motor was not exposed 2 years or more must have their capacitors
to excessive dirt and moisture during replaced (if any).
transportation and storage.
2. HANDLING AND WEG recommends to rotate the shaft (by
hands) at least once a month, and to measure
TRANSPORTATION
the insulation resistance before installing it, if
Motors must not be lifted by motors are stored for more than 6 months or
the shaft, but by the eyebolts
when subject to high humidity areas.
specific for such purpose.
If motor is fitted with space heaters, it is
recommended to switch them on during
Lifting devices, when supplied, are designed storage period if the relative humidity exceeds
only to support the motor. If the motor has 50%.
two lifting devices, then a double chain must If motor remains in stock for a long period
be used to lift it. without having the space heaters switched-
Lifting and lowering must be done gently on or when installed but not in operation,
without any shocks, to avoid bearing moisture/water inside the motor may
damage. condense. On these cases, water must be
drained by removing the threaded drain
During transportation, motors plugs. When drainage is done, switch-on the
fitted with roller or angular space heaters and make sure the motor is
contact bearings are protected completely dry, then reinstall the drain plugs
against bearing damages with a to ensure proper Degree of Protection (see
shaft locking device. figure 1).

The space heaters should NEVER be Where:
energized while motor is running. R(25°C) = insulation resistance related to
25ºC ambient temperature
K = constant value 234.5 for copper
Ta = ambient temperature where the
resistance was measured
R(Ta) = resistance value measured in
ambient temperature Ta
4. INSTALLATION
4.1 – Safety.
Drain plug position
All personnel involved with electrical installa-
tions, either handling, lifting, operation, start
up, maintenance or repair must be well in-
Figure 1 formed and updated concerning safety stan-
Drain plugs
Insulation Resistance Checking dards and principles that govern the work
and carefully follow them.
Disconnect motor from power supply
before making any insulation resistance For practical reasons, it is not possible to
measurement. include in this Manual detailed information
To avoid electric discharge risks, discharge that covers all constructive variables, nor
the terminals right after performing the covering all possible assembly, operation or
measurement. maintenance alternatives.
For this reason, the present Manual only
Measure the insulation resistance before includes required information that allows
operating the motor and/or when there is any qualified and trained personnel to carry out
sign of moisture in the winding. the work.
The resistance measured at 25ºC must be: If you still have further questions about it,
especially in reference to specific product
Ri ≥(20 x U) / (1000 + 2P) [MΩ] information, WEG is willing to provide such
(measured with a MEGGER at 500 V d.c.) information via its network of authorized ser-
where U = voltage (V); P = power (kW). vice agents and/or distributors.
In order to allow WEG to provide prompt ser-
If the insulation resistance detected is less
vice, within technical standards, the motor
than 2 M W, the winding must be dried
serial number that is available on the identifi-
according to the following procedure:
cation nameplate should be supplied.
Dismantle the motor and warm up the
Use always appropriate tools for installation
frame and stator in an oven at a minimum
and removal.
temperature of 80ºC increasing 5ºC every
hour until reaching 105ºC, remaining under Make sure that electric motors
this temperature for at least one hour. are switched off before starting
Check if the stator insulation resistance any maintenance service.
remains constant within accepted values.

If not, stator must be reimpregnated. If All rotating parts such as pulleys, couplings,
necessary, replace bearings and seals. outside fans, shaft, etc. must be protected
against accidental contacts.
Notes: Motors must be protected against unexpec-
1 - Measure the insulation resistance in ted starts.
ambient temperature. If different than 25ºC When performing any maintenance service,
it should be corrected using the following disconnect the motor from the power supply.
formula: Make sure all accessories have been swi-
R(25°C) = [( K+25 ) / ( K + Ta )] . R(Ta) tched off and disconnected.
In order to prevent from penetrating dust

and/or water inside the terminal box, cable with moisture, dirt and/or corrosive materials
glands or threaded pipe in the lead passage either in enclosed or open environments.
holes must be installed. It must be equal or
higher IP rating than the motor. 4.3 - Foundation
Lead connection insulation
ENGLISH
Motors provided with feet must be installed
inside the terminal box must be on solid foundations to avoid excessive
done with an insulating material vibrations.
compatible with motor thermal All motors must be fully fixed and aligned.
class which is shown on the The purchaser is fully responsible for the
motor nameplate. foundation.
Metal parts must be painted to avoid
If installation and safety instructions are not
corrosion.
followed accordingly, warranty may be void.
The foundation must be uniform and
4.2 - Operating Conditions
sufficiently strong to support any shock. It
must be designed in such a way to stop any
In general electric motors are designed for
vibration originated from resonance.
operation up to an altitude of 1000m above
sea level for an ambient temperature ranging
Note: Considering that rotation direction is
from -20ºC to 40ºC. Any variation is stated
important for correct operation, then check
on the nameplate.
it carefully before connecting motor to the
The recommended installation distance be-
load.
tween air inlet from the motor and the wall
should be at least ¼ of the air inlet diameter. 4.4 - Drain Holes
A person should have enough room to carry
out cleaning services. Make sure drains are placed at the lower motor
Machines that are cooled with ambient air, position when the mounting configuration
air inlet screens must be cleaned at regular differs from that specified on the motor
intervals so as to ensure free air circulation. purchase order.
Warm air can not return to the motor. 4.5 – Balance
- For vertically mounted motors with air inlet
on top, the air opening must be protected by
When special balance is
a proper cover so as to avoid dropping of
required, contact the factory.
foreign materials on the motors.
- Considering that direct sun heat causes
increase in temperature, externally installed All motors are dynamically balanced at the
motors should be always protected against factory with half key.
weathering.
Transmission elements such as pulleys, cou-
Compare the current, voltage, plings etc must be dynamically balanced with
frequency, speed, output and half key before installation.
other values required by the
application with motor nameplate Use always appropriate tools for installation
information. and removal.
ODP MOTORS – Open motors (IP21, IP23) 4.6 – Alignment
are machines designed for operation in clean, Align the shaft ends and use
dry areas, with enough air circulation for flexible coupling, whenever
proper cooling. These motors should never possible.
be used in areas with flammable materials.
Open motors may cause sparks and release Make sure that the motor mounting devices
cast particles under any eventual insulation do not allow modifications on the alignment
failure (short-circuit). and further damages to the bearings.
TEFC MOTORS – Totally enclosed motors When assembling a coupling, make sure to
are machines suitable to operate in areas use suitable equipment and tools to protect

the bearings. duly trained as well as laser equipment to
Suitable assembly of coupling: make motor and driven machine alignment/
Specially in cases of direct couplings, motor leveling.
shaft must be aligned axially and radially with
the driven machine shaft. Expansion effect of the components may
change the alignment/leveling conditions
Incorrect alignment can lead to bearing during motor operation.
damage, vibrations or even cause shaft
rupture. 4.7 - Couplings
Correct alignment can be ensured with the
use of dial gauges, as shown in figures 4.6.1, When using pulley and belt/chain drive
(coupling), follow the instruction given
4.6.2 and 4.6.3.
below:
If considering a complete shaft rotation,
 Remove shaft-locking device (if any) before
misalignment should not exceed 0.05 mm.
installing the motor.
Belts must be tighten just enough to avoid

slippage when running, according to the
specifications stated on the belt supplier
recommendation.
To make the installation of the pulley on the

shaft easier, it is recommended to heat up
the pulley at 80°C and have it mounted at
Fig. 4.6.1 - Axial reading (parallelism) hot, using suitable tools.
To avoid bearing and shaft end damage,

assembly and disassembly the pulleys must
be made with suitable tools.
While assembly and disassembly a pulley,

never make pressure or knocks on the
bearings.
Always use flexible couplings; rigid couplings

require special bearing arrangement as well
as axial and radial alignment of the shafts.
WARNING:
Fig. 4.6.2 – Radial reading (concentricity) Excessive belt/chain tension will
damage the bearings and lead to a
probable shaft rupture.
Couplings used must be suitable to

withstand radial and axial vibrations during
operation. Special care must be taken to
avoid that the allowable load and speed
limit values showing in the catalogs are not
exceeded.
4.8 – Electrical Connection
Fig. 4.6.3 – Axial and radial reading combined Make sure the motor is connected to the
correct power supply.
The axial alignment (“E” dimension) between
Cable gauges and protection devices must
the couplings must be 3mm minimum to
be designed based on motor rated current.
compensate the thermal shaft dilation.
If required, WEG can offer its personnel

Voltage may be connected at motor Rotation direction is clockwise when motor is
~ standstill inside the terminal box for
heating elements or direct winding
viewed from Drive Endshield side and if the
phases are connected according to sequence
heating. L1, L2, L3. This phase sequence and power
system must be positive.
ENGLISH
The capacitor on single-phase
motors can retain a charge which
~ appears across the motor terminals,
To change the rotation direction, reverse two
of the connecting leads.
even when the motor has reached
standstill condition. So, avoid Note: For single-phase motor connections,
touching them at such condition. please check the motor nameplate.
A wrong connection can The connection to the power
burn out the motor. supply must be done by qualified
personnel and with full attention
to assure safe and permanent
Voltage and connection are indicated on the
connection. after connecting the
motor nameplate according to IEC 60034-1.
motor, check for any strange
The acceptable voltage variation is ±5% and
body inside the terminal box. the
the acceptable frequency variation is ±2%,
cable inlets not in use must be
according Zone A - IEC
closed.
60034-1 Standard.
Note: For rated voltage range (multivoltage), Before energizing the terminals,
check if the grounding is made
the acceptable variation is ± 5%.
according to the applicable
standards. this is essential to
4.9 - Starting Methods
avoid accidents.
The motor is rather started through direct
starting. In case this is not possible, use 4.10 – Protection Device
compatible start methods to the motor load
and voltage. When the motor is supplied with protective
When applying reduced voltage starting me- or monitor temperature device such
thod, remember that the starting torque will as thermostats, thermistors, thermal
also reduce. protector etc, connect their terminals to the
corresponding devices on the control panel.
Possible motor Connections: If this procedure is not followed accordingly,
warranty will be void.
 3 leads single voltage and 9 leads dual vol-
Do not change protection devices settings as
tage motors can be started as follows:
they may not operate.
- Full Voltage Direct online
- Auto-Transformer starting Protection Device Diagram
- Electronic Soft-Starting
- VFD Starting – subject to verification and
application analysis.
- Series - Parallel starting (only for 9 leads) Overtemperature
Protected motor
 6 leads single and dual voltage motors with thermostats
and 12 leads dual voltage motors can be
connected as follows: L1 L2 L3
- Full Voltage Direct online Stop switch
- WYE/DELTA starting
- Auto-Transformer starting RATED CURRENT
VOLTAGE(V) (A)
- Electronic Soft-Starting 3x 110-120 3.00
220-240 1.50
- VFD Starting – subject to verification and 440-480 0.75
550-600 0.60
application analysis. THERMOSTATS LEADS
- Series - Parallel starting (only for 12 leads)

 Check bearing condition and pay attention
to: Any excessive noise, vibration, bearing
Overtemperature temperature and grease condition.
Protected motor  When a change, under normal conditions
with thermistors is detected, check the motor and replace
required parts.
L1 L2 L3
do not reuse damaged or worn
parts. replace them by new ones
supplied by the factory.
3x Periodical inspection depends on motor type

RELEASE DEVICE and on application conditions.
THERMISTORS LEADS
5.1 – Lubrication.
4.11 - Start-Up follow regreasing intervals. this
is fundamental for proper motor
If the motor is running bare operation.
shaft, the key must be fastened
or removed before starting. 5.1.1 - Machines without Grease Nipples
Motors up to frame size 200 are normally
a) The motor must start and operate smoothly. fitted without grease fittings. In these
In case this does not occur, turn it off and cases the regreasing shall be done during
check all connections and the mounting preventive maintenance service paying
before starting it again. attention to the following aspects:
 Take motor apart carefully.
b) In case there is excessive vibration, check  Take all the grease out.
if the fixing screws are correctly fastened.  Wash the bearing with kerosene or diesel.
Check also if the vibration comes from a  Dry the bearings.
neighbor machine. Periodical vibration check  Regrease the bearing immediately.
must be done.
5.1.2 – Motors Fitted with Grease Fitting
c) Run the motor under rated load for a short It is strongly recommended to grease the
period of time and compare if the running machine while running. This allows the
current is in accordance to the nameplate grease renewal in the bearing housing.
current. When this is not possible due to rotating
parts by the grease device (pulleys, bushing,
5 - MAINTENANCE etc) that offer some risk to physical integrity
of the operator, proceed as follows:
Any service in electric machines should only  Turn off the motor
be carried out when it is completely stopped  Clean the area near the grease nipple.
and all phases disconnected from the power  Put approximately half of the total grease
supply. and run the motor for 1 minute at full speed.
Then turn off the motor and pump in the rest
of the grease.
WARNING:
 The injection of all the grease with the
safety check list
motor in standstill can make the grease
penetrate into the motor, through the bearing
General Inspection housing inner seal.
 Check motor periodically. Inspections intervals depend on motor type
 Keep motor clean and ensure free air flow. and on application conditions.
 Check seals and replace them, if required.
use only manual grease gun for
 Check connections as well as supporting
lubrication.
screws.
10
TABLE 1 - BALL BEARINGS - Series 62/63
Relubrication intervals (running hours – horizontal position)
62 Series
II pole IV pole VI pole VIII pole X pole XII pole Grease
Bearing
60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz 60Hz 50Hz (g)
ENGLISH
6209 18400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 9
6211 14200 16500 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 11
6212 12100 14400 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
63 Series
II pole IV pole VI pole VIII pole X pole XII pole Grease
Bearing
6309 15700 18100 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
6311 11500 13700 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
6312 9800 11900 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
6314 3600 4500 9700 11600 14200 16400 17300 19700 19700 20000 20000 20000 27
6316 - - 8500 10400 12800 14900 15900 18700 18700 20000 20000 20000 34
6319 - - 7000 9000 11000 13000 14000 17400 17400 18600 18600 20000 45
6322 - - 5100 7200 9200 10800 11800 15100 15100 15500 15500 19300 60
TABLE 2 - ROLLER BEARINGS - NU 3 Series

Relubrication intervals (running hours – horizontal position)
II pole IV pole VI pole VIII pole X pole XII Pole Grease
Bearing
NU 309 9800 13300 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 13
NU 311 6400 9200 19100 20000 20000 20000 20000 20000 20000 20000 20000 20000 18
NU 312 5100 7600 17200 20000 20000 20000 20000 20000 20000 20000 20000 20000 21
NU 314 1600 2500 7100 8900 11000 13100 15100 16900 16900 19300 19300 20000 27
NU 316 - - 6000 7600 9500 11600 13800 15500 15500 17800 17800 20000 34
NU 319 - - 4700 6000 7600 9800 12200 13700 13700 15700 15700 20000 45
NU 322 - - 3300 4400 5900 7800 10700 11500 11500 13400 13400 17300 60
NU 324 - - 2400 3500 5000 6600 10000 10200 10200 12100 12100 15000 72
Notes:
The tables above are specifically intended of grease and relubrication intervals is given
for relubrification with MOBIL Polyrex EM on an nameplate attached to the motor.
grease and bearing absolute operating
temperature of: We recommended to use ball
 70ºC (158ºF) for 160 to 200 frame size bearings for motors directly
motors coupled to the load
 85ºC (185ºF) for 225 to 355 frame size
motors
WARNING:
For every 15ºC (59ºF) above these limits,
Excess of grease can cause
relubrification intervals must be reduced by
bearing overheating resulting
half. Shielded bearing (ZZ) are lubricated for
in complete damage.
bearing life as long are they operate under
normal conditions and temperature of 70ºC 5.1.3 - Compatibility of MOBIL Polirex EM
(158ºF). grease with other types of grease:
 Relubrication periods given above are for
those cases applying MOBIL Polyrex ® EM Containing polyurea thickener and mineral oil,
grease. the MOBIL Polyrex EM grease is compatible
 When motors are used on the vertical with other types of grease that contain:
position, their relubrication intervals are
reduced by half if compared to horizontal  Lithium base or complex of lithium or
position motors. polyurea and highly refined mineral oil.
 On applications with high or low  Inhibitor additive against corrosion, rust
temperatures, speed variation etc., the type and anti-oxidant additive.
11
Note: Before installing a new bearing it is required
 Although MOBIL Polyrex EM is compatible to check the shaft fitting for any sharp edge
with the types of grease given above, we do or strike signals.
not recommend mixing it with any other types
of grease. For bearing assembly, warm their inner parts
 If you intend to use a type of grease with suitable equipment – inductive process
different than those recommended above, – or use suitable tools.
first contact WEG.
Before using standard motors 6 - SPARE PARTS
in specific areas or on special
applications, first contact the When ordering spare parts, please specify
grease manufacturer or weg the full type designation and product code
5.2 Assembly and Disassembly as stated on the motor nameplate. Please
also inform the motor serial number stated
Disassembly and assembly must be done by on the nameplate.
qualified personnel using only suitable tools
and appropriate methods. 7 - VARIABLE FREQUENCY DRIVE
The bearing extractor grips must be applied MOTORS
over the side face of the inner ring to be
disassembled or over an adjacent part. 7.1 - Standard Motors Line
It is essential to assemble bearings under
Motors with voltages up to 575V and fed by
clean conditions to ensure good operation
VFD do not require filters if follow the criteria
and to avoid damages. New bearings shall
below:
only be taken out from their packages when
mounting them.
(*) Informed by the drive manufacturer. * Other frame sizes, under request.
Note:
7.2 - Inverter Duty Motors Line
1) Nameplate showing voltage 380-
415V/660-690V – 50Hz and 440-480 – 60Hz, Motors with voltages above 575V and equal
and fed by VFD on voltage 660-690V – 50Hz or below 690V and fed by VFD do not require
or 480V – 60Hz require filters. filters when following the criteria below:
TECHNICAL CRITERIA FOR VFD APPLICATION

Insulation dV/dt Rise Time(*)
Rated Voltage Voltage Spikes MTBP(*)
System inverter inverter
motor terminals Minimum Time
terminals terminals
(maximum) Between Pulse
(maximum) (minimum)
Reinforced
575V Vrated 690V 2140V 7800 V/ s 0,1 s 6 s
Insulation
(*) Informed by the drive manufacturer.  Check power supply voltage of the forced
cooling set.
12
7.3– Bearing insulation: 8.2 Hazardous area motors
Inverter Duty Motors Line in frame sizes 8.2.1 General
315S/M and 355M/L* are supplied with
Besides the recommendations given above,
ground system between the shaft and frame
these recommendations must be also
ENGLISH
on D.E. Also, on request can be supplied
followed.
with insulated bearings.
Hazardous area motors are manufactured
For other lines, in frame sizes 315S/M and according to specific standards for such
355M/L* when used with VFD’s, it is required environments.
ground system between the shaft and frame Motors supplied for hazardous area (classified
or insulated bearings. areas) must be installed in areas that comply
with those specified on the motor nameplate.
(*) Other frame sizes, under request.
Notes:
8 - ADDITIONAL INSTRUCTIONS - Motors of Zone 1 are also suitable for Zone 2.
8.1 - Smoke extraction motors - Motors of the group IIB are suitable also for
the group IIA.
Due to their application, Smoke Extraction - Motors of the group II or IIC are suitable also
Motors require the following additional for the groups IIA and IIB.
operating instructions: - Motors of a given class of temperature are
suitable also for combustible environments of
- Ensure that the motor temperature class,
a greater class of temperature (example, T4
indicated on the identification nameplate,
motors are suitable for environments of class
matches with the maximum operating
T3, T2, T1).
temperature.
- Install non-ventilated motors right on the 8.2.2 Installation
air flow of the cooling fan. Self-ventilated
motors can be installed out of the air flow. A complete installation must follow procedures
- Bearings of Smoke Extraction Motors given by local legislation in effect.
must be relubricated with Krytox GPL 226 The installation of hazardous
grease (special grease for Smoke Extraction area motors must be carried out
Motors). The relubrication intervals are by skilled people.
5 times higher (limiting on 20.000 hours)
as those applied to MOBIL Polyrex® EM The specification of the motor
grease, specified on table 1 and 2. After installation site is for customer’s
20.000 accumulated running hours the responsibility, who will also
bearings must be replace. determine the environment
- The amount of grease for Krytox GPL characteristics.
226 is the double of the values indicated to
MOBIL Polyrex® EM on the table 1 and 2. When cable entrance is made by a cable
- Provide a control system to switch-off gland, this must be suitable to the unit and
motor thermal protection devices during to the type of cable; the cable gland has to
Smoke Extract Duty. be assembled, completely screwed in order
- If the motor at normal condition (40°C to get the necessary pressure on the sealing
ambient) is driven by Inverter (VFD), at rings, so as to:
Smoke Extraction Duty it must be connected - Avoid transmission of mechanical vibrations
direct on line. to the motor terminals.
- The lifetime of the winding is 40.000 hours. - Guarantee mechanical protection “IP” to the
Change the whole motor when the winding terminal box.
has been use for this time.
- Every time a motor is used for Smoke 8.2.3 Checking and maintenance
Extract Duty, this motor must be replaced Maintenance must be carried out by repair
as it should be used only once under such shops duly authorized and accredited by
condition. WEG.
13
Repair shops and people without WEG’s they can be oiled by means of a thin coat of
authorization who will perform any service silicon grease.
on hazardous area motors will be fully  Check if all components are free of edges,
responsible for such service as well as for any knocks or dirt.
consequential damage.  Make sure all parts are in perfect
conditions.
When performing maintenance, installation or  Lubricate the surfaces of the endshield
relubrication, follow these instructions: fittings with protective oil to make the
 Electric connections must be correctly assembly easier.
locked to avoid resistance-increases, with  Use only rubber hammer to fit the parts.
consequent contact overheating.  Check correct bolt fastening.
 Insulation air-distance and surface-  Use clearance calibrator for correct
distance between conductors, required by connection Terminal box fitting (less than
the Standards, must be respected. 0.05mm).
 All screws, used to assemble motor
parts and terminal box, must be completely 8.2.4 Explosion proof motor repairs
screwed.
Repair of parts, directly involved in the
 Seals and components replacement for
protection against risk of an explosion, must
cable entrance would be made using spare
be done without any modification to the
parts, supplied from the manufacturer, in order
original motor design.
to guarantee the original type of protection.
 Explosion Proof motors joint surfaces have After the repair, these parts must be
not to be machined and it is not allowed to submitted to a check and test control and
insert, between them, any kind of seals, not when concluded, the repair shop must issue
foreseen or supplied by the manufacturer. a statement about all operations performed
Joint surfaces have just to be cleaned and, in on a specific motor.
order to avoid corrosion or water penetration;
9. WARRANTY TERMS
WEG warrants its products against defects in workmanship and materials for eighteen (18)
months from the invoice date issued by the factory, authorized distributor or agent limited to
twenty four (24) months from manufacturing date independent of installation date as long as
the following items are fulfilled accordingly:
- Proper transportation, handling and storage;
- Correct installation based on the specified ambient environmental conditions;
- Operation under motor capacity limits;
- Observation of the periodical maintenance services;
- Repair and/or replacement effected only by personnel duly authorized in writing by WEG;
- The failed product be available to the supplier and/or repair shop for a required period to
detect the cause of the failure and corresponding repair;
- Immediate notice by the purchaser about failures occurred and that these are accepted by
WEG as manufacturing defects.
This warranty does not include disassembly services at the purchaser facilities, transportation
costs with product, tickets, accommodation and meals for technical personnel when
requested by the customer.
The warranty service will be only carried out at WEG Authorized Repair Shops or at WEG’s
facilities.
Components whose useful life, under normal use, is shorter than the warranty period are not
covered by these warranty terms.
The repair and/or replacement of parts or components, when affected by WEG and/or any
WEG Authorized Repair Shop, will not give warranty extension.
This constitutes WEG’s only warranty in connection with this sale and the company will have
no obligation or liability whatsoever to people, third parties, other equipment or installations,
including without limitation, any claims for consequential damages or labor costs.
14
DECLARATION OF CONFORMITY
Manufacturer’s name and WEG EQUIPAMENTOS ELÉTRICOS S.A. - MOTORES
Address: Av. Prefeito Waldemar Grubba, 3000
89256-900 Jaraguá do Sul –SC - Brazil
ENGLISH
We declare under sole responsibility that the products:
* Single- or three-phase induction motors (cast iron frame)
IEC frame 63 up to 355M/L
* Single- or three-phase induction motors (aluminum frame)
IEC frame 63 up to 132M
* Single- or three-phase induction motors (cast iron frame)
NEMA frames 143 up to 587 and 56
to which this declaration relates are in conformity with the following standards:
* IEC 60034-1/2 / 2A/5/6/7/8/9/11/12/14
* IEC 60072 - 1/2
European Standard German Standard VDE-Classification.
EN 55014-1:1993+A1:1997+A2:1999 DIN EN 55014-1:1999-10 VDE 0875 Part 14-1:1999-
10
EN 61000-6-2:1999 DIN EN 61000-6-2:2000-03 VDE 0839 Part 6-2:2000-03
EN 61000-3-2:1995+Corr.:1997+A1:1998 + A2:1998 DIN EN 61000-3-2:1998-10
VDE 0838 Part 2:1998-10
EN 61000-3-2:1995/A14:2000 DIN EN 61000-3-2/A14:2001-01 VDE 0838 Part 2/A14:2001-
01
Designation:
The motors are provided with a CE mark, since January 1st, 1996.
By design, the motors, considered as components, comply with the requirements of following
European Directives:
Low Voltage Directive 73/23/EEC from February 19th, 1973, amended by Directive 93/68/EEC
of July 22nd, 1993,
EMC Directive 89/336/EEC from May 3rd, 1989, including amendments, regarding to the
intrinsic characteristics to emission and immunity levels of Electromagnetic Compatibility
(EMC),
Machinery Directive 89/392/EEC from June 14th, 1989, amended by 91/368/EEC, 93/44/
EEC and 93/68/EEC, in accordance with article 4(2) and annex IIB, Paragraph B, provided
the motors are installed according to our Installation and Maintenance Instructions. The
above mentioned directives were combined, without deviation, in one document as Directive
98/37/EC from June 22nd, 1998. The Directive 98/37/EC cancels and replaces these old
Directives.
Certificate of Incorporation:
The above products cannot be put into service until the machinery into which they are
incorporated has been declared to be in conformity with the Machinery Directive (89/392/
EEC).
The Safety Notices in the product documents and the applicable installation specification (for
instance EN 60204) must be followed.
Jaraguá do Sul, June 16th, 2006
Siegfried Kreutzfeld
Engineering Director
15
WEG EXPORTADORA S.A.
Av. Pref Waldemar Grubba, 3000
89256-900 Jaraguá do Sul, SC – Brazil
phone: +55 47 3372-4002 - fax: +55 47 3372-4060
www.weg.net
FOR FUTHER INFORMATION PLEASE CONTACT YOUR NEAREST SALES OFFICE
No.: 1
1 Date: 9/24/2010 4:09:38 AM
Customer : 1
TECHNICAL PROPOSAL
Three-phase induction motor - Squirrel cage rotor
Product line : W21 - Cast Iron Frame - EFF2 Improved Efficiency
Catalog Number :
List Price : $
Notes:
W21 - Cast Iron Frame - EFF2 Improved Efficiency
Performed by: Checked:

1 1
No.: 1
1 Date: 9/24/2010 4:09:38 AM
DATA SHEET
Customer : 1
Frame : 160L
Output : 15 kW
Frequency : 50 Hz
Poles : 4
Full load speed : 1465
Slip : 2.33 %
Voltage : 415 V
Rated current : 28.4 A
Locked rotor current : 165 A
Locked rotor current (Il/In) : 5.8
No-load current : 14.0 A
Full load torque : 9.97 kgfm
Locked rotor torque : 240 %
Breakdown torque : 260 %
Design : N
Insulation class : F
Temperature rise : 80 K
Locked rotor time : 12 s (hot)
Service factor : 1.00
Duty cycle : S1
Ambient temperature : -20°C - +40°C
Altitude : 1000 m
Degree of Protection : IP55
Approximate weight : 121 kg
Moment of inertia : 0.10539 kgm²
Noise level : 67 dB(A)
D.E. N.D.E. Load Power factor Efficiency (%)

Bearings 6309 C3 6209 Z-C3 100% 0.82 89.0
Regreasing interval 20000 h 20000 h 75% 0.75 88.5
Grease amount 13 g 9g 50% 0.64 87.0
Notes:
Efficiencies according to the indirect method of IEC 60034-2-1:2007 with stray load losses determined from
measurement.

1 1
No.: 1
1 Date: 9/24/2010 4:09:38 AM
PERFORMANCE CURVES RELATED TO RATED OUTPUT

100 1.0 0.0
C - Slip
C
90 0.9 1.0
A
80 0.8 2.0
70 0.7 3.0
60 0.6 4.0
B
50 0.5 5.0
D - Current at 415V (A)

40 0.4 40
30
A - Efficiency (%)
B - Power factor
D 20
10
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Percent of rated output (%)
Customer : 1
Output : 15 kW Locked rotor current (Il/In) : 5.8

Frame : 160L Duty cycle : S1
Full load speed : 1465 Service factor : 1.00
Frequency : 50 Hz Design : N
Voltage : 415 V Locked rotor torque : 240 %
Insulation class : F Breakdown torque : 260 %
Notes:

1 1
No.: 1
1 Date: 9/24/2010 4:09:38 AM
CHARACTERISTIC CURVES RELATED TO SPEED

5.0 10.0
B - Current related to rated current (I/In)

4.5 9.0
4.0 8.0
A - Torque related to rated torque (C/Cn)
3.5 7.0
3.0 B 6.0
A
2.5 5.0
2.0 4.0
1.5 3.0
1.0 2.0
0.5 1.0
0.0 0.0
0 10 20 30 40 50 60 70 80 90 100
Speed related to rated speed (%)
Customer : 1
Output : 15 kW Locked rotor current (Il/In) : 5.8

Frame : 160L Duty cycle : S1
Full load speed : 1465 Service factor : 1.00
Frequency : 50 Hz Design : N
Voltage : 415 V Locked rotor torque : 240 %
Insulation class : F Breakdown torque : 260 %
Notes:

1 1
1 2 3 4 5 6 7 8
Notes:
E
A AA AB AC AD Performed by: 1
254 64 308 312 255
B BA BB C CA Checked: 1
254 65 298 108 174
D E ES F G Customer: 1
42k6 110 80 12 37
GD DA EA TS FA W21 - Cast Iron Frame - EFF2 Improved Efficiency
8 42k6 110 80 12
F GB GF H HA HC
37 8 160 22 317
HD K L LC S1
370 14.5 642 756 2XPG 29 Three-phase induction motor 9/24/2010 4:09:38 AM
d1
DM16
d2
DM16
Frame 160L - IP55 1
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.2 High Speed Coupling
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.3 Low Speed Coupling
Type G20 Standard Flanged Sleeve
Double Engagement/Dimensions — Millimeters
MIN IMU M CL EAR AN CE R EQ U IR ED FO R AL IGN IN G
M M
GASK ET
GAP
C C
D
F
A
H H
L U BR ICATE
F or S iz es 1010G th ru 1055G , Ty p e
J J TH R U SL EEV E G 10 S h rouded B olts furnish ed
B only w h en sp ec ified on order.
Torque Allow Max Min Cplg Wt With Lube DIMENSIONS — Millimeters

SIZE No Bore-kg SIZE
H Rating Speed Bore Bore Wt H
(Nm) † rpm ‡ (mm) l (mm) n (kg) A B C D F H J M Gap
G10 G20
1010G 1 140 8000 50 13 4,08 4,54 0,0408 115,9 88,9 42,9 68,6 83,8 14,0 38,9 51 3 1010G
1015G 2 350 6500 65 20 7,71 9,07 0,0726 152,4 101,6 49,3 86,4 105,2 19,0 47,8 61 3 1015G
1020G 4 270 5600 78 26 13,6 15,9 0,113 177,8 127,0 62,0 105,2 126,5 19,0 59,4 77 3 1020G
1025G 7 470 5000 98 32 24,9 29,5 0,2127 212,7 158,9 77,0 130,6 154,9 21,8 71,6 92 5 1025G
1030G 12 100 4400 111 39 38,6 43,1 0,363 239,7 187,4 91,2 152,4 180,3 21,8 83,8 107 5 1030G
1035G 18 500 3900 134 51 61,2 68,0 0,544 279,4 218,9 106,4 177,8 211,3 28,4 97,5 130 6 1035G
1040G 30 600 3600 160 64 88,5 97,5 0,907 317,5 247,3 120,6 209,6 245,4 28,4 111,3 145 6 1040G
1045G 42 000 3200 183 77 127 136 1,04 346,1 277,7 134,9 235,0 274,1 28,4 122,9 166 8 1045G
1050G 56 600 2900 200 89 177 191 1,77 388,9 314,3 153,2 254,0 305,8 38,1 140,7 183 8 1050G
1055G 74 000 2650 220 102 238 249 2,22 425,4 344,3 168,1 279,4 334,3 38,1 158,0 204 8 1055G
1060G 90 400 2450 244 115 ... 306 3,18 457,2 384,4 188,2 304,8 366,0 25,4 169,2 229 8 1060G
1070G 135 000 2150 289 127 ... 485 4,35 527,0 451,5 220,7 355,6 424,9 28,4 195,6 267 10 1070G
H S ee P a g e 15 for G enera l Inform a tion a nd oth er Referenc e N otes.
TABLE 7 — Limited End Float &

Standard Gap Disc
Dimensions AX IAL LY
MO V ABL E
DIMENSIONS — Millimeters GAP SH AFT R O TO R EN D FL O AT
DISC (O N E-H AL F FL O AT EACH SIDE)
SIZE End Gap Disc Q
B Gap
Float t Thic kness Dia
1010G 90,9 2,39 4 75 5
1015G 103,6 2,39 4 94 5
1020G 129,8 2,39 5 114 6
1025G 162,3 2,39 7 141 8
1030G 191,5 2,39 8 165 9
1035G 223,3 4,78 8 192 10 AX IAL LY
FIX ED H U B
1040G 251,7 4,78 8 227 10 SH AFT GAP
1045G 283,2 4,78 11 253 13
1050G 319,8 4,78 11 278 13
1055G 350,5 4,78 12 305 14
1060G 392,4 4,78 14 333 16
1070G 459,7 4,78 16 384 18
© If th ese v a lues exc eed one-h a lf rotor end floa t or eq uiv a lent
m a nufa c turer’s sp ec ific a tion, refer to th e F a c tory.
Q G a p disc m a teria l: N eop rene, 7 0 durom eter.
© Rexnord Industries, LLC, 2004, 2006. (M451-110) 19

Falk™ Double & Single Engagement Gear Couplings • Install. & Maint.
Sizes 1010 thru 1070G & GP & Sizes 1 thru 7GF (Page 1 of 8)
How To Use This Manual Type G/GP/GF20 Type G/GF32 Type G/GP/GF52
This manual provides detailed instructions on installation,
maintenance, and parts identification for Falk Lifelign ® gear
couplings, Types G & GF10, 20, 31, 32, 51, 52, & GP20 & GP52.
Use the table of contents below to locate required information.
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Lube Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1 1000G Series Pictured
Limited End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1 highly recommended.
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1-2 Gear couplings initially lubricated with Falk Long Term Grease
Balanced Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3 (LTG) will not require re-lubrication for up to three years.
Bi-Annual & Annual Maintenance . . . . . . . . . . . . . . . . Page 3 The use of general purpose grease requires re-lubrication of
Installation & Alignment Instructions . . . . . . . . . Pages 3-6 & 7 the coupling at least once every six months. If coupling leaks
Installation & Alignment Data . . . . . . . . . . . . . . . . . . . Page 6 grease, is exposed to extreme temperatures, excessive moisture,
Parts Identification & Parts Interchangeability. . . . . . . Page 7-8 experiences frequent reversals or axial movements; more
frequent lubrication may be required.
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS
MANUAL FOR OPTIMUM PERFORMANCE AND USDA Approval
TROUBLE FREE SERVICE. LTG has the United States Department of Agriculture Food
Safety & Inspection Service approval for applications where
INTRODUCTION there is no possibility of contact with edible products.
This manual applies to standard coupling Types G & GF10, 31 (H-2 ratings.)
and 51 with shrouded bolts, and G & GF20, 32, 52, and GP20 &
GP52 with exposed bolts. For couplings furnished with special Long Term Grease (LTG)
features, refer to assembly drawing furnished with coupling for The high centrifugal forces encountered in couplings separate
proper assembly arrangement and any additional installation or the base oil and thickener of general purpose greases. Heavy
maintenance requirements. Refer to the specific manuals for GV thickener, which has no lubrication qualities, accumulates in the
vertical gear couplings installation and maintenance. tooth mesh area of gear couplings resulting in premature mesh
IMPORTANT: Use G/GF51 & 52 couplings for floating shaft failure unless periodic lubrication cycles are maintained.
assemblies or as the fourth bearing in three bearing systems. Falk Long Term Grease (LTG) was developed specifically for
When gear couplings are mounted on a horizontal floating couplings. It resists separation of the oil and thickener. The
shaft, use a gap disc in each coupling. Where limited end float consistency of Falk LTG changes with operating conditions. As
is required or where sleeve bearing motors are used, consult manufactured, it is an NLGI #1/2 grade. Working of the
the Factory. Type GP52 couplings are recommended for lubricant under actual service conditions causes it to become
horizontal application only. Refer Type GP52 floating shaft semifluid, while the grease near the seals will set to a heavier
applications to the Factory. grade, helping to prevent leakage.
CAUTION: Consult applicable local and national safety codes LTG is highly resistant to separation, easily out performing all
for proper guarding of rotating members. Observe all safety other lubricants tested. The resistance to separation allows the
rules when installing or servicing couplings. lubricant to be used for relatively long periods of time.
WARNING: Lockout starting switch of prime mover and remove Although LTG grease is compatible with most other coupling
all external loads from drive before installing or servicing couplings. greases, the mixing of greases may dilute the benefits of LTG.
CAUTION: Do not use LTG in bearings. Do not use LTG for
LUBE FITTINGS low speed applications. Refer to Table 4, Page 6 for coupling
Sleeves have 18” NPT lube holes for sizes 1010G20 - 1035G20, speed range of LTG grease.
1GF20 - 7GF20, 1025G10 - 1035G10, and 2 12 GF10 - 5 12
GF10. (Sizes 1010G10 - 1020G10 and 1GF10 - 2GF10 use Packaging
1 “-28 SAE LT automotive plugs and fittings.) Sizes 1040G thru
4
14 oz. (0,4 Kg) CARTRIDGES — Individual or case lots of 10
1070G have 14” NPT holes. Use a standard grease gun and or 30.
lube fittings.
35 lb. (16 Kg) PAILS, 120 lb. (54 Kg) KEG & 400 lb. DRUMS.
LIMITED END FLOAT Specifications — Falk LTG (Long Term Grease)
Where limited end float is required or where sleeve bearing
motors are used, consult the Factory. TEMPERATURE RANGE — –20°F (–29°C) to 250°F (121°C).
Minimum pump = 20°F (–7°C).
LUBRICATION MINIMUM BASE OIL VISCOSITY — 3300SSU (715cSt) @
Adequate lubrication is essential for satisfactory operation. 100°F (38°C).
Because of its superior lubricating characteristics and low THICKENER — Lithium soap/polymer.
centrifuge properties, Falk Long Term Grease (LTG) is
Rexnord Industries, LLC, Coupling Group 458-110

5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060 April 2005
Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com Supersedes 6-02
Install. & Maint. • Falk™ Double & Single Engagement Gear Couplings
(Page 2 of 8) Sizes 1010 thru 1070G & GP & Sizes 1 thru 7GF
CENTRIFUGE SEPARATION CHARACTERISTICS — ASTM For temperatures beyond this range, consult Facotyr. The
#D4425–84 (Centrifuge Test) — K36 = 2/24 max., very high minimum operating temperature must not be lower than the
resistance to centrifuging. pour point of the oil. The specified amount of grease listed in
NLGI GRADE (ASTM D-217) — 1/2 Table 4, Page 6, is in pounds and also applies to the volume of
oil in pints.
CONSISTENCY (ASTM D-217) — 60 stroke worked
penetration value in the range of 315 to 360 measured @ Specifications
77°F (25°C).
Type: Mild EP gear oil that meets AGMA
DROPPING POINT — 350°F (177°C) minimum. Specifications 250.04.
MINIMUM TIMKEN EP O.K. LOAD — 40 lb. (18 kg). Grade: AGMA #8EP (ISO VG 680).
ADDITIVES — Rust and oxidation inhibitors that do not corrode Viscosity: 612-748 cSt @ 104°F (40°C).
steel or swell or deteriorate synthetic seals. Pour Point: 20°F (–7°C) Maximum.
Must not corrode steel or swell or deteriorate synthetic seals.
General Purpose Grease
Bi-annual Lubrication — The following specifications and TABLE 1 — NLGI #1 Grease
lubricants for general purpose grease apply to gear couplings that Manufacturer Lubricant H
are lubricated bi-annually and operate within ambient
Amoco Oil Co. Rykon Grease #1 EP
temperatures of –30°F (–34°C) to 200°F (93°C). For temperatures BP Oil Co. Energrease LS-EP1
beyond this range, consult Factory. For normal service, use a NLGI Chevron U.S.A., Inc. Dura-Lith EP1
#1 extreme pressure (EP) grease EXCEPT when the coupling speed Citgo Petroleum Corp Premium Lithium Grease EP1
Conoco Inc. EP Conolith Grease #1
is less than the minimum specified in Table 4, Page 6. At these
Exxon Company, U.S.A.. Lidok EP1
lower speeds, use a NLGI #0 extreme pressure (EP) grease. When Imperial Oil Ltd. Ronex EP1
one or more gear couplings in an application require NLGI #0 Kendall Refining Co. Lithium Grease L-416
grease, the same grease may be used in all of the couplings. DO Keystone Div., Pennwalt Corp. Zeniplex-1
Lyondell Lubricants Litholine Complex EP1
NOT use cup grease.
Mobil Oil Corp.. Mobilux EP1
If coupling leaks grease, is exposed to extreme temperatures, Petro-Canada Products Multipurpose EP1
Phillips 66 Co. Philube Blue EP
excessive moisture or experiences frequent reversals or axial Shell Oil Co. Alvania EP Grease 1
movements; more frequent lubrication may be required. Shell Canada Ltd. Alvania Grease EP1
Lubricants listed in Tables 1, 2 & 3 are typical products only and Sun Oil Co. Sun Prestige 741 EP
Texaco Lubricants Multifak EP1
should not be construed as exclusive recommendations. Unocal 76 (East & West) Unoba EP1
Specifications — General Purpose
Coupling Lubricants TABLE 2 — NLGI #0 EP Grease
COUPLING SPEED RANGE — See Table 4, Page 6.
Manufacturer Lubricant H
TEMPERATURE RANGE — –30°F to +200°F(–34°C to +93°C)
Amoco Oil Co. Rykon Premium Grease 0 EP
WORKED PENETRATION AT 77°F(25°C) — BP Oil Co. Energrease LS-EP 0
NLGI #1 . . . . . . . . 310-340 (See Table 1) Chevron U.S.A., Inc. Dura-Lith EP 0
Citgo Petroleum Corp Premium Lithium Grease EP 0
NLGI #0 . . . . . . . . 355-385 (See Table 2) Conoco Inc. EP Conolith Grease #0
DROPPING POINT — 300°F(149°C) or higher Imperial Oil Ltd. Unirex EP0
Exxon Company, U.S.A.. Lidok EP 0
TEXTURE — Smooth or fibrous Kendall Refining Co. Lithium Grease L-406
Keystone Div., Pennwalt Corp. Zeniplex-0
MINIMUM TIMKEN O.K. LOAD — 30 lb. Mobil Oil Corp.. Mobilux EP 0
SEPARATION AND RESISTANCE — Low oil separation rate and Petro-Canada Products Multipurpose Lotemp EP Grease
high resistance to separation from centrifuging. Phillips 66 Co. Philube Blue EP
Shell Oil Co. Alvania EP Grease RO
LIQUID CONSTITUENT — Possess good lubricating Shell Canada Ltd. Alvania Grease EPW
properties . . . equivalent to a high quality, well refined Sun Oil Co. Sun Prestige 740 EP
petroleum oil with EP additives. Texaco Lubricants Multifak EP 0
Unocal 76 (East & West) Unoba EP 0
INACTIVE — Must not corrode steel or cause swelling or
deterioration of synthetic seals. TABLE 3 — Oil Lubricants
Oil Lubrication Manufacturer Lubricant H
EP oils may be a more effective lubricant than grease when the Amoco Permagear EP 160
Chevron, U.S.A. NL Gear Compound 680
required coupling speed is one half of the minimum speed Exxon Co., U.S.A. Spartan EP680
range of NLGI #1 grease listed in Table 4, Page 6 (Minimum Gulf Oil Co. EP Lubricant HD 680
rpm ¸ 2). Oil lubricated couplings must be sealed to prevent Mobil Oil Co. Mobilgear 636
leakage, i.e. keyways, etc. Couplings must be drained and Shell Oil Co. Omala Oil 680
Texaco Inc. Meropa 680
refilled with new oil every six months for operating temperatures Union Oil Co. of Calif. Extra Duty NL Gear Lube 8EP
up to 160°F (71°C) and every three months for couplings H Lubricants listed may not be suitable for use in the food processing industry;
operating at temperatures of 160°F (71°C) up to 200°F (93°C). check with lube manufacturer for approved lubricants.
458-110 Rexnord Industries, LLC, Coupling Group

April 2005 5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone : 262-796-4060
Supersedes 6-02 Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com
HORIZONTAL COUPLING INSTALLATION, ANNUAL MAINTENANCE

ALL TYPES For extreme or unusual operating conditions, check coupling
Only standard mechanics tools, torque wrenches, inside more frequently.
micrometer, dial indicator, straight edge, spacer bar, and feeler 1. Check alignment per Step 7, Page 7. If the maximum
gauges are required to install gear couplings. Clean all parts operating misalignment values are exceeded, realign the
using a non-flammable solvent. Check hubs, shafts, and coupling to the recommended installation values. See Table
keyways for burrs. DO NOT heat clearance fit hubs. Use a 4, for installation and maximum operating misalignment
lubricant that meets the specifications on Page 2. Pack sleeve values.
teeth with grease and lightly coat seals with grease BEFORE 2. Check tightening torques of all fasteners.
assembly. The required amount of grease is listed in Table 4. 3. Inspect seal ring and gasket to determine if replacement
Make certain flange fasteners are tightened to the required is required.
torque listed in Table 4. 4. Re-lubricate coupling if using general purpose grease.
Interference Fit Hubs — Unless otherwise specified, gear
couplings are furnished for an interference fit without setscrews.
Heat hubs to 275°F(135°C) using an oven, torch, induction NOTE: Longer
shank toward
heater, or an oil bath. gap end.
CAUTION: To prevent seal damage DO NOT heat hubs
beyond a maximum temperature of 400°F (205°C) for Type G
and 500°F (260°C) for Type GF.
When an oxy-acetylene or blow torch is used, use an excess
acetylene mixture. Mark hubs near the center of their length in NOTE:
several places on hub body with a temperature sensitive FLEX HUB Flush here. RIGID HUB
crayon, 275°F (135°C) melt temperature. Direct flame towards
hub bore using constant motion to avoid overheating an area. ALL TYPES G/GF/GP HORIZONTAL
WARNING: If an oil bath is used, the oil must have a flash COUPLING INSTALLATION
point of 350°F (177°C) or higher. Do not rest hubs on the
bottom of the container. Do not use an open flame in a
1 — Mount Flanged Sleeves, Seals & Hubs
combustible atmosphere or near combustible materials. Place the flanged sleeves WITH seal rings on shafts BEFORE
mounting flex hubs. Mount flex or rigid hubs on their respective
Maximize Performance & Life shafts, as shown above, so that each face is flush with the end
The performance and life of couplings depend largely upon of its shaft. Allow hubs to cool before proceeding. Seal keyways
how you install and maintain them. Before installing couplings, to prevent leakage. Insert setscrews (if required) and tighten.
make certain that foundations of equipment to be connected Position equipment in approximate alignment with approximate
meet manufacturers’ requirements. Check for soft foot. The use hub gap.
of stainless steel shims is recommended. Measuring For Type G/GF10 & 20 and GP20, position equipment in
misalignment and positioning equipment within alignment approximate alignment with gap equal to that given in Table 4.
tolerances is simplified with an alignment computer. These For Type G/GF31 & 32 spacer and G/GF/GP51 & 52 floating
calculations can also be done graphically or mathematically, shaft, with rigid hubs on floating shaft, position equipment in
and allow the incorporation of “cold offsets”, which will approximate alignment with approximate distance between
compensate for shaft position changes due to thermal growth. shafts per Step 4A, Figure 2 on Page 5.
For G/GF/GP51 & 52 with flex hubs on the floating shaft, refer
Balanced Couplings to Step 4A, Figure 1 on Page 5, to determine distance
The fasteners provided are matched sets and must not be between shafts.
mixed or substituted. Assembly
balanced couplings are match
marked and must be assembled with
mating match marks aligned. In
some sizes, the flanges are not match A1 A1 A1 A1 B1 B1
marked. Coupling flanges must be

assembled with O.D.’s aligned to
within .002" (0,05 mm). Component
parts of assembly balanced couplings must not be replaced
without re-balancing the complete assembly.
BI-ANNUAL MAINTENANCE
Re-lubricate coupling if using general purpose grease. If
coupling leaks grease, is exposed to extreme temperatures,
excessive moisture or frequent reversals; more frequent
lubrication may be required.

2 — Gap & Angular Alignment for Close 3 — Offset Alignment for Close Coupled,
Coupled, Spacer, Short Floating Shaft, and Spacer, Short Floating Shaft, and Insulated
Insulated Couplings Couplings
ALWAYS MEASURE
TO SAME DEPTH
GAP
2A — Type G/GF10 & 20 & GP20 3A — Type G/GF10 & 20 & GP20
Use a spacer bar equal in thickness to gap specified in Table 4. Align so that a straight edge rests squarely on both hubs as
Insert bar, as shown above, to same depth at 90° intervals and shown above and also at 90° intervals. Check with feelers. The
measure clearance between bar and hub face with feelers. The clearance should not exceed the INSTALLATION OFFSET limit
difference in minimum and maximum measurements must not specified in Table 4. Tighten foundation bolts and repeat Steps
exceed the INSTALLATION ANGULAR limit specified in Table 4. 2A and 3A. Realign coupling if necessary. Use a dial indicator
if hub extension is too short for accurate use of a straight edge.
2B — G/GF31 & 32 (Spacer), and Type

G/GF51 & 52 (Short Floating Shaft, See Step 4 3B — Type G/GF31 & 32 (Spacer), and Type
for Long Floating Shaft) G/GF51 & 52 (Short Floating Shaft, See Step 4
Use an inside micrometer as shown above and at 90° intervals for Long Floating Shaft)
to measure the distance between hubs. The difference in
Align so that a straight edge rests squarely (or within the limits
minimum and maximum measurements should not exceed the
specified in Table 4) on both hubs as shown above and also at
INSTALLATION ANGULAR limit specified in Table 4.
90° intervals. Check with feelers. The clearance should not
exceed the INSTALLATION OFFSET limit specified. Tighten all
foundation bolts and repeat Steps 2B and 3B. Realign coupling
if necessary.
GAP
RIGID HUB
2C — G/GF51 & 52 & GP52 (As Fourth

Bearing in Three Bearing System) RIGID HUB
Use a spacer bar equal in thickness to the “X” dimension 3C — Type G/GF51 & 52 & GP52 (As Fourth
specified in Table 4. Insert bar, as shown above to same depth Bearing in Three Bearing System)
at 90° intervals and measure clearance between bar and hub Clamp a dial indicator to the rigid hub as shown and rotate the
face with feelers. The difference in minimum and maximum rigid hub one complete turn. The total indicator reading DIVIDED
measurements must not exceed the INSTALLATION ANGULAR by two must not exceed the INSTALLATION OFFSET limit
limit specified in Table 4. specified in Table 4. Tighten all foundation bolts and repeat

Steps 2C and 3C. Realign coupling if necessary. ANGULAR limit specified in Table 4.
4 — Type G/GF/GP51 & 52 With Long Floating 4B2 — Refer to Figure 3

GAP DISCS
Align coupling & floating shaft so that, with the square head (or
(BOTH ENDS) depth micrometer) resting squarely on the flange, equal
clearance measurements are obtained between flange and the
hub O.D. in four places 90° apart. The difference between
GAP GAP minimum and maximum feeler readings should not exceed the
X X
INSTALLATION OFFSET limit in Table 4 divided by 2. The
above measurement is TIR.
4C — Position Second Drive

RIGID DISTANCE BETWEEN RIGID HUB FLANGE RIGID
HUB FACES EQUALS SHAFT LENGTH PLUS 2 "X" HUB Position second drive for the correct “X” dimension and align
per Steps 4B1 & 4B2. DO NOT move the floating shaft. Bolt
Figure 1 drive in place and recheck alignment and gap. Realign if
necessary. For greater accuracy, check alignment with a depth
Shaft micrometer or dial indicator.
4A — Determine Distance Between Shafts
For Figure 1 above, measure the length of the floating shaft
and add 2 times the gap dimension from Table 4 to get the
distance between the shafts to be coupled.
GAP DISCS
RIGID HUBS OR SPACER (BOTH ENDS)
GAP GAP
X X
5 —Assemble Coupling — G and GF Only

DISTANCE BETWEEN SHAFTS EQUALS
Insert gasket between flanges and gap disc into counterbore of
each rigid hub for floating shaft assemblies and bolt flanges
Figure 2 DISTANCE BETWEEN FLANGE FACES PLUS 2 "X"
together. Use only the fasteners furnished with the coupling.
For Figure 2 above, measure the overall floating shaft or IMPORTANT: Tighten fasteners to torque specified in Table 4.
spacer assembly length from flange to flange and add 2 times
the “X” dimension from Table 4 to get the distance between the 5A — Assemble Coupling – Insert Insulator
shafts to be coupled. Parts and Join Flanged Sleeves (GP20 & GP52)
Clean flange faces and coat with Permatex #2 or equivalent.
4B — Position First Drive & Floating Shaft
DO NOT install gaskets. Insert insulator bushings into flanged
Set the drive most difficult to move to true level and bolt it in holes. Draw one sleeve onto hub and position insulator center
place. Set the floating shaft on V-blocks. Then align coupling plate on flange face. Draw other sleeve onto hub and assemble
on fixed drive as follows: fasteners with insulator washers. Use only fasteners furnished
with coupling. IMPORTANT: Tighten fasteners to torque
USE
FEELERS FLEX HUB specified in Table 4.
(ANGULAR) GASKET
RIGID HUB
SLEEVE
X
GAP
USE
FEELERS
(OFFSET)
Figure 3
6 — Lubricate
Remove all grease plugs and fill with recommended grease
4B1 — Refer to Figure 3 until an excess appears at an open hole; then insert plug.
Use a spacer bar equal in thickness to the “X” dimension Continue procedure until all plugs have been inserted.
specified in Table 4. Insert the bar to the same depth at 90° CAUTION: Remove grease fitting and make certain all plugs
intervals and measure the clearance between the bar and hub are inserted after lubricating.
face with feelers as shown. The difference in minimum and
maximum measurements should not exceed the INSTALLATION

TABLE 4 — Installation & Alignment Data For Types G/GF10, 20, 31, 32, 51, 52 & GP20 &
GP52 H — Dimensions – Inches (Metric – mm)
1010G 1015G 1020G 1025G 1030G 1035G 1040G 1045G 1050G 1055G 1060G 1070G
COUPLING SIZE
1GF 1-½GF 2GF 2-½GF 3GF 3-½GF 4GF 4-½GF 5GF 5-½GF 6GF 7GF
G/GF10 & 20 .125 .125 .125 .188 .188 .250 .250 .312 .312 .312 .312 .375
(3) (3) (3) (5) (5) (6) (6) (8) (8) (8) (8) (10)
.325 .325 .385 .385 .450 .450 .450 .450 .510
GP20 ... ... ...
(8) (8) (10) (10) (11) (11) (11) (11) (13)
Gap
G/GF51 & 52 .156 .156 .156 .188 .188 .218 .281 .312 .344 .344 .406 .500
(4) (4) (4) (5) (5) (6) (7) (8) (9) (9) (10) (13)
.325 .325 .350 .420 .450 .480 .480 .540 .635
GP52 ... ... ...
(8) (8) (9) (11) (11) (12) (12) (14) (16)
G/GF51 & 52 .056 .056 .056 .088 .088 .118 .121 .152 .144 .144 .146 .170
(1) (1) (1) (2) (2) (3) (3) (4) (4) (4) (4) (4)
“X” Dimension
.215 .215 .245 .246 .280 .270 .270 .270 .295
GP52 ... ... ...
(5) (5) (6) (6) (7) (7) (7) (7) (8)
G/GF10, 20, 31, 32, 51 & 52
Angular .006 .007 .009 .011 .013 .015 .018 .020 .022 .024 .026 .031
& GP20 & GP52 (0,15) (0,19) (0,23) (0,28) (0,33) (0,39) (0,46) (0,51) (0,55) (0,61) (0,66) (0,78)
G/GF10 & 20 & GP20 Offset .002 .003 .003 .004 .005 .006 .007 .008 .009 .010 .011 .013
Installation (0,05) (0,07) (0,8) (0,10) (0,13) (0,15) (0,18) (0,20) (0,23) (0,26) (0,28) (0,33)
Limits .001 .001 .001 .002 .002 .002 .003 .003 .003 .003 .004 .005
G/GF51 & 52 & GP52 Offset
(0,03) (0,03) (0,03) (0,04) (0,05) (0,05) (0,06) (0,08) (0,08) (0,08) (0,10) (0,11)
G/GF31 & 32 Offset .006 .006 .007 .008 .009 .011 .012 .013 .015 .016 .017 .017
(0,14) (0,16) (0,17) (0,20) (0,23) (0,28) (0,30) (0,32) (0,38) (0,41) (0,43) (0,44)
Installation Check All Types .006 .007 .009 .011 .013 .015 .018 .020 .022 .024 .026 .031
(0,15) (0,19) (0,23) (0,28) (0,33) (0,39) (0,46) (0,51) (0,55) (0,61) (0,66) (0,78)
“W”†
Operating Limit Check All Types .035 .045 .054 .067 .079 .092 .108 .121 .131 .144 .157 .183
(0,90) (1,13) (1,38) (1,71) (2,00) (2,33) (2,74) (3,08) (3,33) (3,66) (3,99) (4,66)
G10, 20, NLGI #0 Grease-Max. ‡ 7000 6000 5000 4750 4400 3900 3600 3200 2900 2650 2450 2150
51, 52 &
GP20 & Falk LTG or Min. 1030 700 550 460 380 330 290 250 230 210 190 160
Coupling NLGl #1 Grease
Speed GP52 Allow. 8000 6500 5600 5000 4400 3900 3600 3200 2900 2650 2450 2150
Range NLGI #0 Grease-Max. ‡ 7000 5500 4600 4000 3600 3100 2800 2600 2400 2200 2100 1800
(rpm)
G31 & 32 Falk LTG or Min. 1030 700 550 460 380 330 290 250 230 210 190 160
NLGl #1 Grease Allow. 7000 5500 4600 4000 3600 3100 2800 2600 2400 2200 2100 1800
G10 & 20 .09 .16 .25 .50 .80 1.20 2.00 2.30 3.90 4.90 7.00 9.60
(0,041) (0,073) (0,11) (0,23) (0,36) (0,54) (0,91) (1,0) (1,8) (2,2) (3,2) (4,4)
G51 & 52 .05 .09 .15 .26 .40 .60 1.03 1.25 2.00 2.50 3.75 5.00
(0,023) (0,041) (0,068) (0,12) (0,18) (0,27) (0,47) (0,57) (0,91) (1,1) (1,7) (2,3)
.03 .06 .06 .12 .20 .20 .20 .20 .20 .20
G31 & 32 per in. Spacer Length .... ....
(0,014) (0,027) (0,027) (0,054) (0,091) (0,091) (0,091) (0,091) (0,091) (0,091)
G31 & 32 Less Spacer .09 .16 .25 .50 .80 1.20 2.00 2.30 3.90 4.90 7.00 9.60
(0,041) (0,073) (0,11) (0,23) (0,36) (0,54) (0,91) (1,0) (1,8) (2,2) (3,2) (4,4)
GF10 & 20 .09 .15 .27 .47 .74 .88 1.48 2.62 2.87 4.44 4.95 6.79
Grease - (0,039) (0,068) (0,12) (0,21) (0,33) (0,40) (0,67) (1,2) (1,3) (2,0) (2,2) (3,1)
pounds
.50 .80 1.20 2.00 2.30 3.90 4.90 7.00 9.60
(kg) GP20 ... ... ...
(0,227) (0,363) (0,544) (0,907) (1,04) (1,77) (2.22) (3,18) (4,35)
GF51 & 52 .06 .09 .15 .27 .41 .50 .87 1.46 1.66 2.47 2.93 4.27
(0,025) (0,042) (0,070) (0,12) (0,19) (0,23) (0,40) (0,66) (0,75) (1,1) (1,3) (1,9)
.26 .40 .60 1.03 1.25 2.00 2.50 3.75 5.00
GP52 ... ... ...
(0,118) (0,181) (0,272) (0,467) (0,567) (0,907) (1,13) (1,70) (2,27)
GF31 & 32 per in. Spacer Length .06 .07 .07 .08 .02 .16 .21 .12 .13 .14 .71 .91
(0,027) (0,032 (0,032 (0,037) (0,009) (0,072) (0,095) (0,053) (0,059) (0,065) (0,322) (0,413)
GF31 & 32 Less Spacer .09 .15 .27 .47 .74 .88 1.48 2.62 2.87 4.44 4.95 6.97
(0,039) (0,068) (0,12) (0,21) (0,33) (0,40) (0,67) (10,2) (1,3) (2,0) (2,2) (3,2)
108 372 372 900 900 1800 1800 1800 3000 3000
G/GF10, 31 & 51 .... ....
(12) (42) (42) (102) (102) (203) (203) (203) (339) (339)
Flange Bolt Torque -
G/GF20, 32 & 52 108 372 900 1800 1800 3000 3000 3000 3000 3000 3000 3000
lb-in (Nm) (12) (42) (102) (203) (203) (339) (339) (339) (339) (339) (339) (339)
420 420 840 840 840 1440 1440 1440 1800
GP20 & GP52 ... ... ...
(47,5) 47.5) (94,9) (94,9) (94,9) (162,7) (162,7) (162,7) (203,4)
H Refer to Selection Guide for maximum bores and Manual 427-108 for reboring instructions.
† Flexible couplings are designed to accommodate changes in operating conditions. Coupling life expectancy between initial alignment and maximum operating limits is a
function of load, speed and lubrication. Application requirements in excess of 3/4° misalignment per flex half coupling should be referred to the Factory for review.
‡ Couplings with NLGI #0 grease may be operated at any speed between zero and the maximum shown.

7 — Assembled Coupling Alignment Check – "W" = Wmax. – Wmin.

All Styles Wmax.
The alignment can be checked without disassembling the
coupling as shown at left. Determine “W” by measuring
distances “W”max. and “W”min. between flex hub and sleeve
using a depth micrometer or feeler gauges. The difference
between “W”max. and “W”min. must not exceed the “W”
value given in Table 4. Check “W” at each coupling end. Wmin.
Check "W" at each flexible hub.
PARTS IDENTIFICATION AND PART

NUMBER LOCATION EXAMPLE:
Complete 1050G20 Gear Coupling
Coupling parts have identifying size and part numbers as Consisting of:
illustrated below. When ordering parts, always SPECIFY SIZE, 2 – 1050G20 Sleeves
TYPE, HUB BORE, KEYWAY, and PART NUMBER found on (Includes: Gasket & Seal)
each item. 2 – 1050G Flex Hubs
Contact your Rexnord Distributor or Rexnord for price Bore: 6.750 Keyway: 1.750 x .750
and availability. Bore: 7.375 Keyway: 1.750 x .750
1 – Fastener Set
TYPE G/GF10 & 20 1015 G 20

1-1/2 GF 20
COUPLING TYPE
LUBE SIZE PRODUCT
PLUG CLASSIFICATION
SLEEVE FLEX HUB SLEEVE
FLEX HUB
(SPECIFY BORE (SPECIFY BORE
& KEYWAY) & KEYWAY)
LUB E
L UB E FAL K 1015G 20
F AL K 1015G 20
F AL
K 10
5G 23730 744671
15G 2.370744671
101
LK
FA
SEAL RING
LUBE
SIZE, BORE & PLUG
SEAL RING PART NUMBER
GASKET (EITHER LOCATION)
FASTENERS
TYPE G/GF31 & 32

1015 G 32
1-1/2 G 32
COUPLING TYPE
LUBE SIZE PRODUCT
PLUG CLASSIFICATION
FLEX HUB
& KEYWAY) & KEYWAY)
L UB E F
F AL
AL K 1015G 20
K 10
5G 23730 744671
15G 2.370744671
101
LK
FA
SEAL RING
LUBE
SEAL RING SIZE, BORE & PLUG
SPACER GASKET PART NUMBER
GASKET (EITHER LOCATION)
(SPECIFY
LENGTH)
FASTENERS
FASTENERS

TYPE G/GF51 & 52

1015 G 52
1-1/2 G 52
COUPLING TYPE
LUBE SIZE PRODUCT
PLUG CLASSIFICATION
SLEEVE FLOATING SHAFT SLEEVE
FLEX HUB GAP (SPECIFY DIAMETER FLEX HUB
(SPECIFY BORE DISC & LENGTH) GAP (SPECIFY BORE
& KEYWAY) DISC & KEYWAY)
L UB E
F AL K 1015G20
F AL
K 10
5G 23730 744671
15G 2.370744671
101
LK
FA
SEAL
SIZE, BORE & LUBE RING
SEAL RIGID HUB PLUG
RING GASKET RIGID HUB GASKET PART NUMBER
(SPECIFY BORE (SPECIFY BORE (EITHER LOCATION)
& KEYWAY) & KEYWAY)
FASTENERS
FASTENERS
TYPE GP20
1015 GP 20
COUPLING TYPE
LUBE SIZE PRODUCT
PLUG CLASSIFICATION
FLEX HUB
& KEYWAY) & KEYWAY)
LUB E
F AL K 1015G 20
F AL
K 10
5G 23730 744671
15G 2.370744671
101
LK
FA
SEAL RING
LUBE
INSULATOR SIZE, BORE & PLUG
SEAL RING WASHERS PART NUMBER
INSULATOR (EITHER LOCATION)
CENTER PLATE
FASTENERS
INSULATOR
BUSHINGS
TYPE GP52
1015 GP 52
COUPLING TYPE
LUBE SIZE
PLUG PRODUCT
CLASSIFICATION
SLEEVE FLEX HUB
(SPECIFY BORE
& KEYWAY)
L UB E
F AL K 1015GL 20
FALK
5G 23730 744671
1015G GA P E ND
101
LK
FA
SEAL INSULATOR
RING INSULATOR RIGID HUB
WASHERS CENTER PLATE (SPECIFY BORE
& KEYWAY)
FASTENERS
INSULATOR
BUSHINGS

16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.4 Lubrication & Control Oil Filter
Inline Filter LF
up to 660 l/min, up to 100 bar
LF 30 LF 60 LF 110 LF 160 LF 240 LF 330 LF 660
1. TECHNICAL 1.3 FILTER SPECIFICATIONS

SPECIFICATIONS Nominal pressure 100 bar
1.1 FILTER HOUSING Fatigue strength at nominal pressure 106 load cycles
Construction from 0 to nominal pressure
The filter housings are designed (For other pressures, see graph at 1.8)
in accordance with international
regulations. They consist of a filter Temperature range -30 °C to +100 °C
head with screw-in filter bowl. (LF 660: -30 °C to -10 °C: pmax= 75 bar)
Standard equipment: Material of filter head Aluminium
zzport for clogging indicator in filter head Material of filter bowl Aluminium (LF 660: steel)
zzmounting holes in the head
Type of clogging indicator VM (differential pressure indicator up to
zzpressure release/oil drain plug 210 bar operating pressure)
(LF 330 and above)
Setting pressure of clogging indicator 5 bar (others on request)
1.2 FILTER ELEMENTS
Bypass cracking pressure (optional) 6 bar (others on request)
Hydac filter elements are validated
and their quality is constantly
monitored according to the following 1.4 SEALS 1.10 COMPATIBILITY WITH
standards: NBR (= Perbunan) HYDRAULIC FLUIDS ISO 2943
zzISO 2941
1.5 MOUNTING zzHydraulic oils H to HLPD DIN 51524
zzISO 2942
As inline filter zzLubrication oils DIN 51517, API,
zzISO 2943
ACEA, DIN 51515, ISO 6743
zzISO 3724 1.6 SPECIAL MODELS AND
ACCESSORIES zzCompressor oils DIN 51506
zzISO 3968
zzISO 11170 zzbypass valve built into the head, zzBiodegradable operating fluids VDMA
separate from the main flow 24568 HETG, HEES, HEPG
zzISO 16889
Contamination retention capacities in g zzNon-flam operating fluids HFA, HFB,
zzoil drain plug up to LF 240
Betamicron® (BN4HC) HFC and HFD
zzseals in FPM, EPDM zzOperating fluids with high water
LF 3 µm 5 µm 10 µm 20 µm
30 4.6 5.1 5.4 5.6 zztest and approval certificates content (>50% water content) on
60 6.5 7.3 7.8 8.0 1.7 SPARE PARTS request
110 13.8 15.5 16.4 16.9
160 19.8 22.2 23.5 24.3 See Original Spare Parts List 1.11 IMPORTANT INFORMATION
240 32.3 36.3 38.4 39.6 1.8 FATIGUE STRENGTH zzFilter housing must be earthed
330 47.2 53.1 56.1 57.9
660 102.2 114.9 121.5 125.4
zzWhen using electrical clogging
indicators, the electrical power supply
Betamicron® (BH4HC) to the system must be switched off
LF 3 µm 5 µm 10 µm 20 µm before removing the clogging indicator
30 3.0 2.9 3.2 3.7 connector
60 4.6 4.5 5.0 5.7
110 10.1 9.9 10.9 12.4
160 12.9 12.6 13.9 15.9 Symbol for hydraulic systems
240 21.6 21.1 23.2 26.5
330 34.6 33.9 37.2 42.5
660 76.8 75.2 82.6 94.3
Filter elements are available with the
following pressure stability values: 1.9 CERTIFICATES AND APPROVALS
Betamicron® (BN4HC): 20 bar On request
Betamicron® (BH4HC): 210 bar
Wire mesh (W): 20 bar
Stainless steel fibre (V): 210 bar
E 7.563.2/02.08
195
2. mODEL CODE (also order example) LF BN/HC 60 I C 10 D 1 . X /-L24
2.1 COMPLETE FILTER
Filter type
LF
Filter material of element
BN/HC Betamicron® (BN4HC)
BH/HC Betamicron® (BH4HC)
W Stainless steel wire mesh
V Stainless steel fibre
Size of filter or element
LF: 30, 60, 110, 160, 240, 330, 660
Operating pressure
I = 100 bar
Type and size of port
Type Port Filter size
30 60 110 160 240 330 660
B G½ 
C G¾  
E G1 ¼  
F G1 ½  
Filtration rate in µm
BN4HC, BH4HC, V: 3, 5, 10, 20
W: 25, 50, 100, 200
Type of clogging indicator
Y plastic blanking plug in indicator port
A steel blanking plug in indicator port
B visual for other clogging indicators
C electrical see brochure no. E 7.050../..
D visual and electrical
Type code
1
Modification number
X the latest version is always supplied
Supplementary details
B. cracking pressure of bypass (e.g.: B6 = 6 bar); no details = without bypass valve
L... light with appropriate voltage (24V, 48V, 110V, 220V) only for clogging
LED 2 light emitting diodes up to 24 Volt indicators Type D
SO 184 pressure release/oil drain plug (LF 330 series and above)
V FPM seals
W suitable for HFA and HFC emulsions
(only required when using a clogging indicator, or V or W elements)
2.2 REPLACEMENT ELEMENT 0060 D 010 BN4HC /-V

Size
0030, 0060, 0110, 0160, 0240, 0330, 0660
Type
D
Filtration rate in µm
BN4HC, BH4HC, V: 003, 005, 010, 020
W: 025, 050, 100, 200
Filter material
BN4HC, BH4HC, V, W
V, W (for descriptions, see point 2.1)
2.3 REPLACEMENT CLOGGING INDICATOR VM 5 D . X /-L24
Type
VM differential pressure indicator up to 210 bar operating pressure
Pressure setting
5 5 bar standard, others on request
D (see point 2.1 )
Modification number
E 7.563.2/02.08
L..., LED, V, W (for descriptions, see point 2.1)
196
3. FILTER CALCULATION / 3.2 GRADIENT COEFFICIENTS (SK) FOR FILTER ELEMENTS
SIZING The gradient coefficients in mbar/(l/min) apply to mineral oils with a kinematic
viscosity of 30 mm2/s. The pressure drop changes proportionally to the change in
The total pressure drop of a filter at a
viscosity.
certain flow rate Q is the sum of the
housing ∆p and element ∆p and is
calculated as follows: LF V W BH4HC
∆ptotal = ∆phousing + ∆pelement 3 µm 5 µm 10 µm 20 µm – 3 µm 5 µm 10 µm 20 µm
∆phousing = (see point 3.1) 30 18.0 13.0 7.4 3.7 3.367 91.2 50.7 36.3 19.0
60 16.0 11.0 6.5 3.3 1.683 58.6 32.6 18.1 12.2
∆pelement = Q • SK* • viscosity
1000 30 110 8.3 6.0 4.2 2.1 0.918 25.4 14.9 8.9 5.6
(*see point 3.2) 160 4.5 3.2 2.3 1.4 0.631 16.8 10.4 5.9 4.4
For ease of calculation, our Filter 240 3.2 2.4 1.9 1.1 0.421 10.6 6.8 3.9 2.9
Sizing Program is available on request 330 2.1 1.5 1.3 0.8 0.307 7.7 4.5 2.8 2.0
free of charge. 660 1.1 0.9 0.6 0.3 0.153 3.3 1.9 1.0 0.9
NEW: Sizing online at www.hydac.com
BN4HC: LF 30 BN4HC: LF 240
3.1 ∆p-Q HOUSING GRAPHS BASED
ON ISO 3968
The housing graphs apply to mineral
∆p [bar]
∆p [bar]
oil with a density of 0.86 kg/dm3 and a

kinematic viscosity of 30 mm2/s. In
this case, the differential pressure
changes proportionally to the density.
LF 30
Q [l/min] Q [l/min]
∆p [bar]
∆p [bar]
∆p [bar]
Q [l/min]
LF 60-110
Q [l/min] Q [l/min]

∆p [bar]
∆p [bar]
∆p [bar]
Q [l/min]
LF 160-240
Q [l/min] Q [l/min]
∆p [bar]
BN4HC: LF 160
∆p [bar]
Q [l/min]
LF 330-660
∆p [bar]
Q [l/min]
E 7.563.2/02.08
Q [l/min]
197
4. DIMENSIONS
LF b1 b2 b3 b4 d1 d2 d3 d4 h1 h2 h3 h4 SW t1 t2 Weight Volume of
including pressure
element chamber
[kg] [l]
30 69 36 45 30 67 52 G½ M5 125.5 31 7 75 24 15 8 0.8 0.13
60 90 48 56 32 84 68 G¾ M6 137.5 39 6 75 27 17 9 1.5 0.20
110 90 48 56 32 84 68 G¾ M6 207.0 39 6 75 27 17 9 1.8 0.33
160 125 65 85 35 116 95 G1¼ M10 190.5 46 6 95 32 21 14 3.7 0.60
240 125 65 85 35 116 95 G1¼ M10 250.5 46 6 95 32 21 14 4.3 0.80
330 159 85 115 60 160 130 G1½ M12 252.5 50 6 105 36 23 17 8.0 1.50
660 159 85 115 60 160 127 G1½ M12 417.5 50 6 105 36 23 17 17.6 3.00
NOTE Filtertechnik GmbH

The information in this brochure relates to the operating Industriegebiet
conditions and applications described. D-66280 Sulzbach/Saar
E 7.563.2/02.08
Tel.: 0 68 97 / 509-01
For applications or operating conditions not described,
Fax: 0 68 97 / 509-300
please contact the relevant technical department.
Internet: www.hydac.com
Subject to technical modifications. E-Mail: filter@hydac.com
198
Filter Elements
for use in HYDAC filters*
* For HYDAC filter elements for use in other manufacturers' filters,
please see brochure no. 7.205
Return line Pressure Suction
filter filter Return line filter
Return elements Pressure elements filter elements
line filter (to filter (to elements for for suction
elements DIN 24550) elements DIN 24550) RKM filters filters
R RN D DN RK RS
1. TECHNICAL 1.2 SPECIFICATIONS

SPECIFICATIONS Pressure stability 10 to 210 bar
1.1 construction (permissible ∆p across the element) depending on the selection of
As the core of the filter, it is the filter filter material (see point 2.2)
element which performs the actual Temperature range -30 °C to +100 °C
filtration and/or dewatering function in for FPM seal material to -10 °C
the housing.
They consist of several pleated 0 °C to +100 °C
filtration and support layers which are (for water-absorbing filter material)
placed as a cylinder around or inside Filtration ratings 3 µm to 200 µm (1 µm on request)
the stabilising support tube. These Filtration performance depending on filter material, nominal or
mesh packs are sealed by the end- absolute filtration up to βx(c) ≥ 1000
caps.
Regardless of the type of filter, flow
direction through the filter elements is long seam weld 1.5 COMPATIBILITY WITH
from out to in. plastic sleeve plastic clip HYDRAULIC FLUIDS ISO 2943
flow
on long zzHydraulic oils H to HLPD DIN 51524
Depending on the filter material, the seam
filter mesh pack is encased in an
direction zzLubrication oils DIN 51517, API,
additional outer plastic sleeve. ACEA, DIN 51515, ISO 6743
zzCompressor oils DIN 51506
The example below shows the
construction of a Betamicron®-4 zzBiodegradable operating fluids VDMA
element. 24568 HETG, HEES, HEPG
support tube in zzNon-flam operating fluids HFA, HFB,
mesh pack
steel / plastic
HFC and HFD
zzOperating fluids with high water
end cap 1.3 seals content (>50% water content) on
support tube NBR (= Perbunan) request
1.4 installation 1.6 quality assurance
support Hydac filter elements are validated
zzin return line filters
mesh and their quality is constantly
(element type R)
monitored according to the following
filtration zzin return line filters to DIN 24550
standards:
media (element type RN)
zzISO 2941
zzin inline pressure filters zzISO 2942
(element type D)
zzISO 2943
support zzin inline pressure filters to DIN 24550 zzISO 3724
mesh (element type DN)
plastic zzISO 3968
sleeve zzin return line & suction boost filters zzISO 11170
(element type RK) zzISO 16889
end cap
zzin suction filters (element type RS)
1.7 SPECIAL MODELS AND
Please refer to the table at point 2.1 ACCESSORIES
for the allocation of the element types zzBypass valve models which differ from
to the HYDAC housings. the particular standard
zzOnly wire mesh elements are suitable
for filtering HFA and HFC emulsions
zzSeals in FPM, EPDM
E 7.200.10/02.08
zzCustomized versions
41
2. selecting the filter element
2.1 models
From the table, please select the type of HYDAC housing for which the element is required.
For installation in Element Sizes Direction of flow Element description
housing types type
DF, DFF, DFDK, DFM, DF...M A, D 30, 35, 55, 60, 75, 95, 110, 140, 160, 240, From out to in - without bypass valve
DF...Q E, DFP, DFZ, HFM, LF, 280, 330, 500, 660, 990, 1320, 1500
LFM, LPF, MDF, MFM, LPF...DA
DFN, LFN, LFNF, FLN, FLND, DN 40, 63, 100, 160, 250, 400 From out to in - without bypass valve
FMND, DFDKN, DFN...Q E
NF, NFD, RF, RFD, RFL, RFLD, R 30, 60, 75, 90, 110, 150, 160, 165, 185, From out to in - with bypass valve
RFM 210, 240, 270, 330, 500, 600, 660, 750,
850, 950, 1300, 1700, 2600
RFN, RFND, RFLN, RFLND RN 40, 63, 100, 160, 250, 400, 630 From out to in - without bypass valve
RKM RK 80, 100, 120, 151, 201, 251, 300, 350, 400, 800 From out to in - without bypass valve
SF, SFF, SFM RS 60, 110, 160, 240, 330, 400, 500 From out to in - with bypass valve
2.2 FILTER MATERIALs

The following are available for the filtration of solid particles:
Photo Filter material Short Filtration rating in µm Pressure
description stability
BN4HC Betamicron®4 3, 5, 10, 20* 20 bar
BH4HC glass fibre, 3, 5, 10, 20* 210 bar
BNK multi-layer, with support 3, 5, 10, 20* 20 bar
BHK 3, 5, 10, 20* 210 bar
*or 3, 6, 10, 25 when dimensions are to DIN 24550
MM Mobilemicron 10, 15 10 bar
synthetic fibre,
multi-layer, with support
ECON2 ECOmicron® 3, 5, 10, 20 10 bar
synthetic fibre,
G/HC Lubimicron 10 10 bar
synthetic fibre,
W, W/HC Stainless steel wire mesh 25, 50, 100, 200,.... 20 bar
P, P/HC Paper 10, 20 10 bar

(cellulose fibre)
V Metal fibre 3, 5, 10, 20 210 bar

VB 3, 5, 10, 20 210 bar
For the removal of emulsified or free water, we recommend using HYDAC-Aquamicron® filter elements: A super
absorber reacts with the water present in the medium and expands to form a gel, from which the water can no longer
be extracted even by increasing the pressure.
These filter elements cannot remove dissolved water from the system, i.e. water below the saturation level of the
hydraulic medium.
BN4AM Betamicron® / Aquamicron® 3, 10 10 bar
glass fibre with super absorber

AM Aquamicron® 40 10 bar
super absorber
E 7.200.10/02.08
42
2.3 example model code 0060 D 010 BN4HC /-V
Size
0060
Type
D
Filtration rating in µm
010
Filter material
BN4HC
V = FPM seal
To order the filter element with the correct size, filtration rating and material for the filter you are using, see the "REPLACEMENT
ELEMENT" section, Point 2.2, of the relevant complete filter brochure.
Plastic Flow Notes Typical

sleeve direction applications
Yes From out to in 4th generation, improved performance working filter in mobile and industrial systems;
data for systems with high pressure-flow rate fluctuations;
improved static conductivity
Yes From out to in particularly low pressure drop; for mobile applications; transmission lubrication,
ECON2 is 100% incinerable systems with high temperature fluctuations and
high viscosity oils > ISO VG 100, ...

No, From out to in low pressure drop; protective filter in cooling lubricant systems
cleaning effect can be cleaned to limited extent;
is improved!
No From out to in for low filtration demands waste compacters, high viscosity oils > ISO VG 100, ...

No, From out to in can be cleaned to limited extent as protective filter for high dynamic applications
cleaning effect
is improved! as working filter for high dynamic applications
As an added bonus when using the straight Aquamicron® elements (filter material AM), solid contamination is also
filtered out of the hydraulic medium;
with the combined element Betamicron®/Aquamicron® (BN4AM) the particle filtration is further increased by the
integration of glass fibre in the construction.
These filter elements are particularly suitable for use offline for servicing fluids.
No From out to in filtration of particles and water removal fluid servicing in mobile machines,
hydraulic steel engineering, blast furnace and foundry
machines

No From out to in primarily for water removal where hydraulic steel engineering, blast furnace and foundry
there is a risk of water condensation machines
forming

E 7.200.10/02.08
43
3. FILTER CALCULATION / SIZING 3.2 quick sizing for
The total pressure drop of a filter at a certain flow rate Q is AQUAMICRON eLEMENTs
the sum of the housing ∆p and element ∆p and is calculated When sizing elements with the water absorbing filter
as follows: material Aquamicron® (AM or BN/AM) we recommend using
∆ptotal = ∆phousing + ∆pelement the quick sizing tables:
∆phousing = (see point 3.1)
∆pelement = Q • SK* • viscosity Betamicron® - Aquamicron® BN4AM
1000 30 Size Recommended Water retention
(*see point 3.2) filter flow rate capacity in cm³ at
For ease of calculation, our Filter Sizing Program is [l/min] ∆p=2.5 bar
available on request free of charge. and a viscosity
NEW: Sizing online at www.hydac.com of 30 mm²/s
330 13 190
3.1 determining the element graph 660 28 400
The element graph is determined according to ISO 3968 and 950 39 560
always corresponds to a straight line with a specific gradient 1300 54 790
coefficient SK.
2600 109 1570
This represents the ratio of the flow rate to the pressure drop
for a clean element (see below). Aquamicron® AM
Size Recommended Water retention
filter flow rate capacity
[l/min] in cm³ at ∆p=2.5 bar
and a viscosity
of 30mm²/s
∆p [mbar]
330 13 ideal 260

100 maximum 180
500 19 ideal 400
155 maximum 280
660 28 ideal 570
255 maximum 400
850 35 ideal 730
286 maximum 520
950 39 ideal 800
314 maximum 570
SK = Y [mbar] Q [l/min]
1300 54 ideal 1120
X [l/min] 437 maximum 790
2600 109 ideal 2230
870 maximum 1570
E 7.200.10/02.08
44
3.3 GRADIENT COEFFICIENTS (SK) FOR FILTER Size Filter material: W and W/HC
ELEMENTS Element type: D Element type: R
The gradient coefficients in mbar/(l/min) apply to mineral oils W -W/HC W/HC
with a kinematic viscosity of 30 mm2/s. The pressure drop 30 3.030 -
60 0.757 0.912
changes proportionally to the change in viscosity.
75 - 0.720
110 0.413 0.502
Size Filter material: BN4HC 140 0.324 -
Element type: D Element type: R 150 - 0.320
3 µm 5 µm 10 µm 20 µm 3 µm 5 µm 10 µm 20 µm 160 0.284 0.348
30 63.9 43.3 22.8 11.3 68.4 43.9 26.8 14.7 165 - 0.328
35 23.6 19 14.8 9.3 - - - - 240 0.189 0.228
55 13.7 11 8.1 4.8 - - - - 280 0.162 0.114
60 28.9 20.4 13.2 7.9 26.8 18.3 10.9 6.9 330 0.138 0.164
75 9.3 7.5 5.3 3.1 22 14.2 8.1 4.4 500 0.091 0.109
90 - - - - 14.9 10.1 6.7 3.2 660 0.069 0.082
95 7.5 6 4.1 2.4 - - - - 750 - 0.049
110 14.9 10.7 6.6 3.7 14.9 9.4 6 3.2 850 - 0.063
140 12.8 8.2 4.8 2.9 - - - - 950 - 0.058
150 - - - - 8.9 6 4 1.9 990 0.046 -
160 13.1 8.8 4.6 3.5 9.5 5.9 3.8 2.9 1300 - 0.043
165 - - - - 11.2 7.8 4.5 2.4 1320 0.035 -
1700 - 0.033
185 - - - - 8.9 6.1 3.3 1.8
2600 - 0.022
210 - - - - 3.9 2.6 1.8 1.1
240 8.2 6.1 3.6 2.3 6.2 3.8 2.6 1.8 Size Filter material: V
270 - - - - 2.5 1.7 1.1 0.7 Element type: D Element type: R
280 4 3.1 1.7 1.3 3.1 2.2 1.6 1 3 µm 5 µm 10 µm 20 µm 3 µm 5 µm 10 µm 20 µm
330 5.4 3.9 3 1.7 4.2 2.7 1.7 1.2 30 18.4 13.5 7.5 3.6 19.4 14.2 7.9 3.8
500 3.3 2.4 1.5 1.1 3 1.9 1.3 0.8 60 16.0 9.3 5.4 3.3 15.9 9.3 5.4 3.3
600 - - - - 1.4 1.1 0.7 0.4 110 8.2 5.6 3.3 2.2 7.6 5.1 3.0 2.0
660 2.5 1.8 1.1 0.8 1.9 1.2 0.8 0.5 140 5.8 4.8 3.1 2.3 - - - -
750 - - - - 1.3 0.9 0.6 0.4 160 4.6 3.2 2.3 1.4 4.9 3.5 2.4 1.5
850 - - - - 1.5 1 0.7 0.4 240 3.1 2.5 1.7 1.1 3.2 2.6 1.7 1.2
950 - - - - 1.2 0.8 0.5 0.4 280 2.3 1.7 1.2 0.8 1.4 1.1 0.7 0.5
990 1.6 1.2 0.7 0.5 - - - - 330 2.2 1.8 1.2 0.8 2.1 1.7 1.1 0.8
1300 - - - - 0.8 0.6 0.4 0.3 500 1.5 1.2 0.8 0.5 1.5 1.2 0.8 0.5
660 1.1 0.9 0.6 0.4 1.0 0.8 0.6 0.4
1320 1.2 0.9 0.5 0.4 - - - -
750 - - - - 0.6 0.5 0.3 0.2
1500 1.1 0.8 0.6 0.4 - - - - 850 - - - - 0.8 0.6 0.4 0.3
1700 - - - - 0.7 0.5 0.3 0.2 950 - - - - 0.7 0.6 0.4 0.2
2600 - - - - 0.4 0.3 0.2 0.1 990 0.8 0.6 0.4 0.3 - - - -
1300 - - - - 0.5 0.4 0.3 0.2
Size Filter material: BH4HC 1320 0.6 0.5 0.3 0.2 - - - -
Element type: D 1700 - - - - 0.4 0.3 0.2 0.1
3 µm 5 µm 10 µm 20 µm 2600 - - - - 0.3 0.2 0.1 0.1
30 91.2 50.7 36.3 19.0
60 58.6 32.6 18.1 12.2 Size Filter material: P/HC Filter material: ECON2
110 25.4 14.9 8.9 5.6 Element type: R
140 19.9 11.3 8.1 4.3 10 µm 20 µm 3 µm 5 µm 10 µm 20 µm
160 16.8 10.4 5.9 4.4 30 3.30 1.67 68.4 43.9 26.8 14.7
240 10.6 6.8 3.9 2.9 60 1.67 0.83 26.8 18.3 10.9 6.9
75 1.29 0.65 22.0 14.2 8.1 4.4
280 5.7 3.4 1.8 1.6
90 - - 14.9 10.1 6.7 3.2
330 7.7 4.5 2.8 2.0 110 0.91 0.46 14.9 9.4 6.0 3.2
500 4.2 2.6 1.5 1.2 150 - - 8.9 6.0 4.0 1.9
660 3.3 1.9 1.0 0.9 160 0.63 0.31 9.5 5.9 3.8 2.9
990 2.2 1.3 0.8 0.6 165 0.61 0.30 11.2 7.8 4.5 2.4
1320 1.6 1.0 0.6 0.4 185 - - 8.9 6.1 3.3 1.8
1500 1.4 0.8 0.6 0.5 240 0.42 0.21 6.2 3.8 2.6 1.8
280 - - 3.1 2.2 1.6 1.0
Size Filter material: BN4HC (dimensions to DIN 24550) 330 0.30 0.15 4.2 2.7 1.7 1.2
Element type: DN Element type: RN 500 0.20 0.10 3.0 1.9 1.3 0.8
3 µm 6 µm 10 µm 25 µm 3 µm 6 µm 10 µm 25 µm 660 0.15 0.08 1.9 1.2 0.8 0.5
40 23.9 14.9 8.6 6.6 14.2 7.8 4.8 2.6 750 - - 1.3 0.9 0.6 0.4
63 16.3 9.9 6.0 4.6 9.5 5.2 3.4 1.8 850 0.12 0.06 1.5 1.0 0.7 0.4
950 0.11 0.05 1.2 0.8 0.5 0.4
100 11.9 6.6 4.0 3.2 6.8 3.3 2.3 1.2
1300 0.08 0.04 0.8 0.6 0.4 0.3
160 7.9 5.1 3.4 2.6 3.6 1.8 1.2 0.5 1700 0.06 0.03 0.7 0.5 0.3 0.2
250 5.1 3.2 2.1 1.8 2.8 1.4 0.9 0.4 2600 0.04 0.02 0.4 0.3 0.2 0.1
400 3.2 2.0 1.3 1.0 2.2 1.6 1.3 1.0
630 - - - - 2.1 1.2 0.9 0.7 Size Filter material: W
Element type: RS
Size Filter material: BH4HC (dimensions to DIN 24550) 25 µm 50 µm 75 µm 125 µm
Element type: DN 60 2.00 1.70 1.03 0.54
3 µm 6 µm 10 µm 25 µm
110 0.98 0.83 0.50 0.26
40 40.4 24.8 16.4 10.9
160 - - 0.36 0.19
63 29.0 18.2 11.7 7.6
240 - - 0.25 0.13
E 7.200.10/02.08
100 19.0 11.7 7.7 5.3

330 - - 0.19 0.10
160 8.0 5.1 3.8 2.5
400 - - 0.20 0.16
250 5.4 3.4 2.8 1.9
500 - - 0.20 0.16
400 3.4 2.1 1.7 1.1
45
Size Filter material: AM Filter material: BN4AM 4.1 explanation of the MULTIPASS-TEST
Element type: R The multipass-test is an idealised hydraulic circuit, in which
40 µm 3 µm 10 µm the filter element under test is subjected to a constant flow
330 2.10 8.7 3.0 rate. The size and number of contamination particles are
500 1.38 - - calculated before and after the element,.
660 0.93 3.5 1.2
850 0.72 - -
The ratio of the number of particles of a certain size (and
950 0.66 2.4 0.8 larger) before the filter to the number of particles of a certain
1300 0.47 1.6 0.6 size after the filter indicates the filtration performance, the
2600 0.23 1.0 0.3 so-called βx(c) value. The "x" stands for the particular particle
size under consideration. A βx(c) value of 200 or above is
considered to be absolute filtration (to ISO 24550).
Size Filter material: MM
Element type: RK It is important that the βx(c) values remain at absolute level
10 µm 15 µm over a wide differential pressure range and do not fall as the
80 2.70 1.60 element contamination and operating time increase.
100 1.80 1.10 The filtration rating is determined from the βx(c) value (see
120 1.40 0.90 illustration).
151 1.00 0.65
201 0.75 0.47
251 0.58 0.36
300 0.62 0.39
350 0.30 0.20
400 0.56 0.35
800 0.44 0.27
Size Filter material: G/HC Test

Element type: R
10 µm filter
110 1.91 element
240 0.92
330 0.69
500 0.45 nflow before element nflow after element
660 0.30
850 0.23 nflow before ≥ x µm
950 0.21 βx(c) = Filtration = 1- 1 x 100%
1300 0.15 nflow after ≥ x µm βx(c)
1700 0.11
2600 0.08
Performance features
4. MULTI-PASS FILTER performance data Owing to their high performance standard, HYDAC absolute
to ISO 16889 elements protect the functions of important and expensive
The contamination retention and particle filtration hydraulic components and increase their service life. The
performance of an element (with the exception of: paper most important performance features are:
P, P/HC, wire mesh W, W/HC, V and super absorber AM) zzHigh level of particle filtration (βx(c) values)
are established in the multipass-test to ISO 16889. This zzHigh level of particle filtration over a wide range of
procedure with its precisely defined test conditions and differential pressure (high βx(c) value stability)
standard test dust (ISO MTD) enables the performance data
of different elements to be compared. zzHigh contamination retention capacity
zzHigh pressure stability values
zzLow initial differential pressure
zzGood flow fatigue strength
zzGood water retention capacity (for water-absorbing filter
material)
4.2 filtration performance

The graph below shows the filtration performances of
different filtration ratings.
Filtration performance βx(C) (ISO 16889)
E 7.200.10/02.08
Particle size [µm]
46
4.3 REAL contamination retention capacity [g] Size Filter material: MM
Element type: RK
Size Filter material: BN4HC 10 µm 15 µm
Element type: D Element type: R 80 11.0 13.3
3 µm 5 µm 10 µm 20 µm 3 µm 5 µm 10 µm 20 µm
100 16.3 19.6
30 4.6 5.1 5.4 5.6 2.6 2.9 3.5 4.0 120 20.7 25.0
35 7.2 8.1 8.6 8.8 - - - - 151 26.6 31.4
55 14.0 15.8 16.6 17.2 - - - - 201 50.9 61.4
60 6.5 7.3 7.8 8.0 5.7 6.3 7.6 8.6 251 61.9 74.7
75 21.6 24.3 25.7 26.5 10.3 11.4 13.7 15.5 300 55.6 67.1
90 - - - - 12.2 13.5 16.2 18.3 350 87.0 105.0
95 27.5 30.9 32.7 33.7 - - - - 400 67.4 81.3
110 13.8 15.5 16.4 16.9 12.0 13.3 16.0 18.1 800 86.3 104.2
140 18.1 20.3 21.5 22.2 - - - -
150 - - - - 20.4 22.6 27.2 30.8 Size Filter material: ECON2
160 19.8 22.2 23.5 24.3 18.6 20.7 24.9 28.1 Element type: R
165 - - - - 18.7 20.7 24.9 28.2 3 µm 5 µm 10 µm 20 µm
185 - - - - 25.6 28.4 34.1 38.6 30 2.6 2.9 3.5 4.0
210 - - - - 50.7 56.2 67.6 76.5 60 5.7 6.3 7.6 8.6
240 32.3 36.3 38.4 39.6 29.3 32.5 39.1 44.2 75 10.3 11.4 13.7 15.5
270 - - - - 78.4 86.9 104.5 118.2 90 12.2 13.5 16.2 18.3
280 70.6 79.3 83.9 86.6 62.3 69.0 83.0 93.9 110 12.0 13.3 16.0 18.1
330 47.2 53.1 56.1 57.9 38.4 42.6 51.2 57.9 150 20.4 22.6 27.2 30.8
500 76.9 86.5 91.5 94.4 58.9 65.3 78.6 88.9 160 18.6 20.7 24.9 28.1
600 - - - - 145.5 161.3 194.0 219.4 165 18.7 20.7 24.9 28.2
660 102.2 114.9 121.5 125.4 87.1 96.5 116.1 131.3 185 25.6 28.4 34.1 38.6
750 - - - - 147.1 163.0 196.1 221.9 240 29.3 32.5 39.1 44.2
850 - - - - 112.1 124.2 149.5 169.1 280 62.3 69.0 83.0 93.9
950 - - - - 130.0 144.1 173.3 196.1 330 38.4 42.6 51.2 57.9
990 154.5 173.7 183.7 189.5 - - - - 500 58.9 65.3 78.6 88.9
1300 - - - - 181.0 200.7 241.4 273.1 660 87.1 96.5 116.1 131.3
1320 209.9 236.0 249.6 257.5 - - - - 750 147.1 163.0 196.1 221.9
1500 220.0 226.0 238.0 246.0 - - - - 850 112.1 124.2 149.5 169.1
1700 - - - - 229.8 254.7 306.4 346.6 950 130.0 144.1 173.3 196.1
2600 - - - - 369.4 409.4 492.5 557.2 1300 181.0 200.7 241.4 273.1
1700 229.8 254.7 306.4 346.6
2600 369.4 409.4 492.5 557.2
Size Filter material: BH4HC
Element type: D
3 µm 5 µm 10 µm 20 µm Size Filter material: BN4AM
30 3.0 2.9 3.2 3.7 Element type: R
60 4.6 4.5 5.0 5.7 3 µm 10 µm
110 10.1 9.9 10.9 12.4 330 55.0 60.0
660 120.0 140.0
140 13.3 13.0 14.3 16.3
950 170.0 190.0
160 12.9 12.6 13.9 15.9 1300 240.0 270.0
240 21.6 21.1 23.2 26.5 2600 490.0 540.0
280 48.1 47.1 51.8 59.1
330 34.6 33.9 37.2 42.5
500 57.5 56.3 61.8 70.5
660 76.8 75.2 82.6 94.3
990 111,8 109.4 120.2 137.2
1320 153.8 150.7 165.5 188.8
1500 126.4 137.8 160.9 195.3
Size Filter material: BN4HC (Dimensions to DIN 24550)

Element type: DN Element type: RN
3 µm 6 µm 10 µm 25 µm 3 µm 6 µm 10 µm 25 µm
40 5.2 5.6 6.3 7.0 7.1 8.0 8.9 10.6
63 9.2 9.9 11.1 12.8 13.0 14.7 16.3 19.6
100 15.4 16.5 18.6 20.6 22.0 24.7 27.5 33.0
160 27.5 29.3 33.1 36.7 36.2 40.7 45.3 54.2
250 46.0 49.0 55.2 61.3 61.4 69.1 76.8 92.1
400 76.2 81.3 91.4 101.5 88.2 99.2 110.2 132.3
630 - - - - 148.6 167.3 185.8 222.9
Size Filter material: BH4HC (Dimensions to DIN 24550)

Element type: DN
3 µm 6 µm 10 µm 25 µm
40 4.1 4.4 5.2 6.2
63 7.3 7.9 9.2 11.2
100 12.2 13.2 15.5 18.9
160 21.8 23.9 27.8 33.8
250 38.1 41.7 48.6 59.0
400 63.6 69.5 81.0 98.3
E 7.200.10/02.08
47
5. filter areas [cm²]
Size Filter material: Filter material: Filter material: Filter material: Filter material: Filter material: Filter material:
V W/HC W V W W/HC P/HC
(VB on request) Element type: D (VB on request) Element type: R
30 268 - 256 221 256 - 283
60 318 418 330 372 330 507 572
110 648 910 672 758 672 1034 1166
140 852 1200 884 - - - -
160 1082 1144 857 1071 857 1607 1978
165 - - - - 1556 1556 1915
240 1702 1911 1348 1685 1348 2527 3110
280 3615 4264 2862 - - - -
330 2260 3133 1795 2081 1795 3695 4230
500 3640 5207 2891 3182 2745 5651 6470
660 4770 6958 3795 4659 3998 8232 8722
850 - - - 5999 5148 10599 11230
950 - - - 6813 5596 11521 15221
990 - 10091 - - - - -
1300 - - - 9520 7820 16099 21269
1320 - 13916 - - - - -
1700 - - - - 10550 21730 23020
2600 - - - 19424 15954 32847 43394
6. BYPASS Valve graphs 660, 850, 1700

The bypass graphs apply to mineral oil with a density of 0.86 kg/dm³.
The valve differential pressure changes proportionally to the density.
∆p [bar]
30 75, 160, 165, 185, 240, 280
∆p [bar]
∆p [bar]
Q [l/min]
950, 1300, 2600
Q [l/min] Q [l/min]
∆p [bar]
60, 90, 110, 140, 150 210, 270, 330, 500, 750
∆p [bar]
∆p [bar]
Q [l/min]
Q [l/min] Q [l/min]

E 7.200.10/02.08

Tel.: 0 68 97 / 509-01
Fax: 0 68 97 / 509-300
48
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.5 Pressure Control Valve
Self-operated Pressure Regulators
Universal Excess Pressure Valve
Type 41-73
ANSI version
Application
Pressure regulators for set points from 0.075 to 400 psi
(5 mbar to 28 bar) · Valves in NPS ½ to 4 (DN 15 to
100) · Pressure rating Class 125 to 300 (PN 16 to
40) · Suitable for water, gases and vapors up to 660 °F
(350 °C) The valve opens when the upstream pressure rises
Special features
• Low-maintenance proportional regulators requiring no au-
xiliary energy
• Frictionless plug stem seal with stainless steel bellows
• Control line kit available for tapping the pressure directly at
the valve body
• Wide set point range and easy set point adjustment over a
nut
• Exchangeable actuator and positioning springs
• Spring-loaded, single-seated valve with upstream and
downstream pressure balancing1) by a stainless steel bellow
• Plug with soft sealing for high sealing requirements
• Low-noise standard plug · Special version with flow divider
St I for further noise level reduction (see Data Sheet
T 8081 EN)
Versions
Excess pressure valve for controlling the upstream pressure p1
to the adjusted set point. The valve opens when the upstream
pressure rises.
Type 41-73 · Standard version
Fig. 1 · Type 41-73 Universal Excess Pressure Valve
Type 2417 Valve · Valve in NPS ½ to 4 (DN 15 to 100) · Plug
with metal sealing · Body made of either cast iron A126B,
carbon steel A216 WCC or stainless carbon steel A351 CF8M
– EPDM diaphragm with PTFE protective foil
Type 2413 Actuator with EPDM rolling diaphragm and screw
fitting · All wetted parts are free of non-ferrous metal – Actuator for remote set point adjustment (autoclave control)
– Bellows actuator for valves DN 15 to 100 · Set point range
Extended versions NPS 3 (DN 80) · Set point ranges 30 to 85 psi, 75 to
Millibar excess pressure valve · NPS ½ to 3 (DN 15 to 150 psi, 150 to 300 psi, 300 to 400 psi (2 to 6 bar, 5 to
DN 80) · For pressure set points from 0.075 to 0.75 psi (5 to 10 bar, 10 to 22 bar, 20 to 28 bar)
50 mbar) – Valve with flow divider St I for particularly low-noise opera-
tion with gases and vapors
Safety excess pressure valve · With leakage line connection
and seal or two diaphragms and diaphragm rupture indicator – Version completely in stainless steel
– Stainless Cr steel seat and plug with PTFE soft sealing
Special versions (max. 440 °F/max. 220 °C) · With EPDM soft sealing
– Control line kit for pressure tapping at the valve body (acces- (max. 300 °F/max. 150 °C)
sories) – Seat and plug armored for low-wear operation
– FPM rolling diaphragm for oils – Free of lubricants for high-purity water/gas
– Free of oil and grease for oxygen with FPM diaphragm – Free of oil and grease for high-purity applications
– Wetted plastic parts conforming to FDA regulations
1) For CV ≤ 1.2/KVS ≤ 1: without balancing bellows (max. 140 °F/max. 60 °C)
Associated Information Sheet T 2500 EN Edition October 2009
Associated Data Sheet for accessories T 2595 EN Data Sheet T 2518 EN

Principle of operation (see Fig. 2) according to the force of the positioning springs (7), which is
The medium flows through the valve (1) as indicated by the adjustable at the set point adjuster (6). When the force resulting
arrow. The position of the valve plug (3) and the area released from the upstream pressure p1 rises above the adjusted set
between the plug and seat (2) determine the flow rate. The plug point, the valve opens proportionally to the change in pressure.
stem (5) with the plug is connected to the stem (11) of the The fully balanced valves are equipped with a balancing
actuator (10). bellows (4). The downstream pressure p2 acts on the inside of
To control the pressure, the operating diaphragm (12) is the bellows, whereas the upstream pressure p1 acts on the
tensioned by the positioning springs (7) and the set point outside of the bellows. As a result, the forces produced by the
adjuster (6) so that the valve is closed by the force of the upstream and downstream pressures acting on the plug are
positioning springs when it is relieved of pressure (p1= p2). balanced.
The upstream pressure p1 to be controlled is tapped upstream of The valves are available with flow divider St I. When the flow
the valve and transmitted via the control line (14) to the divider St I is retrofitted, the valve seat must be replaced.
operating diaphragm (12) where it is converted into a
positioning force. This force is used to move the valve plug (3)
NPS ½ to 2 NPS 2½ to 4
DN 15 to 50 DN 65 to 100
Actuator with two diaphragms and diaphragm rupture indicator
Pillars are
turned into
the plane of
projection
Actuator with leakage line connection
30 to 85 psi
For 300 to For 150 to (2 to 6 bar)/
400 psi (20 315 psi (10 75 to 150 psi
to 28 bar) to 22 bar) (5 to 10 bar)
Fig. 2.1 · Type 41-73 Universal Excess Pressure Valve,
sectional view
1 Valve body (Type 2417) 14 Control line

2 Seat (exchangeable) 15 Condensation chamber
3 Plug (with metal sealing) 16 Filler plug
4 Balancing bellows 20 Two diaphragms
5 Plug stem 21 Diaphragm rupture indicator
6 Set point adjuster 25 Leakage line connection G ¼
7 Positioning springs 30 Metal bellows actuator
8 Bellows seal 31 Bellows with lower part
10 Type 2413 Actuator 32 Additional springs
11 Actuator stem 33 Control line connection G 3 8
12 Operating diaphragm 34 Bellows stem
with diaphragm plate 35 Bracket
13 Control line connection G 3 8 Metal bellows actuator
(screw joint with restriction)
Fig. 2.2 · Type 2413 Actuators, various versions
Fig. 2 · Principle of operation, Type 41-73 Universal Excess Pressure Valve
2 T 2518 EN
Valve for small flow rates
– CV ≤ 1.2 (KVS ≤ 1) – without balancing bellows
2 Seat
Plug with metal sealing, with Plug with soft sealing
3.1 Plug with metal sealing
flow divider St I
3.2 Plug with soft sealing
Fig. 3 · Type 41-73 Universal Excess Pressure Valve, equipped 3.3 Flow divider
Table 1 · Technical data · All pressures specified as gauge pressure

Valve Type 2417
Class 125, 150 or 300
Pressure rating
PN 16, 25 or 40
NPS ½ to 2 2½ and 3 4
Nominal size
DN 15 to 50 65 and 80 100
Max. perm. differential psi 360 1) 290 1) 230
pressure Δp bar 25 1) 20 1) 16
Temperature ranges See Fig. 6 · Pressure-temperature diagram
Valve Metal sealing: max. 660 °F (350 °C) · PTFE soft sealing: max. 430 °F (220 °C) · EPDM, FPM soft sealing:
plug max. 300 °F (150 °C) · NBR soft sealing: max. 140 °F (60 °C)
Leakage rate (standard version) Metal sealing: Leakage rate I ≤ 0.05 % of CV/KVS · Soft sealing: Leakage rate IV
Actuator with diaphragm Type 2413
0.075 to 0.42 psi 2) 2)
· 0.35 to 0.75 psi · 0.75 to 3.5 psi · 1.5 to 8.5 psi · 3 to 17 psi · 10 to 35 psi
30 to 75 psi · 65 to 145 psi · 115 to 230 psi
Set point ranges
5 to 30 mbar 2) · 25 to 50 mbar 2) · 0.05 to 0.25 bar · 0.1 to 0.6 bar · 0.2 to 1.2 bar · 0.8 to 2.5 bar
2 to 5 bar · 4.5 to 10 bar · 8 to 16 bar
Max. perm. pressure at actuator 1.5 times max. set point of the actuator used 3)
Gases 660 °F (350 °C), however, max. 175 °F (80 °C) 5) at the actuator · Liquids 300 °F (150 °C), with
Max. perm. temperature
condensation chamber max. 660 °F (350 °C) · Steam with condensation chamber max. 660 °F (350 °C)
Actuator with bellows Type 2413
Effective area 5.1 sq.in (33 cm²) 9.6 sq.in (62 cm²)
Max. perm. pressure at actuator 435 psi (30 bar) 220 psi (15 bar)
150 to 315 psi (10 to 22 bar) 30 to 85 psi (2 to 6 bar) 4)
Set point ranges
300 to 400 psi (20 to 28 bar) 75 to 150 psi (5 to 10 bar)
Set point spring 8000 N
1) For millibar excess pressure valve, max. perm. differential pressure Δp: 150 psi (10 bar) · For millibar excess pressure valve only ·
2)
3) Millibar excess pressure valve: max. 7.25 psi (0.5 bar) · 4) Set point spring 4400 N · 5) For oxygen max. 140 °F (60 °C)
Table 2 · Materials
Valve Type 2417
Pressure rating Cl 125 (PN 16) Cl 150 (PN 25) · Cl 300 (PN 40) Cl 150 (PN 25) · Cl 300 (PN 40)
Max. perm. temperature 570 °F (300 °C) 660 °F (350 °C) 660 °F (350 °C)
Body Cast iron A126B Carbon steel A216 WCC Stainl. carbon steel A351 CF8M
Seat CrNi steel CrNiMo steel
Plug CrNi steel CrNiMo steel
Seal ring for soft
PTFE with 15 % glass fiber · EPDM · NBR · FPM
seal
Guide bushing PTFE/Graphite
Balancing bellows and bellows seal Stainless forged steel 1.4571
Actuator Type 2413
Diaphragm cases Sheet steel DD11 (StW22) 1)
Diaphragm EPDM with fabric insert 2) · FPM for oils · NBR · EPDM with PTFE protective foil
1) In stainless steel version, CrNi steel · 2)Standard version; further details in “Special versions”
3 T 2518 EN
Table 3 · CV (KVS) coefficients and z values
Nominal Seat Ø CV · KVS 2) CV I · KVS I 1) z 1)
size Standard version Special version With flow divider
NPS · DN inch mm CV KVS CV KVS CV I KVS I
0.47 12 0.12 2) · 0.5 2) · 1.2 2) 0.1 · 0.4 · 1 – –
½ · 15
0.87 22 5 4 3 2.5 3.5 3 0.65
0.47 12 0.12 2) · 0.5 2) · 1.2 2) 0.1 · 0.4 · 1
¾ · 20 3·5 2.5 · 4 – –
0.87 22
7.5 6.3 6 5 0.6
0.47 12 0.12 2) · 0.5 2) · 1.2 2) 0.1 · 0.4 · 1 – –
1 · 25 – –
0.87 22
9.4 8 3 · 5 · 7.5 2.5 · 4 · 6.3 7 6 0.55
9.4 · 20 8 · 16
1½ · 40 1.5 38
23 20 17 15 0.45
20 16
2 · 50 1.5 38
37 32 30 25 0.4
23 · 37 20 · 32
2½ · 65 2.5 64
60 50 45 38 0.4
37 32
3 · 80 2.5 64
94 80 70 60 0.35
60 50
4 · 100 3.5 89
145 125 110 95 0.35
1) Terms for noise level calculation according to VDMA 24422 (edition 1.89)
2) For KVS ≤ 1.2/KVS ≤ 1: Valve without balancing bellows
Valve-specific correction terms

ΔLG · For gases and vapors: ΔLF · For liquids:
Values as specified in the diagram in Fig. 4 ΔLF = –10 · (XF – z) · y
with XF =
Δp and y = KV
p1 − pv KVS
ΔLG [dB(A)] Terms for control valve sizing according to DIN EN 60534,
Parts 2-1 and 2-2:
0
FL = 0.95 XT = 0.75
-4
z · Acoustical valve coefficient
-8
Seat Ø 1.0 0.8 0.6 0.4 0.2 CV I, KVS I · For installation of a flow divider St I as a
DN noise-reducing component · Flow characteristic differences
-12
between valves with and valves without flow dividers do not
occur until the valve has passed through approx. 80 % of its
-16
Δp
travel range.
X= p
1
-20
0 0.2 0.4 0.6 0.8 1.0
Fig. 4 · Diagram - ΔLG for gases and vapors -
4 T 2518 EN
Table 4 · Dimensions and weights
Excess pressure valve Type 41-73
Nominal size NPS (DN) ½ (15) ¾ (20) 1 (25) 1½ (40) 2 (50) 2½ (65) 3 (80) 4 (100)
inch – – 7.25 8.75 10.0 10.87 11.75 13.87
Cl 125
mm – – 184 222 254 276 298 352
inch 7.25 7.25 7.25 8.75 10.0 10.87 11.73 13.88
Length L Cl 150
mm 184 184 184 222 254 276 298 352
inch 7.50 7.63 7.75 9.25 10.50 11.50 12.50 14.50
Cl 300
mm 191 194 197 235 267 292 318 368
inch 13.19 15.35 20.08 20.67
Height H1
mm 335 390 510 525
inch 2.17 2.83 3.94 4.73
Height H3
mm 55 72 100 120
Set point ranges Dimensions Dimensions in inches and mm ( )
psi bar
0.075 to 0.005 Height H 17.63” (425)
0.42 2) to 0.03 Actuator Ø D = 19.29” (490 mm), A = 186 in² (1200 cm²)
0.35 to 0.025 Height H 17.63” (425 mm) 19.9” (480 mm) 24” (610 mm)
0.75 2) to 0.05 Actuator Ø D = 19.3” (490 mm), A = 186 in² (1200 cm²)
0.75 to 0.05 to Height H 16.73 (425 mm) 18.9” (480 mm) 24” (610 mm) 24.6” (625)
3.5 0.25 Actuator Ø D = 15” (380 mm), A = 100 in² (640 cm²)
1.5 to 0.1 Height H 16.73” (425 mm) 18.9” (480 mm) 24” (610 mm) 24.6” (625)
8.5 to 0.6 Actuator Ø D = 15” (380 mm), A = 100 in² (640 cm²)
0.2 to Height H 16.14” (410 mm) 18.11” (460 mm) 23.23” (590 mm) 241” (610)
3 to 17
1.2 Actuator Ø D = 11.2” (285 mm), A = 50 in² (320 cm²)
0.8 to Height H 16.14” (410 mm) 18.31” (465 mm) 23.43” (595 mm) 24” (610)
10 to 35
2.5 Actuator Ø D = 8.86” (225 mm), A = 25 in² (160 cm²)
23.23”
Height H 15.35” (390 mm) 17.52” (445 mm) 22.64” (575 mm)
30 to 75 2 to 5 (590)
Actuator Ø D = 6.69” (170 mm), A = 12 in² (80 cm²)
23.23”
65 to 4.5 to Height H 15.35” (390 mm) 17.52” (445 mm) 22.64” (575 mm)
(590)
150 10
Actuator Ø D = 6.69” (170 mm), A = 6 in² (40 cm²)
115 to Height H 15.35” (390 mm) 17.52” (445 mm) 22.64” (575 mm) 23.23”(590)
8 to 16
230 Actuator Ø D = 6.69” (170 mm), A = 6 in² (40 cm²)
0.075 to 0.005 lb 63 65 82.7 90.4 125.7 141 –

0.75 to 0.05 28.5 29 37.5 41 57 64 −
kg
lb 51 53 73 80 121 130 158

1.5 to 0.05 to
8.3 0.6 Weight for
kg 23 24 33 36 55 59 72
Class
150 1),
lb 39 41 58 68 107 124 146
0.2 to approx.
3 to 35
2.5 18 19 26 31 49 56 66
kg
30 to lb 29 32 51 58 97 114 136
2 to 16
230 14 15 23 27 44 52 62
kg
1) +10 % for Class 300
2) Millibar excess pressure valve
5 T 2518 EN
Type 2413
Actuator with metal
bellows
Diaphragm area · Height

Diaphragm area 5.1 in² (33 cm²) 9.6 in² (62 cm²)
Type 41-73
Universal Excess Pressure H4 7.9 in (200 mm) 8.5 in (215 mm)
Valve Weight
NPS ½ to 2 (DN 15 to 50) 17.6 lb (8 kg) 37.5 lb (17 kg)
NPS 2½ to 4 (DN 65 to 100) 26.5 lb (12 kg) 39.7 lb (18 kg)
Fig. 5 · Dimensions
Installation Accessories
Normally, the valve is installed with the actuator suspended – Screw joints for connection of the control line 3 8” to the filler
downwards. Install pipelines horizontally with a slight neck (included in the scope of delivery and in the price). Ot-
downward slope on both sides of the valve for drainage of the her screw joints are available on request.
condensate. – Condensation chamber for steam condensation and protec-
Millibar excess pressure valves are to be installed standing tion of the operating diaphragm against extreme temperatu-
upright with the actuator pointing upwards. res. This chamber is necessary for steam and liquids above
For further details on installation, refer to Mounting and 300 °F (150 °C).
Operating Instructions EB 2517 EN. – Control line kit - optionally with or without condensation
The direction of medium flow must correspond with the arrow chamber - for direct attachment to the valve and actuator
on the valve body. (pressure tapped directly at the valve body, for set points
– Valve and actuator are delivered separately. ≥ 10 psi (≥ 0.8 bar).
– The control line must be adapted to match the onsite condi- Detailed information on accessories can be found in Data Sheet
tions and is not delivered with the valve; on customer re- T 2595 EN.
quest, a control line kit for the direct pressure tapping at the
valve body (see accessories) is available.
Pressure-temperature diagram – ASTM materials –

The range of application of the valves and the permissible Ordering text
pressures and temperatures are limited by the Universal Excess Pressure Valve Type 41-73
pressure-temperature diagram and the nominal pressure Extended version ...
ratings.
Nominal size NPS (DN) ...
Body material ..., Class (PN) ...
CV coefficient (KVS coefficient) …
Set point range ... psi (bar)
Optionally, accessories ...
Optionally, special version ...
Fig. 6 · Pressure-temperature diagram

Specifications subject to change without notice.
SAMSON AG · MESS- UND REGELTECHNIK

Weismüllerstraße 3 · 60314 Frankfurt am Main · Germany
2009-11
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507

Internet: http://www.samson.de T 2518 EN
Self-operated Regulators
Universal Excess Pressure Valve

Type 41-73
Type 41-73 Excess Pressure Valve
Mounting and
Operating Instructions
EB 2517 EN
Edition December 2007
Contents
Contents Page
1 Design and principle of operation . . . . . . . . . . . . . . . . . . . . . . 4
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Control line, condensation chamber and needle valve. . . . . . . . . . . . . 7
2.4 Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Set point adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Cleaning and maintenance . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Replacing the operating diaphragm . . . . . . . . . . . . . . . . . . . . 10
5 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7 Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Definitions of the signal words used in these instructions
CAUTION! Note:
CAUTION indicates a hazardous situation Supplementary explanations, information
which, if not avoided, may result in minor or and tips
moderate injury.
NOTICE
NOTICE indicates a property damage
message.
2 EB 2517 EN
Safety instructions
General safety instructions

4 The regulators must be installed, started up and serviced by fully trained
and qualified personnel only, observing the accepted industry codes and
practices. Make sure employees or third persons are not exposed to any
danger
All safety instructions and warnings in these instructions, particularly those
concerning installation, start-up, and maintenance, must be observed.
4 The regulator complies with the requirements of the European Pressure
Equipment Directive 97/23/EC. The declaration of conformity issued for a
valve bearing the CE marking includes information on the applied
conformity assessment procedure.
The declaration of conformity can be provided on request.
4 For appropriate operation, make sure that the regulator is only used in
applications where the operating pressure and temperatures do not exceed
the operating values based on the sizing data submitted in the order.
4 Note that the manufacturer does not assume any responsibility for damage
caused by external forces or any other external factors.
Any hazards which could be caused in the regulator by the process
medium or operating pressure are to be prevented by means of
appropriate measures.
4 Proper shipping and appropriate storage are assumed.
EB 2517 EN 3
Design and principle of operation
1 Design and principle of 2 Installation

operation
2.1 Assembly
The Type 41-73 Excess Pressure Valve con-
sists of a Type 2417 Opening Valve and a Valve and actuator can be assembled before
Type 2413 Actuator. The valve and actuator or after the valve has been installed in the
are delivered separately and must be assem- pipeline. Push the actuator (10) together with
bled according to the instructions in section the actuator stem (11) through the hole in the
2.1. bracket (8) onto the spigot of the bellows seal
(5.1). Align and secure it with the nuts (9,
The excess pressure valve is used to maintain
width across flats SW 17).
the pressure upstream of the valve at an ad-
For actuators in DN 65 to DN 100 and with a
justed set point.
metal bellows, remove the bracket (8) from
The process medium to be regulated flows the valve and unscrew the pillars. Screw the
through the valve between the seat (2) and the pillars into the actuator flange. Push the actu-
plug (3) in the direction indicated by the ar- ator onto the valve and secure the pillar at the
row on the body. The position of the valve valve flange using the nuts.
plug determines the flow rate, and thus the
pressure ratio across the valve. The plug stem
is sealed by a frictionless metal bellows (5.1). 1 Valve body
2 Seat
The upstream pressure p1 is transmitted 3 Plug
through the condensation chamber (18) and 4 Balancing bellows
the control line (17) to the operating dia- 5 Plug stem
phragm (12) where it is converted into a posi- 5.1 Bellows seal
tioning force. For actuator versions with a 6 Set point adjustment
bellows, the pressure is transmitted to the op- 7 Positioning springs
erating bellows (12.1). The positioning force 8 Bracket
9 Fastening nuts
is used to move the valve plug according to
10 Actuator
the force of the positioning springs (7). The
11 Actuator stem
spring force is adjustable at the set point ad- 12 Operating diaphragm
justment (6). Valves with Kvs 2.5 or higher 12.1 Operating bellows
feature a balancing bellows (4). The up- 13 Diaphragm plate
stream pressure acts on the outside of the bel- 14 Nut
lows and the downstream pressure on the in- 15 Nuts and bolts
side of the bellows. As a result, the forces pro- 16 Control line connection (for steam
duced by the upstream and downstream including screw joint with restriction)
pressures acting on the plug are balanced. 17 Control line to be provided on site
(control line kit (accessory) for direct
Depending on the valve and actuator used, connection to the body)
the regulator can be upgraded to create a 18 Condensation chamber
millibar excess pressure valve or a safety ex- 19 Filler plug
cess pressure valve.
4 EB 2517 EN
Design and principle of operation
Type 2417 Valve
DN 15 to DN 50
Pillars turned 90°

into the plane of
projection
Type 2413 Actuator with bellows for 2 to 6,

5 to 10, 20 to 28 and 10 to 22 bar
Type 2413 Diaphragm Actuator
DN 65 to DN 100
Fig. 1 · Sectional drawings
EB 2517 EN 5
Installation
2.2 Mounting position

Standard mounting position for
medium temperatures above 0 °C.
NOTICE
Not permissible for millibar pressure
Protect the regulator from icing up when con- regulators.
trolling media that can freeze. Remove the
regulator from the pipeline when the plant is
shut down if the regulator is not installed ar-
eas free from frost.
Mounting position for gases and
liquids with medium temperatures
up to 80 °C.
Flush the pipeline thoroughly before installing
the regulator to ensure that any sealing parts, Mounting position compulsory for
millibar pressure regulators.
weld spatter and other impurities carried
along by the process medium do not impair
the proper functioning of the valve, above all
the tight shut-off. Not permissible!
NOTICE
Fig. 2 · Mounting positions
Install a strainer (e.g. SAMSON Type 2) up-
stream of the regulator (see section 2.4).
Install the excess pressure valve in a horizon-

tal pipeline. On installing the valve, make NOTICE
sure the direction of flow corresponds with the Do not attach supports directly to the valve or
arrow on the body. For media with a ten- actuator.
dency to condensate, install the pipeline with
a slight downward slope on both sides so that
the condensate can drain properly. If the If a bypass line is to be used, it must be con-
pipeline upstream and downstream of the nected downstream of the pressure tapping
valve run vertically upwards, an automatic point. Install a shut-off valve in the bypass
water drainage (SAMSON Type 13E Steam line.
Trap) is required. Make sure you choose a
place of installation that allows you to freely Notice: Do not install any instruments (e.g.
access the regulator even after the entire plant temperature regulators or shut-off valves)
has been completed. The regulator must be which restrict the cross-section of the pipe be-
installed free of stress. If necessary, support tween the pressure tapping point and the
the piping near the connections. valve.
6 EB 2517 EN
Installation
2.3 Control line, condensation mounting position of the condensation cham-

chamber and needle valve ber is indicated by an adhesive label on the
chamber itself as well as by an arrow and the
Control line · A control line must be provided word "top" stamped onto the top of the cham-
at the site of installation, e.g. a 3 8“ pipe for ber.
steam and an 8 x 1 or 6 x 1 mm pipe for This mounting position must be adhered to;
air/water. otherwise the safe functioning of the excess
Connect the control line to the upstream line pressure valve cannot be guaranteed.
(p1) at least one meter away from the valve Weld the line coming from the pressure tap-
inlet. ping point to the 3 8“ pipe socket on the cham-
Weld the control line at the side in the middle ber. Install the condensation chamber at the
of the pipe, inclining at a ratio of approxi- highest point of the pipeline. Consequently,
mately 1:10 up to the condensation chamber. the control line between condensation cham-
ber and actuator must also be installed with a
Control line kit · A control line kit for tapping
downward slope. In this case, use a 3 8“ pipe
pressure directly at the valve body is avail-
with screw fittings.
able as an accessory from SAMSON.
If the control line connection is located below
Condensation chamber · Refer to Table 1. A
the middle of the valve inlet flange, arrange
condensation chamber is required for liquids
the condensation chamber at the same level
above 150 °C as well as for steam. The
Table 1 · Assignment of condensation chamber (4) Actuator Item no. · Condensation chamber
to regulator A in cm² DN 15 to DN 50 DN 65 to DN 250
640 1190-8789 1190-8790
320 1190-8788 1190-8789
160/80/40 1190-8788
1 Shut-off valve 6 Downstream

2 Upstream pressure gauge pressure gauge
3 Strainer 7 Shut-off valve NOTICE
4 Condensation chamber Always install millibar pressure regulators
5 Excess pressure valve upright with actuator on top.
Fig. 3 · Examples of installation with steam
EB 2517 EN 7
Operation
as the inlet flange. In this case, use a pipe upstream pressure tapping point (not be-
which is at least ½“ in size for the control line tween the tapping point and the valve!).
from the tapping point to the condensation
chamber. 3 Operation
If the control line is connected above the mid-
dle of the valve inlet flange, install the con-
3.1 Start-up
densation chamber at the same level of the First start up the regulator after mounting all
upstream pressure tapping point. The addi- the components. Make sure the control line is
tional pressure of the condensate head must open and correctly connected.
be compensated for by adjusting the set point Fill the plant s l o w l y with the process me-
to a higher value. dium.
Needle valve · If the regulator tends to hunt,
we recommend installing a SAMSON screw NOTICE
joint with restriction (needle valve) at the con- The permissible pressure at the actuator must
trol line connection (16). not be exceeded on testing the pressure of the
plant (refer to Technical data in section 8).
2.4 Strainer The maximum permissible differential pres-
The strainer must be installed upstream of the sure for millibar excess pressure valves
excess pressure valve. Make sure the direc- (1200 cm² actuator) is 10 bar. The maximum
tion of medium flow corresponds with the di- permissible pressure at the actuator must not
rection indicated by the arrow on the strainer. exceed 0.5 bar.
The filter element must be suspended to hang
downwards. Remember to leave enough
For regulating steam
space to remove it.
Unscrew filler plug (19) on the condensation
chamber. Use the included plastic funnel or a
2.5 Shut-off valve jug to pour in water until it starts to overflow.
We recommend installing a hand-operated Screw the filler plug back in and tighten it.
shut-off valve both upstream of the strainer The excess pressure valve is now ready for
and downstream of the regulator to be able to operation.
shut down the plant for cleaning and mainte-
Open the hand-operated shut-off valves
nance, and when the plant is not used for lon-
slowly to prevent water hammer.
ger periods of time.
For regulating liquid
2.6 Pressure gauge To start up the excess pressure valve, open
To monitor the pressures in the plant, install a shut-off valves slowly. For actuators with an
pressure gauge both upstream and down- effective diaphragm area of 640 cm², loosen
stream of the regulator. Install the pressure the vent screw. Allow all the air to escape,
gauge on the upstream side in front of the then retighten it. For temperatures above
8 EB 2517 EN
Operation
150 °C, first fill the required condensation Table 2 · Initial adjustment of the set point
chamber with the process medium.
Set point
Nominal size DN
range
3.2 Set point adjustment
8 to 16 bar 15 to 25 32 to 50 65 to 100
The required upstream pressure is set by turn-
Set point
10 bar x = 74 mm x = 91 mm x = 133 mm
ing the set point adjustment (6) using an
open-end wrench up to DN 50 with width 12 bar x = 82 mm x = 102 mm x = 150 mm
across flats SW 19 and for DN 65 and larger 14 bar x = 89 mm x = 113 mm x = 168 mm
with SW 22. Turn clockwise to increase the
4.5 to 10 bar
upstream pressure and turn counterclockwise
Set point
to reduce it. 5.9 bar x = 70 mm x = 85 mm x = 131 mm
7.3 bar x = 78 mm x = 97 mm x = 152 mm
The pressure gauge located on the upstream
pressure side (in front of the valve) allows the 8.6 bar x = 86 mm x = 103 mm x = 172 mm
adjusted set point to be monitored. 2 to 5 bar
An initial adjustment of the set point can also

Set point
2.8 bar x = 68 mm x = 82 mm x = 126 mm
be made by turning the set point adjustment 3.5 bar x = 77 mm x = 95 mm x = 148 mm
until the distance x (see Fig. 4) is reached.
4.3 bar x = 85 mm x = 107 mm x = 170 mm
Table 2 lists the set points and their assigned 0.8 to 2.5 bar
distance x for the regulators and their various
Set point
1.2 bar x = 64 mm x = 77 mm x = 117 mm

set point ranges.
1.7 bar x = 74 mm x = 91 mm x = 142 mm
2.1 bar x = 84 mm x = 106 mm x = 167 mm
0.2 to 1.2 bar
Set point
0.45 bar x = 56 mm x = 66 mm x = 98 mm
0.70 bar x = 68 mm x = 83 mm x = 127 mm
1.0 bar x = 80 mm x = 100 mm x = 157 mm
0.1 to 0.6 bar
Set point
Set point 0.23 bar x = 56 mm x = 66 mm x = 98 mm

adjustment (6)
0.35 bar x = 68 mm x = 83 mm x = 127 mm
0.48 bar x = 80 mm x = 100 mm x = 157 mm
0.05 to 0.25 bar
Fig. 4 · Initial adjustment of set point using “x”
Set point
0.10 bar x = 55 mm x = 65 mm x = 92 mm
0.15 bar x = 66 mm x = 80 mm x = 116 mm
0.20 bar x = 76 mm x = 95 mm x = 139 mm
EB 2517 EN 9
Cleaning and maintenance
3.3 Decommissioning NOTICE

Close first the shut-off valve on the upstream Make absolutely sure that no torque is ap-
side of the valve and then on the downstream plied to the bellows seal (5.1) during assem-
side of the valve. bly or disassembly. Otherwise, the metal bel-
lows will be destroyed.
4 Cleaning and maintenance
The excess pressure valve is maintenance
free. Nevertheless, it is subject to natural
4.1 Replacing the operating
wear, particularly at the seat, plug and oper- diaphragm
ating diaphragm. If the upstream pressure deviates from the set
Depending on the operating conditions, the point considerably, check if the diaphragm is
regulator needs to be checked at regular in- leaking and, if necessary, replace it.
tervals to avoid possible malfunctions. Details 1. Shut down the plant by slowly closing the
on faults and how to remedy them can be shut-off valves. Relieve the relevant sec-
found in Table 3 on page 11. tion of the pipeline of pressure and, if
necessary, drain it as well.
CAUTION! 2. Unscrew the control line (17) and clean it.
On performing any work on the pressure reg-
ulator, make sure the relevant section of the 3. Loosen the bolts (15) at the actuator and
pipeline is depressurized and, depending on remove the cover plate.
the process medium, drained as well. We rec- 4. Unscrew the nut (14) and lift off the dia-
ommend to remove the valve from the pipe- phragm plate (13).
line.
5. Replace the operating diaphragm (12)
For high temperatures, allow the regulator to
with a new one.
cool down to ambient temperature before
starting any work on it. 6. Proceed in the reverse order to reassem-
Interrupt or shut off the control line to avoid ble the regulator. For start-up, proceed
any hazards which could be caused by mov- as described in section 3.1.
ing parts.
As valves are not free of cavities, remember
that residual process medium might still be
contained in the valve. This applies in particu-
lar to valve versions with a balancing bel-
lows.
10 EB 2517 EN
Cleaning and maintenance
Table 3 · Troubleshooting
Fault Possible reasons Remedy
Insufficient pressure pulses on the Clean the control line and the screw joint
actuator diaphragm with restriction.
Seat and plug worn down by deposits Disassemble the regulator and replace
or foreign particles damaged parts.
Reconnect control lines at a different place.
Pressure tapped at the wrong place Do not tap pressure at pipe bends or
necks.
Pressure exceeds
the adjusted set With steam: Condensation chamber in Reconnect chamber at a different place or
point the wrong position or too small replace it (see p. 7, Table 1 and sec. 2.3).
Install larger screw joint at the diaphragm
Control response too slow
actuator.
Disassemble the regulator and replace
Foreign particles blocking the plug
damaged parts.
Valve installed against the flow; see Check direction of flow. Install valve
arrow on body correctly.
Pressure tapped at the wrong place Reconnect control lines at a different place.
Pressure drops
With steam: Condensation chamber in Reconnect chamber at a different place or
below the
the wrong position or too small replace it (see p. 7, Table 1 and sec. 2.3).
adjusted set
point Disassemble the regulator and replace
Foreign particles blocking the plug
damaged parts.
Jerky control Increased friction, e.g. due to foreign Remove foreign particles. Replace
response particles between seat and plug damaged parts.
Restriction in the screw joint of the Remove foreign particles. Replace
Slow control actuator dirty or too small damaged parts.
response
Dirt in the control line Clean the control line.
Check valve sizing. Select smaller KVS
Valve too large
coefficient, if necessary.
Upstream
pressure Restriction in the screw joint of the
Install smaller screw joint.
fluctuates actuator too large
Pressure tapped at the wrong place Select better place for pressure tapping.
Check sizing. Install flow divider with
Loud noises High flow velocity, cavitation
gases and steam.
EB 2517 EN 11
Customer service
5 Customer service
Should any malfunctions or any defect occur, SAMSON's After-Sales Service is prepared to
help you on site.
You can also send the defective regulator directly to your local SAMSON representative for re-
pair. Addresses of SAMSON subsidiaries, agencies and service centers are listed in the prod-
uct catalogs and in the Internet at www.samson.de.
To allow SAMSON to find the fault and to have an idea of the installation situation, specify the
following details (refer to the nameplate):
4 Type and nominal size of the valve
4 Model number with index
4 Upstream and downstream pressure
4 Temperature and control medium
4 Minimum and maximum flow rate
4 Has a strainer been installed?
4 Sketch of the installation with exact position of regulator and all additional installed
components (shut-off valves, pressure gauges, etc.).
6 Dimensions
Type 2417 Valve

Type 2413
Actuator with
Type 41-73 bellows
Universal
Excess Pressure
Valve
Actuator with bellows
Type 2413 Height
Diaphragm Actuator Effective area 33 cm² 62 cm²
H4 200 mm 215 mm
Weight
DN 15 to 50 8 kg 17 kg
DN 65 to 100 12 kg 18 kg
Fig. 5 · Dimensions
12 EB 2517 EN
Dimensions
Table 4 · Dimensions in mm and weights

Excess Pressure Valve Type 41-73
Nominal size DN 15 20 25 32 40 50 65 80 100
Length L 130 150 160 180 200 230 290 310 350
Set point range Height H1 315 370 500 515
in bar Height Other materials 55 72 100 120
H3 Forged steel 53 − 70 − 92 98 − 128 −
Height H 425
0.005
Actuator Ø D = 490 mm, A = 1200 cm²
to 0.03
Valve spring force F 600 N
Height H 425 480 610
0.025 to 0.05 Actuator Ø D = 490 mm, A = 1200 cm²
Height H 425 480 610 625
Height H 425 480 610 625
0.1
Actuator Ø D = 380 mm, A = 640 cm²
to 0.6
Height H 410 460 590 610
Height H 410 465 595 610
Height H 390 445 575 590
2 to 5 Actuator Ø D = 170 mm, A = 80 cm²
Height H 390 445 575 590
4.5 to 10 Actuator Ø D = 170 mm, A = 40 cm²
Height H 390 445 575 590
8 to 16 Actuator Ø D = 170 mm, A = 40 cm²
0.005 to 0.05 28.5 29.5 35.5 37.5 41 57 64 −
0.05 to 0.6 Weight, based on cast 22.5 23.5 29.5 31.5 35 51 58 67
0.2 to 2.5 iron1), approx. kg 16 18 23.5 25.5 29 45 52 61
2 to 16 12 13 18.5 21 24 40 47 56
1) +10 % for other materials
EB 2517 EN 13
Nameplates
7 Nameplates
A nameplate is attached to the valve and actuator.
Valve nameplates DIN version

DIN version
1 Valve type
2 Model number
3 Model number index
4 Order number or order date
5 KVS coefficient
8 Nominal size
9 Nominal pressure
10 Perm. differential pressure
ANSI version 11 Perm. temperature
12 Body material
ANSI version
5 Nominal size
8 Perm. differential pressure
9 Perm. temperature (°F)
10 Body material
11 CV coefficient (KVS x 1.17)
12 ANSI Class (pressure rating)
Actuator nameplate
1 Model number
2 Model number index
3 Order number or order date
4 Effective area
5 Labeling acc. to DIN
6 Labeling acc. to ANSI
7 Max. perm. pressure
8 Nominal size
9 Differential pressure
10 Set point range
11 Diaphragm material
12 Year of manufacture
Fig. 6 · Nameplates
14 EB 2517 EN
Technical data
8 Technical data
Table 5 · Technical data · All pressures in bar (gauge)
Valve Type 2417
Nominal pressure PN 16, 25 or 40
Nominal size DN 15 to 50 65 to 80 100
Max. perm. differential pressure Δp 25 bar1) 20 bar1) 16 bar
Temperature ranges Refer to T 2517 EN · Pressure-temperature diagram
Metal sealing: max. 350 °C · Soft PTFE sealing: max. 220 °C
Valve plug
Soft EPDM or FPM sealing: max. 150 °C · Soft NBR sealing: max. 60 °C
Metal sealing: Leakage class I ≤ 0.05 % of Kvs
Leakage rate (standard version)
Soft sealing: Leakage class IV
Diaphragm actuator Type 2413
5 to 30 mbar 2) · 25 to 50 mbar 2) · 0.05 to 0.25 bar · 0.1 to 0.6 bar
Set point ranges 0.2 to 1.2 bar · 0.8 to 2.5 bar · 2 to 5 bar · 4.5 to 10 bar
8 to 16 bar
Max. perm. pressure at actuator 1.5 x max. set point of the actuator 3)
Gases 350 °C, however, at actuator max. 80 °C
Max. perm. temperature Liquids 150 °C, with condensation chamber max. 350 °C
Steam with condensation chamber max. 350 °C
Actuator with bellows Type 2413
Effective area 33 cm² 62 cm²
Max. perm. pressure at actuator 30 bar 20 bar
10 to 22 bar 2 to 6 bar 4)
Set point ranges
20 to 28 bar 5 to 10 bar
Positioning spring 8000 N
1) For millibar excess pressure valve: max. perm. differential pressure Δp: 10 bar
2) Only for millibar excess pressure valve
3) Millibar excess pressure valve: max. 0.5 bar
4) Positioning spring 4400 N
EB 2517 EN 15
S/Z 2008-01
SAMSON AG · MESS- UND REGELTECHNIK

Weismüllerstraße 3 · 60314 Frankfurt · Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507
Internet: http://www.samson.de EB 2517 EN
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.6 Adjustable Orifice
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.7 Speed Governor Woodward 2301D-ST
Installation and Operation Manual
2301D-ST Digital Electronic Load Sharing

& Speed Control for Small Steam Turbines
8273-128—Normal Mounting Location

8273-1001—Hazardous Mounting Location
Manual 26184 (Revision E)

WARNING—DANGER OF DEATH OR PERSONAL INJURY
WARNING—FOLLOW INSTRUCTIONS
Read this entire manual and all other publications pertaining to the work to be performed
before installing, operating, or servicing this equipment. Practice all plant and safety
instructions and precautions. Failure to follow instructions can cause personal injury and/or
property damage.
WARNING—OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify
that you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The
latest version of most publications is available at:
www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get
the latest copy.
WARNING—OVERSPEED PROTECTION
The engine, turbine, or other type of prime mover should be equipped with an overspeed
shutdown device to protect against runaway or damage to the prime mover with possible
personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover control
system. An overtemperature or overpressure shutdown device may also be needed for
safety, as appropriate.
WARNING—PROPER USE
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or property
damage, including damage to the equipment. Any such unauthorized modifications: (i)
constitute "misuse" and/or "negligence" within the meaning of the product warranty
thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product
certifications or listings.
CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

CAUTION—BATTERY CHARGING
To prevent damage to a control system that uses an alternator or battery-charging device, make
sure the charging device is turned off before disconnecting the battery from the system.
CAUTION—ELECTROSTATIC DISCHARGE
Electronic controls contain static-sensitive parts. Observe the following precautions to
prevent damage to these parts.
• Discharge body static before handling the control (with power to the control turned off,
contact a grounded surface and maintain contact while handling the control).
• Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit
boards.
• Do not touch the components or conductors on a printed circuit board with your hands
or with conductive devices.
IMPORTANT DEFINITIONS
• A WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
• A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in
damage to equipment or property.
• A NOTE provides other helpful information that does not fall under the warning or caution
categories.
Revisions—Text changes are indicated by a black line alongside the text.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is
assumed by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 2002
All Rights Reserved
Manual 26184 2301D-ST
Contents
REGULATORY COMPLIANCE........................................................................ IV
ELECTROSTATIC DISCHARGE AWARENESS .................................................. V
CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Description..............................................................................................................1
Applications ............................................................................................................2
References .............................................................................................................3
CHAPTER 2. INSTALLATION.......................................................................... 4
Introduction.............................................................................................................4
Unpacking...............................................................................................................4
Mounting Considerations........................................................................................4
Electrical Connections............................................................................................9
Installation Check-out Procedure .........................................................................21
CHAPTER 3. SERVICE AND CONFIGURATION PROCEDURES ......................... 22
Introduction...........................................................................................................22
Watch Window Program.......................................................................................22
Configure Menu Descriptions ...............................................................................27
Save and Reset 2301D-ST Control......................................................................36
Service Menu Descriptions...................................................................................36
CHAPTER 4. DESCRIPTION OF OPERATION ................................................. 70
CHAPTER 5. PRE-START AND START-UP PROCEDURES .............................. 83
Introduction...........................................................................................................83
Start-up Adjustments ............................................................................................83
Dynamic Adjustment.............................................................................................84
Speed Sensor Check ...........................................................................................85
Current Transformer (CT) Phasing Check ...........................................................85
Phase Correction Procedure ................................................................................86
Load Calibration Adjustment ................................................................................88
Droop Adjustment.................................................................................................89
CHAPTER 6. TROUBLESHOOTING ............................................................... 90
Introduction...........................................................................................................90
Troubleshooting Procedure ..................................................................................90
Control Start-up ....................................................................................................90
Control Test and Calibration.................................................................................91
CHAPTER 7. COMMUNICATIONS ................................................................. 96
Modbus Communication.......................................................................................96
Monitor Only .........................................................................................................96
Monitor And Control..............................................................................................96
Modbus Communication Mode.............................................................................96
Modbus Function Codes ......................................................................................97
Port Adjustments ..................................................................................................98
2301D-ST Control Modbus Addresses ................................................................98
Boolean Writes .....................................................................................................98
Boolean Reads .....................................................................................................99
Analog Reads .......................................................................................................99
Analog Writes .......................................................................................................99
Modbus Scale Factors........................................................................................100
Shutdown Command through Modbus...............................................................100
Start Command through Modbus .......................................................................100
For More Modbus Information ............................................................................100
Woodward i
2301D-ST Manual 26184
Contents
CHAPTER 8. SERVICE OPTIONS ................................................................101

Product Service Options.................................................................................... 101
Returning Equipment for Repair........................................................................ 102
Replacement Parts ............................................................................................ 103
How to Contact Woodward................................................................................ 103
Engineering Services......................................................................................... 104
Technical Assistance......................................................................................... 105
APPENDIX A. SERVICE/CONFIGURATION CHART .......................................106
APPENDIX B. MODBUS COMMUNICATION LIST ..........................................114
DECLARATIONS .......................................................................................116
2301D-ST CONTROL SPECIFICATIONS .....................................................117
Illustrations and Tables
Figure 1-1. Functional Control Overview................................................................2

Figure 2-1. 2301D-ST Outline Drawing (8273-128) ...............................................5
Figure 2-2. 2301D-ST Outline Drawing (8273-1001) .............................................6
Figure 2-3a. 2301D-ST Plant Wiring Diagram (sheet 1) ........................................7
Figure 2-3b. 2301D-ST Plant Wiring Diagram (sheet 2) ........................................8
Figure 2-3c. 2301D-ST Plant Wiring Diagram (notes) ...........................................9
Figure 2-4. Installation of Wiring into Terminal.....................................................10
Figure 2-5. RS232 Pin assignments for Serial Communication Cable ................18
Figure 2-6. Typical RS422 Communications Connections ..................................19
Figure 2-7. RS-422 Terminator Locations ............................................................19
Figure 2-8. Preferred Multipoint Wiring Using Shielded Twisted-pair Cable with a
Separate Signal Ground Wire..........................................................20
Figure 2-9. Alternate Multipoint Wiring Using Shielded Twisted-pair Cable without
a Separate Signal Ground Wire.......................................................20
Figure 3-1.Basic Configuration Procedures .........................................................24
Figure 3-2. Connection between PC and 2301D-ST............................................25
Figure 3-3. Setup ServLink Communication ........................................................26
Figure 3-4. Reading Control Information ..............................................................26
Figure 3-5. Watch Window Menu and Explore (Configure) .................................27
Figure 3-6. Configure: A**SPD, LOAD, STRT OPTIONS** Menu ......................28
Figure 3-7. Speed Relationships ..........................................................................28
Figure 3-8. Configure: B**DISCRETE IN OPTIONS** Menu ...............................30
Figure 3-9. Configure: C**DISCRETE OUT OPTIONS** Menu...........................32
Figure 3-10. Configure: D**ANALOG INPUT OPTIONS** Menu.........................34
Figure 3-11. Configure: E**ACTUATOR OUT OPTIONS** Menu .......................35
Figure 3-12. Watch Window Menu and Explorer (Service)..................................36
Figure 3-13. Service: A** DISPLAY ANALOG INFO ** Menu ..............................37
Figure 3-14. Service: B** DISPLAY LOAD INFO ** Menu ...................................38
Figure 3-15. Service: C** SHUTDOWN ** Menu .................................................39
Figure 3-16. Service: D** ALARM ** Menu ..........................................................40
Figure 3-17. Service: E** SPEED DYNAMICS ** Menu.......................................42
Figure 3-18. Control Gain as a Function of Speed Error......................................43
ii Woodward
Figure 3-19. Typical Transient Response Curves................................................44

Figure 3-20. Service: F** REMOTE SPEED CONTROL** Menu.........................46
Figure 3-21. Service: G** SPEED SETTING ** Menu..........................................47
Figure 3-22. Speed Relationships ........................................................................47
Figure 3-23. Service: H** PROCESS CONTROL ** Menu ..................................49
Figure 3-24. Service: I** OVERSPEED TEST ** Menu........................................51
Figure 3-25. Service: J** FAILED MPU OVERRIDE** Menu...............................52
Figure 3-26. Service: K** SYNCHRONIZER SETUP** Menu..............................53
Figure 3-27. Service: L* VALVE LIMITER SET ** Menu......................................53
Figure 3-28. Service: M** LOAD SENSOR AND DROOP ** Menu .....................55
Figure 3-29. Service: N** ACT LINEARIZATION ** Menu ...................................57
Figure 3-30. Service: O** ACTUATOR CALIBRATION ** Menu .........................59
Figure 3-31. Service: P** ANALOG I/O SETTINGS ** Menu ...............................60
Figure 3-32. Service: Q** DISCRETE OUT SETTINGS ** Menu ........................62
Figure 3-33. Service: R** DISPLAY D_I/O STATUS ** Menu..............................65
Figure 3-34. Service: S** HARDWARE OUTPUT TEST ** Menu........................66
Figure 3-35. Service: T** COMM PORT (MODBUS) ** Menu .............................67
Figure 3-36. Service: U** APPLICATION INFO ** Menu .....................................69
Figure 4-1. Basic Operational Architecture ..........................................................71
Figure 4-2. Automatic Start-up .............................................................................72
Figure 4-3 Semi-automatic Start-up .....................................................................73
Figure 4-4 Manual Start-up ..................................................................................74
Figure 4-5. Critical Speed Avoidance Band .........................................................77
Figure 4-6. Paralleling System .............................................................................79
Figure 4-7. Droop Mode .......................................................................................80
Figure 4-8. Isochronous Mode .............................................................................81
Figure 4-9. Droop/Isochronous Load Sharing ......................................................81
Figure 4-10. Isochronous Load Sharing...............................................................81
Figure 5-1. Temporary Wiring for Transformer Phase Correction .......................87
Figure 5-2. Droop Adjustment ..............................................................................89
Table 3-1. Communication Error Code ................................................................68

Table 7-1. RTU Modbus .......................................................................................96
Table 7-2. Modbus Frame Definition ....................................................................97
Table 7-3. Modbus Function Codes .....................................................................97
Table 7-4. Port Adjustments.................................................................................98
Woodward iii
Regulatory Compliance
General Installation and Operation Notes and Requirements:
The 2301D-ST is suitable for use in Class I, Division 2, Groups A, B, C, and D

per CSA for Canada and U.S. or non-hazardous locations only. These listings
are limited only to those units bearing the CSA agency identification and
hazardous location markings.
The 2301D-ST is suitable for use in Ordinary Locations per UL and CSA for
Canada and U.S. or non-hazardous locations only. These listings are limited only
to those units bearing the UL and CSA agency identification and ordinary
location markings.
Wiring must be in accordance with North American Class I, Division 2 wiring

methods as applicable, and in accordance with the authority having jurisdiction.
Connector J1 shall not be used in hazardous locations.
The 2301D-ST shall be installed in a suitable enclosure. A local authority having

jurisdiction shall approve the final combination.
Connect the ground terminal to earth ground.
WARNING—EXPLOSION HAZARD
Do not remove covers or connect/disconnect electrical connectors unless
power has been switched off or the area is known to be non-hazardous.
Substitution of components may impair suitability for Class I, Division 2, or

Zone 2.
AVERTISSEMENT—RISQUE D’EXPLOSION
Ne pas enlever les couvercles, ni raccorder / débrancher les prises
électriques, sans vous en assurez auparavant que le système a bien été mis
hors tension; ou que vous vous situez bien dans une zone non explosive.
La substitution de composants peut rendre ce matériel inacceptable pour

les emplacements de Classe I, Division 2, ou Zone 2.
iv Woodward
Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static

electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
• Do not touch any part of the PCB except the edges.
• Do not touch the electrical conductors, the connectors, or the

components with conductive devices or with your hands.
• When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
To prevent damage to electronic components caused by improper handling,
read and observe the precautions in Woodward manual 82715, Guide for
Handling and Protection of Electronic Controls, Printed Circuit Boards, and
Modules.
Woodward v
vi Woodward
Chapter 1.
General Information
Description
The 2301D-ST is a digital control with integral application software program
designed for single-valve steam turbines. Like Woodward’s 2301A line of
controls, this control is housed in a sheet metal chassis and consists of a single
printed circuit board. To facilitate unit retrofits, the 2301D-ST’s I/O terminals are
located in the same general location as Woodward’s 2301A line of controls. This
control is designed to perform the speed and load control functions of a small
steam turbine package. The 2301D-ST’s application software is field
configurable, allowing it to be configured and modified to meet site-specific
requirements.
With more I/O than its predecessor (the 2301A LSSC), the 2301D-ST also has
serial communications, allowing it to easily interface with a Human Machine
Interface (HMI), PLC or plant DCS. The 2301D-ST is configured and serviced
(dynamic adjustments made) via a laptop computer connected to the control’s
RS232 communications port. These configuration and dynamic settings are set,
changed, tuned and saved via a laptop computer and Woodward’s user-friendly
Watch Window software program. This program allows users to set and adjust all
application-based parameters, plus upload and download configurations to and
from the control. The 2301D-ST includes the following basic turbine control
functions:
• Speed control
• Valve Limiter
• Over speed trip
• Shutdown logic
• Alarm Logic
• Platform Diagnostics
The following functions can be configured, depending on application

requirements:
• Manual, Semi-Automatic or Automatic Start Sequencing
• Remote Speed Control
• Isochronous Load sharing with soft load / unload transfer
• Droop Load Control
• Actuator Feedback Droop Control
• Synchronizer Bias Signal Input
• Power sensor Input (CTs, PTs)
• Process Control
• ServLink (DDE) / Modbus® * Communications
• Self Powered Actuator Option
* Modbus is a trademark of Modicon, Inc.
The 2301D-ST Hardware includes:

• 1 Load Sensor
• 3 PT Inputs, 3 CT Inputs
• 1 Actuator Driver
• 1 MPU Speed Sensor
• 1 Configurable Analog Output
• 2 Configurable Analog Inputs
• 8 Discrete (Switch) Inputs
• 4 Discrete (Relay Driver) Outputs
Woodward 1
Applications
The 2301D-ST is a field-configurable control designed to perform the basic
speed and load control functions for single-valve steam turbines. It can be
configured to allow a user to match the control’s functionality to the application.
Configuration and service (dynamic adjustments made) is done via a laptop
computer, connected to the control’s RS-232 communications port and utilizing
Woodward’s Watch Window program which is a Windows-based PC software
program. These configuration and dynamic settings can be set, changed, tuned
and saved using this same program. See Chapter 3 for instructions on
configuring the control for your specific application.
Dual
52G Breaker (C)
Dynamics
Load Sharing Lines AI
Droop
Load
PTs AI Isoch
Sensor
Logic
CTs AI
LSS
SPM-A Input (C) AI
Speed MPU N - +- PID
Critical
Actuator
Speed AO Actuator Signal
Driver
Logic
Overspeed Test
Enable (C)
Select Both To Raise
Enable Remote
Speed Setpoint Lower Speed
Ref
Remote Speed Remote
AI Relay 1 DO
Set Point (C) Speed Logic Shutdown
Alarm
Overspeed Relay 2 DO
Discrete
Valve Limiter in Control Outputs
Process Input (C) AI Speed PID in Control (C)
Relay 3 DO
Modbus Relay #1-#4
Level Switch #1-#4
Process
Process Setpoint (C) AI +- PID Relay 4 DO
Setpoint
Process Control
Enable (C)
Turbine Speed
Speed Reference
Idle/Rated (C) Idle/Rated Valve Limiter Reference
Analog Analog Output
Actuator Demand AO
Start/Unload Gov Control Generator Output
Output (C)
Shutdown & Valve

Run/Shutdown
Alarms Ramp
Reset
Signal Monitor (C) AI Servlink/ RS232/

Modbus Select (C) Modbus RS422
(C) = Configurable
Figure 1-1. Functional Control Overview
2 Woodward
References
The following publications contain additional product or installation information on
Load Sharing and Speed Controls and related components. They can be
obtained from the Woodward website (www.woodward.com/ic) or ordered from
any Woodward office.
Manual Title
25070 Electronic Control Installation Guide
25195 Governing Fundamentals
82384 SPM-A Synchronizer
82510 Magnetic Pickups and Proximity Switches for Electronic Governors
82715 Guide for Handling and Protection of Electronic Controls, Printed
Circuit Boards, and Modules
Product
Spec Title
03297 2301D-ST Digital Load Sharing and Speed Control
82383 SPM-A Synchronizer
82516 EG3P/6P/10P Actuator
82575 EGB1P/2P Governor/Actuator
03202 Woodward Watch Window Standard
Woodward 3
Chapter 2.
Installation
Introduction
This chapter contains general installation instructions for the 2301D-ST control.
Power requirements, environmental precautions and location considerations are
included to determine the best location for the control. Additional information
includes unpacking instructions, electrical connections and an installation check-
out procedure.
Unpacking
Before handling the control, read the “Electrostatic Discharge Awareness”
information on page v. Be careful when unpacking the electronic control. Check
the control for signs of damage such as bent or dented panels, scratches and
loose or broken parts. If any damage is found, immediately notify the shipper.
Mounting Considerations
This product is intended for installation in a “closed electrical operating
area” or in an enclosed industrial control cabinet. Consider these
requirements when selecting the mounting location:
• Adequate ventilation for cooling
• Space for servicing and repair
• Protection from direct exposure to water or to a condensation-prone
environment
• Protection from high-voltage or high-current devices, or devices which
produce electromagnetic interference
• Avoidance of vibration
• Selection of a location that will provide an operating temperature range of
–40 to +70 °C (–40 to +158 °F)
• The control must NOT be mounted on the turbine.
4 Woodward
2301D−ST
Figure 2-1. 2301D-ST Outline Drawing (8273-128)
Woodward 5
Figure 2-2. 2301D-ST Outline Drawing (8273-1001)

(Hazardous Locations, external cover installed)
6 Woodward
( 0 - 20 mA, 4 - 20 mA, 0 - 200 mA, 20 - 200 mA )
Figure 2-3a. 2301D-ST Plant Wiring Diagram (sheet 1)
Woodward 7
DISCRETE INPUTS WITH INTERNAL POWER SUPPLY
24 VDC POWER, USED WHEN

POWERING DISCRETE INPUTS
RUN / SHUTDOWN
START / UNLOAD
DISCRETE INPUTS
DISCRETE INPUTS WITH EXTERNAL POWER SUPPLY
NOT USED WHEN USING

EXTERNAL POWER SUPPLY
18-40 Vdc EXTERNAL POWER

SUPPLY INPUT
(100mA MAX AT 24 Vdc)
RUN / SHUTDOWN
START / UNLOAD
DISCRETE INPUTS
Figure 2-3b. 2301D-ST Plant Wiring Diagram (sheet 2)
8 Woodward
WARNING ! DO NOT USE FOR EMERGENCY SHUTDOWN, THE PRIME MOVER SHOULD BE EQUIPPED WITH A SEPARATE OVER SPEED, OVER
TEMPERATURE, OR OVER PRESSURE SHUTDOWN DEVICE (S) TO PROTECT AGAINST RUN AWAY OR DAMAGE TO THE PRIME MOVER WITH
POSSIBLE PERSONAL INJURY OR LOSS OF LIFE.
DISCRETE INPUTS WITH CABLE LENGTHS GREATER THEN 30 METERS THAT ARE USED FOR CRITICAL FUNCTIONS, SUCH AS SHUTDOWN,
SHOULD NOT BE FLOATED IN EITHER AN ON OR OFF STATE. THESE INPUTS SHOULD BE SWITCHED TO EITHER 24 VDC OR GROUND.
THIS ANALOG OUTPUT IS CONFIGURABLE.
THESE ANALOG INPUTS ARE CONFIGURABLE.
Figure 2-3c. 2301D-ST Plant Wiring Diagram (notes)
Electrical Connections
CAUTION—WIRING
Due to the hazardous location listings associated with this product, proper
wire type and wiring practices are critical to operation.
Do not connect any cable grounds to “instrument ground”, “control

ground”, or any non-earth ground system. Make all required electrical
connections based on the wiring diagrams.
All inputs and outputs are made through screwless spring-actuated terminal
blocks. For EMI reasons, it is recommend that all low-current wires be separated
from all high-current wire.
The spring clamp can be actuated using a standard 2.5 mm or 3/32 inch flat
bladed screwdriver. The terminal blocks accept wires from 0.08–4 mm² (27–12
AWG). Two 0.8 mm² (18 AWG) or three 0.5 mm² (20 AWG) wires can be easily
installed in each terminal. Wires for the fixed mounted power terminals should be
stripped 5–6 mm (0.22 inch) long.
Woodward 9
NOTE
It is recommended that stranded wire be used for connections to the
terminal block. Do not tin (solder) the wires that terminate at the terminal
blocks. The spring-loaded terminal blocks are designed to flatten stranded
wire and if those strands are tinned together, the connection loses surface
area and is degraded.
Shields and Grounding

An individual shield termination is provided at the terminal block for each of the
signals requiring shielding. All of these inputs should be wired using shielded,
twisted-pair wiring. The exposed wire length beyond the shield should be limited
to one 25 mm (1 inch). Relay outputs, contact inputs and power supply wiring do
not normally require shielding, but can be shielded if desired.
The 2301D-ST is designed for shield termination to earth ground at the control. If
intervening terminal blocks are used in routing a signal, the shield should be
continued through the terminal block. If shield grounding is desired at the
terminal block, it should be ac coupled to earth. All other shield terminations
except at the control should be ac coupled to earth through a capacitor. A 1000
pF, 500 V capacitor is sufficient. The intent is to provide a low impedance path to
earth for the shield at frequencies of 150 kHz and up. Multiple direct connections
of a shield to earth risk high levels of current to flow within the shield (exception,
see note below on cabinet installations).
Shields can be grounded at both ends (2301D-ST and load) if the cable length is
sufficiently short (within a cabinet) to prevent ground loop current in the shield.
NOTE
Cabinet Installations: If the 2301D-ST is installed in a cabinet, shielded I/O
can be terminated directly to the cabinet (earth ground) at the entry to the
cabinet, as well as at the control.
For EMC reasons, it is recommend that all low-current wires be separated

from all high-current wires. Input Power ground terminal should also be
wired to earth ground.
Figure 2-4. Installation of Wiring into Terminal
10 Woodward
Power Supply Connections

The 2301D-ST requires a voltage source of 18 to 40 Vdc, with a current capacity
of at least 900 mA for operating power. If a battery is used for operating power,
an alternator or other battery charging device is necessary to maintain a stable
supply voltage.
Connect 18–40 Vdc input power to terminals 45(+) and 46(–).
NOTE
The 18–40 Vdc input power must be supplied from a power supply/battery
charger certified to IEC standard with SELV (Safety Extra Low Voltage)
classified output. The installer should properly size wiring and fusing for the
input power and PT/CT circuits.
Potential Transformer Connections

The control’s potential transformer inputs accept line-to-line voltages of 90 to 240
Vac. Refer to plant wiring diagram Figure 2-3. Connect the potential transformer
secondary leads to the following terminals:
Phase A to Terminal 1
Phase B to Terminal 2
Phase C to Terminal 3
Current Transformer Connections

The control’s current transformer inputs accept a current range of 0 to 7.2 A.
Refer to plant wiring diagram Figure 2-3. Connect the current transformer leads
to the following terminals:
Phase A to Terminals 4 & 5
Phase B to Terminals 6 & 7
Phase C to Terminals 8 & 9
Load Sharing Lines Connections

The Load Sharing Lines provide an analog communication path between
compatible controls. The 2301D-ST provides an internal relay for connecting the
Load Sharing Signal to the internal circuitry at the appropriate times. When the
internal relay is closed, a green LED will illuminate between terminals 9 and 10.
Because the load-sharing-line relay is contained in the control, no relay is
required between the control and the load-sharing-line bus. Use shielded cable
and connect the load-sharing lines directly to terminals 10(+) and 11(–). Connect
the shield to terminal 12. When all controls in the system are 2301D-STs, the
shields may be connected continuously between controls. When load sharing
with different controls, do not connect the shields at the point where connections
are made to the load-sharing-line bus. The optional 52G (Generator Breaker)
contact is used in conjunction with the control’s load sharing lines. When
isochronous control is selected via the 52G (Generator Breaker) input contact,
the unit’s load sharing lines are enabled.
Woodward 11
Discrete Input Connections

In general, discrete inputs must change state for a minimum of 15 milliseconds
for the control to sense and register a change in state. All contact inputs accept
dry contacts. Contact wetting voltage is available through terminals 28 and 29. If
desired, an external 18-40 Vdc power source can be used for the circuit wetting
voltage. In this case terminal 30 (contact input common) must be connected to
the external power source’s negative common to establish a common reference
point. Each contact input pulls 3 mA when closed and requires at least 14 Vdc to
recognize a closure command. See Figure 2-3 for wiring information and
2301D-ST Control Specification for input specifications.
A positive voltage on any discrete input terminal is sensed by the control as a

closed contact or “TRUE” state. With no voltage applied to a discrete input
terminal the control senses an open contact or “False” state.
For power loading reasons, it is recommended that the control’s internal 24 Vdc
not be used to power other external equipment.
NOTE
Discrete inputs with cable lengths greater than 30 meters that are used for
critical functions, such as emergency stop, should not be floated in either an
on or off state. These inputs should be switched to +24 Vdc or ground.
External Shutdown Contact (Terminal 31)

Terminal 31 functions as the control’s External Shutdown contact input. Before
the unit can be started, this External Shutdown input command must be cleared.
This input can be configured for open-to-shutdown or close-to-shutdown
functionality. The control will initiate an emergency shutdown any time a
shutdown command is given and will immediately step its actuator drive current
to zero and, if so configured, change the state of its shutdown output. This input
is typically tied into the system’s trip string to enable it to react to any system trip
command.
Reset Contact (Terminal 32)

Terminal 32 functions as the control’s Reset contact input. The external Reset
contact is used to reset any latched alarms and/or shutdown conditions, if the
condition has been cleared. If the alarm or shutdown condition has not been
cleared the Reset command will not affect its status. To issue a reset, the contact
must be pulsed to close. No action is taken if contact is either left closed or open
after pulse.
NOTE
If the RUN and Start contact inputs are closed (activated), and the Reset
contact input is pulsed closed to open, the turbine may start!
Start/Unload Contact (Terminal 33)

Terminal 33 functions as the control’s External Start/Unload contact input. When
an external start command is given (a closed contact state) and all shutdown
conditions have been cleared, the control will cycle through its configured start
routine. If all shutdown conditions have not been cleared the unit will not begin to
cycle through its start routine.
12 Woodward
The turbine can also be re-started as the turbine is coasting down in speed.
There are two ways to start the turbine in this manner:
1. The first method:
a. While the turbine is coasting down in speed, the Run / Stop contact
must be closed to the Run position and the Start contact must be in
the Start position.
b. The Reset contact can then be toggled, to clear any shutdowns.
c. The speed reference will start increasing, and the valve ramp will
also start increasing at the specified ramp rates.
d. When the speed reference matches the actual turbine speed, the
speed PID will take control, and continue to ramp the speed up to
the Rated Speed.
2. The second method:
a. While the turbine is coasting down in speed, the Run / Stop contact
must be closed to the Run position.
b. The Reset contact can then be toggled, to clear any shutdowns.
c. The Start / Unload contact, should be toggled to Unload and back to
Start.
d. The speed reference will instantly jump to the actual speed of the
turbine, and start ramping up to the Rated speed.
e. The valve ramp will also start opening at the Valve Ramp rate.
f. When the speed reference matches the actual turbine speed, the
speed PID will take control, and continue to ramp the speed up to
the Rated Speed.
g. The second method is the faster of the two methods, as the speed
reference does not start from zero.
This contact input also functions as an external unload command input, when the
control is in the isochronous load-sharing mode and this contact input is opened.
Raise Speed/Load Contact (Terminal 34)

Terminal 34 functions as a raise speed contact input when the unit’s generator
breaker contact is open, and a raise load contact when the unit is in the droop
mode. When the control is in the isochronous load-sharing mode, this contact will
increase the speed reference.
If both a Lower Speed contact and a Raise Speed contact are closed, the remote
analog setpoint (4–20 mA) mode is enabled, and the control’s internal
speed/load setpoint will follow the respective analog input signal.
Lower Speed/Load Contact (Terminal 35)

Terminal 35 functions as a lower speed contact input when the unit’s generator
breaker contact is open, and a lower load contact when the unit is in the droop
mode. When the control is in the isochronous load-sharing mode, this contact will
lower the speed reference.
If both a Lower Speed contact and a Raise Speed contact are closed, the remote
analog setpoint (4–20 mA) mode is enabled, and the control’s internal
speed/load setpoint will follow the respective analog input signal.
Woodward 13
Contact Inputs (Terminal 36–38)

The 2301D-ST has three other discrete input channels that are available for use.
These contacts are configurable and can be programmed to perform one of the
following functions:
• IDLE - RATED SPEED

When the state of this contact is open the speed reference moves toward
the programmed IDLE speed setpoint at it’s own configured rate set in
service menus. When the state of this contact is closed the speed reference
moves toward the programmed RATED speed setpoint at it’s own
configured rate set in service menus.
• 52G BREAKER
The state of this input should directly reflect the state of the unit’s generator
breaker. This input is used to activate the correct control mode. When this
contact input is open, the droop is enabled. When this contact input is
closed the unit will be in the isochronous mode.
Typically when used as the isoch/droop select contact, this contact is wired
to directly reflect the state of the system’s utility tie breaker, with a switch or
relay wired in series with the tie breaker aux contact to allow users to
manually select the load mode the control operates in when paralleled to the
utility. The control is always set to droop mode by opening the 52G
BREAKER input.
• OVERSPEED TEST ENABLE

When overspeed testing is performed, this contact is used. An overspeed
test is allowed only under the condition that the remote speed setpoint
function must be disabled and the turbine speed is within speed range. An
overspeed test will allow the control’s speed setpoint to be increased above
the normal maximum limit. When this contact is closed, the control detects
overspeed and issues a trip. After overspeed testing ends, the contact
should be opened.
• MODBUS / SERVLINK SELECT

This contact functions as the control’s Modbus communications enable
contact input for the control’s 9-Pin Sub-D communication port. When this
contact is open or is not used, the control’s communications port
communicates using a ServLink\DDE protocol. This is used to communicate
with Woodward’s Watch window program for unit configuration and/or
service.
When this contact is closed, the control’s 9-Pin Sub-D communications port
communicates using a Modbus RTU protocol and the control functions as a
Modbus Slave device. The 2301D-ST can be fully operated and all control
values monitored via Modbus communications. Alternatively Modbus
communications can be used to interface with a PLC or plant DCS.
CAUTION—MODBUS
Do not use Modbus communications to perform configuration, I/O test, or
calibration.
• PROCESS CONTROL ENABLE

This contact is used to enable the process control logic when closed. In
order for process control to work correctly an external 4–20 mA signal
needs to be setup on one of the analog inputs to provide feedback for the
process PID.
14 Woodward
Actuator Output
Connect the unit’s actuator wires to the control’s actuator driver output on
terminals 13(+), 14(–), and 15(shield). This output’s current range is software
configurable and can be programmed to output a drive current of 0–200 mA,
20–200 mA, 4–20 mA, or 0–20 mA. Do not connect the shield wire to the
actuator or any other point. Verify that the output’s shield wire has continuity its
entire distance to the actuator and is insulated from all other conducting
surfaces.
Analog Inputs (#1, #2)

Connect input wiring to terminals 19(+), 20(–), and 21(shield) to use Analog Input
#1 and connect input wiring to terminals 22(+), 23(–), and 24(shield) to use
Analog Input #2. These Analog Inputs are software configurable to function as
one of the following options:
• Remote Speed Setpoint
• Monitor Signal
• Synchronizer Bias Signal Input (–2.5 to +2.5 Vdc signal)
• Process Setpoint
• Process Signal
The type of the analog input signals can also be chosen from one of the following
options:
• 4–20 (mA)
• 0–5 (V)
• ±2.5 (V)
• 1–5 (V)
NOTE
Synchronizer Bias Signal Input is determined as ±2.5 V that is automatically
set up by software.
MPU Speed Sensor Input

To sense turbine speed, the control accepts a signal from a passive magnetic
pickup unit (MPU) mounted off a gear connected or coupled to the turbine’s rotor.
Connect the MPU speed sensor to terminals 25, 26, and 27(shield). This input is
limited to a frequency range of 100–24 950 Hz, (90–20 000 rpm) and a voltage
range of 1.7–35 Vac (it needs the voltage above 2.7 Vac in case of a signal
above 13 000 Hz). Verify that the input’s shield wire has continuity its entire
distance to the input sensor and is insulated from all other conducting surfaces.
With proper MPU, gear size and MPU-to-gear clearance, speed measurement
should be capable down to 100 Hz. Check the speed sensor for visible damage.
Standard MPU clearance is recommended to be between 0.25 and 1.0 mm
(0.010 and 0.040 inch) at the closest point. Make sure the gear has less than 0.5
mm (0.020 inch) diametric run out. See manual 82510, Magnetic Pickups and
Proximity Switches for Electronic Governors.
Woodward 15
Relay Driver Outputs (Terminals 41–44)

The 2301D-ST has four discrete output driver channels. Terminals 41, 42, 43,
and 44 are configurable and can be programmed to perform one of the following
functions:
• SHUTDOWN
• ALARM
• ELECTRICAL OVERSPEED TRIP TEST
• VALVE LIMITER IN CONTROL
• SPEED PID IN CONTROL
• VALVE LIMITER IN CONTROL
• MODBUS CONTROLLED RELAY #1
• LEVEL SWITCH
NOTE
For fail-safe operation, the Shutdown relay should be energized during
normal system operation, and will de-energize when a shutdown occurs.
Any of the four relays can be programmed to function as a level switch. When
programmed as a level switch the relay will change state when the selected
parameter reaches the programmed level (energizes when value is higher the
programmed level). The following is a list of the level switches:
• TURBINE SPEED
• TURBINE SPEED REFERENCE
• VALVE LIMITER REFERENCE
• ACTUATOR DEMAND
• GENERATOR OUTPUT
• SIGNAL MONITOR
These discrete outputs are low-side drivers with a maximum output current of
160 mA. The discrete output drivers are isolated from the control’s internal power
supply, but not from each other and are powered by an external +12 Vdc or +24
Vdc source connected at terminals 39(+) and 40(–). Refer to Figure 2-3 for plant
wiring information.
Relay Driver Clarifications

1. SHUTDOWN
Each relay driver can be programmed to indicate a Shutdown Condition
(energizes for a shutdown condition) or a Trip Relay (de-energizes for a
shutdown/trip).
2. ALARM
Each relay driver can be programmed to indicate a general Alarm Condition
(energizes for an alarm condition) or an Alarm Relay (de-energizes for an
alarm).
3. ELECTRICAL OVERSPEED TEST

Each relay driver can be programmed to indicate that the electrical turbine
overspeed was sensed.
4. VALVE LIMITER IN CONTROL

Each relay driver can be programmed to indicate the valve limiter controls
the actuator/ valve.
16 Woodward
5. SPEED PID IN CONTROL
Each relay driver can programmed to indicate the speed PID controls the
actuator/valve.
6. MODBUS CONTROLLED RELAY #1

Each relay driver can be programmed to indicate the Modbus controlled
relay #1 according to the following function.



10. LEVEL SWITCH

Each relay driver can be programmed to function as a level switch. If the
level switch feature is selected, its ON level and OFF level must also be
configured.
Level Switch Options

1. TURBINE SPEED
2. TURBINE SPEED REFERENCE
3. VALVE LIMITER REFERENCE
4. ACTUATOR DEMAND
5. GENERATOR OUTPUT
6. MONITOR SIGNAL
Analog Output
Connect readout wiring to terminals 16(+), 17(–), and 18(shield) to use the
control’s 4–20 mA Analog Output. This Analog output is software configurable to
function as one of the following readout options:
• TURBINE SPEED
• TURBINE SPEED REFERENCE
• VALVE LIMITER SETPOINT
• ACTUATOR DEMAND
• GENERATOR OUTPUT
• SIGNAL MONITOR
Verify that the output’s shielded wire has continuity its entire distance to the
output device and is insulated from all other conducting surfaces. This current
driver based output is designed to drive into impedances of up to 250 Ω. This
output is not isolated from the other control inputs and outputs, thus an isolation
device may be required with this output if the device being interfaced to is not
isolated.
This analog output’s 4–20 mA current drive signal is directly proportional to the
programmed function signal that it is configured to represent. Refer to Chapter 3
for output configuration instructions. Its clarifications are the same as Level
Switches.
Woodward 17
Communication Port
The control’s serial communications port is used to configure and service the
unit, as well as communicate to a Human Machine Interface (HMI) or plant
distributed control system (DCS). This port’s protocol is switchable via the
control’s “Modbus communications enable” contact input. When this contact input
is open or has no connection to it, the control’s communications port
communicates using an RS-232 driver and a ServLink/DDE protocol. The
ServLink/DDE protocol is used to communicate with Woodward’s Watch Window
program for unit configuration and or service. Refer to Chapter 3 for configuration
and setup instructions.
When the control’s “Modbus Communications Enable” contact input is closed,

the control’s communications port then communicates using a Modbus RTU or
ASCII protocol, functioning as a Modbus Slave device, via RS-232 or RS-422
drivers, depending on the configuration. The 2301D-ST can be fully operated and
all control values monitored via Modbus communications. Alternatively Modbus
communications can be used to interface with a PLC or plant DCS. Refer to
Figure 2-3 for plant wiring information.
NOTE
The communication port must be connected with an approved jacketed
serial communication cable. The connector must be secured to the
2301D-ST to prevent contact with other circuits.
RS-232
See Figure 2-5 for cable connection.
2301D-ST
Figure 2-5. RS232 Pin assignments for Serial Communication Cable
18 Woodward
RS-422
See Figure 2-6 for termination and cable connection example.
Figure 2-6. Typical RS422 Communications Connections
Termination
For RS-422, termination should be located at the receiver when one or more
transmitters are connected to a single receiver. When a single transmitter is
connected to one or more receiver, termination should be at the receiver farthest
from the transmitter. Figure 2-7 is an example.
Figure 2-7. RS-422 Terminator Locations
Grounding and Shielding

The RS-422 specifications state that a ground wire is needed if there is no other
ground path between units. The preferred method to do this is to include a
separate wire in the cable that connects the circuit grounds together. Connect
the shield to earth ground at one point only. The alternate way is to connect all
circuit grounds to the shield, and then connect the shield to earth ground at one
point only. If the latter method is used, and there are non-isolated nodes on the
party line, connect the shield to ground at a non-isolated node, not at an isolated
node. Figures 2-8 and 2-9 illustrate these cabling approaches.
Woodward 19
NOTE
Non-isolated nodes may not have a signal ground available. If signal ground
is not available, use the alternate wiring scheme in Figure 2-9 with the signal
ground connection removed on those nodes only.
Figure 2-8. Preferred Multipoint Wiring Using Shielded Twisted-pair Cable with a
Separate Signal Ground Wire
NOTE
The SG (signal ground) connection is not required if signal ground is
unavailable.
Figure 2-9. Alternate Multipoint Wiring Using Shielded Twisted-pair Cable without
a Separate Signal Ground Wire
20 Woodward
Installation Check-out Procedure

Once the 2301D-ST is installed, perform the following checkout procedure before
beginning the start-up adjustments in Chapter 4.
Visual Inspection
1. Check the linkage between the actuator and the valve on the steam turbine
for looseness or binding. Refer to the appropriate actuator manual and to
manual 25070, Electronic Control Installation Guide, for additional
information on linkage.
WARNING—MINIMUM FUEL POSITION

The actuator lever should be near but not at the minimum position when the
steam rack is at the minimum position. If the actuator lever gets to its
minimum position before completely shutting off steam, the control may not
be able to shut down the prime mover, causing damage to equipment or
injury or death.
2. Check for correct wiring in accordance with the plant wiring diagram, Figure
2-3.
3. Check for broken terminals and loose terminal screws.
4. Check the speed sensor for visible damage.
5. Check the clearance of the magnetic pickup between the gear and the
sensor and adjust if necessary.
Woodward 21
Chapter 3.
Service and Configuration Procedures
Introduction
This chapter contains information on control configurations, setting adjustments
and the use of Woodward’s Watch Window software tool. Because of the variety
of installations, system and component tolerances, the 2301D-ST must be tuned
and configured for each system to obtain optimum performance. Refer to
Chapter 4 for start-up settings, adjustments and instructions.
WARNING—OVERSPEED
An improperly calibrated control could cause an overspeed or other damage
to the prime mover. To prevent possible serious injury from an overspeeding
prime mover, read this entire procedure before starting the prime mover.
Watch Window Program

Watch Window is the primary troubleshooting tool for Woodward controls that
support the ServLink protocol. Watch Window runs on a PC connected to the
control system through a serial communications port. The PC may be
permanently connected to the control or only as needed. The communications
server, ServLink I/O Server, is included in the same CD-ROM with the Watch
Window software.
An “inspector” provides a window for real-time monitoring and editing of all

control Configuration and Service Menu parameters and values. Custom
“inspectors” can easily be created and saved. Each window can display up to 28
lines of monitoring and tuning parameters without scrolling. The number with
scrolling is unlimited. Two windows can be open simultaneously to display up to
56 parameters without scrolling. Tunable values can be adjusted at the inspector
window. Watch Window communicates with the control through an RS-232 cable
connection to the comm. port configured as a point-to-point only ServLink Server.
Watch Window is a typical Windows application that provides a powerful and

intuitive interface. The menu structures are familiar to Windows users. Variable
navigation is provided through the Explorer window similar to the Explorer in
Windows.
Watch Window performs these primary functions:

• Monitoring and Tuning of Control Variables—Watch Window presents
variables in a tabular format. The user chooses the variables to view.
Multiple pages of variables can be created, each with useful parameters for
various troubleshooting or tuning procedures. The user can toggle between
pages depending on the task being performed.
• Control Configuration and Set Point Management—Watch Window can
upload or download all tunable variables from the control system. This
feature allows a user (e.g., fleet owner, distributor, packager) to upload (and
save) all tunable parameters from one control and download the same
settings to other controls for similar turbine configurations.
22 Woodward
Watch Window version 1.05 and higher, allows for automatic generation of
inspector sheets. Click on the Q icon (Quick Inspector) on the tool bar. A sheet
will automatically be created from each Service and Configure Header
programmed into the control. Multiple inspectors can be created to allow for
viewing more than one sheet at a time.
To enter the I/O Lock mode and enable a configure value to be entered,
click on the I/O Lock icon on the Tool Bar. Because the values set in Configure
are critical to turbine operation, it is not safe to operate the prime mover while
these parameters are being configured. In the Configure mode the control
outputs will be set to their off state and the microprocessor will stop executing the
application code. The control will have to be reset to continue operation.
The Reset icon allows the microprocessor to store the configure

parameters, to return the outputs to their active state and to resume executing
the application software.
When the tuning or setting of parameters is complete, the values must be

saved in the control’s non-volatile memory. Go to the Tool Bar and click the
PROM icon for Save Values. The values will be saved in non-volatile memory
and will be unaffected by loss of power to the control.
If an application configuration has been previously saved to a *.CFG file,

the saved set of parameters can be loaded into the 2301D-ST as a group by
selecting the Load Application Settings icon.
To save the configuration to a file in the external computer for backup or

download later into another 2301D-ST, select the Save Application Settings icon.
All the tunable values presently set in the control will be saved to a file and can
be loaded into this 2301D-ST to reprogram it to the saved values or into another
2301D-ST at a later time.
Woodward 23
Start
Configuration
Install the Watch Window Software to

generic PC
Connect PC and 2301D-ST control

using RS-232 Serial Cable
Apply power for 2301D-ST
2301D-ST Self Test, 30s

(Status LED is turned off)
Start "ServLink"
Start "Watch Window"
Lock I/O
Set Configuration parameters
Save Values, and Reset Control
"RUN" mode
Figure 3-1.Basic Configuration Procedures
24 Woodward
Install Watch Window Software

Woodward’s Watch Window Standard configuration and service tool may be
downloaded at no cost from the Woodward website (www.woodward.com). As an
alternative a Watch Window CD Install Kit may be purchased from the nearest
Woodward distributor. Once downloaded, select the kit’s Setup.exe program on
the computer on which you wish to install the Watch Window software program.
Please refer the product specification 03202 for detailed installation procedures.
Connect PC to 2301D-ST
The connection of a computer is only required for calibration and setup of the
2301D-ST on a prime mover as shown in Figure 3-2 below. The computer and
Watch Window software program are not required or necessary for normal
operation of the control. The cable is a 9-pin female to 9-pin male, null modem
(crossover) cable.
2301D-ST
9-pin D sub
Connector
RS-232
Serial Cable
N ote B ook P C
Figure 3-2. Connection between PC and 2301D-ST
Apply Power to the 2301D-ST

At power-up, the 2301D-ST runs through its boot-up routine and performs a set
of initial diagnostics to verify CPU, memory and bus health. This boot-up routine
takes approximately 30 seconds to execute. During this time, the control’s red
status LED (located between terminals 27 and 28) should be on. When boot-up
is complete, the application program code begins running, the control outputs will
be enabled and system control will begin - the control’s red status LED will be
turned off and should remain off as long as the control is running.
Woodward 25
Initial 2301D-ST Communications:
Before communications can begin between the Watch Window program and a
control, a network definition file must be created. Once this network definition file
is created and saved, it never has to be recreated.
To create a network definition file:

1. Open the Watch Window program’s associated ServLink server by Clicking
on Start > Programs > Woodward > ServLink Server.exe
2. Select the communications port the control is connected to
3. Select “Point-to-Point” communications
4. Select the a Baud Rate of 38400
5. Select the OK button
Figure 3-3. Setup ServLink Communication
At this point the ServLink Server program will establish control communications,
begin reading all control setting registers and create a lookup table for these
registers to expedite future control communications. Upon reading register
location information from the control the following Windows pop-up box will
appear. (This step can take several minutes to complete.)
Figure 3-4. Reading Control Information
Once all control program registers have been read, the text “Dflt Control ID” will
appear within the ServLink program window and the network definition file can be
saved for future retrieval by the Watch Window program. If the network definition
file is not saved it will have to be re-created before computer-to-control
communications can be established again.
26 Woodward
Start Watch Window Software

At this point, start the Watch Window software program by clicking on Start >
Programs > Woodward > Watch Window Standard.exe.
The Watch Window Menu bar, Explorer and Inspector will appear as shown in
Figure 3-5. Click on the icon (Quick Inspector) on the tool bar. Multiple sheets
will automatically be created from each Service and Configure Header
programmed into the control. Refer to Figure 3-6. Optionally, other inspectors
can be created to allow viewing of more than one sheet at a time.
Figure 3-5. Watch Window Menu and Explore (Configure)
Configure Menu Descriptions

The 2301D-ST has “5” Configure menus and “21” Service menus to simplify and
protect control settings and their adjustments. All menus appear as pages, are
arranged alphabetically and can be located by using the inspector’s arrow
buttons located above the pages to scroll to the desired menu.
The program’s Configure menu items are protected when the control is in
operation and cannot be changed. Before configuration values can be changed
the control must be in its I/O Lock mode. Service menus are not protected and
can be modified at any time.
To enter the I/O Lock mode and enable configure changes, click on the I/O
Lock icon on the Tool Bar. Because the values set in Configure are critical to
turbine operation, it is not safe to operate the prime mover while these
parameters are being configured. In the I/O Lock mode the control outputs will be
set to their off state and the microprocessor will stop executing the application
code.
Woodward 27
Once the configuration changes have been completed click on the Reset icon
to allow the control to store the configured parameters, return the outputs to their
active state and resume executing the application software.
CONFIGURE: A**SPD, LOAD, STRT OPTIONS**
Figure 3-6. Configure: A**SPD, LOAD, STRT OPTIONS** Menu
ZERO RATED OVERSPEED

IDLE
SPEED TEST
SPEED
LIMIT
CRITICAL
SPEED
BAND ELECTRICAL
OVERSPEED
OPERATING TRIP LEVEL
RANGE
MINIMUM MAXIMUM
GOVERNOR GOVERNOR
Figure 3-7. Speed Relationships
01 RATED SETPOINT (RPM) dflt=3600.0 (0.0, 300000)

Set to the rated synchronous rpm of the turbine / generator. This value is used to
set the 2301D speed sensor hardware to software conversion.
02 ENTER RATED/MAX LOAD (KW) dflt=1000 (10, 30000)

This value sets the rated/maximum load of the generator.
03 GEN FREQ IS 50HZ? dflt= FALSE(FALSE, TRUE)

This value sets the frequency of the generator. False equals 60 Hz., True equals
50 Hz. This value is used for display purposes only.
28 Woodward
04 MPU MIN SPD LEVEL (RPM) dflt= 250.0 (0.0, 2000)
Enter the minimum detectable speed level for the control. Below this level the
MPU would be detected as failed and a trip will be issued. The MPU input signal
must be at least 1.0 Vrms at the minimum speed level programmed.
05 NUMBER OF TEETH dflt=60 (16, 500)

Enter the number of teeth or holes of the gear that the magnetic pickup unit
(MPU) is mounted to. This value is used to determine the hertz-to-rpm
relationship.
NOTE
The maximum input frequency that can be measured by the speed sensing
circuit is 25,000 Hz. Therefore to allow for transient conditions, the Number
of Teeth times Rated RPM divided by 60 should be less than 19,000.
WARNING—GEAR TOOTH COUNT

The number of gear teeth is used by the control to convert pulses from the
speed-sensing device to turbine rpm. To prevent possible serious injury
from an over speeding turbine, make sure the control is properly
programmed to convert the gear-tooth count into turbine rpm. Improper
conversion could cause turbine overspeed.
06 MAX OVERSPD TEST LMT (RPM) dflt=4140.0 (0.0, 32000)

Enter the maximum overspeed trip speed setting. This is the overspeed trip
setpoint used to test the mechanical overspeed shutdown device.
(Must be greater than or equal to the ELEC OVERSPEED TRIP SETPOINT).
Note: This menu item was moved here from Service Menu I**Overspeed Test**
in revision “G” software or later.
07 USE SELF POWERED ACTUATOR? dflt=FALSE(FALSE, TRUE)

Set to true if the actuator gets its hydraulic power from the turbine. If this value is
set TRUE, the shutdown discrete output will still operate, but as the turbine slows
down and reaches the MPU Override %, the actuator will ramp open. If the MPU
fails and a trip occurs, the SELF PWRED DELAY TIME (SEC) will be used to
ramp the valve open. If the turbine speed is decreased from an upstream valve
such as the Trip and Throttle Valve or a Control Valve, as the speed reaches the
MPU Override % the magnetic pickup failed signal will be overridden. The
Actuator will ramp open.
WARNING—OVERSPEED
Using the SELF POWERED ACTUATOR option will disable the internal
shutdowns and on the event of a shutdown will cause the actuator to ramp
open. To prevent possible serious injury from an overspeeding turbine,
make sure the trip and throttle valve or control valve will properly shut off
steam to the turbine. Improper set-up could cause turbine overspeed.
08 MPU OVERRIDE % dflt=20.0 (0.1, 100.0)

Enter the percent of actual speed that the magnetic pickup failed signal will be
overridden, so that the turbine can be controlled by an upstream valve. This
option is used only with the USE SELF POWERED ACTUATOR feature.
09 SELF PWRD TIME DLY (SEC) dflt=60.0 (5.0, 30000.0)

Enter the delay time in seconds that will open the actuator upon loss of the
magnetic pickup. This option is used only with the USE SELF POWERED
ACTUATOR feature.
Woodward 29
10 GEAR RATIO dflt=1.0 (0.1, 10)
Enter the result of the (MPU gear speed) / (turbine shaft speed) speed ratio. This
value is used to determine the internal hertz-to-rpm relationship and is calculated
by dividing the speed of the MPU gear by the speed of the turbine shaft.
WARNING—OVERSPEED
Using the wrong the gear teeth setting or the Speed Ratio Setting could
cause an overspeed condition, resulting in damage to equipment, personal
injury or death.
11 USE CRITICAL BAND? dflt=FALSE (FALSE, TRUE)

Set to TRUE to use the critical speed avoidance logic. When the speed setpoint
is within the band, the speed setpoint cannot be stopped. This band is used to
protect the turbine and driven device from speeds that have inherently high
vibration.
12 CRIT SHDN TIME DLY (SEC) dflt=300 (0.0, 1200)

When the speed is in the critical band for longer than the delay time a trip is
initiated. The tunable 09 Use Critical Band must be set to TRUE to activate this.
13 USE MANUAL START? dflt=FALSE (FALSE, TRUE)

Set to TRUE to enable manual start mode of operation. Using this feature will
cause the actuator output to ramp fully open. This allows the operator to
manually control speed of the turbine until governor speed is reached. Only
select one of the three start modes.
14 USE SEMI-AUTO START? dflt=FALSE (FALSE, TRUE)

Set to TRUE to enable the semi-automatic mode of operation. Using this feature
will allow the operator to control the valve ramp using the discrete input raise and
lower switches. Only select one of the three start modes.
15 USE AUTOMATIC START? dflt=TRUE (FALSE, TRUE)

Set to TRUE to enable the automatic mode of operation. Using this feature will
allow the operator to automatically start the turbine. Only select one of the three
start modes.
16 START MODE = Displays the current start mode of operation selected.
CONFIGURE: B**DISCRETE IN OPTIONS**
Figure 3-8. Configure: B**DISCRETE IN OPTIONS** Menu
30 Woodward
01 CONFIGURATION ERROR? dflt=FALSE (FALSE, TRUE)
This value will show TRUE if you have selected two discrete inputs to perform
the same function. This value should never be true in normal operation.
02 SEL DI F FUNCTION (1-6) dflt=1 (1, 6)

Select one of the following parameters for Discrete Input F at terminal 36.
1=NOT USED
2=IDLE / RATED
3=GEN BRKR 52G (ISOCH/DROOP)
4=OVERSPEED TEST ENABLE
5=MODBUS ENABLE
6=ENABLE PROCESS CONTROL
03 DISPLAY DI F FUNCTION displays the current Discrete Input F selected

function.
04 SEL DI G FUNCTION (1-6) dflt=1 (1, 6)

1=NOT USED
2=IDLE / RATED
5=MODBUS ENABLE
05 DISPLAY DI G FUNCTION displays the current Discrete Input G selected

function.
06 SEL DI H FUNCTION (1-6) dflt=1 (1, 6)

1=NOT USED
2=IDLE / RATED
5=MODBUS ENABLE
07 DISPLAY DI H FUNCTION displays the current Discrete Input H selected

function.
NOTE
Each configurable discrete input option may be configured only once.
08 ENABLE R/L WHEN LS dflt=FALSE (FALSE, TRUE)

Set to TRUE to use the Raise Speed/Load and Lower Speed/Load discrete
inputs while in isochronous load sharing. Typically this is not used as the control
will balance the loads automatically.
Woodward 31
CONFIGURE: C**DISCRETE OUT OPTIONS**
Figure 3-9. Configure: C**DISCRETE OUT OPTIONS** Menu
The 2301D-ST has four discrete output driver channels. Terminals 41, 42, 43
and 44 are configurable and can be programmed to perform one of several
functions (listed below).
Any of the four relay drivers can also be programmed to function as a level
switch. When programmed as a level switch the relay will change state when the
selected parameter reaches the programmed level (energizes when value is
higher the programmed level). Level Switch set up is in Menu “Q”.
01 IS TRIP RELAY NC? dflt=TRUE (FALSE, TRUE)

This option sets the logic of the Shutdown Relay. Set to TRUE if the Shutdown
Relay output is normally closed. Set to FALSE if the Shutdown Relay output is
normally open.
02 IS ALARM RELAY NC? dflt=TRUE (FALSE, TRUE)

This option sets the logic of the Alarm Relay. Set to TRUE if the Alarm Relay
output is normally closed. Set to FALSE if the Alarm Relay output is normally
open.
03 RELAY 1 ENERGIZES (1-11) dflt=1 (1, 11)

Select one of the following parameters for discrete output at terminals 41.
1=NOT USED
2=SHUTDOWN
3=ALARM
4=ELEC. OVERSPEED TRIP TEST
5=VALVE LIMITER IN CONTROL
6=SPEED PID IN CONTROL
7=MODBUS CONTROLLED RELAY #1
11=LEVEL SWITCH
04 RELAY 1 SELECTED displays the relay function for terminal 41.
32 Woodward
1=NOT USED
2=SHUTDOWN
3=ALARM
11=LEVEL SWITCH

1=NOT USED
2=SHUTDOWN
3=ALARM
11=LEVEL SWITCH

1=NOT USED
2=SHUTDOWN
3=ALARM
11=LEVEL SWITCH
11 RESET CLEARS TRIPS? dflt=TRUE (FALSE, TRUE)

If set TRUE the Shutdown Relay will be reset when a Reset input is given. If set
FALSE all shutdown conditions including the external Shutdown input must be
cleared before a Reset input will reset the Shutdown Relay.
Woodward 33
CONFIGURE: D**ANALOG INPUT OPTIONS**
Figure 3-10. Configure: D**ANALOG INPUT OPTIONS** Menu
01 CONFIGURATION ERROR? dflt=FALSE (FALSE, TRUE)

Displays a TRUE if any of the two analog inputs are set the same. Not Used and
Monitor Signal Input can be set the same. Displays a FALSE if the analog input
configuration is correct.
02 SEL AI #1 FUNCTION (1-6) dflt=1 (1, 6)

Select one of the following parameters for Analog Input #1 at terminal 19-21.
1=NOT USED
2=REMOTE SPEED SETPOINT
3=MONITOR SIGNAL INPUT
4=SYNCHRONIZER BIAS SIGNAL
5=REMOTE PROCESS SETPOINT
6=PROCESS SIGNAL
03 DISPLAY AI #1 FUNCTION
Displays the function selected for Analog Input #1.
04 SEL AI #1 TYPE (1-4) dflt=1 (1, 4)

This value is used to set the Analog Input #1 type.
1 = 4–20 (mA)
2 = 0–5 (V)
3= ±2.5 (V)
4= 1–5 (V)
05 DISPLAY AI #1 TYPE
Displays configured Analog Input #1 type.
06 USE INPUT #1 FAIL TRIP dflt=FALSE (FALSE, TRUE)

Set to TRUE to use the trip function that Analog Input #1 has failed.
Input Set For: Low Trip Point: High Trip Point:
4–20 mA 2.0 mA 22.0 mA
0–5 Vdc –0.63 Vdc 5.63 Vdc
±2.5 Vdc –3.13 Vdc +3.13 Vdc
1–5 Vdc 0.5 Vdc 5.5 Vdc
34 Woodward
07 SEL AI #2 FUNCTION (1-6) dflt=1 (1, 6)
Select one of the following parameters for Analog Input #2 at terminal 22-23.
1=NOT USED
2=REMOTE SPEED SETPOINT
3=MONITOR SIGNAL INPUT
4=SYNCHRONIZER BIAS SIGNAL
5=REMOTE PROCESS SETPOINT
6=PROCESS SIGNAL
08 DISPLAY AI #2 FUNCTION
Displays the function selected for Analog Input #2.
09 SEL AI #2 TYPE (1-4) dflt=1 (1, 4)

This value is used to set the Analog Input #2 type.
1 = 4–20 (mA)
2 = 0–5 (V)
3= ±2.5 (V)
4= 1–5 (V)
10 DISPLAY AI #2 TYPE
Displays configured Analog Input #2 type.
11 USE INPUT #2 FAIL TRIP dflt=FALSE (FALSE, TRUE)

Set to TRUE to use the trip function that Analog Input #2 has failed.
Input Set For: Low Trip Point: High Trip Point:

4–20 mA 2.0 mA 22.0 mA
0–5 Vdc –0.63 Vdc 5.63 Vdc
±2.5 Vdc –3.13 Vdc +3.13 Vdc
1–5 Vdc 0.5 Vdc 5.5 Vdc
CONFIGURE: E**ACTUATOR OUT OPTIONS**
Figure 3-11. Configure: E**ACTUATOR OUT OPTIONS** Menu
01 ACTUATOR OUT TYPE (1-4) dflt=1 (1, 4)

This value is used to set the actuator output type.
1 = 20–200 (mA)
2 = 0–200 (mA)
3 = 4–20 (mA)
4 = 0–20 (mA)
02 DISPLAY ACTUATOR TYPE displays the configured actuator output type.
Woodward 35
03 INVERT DRIVER OUTPUT? dflt=FALSE (FALSE, TRUE)
Set to TRUE for reverse acting actuators and FALSE for forward acting
actuators. Forward acting actuators require increase current to increase
speed/load. Reverse acting actuators require decrease current to increase
speed/load (reverse acting actuators should always incorporate a mechanical
ballhead backup governor).
Save and Reset 2301D-ST Control.

When the tuning or setting of parameters is complete, the values must be saved
in the control’s non-volatile memory. Go to the Tool Bar and click the PROM
icon for Save Values. The values will be saved in non-volatile memory and will
be unaffected by loss of power to the control.
Once the all configuration changes have been completed, click on the Watch
Window program’s Reset icon to allow the control to store the configured
parameters, return the outputs to their active state and resume executing the
application software.
Service Menu Descriptions
Figure 3-12. Watch Window Menu and Explorer (Service)
36 Woodward
A** DISPLAY ANALOG INFO **
Figure 3-13. Service: A** DISPLAY ANALOG INFO ** Menu
This is a display group for general monitoring of the turbine.
01 SPEED CONTROL STATUS displays the status of the speed control. Will
display one of the following:
SHUTDOWN
READY FOR RESET
READY TO START
VALVE LIMITER
SPEED PID RAMP
AT IDLE SPEED
AT MIN GOVERNOR SPEED
AT RATED SPEED
AT MAX GOVERNOR SPEED
IN CRITICAL RAMP
02 TURBINE SPEED (RPM) displays actual turbine speed in rpm.
03 GENERATOR FREQUENCY (HZ) displays the calculated generator

frequency in hertz. This will typically be a value from the following table:
Generator 60 Hz 50 Hz
Poles Generator Generator
2 3600 rpm 3000 rpm
4 1800 rpm 1500 rpm
6 1200 rpm 1000 rpm
8 900 rpm 750 rpm
If a rated speed other than the values listed here is entered, the calculated
generator frequency shown may not be correct.
Woodward 37
04 SPEED REFERENCE (RPM) displays turbine speed setpoint in rpm.
05 ACTUATOR SIGNAL (%) displays actuator demand percentage (0-100%).
06 ACTUATOR CURRENT (mA) displays the current output to the actuator in

milliamps.
07 VALVE LIMITER (%) displays the valve limiter demand percentage (0-100%).
08 SPEED PID (%) displays the speed PID output percentage (0-100%).
09 CRITICAL SPEED BAND? displays a TRUE or a FALSE denoting that the

speed reference is in the critical band.
10 SPEED REF BIAS (RPM) displays the total speed bias into the summing
junction.
11 ANALOG INPUT #1 displays analog input #1 value.
12 ANALOG INPUT #2 displays analog input #2 value.
13 START MODE SELECTED displays the START MODE selected. Will display
one of the following:
NO CONTROL MODE SELECTED
MANUAL CONTROL MODE SELECTED
SEMI-AUTOMATIC CONTROL MODE
AUTOMATIC CONTROL MODE SELECTED
IN-CORRECT MODE SET-UP
B** DISPLAY LOAD INFO **
Figure 3-14. Service: B** DISPLAY LOAD INFO ** Menu
This menu is used for general monitoring of the generator information.
01 LOAD CONTROL STATUS displays generator load control mode. Will

display one of the following:
NO LOAD CONTROL
KW DROOP
SPEED DROOP
ISOCHRONOUS
LOADING
UNLOADING
38 Woodward
02 LOAD SENSOR INPUT (KW) displays generator load in kilowatt. This value
is calculated as the current (I) multiplied by the phase angle between the voltage
(V) and the current (I), (cos theta).
03 LOAD SENSOR PERCENTAGE displays the generator load in percentage

(0-100%).
04 LOAD SHARING BIAS (RPM) displays the speed bias, in rpm, from the load
sharing input.
05 LOAD SIGNAL OUT (VDC) indicates the generator KW in units of load Gain
voltage. The value will vary from 0.0 to 6.0 Vdc as the generator load varies from
0 to rated KW.
06 SYSTEM LOAD 0-3 (Vdc) displays the system load on the load sharing line
as a function of the load sharing lines. 0 equals zero percent load, 3 equals 100
percent load.
07 LOAD SHARING BIAS displays the speed bias percentage (0-100%).
C** SHUTDOWNS **
Figure 3-15. Service: C** SHUTDOWN ** Menu
This menu displays the status of the shutdown modes.
01 SHUTDOWN STATUS displays the shutdown condition. If the control has

shutdowns, it displays TRUE. If no shutdowns exist, it displays FALSE.
02 FIRST SHUTDOWN displays the cause of the first shutdown. If the control
has a shutdown condition, this menu item indicates the first shutdown:
POWER UP SHUTDOWN
OVERSPEED
MPU FAIL
ANALOG INPUT #1 FAIL (if configured as such)
ANALOG INPUT #2 FAIL (if configured as such)
MODBUS ISSUED TRIP
TEST MODE
EXTERNAL SHUTDOWN
03 POWER UP SHUTDOWN (1) displays the status of power up shutdown.

Shutdown is detected when the power supply to the 2301D-ST is turned off.
Woodward 39
04 OVERSPEED (2) displays the status of overspeed trip. Shutdown is detected
when the turbine reaches an overspeed.
05 MPU FAIL (3) displays the status of MPU fail. Shutdown is detected if the
MPU fails.
06 ANALOG INPUT #1 FAIL (4) displays the status of Analog Input #1 (if configured).
A failed input is detected when the analog #1 exceeds the following ranges:
Input Set For: Low Trip Point High Trip Point

4–20 mA 2.0 mA 22.0 mA
0–5 Vdc –0.63 Vdc 5.63 Vdc
±2.5 Vdc –3.13 Vdc +3.13 Vdc
1–5 Vdc 0.5 Vdc 5.5 Vdc
07 ANALOG INPUT #2 FAIL (5) displays the status of Analog Input #2 (if configured).
A failed input is detected when the analog #2 exceeds the following ranges:
Input Set For: <Low Trip Point >High Trip Point
4–20 mA 2.0 mA 22.0 mA
0–5 Vdc –0.63 Vdc 5.63 Vdc
±2.5 Vdc –3.13 Vdc +3.13 Vdc
1–5 Vdc 0.5 Vdc 5.5 Vdc
08 MODBUS ISSUED TRIP (6) displays the status of the Modbus Issued Trip (if
configured). A trip is detected when an input from the Modbus controller has
issued a trip command.
09 TEST MODE (7) displays the status of Test Mode input. A trip is detected
when the Actuator Calibration or the Enable Hardware Test is enabled.
10 EXTERNAL SHUTDOWN (8) displays the status of SHUTDOWN / RUN DISCRETE

input. A shutdown is detected when the discrete input on terminal 31 is FALSE.
11 STUCK IN CRITICAL (9) displays the status of a shutdown caused by a stuck

in critical band failure.
12 SHUTDOWN ACKNOWLEDGE dflt=FALSE (FALSE, TRUE)

When set to TRUE will reset the SHUTDOWN RELAY discrete output. (See also description
of RESET CLEARS TRIPS in the configure menu C**DISCRETE OUT OPTIONS**.
D** ALARMS **
Figure 3-16. Service: D** ALARM ** Menu
40 Woodward
This menu displays the status of the alarm modes.
01 ALARM STATUS gives the existing alarm conditions. If control has alarms, it
displays TRUE. If no alarms exist, it displays FALSE.
02 FIRST ALARM displays the cause of the first alarm. If the control has an
alarm condition, this menu item indicates the first alarm:
NO ALARMS
ANALOG INPUT #1 FAIL
ANALOG INPUT #2 FAIL
LOAD SENSOR FAIL
LOAD SHARING LINE FAIL
03 ANALOG INPUT #1 FAIL (1) displays the status of Analog Input #1 (if
configured). A failed input is detected when the analog #1 exceeds the following
ranges:
4–20 mA 2.0 mA 22.0 mA
0–5 Vdc –0.63 Vdc 5.63 Vdc
±2.5 Vdc –3.13 Vdc +3.13 Vdc
1–5 Vdc 0.5 Vdc 5.5 Vdc
04 ANALOG INPUT #2 FAIL (2) displays the status of Analog Input #2 (if
configured). A failed input is detected when the analog #2 exceeds the following
ranges:
4–20 mA 2.0 mA 22.0 mA
0–5 Vdc –0.63 Vdc 5.63 Vdc
±2.5 Vdc –3.13 Vdc +3.13 Vdc
1–5 Vdc 0.5 Vdc 5.5 Vdc
05 LOAD SENSOR FAIL (3) displays the status of load sensor inputs (if
configured). A failed input is detected when the CT input goes less then –150
mA.
06 LOAD SHARE LINE FAIL (4) displays the status of load sharing input. A
failed input is detected when the input goes less then –0.05 VDC.
07 ALARM ACKNOWLEDGE dflt=FALSE (FALSE, TRUE)

By setting this input to TRUE momentarily, the ALARM discrete output will be
reset to a normal state.
Woodward 41
E** SPEED DYNAMICS **
Figure 3-17. Service: E** SPEED DYNAMICS ** Menu
This menu gives the operator the ability to tune the dynamic adjustments.
Dynamic adjustments are settings that affect the stability and transient
performance of the turbine. There are two sets of dynamics provided. The 52G
GENERATOR BREAKER contact input selects the Dynamics being used for
control.
If the “Select Modbus Speed PID” is set to TRUE from Modbus, Dynamics
switching from Modbus will take priority over the operation of the dynamics
switching. By setting the “Select Speed PID Dynamic Settings #1” to TRUE
momentarily from Modbus, OFF LINE Dynamic Settings are used in the control.
Otherwise, by setting the “Select Speed PID Dynamic Settings #2” to TRUE
momentarily from Modbus, ON LINE Dynamic Settings are used in the control.
01 OFF LINE PROP GAIN dflt=5.0 (0.01, 100.0)

Determines how fast the control responds to an error in turbine speed from the
speed-reference setting. The Proportional Gain is used to provide stable control
of the turbine in an unloaded condition.
02 OFF LINE INT GAIN dflt=1.8 (0.01, 50.0)

Compensates for the lag time of the turbine. It adjusts the time required for the
control to return the speed to zero error after a disturbance. The Integral Gain is
adjusted to prevent slow hunting and to minimize speed overshoot after a load
disturbance in an unloaded condition.
03 OFF LINE DERIV RATIO dflt=20.0 (0.01, 100.0)

Compensates for the actuator system time constant. Increasing the value makes
the actuator transient performance increase in an unloaded condition.
42 Woodward
04 OFF LINE WINDOW WIDTH 1 (RPM) dflt=60.0 (1.00, 200.0)
The magnitude (in rpm) of speed error at which the control automatically
switches to fast response. The control uses the absolute value of speed error to
make this switch. The absolute value is the difference between the speed
reference and the speed. A Window Width too narrow will result in cycling that
always factors in the Gain Ratio (see Figure 3-18). Note: This menu item was
added in revision “G” version of software. It will not show up in previous versions.
05 OFF LINE GAIN RATIO dflt=1.0 (1.00, 10.0)

The ratio of the Gain setting at steady state to the Gain setting during transient
conditions. The Gain Ratio operates in conjunction with the Window Width and
Gain adjustments by multiplying the Gain set point by the Gain Ratio when the
speed error is greater than the Window Width. This makes the control dynamics
fast enough to minimize engine-speed overshoot on start-up and to reduce the
magnitude of speed error when loads are changing. This allows a lower gain at
steady state for better stability and reduced steady-state actuator linkage
movement (see Figure 3-18). Note: This menu item was added in revision “G”
version of software. It will not show up in previous versions.
Figure 3-18. Control Gain as a Function of Speed Error
06 USE ON LINE DYNAMICS? dflt=FALSE (FALSE, TRUE)

Set to TRUE when selecting the ON LINE dynamics feature when the 52G
GENERATOR BREAKER contact input is closed.
07 ON LINE PROP GAIN dflt=5.0 (0.01, 100.0)

Determines how fast the control responds to an error in turbine speed from the
speed-reference setting. The Proportional Gain is used to provide stable control
of the turbine in a loaded condition.
Woodward 43
Figure 3-19. Typical Transient Response Curves
44 Woodward
08 ON LINE INT GAIN dflt=1.8 (0.01, 50.0)
Compensates for the lag time of the turbine. It adjusts the time required for the
control to return the speed to zero error after a disturbance. The Integral Gain is
adjusted to prevent slow hunting and to minimize speed overshoot after a load
disturbance in a loaded condition.
09 ON LINE DERIV RATIO dflt=20.0 (0.01, 100.0)

Compensates for the actuator system time constant. Increasing the value makes
the actuator transient performance increase in a loaded condition.
10 ON LINE WINDOW WIDTH 1 (RPM) dflt=60.0 (1.00, 200.0)

The magnitude (in rpm) of speed error at which the control automatically
switches to fast response. The control uses the absolute value of speed error to
make this switch. The absolute value is the difference between the speed
reference and the speed. A Window Width too narrow will result in cycling that
always factors in the Gain Ratio (see Figure 3-18). Note: This menu item was
added in revision “G” version of software. It will not show up in previous versions.
11 ON LINE GAIN RATIO dflt=1.0 (1.00, 10.0)

The ratio of the Gain setting at steady state to the Gain setting during transient
conditions. The Gain Ratio operates in conjunction with the Window Width and
Gain adjustments by multiplying the Gain set point by the Gain Ratio when the
speed error is greater than the Window Width. This makes the control dynamics
fast enough to minimize engine-speed overshoot on start-up and to reduce the
magnitude of speed error when loads are changing. This allows a lower gain at
steady state for better stability and reduced steady-state actuator linkage
movement (see Figure 3-18). Note: This menu item was added in revision “G”
version of software. It will not show up in previous versions.
12 USING ON LINE DYNAMICS?

Displays TRUE when ON LINE Dynamic Settings are being used in the control.
Displays FALSE when the OFF LINE dynamics are being used in the control.
13 USE LOAD REJECTION? dflt=FALSE (FALSE, TRUE)

Load Rejection is used when the possibility of large load transients could trip the
turbine out on overspeed. For example, when a generator breaker opens, while
load is on the turbine. This logic, when set to True, will sample the fuel demand
setting at the time the breaker is closed, will limit the Maximum PID output to this
value, and will pulse the Integral Gain value of the PID, if the speed changes
faster then the values listed: LD REJ SPD CHG, and LD REJ PERCENT
SPEED). Note: This menu item was added in revision “G” version of software. It
will not show up in previous versions.
14 LD REJ SPD CHG (RPM/SEC) dflt=50.0 (50.0, 250.0)

This value when exceeded, and the USE LOAD REJECTION? Value is true, and
the LD REJ PERCENT SPEED (%) is exceeded, will enable the load rejection
logic. Note: This menu item was added in revision “G” version of software. It will
not show up in previous versions.
15 LD REJ PERCENT SPEED (%) dflt=102.0 (10000, 105.0)

This value when exceeded, and the USE LOAD REJECTION? Value is true, and
the LD REJ SPD CHG (RPM/SEC) is exceeded, will enable the load rejection
logic. Note: This menu item was added in revision “G” version of software. It will
not show up in previous versions.
Woodward 45
F** REMOTE SPEED CONTROL **
Figure 3-20. Service: F** REMOTE SPEED CONTROL** Menu
THIS MENU IS USED FOR THE REMOTE SPEED CONTROL LOGIC. The
operation of two kinds of remote speed setting is possible for the control. One is
the control by the analog input. Another is the control from Modbus. These two
cannot be performed simultaneously. Priority is given to an analog input over
Modbus input.
01 REMOTE CONTROL MODE displays the status of remote control speed

operation. Will display one of the following:
NOT IN REMOTE CONTROL
MODBUS REMOTE
ANALOG INPUT REMOTE
02 RMT/PROC SLW RATE (RPM/S) dflt=5.0 (0.0, 1000.0)

Enter the speed remote / process control rate (rpm/second). This is the rate of
speed change for remote or process operation if using an analog input or a
Modbus Entered Speed Setpoint to set the Speed/Load Setpoint.
03 RMT SETPT DEADBAND (RPM) dflt=2.0 (0.0, 100.0)

Enter the dead band of remote speed setpoint operation. When the difference
between the control’s speed setpoint and the remote speed setpoint is equal to
or less than the dead band window size, the control will not take any action.
04 RMT STPT FST RATE (RPM/S) dflt=10.0 (0.0, 1000.0)

Enter the speed setpoint remote control rate (rpm/second). This is the rate of
speed change for remote operation if using an analog input or a Modbus Entered
Speed Setpoint to set the Speed/Load Setpoint.
05 RMT 2ND DEADBAND (RPM) dflt=10.0 (0.0, 100.0)

Enter the second dead band for the remote speed setpoint operation. When the
difference between the control’s speed setpoint and the remote speed setpoint is
equal to or greater than the dead band window size, the control will change at
the RMT STPT FST RATE.
06 SPEED REFERENCE (RPM) displays the speed setpoint in rpm.
07 REMOTE SPEED SETPT (RPM) displays the remote speed setpoint in rpm.
46 Woodward
G** SPEED SETTING **
Figure 3-21. Service: G** SPEED SETTING ** Menu
ZERO RATED OVERSPEED

IDLE
SPEED TEST
SPEED
LIMIT
CRITICAL
SPEED
BAND ELECTRICAL
OVERSPEED
OPERATING TRIP LEVEL
RANGE
MINIMUM MAXIMUM
GOVERNOR GOVERNOR
Figure 3-22. Speed Relationships
This menu is used for setting up the speed set points of the turbine.
01 IDLE SPD SETPOINT (RPM) dflt=1000 (0.0, 32000)

Enter the idle speed setting. This is the speed setting when using the optional
IDLE / RATED discrete input.
02 IDLE TO RATED (RPM/SEC) dflt=25.0 (0.0, 32000)

Enter the idle to rated rate (rpm/second). This is the rate at which the speed
setpoint moves to the Rated speed setpoint when using the optional Idle / Rated
discrete input.
03 RATED TO IDLE (RPM/SEC) dflt=25.0 (0.0, 32000)

Enter the rated to idle rate (rpm/second). This is the rate the speed setpoint
moves to the Idle speed setpoint when using the optional Idle / Rated discrete
input.
Woodward 47
04 MIN GOV SETPOINT (RPM) dflt=3550.0 (0.0, 32000)
Enter the minimum governor speed setting. This is the normal operation lower
limit. (Must be greater then or equal to the IDLE SPEED SETPOINT and less
than or equal to the RATED SPEED SETPOINT).
05 MAX GOV SETPOINT (RPM) dflt=3843.0 (0.0, 20000)

Enter the maximum speed setting. This is the normal operation upper limit. (Must
be greater than or equal to the RATED SPEED SETPOINT and less then or
equal to the ELECTRICAL OVERSPEED TRIP SETPOINT).
06 LOWER SLOW RATE (RPM/S) dflt=25.0 (0.0, 1000)

Enter the lower speed slow rate (rpm/second). This is the rate the speed setpoint
moves when using the LOWER SPEED / LOAD discrete input until the Raise /
Lower Time Delay has expired. At this time the Lower Fast Rate takes over.
07 LOWER FAST RATE (RPM/S) dflt=25.0 (0.0, 1000)

Enter the lower speed rate (rpm/second). This is the rate the speed setpoint
moves when using the LOWER SPEED / LOAD discrete input after the Raise /
Lower Time Delay has expired.
08 RAISE SLOW RATE (RPM/S) dflt=25.0 (0.0, 1000)

Enter the raise speed rate (rpm/second). This is the rate the speed setpoint
moves when using the RAISE SPEED / LOAD discrete input until the Raise /
Lower Time Delay has expired. At this time the Lower Fast Rate takes over.
09 RAISE FAST RATE (RPM/S) dflt=25.0 (0.0, 1000)

Enter the raise speed rate (rpm/second). This is the rate the speed setpoint
moves when using the RAISE SPEED / LOAD discrete input.
10 R/L TIME DELAY (SEC) dflt=5.0 (0.5, 30.0)

Enter the time in seconds that the Raise or Lower Slow Rates has control of the
speed setpoint. After this time has expired, the Raise or Lower Fast Rate has
control of the speed setpoint.
11 CRITICAL LOW POINT (RPM) dflt=2500.0 (0.0, 32000)

Enter the lower limit of the critical speed avoidance band.
(Must be less than the CRITICAL HI POINT and greater than IDLE SPEED
SETPOINT)
12 CRITICAL HI POINT (RPM) dflt=3000.0 (0.0, 32000)

Enter the upper limit of the critical speed avoidance band.
(Must be greater than the CRITICAL LOW POINT must be less than the MIN
GOV SETPOINT).
13 CRITICAL RATE (RPM/SEC) dflt=100.0 (0.0, 32000)

Enter the rate that the speed setpoint will move through the critical speed
avoidance range (in rpm/second).
14 USE SET POINT SET-BACK? dflt=FALSE (FALSE, TRUE)

Set this value to TRUE to use the SET POINT SET-BACK feature. This feature
will instantly reset the speed setpoint to the actual running speed of the turbine
when the RAISE SPEED / LOAD or LOWER SPEED / LOAD discrete inputs are
switched. During a ramp, this input can be used to stop the ramp from changing
the speed set point. Set this value to FALSE to disable this feature.
(This feature must be left FALSE when using this control for generator
applications)!
48 Woodward
H** PROCESS CONTROL **
Figure 3-23. Service: H** PROCESS CONTROL ** Menu
THIS MENU IS USED FOR THE PROCESS CONTROL OF THE TURBINE.
01 PROCESS CONTROL ENABLED

Displays the state of the process control. TRUE means the Process Control is
enabled, FALSE means it is disabled.
02 USE PROCESS CONTROL? dflt=FALSE(FALSE, TRUE)

The Process control can be configured to control any system process, related to
or affected by turbine speed or load. Typically this controller is configured and
used as a turbine inlet or exhaust pressure controller. When this value is set
TRUE, the Process PID can move the speed setpoint at a variable rate up to the
REMOTE PROC MAX RATE setting. If the USE PROCESS CONTROL is FALSE
the inputs will have no effect on the control.
03 INVERT PROCESS? dflt= FALSE(FALSE, TRUE)

Select TRUE if the process control will be reverse acting. If FALSE is selected,
the control will be forward acting. Typically this will be set to FALSE, the only
time the input would be inverted is if the valve needs to open when the input
exceeds the setpoint. An example where the invert would be TRUE is for turbine
inlet pressure control.
04 MIN PROC SETPT (UNITS) dflt=0.0 (-20000.0, 20000.0)

This value is the minimum setpoint value that the process setpoint can be
decreased/lowered to (lower limit of process setpoint). This value should set to
the same value as the INPUT#X MIN VALUE (UNITS) under the Configure menu
D**ANALOG INPUT OPTIONS**.
Woodward 49
05 MAX PROC SETPT (UNITS) dflt=0.0 (-20000.0, 20000.0)
This value is the maximum setpoint value that the process setpoint can be
increased/raised to (upper limit of process setpoint). This value should set to the
same value as the INPUT#X MAX VALUE (UNITS) under the Configure menu
D**ANALOG INPUT OPTIONS**.
(Must be greater than the ‘Min Proc Setpt’ Setting)
06 PROC SETPT RT (UNITS/SEC) dflt=5.00 (0.01, 1000.00)

This value is the rate (in units per second) at which process setpoint moves
when adjusted.
07 USE SETPOINT TRACKING? dflt= FALSE(FALSE, TRUE)

If TRUE, the process setpoint tracks the process input to provide bumpless
transfer to process control when it is enabled. If FALSE, the process setpoint
remains at the last position except on power-up.
08 SETPT INIT VALUE (UNITS) dflt=0.0 (-20000.0, 20000.0)

When not using the Setpoint Tracking function, this is the value that the process
setpoint initializes to upon power-up.
(Must be less than or equal to the ‘Max Process Setpt’ Setting)
09 SPD SETPT LOW LMT (RPM) dflt=0.0 (0.0, 20000.0)

Set the minimum speed setpoint that the process controller can lower the speed
setpoint to. To protect the unit, this value should be at or above rated speed if the
unit is a generator. (Must be greater than or equal to the ‘Minimum Governor
Speed Setpt’ Setting)
10 SPD SETPT HIGH LMT (RPM) dflt=0.0 (0.0, 20000.0)

Set the maximum speed setpoint that process controller can raise the speed
setpoint to.
(Must be less than or equal to the ‘Maximum Governor Speed Setpt’ Setting)
11 PROCESS PID PROP GAIN dflt=1.0 (0.0, 100)

Enter the process PID proportional gain value. This value is used to set process
control response.
12 PROCESS PID INTEG GAIN dflt=0.3 (0.001, 50.0)

Enter the process PID integral gain value. This value is used to set process
control response.
13 PROCESS DERIVATIVE RATIO dflt=100.0 (0.01, 100.0)

Enter the process PID derivative ratio value. This value is used to set process
control response.
14 PROCESS CNTRL DEADBAND dflt=0.01 (0.01, 5.0)

Enter the process control deadband value. This value is used to set the
deadband the process control will respond to.
15 USE REMOTE PROC SETTING? dflt= FALSE(FALSE, TRUE)

Set to TRUE to allow the Process setpoint to be adjusted from an analog input.
(Must program a ‘Remote Process Setpoint’ analog input
16 REMOTE PROC MAX RATE dflt=5.0 (0.01, 1000.0)

Enter the maximum rate at which the remote input will move the process
setpoint.
17 ANALOG INPUT #1
Displays the input of analog input #1.
50 Woodward
18 ANALOG INPUT #2
Displays the input of analog input #2.
19 PROCESS SETPOINT (UNITS)

Displays the process setpoint in engineering units.
20 PROCESS ACTUAL (UNITS)

Displays the process control variable in engineering units.
I** OVERSPEED TEST **
Figure 3-24. Service: I** OVERSPEED TEST ** Menu
01 OVERSPEED TEST STATUS displays the state of the overspeed test

function.
02 OVERSPEED TEST ENABLE dflt=FALSE (FALSE, TRUE)

Set the overspeed test discrete input TRUE when this optional test is performed.
An overspeed test is allowed only under the condition that the remote speed
setpoint function is disabled and the 52G generator breaker is open. An
overspeed test will allow the control’s speed setpoint to be increased above the
normal maximum limit. When the actual speed reaches the ELEC OVRSPEED
TRIP SETPT, the ELECT OVERSPD TRIP TEST will switch from FALSE to
TRUE. When this input is FALSE, the control will detect an over speed and will
issue a trip. After overspeed testing ends, manually lower the turbine speed
below the ELEC OVRSPD TRIP SETPT or else the turbine will trip. When testing
is done, return the input to FALSE.
03 ELEC OVRSPEED TRIP SETPT dflt=4032.0 (0.0, 32000)

Enter the electrical overspeed trip speed setting in rpm. This is the controls
electrical overspeed trip setpoint only and should not be used as the ultimate
overspeed protection.
(Must be greater than or equal to the MAX GOVERNOR SETPOINT and less
than the MAXIMUM OVERSPEED SETPOINT).
04 ELEC OVERSPD TRIP TEST displays the status of the electrical overspeed
trip set point latch. When testing the overspeed function, this value will go true
when the actual speed reaches the ELEC OVRSPEED TRIP SETPT.
05 TURBINE SPEED (RPM) displays actual turbine speed in rpm.
Woodward 51
06 SPEED REF (RPM) displays turbine speed setpoint in rpm.
J** FAILED MPU OVERRIDE **
Figure 3-25. Service: J** FAILED MPU OVERRIDE** Menu
THIS MENU IS USED FOR SETTING THE MPU OVERRIDE LOGIC.
01 AUTO-OVRD OFF SPEED dflt=450.0 (0.0, 2000.0)

This is the setpoint at which the auto MPU override goes off. Once the MPU
speed is greater than this value, the MPU override will go off. If the speed drops
below the MPU MIN SPD LEVEL (RPM) (see Configure Menu – A**SPEED AND
STRT OPTIONS**) after the override goes off, the turbine will trip on loss of
speed.
02 AUTO-OVRD ON SPEED dflt=650.0 (0.0, 2000.0)

This is the setpoint where the rolldown override will start if Use Rolldown
Override is set to TRUE. When the speed drops below this low-speed setting for
the delay time, the override is turned on.
03 AUTO-OVRD ON DELAY (SEC) dflt=5.00 (0.0, 100.0)

This is the delay time before the MPU override goes TRUE. It is used with the
Rolldown Override option - the delay time associated with turning on the
override. If the speed drops below the Minimum Speed Level setting before the
time expires, the unit will trip on loss of MPU signal and reset the speed set-point
to minimum.
04 AUTO-OVRD ON SPEED dflt=650.0 (0.0, 2000.0)

This is the setpoint where the rolldown override will start if Use Rolldown
Override is set to TRUE. When the speed drops below this low-speed setting for
the delay time, the override is turned on.
05 USE ROLLDOWN OVERRIDE? dflt=FALSE (FALSE, TRUE)

Set this to TRUE to enable the rolldown MPU override. This option turns on the
Failed MPU Override if the speed is being slowly reduced by closing the Trip-
and-Throttle valve or stop valve — this override is turned on after the speed
drops below the AUTO-OVRD ON SPEED setting for the AUTO-OVRD ON
DELAY time.
06 MAX STARTING TIME dflt=60.0 (0.0, 3000.0)

Maximum time required to start; if this time expires the MPU will no longer be
overridden. If the turbine has not reached the MPU MIN SPD LEVEL before this
time expires, the turbine will trip on loss of speed
52 Woodward
K** SYNCHRONIZER SETUP **
Figure 3-26. Service: K** SYNCHRONIZER SETUP** Menu
THIS MENU IS USED TO SETUP THE SYNCHRONIZER LOGIC.
01 ENBL SYNC INPUT displays whether the sync input is being used. If it is
TRUE, the SYNC INPUT can be used.
02 SYNC INPUT SCALE (%/V) dflt=0.7 (0.1, 5.0)

Should be set to the Analog Input sync input scale.
03 SYNC BIAS SPD (RPM) displays the value of sync bias speed.
04 TURBINE SPEED (RPM) displays actual turbine rpm.
05 SPD REF (RPM) displays turbine speed setpoint rpm.
L* VALVE LIMITER SET **
Figure 3-27. Service: L* VALVE LIMITER SET ** Menu
THIS MENU IS USED TO SET UP THE VALVE LIMITER CONTROL.
Woodward 53
01 ENABLE MANUAL CNTRL RAMP dflt=FALSE (FALSE,TRUE)
Set this value to TRUE to manually control the valve ramp. MANUAL CNTRL
RAMP SETPNT is used manually lower the ramp. This value is low signal
selected (LSS) with the turbine speed control. If manually lowered below the
speed control PID value, the valve ramp will take control.
02 MANUAL RAMP STATUS displays the status of the MANUAL CONTROL

RAMP.
03 MANUAL CNTRL RAMP SETPNT dflt=100.0 (0.0, 100.0)

Set this value to manually control the valve ramp. This value is low signal
selected (LSS) with the turbine speed control.
WARNING—OVERSPEED
If manually lowered below the speed control PID value, the valve ramp will
take control. This could cause serious consequences, overspeed, or
shutdown.
04 DISPLAY ACTUATOR % displays the actual actuator output percentage.
05 ACTUAL VALVE RAMP % displays the actual valve ramp output percentage.
06 MAN START RATE (%/SEC) dflt=10.0 (0.0, 100.0)

If configured for MANUAL START, this value sets the valve ramp start rate in
percent per second.
07 AUTO START RATE (%/SEC) dflt=0.5 (0.0, 100.0)

If configured for a SEMI-AUTOMATIC START, this value sets the valve ramp
start rate in percent per second.
08 MAN/AUTO PID RAMP RATE dflt=50.0 (1.0, 100.0)

If configured for a MANUAL START OR AUTOMATIC START MODE, this value
sets the PID ramp that sets the PID controller out of the way. This value is set in
percent per second.
54 Woodward
M** LOAD SENSOR AND DROOP **
Figure 3-28. Service: M** LOAD SENSOR AND DROOP ** Menu
THIS MENU IS USED TO SET UP THE GENERATOR LOAD CONTROL

PARAMETERS.
01 USE LOAD SENSOR? dflt=FALSE (FALSE, TRUE)

Set to TRUE to use the built in generator load sensor for generator applications
or FALSE when using control for pump, blower, or compressor applications.
02 USE ACT POS DROOP? dflt=FALSE (FALSE, TRUE)

Set to TRUE to use internal LSS demand/actuator position to calculate a droop
percentage. When this setting is TRUE, actuator position feedback is used as the
controlling parameter for stability when the unit is on-line. Droop percentage is
set up in Service Menu “M” below. Actuator position levels in Service Menu “M”,
below, must be set properly when this value is set to TRUE. If these values are
not set properly, the droop percentage will be off. When this setting is FALSE,
Actuator Position Droop will not be used. Note: Do not set this value to True if
applying the Potential Transformer and Current Transformer inputs to
calculate the true KW load value.
03 DROOP PERCENTAGE (%) dflt=5.0 (0.00, 12.0)

This value is the percentage of rated speed the speed reference will droop when
the generator load is increased to maximum load. This value is used for KW
Droop and Actuator Position Droop.
04 ACT % @ NO LD (POS DRP) dflt=20.0 (0.0, 100.0)

This value is the percentage of actuator output used to calibrate the actuator
position droop feedback at no load. If actuator position feedback droop is used,
this value must match the actuator output position at no load.
Woodward 55
06 ACT % @ FULL LD (POS DRP) dflt=80.0 (0.0, 100.0)
This value is the percentage of actuator output used to calibrate the actuator
position droop feedback at full load. If actuator position feedback droop is used,
this value must match the actuator output position at full load.
07 ENTER RATED LOAD (KW) dflt = 1000 (10, 30000)

This value should be set to the generator full load (100%) in kW.
08 LOAD GAIN VOLTAGE dflt=6.00 (0.1, 9.0)

Enter the load gain desired at 100% load. The software will use the Rated KW
value above and this Load Gain voltage value to scale the analog output to the
load sharing circuitry to perform load sharing with other controls in the system. A
value of 6.0 is usually sufficient to allow load sharing with other units utilizing 0–3
Vdc analog load sharing lines. This value must be common with all other controls
connected to the common Load Sharing Signal lines.
09 KW CALIBRATION ZERO dflt=0.00 (-20.00, 20.00)

Adjust until the KW reading is zero when the generator output is zero.
10 KW CALIBRATION GAIN dflt=10.0 (5.0, 40.0)

Adjust until the KW reading for the load sensor output matches the external
instrumentation readings.
11 LOAD TIME (KW/SEC) dflt=20.0 (1.0, 600.0)

Set this value for loading rate. This sets the rate at which the Load Ramp will
increase for soft loading.
12 ENABLE FAST LOAD RATE dflt=FALSE (FALSE, TRUE)

Set to TRUE if the function to activate a faster loading ramp rate than the LOAD
TIME entered above when the system load level is high.
13 FAST LOAD TIME (KW/SEC) dflt=60.0 (1.0, 600.0)

Enter the loading rate at which the load will increase when the system load is
above the percentage entered for the FAST RAMP LOAD (%).
14 FAST RAMP LOAD (%) dflt=80.0 (1.0, 600.0)

When the system load, as measured through the load sharing lines, is
determined to be above this percentage the soft load ramp rate will switch to a
faster rate to allow this oncoming unit to pick up it share of the load faster.
15 UNLOAD TIME (KW/SEC) dflt=20.0 (1.0, 600.0)

Set this value for loading rate. This sets the rate at which the Load Ramp will
increase for soft loading.
16 LOAD SHARE GAIN dflt=0.20 (0.01, 10.0)

Set this value for stable load control while in isochronous load sharing on an
isolated bus.
17 GEN OUTPUT (KW) is the output of the generator sensed load and should
match external instrumentation
18 LOAD SIGNAL OUT (VDC) converts the generator kW into the load Gain
voltage value.
56 Woodward
N** ACT LINEARIZATION **
Figure 3-29. Service: N** ACT LINEARIZATION ** Menu
THIS MENU IS USED TO LINEARIZE THE ACTUATOR / VALVE.
01 X-1 VALUE dflt=0.0 (-10.0,110.0)

Input point #1 of actuator linearization curve, in percentage.
(Must be less than the ‘X-2 Value’)
02 Y-1 VALUE dflt=0.0 (-10.0,110.0)

Output point #1 of actuator linearization curve, in percentage.
03 X-2 VALUE dflt=10.0 (-10.0,110.0)

04 Y-2 VALUE dflt=10.0 (-10.0,110.0)

05 X-3 VALUE dflt=20.0 (-10.0,110.0)

06 Y-3 VALUE dflt=20.0 (-10.0,110.0)

Woodward 57
07 X-4 VALUE dflt=30.0 (-10.0,110.0)
08 Y-4 VALUE dflt=30.0 (-10.0,110.0)

09 X-5 VALUE dflt=40.0 (-10.0,110.0)

10 Y-5 VALUE dflt=40.0 (-10.0,110.0)

11 X-6 VALUE dflt=50.0 (-10.0,110.0)

12 Y-6 VALUE dflt=50.0 (-10.0,110.0)

13 X-7 VALUE dflt=60.0 (-10.0,110.0)

14 Y-7 VALUE dflt=60.0 (-10.0,110.0)

15 X-8 VALUE dflt=70.0 (-10.0,110.0)

16 Y-8 VALUE dflt=70.0 (-10.0,110.0)

17 X-9 VALUE dflt=80.0 (-10.0,110.0)

18 Y-9 VALUE dflt=80.0 (-10.0,110.0)

19 X-10 VALUE dflt=90.0 (-10.0,110.0)

20 Y-10 VALUE dflt=90.0 (-10.0,110.0)

21 X-11 VALUE dflt=100.0 (-10.0,110.0)

22 Y-11 VALUE dflt=100.0 (-10.0,110.0)

23 ACTUATOR DEMAND (%) displays the actuator demand before the

linearization curve, in percentage.
58 Woodward
24 ACTUATOR OUT (MA) displays the actuator demand after the linearization
curve, in milliamps.
O** ACTUATOR CALIBRATION **
Figure 3-30. Service: O** ACTUATOR CALIBRATION ** Menu
Before initial operation or after a turbine overhaul where any actuator or valve
travel may have been affected, the below Valve Calibration procedure will allow
the 2301D-ST to be calibrated to the valve.
01 CALIBRATION ENABLE dflt=FALSE (FALSE, TRUE)

Set to TRUE to calibrate the actuator or valve. Will not be enabled unless
Shutdown is active, and speed is zero. If calibration is completed, it should be set
to FALSE.
02 CALIBRATION STATUS
Displays the status of the CALIBRATION ENABLE input.
03 DUMMY DRIVE SIGNAL (%) dflt=0 (0,100)

Set the valve’s output percentage between 0-100%. This allows both the actuator
and valve to be tested for binding, play, resolution, linearity, and repeatability.
04 DRIVER OFFSET dflt=0.0 (-100.0,100.0)

Adjust the valve’s output current for a minimum stop.
05 DRIVER GAIN dflt=1.0 (0.0,10.0)

Adjust the valve’s output current for a maximum stop.
06 ACTUATOR DITHER (MA) dflt=0.0 (0.0, 10.0)

Enter the dither, in milliamps. Enter 0.0 if no dither is required. Woodward TM-
type actuators typically require dither.
07 ACTUATOR OUT (MA) displays the actuator output, in milliamps.
Woodward 59
P** ANALOG I/O SETTINGS **
Figure 3-31. Service: P** ANALOG I/O SETTINGS ** Menu
This section calibrates the analog inputs and selects the parameter to be sent to
the analog output driver and the desired scaling of the output.
01 DISPLAY AI #1 FUNCTION displays the programmed function of analog

input #1.
02 INPUT #1 MIN VALUE (UNIT) dflt=0.0 (-32000.0, 32000.0)

Set the value (in engineering units) that corresponds to the minimum range on
Analog Input #1.
03 INPUT #1 MAX VALUE (UNIT) dflt=100.0 (-32000.0, 32000.0)

Set the value (in engineering units) that corresponds to the maximum range on
Analog Input #1.
CAUTION—ANALOG INPUTS
When setting the Min and Max Values for Analog Input #1 or #2, the
following equation must be followed: [(Max Value) – (Min Value) * 16] <
32000
04 ANALOG IN #1 UNITS displays the conversion of the analog input to

engineering units.
05 DISPLAY AI #2 FUNCTION displays the programmed function of analog

input #2.
06 INPUT #2 MIN VALUE (UNIT) dflt=0.0 (-32000.0, 32000.0)

Set the value (in engineering units) that corresponds to the minimum range on
Analog Input #2.
60 Woodward
07 INPUT #1 MAX VALUE (UNIT) dflt=100.0 (-32000.0, 32000.0)
Set the value (in engineering units) that corresponds to the maximum range on
Analog Input #2.
CAUTION—ANALOG INPUTS
When setting the Min and Max Values for Analog Input #1 or #2, the
following equation must be followed: [(Max Value) – (Min Value) * 16] <
32000
08 ANALOG IN #2 UNITS displays the conversion of the analog input to

engineering units.
09 ANALOG OUTPUT SEL (1-7) dflt=1 (1, 7)

Select one of the following parameters for 4–20 mA output at terminals 16,17
and 18.
1=NOT USED
2=TURBINE SPEED
3=TURBINE SPEED REFERENCE
4=VALVE LIMITER SETPOINT
5=ACTUATOR DEMAND
6=GENERATOR OUTPUT
7=MONITOR SIGNAL
10 ANALOG OUTPUT SELECTED displays the item name of analog output.
11 ANOUT MINIMUM VALUE (UNIT) dflt=0.0 (-32000.0, 32000.0)

Adjust for the value of the displayed parameter in engineering units when the
analog output is at 4 mA.
12 ANOUT MAXIMUM VALUE (UNIT) dflt=100.0 (-32000.0, 32000.0)

Adjust for the value of the displayed parameter in engineering units when the
analog output is 20 mA.
13 ANALOG OUT (MA) displays the analog output, in milliamps.
Woodward 61
Q** DISCRETE OUT SETTINGS **
Figure 3-32. Service: Q** DISCRETE OUT SETTINGS ** Menu
The 2301D-ST has four discrete output driver channels. Terminals 41, 42, 43
and 44 are configurable and can be programmed to perform one of the following
functions.
And any of the four relay drivers can also be programmed to function as a level
switch. When programmed as a level switch the relay will change state when the
selected parameter reaches the programmed level (energizes when value is
higher the programmed level).
01 RELAY 1 SELECTED AS displays the function selected for terminal 41. This
relay is selected in the configure menu - C**DISCRETE OUT OPTIONS**
02 RELAY 1 LEVEL SW (1-7) dflt=1 (1, 7)

Select one of the following parameters for discrete output at terminals 41 when it
was selected as a level switch.
1=NOT USED
2=TURBINE SPEED
5=ACTUATOR DEMAND
6=GENERATOR OUTPUT
7=MONITOR SIGNAL
03 RELAY 1 LEVEL SELECT FOR displays the level function selected for
terminal 41.
62 Woodward
04 RELAY 1 ON LEVEL dflt=0.0 (-32000.0, 32000.0)
Enter the level switch ON setting in engineering units. There is an ON and an
OFF setting for each level switch option. This allows the user to program the
desired hysteresis for the function selected.
05 RELAY 1 OFF LEVEL dflt=0.0 (-32000.0, 32000.0)

Enter the level switch OFF setting in engineering units.
(Must be less than the ‘Relay On Level’)

1=NOT USED
2=TURBINE SPEED
5=ACTUATOR DEMAND
6=GENERATOR OUTPUT
7=MONITOR SIGNAL
terminal 42.


(Must be less than the ‘Relay On Level’).

1=NOT USED
2=TURBINE SPEED
5=ACTUATOR DEMAND
6=GENERATOR OUTPUT
7=MONITOR SIGNAL
terminal 43.

Woodward 63
(Must be less than the ‘Relay On Level’)

1=NOT USED
2=TURBINE SPEED
5=ACTUATOR DEMAND
6=GENERATOR OUTPUT
7=MONITOR SIGNAL
terminal 44.


(Must be less than the ‘Relay On Level’).
WARNING—CONFIGURED SHUTDOWN RELAY

The Discrete outputs can be changed for other functions when the turbine is
running. Therefore, do not change the Configured Shutdown Relay when the
turbine is running.
64 Woodward
R** DISPLAY D_I/O STATUS **
Figure 3-33. Service: R** DISPLAY D_I/O STATUS ** Menu
This section has no adjustments to set, it is used only for display status of
discrete inputs and the status of the discrete outputs.
01 DI EXTERNAL SHUTDOWN indicates status of discrete input A.
02 DI RESET indicates status of discrete input B.
03 DI START / UNLOAD indicates status of discrete input C.
04 DI RAISE SPEED indicates status of discrete input D.
05 DI LOWER SPEED indicates status of discrete input E.
06 DISCRETE INPUT F indicates status of discrete input F.
07 DISCRETE INPUT G indicates status of discrete input G.
08 DISCRETE INPUT H indicates status of discrete input H.
09 DISCRETE OUTPUT #1 indicates status of discrete output #1.
13 INTERNAL L/S RELAY K1 indicates status of discrete output driving the

internal load-sharing relay.
Woodward 65
S** HARDWARE OUTPUT TEST **
Figure 3-34. Service: S** HARDWARE OUTPUT TEST ** Menu
This section allows the operator to test the analog output and the relay driver
outputs by artificially forcing the signals. This test can only be performed in the
shutdown state.
01 ENABLE HARDWARE TEST dflt=FALSE (FALSE, TRUE)

Set to TRUE to test the hardware output. When test is finished, it should set to
FALSE.
02 HARDWARE TEST MODE displays the status of the HARDWARE TEST

mode.
03 AO FORCE VALUE (4–20 MA) dflt=4 (4, 20)

Set this value to the desired value, to test the analog output on terminals 16, 17.
04 ANALOG OUT (mA) displays the actual current output in milliamps.
05 ANOUT, 4 MA OFFSET dflt=0.0 (-100.0,100.0)

Adjusts the analog output current to a specified offset.
06 ANOUT, 20 MA GAIN dflt=1.0 (0.0,10.0)

Adjusts the analog output current to a specified gain or level.
66 Woodward
07 TURN ON DO-1 dflt=FALSE (FALSE, TRUE)
Set to TRUE to turn ON the relay driver output #1. If test is finished, it should set
to FALSE.
08 DISCRETE OUTPUT #1 displays the state of discrete output #1.

to FALSE.

to FALSE.

to FALSE.
15 TURN ON LS LINE RELAY dflt=FALSE (FALSE, TRUE)

Set to TRUE to turn ON the internal load-sharing relay, observe the green LED
between terminal 9 and 10. If test is finished, it should set to FALSE.
16 LOAD SHARE RELAY displays the state of the load sharing relay.
T** COMM PORT (MODBUS) **
Figure 3-35. Service: T** COMM PORT (MODBUS) ** Menu
The menu is used to setup the serial port for Modbus use.
01 PORT FAIL indicates a hardware fault of RS-232/RS-422 communication

port.
Woodward 67
02 LINK ERROR indicates Link Error sets TRUE when the slave fails to answer
a data request in specified number of time-out seconds.
03 ERROR PERCENT
Error Percent outputs reflects communication quality as a percentage by dividing
the number of exception errors detected by the total number of communication
transactions. This essentially gives the number of message/packet errors
detected.
04 ERROR NUMBER
Error Number outputs the code number of the communication/exception error
that occurred.
CODE NAME MEANING

00 NO ERROR Error free
The following are returned to the master.
01 ILLEGAL Message function received is not an allowable action for
FUNCTION addressed slave. (Unsupported or illegal function code).
02 ILLEGAL Address referenced in data field is not an allowable address for
DATA the addressed slave location. (Master requested data, which is
ADDRESS not configured from slave).
03 ILLEGAL Amount of data requested from slave was too large for slave to
DATA VALUE return in a single response. Woodward maximum is 118
registers.
The following are displayed only.
09 CHECKSUM Error in the checksum. Can indicate link quality and/or noise
ERROR problems.
10 GARBLED Data received by the slave, but it is too short to be a valid
MESSAGE Modbus message/command.
Table 3-1. Communication Error Code
05 BAUD RATE dflt=10 (1, 10)

Set the Baud rate, which defines the transfer rate for port communications.
1=110 2=300
3=600 4=1200
5=1800 6=2400
7=4800 8=9600
9=19200 10=38400
06 BAUD RATE IS SET FOR

Shows the selected Baud rate.
07 DATA BITS dflt=1 (1, 2)

Set the Data bits input defines the protocol for the number of data bits in the data
packets.
1=7
2=8
08 DATA BITS ARE SET FOR

Shows the selected data bits.
09 STOP BITS dflt=1 (1, 3)

Set the Stop bits, which defines the number of stop bits for the communications
protocol. Stop bits specify the time that elapses between transmitted characters.
1=1 stop bit
2=2 stop bits
3=1.5 stop bits
68 Woodward
10 STOP BITS ARE SET FOR
Shows the selected stop bits setting.
11 PARITY dflt=1 (1, 3)

Set the Parity input defines protocol for the parity. If you selected 8 data bits
select '1' for none.
1=OFF (none)
2=ODD
3=EVEN
12 PARITY IS SET FOR

Shows the parity setting.
13 DRIVER dflt=1 (1, 2)

Set the Driver input defines the type of driver output for this port.
1=RS232
2=RS422
14 DRIVER IS SET FOR

Shows the selected driver.
15 TIME OUT (SEC) dflt=4.0 (0.0, 100.0)

Set the Time-out Number of Seconds input defines the Modbus link dead time
allowed before a link error occurs.
16 NETWORK ADDRESS dflt=1 (1, 247)

Set the Network Address input defines the slave block address on the Modbus
network. The network address may depend on master device allowable
addresses.
17 ENABLE MODBUS CONTROL dflt=FALSE (FALSE, TRUE)

When set TRUE you are able to control using Modbus.
U** APPLICATION INFO **
Figure 3-36. Service: U** APPLICATION INFO ** Menu
This section shows the application software information.
01 APP Software Number indicates the software part number.
02 APP Software Revision indicates the status of the application software

revision.
03 Application Name indicates the application name.
Woodward 69
Chapter 4.
Description of Operation
This chapter provides an overview of the features and operation of the 2301D-ST
Load Sharing and Speed Control.
The 2301D-ST Load Sharing and Speed Control uses a 32 bit microprocessor for
all control functions. All control adjustments are made with an external computer
that communicates with the control via a serial port. The external computer can
be disconnected from the control during normal operation, to provide security
against tampering.
When power is applied, the 2301D-ST performs internal memory tests to ‘boot-
up’ the processor. This takes approximately 30 seconds to complete. The CPU
Status LED between terminals 27 and 28 remains on during this boot-up. The
control will remain in I/O lock and will not provide control to the prime mover until
the boot-up is complete. For systems requiring fast start functions, it is necessary
to continuously power the 2301D-ST.
WARNING—DO NOT START

DO NOT attempt to start the prime mover while the CPU Status LED is ON.
WARNING—DO NOT APPLY POWER

DO NOT apply power to the control at this time. Applying power before a
control is completely connected may damage the control.
The 2301D-ST’s normal operating architecture is divided into two sections: The
Service Mode and the Configuration Mode. The Configuration Mode is used to
configure the 2301D-ST for the specific application and to set all operating
parameters (see Chapter 5). The Service Mode is the normal turbine operation
mode and is used to view operating parameters and run the turbine.
The 2301D-ST is controllable from the Discrete Inputs or Modbus commands.

The following processes are explained by using the Discrete Inputs. These
Discrete Inputs currently used here exist in the commands (Boolean Writes) of
Modbus. They can be operated similarly through the Modbus communication.
70 Woodward
A P P LY P O W E R
S E LF TE S T
R U N 2301D -S T
S TA R T W atch W indow
C oinfigure
M ode?
O P E N "C onfigure" M enu
O P E N "S ervice" M enu I/O LO C K
S ervice M ode C onfigure M ode
R E S E T C ontrol
Figure 4-1. Basic Operational Architecture
AUTOMATIC START-UP PROCEDURE
1. Initial – all discrete Initial Settings:

inputs are off. Speed reference is set to 0%.
Shutdown input is in Valve limiter is 0%.
the shutdown state. Actuator Output (Terminal 13-14) will be at 0 mA.
Shutdown Relay (Terminal 41) will be Shutdown condition.
The turbine should be stopped, the speed signal (Terminal 25-26) is
minimum.
Analog Input 1 and 2, Load sharing line and PT’s, CT’s are normal range
based on their configurations.
2. Shutdown / Run Discrete Input- A (Terminal 31) should be set to the RUN (Closed) position to
discrete input. start and run the turbine, and Shutdown (Open) to shutdown the actuator
output. Set the Modbus Controlled Shutdown from the Modbus controller to
True to run the turbine, and to False to shutdown the, if used.
3. Reset all alarms and Discrete Input- B (Terminal 32) should be toggled to reset all alarms and
shutdown latches. shutdown latches. This will affect the initial speed setpoint only after all trip
conditions are cleared. The actuator or valve does not open by the reset
input.
Woodward 71
4. Start / Unload. The Discrete Input Start / Unload should be toggled to start the turbine. If this
input is being used as a Load / Unload contact, do not toggle this input to
start the turbine. By closing this contact, will start the turbine and if this a
generator application will also soft load the generator from an isolated bus.
The start mode of operations determines what the actuator will do when a
start condition is given. The open of valve limiter may be aborted at any time
by issuing valve limiter raise or lower commands, or an emergency shutdown.
Automatic Start. The Valve Ramp Limiter will ramp up to its maximum limit after the Start
Command is issued. The speed reference increases to the rated speed by
the programmed sequence. Once the turbine speed reaches the speed
reference, the valve ramp limiter goes out of the way (100%), and the speed
is controlled by the PID. The speed will continue to ramp to rated speed.
Figure 4-2 is an example of an automatic start sequence.

1. Close the Run / Shutdown discrete input, toggle the Reset discrete
input, and close the Start / Unload contact.
2. The speed reference ramps up by the programmed rate.
3. As the turbine speed increases, the PID controller will take over control,
and the valve ramp jumps to 100%, which is out of the way.
4. The speed PID controller then ramps the speed reference at a
controlled rate to the rated speed setpoint. At any time, momentarily
closing the Speed Raise or Speed Lower discrete input will stop the
turbine from ramping. This allows the operator to heat soak the turbine
at various speeds. To continue the ramp, manually close the Speed
Raise Contact.
5. If for some reason the turbine shuts down, due to a 2301D-ST
shutdown, and the Run and Start contact inputs are closed, a toggle on
the Reset contact will initiate the start sequence.
Figure 4-2. Automatic Start-up
72 Woodward
Semi-automatic Start. The Speed Reference will increase up to the rated speed reference after the
Start Command is issued. The valve reference and actuator demand are
controlled by the raise / lower contact inputs.
Figure 4-3 is an example of a semiautomatic start sequence.

2. The speed reference ramps up to by the programmed rate to the rated
speed reference.
3. By closing the raise speed contact, the valve ramp reference will start
increasing, thus increasing the turbine speed. The operator has control
over where the valve ramp reference is set at by using the raise speed
and lower speed discrete inputs. This allows the operator to heat soak
the turbine at different speed levels.
4. Continuing to raise the valve ramp reference will cause the speed to
increase until the speed matches the speed reference. The PID
controller will then take over control. The valve ramp reference will
quickly ramp out of the way (100%).
5. The operator can allow control the speed of the turbine with the raise
and lower speed discrete inputs.
Figure 4-3 Semi-automatic Start-up
Woodward 73
Manual Start The Speed Reference will increase up to the rated speed reference after the
Start Command is issued. The speed of the turbine is controlled by the trip
and throttle valve or control valve until turbine speed reaches speed
reference.
Figure 4-4 is an example of a manual start sequence.

2. The speed reference, the valve ramp reference, and the actuator
demand ramp up by the programmed rate to the rated speed reference.
3. By opening the trip and throttle valve or control valve the turbine speed
will increase. The operator has control over where the speed of the
turbine is at by using the trip and throttle valve. This gives the operator
a chance to heat soak the turbine at different speed levels.
4. Continuing to open the trip and throttle valve will cause the speed to
increase until the speed matches the speed reference. The PID
controller will then take over control.
5. The operator can then control the speed of the turbine with the raise
and lower speed discrete inputs.
Figure 4-4 Manual Start-up
5. Rolling Turbine Restart In Automatic Start mode, the turbine may be re-started, even though the
turbine is still rolling. If a re-start is needed, the only requirement is that the
Run contact is closed, the Reset contact is toggled off to on and the Start
contact is toggled off to on. When the Start contact is set to the Start position,
the speed reference will immediately jump to the actual speed of the turbine.
The governor valve will start opening. The speed of the turbine will start
increasing back to Rated Speed. The speed reference will not jump higher
then the Rated Speed value. If the Start contact is not toggled, and the Reset
contact is the only input that is toggled, the turbine will go through a normal
start sequence with the speed reference slowly ramping up, and the governor
valve opening on the valve limiter.
74 Woodward
6. Raise - Lower Speed / The speed PID’s reference may be adjusted from the external contacts or
Load Modbus commands.
The speed reference moves in the range of minimum governor speed to

maximum governor speed.
If the application is power generation and the generator is in Droop against a

utility bus, Raise / Lower contacts will raise and lower the load setting.
If Process Control is selected, the Raise / Lower contacts will raise and lower
the process setpoint.
7. Remote Speed Control Closing both the Raise and Lower speed discrete inputs will put the control
into Remote Speed control. The speed setpoint can be positioned remotely
through an analog signal by the configured Remote Speed Input or through a
Modbus directly entered value. This allows the Speed setpoint to be set
remotely by a process control or distributed plant control system.
Remote Speed example:

1. Not in overspeed test mode, Raise Speed discrete input is closed,
Lower Speed discrete input is closed, Run discrete input is closed.
2. If remote is selected, and the turbine is started, the speed reference will
ramp at the Remote Setpoint Fast Rate.
3. If remote is not selected, the speed reference will ramp at the Idle to
Rated Rate.
4. If the turbine is running, and Remote Control is selected, the speed
reference will ramp to the Remote Speed Setpoint. Found in F**Remote
Speed Control.
5. As the analog input, remote speed input is changed, the speed
reference will ramp up or down at the Remote Setpoint Slow Rate
unless the difference between the setpoint and the actual speed is
greater then the Remote 2nd Deadband. At this point the ramp will
change to the Remote Setpoint Fast Rate until the deadband is met.
6. If the analog input USE INPUT #X FAIL TRIP is set TRUE and if the
input goes less then 2 mA or greater the 22 mA, the control will shut
down.
8. Over Speed Test The 2301D-ST’s Over Speed test Function allows an operator to increase
Function turbine speed above its rated operating range to periodically test turbine
electrical and/or mechanical over speed protection logic and circuitry. The
Over Speed Test will allow the control’s speed setpoint to be increased above
the normal maximum limit. This test can be performed from the Service Mode
of Watch Window software, through external commands or via the Modbus
commands.
Overspeed Test
1. Close the Overspeed Test Enable discrete input (if configured) or the
Overspeed Test Enable in the service menu I**Overspeed Test**.
2. The Overspeed Test Status menu item in service menu I**Overspeed
Test** should switch from Overspeed Trip Test In-active to Overspeed
Trip Test Active.
3. The Speed Raise contact can now be closed, to allow the speed
setpoint to be set above rated speed range.
4. When the turbine speed reaches the Electrical Overspeed Trip Setpoint,
the Electrical Overspeed Trip Test discrete output will activate (if
Configured). This indicates that the Electrical Overspeed Trip Setpoint
was reached. No Shutdowns will occur.
5. Continuing to close the Speed Raise contact will increase the turbine
speed up to the MAX OVRSPD TEST LIMIT. At this point, the
mechanical overspeed trip should have occurred. If not the MAX
OVRSPD TEST LIMIT will have to be raised.
WARNING—OVERSPEED
To prevent possible serious injury from an overspeeding turbine, make sure the
turbine is equipped with another shutdown device(s) that operate totally
independently of the control to protect against runaway or damage to the turbine.
Woodward 75
9. SPM-A Synchronizer To use a synchronizer to synchronize a generator, one analog input #1 or

#2 must be configured as Synchronizer Bias Signal Input.
The synchronizer input is used to match the prime movers speed and
generator phase with bus that it is being paralleled to. Analog input #1 at
terminals 19,20,and 21 (or Analog input #2 at terminals 22,23,and 24) can
be used as the synchronizer input. The sensitivity of the synchronizer can
be adjusted.
10. KW Droop / Actuator KW Droop or Actuator Position Droop mode.

Position Droop
Operation The 2301D-ST should be connected to the generator through the internal
load sensor using the PT’s and CT’s. When using the optional 52G
BREAKER discrete input is open, Droop will be the control mode. In the
Droop mode, the load sensor provides feedback to the speed control to
decrease the speed reference based on load. Raise or Lower discrete
inputs can be used to control the amount of load on the generator, when
tied to the utility bus. The controls power sensor output can be monitored
via serial communication or through the control’s analog readout. If
required, any of the control’s four relay outputs can be configured as power
level switches to drive auxiliary devices or indicators.
11. Isochronous Load ISOCHRONOUS mode

Control Operation
The operator can control the speed reference with the Raise or Lower
discrete inputs. In this mode, the 2301D-ST will operate in isochronous
operation or in isochronous load sharing operation.
The 2301D-ST includes an analog load sharing network input, which is

compatible with Woodward’s 2301A line of controls. The control’s soft load
/ unload transfer function can also be configured to rate limit unit loading
and unloading.
76 Woodward
12. Critical Speed Critical Speed Avoidance
In many turbines, it is desirable to avoid certain speeds or speed ranges (or

pass through them as quickly as possible) due to excessive turbine
vibration or other factors. During programming, one critical speed
avoidance band may be selected. This band may be any speed range that
is less than the minimum governor speed setting. Within a critical speed
range, the 2301D-ST moves the speed setpoint at the critical speed rate
programmed and does not allow the speed setpoint to stop within the
critical speed avoidance band. If the turbine is accelerating through a
critical avoidance band and excessively high vibrations are experienced,
selecting the speed setpoint lower command will bring the unit back to the
lower limit of the band. Refer to Figure for an example of the critical speed
avoidance.
Figure 4-5. Critical Speed Avoidance Band
Woodward 77
13. Process Control Process Control
The process control can be configured to control any system process,

related to or affected by turbine speed or load. Typically this controller is
used as a turbine inlet or exhaust pressure controller. The process control
is a PID controller that compares a 4–20 mA process signal with the
process setpoint. The PID controller sets the speed controller setpoint until
the process signal and the setpoint match. The process setpoint is
adjustable with raise or lower contact inputs, or the communication links.
Also, the setpoint can be directly set by entering the new setpoint through
Modbus communications. In addition, a remote process setpoint analog
input can be programmed to remotely position the cascade setpoint.
Process Control Example:

1. Let’s take for example that we want to control the turbine exhaust
pressure with a transducer range of 0–100 psi (0–690 kPa).
2. The generator is tied to the utility bus in droop, so as the process
changes, the load will change.
3. Here are the variables that need to be set:
a) Under the Service menu P**ANALOG I/O SETTINGS**.
• 02 INPUT #1 MIN VALUE (UNITS) = 0 psi (0 kPa)
• 03 INPUT #1 MAX VALUE (UNITS) = 100 psi (690 kPa)
b) Under the Service menu H**PROCESS CONTROL**:
• 05 MIN PROC SETPNT (UNITS) = 0 psi (0 kPa)
• 06 MAX PROC SETPNT (UNITS) = 100 psi (690 kPa)
• 08 SETPT INIT VALUE (UNITS) = 60 psi (414 kPa)
• 09 SPEED SETPT LOW LIMIT = 3610 rpm
• 10 SPEED SETPT HIGH LIMIT = 3780 rpm
c) Under the Service menu F**REMOTE SPEED CONTROL **:
• 02 RMT/PROC CNTRL SLOW RATE (RPM/S) = 5
d) Under the Configure menu D**ANALOG INPUT OPTIONS**:
• 02 SEL AI#1 FUNCTION (1-7) = 7 (Process Signal)
• 03 SEL AI#1 TYPE (1-4) = 1 (4–20 mA)
• 08 USE INPUT #1 FAIL TRIP = Optional
e) Under the Configure menu C**DISCRETE INPUT OPTIONS**:
• 02 SEL DI F FUNCTION (1-6) = 6 (Process Enable)
4. This is just a partial list of the variables needed to run the turbine, the
variable listed here pertain just to the Process Control.
5. With the turbine running at synchronous speed and the breaker
closed to the utility bus in droop mode, enable the process control.
The load will change to control the exhaust pressure at 60 psi (414
kPa).
6. Adjust the ramp rates, deadband, and PID Dynamic adjustments for
the proper operation and stability of the turbine and process.
14. Power System This section provides a summary review of droop, isochronous,
Management droop/isochronous, and isochronous load sharing operating concepts.
Concepts These concepts provide an understanding for power management.
Paralleling There are two basic methods used for paralleling: droop, where speed
decreases with load increase and isochronous, where speed remains
constant with load increase. The paralleling system shown in Figure 4-6
consists of a load matching circuit and kW sensor circuitry.
78 Woodward
2301D-ST
LOAD VALVE DEM AND

kW SENSOR SPEED
M ATCHING
CIRCUIT REFERENCE
CIRCUIT
INLET
B
Turbine Generator
C
LOAD SHARING LINE
STEAM
CB AUX CONTACTS TURBINE
EXHAUST
LOAD SIGNAL
Figure 4-6. Paralleling System
An auxiliary contact on the generator breaker connected to the discrete

input is used to select speed and load control operation. When the input to
the 52G BREAKER contact is open, the control is in droop speed control.
When the 52G BREAKER contact is closed, the control is in isochronous
load control or droop control.
The Load sensor computes the load carried by each phase of the
generator. The current load on each phase is multiplied by the cosine of
the phase difference between the current and the voltage and the three
phases are added to determine the total load.
The output of the load amplifier is adjusted by the load gain set point. By
setting the load gain voltage on each unit to the same level at full load,
proportional load sharing is achieved. Regardless of differences in
generator set capacities in the system, each generator set is loaded to the
same percentage of its capacity. A final adjustment of the individual load
gain adjustment will compensate for minor differences in the generator
sets.
Droop mode allows operation of a generator on an infinite bus or in parallel

with other turbine generator units using hydro mechanical governors. In
droop, speed changes as the load on the generator changes. An increase
in load results in a decrease in speed. The amount of speed change or
droop is expressed in percent (of rated speed) and is set by the load droop
set point.
Droop Mode Droop is a decrease in speed or frequency, proportional to load. That is, as
the load increases, the speed or frequency decreases, as illustrated in
Figure 4-7. This reduction in speed is accomplished with negative
feedback. The feedback increases as the system is loaded.
Woodward 79
Figure 4-7. Droop Mode
Droop is the speed reduction, expressed in percentage that occurs when

the generator is fully loaded. With a given droop setting, a generator set will
always produce the same power output at a particular speed or frequency.
Droop is sometimes called the percent speed regulation. If all generator
sets in a droop system have the same droop setting, they will each share
load proportionally. The amount of load will depend on their speed settings.
If the system load changes, the system frequency will also change. A
change in speed setting will then be required to offset the change in
feedback and return the system to its original speed or frequency. In order
for each generator set in the system to maintain the same proportion of the
shared load, each generator will require the same change in speed setting.
Isochronous Mode A generator set operating in the isochronous mode will operate at the same
set frequency regardless of the load it is supplying, up to the full load
capability of the generator set (see Figure 4-8). This mode can be used on
one generator set running by itself in an isolated system.
The isochronous mode can also be used on a generator set connected in

parallel with other generator sets. If two generator sets operating in the
isochronous mode without load sharing controls are tied together to the
same load, one of the units will try to carry the entire load and the other will
shed all of its load. In order to share load with other units, some additional
means must be used to keep each generator set from either trying to take
all the load or from motoring.
80 Woodward
Figure 4-8. Isochronous Mode
Figure 4-9. Droop/Isochronous Figure 4-10. Isochronous Load Sharing

Load Sharing
Woodward 81
Droop/Isochronous Droop/isochronous load sharing combines the first two modes. All
Load Sharing on an generator sets in the system, except one, are operated in the droop mode.
Isolated Bus The one unit not in droop is operated in the isochronous mode. It is known
as the swing machine. In this mode, the droop machines will run at the
frequency of the isochronous unit. The droop and speed settings of each
droop unit are adjusted so that each generates a fixed amount of power
(see Figure 4-9). The output power of the swing machine will change to
follow changes in the load demand. Maximum load for this type of system
is limited to the combined output of the swing machine and the total set
power of the droop machines. The minimum system load cannot be
allowed to decrease below the output set for the droop machines. If it does,
the system frequency will change and the swing machine can be motored.
The machine with the highest output capacity should be operated as the
swing machine, so that the system will accept the largest load changes
within its capacity.
Isochronous Load Isochronous load sharing operates all generator sets in a system in the
Sharing on an Isolated isochronous mode. Load sharing is accomplished by adding a load sensor
Bus to each electric isochronous control system. The load sensors are
interconnected by the load sharing lines. Any imbalance in load between
units will cause a change to the regulating circuit in each control system.
While each unit continues to run at isochronous speed, these changes
force each machine to supply a proportional share of power to meet the
total load demand on the system (see Figure 4-10).
82 Woodward
Chapter 5.
Pre-Start and Start-up Procedures
Introduction
This chapter provides an overview of the start-up procedures and operation of
the 2301D-ST Load Sharing and Speed Control.
WARNING—START-UP
Read this entire procedure before starting the prime mover.
Start-up Adjustments
1. Complete the Installation Procedure in Chapter 2 and the Service and
Configuration Procedures in Chapter 3.
CAUTION—CORRECT SETTINGS
Be sure the Start Mode is set correctly for your application.
Be sure the Rated Speed and Number of Teeth are set correctly for your
application as described earlier in this chapter.
2. Apply input power to the control.
3. Check the speed-reading.
When using a signal generator to verify the proper configuration setting: set
the signal generator for the frequency of the speed sensor at rated speed
and connect it to terminals 25 and 26. (The rated speed frequency in Hz
equals the rated turbine speed in rpm times the number of teeth on the
speed sensing gear divided by 60.)
Open the Service Menu A** DISPLAY ANALOG INFO **: 02 TURBINE
SPEED (RPM), the value should be a same number as RATED Speed
(rpm). If the Monitor value is different, need to check the configuration
parameters, Number of Gear teeth, etc.
4. Check the speed sensor.
Minimum voltage required from the speed sensor to operate the electronic
control is 1.0 Vrms, measured at the lowest controlling speed. The Loss of
Speed shutdown is not recognized until the turbine speed exceeds the
override setpoint.
WARNING—START-UP
Be prepared to make an emergency shutdown when starting the engine,
turbine, or other type of prime mover, to protect against runaway or
overspeed with possible personal injury, loss of life, or property damage.
Woodward 83
Actuator Calibration
The actuator output from the control can be stroked (or calibrated) from the
Service Menu O** ACTUATOR CALIBRATION **. Set TRUE the CALIBRATION
ENABLE to calibrate the actuator or valve. Adjust 0% position related to the
OFFSET, and 100% position related to the GAIN by moving the DUMMY
SIGNAL.
When the valve position (%) is equal to 0%, the actuator should be below
minimum. This is important. The actuator must have sufficient under-travel at the
minimum stop to ensure that the actuator can fully close the steam valve
completely. When the valve position (%) is 100%, the actuator should be at
maximum to ensure full load can be attained. This process of going between
minimum and maximum will have to be repeated several times before the initial
start to ensure the actuator and linkages are properly set up.
WARNING—OVERSPEED
STEAM TO THE TURBINE MUST BE SHUT OFF BY OTHER MEANS DURING
THIS PROCESS. Overspeeding the turbine will cause damage to the turbine
and can cause personnel injury or death to personnel.
Check Discrete Inputs/Outputs

Open the Service Menu R** DISPLAY D_I/O STATUS ** window, operation of
programmed input switches or relay outputs will be checked. Even if the control
plans to use Modbus communication, while performing configuration or I/O test
or calibration, don't turn ON the assigned Modbus switch.
Check Analog Inputs

When using a signal generator to verify the proper configuration setting: set the
signal generator for the value of analog input, and connect it to each terminal.
Open the Service Menu A** DISPLAY ANALOG INFO **: 10, 11 if the readings
are correct as the signals are applied.
Dynamic Adjustment
The object of the PROPORTIONAL GAIN and INTEGRAL GAIN adjustment is to
obtain the optimum, or desired, stable prime mover speed response. Connect a
dc analog voltmeter to terminals 13(+) and 14(–) to monitor the actuator voltage.
Increasing the setting of the PROPORTIONAL GAIN to provide faster transient

response (decreases the magnitude of the speed change from a sudden change
in load). To achieve optimum response, slowly increase the PROPORTIONAL
GAIN until the voltage on the voltmeter becomes slightly unstable, then slowly
lower the PROPORTIONAL GAIN as necessary to stabilize the meter reading.
Step load the generator, bump the actuator terminal shaft, to make sure that the
prime mover returns to the proper speed with little overshoot or undershoot of the
speed setting. To reduce overshoot, decrease the INTEGRAL GAIN. When the
INTEGRAL GAIN is in the lower part of its adjustment (0 to 10 ), by decreasing
the INTEGRAL GAIN, you may need to decrease the P_GAIN to maintain stable
operation. If the prime mover is slow in returning to the proper speed, increase
the INTEGRAL GAIN.
84 Woodward
Speed Sensor Check

Measure the voltage across terminals 25 and 26 to be sure there is a minimum of
1.0 Vrms at low limit speed and a maximum of 25 Vrms at rated speed. If the
voltage exceeds 25 Vrms, increase the gap of the speed sensor and be sure that
there is still a minimum of 1.0 Vrms at low limit speed.
Current Transformer (CT) Phasing Check

NOTE
This control contains internal current transformers. Due to their low
impedance, shorting their inputs is not effective. The current input must be
removed from the control and shorted externally
WARNING—HIGH VOLTAGE
Never disconnect any wire attached to load sensor terminals 4 through 9
when the prime mover is running unless temporary 0.5 Ω, 20 W resistors are
installed as shown in Figure 5-1 and all load is removed. The current
transformers can develop dangerously high voltages when open circuited
while the prime mover is running.
1. Go to the B** DISPLAY LOAD INFO ** service menu and observe 02 LD

SENSOR INPUT (KW) and 05 LOAD SIGNAL OUT (VDC) to measure the
load sensor output. The displayed values are not yet calibrated to read
Kilowatts, but are used here for indication.
2. Start the prime mover. With the generator operating in the isochronous
mode and not in parallel, load the generator to as near full load as possible.
3. Use a clamp-on ammeter and measure the per phase current of the Current
transformer output. Check that current in each of the three CT's is equal. In
a balanced three phase system the Load Signal Out reading will be
approximately:
Load Signal Out = kW Input Calibration Gain X 0.1 X AMPs (rms reading of one
phase)
The kW Input Calibration Gain setting is in Service Menu M**LOAD SENSR

AND DROOP**.
A clamp-on ammeter is recommended to eliminate the need to open CT

wiring to insert an ammeter in series with the CT output.
4. If the Load Signal Out Reading is within 10% of the above calculation, the
PT/CT phasing is correct. If the phasing is incorrect, proceed to the Phase
Correction Procedure. If the phasing appears correct, skip the Phase
Correction Procedure and go to the Load Calibration Adjustment procedure.
Woodward 85
NOTES
If after completing the LOAD SENSOR CALIBRATION and DROOP
adjustments, the control loading is extremely sensitive to changes in the
power factor when operating in parallel, complete the phase correction
procedure.
The most accurate calibration is made at full load. However, if it is not
possible to run the generator set at full load, run it at less than full load and
reduce the voltage reading given in this calibration procedure
proportionally. For example: run a 200 kW generator set at 100 kW and
divide all voltages given in this calibration procedure by 2. If you reduce the
load in this manner, be sure to reduce it by the same amount throughout the
calibration procedure.
Phase Correction Procedure

NOTE
This procedure requires a minimum power factor of (.9). If a .9 power factor
cannot be obtained, tracing through the wiring is the only means of
correcting the current transformer phasing.
The highest positive reading of kW or Load Signal Out will be obtained when the
CT's are correctly matched to the load sensor terminals in both phase and
polarity. The following procedure will assure the correct connection of the current
transformers. It is required only if the phasing check indicates incorrect phasing,
or loading stability is extremely sensitive to the power factor.
Make trial connections of the first CT to all three load sensor inputs, polarized
both ways (a total of six connections). Record the Load Signal Out reading for
each connection. Connect the first CT to the terminals that produce the highest
positive reading and with the polarity that produces the highest positive voltage.
The displayed Load Gain reading is limited to about 0.2, therefore a negative
reading indicates a phasing or polarity error.
Try the second CT on each of the remaining two CT input terminals, in each
polarity and record the Load Signal Out reading. Connect the second CT to the
terminals that produce (and with the polarity that produces) the highest positive
reading.
Try the last CT on the remaining input terminals, polarized both ways and record
the voltage. Connect the last CT in the polarity that produces the highest Load
Signal Out reading.
The Phase Correction Procedure requires that the prime mover be shut down
many times to disconnect the current transformers. For convenience, a
temporary method of connecting the current transformers shown in Figure 5-1 is
recommended. Connecting a 0.5 Ω, 20 W burden resistor across each current
transformer allows the current transformers to be disconnected from the terminal
strip with the prime mover running, after removing all load.
The current transformers can develop dangerously high voltages. Do not
disconnect a current transformer while the prime mover is running unless
temporary 0.5 Ω, 20 W resistors are installed as shown in Figure 5-1 and all
load is removed.
86 Woodward
Figure 5-1. Temporary Wiring for Transformer Phase Correction
If the temporary burden resistors described above are not used, the prime mover
MUST be shut down in addition to removing the load in the following procedure.
Monitor the load sensor output in this procedure by connecting an external

computer and entering the Watch Window sheet for B** DISPLAY LOAD INFO **
sheet and observe 02 LOAD SENSOR INPUT (KW) Load Sensor calibration and
monitoring. Since the kW calibration cannot be completed until the phasing is
correct, the value shown is for reference only. The Load Sensor of the 2301D-ST
will only read a small negative value.
1. Shut down the prime mover.
The current transformers can develop dangerously high voltages. Do not
disconnect a current transformer while the prime mover is running unless
temporary 0.5 Ω, 20 W resistors are installed as shown in Figure 5-1 and all
load is removed.
2. Label each CT wire with the phase and polarity that you think it should be.
Even though this identification may prove to be incorrect, this step is
necessary so that the individual wires can be identified during the
description of the procedure.
3. Disconnect the phase B CT wires from terminals 6 and 7. Connect these
two wires together using a small screw and nut and tape the connection.
4. Disconnect the phase C CT wires from terminals 8 and 9. Connect and tape
these two wires together as in Step 3.
5. Connect the two wires from the phase A CT to the phase A input terminals 4
and 5.
6. Start the prime mover, apply full load and monitor the load sensor output.
Start a list and record this value.
7. Unload the system and reverse the phase A CT wires on terminals 4 and 5.*
8. Apply full load, monitor the load sensor and record this value.
9. Unload the system, remove phase A CT wires from terminals 4 and 5 and
connect them to phase B input terminals 6 and 7.*
12. Apply full load, monitor the load signal and record this value.
13. Unload the system, remove phase A CT wires from terminals 6 and 7 and
connect them to phase C input terminals 8 and 9.*
Woodward 87
16. Apply full load, measure the load signal and record this reading.
17. Unload the system and compare the six readings taken.*
18. Remove the phase A CT wires from terminal 8 and 9 and connect the phase
A wires to the pair of terminals that produced the highest positive load value
and in the polarity that produced the highest positive load value.
19. Remove tape and disconnect the phase B CT wires. Connect the phase B
CT wires to one pair of the two remaining pairs of CT input terminals on the
load sensor.
20. Apply full load and measure the load signal. Start a new list and record this
reading.
21. Unload the system and reverse the phase B CT wires on the same
terminals.*
23. Unload the system, remove phase B CT wires and connect them to the
other pair of terminals.*
25. Unload the system and reverse phase B CT wires on the same terminals.*
26. Apply full load and measure the load signal. Record this reading and
compare the four readings on the list.
27. Unload the system. Remove the phase B CT wires and connect them to the
pair of CT input terminals that produced the highest positive load signal
reading and with the polarity that produced the highest positive load signal
reading.*
28. Remove tape and disconnect the phase C CT wires. Connect these two
wires to the remaining pair of CT input terminals.
30. Unload the system and reverse the phase C CT wires on the same
terminals.*
32. Unload and shut down the system. Compare the two readings.*
33. Connect the phase C CT wires to the same pair of CT input terminals, but in
the polarity that produced the highest positive load signal reading.
34. Re-label each wire with the phase designation of the terminal that it is now
connected to.
35. Remove the burden resistors and terminal block.
Load Calibration Adjustment

For this procedure, the generator must be running isochronously and not
paralleled.
Start the prime mover and apply full load. With the Watch Window at the B**
DISPLAY LOAD INFO ** sheet and observe 02 LOAD SENSOR INPUT (KW). If
this reading does not match external instrumentation, adjust calibration gain and
offset under the Service Menu M**LOAD SENSR AND DROOP** until Watch
Window value matches metering. The values should match at all intermediate
points.
CAUTION—CT SIZE
*–If values at full load (or a lower reading proportional to a load less than
100%) cannot be obtained and the phasing has been checked and is correct,
the current transformers are probably the wrong size. The current-
transformer output must be from 3 to 7 A (5 A nominal) at full load.
88 Woodward
When in parallel operation in isochronous mode or on an isolated bus, generator
speeds must be the same. If they are not equal, load sharing will not remain
proportional as the load varies. Any difference in loads between the units can be
corrected by adjusting the Load Gain. Increasing the LOAD GAIN will cause that
generator to carry less load. If stability problems occur when in parallel operation
at a particular load signal reading, reduce the reading by reducing the LOAD
GAIN and reduce the load signal reading setting of all other generators in the
system to the same reading. When the load signal readings of all generators in a
system are reduced, the load sharing gain will be reduced and this may result in
some loss of load sharing sensitivity.
It may be necessary to reduce the load signal reading of each unit in the system
to as low as 3 volts in cases of extremely poor system dynamics. If your system
requires a load signal reading as low as 3 volts, consult Woodward for
suggestions for possible remedies.
Droop Adjustment
Because of the calculation available in the control, the droop percentage entered
will result in the correct speed change if the KW sensor is properly calibrated.
The droop percent is automatically corrected for load gain voltage values. The
speed trim range can be configured to stop the speed reference at 100% load, or
if a remote reference source is used its range can be set to give no load to full
load limits.
Figure 5-2. Droop Adjustment
Woodward 89
Chapter 6.
Troubleshooting
Introduction
The following troubleshooting guide is an aid in isolating trouble to the control
box, actuator, plant wiring, or elsewhere. Troubleshooting beyond this level is
recommended ONLY when a complete facility for control testing is available.
CAUTION—INPUT VOLTAGE
Incorrect voltage can damage the control. When replacing a control, check
the power supply, battery, etc., for the correct voltage.
Troubleshooting Procedure
This chapter is a general guide for isolating system problems. The guide
assumes that the system wiring, soldering connections, switch and relay contacts
and input and output connections are correct and function properly. Make the
checks in sequence. Various system checks assume that the prior checks have
been done correctly.
WARNING—START-UP
Control Start-up
When the control is powered on, the CPU begins execution of a section of the
software program known as the boot code. This code performs hardware
diagnostics and checks that a valid application program has been installed.
During this period all control outputs will remain disabled. The boot code takes
approximately 30 seconds to execute. During this period the red status LED
should be on. When execution of the boot code has completed, control will be
transferred to the application program. When the application program begins, the
control outputs will be enabled and system control will begin. At that point the red
status LED will be turned off and should remain off as long as the control is
running.
If the control fails its self-test diagnostics during boot, fails its on-line self-tests
while running the application program, or fails in any other way that it can detect,
then the CPU will blink the red status LED to indicate the failure.
CAUTION—SHUT PRIME MOVER DOWN

To prevent damage to the prime mover, the prime mover must be shut down
for all system checks.
90 Woodward
Control Test and Calibration

General
Conduct the following checks on the 2301D-ST. Then verify the functioning of set
points and adjustments.
1. Connect a computer to the communication port. Start the SERVLINK /

WATCH WINDOW software in accordance with the instructions in Chapter
3. Verify that correct voltage and polarity are input to the control.
2. Verify the controller ID on the 2301D-ST Standard PC Interface by clicking

“Control” then “Properties”. The Application ID message “5418-047” with the
revision level (new, A, etc) should appear.
3. Select the Configure and Service Menu. Verify that all set points are as
recorded during installation. Repeat for the other menus. If any differences
are found, change the set point(s) to the correct value. Click the “SAVE
VALUES” icon on the tool bar. Remove power from the control for at least
10 seconds. Verify correct values were retained during power down. Failure
indicates the control has failed and should be replaced.
Discrete Inputs
Run the following test to verify the function of the discrete inputs. DO NOT
PERFORM THIS TEST WITH THE TURBINE RUNNING!
Repeat this step for all discrete inputs. Close the appropriate input. The status in
the Service Menu R** DISPLAY D_I/O STATUS** should switch from OPEN to
CLOSED. If the value does not change when the contact is closed, the control
has failed and should be replaced.
Discrete Outputs
Verify operation of the Discrete Outputs, by referring to the Service Menu
S**HARDWARE OUTPUT TEST** sheet.
With the turbine shut down, enable the manual relay driver test. Open another
inspector sheet, select Service R**DISPLAY D_I/O STATUS** and monitor the
discrete outputs. From the relay test procedure, each discrete output may be
activated and its operation verified. If the output is activated, the voltage
measured between terminal 39 and the appropriate output terminal (41–44)
should equal input voltage at terminal 39 and 40. Testing can be monitored
visually by observation of the green LED near terminal 9 and 10, or by listening
for an audible ‘click’. The manual relay test must be disabled (status “FALSE”) or
the control will hold the actuator current to minimum.
Woodward 91
Symptom Cause Solution

Prime mover will not Supply voltage polarity reversed On power up the CPU status LED should
start. Actuator not (dc only), or no supply voltage. come on for 30 seconds.
moving to start steam
position. Check for proper voltage from terminals
45(+) to 46(–). Reverse leads if polarity is
incorrect.
NOTE Actuator not responding to input If there is a voltage output at control
If the actuator moves to signal from control. terminals 13(+) and 14(–), but the actuator
start position, a problem does not move, the wiring to the actuator
with the prime mover NOTE should be checked for opens or shorts.
steam supply is The hydraulic actuator must have With the EG3P actuator, remember that
indicated. oil pressure and gear rotation to terminals C and D of the mating plug
operate (respond). should be jumpered.
Make resistance checks at the actuator.

Coil resistance on Woodward actuators is
approximately 35 Ω. (Read with leads at
terminals 13 and 14 disconnected.)
Shutdown cause Check Shutdown status in the Service
Menu C** SHUTDOWN** #01. If the
status is TRUE, check all Shutdown
causes; release each cause one by one.
(See Chapter 3)
Actuator or linkage. Check actuator or linkage for proper
installation and operation. Problems may
be oil supply, direction of rotation,
insufficient drainage, linkage, worn
actuator components, or improper
adjustment.
No actuator voltage at terminals Check for shorted or grounded actuator
13 and 14. leads by removing wires to terminals 13
and 14. Stop prime mover. Check for 18
to 24 V at terminals 13 and 14.
Check that A**DISPLAY ANALOG INFO**

Menu is reading the turbine speed during
spinning. If no speed-reading, check the
MPU.
92 Woodward

Prime mover will not Speed sensor signal not clearing Check for at least 1 Vrms at terminals 28
start. Actuator not failed speed signal circuit. and 29 and at least 5% of the minimum
moving to start steam rated speed frequency range.
position Check wiring for proper connection. Check
(continued). shields for proper installation.
Check the A**DISPLAY ANALOG INFO**
Menu for Turbine Speed reading.
Speed sensor not spaced properly—check

for at least 1.0V ac at terminals 25 and 26
during cranking. If less that 1.0 Vac,
magnetic pickup may be spaced too far
from gear. Make sure there are no metal
chips on end of pickup.
If no voltage is present, magnetic pickup

may be open-circuited or shorted. Make
resistance check with the leads
disconnected from control. Should be
about 100 to 300 Ω.
WARNING—START-UP
Be prepared to make an emergency
shutdown when starting the engine,
turbine, or other type of prime mover,
to protect against runaway or
overspeed with possible personal
injury, loss of life, or property damage.
Faulty 2301D-ST control. Replace.
Prime mover will not Check for Actuator Demand % after Start
start. command is issued.
Prime mover Ramp adjustment. Increase RAMP TIME. This decreases
overspeeds only on acceleration rate.
starts.
Wrong SPEED settings. Check that SPEED settings are entered
as described in Chapter 3. Verify the
Actuator Demand % drops to minimum
(0%) when turbine speed is greater than
speed reference.
Dynamics adjustment. Dynamics may be adjusted for sluggish
operation, causing overspeed on start.
Adjust GAIN for fastest stable response.
RESET may be adjusted too low. Increase
RESET setting.
Prime mover Prime mover. Check for proper operation of prime
overspeeds after mover steam system. If actuator moves
operating at rated toward minimum steam during overspeed,
speed for some time. problem is in steam system.
Magnetic pickup and 2301D-ST Check the magnetic pickup output voltage
control. at speeds above idle—at least 1.0 Vrms. If
magnetic pickup should fail and the
override failed speed signal circuit is
disabled, the 2301D-ST will call for
maximum steam.
Woodward 93

Prime mover 2301D-ST control. Control the prime mover manually at rated
overspeeds after speed. If the Turbine Speed reading in the
operating at rated Display Menu does not match external
speed for some time indicators, the control is not configured
(continued). properly. When the turbine speed value is
greater than the speed reference value,
the output voltage should be zero. If
speed range is correct for the application,
replace the control.
Prime mover will not 2301D-ST control. Adjust PROP GAIN, INTEGRAL GAIN
stabilize at rated no and DERIVATIVE RATIO as described in
load speed. The “Adjust for Stable Operation” and
instability may occur at “Dynamic Adjustment” in Chapter 3.
no load or it may vary Speed reference controls. Check display menu. The speed reference
with load Control may value should be constant. If speed
be erratic. reference is erratic, check remote input (if
used), intermittent raise/lower contact
inputs. The speed bias sum at no load
should be constant.
Improper linkage adjustment. Make sure that actuator moves
approximately 2/3 of its travel from no load
to full load. Be sure linkage is linear on
turbine, diesel and steam-injected prime
movers. Be sure linkage is non-linear on
carbureted prime movers. Refer to
actuator manual for proper installation.
Necessary external wires not The following tests will isolate noise and
properly shielded. interference.
Electrical noise, caused by wiring CAUTION—SINGLE UNIT

carrying an ac voltage, stray Do not perform these tests in other
magnetic fields from than single-unit operating
transformers, etc., can be picked configuration.
up by improperly shielded wire.
Noise will cause instability if Verify that the switchgear frame, governor
picked up by lines associated chassis and prime mover have a common
with the amplifier summing point ground connection. Temporarily remove
such as external speed trim, the battery charger cables from the control
paralleling lines, droop contact, battery system.
magnetic pickup lines and
synchronizer input. If the prime mover operation is
significantly improved by these
modifications, replace the wiring one at a
time to locate the source of the trouble.
External wiring may require additional

shielding or rerouting from high-current
lines or components.
If the problem cannot be resolved by

these checks, it will be necessary to
remove the 2301D-ST from the
switchgear. Temporarily mount it next to
the prime mover and connect only a
battery, magnetic pickup and actuator to
the control (use a separate battery placed
next to the prime mover).
94 Woodward

Prime mover will not Necessary external wires not If stability occurs when the control is
stabilize at rated no properly shielded (continued). mounted next to the prime mover, return
load speed. The the control to the switchgear. Run new
instability may occur at magnetic pickup, actuator, and battery
no load or it may vary power lines. Shield all wires to the control.
with load Control may Route all wires through conduit or an outer
be erratic shield. Tie the outer shield to system
(continued). ground at end opposite of the control.
Prime mover may not be Check actuator linkage to steam
receiving steam as called for by controlling mechanism for any lost motion,
the actuator voltage. binding, or excessive loading. Verify a
steady steam pressure of proper value.
Check actuator per appropriate actuator

manual.
Prime mover not operating Prime mover may be causing speed
properly. variations. Control turbine manually to
determine if instability is in prime mover or
governor control. Verify proper adjustment
of steam control linkage.
Input voltage low. Check supply voltage. It should be at least
18 Vdc.
Prime mover does not Prime mover not receiving steam If voltage to actuator is maximum, visually
share load with other as called for by the governor. determine if actuator shaft is at maximum
units. position. If it is not, an actuator problem is
indicated, or the linkage or steam system
is restricted.
Unequal speed settings. Be sure that speed settings of all units at
no load are identical.
Unequal load gain voltages. With the prime mover operating in single
unit configuration, LOAD GAIN must be
set at 6.0 Vdc. See LOAD GAIN
ADJUSTMENT in Chapter 3.
Improper load sensing phasing. Perform phasing procedure in Chapter 3.
Circulating currents between Refer to appropriate voltage regulator
generators. manual.
Prime mover does not Actuator. If actuator has a ballhead backup, verify
maintain constant that its hydraulic governor section, speed
speed (isochronous). setting, and speed droop adjustments are
properly set (see the applicable governor
manual).
Prime mover. If the droop occurs near the full-load point
only, it is possible the prime mover is not
producing the horsepower called for by
the steam control, or is being overloaded.
Either is indicated if the steam control is at
maximum position.
Woodward 95
Chapter 7.
Communications
Modbus Communication
The 2301D-ST control can communicate with plant distributed control systems or
CRT based operator control panels through one Modbus communication port.
The communication port support RS-232 and RS-422 communications using
RTU MODBUS transmission protocols. Modbus utilizes a master/slave protocol.
This protocol determines how a communication network’s master and slave

devices establish and break contact, how a sender is identified, how messages
are exchanged, and how errors are detected.
Monitor Only
The Modbus communication port, as defaulted from the factory, is not
programmed. Although this port is not programmed it continue to update all
information to all registers. This allows the 2301D-ST to be monitored but not
controlled from an external device. By simply connecting a monitoring device,
configured to communicate through Modbus, and to the 2301D-ST’s defaulted
protocol settings (parity, stop bits, etc.), this device can be used to monitor all the
2301D-ST’s controlling parameters, modes, etc. without effecting control. To use
a 2301D-ST port it must be configured properly.
Monitor And Control

Once a Modbus port is activated by the Modbus selector command, the
2301D-ST will accept an external network master device. This allows a Modbus
compatible device to monitor and perform all 2301D-ST mode parameters and
commands to use a 2301D-ST port it must be configured properly.
Modbus Communication Mode

The 2301D-ST control supports two Modbus transmission modes. A mode
defines the individual units of information within a message and the numbering
system used to transmit the data. Only one mode per Modbus network is
allowed. The supported RTU (Remote Terminal Unit). These modes are defined
in the following table.
Characteristic RTU
Coding System 8-bit binary
Start Bits 1
Data Bits per Character 8
Parity none
Stop Bits 1
Baud Rate 110,300, 600, 1200, 1800, 2400, 4800, 9600, 19200,
or 38400
Error Checking CRC (Cyclical Redundancy Check)
Table 7-1. RTU Modbus
96 Woodward
In the RTU mode, data is sent in 8-bit binary characters and transmitted in a
continuous stream.
The Modbus protocol allows one master and up to 247 slaves on a common
network. Each slave is assigned a fixed, unique device address in the range of 1
to 247. With the Modbus protocol, only the network master can initiate a
transaction. A transaction consists of a request from the master to a slave unit
and the slave’s response. The protocol and Modbus device number are set in the
Program Mode and can be adjusted in the Service Mode, if required.
The 2301D-ST control is programmed to function as a slave unit only. As a slave

unit, the 2301D-ST will only respond to a transaction request by a master device.
The 2301D-ST can directly communicate with a DCS or other Modbus supporting
device on a single communications link, or through a multi-dropped network. If
multi-dropping is used, up to 246 devices (2301D-STs or other customer
devices) can be connected to one Master device on a single network. The control
address is programmed under the 2301D-ST’s communications block
Each message to or from a master has a defined structure called the message
“frame”. A frame consists of the slave device address, a code defining the
requested data and error checking information (see Table 7-2).
Beginning SLAVE Function DATA Error End of

of Frame Address Code Check Frame
Code
RTU 3-Char 1 Char 1 Char 8 bits 1 Char 3-Char

Dead 8 bits 8 bits Data per 8 bits Dead
Time Char Time
Table 7-2. Modbus Frame Definition
The Modbus function code tells the addressed slaves what function to perform.
The following table lists the function codes supported by this control.
Modbus Function Codes

Code Definition Reference Address
01 Read Digital Outputs 0XXXX
(Raise/Lower and Enable/Disable Commands)
02 Read Digital Inputs 1XXXX
(Status Indications / Alarms and Trips)
03 Read Analog Outputs 4XXXX
04 Read Analog Inputs 3XXXX
(Speed, Setpt, etc.)
05 Write Single Discrete Output 0XXXX
(Raise/Lower and Enable/Disable Commands)
08 Loopback Diagnostic Test N/A
(Subfunction 0 only)
15 Write Digital Outputs 0XXXX
16 Write Analog Outputs 4XXXX
Table 7-3. Modbus Function Codes
Woodward 97
When a Modbus message is received, it is checked for any errors or invalid data.
If there is invalid data in the message, an error code is sent back to the master
and the control issues an alarm message. The error codes are defined in the
following table. The exception error status and respective error codes can be
viewed in the Service mode under U**COM PORT (MODBUS)**.
If the control has not received a message for the configured time-out period, the
control will alarm with an error message, but no message is sent to the master.
This time-out is defaulted to 4 seconds and only applies to units using both
monitor and control (adjustable in the Service Mode).
Port Adjustments
Before the 2301D-ST will communicate with the master device, the
communication parameters must be verified. These values are set from the
Service Mode.
Parameter Port Adjustment Range

Baud Rate 110 TO 38400
Data Bits 7 or 8
Stop Bits 1, 2 or 1.5
Parity NONE, ODD or EVEN
Receive Mode Line or Character
Flow OFF, XON/XOFF or CTR-RTS
Auto Echo OFF or ON
End Line LF, CR or CRLF
Ignore OFF or ON
Driver RS232 or RS422
Table 7-4. Port Adjustments
2301D-ST Control Modbus Addresses

The Modbus communication ports in the 2301D-ST are programmed for unique
Modbus addresses. A complete listing of these addresses for your application is
located at the end of this section in the manual. The Modbus address listing
consists of Boolean Writes, Boolean Reads, Analog Reads and Analog Writes.
The Boolean reads and writes are also referred to as input and holding coils. The
analog reads and writes are also referred to as input registers and holding
registers. All values that can be addressed by Modbus are considered to be
discrete and numeric. The discrete values are a 1 bit binary, on or off value and
the numerics are 16 bit values. Discrete values are sometimes referred to as
coils or digitals and numerics are referred to as registers or analogs. All
read/write registers are interpreted by the 2301D-ST as signed 16 bit integer
values. Since Modbus can only handle integers, values that require a decimal
point in the Modbus Master Device are multiplied by a scaling constant before
being sent by 2301D-ST. See Appendix B for defaulted communication constants
and ranges.
Boolean Writes
Boolean Writes are logic signals that are writeable to the 2301D-ST control. An
example of a Boolean write value would be raise or lower commands. A logical
true denoted by the value 1 will cause the command listed in the description to
be executed.
98 Woodward
If a start (address 0.0005) command is given it will be latched. To reset the latch
remove the start command and give a command to unload (address 0.0006).
This is applicable for the following commands:
0.0005 Start (latch)

0.0006 Unload
0.0009 Rated (latch)
0.0010 Idle
0.0017 Isoch (CB close 52G) (latch)
0.0018 Droop
Boolean Reads
Boolean Reads are logic signals that are readable from, but not writeable to, the
2301D-ST. An example of a Boolean read value would be a turbine trip status
indication. The logic true will have the value 1 if the statement in the description
column is true and a 0 if false. The ‘1:’ term in the address identifies an logic true.
The 2301D-ST supports Modbus function code 2, which involves reading
selected logic signals.
Analog Reads
Input registers are analog values that are readable from, but not writeable to, the
2301D-ST. Turbine speed is an example of an analog read value. The values of
the input registers are stored internally to the control as floating point numbers
representing engineering units (kPa or rpm). The values that are transmitted are
integers ranging from –32767 to +32767. Since Modbus can only handle
integers, values that have a decimal point are multiplied by a constant before
being sent by Modbus. For example, these input registers may be listed as the
Modbus value `x100’ or `x10’ under the description heading to denote the value
is multiplied by a scaling constant. This will allow transmission of decimal parts of
a unit if this is necessary for better resolution.
See the 2301D-ST Service mode for defaulted communication constants and
ranges. The 2301D-STsupports Modbus function code 4, which involves reading
selected input registers.
Analog Writes
Holding registers are analog values that are writeable to the 2301D-ST. These
values can also be read by a device performing an error check. An example of
an analog write value would be a direct speed setpoint as opposed to raise and
lower commands. The values of the holding registers are also stored in the
control as numbers representing engineering units (kPa or rpm). The 2301D-ST
supports Modbus function codes 3, 6, and 16. These correspond to reading
selected holding registers, writing to a single holding register and writing to
multiple holding registers, respectively. The following tables give the address and
description of all Boolean and analog reads and writes:
Woodward 99
Modbus Scale Factors

Modbus has two limitations:
• only integers can be sent across;
• the value is limited between –32767 and +32767.
These limitations can be overcome by scaling the value before it is sent across
the Modbus. The default scale factor for the analog values is 1. The scale factor
can be changed in the Watch Window (INTFC.COM) between 1 and 1000.
These scaled parameters and their scale factor are available through the
Modbus. Values that require a decimal point must be multiplied by the scale
factor (10, 100 or 1000) prior to being sent across the Modbus. The value sent is
then divided by the scale factor in the Master. The Scale Factor adjusts all
associated analog reads accordingly. The Multiplier (sale factor) can be changed
in the Watch Window.
Shutdown Command through Modbus

Two different types of shutdown commands (emergency and controlled) can be
issued through Modbus. The Emergency Shutdown command instantly takes the
speed setpoint, valve limiter and actuator current to zero. The Controlled
Shutdown function is used to stop the turbine in a controlled manner, as opposed
to an Emergency Trip. When a STOP command (controlled shutdown) is issued
the Speed Setpoint is ramped to zero at the optional rate. After the Speed
Setpoint reaches zero, the valve limiter is instantly stepped to zero.
The Emergency Shutdown and Controlled Shutdown commands do not influence

operation of Trip Relay.
By setting the Shutdown Acknowledge BW to TRUE (one) momentarily, the Trip

Relay output can be forcedly returned to a normal state. But its trip condition is
not canceled.
Start Command through Modbus

The start-up of a turbine is possible by the command through Modbus. The
Open/Close of Contact inputs (RUN/SHUTDOWN etc.) serve as the independent
command in Modbus BW. These commands operate in a momentary input.
For More Modbus Information

Detailed information on the Modbus protocol is presented in “Reference Guide
PI-MBUS-300” published by AEC Corp./Modicon Inc., formerly Gould Inc. To
implement your own source code, you must register with Modicon. Registration
includes purchasing document PI-MBUS-303 and signing a non-disclosure
agreement. You can register to use Modbus at your nearest Modicon field office.
To find the office nearest you, contact Modicon Technical Support at 1-800-468-
5342.
100 Woodward
Chapter 8.
Service Options
Product Service Options

The following factory options are available for servicing Woodward equipment,
based on the standard Woodward Product and Service Warranty (5-01-1205)
that is in effect at the time the product is purchased from Woodward or the
service is performed:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture
If you are experiencing problems with installation or unsatisfactory performance

of an installed system, the following options are available:
• Consult the troubleshooting guide in the manual.
• Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In most cases, your problem
can be resolved over the phone. If not, you can select which course of
action you wish to pursue based on the available services listed in this
section.
Replacement/Exchange
Replacement/Exchange is a premium program designed for the user who is in
need of immediate service. It allows you to request and receive a like-new
replacement unit in minimum time (usually within 24 hours of the request),
providing a suitable unit is available at the time of the request, thereby
minimizing costly downtime. This is also a flat rate structured program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).
This option allows you to call in the event of an unexpected outage, or in

advance of a scheduled outage, to request a replacement control unit. If the unit
is available at the time of the call, it can usually be shipped out within 24 hours.
You replace your field control unit with the like-new replacement and return the
field unit to the Woodward facility as explained below (see “Returning Equipment
for Repair” later in this chapter).
Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned to Woodward within 60 days, Woodward will issue a credit for
the core charge. [The core charge is the average difference between the flat rate
replacement/exchange charge and the current list price of a new unit.]
Return Shipment Authorization Label. To ensure prompt receipt of the core,

and avoid additional charges, the package must be properly marked. A return
authorization label is included with every Replacement/Exchange unit that leaves
Woodward. The core should be repackaged and the return authorization label
affixed to the outside of the package. Without the authorization label, receipt of
the returned core could be delayed and cause additional charges to be applied.
Woodward 101
Flat Rate Repair

Flat Rate Repair is available for the majority of standard products in the field.
This program offers you repair service for your products with the advantage of
knowing in advance what the cost will be. All repair work carries the standard
Woodward service warranty (Woodward Product and Service Warranty
5-01-1205) on replaced parts and labor.
Flat Rate Remanufacture

Flat Rate Remanufacture is very similar to the Flat Rate Repair option with the
exception that the unit will be returned to you in “like-new” condition and carry
with it the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205). This option is applicable to mechanical products
only.
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned to Woodward for
repair, please contact Woodward in advance to obtain a Return Authorization
Number. When shipping the item(s), attach a tag with the following information:
• name and location where the control is installed;
• name and phone number of contact person;
• complete Woodward part number(s) and serial number(s);
• description of the problem;
• instructions describing the desired type of repair.
To prevent damage to electronic components caused by improper handling,
read and observe the precautions in Woodward manual 82715, Guide for
Handling and Protection of Electronic Controls, Printed Circuit Boards, and
Modules.
Packing a Control
Use the following materials when returning a complete control:
• protective caps on any connectors;
• antistatic protective bags on all electronic modules;
• packing materials that will not damage the surface of the unit;
• at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
• a packing carton with double walls;
• a strong tape around the outside of the carton for increased strength.
102 Woodward
Return Authorization Number

When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [1 (800) 523-2831 in North America or
+1 (970) 482-5811]. They will help expedite the processing of your order through
our distributors or local service facility. To expedite the repair process, contact
Woodward in advance to obtain a Return Authorization Number, and arrange for
issue of a purchase order for the item(s) to be repaired. No work can be started
until a purchase order is received.
NOTE
We highly recommend that you make arrangement in advance for return
shipments. Contact a Woodward customer service representative at
1 (800) 523-2831 in North America or +1 (970) 482-5811 for instructions and
for a Return Authorization Number.
Replacement Parts
When ordering replacement parts for controls, include the following information:
• the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
• the unit serial number, which is also on the nameplate.
How to Contact Woodward

In North America use the following address when shipping or corresponding:
Woodward Governor Company
PO Box 1519
1000 East Drake Rd
Fort Collins CO 80522-1519, USA
Telephone—+1 (970) 482-5811 (24 hours a day)

Toll-free Phone (in North America)—1 (800) 523-2831
Fax—+1 (970) 498-3058
For assistance outside North America, call one of the following international
Woodward facilities to obtain the address and phone number of the facility
nearest your location where you will be able to get information and service.
Facility Phone Number

Brazil +55 (19) 3708 4800
India +91 (129) 230 7111
Japan +81 (476) 93-4661
The Netherlands +31 (23) 5661111
You can also contact the Woodward Customer Service Department or consult
our worldwide directory on Woodward’s website (www.woodward.com) for the
name of your nearest Woodward distributor or service facility.
Woodward 103
Engineering Services
Woodward Industrial Controls Engineering Services offers the following after-
sales support for Woodward products. For these services, you can contact us by
telephone, by email, or through the Woodward website.
• Technical Support
• Product Training
• Field Service
Contact information:
Telephone—+1 (970) 482-5811
Toll-free Phone (in North America)—1 (800) 523-2831
Email—icinfo@woodward.com
Website—www.woodward.com
Technical Support is available through our many worldwide locations or our

authorized distributors, depending upon the product. This service can assist you
with technical questions or problem solving during normal business hours.
Emergency assistance is also available during non-business hours by phoning
our toll-free number and stating the urgency of your problem. For technical
support, please contact us via telephone, email us, or use our website and
reference Customer Services and then Technical Support.
Product Training is available at many of our worldwide locations (standard

classes). We also offer customized classes, which can be tailored to your needs
and can be held at one of our locations or at your site. This training, conducted
by experienced personnel, will assure that you will be able to maintain system
reliability and availability. For information concerning training, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Product Training.
Field Service engineering on-site support is available, depending on the product

and location, from one of our many worldwide locations or from one of our
authorized distributors. The field engineers are experienced both on Woodward
products as well as on much of the non-Woodward equipment with which our
products interface. For field service engineering assistance, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Technical Support.
104 Woodward
Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:
General
Your Name
Site Location
Phone Number
Fax Number
Prime Mover Information

Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application
Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:
Woodward Part Number and Revision Letter
Control Description or Governor Type
Serial Number
Serial Number
Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
Woodward 105
Appendix A.
Service/Configuration Chart
CONFIGURE PROGRAMMED DEFAULT TUNABLE RANGE

MENU VALUE VALUE MIN. MAX.
A**SPD LOAD STRT OPTIONS**
01 Rated Speed (RPM) 3600.0 0.0 32000.0
02 Enter Rated/Max Load (KW) 1000 10 30000
03 MPU Min Spd Level (RPM) 250.0 0.0 2000.0
04 Gen Frequency is 50 Hz? FALSE FALSE TRUE
05 Number of Gear Teeth 60 16 500
06 Use Self Powered Act ? FALSE FALSE TRUE
07 MPU Override % 20.0 1.0 100.0
08 Self Pwrd Time Dly (SEC) 60.0 5.0 30000.0
09 Gear Ratio 1.0 0.1 10.0
10 Use Critical Band? FALSE FALSE TRUE
11 Crit Shdn Time Dly (SEC) 300 0.0 1200
12 Use Manual Start? FALSE FALSE TRUE
13 Use Semi-Auto Start? FALSE FALSE TRUE
14 Use Automatic Start? TRUE FALSE TRUE
15 Start Mode = Monitor
B**DISCRETE IN OPTIONS**
01 Configuration Error Monitor
02 Sel DI F Function (1-6) 1 1 6
03 Display DI F Function Monitor
04 Sel DI G Function (1-6) 1 1 6
05 Display DI G Function Monitor
06 Sel DI H Function (1-6) 1 1 6
07 Display DI H Function Monitor
08 Enable R/L When LS FALSE FALSE TRUE
C**DISCRETE OUT OPTIONS**

01 Is Trip Relay NC? TRUE FALSE TRUE
02 Is Alarm Relay NC? TRUE FALSE TRUE
03 Relay 1 Energizes (1-12) 2 1 12
04 Relay 1 Selected For Monitor
10 Relay 4 Selected Monitor
11 Reset Clears Trips? FALSE FALSE TRUE
106 Woodward
D**ANALOG INPUT OPTIONS**

01 Configuration Error? Monitor
02 Sel AI #1 Function (1-6) 1 1 6
03 Display AI #1 Function Monitor
04 Sel AI #1 Type (1-4) 1 1 4
05 Display AI #1 Type Monitor
06 Use Input #1 Fail Trip FALSE FALSE TRUE
07 Sel AI #2 Function (1-6) 1 1 6
09 Sel AI #2 Type (1-4) 1 1 4
10 Display AI #2 Type Monitor
11 Use Input #2 Fail Trip FALSE FALSE TRUE
E**ACTUATOR OUT OPTIONS**

01 Actuator Out Type (1-4) 1 1 4
02 Display Actuator Type 1 1 2
03 Invert Driver Output? FALSE FALSE TRUE
SERVICE PROGRAMMED DEFAULT TUNABLE RANGE

MENU VALUE VALUE MIN. MAX.
A** DISPLAY ANALOG INFO **
01 Speed Control Status = Monitor
02 Turbine Speed (RPM) = Monitor
03 Generator Frequency (HZ) = Monitor
04 Speed Reference (RPM) = Monitor
05 Actuator Signal (%) = Monitor
06 Actuator Current (mA) = Monitor
07 Valve Limiter (%) = Monitor
08 Speed PID (%) = Monitor
09 Critical Speed Band? = Monitor
10 Speed Ref Bias (RPM) = Monitor
11 Analog Input #1 (mA) = Monitor
12 Analog Input #2 (mA) = Monitor
13 Start Mode Selected = Monitor
B** DISPLAY LOAD INFO **

01 Load Control Status = Monitor
02 Load Sensor Input (KW) = Monitor
03 Load Sensor (%) = Monitor
04 Load Sharing Bias (RPM) Monitor
05 Load Signal Out (Vdc) = Monitor
06 System Load 0-3(Vdc) = Monitor
07 Load Sharing Bias (%) = Monitor
C** SHUTDOWNS **
01 Shutdown Status Monitor
Woodward 107
02 First Shutdown Monitor

03 Power Up Shutdown (1) Monitor
04 Overspeed (2) Monitor
05 MPU Fail (3) Monitor
06 Analog Input#1 Fail (4) Monitor
07 Analog Input#2 Fail (5) Monitor
08 Modbus Issued Trip (6) Monitor
09 Test Mode (7) Monitor
10 External Shutdown (8) Monitor
11 Stuck in Critical (9) Monitor
12 Shutdown Acknowledge FALSE FALSE TRUE
D** ALARMS **
01 Alarm Status Monitor - - -
02 First Alarm Monitor - - -
03 Analog Input#1 Fail (1) Monitor - - -
04 Analog Input#2 Fail (2) Monitor - - -
05 Load Sensor Fail (3) Monitor
06 Load Share Line Fail (4) Monitor
07 Alarm Acknowledge FALSE FALSE TRUE
E** SPEED DYNAMICS **

01 Off Line Prop Gain 5.0 0.01 100.0
02 Off Line Int Gain 1.8 0.01 50.0
03 Off Line Deriv Ratio 5.0 0.01 100.0
04 Off Line Window Width 60.0 1.0 200.0
05 Off Line Gain Ratio 1.0 1.0 10.0
06 Use On Line Dynamics? FALSE FALSE TRUE
07 On Line Prop Gain 20.0 0.01 100.0
08 On Line Int Gain 1.8 0.01 50.0
09 On Line Deriv Ratio 20.0 0.01 100.0
10 On Line Window Width 60.0 1.0 200.0
11 On Line Gain Ratio 1.0 1.0 10.0
12 Using On Line Dynamics? Monitor
13 Use Load Rejection? False True False
14 Ld Rej Spd Chg (RPM/SEC) 50.0 50.0 250.0
15 Ld Rej Percent Speed (%) 102.0 100.0 105.0
F** REMOTE SPEED CONTROL **

01 Remote Control Mode Monitor
02 Rmt/Proc Slw Rate (RPM/S) 5.0 0.0 1000.0
03 Rmt Stpt Deadband (RPM) 2.0 0.0 10.0
04 Rmt Stpt Fst Rate (RPM/S) 10.0 0.0 1000.0
05 Rmt 2nd Deadband (RPM) 10.0 0.0 100.0
06 Speed Reference (Rpm) Monitor - - -
07 Rmt Speed Setpt (Rpm) Monitor - - -
108 Woodward
G**SPEED SETTING**
01 Idle Spd Setpoint 1000.00 0.0 32000.00
02 Idle to Rated (RPM/SEC) 25.0 0.0 32000.0
03 Rated to Idle Rate (RPM/SEC) 25.0 0.0 32000.0
04 Min Gov Setpoint (RPM) 3550.00 0.0 32000.00
05 Max Gov Setpoint (RPM) 3843.00 0.0 32000.00
06 Lower Slow Rate (RPM/S) 10.00 0.00 1000.00
07 Lower Fast Rate (RPM/S) 25.00 0.00 1000.00
08 Raise Slow Rate (RPM/S) 10.00 0.00 1000.00
09 Raise Fast Rate (RPM/S) 25.00 0.00 1000.00
10 R / L Time Delay (Sec) 5.0 0.5 30.0
11 Critical Low Point (RPM) 2500.00 0.00 32000.00
12 Critical Hi Point (RPM) 3000.00 0.00 32000.00
13 Critical Rate (RPM/SEC) 100.00 0.00 32000.00
14 Use Set Point Set-Back? FALSE FALSE TRUE
H** PROCESS CONTROL **

01 Process Control Enabled Monitor
02 Use Process Control? FALSE FALSE TRUE
03 Invert Process? FALSE FALSE TRUE
04 Min Proc Setpt (Units) 0.00 -32000.00 32000.00
05 Max Proc Setpt (Units) 1000.00 -32000.00 32000.00
06 Proc Setpt Rt (Units / Sec) 5.00 0.01 1000.00
07 Use Setpoint Tracking? FALSE FALSE TRUE
08 Setpt Init Value (Units) 5.00 -32000.00 32000.00
09 Spd Setpt Low Lmt (RPM) 0.00 -32000.00 32000.00
10 Spd Setpt High Lmt (RPM) 0.00 -32000.00 32000.00
11 Process PID Prop Gain 1.0 0.00 100.00
12 Process PID Integ Gain 0.3 0.001 50.0
13 Process Derivative Ratio 100.00 0.01 100.00
14 Process Cntrl Deadband 0.01 0.01 5.0
15 Use Remote Proc Setting? FALSE FALSE TRUE
16 Remote Proc Max Rate 5.00 0.01 1000.00
17 Analog Input #1 Monitor
18 Analog Input #2 Monitor
19 Process Setpoint (Units) Monitor
20 Process Actual (Units) Monitor
I** OVERSPEED TEST **

01 Overspeed Test Status Monitor
02 Overspeed Test Enable FALSE FALSE TRUE
03 Elec Overspeed Trip Setpt 4032.00 0.00 32000.00
04 Max Ovrspd Test Lmt (RPM) 4140.00 0.00 32000.00
05 Elec Overspd Trip Test Monitor
06 Turbine Speed(Rpm) Monitor
07 Speed Ref(Rpm) Monitor
Woodward 109
J** FAILED MPU OVERRIDE **

01 Auto-Ovrd Off Speed 450.00 0.00 2000.00
02 Auto-Ovrd On Speed 650.00 0.00 2000.00
03 Auto-Ovrd On Delay (SEC) 5.00 0.00 100.00
04 Use MPU Ovrd Timer FALSE FALSE TRUE
05 Use Rolldown Ovrd? FALSE FALSE TRUE
06 Max Starting Time (SEC) 60.00 0.00 3000.00
K** SYNCHRONIZER SETUP **

01 ENABLE SYNC INPUT Monitor - - -
02 SYNC INPUT SCALE(%/V) 0.7 0.1 5.0
03 SYNC BIAS SPD(rpm) Monitor - - -
04TURBINE SPEED(rpm) Monitor - - -
05 SPEED REF(rpm) Monitor - - -
L** VALVE LIMITER SET **

01 Enable Manual Cntrl Ramp FALSE FALSE TRUE
02 Manual Ramp Status Monitor
03 Manual Cntrl Ramp Setpnt 100.00 0.00 100.00
04 Display Actuator % Monitor
05 Actual Valve Ramp % Monitor
06 Man Start Rate (%/SEC) 10.00 0.00 100.00
07 Auto Strt Rate (%/SEC) 0.5 0.0 100.0
08 Man/Auto PID Ramp Rate 50.00 1.00 1000.00
M** LOAD SENSR AND DROOP **

01 Use Load Sensor? FALSE FALSE TRUE
02 Use kW Droop? FALSE FALSE TRUE
03 Use Act Pos Droop? FALSE FALSE TRUE
04 Droop Percentage (%) 5.0 0.0 12.0
05 Act % @ No Ld (Pos Drp) 20.00 0.00 100.00
06 Act % @ Full Ld (Pos Drp) 80.00 0.00 100.00
07 Enter Rated Load (KW) 1000 10 30000
08 Load Gain Voltage 6.00 0.10 9.00
09 KW Calibration Zero 0.00 -20.00 20.00
10 KW Calibration Gain 10.00 5.00 40.00
11 Load Time (KW/SEC) 20.00 1.00 600.00
12 Enable Fast Load Rate FALSE FALSE TRUE
13 Fast Load Time (KW/SEC) 60.00 1.00 600.00
14 Fast Ramp Load (%) 80.00 1.00 110.00
15 Unload Time (KW/SEC) 20.00 1.00 600.00
16 Load Sharing Gain 0.20 0.01 10.0
17 Gen Output (KW) Monitor
18 Load Signal Out (Vdc) Monitor
110 Woodward
N** ACT LINEARIZATION **

01 X-1 Value 0.0 -10.0 110.0
02 Y-1 Value 0.0 -10.0 110.0
03 X-2 Value 10.0 -10.0 110.0
04 Y-2 Value 10.0 -10.0 110.0
05 X-3 Value 20.0 -10.0 110.0
06 Y-3 Value 20.0 -10.0 110.0
07 X-4 Value 30.0 -10.0 110.0
08 Y-4 Value 30.0 -10.0 110.0
09 X-5 Value 40.0 -10.0 110.0
10 Y-5 Value 40.0 -10.0 110.0
11 X-6 Value 50.0 -10.0 110.0
12 Y-6 Value 50.0 -10.0 110.0
13 X-7 Value 60.0 -10.0 110.0
14 Y-7 Value 60.0 -10.0 110.0
15 X-8 Value 70.0 -10.0 110.0
16 Y-8 Value 70.0 -10.0 110.0
17 X-9 Value 80.0 -10.0 110.0
18 Y-9 Value 80.0 -10.0 110.0
19 X-10 Value 90.0 -10.0 110.0
20 Y-10 Value 90.0 -10.0 110.0
21 X-11 Value 100.0 -10.0 110.0
22 Y-11 Value 100.0 -10.0 110.0
23 Actuator Demand (%) Monitor - - -
24 Actuator Out (mA) Monitor - - -
O** ACTUATOR CALIBRATION **

01 Calibration Enable FALSE FALSE TRUE
02 Dummy Drive Signal (%) 0 0 100
03 Driver Offset 0.0 -100.0 100.0
04 Driver Gain 1.0 0.0 10.0
05 Actuator Dither (mA) 0.0 0.0 10.0
06 Actuator Out (mA) Monitor
P**ANALOG I/O SETTINGS**

02 Input #1 Min Value (Unit) 0.00 -32000.0 32000.0
03 Input #1 Max Value (Unit) 100.00 -32000.0 32000.0
04 Analog In #1 Units Monitor
06 Input #2 Min Value (Unit) 0.00 -32000.0 32000.0
07 Input #2 Max Value (Unit) 100.00 -32000.0 32000.0
08 Analog In #2 Units Monitor
09 Analog Output Sel (1-7) Monitor
10 Analog Output Selected Monitor
11 Anout Min Val (Unit) 0.0 -32000.0 32000.0
12 Anout Max Val (Unit) 100.0 -32000.0 32000.0
13 Analog Out (mA) Monitor
Woodward 111
Q**DISCRETE OUT SETTINGS**

01 Relay 1 Selected As Monitor
02 Relay 1 Level Sw (1-7) 1 1 7
03 Relay#1 Level Select For Monitor
04 Relay 1 ON Level = 0.0 -32000.0 32000.0
05 Relay 1 OFF Level = 0.0 -32000.0 32000.0
07 Relay 21 Level Sw (1-7) 1 1 7
09 Relay 2 ON Level = 0.0 -32000.0 32000.0
10 Relay 2 OFF Level = 0.0 -32000.0 32000.0
12 Relay 3 Level Sw (1-7) 1 1 7
14 Relay 3 ON Level = 0.0 -32000.0 32000.0
15 Relay 3 OFF Level = 0.0 -32000.0 32000.0
17 Relay 4 Level Sw (1-7) 1 1 7
19 Relay 4 ON Level = 0.0 -32000.0 32000.0
20 Relay 4 OFF Level = 0.0 -32000.0 32000.0
R** DISPLAY D_I/O STATUS**

01 DI External Shutdown Monitor
02 DI Reset Monitor
03 DI Start / Unload Monitor
04 DI Raise Speed Monitor
05 DI Lower Speed Monitor
06 Discrete Input F Monitor
07 Discrete Input G Monitor
08 Discrete Input H Monitor
09 Discrete Output #1 Monitor
13 Internal L/S Relay K1 Monitor
S**HARDWARE OUTPUT TEST**

01 Enable Hardware Test FALSE FALSE TRUE
02 Hardware Test Mode Monitor
03 AO Force Value (4–20 mA) 4 4 20
04 Analog Out (mA) Monitor
05 Anout, 4 mA Offset 0.0 -100.0 100.0
06 Anout, 20 mA Gain 1.0 0.0 10.0
07 Turn On Do-1 FALSE FALSE TRUE
112 Woodward

10Discrete Output #2 Monitor
15 Turn On L/S Line Relay FALSE FALSE TRUE
16 Load Share Relay Monitor
T**COM PORT (MODBUS)**

01 PORT FAIL Monitor - - -
02 LINK ERROR Monitor - - -
03 Error Percent Monitor - - -
04 Error Number Monitor - - -
05 BAUD RATE 10 1 10
06 BAUD RATE IS SET FOR Monitor
07 DATA BITS 1 1 2
08 DATA BITS ARE SET FOR Monitor
09 STOP BITS 1 1 3
10 STOP BITS ARE SET FOR Monitor
11 PARITY 1 1 3
12 PARITY IS SET FOR Monitor
13 DRIVER 1 1 2
14 DRIVER IS SET FOR Monitor
15 TIME OUT (sec) 4.0 0.0 100.0
16 Network Address 1 1 247
17 ENABLE MODBUS CONTROL FALSE FALSE TRUE
U**APPLICATION ID**
01 APP Software Number Monitor - - -
02 APP Software Revision Monitor - - -
03 Application Name Monitor - - -
Woodward 113
Appendix B.
Modbus Communication List
This Modbus Communication List is applicable for software revision 5418-047C.
Boolean Writes
Address Description
0:0001 Modbus Controlled Shutdown
0:0002 Alarm Acknowledge
0:0003 Shutdown Acknowledge
0:0004 System Reset
0:0005 Start
0:0006 Unload
0:0007 Raise Speed / Load
0:0008 Lower Speed / Load
0:0009 Rated
0:0010 Idle
0:0011 Enable Process Control
0:0012 Disable Process Control
0:0013 Enable Speed PID dynamic settings
0:0014 Disable Speed PID dynamic settings
0:0015 Select Speed PID Dynamic Settings #1
0:0016 Select Speed PID Dynamic Settings #2
0:0017 Isoch (CB close 52G)
0:0018 Droop
0:0019 Enable Overspeed Trip
0:0020 Disable Overspeed Trip
0:0021 Energize Modbus Relay #1
0:0022 De-energize Modbus Relay #1
0:0029 Enable Modbus Remote Control
0:0030 Disable Modbus Remote Control
Boolean Reads
Address Description
1:0001 Shutdown Status
1:0002 Alarm Status
1:0003 External Shutdown
1:0004 Overspeed Trip Alarm
1:0005 Modbus Issued Trip
1:0006 MPU Fail Trip
1:0007 Analog Input #1 Trip (if configured)
1:0008 Analog Input #2 Trip (if configured)
1:0009 Analog Input #1 Failed
1:0010 Analog Input #2 Failed
114 Woodward
1:0011 Load Sensor Failed
1:0012 Load Share Line Failed
1:0013 Speed PID In-Control
1:0014 Remote Speed Setpoint Enabled
1:0015 Speed Reference Lower Limit
1:0016 Speed Reference Raise Limit
1:0017 Load Sharing Enabled
1:0018 Overspeed Test Enabled
1:0019 Level SW#1 ON
1:0023 Discrete Input A State
1:0024 Discrete Input B State
1:0025 Discrete Input C State
1:0026 Discrete Input D State
1:0027 Discrete Input E State
1:0028 Discrete Input F State
1:0029 Discrete Input G State
1:0030 Discrete Input H State
1:0031 Relay Output #1 State
1:0035 In Critical Band
1:0036 Stuck In Critical Band Trip
1:0037 SPEED PID SELECT ENABLED
1:0038 DYNAMIC SETTING #2
Analog Reads
Address Description Multiplier
3:0001 Trip First Out Indication 1.0
3:0002 Alarm First Out Indication
3:0003 Turbine Speed (RPM) 1.0
3:0004 Speed Reference (RPM) 1.0
3:0005 Turbine Load (KW) *1.0 (0.0, 1000.0)
3:0006 Actuator Output (%) *10.0 (0.0, 1000.0)
3:0007 Speed PID Output (%) *10.0 (0.0, 1000.0)
3:0008 Analog Input #1 *10.0 (0.0, 1000.0)
3:0009 Analog Input #2 *10.0 (0.0, 1000.0)
3:0010 Valve Limiter Position (%) *10.0 (0.0, 1000.0)
Analog Writes
Address Description Multiplier
4:0001 Modbus Remote Speed Setpoint 1.0
Woodward 115
Declarations
116 Woodward
2301D-ST Control Specifications
Woodward Part Numbers:
8273-128 2301D-ST certified for ordinary location
8273-1001 2301D-ST certified for hazardous locations
8923-932 Watch Window Installation
Power Supply Rating 18–40 Vdc (SELV)

Power Consumption less than or equal 20 W nominal
Input Supply Voltage Input Supply Current
18 V 589 mA
24 V (nominal) 431 mA
32 V 319.6 mA
Inrush Current 7 A for 0.1 ms (low-voltage model)
Inrush Current 22 A for 15 ms (high-voltage model)
Steady State Speed Band ±0.25% of rated speed
Magnetic Pickup 100–24 950 Hz (900–20000 rpm)
Discrete Inputs (8) 3 mA at 24 Vdc, impedance approximately 5.2 kΩ
Analog Input #1, #2 4–20 mA, 0–5 Vdc, ±2.5 Vdc, 1–5 Vdc
Synchronizer Bias Signal Input ±2.5 Vdc, externally powered
Analog Output #1 4–20 or 20–200 mA to actuator, software configurable
Analog Output #2 4–20 mA to monitor, internally powered
Discrete Outputs (4) configured to provide various level switches or conditions,
power by external +12 Vdc or +24 Vdc source, max
output current 200 mA
Discrete Output Ratings Low-side drivers with overvoltage protection, 200 mA
maximum
Communication Port (J2) RS-232, RS-422, 9-pin connector, 1200 to 38 400 baud,
full duplex
Ambient Operating Temperature –40 to +70 °C (–40 to +158 °F)
Storage Temperature –40 to +105 °C (–40 to +221 °F)
Humidity 95% at +20 to +55 °C (+68 to +131 °F)
Lloyd’s Register of Shipping Test Specification No. 1,
1996, Humidity Test 1
Mechanical Vibration Lloyd’s Register of Shipping Test Specification No. 1,
1996, Vibration Test 2 (5-25 Hz, ± 1.6 mm; 25-100 Hz,
4.0g)
Mechanical Shock US MIL-STD 810C, Method 516.2, Procedure I (basic
design test), Procedure II (transit drop test, packaged),
Procedure V (bench handling)
Equipment Classification 1 (grounded equipment)
European Compliance for CE Mark:
EMC Directive Declared to 89/336/EEC COUNCIL DIRECTIVE of 03
May 1989 on the approximation of the laws of the
member states relating to electromagnetic compatibility.
Low Voltage Directive Declared to the 73/23/EEC COUNCIL DIRECTIVE of 19
February 1973 on the harmonization of the laws of the
Member States relating to electrical equipment designed
for use within certain voltage limits.
North American Compliance:

CSA: CSA Certified for Class I, Division 2, Groups A, B, C, D,
T4 at 70 °C Ambient. For use in Canada and the United
States
Certificate 1150575
This listing is limited only to those units bearing the CSA agency identification and hazardous
location markings.
CSA: CSA Certified for Ordinary Locations. For use in Canada
and the United States
Certificate 1150575
UL: UL Listed for Ordinary Locations. For use in Canada and
the United States.
UL File E97763
NOTE Wiring must be in accordance with applicable electric
codes with the authority having jurisdiction.
We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com
Please include the manual number from the front cover of this publication.
PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058
Email and Website—www.woodward.com
Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.
06/7/F
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.8 Current to Pressure Converter - Woodward CPC-I
Product Specification
85202 (Rev. G)
CPC
Current‐to‐Pressure Converter
Applications
The Woodward Current to Pressure
Converter (CPC) is designed for
positioning steam and fuel valves
and/or the associated servos. A 4–20 • Precise fluid
mA in/out signal is linearly and pressure control
proportionally converted into a
hydraulic output pressure. The CPC • Linear operation
can thus interface with any electronic
control, such as Woodward • Adjustable output
MicroNet™ systems and the pressure range
Woodward 505 Control. It connects to
pressure-operated servo systems and • Two output signals
to single-acting power cylinders. The
CPC is suited for new as well as • Contaminant
retrofit applications. tolerant
Description • Standard
instrument
The CPC is an electrohydraulic, pressure-regulating valve, which consists of a valve, mounting
an actuator, a pressure sensor, and on-board electronics.
• Models are
The electronics perform the signal conditioning by comparing the actual output available with
pressure with the command, which results in a reference signal for the valve
position. This reference signal is then compared with the actual position, resulting in
certification for
a drive signal. The driver circuit then outputs the appropriate signal to the actuator, Canadian
which positions the hydraulic valve to the required position. Hazardous
The valve consists of two ports; one from supply to output, and one from output to Locations
tank. By opening one of these ports, the output pressure decreases or increases. • Models are
Two output signals are provided: a 4–20 mA signal, representing the actual output available
pressure, and a relay output, indicating a malfunction of the CPC. compliant with the
applicable CE
Features Directives—ATEX,
The CPC has an anodized aluminum housing, coupled with a cast, anodized Machinery, and
aluminum top cover. This enclosure contains the printed circuit board, the pressure EMC
sensor, and the actuator. The rotor of the actuator is directly coupled to the one-
stage hydraulic valve.
The construction of the hydraulic valve in the CPC tolerates contaminant particles up
to 40 µm.
Upon loss of power, a return spring will force the output pressure to the drain
pressure (failsafe).
A brass cable gland is provided for cable access with electrical signals.
The CPC mounts to a manifold with a standard instrument mounting-hole pattern
according to DIN 19213.
Woodward 85202 p.2
Accessories
A standard stainless steel adapter plate (part number 4349-231), with or without close-off valves, can be supplied
with the CPC. To replace the obsolete I/H converter, use adapter plate 3689-097.
Specifications
Electrical
Connections 9 screw terminals on the internal printed circuit board suitable for 0.2–4 mm² solid or
0.2–2.5 mm² stranded wire (24–12 AWG). 1.5mm² (16 AWG) is recommended for
the power lines, and 0.75 mm² (18 AWG) for all other connections.
Cable Entry Via cable gland—cable diameter 9–12 mm
Supply Voltage 18–32 Vdc (24 Vdc nominal)
Power Consumption 8 W during steady state, 120 W peak (3 seconds maximum)
Current Input Signal 4–20 mA into 250 Ω
Analog Output Signal 4–20 mA—maximum external load: 300 Ω. Accuracy = ±1% of full scale
Discrete Output Signal Relay—jumper selectable for normally open or normally closed. Maximum rating 1 A
at 30 Vdc
Dither Frequency 10–30 Hz—Default setting is 30 Hz
Dither Amplitude Zero is minimum and default. Maximum depends on adjusted frequency and
dynamic characteristics of the entire system.
Hydraulic
Connections Flat mounting face, hole pattern according to DIN 19213. Hydraulic connections via
an adapter plate (optional).
Supply Pressure 17 bar (250 psi) maximum. At least 0.5 bar higher than the maximum output
pressure.
Output Pressure Minimum level: 1 bar (14.5 psi)
Maximum level: 15 bar (217.5 psi)
Minimum range: 1 bar (14.5 psi)
Maximum range: 14 bar (203 psi)
Standard Pressure Range 4–20 mA gives 1.5 to 4.5 bar (21.75 to 65.25 psi)
Recommended Filter Rating Nominal 40 µm and 75 µm absolute (B40,=75)
Viscosity 20 to 100 cSt
Leakage Depends on viscosity and supply pressure—see figure
Flow Capacity Depends on viscosity and pressure difference—see figure
Technical Manuals 89543 (standard version)

26248 (explosion-proof version)
Performance
Frequency response 10–30 ms time constant, small step, blocked load (no servo system attached to the
CPC). Ultimate dynamic response depends on total servo system and dynamic
adjustments to the CPC.
Linearity 0.2% of full range
Repeatability 0.1% of full range
Temperature Drift 0.01% full range /°C
Output Pressure vs. Command Input Flow Characteristics

Woodward 85202 p.3
Environmental
Ambient Temperature –20 to +85 °C standard unit
–20 to +60 °C explosion-proof unit
Oil Temperature 60 °C maximum, 80 °C peak
Maximum Surface Temperature 85 °C, provided above temperature requirements are fulfilled
Vibration Lloyd’s LR type approval test specification 1, test 2, 5–100 Hz at 4.0 G
EMC EN 61000-6-2 and EN 61000-6-4
Dust and Waterproof IP65 per EN60529
Physical
Dimensions See outline drawing
Height x Width x Depth Approximately 220 x 170 x 200 mm
Weight Approximately 10 kg without oil
Mounting Four M10 threaded holes, 23 mm deep, on the face with the hydraulic ports,
according to DIN 19213
European Compliance for CE Marking
These listings are limited only to those units bearing the CE Marking.
EMC Directive: Declared to 89/336/EEC COUNCIL DIRECTIVE of 03 May 1989 on the
approximation of the laws of the Member States relating to electromagnetic
compatibility.
ATEX – Potentially Explosive Declared to 94/9/EC COUNCIL DIRECTIVE of 23 March 1994 on the
Atmospheres Directive: approximation of the laws of the Member States concerning equipment and
protective systems intended for use in potentially explosive atmospheres.
KEMA 03ATEX2427X
Zone 1, Category 2, Group II G, EEx d IIC T4
For use in an ambient temperature range of –20 to +60 °C
Other European Compliance
Compliance with the following European Directives or standards does not qualify this product for application of the CE Marking:
Machinery Directive: Compliant as a component with 98/37/EC COUNCIL DIRECTIVE of 23 July 1998 on
the approximation of the laws of the Member States relating to machinery.
North American Compliance
These listings are limited only to those units bearing the CSA agency identification.
CSA: CSA Certified for Class I, Division 2, Groups B, C, and D, T4 at 60 °C Ambient for
use in Canada
Typical System Using the CPC

Woodward 85202 p.4
Hydraulic Schematic
CPC Outline Drawing (Do not use for construction)
For more information contact:

PO Box 1519, Fort Collins CO, USA 80522-1519
1000 East Drake Road, Fort Collins CO 80525
Tel.: +1 (970) 482-5811 Fax: +1 (970) 498-3058
www.woodward.com
Distributors & Service

Woodward has an international network of distributors and service facilities.
For your nearest representative, call the Fort Collins plant or see the
Worldwide Directory on our website.
This document is distributed for informational purposes only. It is not to be construed as

creating or becoming part of any Woodward Governor Company contractual or warranty
obligation unless expressly stated in a written sales contract.
© Woodward 1996, All Rights Reserved 2008/8/Fort Collins
Installation and Operation Manual
CPC Current-to-Pressure Converter
Standard Version: 8901-457, 8901-459

[see manual 26248 for explosion-proof version]
Manual 89543 (Revision G)

This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
• DANGER—Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
DEFINITIONS • WARNING—Indicates a hazardous situation which, if not avoided, could result in
• CAUTION—Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
• NOTICE—Indicates a hazard that could result in property damage only (including
damage to the control).
• IMPORTANT—Designates an operating tip or maintenance suggestion.
The engine, turbine, or other type of prime mover should be equipped with an
overspeed shutdown device to protect against runaway or damage to the prime
mover with possible personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover
control system. An overtemperature or overpressure shutdown device may also
be needed for safety, as appropriate.
Read this entire manual and all other publications pertaining to the work to be performed before
installing, operating, or servicing this equipment. Practice all plant and safety instructions and
precautions. Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised or updated since this copy was produced. To verify that
you have the latest revision, be sure to check the Woodward website:
The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at:
If your publication is not there, please contact your customer service representative to get the
latest copy.
Any unauthorized modifications to or use of this equipment outside its specified mechanical,
electrical, or other operating limits may cause personal injury and/or property damage, including
damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or
"negligence" within the meaning of the product warranty thereby excluding warranty coverage
for any resulting damage, and (ii) invalidate product certifications or listings.
To prevent damage to a control system that uses an alternator or battery-charging

device, make sure the charging device is turned off before disconnecting the battery
from the system.
To prevent damage to electronic components caused by improper handling, read

and observe the precautions in Woodward manual 82715, Guide for Handling and
Protection of Electronic Controls, Printed Circuit Boards, and Modules.
Revisions—Text changes are indicated by a black line alongside the text.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed
by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 1996
All Rights Reserved
Manual 89543 CPC Current-to-Pressure Converter
Contents
REGULATORY COMPLIANCE ........................................................................III

ELECTROSTATIC DISCHARGE AWARENESS ................................................. IV
CHAPTER 1. DESCRIPTION ........................................................................... 1
Introduction .............................................................................................................1
Construction ...........................................................................................................1
CHAPTER 2. SPECIFICATIONS ...................................................................... 6
Electrical Specifications ..........................................................................................6
Hydraulic Specifications .........................................................................................6
Performance ...........................................................................................................7
Environmental .........................................................................................................8
Physical ..................................................................................................................8
Default Factory Settings .........................................................................................8
CHAPTER 3. INSTALLATION.......................................................................... 9
Receiving Instructions ............................................................................................9
Unpacking Instructions ...........................................................................................9
Mounting Instructions .............................................................................................9
Electrical Connections ..........................................................................................11
CHAPTER 4. CALIBRATION......................................................................... 18
Introduction ...........................................................................................................18
Checkout...............................................................................................................18
Calibration ............................................................................................................22
CHAPTER 5. REPAIR INSTRUCTIONS ........................................................... 24
General .................................................................................................................24
Return for Repair Instruction ................................................................................24
Protective Packaging ............................................................................................24
Troubleshooting ....................................................................................................24
CHAPTER 6. SERVICE OPTIONS ................................................................. 27
Product Service Options .......................................................................................27
Woodward Factory Servicing Options ..................................................................28
Returning Equipment for Repair ...........................................................................29
Replacement Parts ...............................................................................................29
Engineering Services............................................................................................30
How to Contact Woodward ...................................................................................30
Technical Assistance ............................................................................................31
DECLARATIONS ......................................................................................... 32
Woodward i
CPC Current-to-Pressure Converter Manual 89543
Figure 1-1. Front View of the CPC .........................................................................1

Figure 1-2. Hydraulic Schematic ............................................................................2
Figure 1-3. Functional Block Diagram (CPC electronics) .......................................3
Figure 1-4. CPC Cross Section ..............................................................................5
Figure 2-1. Flow Characteristics .............................................................................7
Figure 3-1. Obsolete I/H Converters.....................................................................10
Figure 3-2. New CPC with I/H Adapter Block .......................................................11
Figure 3-3. Example of Power Transient Suppression .........................................12
Figure 3-4. Example of I/O Transient Suppression ..............................................13
Figure 3-5. Mounting the CPC ..............................................................................14
Figure 3-6. CPC Outline Drawing .........................................................................15
Figure 3-7. Woodward Adapter Plate ...................................................................16
Figure 3-8. I/H to CPC Adapter Plate ...................................................................17
Figure 4-1. PCB Component Location..................................................................19
Figure 4-2. Output Pressure vs. Command Input.................................................20
Table 3-1. Fuse/Breaker Requirements ...............................................................11

Table 4-1. CPC Wiring ..........................................................................................19
ii Woodward
European Compliance for CE Marking
EMC Directive: Declared to 89/336/EEC COUNCIL DIRECTIVE of
03 May, 1989 on the approximation of the laws on
the Member States relating to electromagnetic
compatibility.
Other European and International Compliance

Compliance with the following European Directive does not qualify this product
for application of the CE marking:
Machinery Directive: Compliance as a component with 98/37/EEC
COUNCIL DIRECTIVE of 23 July, 1998 on the
approximation of the laws of the Member States
relating to machinery.
Woodward iii
Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static

electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
• Do not touch any part of the PCB except the edges.
• Do not touch the electrical conductors, the connectors, or the

components with conductive devices or with your hands.
• When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
iv Woodward
Chapter 1.
Description
Introduction
The Woodward CPC (Current-to-Pressure Converter) is intended for positioning
steam and/or fuel valves and/or associated servo systems. The CPC supplies a
hydraulic fluid output pressure proportional to the 4–20 mA input current signal.
Apart from accurate pressure control, the CPC is designed for easy mounting
and servicing. The flat surface with three hydraulic connections mounts to an
adapter plate with the actual hydraulic fittings. This plate remains a part of the
installation when removing the CPC, for example, during flushing of the lines
when commissioning the installation.
Figure 1-1. Front View of the CPC
The customer’s cable enters the CPC via a cable gland. Unscrewing the cap
reveals the easy-to-access printed circuit board. The wires are connected to
board-mounted terminals. Two sets of potentiometers on the board allow
calibration and dynamic settings.
Construction
The CPC consists of the following main parts:
• Housing
• Hydraulic valve
• Actuator
• Printed circuit board
• Pressure sensor
Woodward 1
Housing
The housing is a cast-aluminum, black anodized block, supporting all other parts.
It contains the hydraulic ports and the mounting holes on one side of the square
section and the cable gland on the other.
Figure 1-2. Hydraulic Schematic
Together with the aluminum cover, the enclosure contains the electronics, the
actuator, and the pressure sensor.
The spiral return spring is installed on the base and protected by a cover.
The CPC is water- and dust-resistant, in accordance with EN 60529 IP65.
Hydraulic Valve
An innovative hydraulic valve controls the oil flow from supply to output port, or
from output to tank. (see Figure 1-2). The valve consists of a steel bushing in
which a steel plunger moves. The special construction ensures proper, reliable,
and contaminant-tolerant operation, using standard lube oil.
Actuator
The CPC uses a Woodward-developed, rotary limited angle torque (LAT) actuator. It
is a type of stepping motor with steps of 90 degrees, operated using a mini-stepping
technique in one quadrant. The rotating angle is mechanically limited to ±22.5°. The
rotor, with the permanent magnet, is directly coupled to the hydraulic valve. The
current signal to the coils is generated by the driver circuit of the electronics.
2 Woodward
Printed Circuit Board

The printed circuit board is mounted on top of the housing (see Figure 1-3). The
printed circuit board performs the following tasks:
• Power supply
• Signal conditioning of input and output signals
• PID output loop for output pressure
• PID output loop for valve position
• Actuator driver
• Current limiting
• Fault detection
• Dither generation
The power supply section performs the EMI filtering on the 18–32 Vdc input
voltage and generates an internal +10 Vdc. The internal voltage powers the
circuit. The filtered input voltage is used to power the pressure sensor and the
actuator driver.
Figure 1-3. Functional Block Diagram (CPC electronics)
Each input and output signal from the printed circuit board is EMI protected.
The 4–20 mA pressure signal from the internal pressure transmitter is

transformed into a voltage signal. The Pressure Level and Pressure Range
potentiometers tune this signal for the specified output pressure range.
The 4–20 mA input signal gives a 1–5 Vdc signal via a 250 Ω resistance.
A relay provides a discrete contact for fault detection. A red lamp will light when
the relay is active. The drive signal is monitored, and is detected when it exceeds
its range for longer than two seconds. This indicates that the required level of
output pressure is either too high or too low. When this occurs, the relay will
change state. Set jumper to either JPR1 or JPR2. JPR1 gives a normally-open
alarm, and JPR2 gives a normally-closed alarm.
Woodward 3
The Signal Range potentiometer adjusts the current output signal so that the
minimum and maximum pressures correspond with 4 and 20 mA respectively.
The actual valve position is measured by a non-contacting position sensor,

integrated into the board.
The pressure output loop, with adjustable gain and stability, generates a valve
position reference signal for the valve position output loop, depending on the
pressure reference signal and measured pressure signal. The dynamic settings
can be adjusted to match the characteristics of the controlled servo system.
The driver provides the actuator with a high-current, pulse-width-modulated

(PWM) signal, depending on the drive demand signal.
The current passing through the actuator is monitored. It can go up to 5 A for a

period of three seconds, boosting the torque of the actuator to its maximum.
Then the current is limited to approximately 1.5 A, in order to protect the circuitry.
The drive demand signal checks that the CPC is functioning correctly. When the
signal exceeds its normal operating window for longer than two seconds, the
CPC is presumably unable to maintain the required pressure level, and the relay
will change state. A red lamp indicates when the alarm relay is active
A dither signal can be superimposed on the drive signal. The amplitude and
frequency can be adjusted. The dither signal is intended to give a relatively high
frequency ripple on the output pressure. It can be used to reduce the effect of
static friction in the CPC and the attached servo system.
Pressure Sensor
The pressure sensor is a two-wire 4–20 mA transmitter (with a third wire for
shielding purposes).
When the CPC is supplied with hydraulic and electric power, and a current input
signal between 4 and 20 mA, it will output a certain pressure within the factory
set pressure range. The operation is as follows. See also Figures 1-3 and 1-4.
1. The pressure reference and actual pressure signals are compared by the
pressure output loop, and generate a reference valve position signal.
2. The valve position is measured with a board-mounted sensor. The position

signal, together with the valve position reference, is used by the position
output loop with fixed dynamics. This provides a fast and stable valve
position output.
3. The output loop outputs a drive signal. The driver generates the correct PWM
high current signal to the actuator, which results in the valve position as
required.
4. The hydraulic valve has two ports: Supply to Output and Output to Tank. The
three hydraulic connections are indicated on the CPC.
5. With the hydraulic valve in its mid position, both ports are closed, and
assuming no leakage is present, the output or output pressure is maintained
at its level.
4 Woodward
Figure 1-4. CPC Cross Section
6. The output pressure is measured by the pressure transmitter. When either

the output pressure or the pressure reference changes, it is detected by the
electronics. As previously described, the valve position will change.
7. For an increase in output pressure, the change will result in an opening of the
Supply to Output port, resulting in a flow from high pressure oil to the output
port. For a decrease in pressure the Output to Tank port will be opened,
allowing the oil to flow from the servo system to the tank.
8. With leakage of the servo system, the valve will always open the Supply to
Output connection to a certain extent to maintain the output pressure.
9. A small difference in desired and actual valve position will cause the position
output loop to integrate to one of the extremes, thus assuring that the full
actuator force is available for changing position.
10. Should this not result in the correct match of pressure reference and
measured pressure, the electronics will detect that the valve position
requirement has been extreme. After two seconds, the relay will change
state, giving an external signal of a failing pressure output.
11. A return spring forces the valve to open the Output to Tank port on loss of
power. This assures a fail-safe operation.
Woodward 5
Chapter 2.
Specifications
Electrical Specifications
Connections 9 terminals on the internal printed circuit board
suitable for 0.5–4 mm² solid or 0.5–2.5 mm²
stranded wire (22–12 AWG)
Cable Entry via cable gland. Cable dia. 10.5–13 mm
Supply Voltage 18–32 Vdc (24 Vdc nominal) (use cable at least
1.5 mm²/16 AWG)
Power Consumption 8 W during steady state, 48 W maximum, 120 W
peak (3 s maximum)
Current Input Signal 4–20 mA into 250 Ω. CMRR max. ±20 Vdc
Analog Output Signal 4–20 mA. Maximum external load: 300 Ω
Accuracy ±1% of full scale
Discrete Output Signal Relay, jumper selectable for NO or NC, 100 000
operations
1.0 A at 30 Vdc, max. 33 Vdc
0.75 A inductive at 28 Vdc 0.2 henry
Dither Frequency 10–30 Hz. Default setting is 30 Hz
Dither Amplitude Zero is minimum and default. Maximum
depends on adjusted frequency and dynamic
characteristics of the entire system.
Hydraulic Specifications
Connections Flat mounting face with 3 holes. See Figure 3-6
for hydraulic connections, and Figures 3-7 or 3-8
for mounting via an adapter plate (optional).
Supply Pressure 17 bar (250 psi) maximum. At least 0.5 bar
higher than the maximum output pressure.
Tank Pressure At least 0.5 bar lower than the minimum output
pressure.
Output Pressure Min. level: 1 bar (14.5 psi), max. level: 15 bar
(217.5 psi)
Min. range: 1 bar (14.5 psi), max. range: 14 bar
(203 psi)
Recommended External 40 µm nominal, 75 µm absolute or better (β40 =
Filter Rating 75 or better)
(customer-installed)
Viscosity 20 to 100 cSt
Leakage Depends on viscosity and supply pressure. See
Figure 2-1.
Flow Capacity Depends on viscosity and pressure difference.
See Figure 2-1. Reverse flow is 30–50% greater
than forward flow, due to the external (customer-
supplied) filter near the supply input.
6 Woodward
Figure 2-1. Flow Characteristics
Performance
Frequency Response 10–30 ms, time constant at small step, blocked
load (no servo systems connected to the
CPC).Time constant 30–300 ms with a total
settle time of 100–500 ms if the hydraulic load
has a time constant of up to two seconds.
Ultimate dynamic response depends on total
servo system and dynamic adjustments of the
CPC.
Linearity 0.2% of full range
Hysteresis 0.1% of full range
Repeatability 0.1% of full range
Temperature Drift < 0.01% full range / °C
Woodward 7
Environmental
Ambient Temperature –20 to +85 °C
Humidity 95% relative humidity
Oil Temperature Continuously 60 °C max. Peak 80 °C (2–3 days)
Max. Surface Temperature 85 °C
Vibration Lloyd’s LR type approval test spec. 1 and 2
(5–100 Hz at 4G)
EMC EN 61000-6-2 and EN 61000-6-4; compliance
with CE Mark immunity and emissions
requirements for heavy industry environments
Ingress Protection IP65 in accordance with EN 60529
Physical
See also Figure 3-6, CPC Outline Drawing.
Height x Width x Depth Approx. 220 x 170 x 170 mm (8.7 x 6.7 x 6.7
inch)
Weight Approx. 10 kg without oil
Mounting Four M10 threaded holes, 20–24 mm deep, on
the face with the hydraulic ports
Default Factory Settings

Gain = 30% (1 turn potentiometer)
Stability = 30% (1 turn potentiometer)
Dither Amplitude = 0% (1 turn potentiometer)
Dither Frequency = 30 Hz (1 turn potentiometer)
Output Pressure Range = 1.5–4.5 bar (4–20 mA)
8 Woodward
Chapter 3.
Installation
Receiving Instructions
The CPC is carefully packed at the factory to protect it from damage during
shipping. However, careless handling during shipment can result in damage. If
any damage to the CPC is discovered, immediately notify both the shipping
agent and Woodward. When unpacking the CPC, do not remove the hydraulic
blanking plugs until you are ready to mount the unit.
Unpacking Instructions
Carefully unpack the CPC and remove it from the shipping container. Do not
remove the shipping plate or plugs, until ready to mount.
Due to typical noise levels in turbine environments, hearing

protection should be worn when working on or around the CPC.
The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.
Mounting Instructions
Location Considerations
When selecting a location for the CPC, consider the following:
• Provide adequate ventilation and avoid placing or attaching the CPC to heat
generating or conducting parts of the installation.
• Locate the CPC as close as possible to the servo: short hydraulic lines (and
volume) help to achieve optimum response.
• Avoid mounting the CPC at places with excessive vibration.
Mounting the CPC

(Figure 3-5)
The CPC is designed for vertical or horizontal mounting.
The CPC mounts to an adapter block (or plate). The adapter block connects the
three hydraulic CPC ports with the external oil supply, turbine drain, and control-
output of the steam valve servo. The CPC is attached (clamped) to the adapter
block by M10 screws. The screws should screw into the CPC a minimum of 20
mm for a reliable and solid mounting.
Construction should allow easy removal and re-connection of the CPC by

loosening or fastening the M10 bolts and electrical connections.
Woodward 9
Allow space for removal of the cover, to gain access to the adjustments on the
printed circuit board.
Place the CPC against the adapter plate with the gasket in between and secure it
with M10 screws and appropriate locking devices. Be sure that the hydraulic
ports correspond with their designation. Optionally, Woodward can provide a
mounting plate. This plate is made of steel (see Figure 3-7). These plates can be
joined to the turbine frame using two M12 screws or can be welded in place.
Hydraulic Connections
Three hydraulic lines must be connected to the adapter block (or plate; see
Figure 3-5):
• S (supply)—Left
• O (Output)—Center
• T (Tank/Drain)—Right
S, O and T are marked on the CPC.
The pipe inner diameters should be large enough to prevent excessive pressure
loss during transient flow conditions. A minimum inner diameter of 12 mm is
required.
The CPC must be installed correctly. The pump capacity and/or associated
accumulators must be large enough for the required slew rate of the attached
servo system.
Before installing the CPC, the hydraulic lines, supply, tank, and the line from
CPC to the controlled servo system, should be thoroughly flushed.
I/H to CPC Special Mounting Adapter

A special mounting pad is available to exchange the CPC’s predecessor, the I/H
converter, with a CPC. See Figures 3-1 and 3-2.
Figure 3-1. Obsolete I/H Converters

(European design, left; US design, right)
10 Woodward
Figure 3-2. New CPC with I/H Adapter Block

(existing hydraulic tubing left in place)
Electrical Connections
Follow local and national procedures, codes, and directives for installing
electrical/electronic equipment.
Input Power
The electrical power supply should be able to output 2 A at 24 Vdc continuously,
with a peak of 5 A for three seconds.
The CPC requires a power source capable of a certain dc output voltage and
current. The maximum power in watts (W) of a dc source can be calculated by
multiplying the rated output voltage times the maximum output current at that
voltage. The calculated power rating of the supply should be greater than or
equal to the CPC requirements.
The CPC is not equipped with input power switches. Some means of switching
input power to the CPC supply must be provided for installation and servicing. A
circuit breaker meeting the above requirements or a separate switch with the
appropriate ratings may be used for this purpose. Refer to Table 3-1 for
recommended fuse ratings or circuit breakers.
Maximum Maximum Maximum Fuse/

Component Input Voltage
Current Power C.B. Rating
18–30 Vdc
CPC 5A 120 W (3 s) 6A
(24 Vdc Nominal
Table 3-1. Fuse/Breaker Requirements
Woodward 11
Transient Suppression
Protecting electrical loads and sensitive digital equipment from hazardous power
disturbances is critical. This is required when the transients exist, I/O cabling is
long (>30 m long) or when the power cable is not connected to local or
distributed power and is not relatively short (<10 m long).
Transient voltage on the input power lines can be caused by external events
such as lightning, or from power factor corrections and grid switching on the
utility network. Transients can also be caused internally by turning on and off
large inductive loads with long cable length. To avoid this problem, Transient
Voltage Suppression (TVS or MOV devices) must be installed.
Figure 3-3 shows an example of input power transient suppression. The return
line-to-ground device (MOV shown) is required. The line-to-line (TVS shown)
devices are required only if a battery charging or large current load can be
switched on the bus. Woodward recommends that the TVS devices be always
used.
CPC control
Optional
Alternator / Generator / Charger
Optional Optional
battery charging system,

Alternator or Genertaor)
buss has a high current
(Optional for when the
15KP17CA or three
Long Cable
24V buss use two
15KP12CA parts.
Battery
1688-411,
V47ZA7 MOV
to chassis at
the control
Figure 3-3. Example of Power Transient Suppression
The parts used for the example may be replaced with comparable or higher
capability parts. The critical parameters are the energy handling capabilities and
the clamping voltages.
Transient voltage on the input and output lines can also be caused by external
events such as lightning or running in close proximity to other cables with large
transients. As a result Transient Voltage Suppression (TVS or MOV devices)
must be installed to avoid this problem.
Figure 3-4 shows an example of Transient suppression.
12 Woodward
4-20 mA input
CPC
Relay out
4-20 mA output
1.5KE62CA
Figure 3-4. Example of I/O Transient Suppression
Grounds
The unit metal frame must be grounded to PE ground. Use a short, low
impedance strap or cable (typically >12 AWG/3 mm² and <18 inches/46 cm in
length).
Shielded Cable
Use shielded cable for all analog signals, and avoid routing power supply wires
and signal wires within the same conduit.
The use of cable with individually-shielded twisted pairs is recommended. All

analog signal lines should be shielded to prevent picking up stray signals from
nearby equipment. Installations with severe electromagnetic interference (EMI)
may require shielded cable run in conduit, double-shielded wire, or other
precautions. Connect the shields at the control system side (not the CPC side) or
as indicated by the control system wiring practices, but never at both ends of the
shield such that a ground loop is created. Wires exposed beyond the shield must
be less than 2 inches (51 mm). The shield should provide signal attenuation to
greater than 60 dB.
Power Cable
The power and return must be paired and placed in the same cable.
The CPC has one cable entry, for cable sizes between 10.5 and 13 mm. The
cable insulation must have a temperature rating of more than 80 °C continuous.
1. Strip the cable insulation (not the individual wire insulation) 12 cm down.
Strip the wire insulation 5 mm down. Mark the wires according to their
designation and install connectors, if required.
2. Remove the clamp screw and the rubber grommet of the cable gland and
slide them over the wires in the correct order, until the grommet is at the end
of the cable insulation.
3. Remove the CPC cover. Move the wires through the cable gland and up to
the printed circuit board.
Woodward 13
4. Re-install and tighten the clamp screw. The Teflon tubing provided with the
CPC can be used to protect the wires inside the CPC.
5. Connect the wires to the terminals on the printed circuit board. The terminals
accept wires as specified in the Electrical Specifications section in Chapter 2.
A wire size of at least 1 mm² or 18 AWG is recommended for signals. A
minimum wire size of 1.5 mm² is recommended for power. The terminal
designations are shown in Table 4-1. Terminals 10 to 13 are pre-wired at the
Woodward factory and should not be changed.
6. Secure the cable outside the CPC to prevent pull forces on the cable gland.
OUTPUT
TANK
SUPPLY
Figure 3-5. Mounting the CPC
14 Woodward
Figure 3-6. CPC Outline Drawing
Woodward 15
Figure 3-7. Woodward Adapter Plate
16 Woodward
Woodward
4X ° 10.5-11.5 THRU
Manual 89543
3X ° 10.5-11.5 4X = ° 20.6-21.4 ? 12.2-13.2
14.1
117.0
153.8
167.9
20.65
20.65
27.0
14.1
27.0
4X ° 10.5-11.5 THRU
36.0 36.0 4X = ° 20.6-21.4 ? 12.2-13.2 FROM OTHER SIDE
83.95
153.8
167.9
2X .750-16 UNJF-2B THD
STRAIGHT THREAD PORT PER SS-145
.750-16 UNJF-2B THD
STRAIGHT THREAD PORT PER SS-145
Figure 3-8. I/H to CPC Adapter Plate

86.5
54.0
46.2
25.4 25.4
S T
the CPC using Woodward adapter plate 3689-097.

85.9 39.9
98.6
CPC Current-to-Pressure Converter
17
The Woodward I/H converter is obsolete. It can easily be replaced by
Chapter 4.
Calibration
Introduction
After installation, the CPC must be checked for proper operation and calibration
before use. The factory has conducted a functional test. Final checkout and
customer calibration must be completed after installation. For default factory
settings, see Chapter 2.
The engine, turbine, or other type of prime mover should be

equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the

prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
Checkout
A checkout of the CPC is done to verify proper installation, wiring, and
connection of the hydraulic lines.
The checkout procedure will verify correct installation. This

procedure is a bench test of the CPC.
The checkout procedure cannot be run, if the prime mover is

running.
18 Woodward
Figure 4-1. PCB Component Location
Table 4-1. CPC Wiring
Wiring List of Terminal Block 2 (for customer)

Pin 1 and 2 + 24 Vdc Power Supply
Pin 3 Ground (Shield, if used)
Pin 4 and 5 + 4–20 mA Input Signal
Pin 6 and 7 + 4–20 mA Output Signal
Pin 8 and 9 Relay Output Signal
Wiring List of Ground Lugs (for customer)
Internal Chassis Ground Lug PE Ground Connection
Terminal Block 1 (factory connected)
Pin 10 Actuator (Yellow)
Pin 11 Actuator (Green)
Pin 12 Pressure Sensor (White)
Pin 13 Pressure Sensor (Grey)
To shield via screw (only Pressure Sensor (Black)
standard version)
Jumper Setting
JPR1 Connected NO
JPR2 Connected NC (factory set)
Explanation of Adjustments and Test Points

Seven adjustments can be made, and 14 test points have been provided. The
adjustments are explained below. See Figure 4-1 for the location of the
potentiometers and test points (TPs). For default factory settings, see Chapter 2.
Woodward 19
Pressure Level This adjustment sets the level of output pressure.
Adjusting the level changes all points of the output
pressure uniformly. Adjusting clockwise increases the
level. See Figure 4-2.
Pressure Range This adjustment sets the slope of the output pressure.
Adjusting clockwise increases the amount of slope of the
line. See Figure 4-2.
Figure 4-2. Output Pressure vs. Command Input
Gain This adjustment sets the amount of gain (proportional

action) for the pressure control circuit. In most cases,
50% gain can be used. High gain provides a fast
response time, but can cause instability.
Stability This adjustment sets the stability (integration action) of

the controller circuit. The stability cooperates with the
Gain setting to provide stable operation. Adjusting
clockwise increases the stability.
Dither Amplitude This adjustment sets the amplitude of the output dither.
Dither is used to keep the hydraulic part of the CPC and
attached servo systems from sticking, if necessary. The
amplitude should be kept at a minimum to prevent
objectionable oscillation. It is factory set to zero.
Adjusting clockwise increases dither amplitude.
Dither Frequency This adjustment sets the frequency of the dither. It can
be changed to accommodate different servo systems. It
is factory set to maximum (~30 Hz). Adjusting
counterclockwise decreases the frequency.
Signal Range This adjustment sets the range of the 4–20 mA output
signal. The level is fixed.
Relay Jumper Using a jumper, the relay contact can be set to normally
open (NO) or normally closed (NC).
20 Woodward
The printed circuit board is provided with 14 test points (for use only by
Woodward personnel). The voltages, measured at those test points, represent
the following signals:
TP1 Alarm
TP2 Pressure (1.5–7.5 V)
TP3 Error Signal (5 V = no error)
TP4 Position
TP5 Correct Position
TP6 Drive Signal (desired current through the core)
TP7 23 V (18–23 V)
TP8 µ – 4–20 mA input signal, 4 mA = 8.5 V, 20 mA = 2.5 V
TP9 Internal Power Supply (+10 V)
TP10 Ref. 5 V
TP11 GND internal CPC (not the same as +24 V GND)
TP12 Triangle Wave Signal
TP13 PWM Signal to Driver
TP14 Current through Coil, 6 V = +0.83 A, 5 V = 0 A, 4 V = –0.83 A
Set-up/Checkout Procedure
1. Verify that the correct hydraulic and electrical connections are complete,
according to chapter 3.
2. Confirm that the hydraulic and electrical power to the CPC is turned off.
3. Remove the top cover of the CPC.
4. Connect a calibrated pressure gauge to the control output line, in order to

measure output pressure.
5. Connect a mA current source with a current meter, in series, to terminals 4

(+) and 5 (–).
To prevent personal injury or death and damage to equipment, the

controlled device must not be allowed to run or operate during this
procedure. The main steam valve or main fuel control must be turned
off to prevent operation of the controlled device.
6. Apply electrical power to the CPC. The green LED will illuminate.
7. Check the power supply by measuring the voltage at terminal 1 and 2.
8. Check internal power supply at test pins TP9 and TP11. The reading should
be +10 ±0.1 Vdc.
9. Start the hydraulic supply system and turn the current source on. Check that
the oil is up to operating temperature and that all air has been purged from
the system. The air can be purged by adjusting the current input signal up
and down several times. Allow for warm-up time.
10. Observe the pressure gauge when changing the current input signal. The
pressure level should correspond with the default values specified in Chapter 2.
Woodward 21
Calibration
This section covers calibration and other electrical adjustments of the CPC. Refer
to Figure 4-1 for the location of the different potentiometers.
Output Pressure vs. Command Input

1. Set the current source to 12 mA and measure the output pressure.
2. Adjust the Pressure Level for the desired output pressure.
3. Adjust the current source to 20 mA and measure the output pressure.
4. Adjust the Pressure Range for the desired output pressure.
5. Check the 12 mA setting again, and adjust the level if necessary.
6. Check the 4 mA setting again, and adjust the output with range if necessary.
Note that turning the range clockwise results in a decrease of pressure.
7. Repeat steps 1 through 6 until the output pressures at both extremes fall in
the desired tolerance.
The pressure level and pressure range adjustments are 25-turn

potentiometers.
Dynamic Adjustments
1. Adjust the current source to 12 mA.
2. Adjust the Gain slowly clockwise to the middle position. If the controlled
output pressure becomes unstable, adjust the Gain counterclockwise.
Normally 50% gain can be used for all types of loads.
3. Turn the Gain counterclockwise for small servo volumes, and clockwise for
bigger servo volumes.
4. Use 10–20% stability for a small or blocked servo. Use 50–60% for a bigger
servo, with about two seconds time constant. Increase the stability further if
the oil is cold or has a high viscosity.
5. If high frequency oscillations are observed, the Stability can be decreased.

Decreasing the Stability normally results in the possibility to further increase
the Gain.
6. Check the stability over the full range by adjusting the input current between
4 and 20 mA in small stepwise changes.
Output Current Signal

This signal is factory calibrated. If needed, re-adjust as follows:
1. Connect a current meter to terminals 6 (+) and 7 (–). Set the input current
source to 12 mA and measure the output current signal.
22 Woodward
2. Adjust the Signal Range until the output signal is 12 mA.
3. Adjust the current source to 4 and 20 mA and measure the output current
signal.
4. Adjust the Signal Range until both the 4 and 20 mA fall within ±1% accuracy.
The level is fixed to 0 mA.
Discrete Output Signal

The jumper setting for a NO or NC contact is shown in Figure 4-1. When an error
condition is present, such as incorrect pressure or incorrect position at the
internal valve, the relay will switch and the red lamp will illuminate. This major
alarm has a set and reset time of two seconds. A non-resettable function of the
relay can be achieved by adding an external relay circuit.
Dither
The dither can be adjusted while the prime mover is operating. Beware of
unacceptable oscillations when introducing dither. It is recommended to always
use some dither.
1. Turn the Dither Amplitude clockwise to increase the amplitude until oscillation
of the output pressure or valve position can be observed. Decrease the
amplitude slightly to prevent objectionable wear in the system.
2. If the frequency is too high for the attached servo system, reduce it by turning
the Dither Frequency counterclockwise.
Due to the dynamic characteristics of the CPC, the amplitude of the pressure
fluctuations will normally increase when reducing the frequency.
Finish Checkout
1. Turn off the milliamp source.
2. Remove the milliamp current source and (re)connect the plant wiring.
3. Remove additional current and/or voltmeters and (re)connect the plant

wiring.
4. If applicable, remove the pressure gauge from the control output hydraulic
line.
5. Re-install the cover.
The CPC is now ready for normal operation.
Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Woodward 23
Chapter 5.
Repair Instructions
General
Repairs and servicing of the CPC must be performed by Woodward or its
authorized service facilities.
Removal or vandalism of the nameplate is prohibited.
Return for Repair Instruction

Should the CPC need to be returned for repair, attach a tag on the unit. Include
the following information on the tag:
• Customer's name and address
• The name and location where the equipment is installed
• Complete Woodward part number and serial number
• Description of the failure
• Instructions as to what type of repair is to be done
Protective Packaging
The following procedures are used for protective packaging of the CPC, if
returning for repair:
1. Install shipping plates or plugs in all hydraulic connection ports or seal with
tape.
2. Wrap the CPC with packaging materials that will not damage the surface of
the unit.
3. Place in a double-walled packing carton.
4. Place at least 10 cm of tightly packed, industry-approved, shock-absorbing
material around the unit.
5. Secure the carton with strong tape around the outside of the carton to
increase the strength of the carton.
Troubleshooting
General
The following troubleshooting guide will help you isolate trouble with the control
circuit board, actuator, wiring, or elsewhere. Troubleshooting beyond this level is
recommended ONLY when a complete facility for control testing is available.
The wrong voltage can damage the control. When replacing a control, check the
power source and wiring connections for the correct voltage.
24 Woodward
Troubleshooting Procedure
This table is a general guide for isolating system problems. Before using the
guide, make sure that the system wiring contacts and input/output connections
are correct and in good working order. Complete the checks in order. Each check
assumes that the preceding checks have been completed and any problems
have been corrected.
Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Problem Cause Remedy

No pressure out. Faulty power, check green lamp. Check power connections, 24 Vdc at
pins 1 and 2 (pin 1 should be +).
Error condition, check red lamp If on: Check actuator wire connection.
(= alarm = discrete output is If off: Check pressure sensor
active). wires.
Power supply too weak. Change power supply. See
specification.
Power supply is limiting current. Change limit level to maximum (>= 5
A).
Bad power supply. Use Woodward recommended power
supply.
Full pressure out. Pressure sensor connected Check wire connections (Table 4-1).
incorrectly.
Other faulty wiring. Check wire connections (Table 4-1).
Slow dynamics. Dynamic adjustments not Raise Stability, and maybe Gain.
optimal.
Cold oil (viscosity too high). Wait until normal temperature is
reached or change dynamic
adjustments (raise Stability).
Tubes too small or too long. Use bigger and/or shorter tubes.
Water in oil. Clean or change the oil.
High-frequency Servo is outside its working Nothing—this is normal.
oscillation. range.
Oil viscosity changed. Re-adjust dynamics or reduce dither.
Faulty valve position feedback. Contact Woodward service.
Low-frequency High friction in servo. Change dither amplitude and
oscillation. frequency.
Abnormal high friction in servo. Clean or change servo piston.
Low CPC internal friction. Change dither amplitude and
frequency.
High CPC internal friction. Contact Woodward service.
Alarm not working. Is the red lamp on? If yes—Check the jumper. It must be
set!
If no—Check the pressure range.
See specifications.
4–20 mA output not Incorrectly calibrated. Adjust the output. See calibration.
working.
Woodward 25
Problem Cause Remedy
Occasional Wires broken. Replace faulty wire(s).
disturbance. Wire protection broken. Replace faulty wire(s).
Wire protection broken inside the Check pressure sensor and actuator.
CPC.
Bad contact at connectors. Re-install all wires.
Too high ambient or oil Lower temperature. See specification.
temperature.
Leaking inside Pressure sensor is loose. Fasten the pressure sensor. Check O-
CPC. ring.
Other reasons. Contact Woodward service.
Large pressure Abnormal high friction in servo. Clean or change servo piston.
hysteresis. Abnormal high internal friction. Contact Woodward service.
Non-zero pressure Return spring is broken. Replace the return spring.
at power off. Tank pressure is too high. Reduce tank pressure.
26 Woodward
Chapter 6.
Service Options
Product Service Options

If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
• Consult the troubleshooting guide in the manual.
• Contact the manufacturer or packager of your system.
• Contact the Woodward Full Service Distributor serving your area.
• Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In many cases, your problem
can be resolved over the phone. If not, you can select which course of action
to pursue based on the available services listed in this chapter.
OEM and Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.
Woodward Business Partner Support: Woodward works with and supports a

global network of independent business partners whose mission is to serve the
users of Woodward controls, as described here:
• A Full Service Distributor has the primary responsibility for sales, service,
system integration solutions, technical desk support, and aftermarket
marketing of standard Woodward products within a specific geographic area
and market segment.
• An Authorized Independent Service Facility (AISF) provides authorized
service that includes repairs, repair parts, and warranty service on Woodward's
behalf. Service (not new unit sales) is an AISF's primary mission.
• A Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
• A Recognized Turbine Retrofitter (RTR) is an independent company that
does both steam and gas turbine control retrofits and upgrades globally, and
can provide the full line of Woodward systems and components for the
retrofits and overhauls, long term service contracts, emergency repairs, etc.
A current list of Woodward Business Partners is available at

www.woodward.com/support.
Woodward 27
Woodward Factory Servicing Options

The following factory options for servicing Woodward products are available
through your local Full-Service Distributor or the OEM or Packager of the
equipment system, based on the standard Woodward Product and Service
Warranty (5-01-1205) that is in effect at the time the product is originally shipped
from Woodward or a service is performed:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture
Replacement/Exchange: Replacement/Exchange is a premium program

designed for the user who is in need of immediate service. It allows you to
request and receive a like-new replacement unit in minimum time (usually within
24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime. This is a flat-rate program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).
This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.
Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned within 60 days, a credit for the core charge will be issued.
Flat Rate Repair: Flat Rate Repair is available for the majority of standard
products in the field. This program offers you repair service for your products with
the advantage of knowing in advance what the cost will be. All repair work carries
the standard Woodward service warranty (Woodward Product and Service
Warranty 5-01-1205) on replaced parts and labor.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat
Rate Repair option with the exception that the unit will be returned to you in “like-
new” condition and carry with it the full standard Woodward product warranty
(Woodward Product and Service Warranty 5-01-1205). This option is applicable
to mechanical products only.
28 Woodward
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
• return number;
• name and location where the control is installed;
• name and phone number of contact person;
• complete Woodward part number(s) and serial number(s);
• description of the problem;
• instructions describing the desired type of repair.
Packing a Control
Use the following materials when returning a complete control:
• protective caps on any connectors;
• antistatic protective bags on all electronic modules;
• packing materials that will not damage the surface of the unit;
• at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
• a packing carton with double walls;
• a strong tape around the outside of the carton for increased strength.
To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
Replacement Parts
When ordering replacement parts for controls, include the following information:
• the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
• the unit serial number, which is also on the nameplate.
Woodward 29
Engineering Services
Woodward offers various Engineering Services for our products. For these services,
you can contact us by telephone, by email, or through the Woodward website.
• Technical Support
• Product Training
• Field Service
Technical Support is available from your equipment system supplier, your local Full-
Service Distributor, or from many of Woodward’s worldwide locations, depending
upon the product and application. This service can assist you with technical
questions or problem solving during the normal business hours of the Woodward
location you contact. Emergency assistance is also available during non-business
hours by phoning Woodward and stating the urgency of your problem.
Product Training is available as standard classes at many of our worldwide

locations. We also offer customized classes, which can be tailored to your needs
and can be held at one of our locations or at your site. This training, conducted
by experienced personnel, will assure that you will be able to maintain system
reliability and availability.
Field Service engineering on-site support is available, depending on the product

and location, from many of our worldwide locations or from one of our Full-
Service Distributors. The field engineers are experienced both on Woodward
products as well as on much of the non-Woodward equipment with which our
products interface.
For information on these services, please contact us via telephone, email us, or
use our website and reference www.woodward.com/support, and then
Customer Support.
How to Contact Woodward

For assistance, call one of the following Woodward facilities to obtain the address
and phone number of the facility nearest your location where you will be able to
get information and service.
Electrical Power Systems Engine Systems Turbine Systems

Facility --------------- Phone Number Facility --------------- Phone Number Facility --------------- Phone Number
Australia ----------- +61 (2) 9758 2322 Australia ----------- +61 (2) 9758 2322 Australia ----------- +61 (2) 9758 2322
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800
China ------------+86 (512) 6762 6727 China ------------+86 (512) 6762 6727 China ------------+86 (512) 6762 6727
Germany: Germany:
Kempen --- +49 (0) 21 52 14 51
Stuttgart ----- +49 (711) 78954-0 Stuttgart ----- +49 (711) 78954-0
India --------------- +91 (129) 4097100 India --------------- +91 (129) 4097100 India --------------- +91 (129) 4097100
Japan -------------- +81 (43) 213-2191 Japan -------------- +81 (43) 213-2191 Japan -------------- +81 (43) 213-2191
Korea--------------- +82 (51) 636-7080 Korea--------------- +82 (51) 636-7080 Korea--------------- +82 (51) 636-7080
The Netherlands - +31 (23) 5661111 The Netherlands - +31 (23) 5661111
Poland -------------- +48 12 618 92 00
United States----- +1 (970) 482-5811 United States----- +1 (970) 482-5811 United States----- +1 (970) 482-5811
You can also contact the Woodward Customer Service Department or consult our
worldwide directory on Woodward’s website (www.woodward.com/support)
for the name of your nearest Woodward distributor or service facility.
For the most current product support and contact information, please refer to the
latest version of publication 51337 at www.woodward.com/publications.
30 Woodward
Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:
General
Your Name
Site Location
Phone Number
Fax Number
Prime Mover Information

Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application
Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:
Serial Number
Serial Number
Serial Number
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
Woodward 31
Please reference publication 89543G.

Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058

2009/3/Fort Collins
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.9 Magnetic Speed Pickup
Reference Manual
Magnetic Pickups and Proximity Switches

for Electronic Controls
Manual 82510 (Revision R)

WARNING—DANGER OF DEATH OR PERSONAL INJURY
WARNING—FOLLOW INSTRUCTIONS
Read this entire manual and all other publications pertaining to the work to be performed
before installing, operating, or servicing this equipment. Practice all plant and safety
instructions and precautions. Failure to follow instructions can cause personal injury and/or
property damage.
WARNING—OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify
that you have the latest revision, be sure to check the Woodward website:
The revision level is shown at the bottom of the front cover after the publication number. The
latest version of most publications is available at:
If your publication is not there, please contact your customer service representative to get
the latest copy.
WARNING—OVERSPEED PROTECTION
The engine, turbine, or other type of prime mover should be equipped with an overspeed
shutdown device to protect against runaway or damage to the prime mover with possible
personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover control
system. An overtemperature or overpressure shutdown device may also be needed for
safety, as appropriate.
WARNING—PROPER USE
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or property
damage, including damage to the equipment. Any such unauthorized modifications: (i)
constitute "misuse" and/or "negligence" within the meaning of the product warranty
thereby excluding warranty coverage for any resulting damage, and (ii) invalidate product
certifications or listings.
CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

CAUTION—BATTERY CHARGING
To prevent damage to a control system that uses an alternator or battery-charging device,
make sure the charging device is turned off before disconnecting the battery from the system.
Electronic controls contain static-sensitive parts. Observe the following precautions to
prevent damage to these parts.
• Discharge body static before handling the control (with power to the control turned off,
contact a grounded surface and maintain contact while handling the control).
• Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit
boards.
• Do not touch the components or conductors on a printed circuit board with your hands
or with conductive devices.
IMPORTANT DEFINITIONS
• A WARNING indicates a potentially hazardous situation which, if not avoided, could result in
• A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in
damage to equipment or property.
• A NOTE provides other helpful information that does not fall under the warning or caution
categories.
Woodward Governor Company reserves the right to update any portion of this publication at any time.
Information provided by Woodward Governor Company is believed to be correct and reliable. However, no
responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 1969
All Rights Reserved
Manual 82510 Magnetic Pickups and Proximity Switches
Magnetic Pickups and Proximity Switches

for Electronic Controls
WARNING—START-UP
Magnetic Speed Pickup

The magnetic speed pickup (MPU) is used to detect the speed of the prime
mover. It is necessary when the prime mover drives something other than an
alternator, and is often used where an alternator is driven directly by the prime
mover and when a control signal is necessary before the alternator comes up to
its proper output voltage. A speed sensor circuit, either a section on the governor
amplifier chassis or a separate unit, is needed to convert the MPU’s output signal
to one usable by the governor amplifier.
The magnetic pickup produces a voltage output when any magnetic material
moves through the magnetic field at the end of the pickup. Since most engines
and turbines have flywheels or other large gears made of magnetic material
(usually iron or steel), magnetic pickups can usually be installed without adding
attachments to a gear or shaft. Nonmagnetic materials, such as aluminum, brass,
and some stainless steels, will not excite the magnetic pickup.
The MPU makes use of a “stray magnetic field” and no provision for return
magnetic circuits or paths is necessary. Any device which produces a dynamic
discontinuity of magnetic material in the field of the pickup will produce an
electrical voltage. Although gears are the normal devices measured by an MPU,
other devices such as a vibrating surface, moving bar, crank, wheel spokes, or a
steel screw head mounted on some moving surface will work equally well if
surface speed and other factors are taken into account. The MPU may be excited
by a keyway or slot in a wheel, but there is likely to be an unwanted background
signal due to varying density or eccentricity of the material. It is better to excite
the MPU from a protrusion on the surface. This places the pickup at a relatively
great distance from the materials between excitation periods and it is less likely
to pick up stray signals.
The output voltage of a magnetic pickup is affected by three factors.

• Voltage increases with increases of the surface speed of the monitored
magnetic material.
• Voltage decreases as the air gap between the magnetic pickup and the
surface of the gear tooth is increased.
• Voltage waveform is determined by the size and shape of the gear tooth in
relation to the size and shape of the pole piece.
With any given speed and clearance conditions, a maximum power output will
result when the field is filled with a relatively infinite mass of magnetic material at
one instant and a complete absence of such material the next. A reasonable
approach to these conditions exists when the cross-section of the exciting masses
is equal to or greater than that of the pole piece, and the space between is equal to
or greater than three times the diameter of the pole piece (see Figure 1).
Woodward 1
Magnetic Pickups and Proximity Switches Manual 82510
Figure 1. Magnetic Pickup Dimensions
In Figure 1, the optimum dimensions of A, B, C, and F are given as they relate to D, the
diameter of the pole piece of the magnetic pickup. The optimum relationship for maximum
output is as follows:
A equal to or greater than D
B equal to or greater than C
C equal to or greater than three times D
F equal to or greater than D
2 Woodward
As the magnetic pickup-gear relationship begins to deviate from the
specifications listed above, the MPU output waveform may deteriorate to an
unacceptable shape. Because the speed sensor detects zero-crossings, the
waveform should cross zero only twice for each tooth (once going positive and
once going negative, see Figure 2).
Figure 2. Magnetic Pickup Output Waveforms
MPU Installation
The magnetic pickup is available in short or long standard models, a standard
metric model, hazardous duty models, and explosion-proof models, including
CSA/ATEX approved models (see Figure 3 for dimensions and part numbers).
Mount the magnetic pickup radially to the outside diameter of the desired gear,
either through a housing or on a rigid bracket. Make sure the gear is of magnetic
material. The gap between the pickup and the outside diameter of the gear
should be set normally between 0.25 mm and 1.02 mm (0.010” and 0.040") at the
closest point [make sure the gear has less than 0.51 mm (0.020") diametric
runout]. Since the signal strength is inversely proportional to gap distance, a
weak signal may be generated with more than 1.02 mm (0.040") gap. A shield of
non-magnetic material may be installed between the gear and the pickup if
necessary for physical shielding. Since this material spaces the pickup face
farther from the gear, and since an electromagnetic force may be generated by
eddy currents in the shielding material, make sure the signal level is still high
enough to operate the speed signal circuit.
Most electronic controls require a minimum output of 1.5 Vac (rms) from the
magnetic speed pickup at the lowest controlling speed. Figures 4 and 5 show the
maximum air gap allowed for each surface speed and diametral pitch or gear
module to produce this minimum required voltage.
Woodward 3
Figure 3a. MPU Models
The surface speed in meters per second (m/s) or inches per second (IPS) is
related to revolutions per minute (rpm) by the following:
rpm x π x gear diameter
Surface Speed =
60
The diametral pitch for the gear is obtained by the formula:

number of teeth + 2
Diametral Pitch =
gear diameter (inches)
The gear module is obtained by the formula:

gear diameter (mm)
Gear Module =
number of teeth + 2
4 Woodward
Figure 3b. CSA/ATEX Models
The standard magnetic pickup may be used with a gear with a diametral pitch
coarser than 8 (gear module 3.2), but the output will not be increased. Gears with
a finer diametral pitch than 8 (gear module 3.2) may be used with a
corresponding decrease in output voltage. A diametral pitch of 20 (gear module
1.27) is the finest that may be used with this pickup without two teeth appearing
over the pole piece at the same time. When adjusting the clearance between the
pickup pole piece and the gear, adjust the pickup so the output voltage is a
minimum of 1.5 Vac (rms) at the lowest speed.
If you cannot measure the gap directly, it can be determined in the following
manner.
Woodward 5
Figure 4. Maximum Air Gap Allowed to Provide Usable Signals for Most
Electronic Controls
With the prime mover shut down, turn the pickup in until it just touches the
outside diameter of the gear. If the pickup has a 5/8-18 thread, one 360° turn
counterclockwise will move the pickup out 0.0555 inch (1.41 mm). The metric
pickup will move 1.5 mm per turn. If the pickup has a 3/4-20 mounting thread, the
pickup will move out 0.050 inch (1.27 mm) per turn. Screw out the amount
required for the desired gap. If possible, run the gear slowly through 360° rotation
to check the clearance of the pickup. When the gap is set, tighten the jam nut
securely against the housing or bracket so the pickup cannot turn in or out.
6 Woodward
Figure 5. Maximum Air Gap Allowed to Provide 1.5 Vac (rms) on EGM Control
The standard models of pickups, including the metric model, require mating
connector number MS-3106A-10SL-4S. These connectors are not furnished with
the pickups, but may be ordered if desired. The hazardous duty and explosion-
proof models have leads attached to the pickups, and the heads have 1/2"
female pipe threads for installing conduit or pipe.
Woodward 7
Troubleshooting Magnetic Pickups

Disconnect the pickup leads. Check between leads with an ohmmeter for
resistance as listed below. Check between the pickup case and leads with an
ohmmeter for near infinity resistance. Start the prime mover and control speed
manually or block the throttle. Check pickup leads with a high-impedance ac
voltmeter for 10 to 20 Vac (rms). Reconnect the pickup and check at the speed
sensor input terminals for a minimum 1.5 Vac (rms) at the lowest controlling
speed. Check the pickup and gear clearance if voltage is low.
MPU Resistance List

Long Standard Model 250 Ω max
Extra Long Standard Model 250 Ω max
Short Standard Model 220 Ω max
Standard Metric Model 250 Ω max
Conduit Model 114 to 140 Ω
Explosion Proof Model 165 to 225 Ω
Inspect for physical damage. Replace pickup if faulty.
8 Woodward
Proximity Switches
Large engines usually have a larger air gap between the speed sensor probe and
the monitored gear than smaller engines. This is necessary because of the
relatively large runout of the monitored gear in a large engine. The monitored
gears on large engines usually also have a slower surface speed. Because of
either, or both, of these conditions, a magnetic pickup may not perform
satisfactorily on a large engine. A proximity switch (zero velocity pickup) will,
however, operate well on large engines because of its abilities to operate with a
large air gap and at low surface speeds.
The output of these pickups depends solely on the position of the gear tooth (or
similar ferrous discontinuity) and not the velocity at which the gear tooth passes
the sensing end of the pickup.
When wired as a “sinking” type proximity switch, the output is normally zero.
When a gear tooth is within the sensing range of the proximity switch, the output
of the switch goes “high” (nearly equal to the supply voltage). After the tooth has
passed, the output switches back to zero volts until another tooth comes into
position. Typical wiring for a “sinking” type proximity switch is shown in Figure 7.
When wired as a “source” type proximity switch, the output is normally “high”
(nearly equal to the supply voltage). When a gear tooth is within the sensing
range of this proximity switch, the switch output goes to zero volts. After the tooth
has passed, the output switches back to nearly the supply voltage until another
tooth comes into position. Typical wiring for a “source” type proximity switch is
shown in Figure 8.
The on-off nature of the output of a proximity switch produces a square wave
which is compatible with nearly all Woodward speed sensors and will directly
replace the signal from a magnetic pickup as a speed sensor input.
Proximity Switch Features

As long as the air gap between the sensor end of the proximity switch and the
gear being monitored does not exceed the sensing range of a particular proximity
switch, changing the air gap will not change the output voltage. The duty cycle of
the signal from the proximity switch varies with the air gap, but this does not
change the reference signals produced in the Woodward control.
For proper operation there cannot be more than one tooth in the sensing field of
a proximity switch. (The distance between the teeth must be greater than the size
of the sensing field.)
Types of Proximity Switches

Two different sizes of proximity switch are available from Woodward:
1. A proximity switch with a fairly narrow sensing field, suitable for medium size
gears with a tooth size from diametral pitch 8 to 12 (gear module 3 to 2).
This switch can be mounted flush with the mounting plate with an air gap up
to 5.00 mm (0.197 inch).
Woodward 9
2. A proximity switch with a wide sensing field is available for large gears
where a wide air gap (maximum of 10 mm/0.4 inch) is necessary. This
sensor requires larger gear sizes for proper operation and should be used
for gears larger than diametral pitch 12 (gear module 2.1). There must be a
30 mm (1.1 inch) radius clearance of metal around the front of the sensor
and mounting bracket.
CAUTION—PROBE DAMAGE
Some Woodward controls have less than 300 Ω of dc impedance. In these
cases the probe may be damaged by excess current when the engine is
stopped. To prevent this possible damage, a 300 Ω, 2 W resistor should be
installed in series with the probe.
Proximity Switch Power Supply

Proximity switches provided by Woodward require an external power supply of a
single dc voltage, usually 24 volts. This may be from the same supply source as
power for the control system. The maximum current rating for these proximity
switches is 80 mA, but actual current is less and dependent on the external load.
CAUTION—RED PLASTIC CAP

The red plastic cap on top of the proximity switch is an integral part of the
device, not a loose shipping cover. The proximity switch can be damaged
beyond repair if an attempt is made to remove the cap.
Figure 6. Air Gaps for Radial and Axial Sensing Proximity Switches
Checking Proximity Switch Operation

To check the operation of a proximity switch, a load resistance must be placed
across the terminals from which the speed control speed sensor was removed.
An oscilloscope may provide adequate load resistance.
10 Woodward
Proximity Switch Wiring

The proximity switches supplied by Woodward are wired for a “sinking” type
output. Figure 7 shows a typical wiring method. Other proximity switches, not
supplied by Woodward, are wired dc “source”. Figure 8 shows a typical dc source
wiring method. AC proximity switches are seldom used with Woodward controls.
Figure 7. Suggested Wiring for a “Sinking” Type Proximity Switch
Figure 8. Suggested Wiring for a “Source” Type Proximity Switch
Woodward 11
Using the Output of a Woodward MPU to Drive a

Remote Tachometer or Other Device
Attach to Control Posts
Should a remote device be driven by a magnetic pickup, it is important that the
connection be made on the governor posts which accept the input from the MPU.
Polarity must be maintained as indicated on these posts or it is possible to short
the system to ground and cause damage to the electronic circuits and render the
governor inoperable. Woodward electronic controls are not directly grounded, but
in many cases the negative (–) post or common is tied to ground through the
battery powered supply. Should an additional device also be grounded or
powered by the same grounded battery system, a short circuit is possible.
The MPU device provided by Woodward is not grounded, and polarity is not
established until connections are made to the governor. Almost all remote
devices will have a power source in addition to two leads for input. One of these
input connections will be circuit common (–) and this should be determined prior
to connection with the governor.
EPG and 2500 Governors

Since these units are indirectly tied to ground, care must be taken that polarity of
the remote device and of the governor is not reversed.
2301 Governor
The 2301 governor is isolated from ground, and care should be taken that any
device added to the system is also isolated from earth ground.
Shielding
Governor circuits have been carefully shielded, and circuits to remote devices
must also be shielded from interference, since this could prevent adequate
governor control. Inadequate shielding could cause unstable control.
Minimum Signal
Most Woodward controls require a minimum speed-signal strength of 1.5 Vac
from the magnetic pickup during cranking. The addition of remote devices to the
output of the magnetic pickup could prevent the reception of an adequate signal
to allow engine start-up.
NOTE
Woodward advises dedicating the entire output of a governor magnetic
pickup to the exclusive use of driving the control system.
This information is provided for those installations where the output of the
magnetic pickup is also used to drive other devices.
WARNING—OVERSPEED
Make sure all polarity has been established and the system is not shorted to
ground before trying to start the engine after adding an auxiliary device to
the MPU output. Attempting to start the system with reversed polarity
between the auxiliary device and the control could destroy either or both
devices. Should the control be damaged due to the reversed polarity,
dangerous overspeed is possible, damaging equipment, causing personal
injury or even death.
12 Woodward
Please include the manual number from the front cover of this publication.

Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058

2008/8/Fort Collins
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
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B/3:
QT?W9QT?[9QT?Z9QT?Q Wcogcp
{Smco_qglk jlbc
3R`g`ô jk`m\odji hj_` amjh ,hj_`- ja O\m\hò`m bmjpk 41
3Sc`m` \m` 46 fdi_n ja jk`m\odji hj_` di LO8R/ LO8X/ LO8V1
Sc`m` \m` 44 fdi_n ja jk`m\odji hj_` di LO8L n`md`n1
3Qlbc J;-Gl`ko`h^s3Nog]`l ia l`pifondih3Sj``_.

Scdn hj_` dn oj _dnkg\t ^\g^pg\o`_ am`lpì^t 3Edmjf\s p\fo` \h_ _dmjf\s ohdn
jm iph]`m ja m`qjgpodji jm nk``_ ]t h`\npmdib
Edmjf\s p\fo` Edmjf\s ohdn ,-Pl`m^\f` p\fo`.
am`lpì^t ja Iikpo A1
It 5 MP9 S`ld`m
Gl`ko`h^s
;5Jocnrckav4Lw5 D d y|
| ZU@ 5-m`^. [ eIt 42445
Nog]`l ia RPS 5
<5Rrj`co ld ocslirqglk4omj5 l`pifondih ljg :4
D d y|| ZU@ :4-m`^. [ gg 3 m`^ 50444L
A ^g 3 m`^ 544L
R`q`m\g o\mbòn *?93w Sj``_ g 3 m`^ L
D
g 3 gdh :4L
=5Wmccb4j9jgk5 D d y|
| ZU@ :4 v L-g. [ Fhî_`l
eg 3 ciol 72:L
MP9 S`ld`m
A yEdmjf\s ohdn ia _à\ofn>ljg
R`q`m\g o\mbòn *?93wKw
D 3Tdg` ^c\ln
zK ? Sc` gìboc ja ^jiq`tjm hjq`_ ajm Chjon B

n5 n6 n7 n8 n9 n:
4 kpgn` ^t^g`Zh[
D B DSLFGP NH QGMQJMI REPIGR Iif_
?DSLFGP NH OSKQG OGP PGTNKSRJNM@ dhjon
*= Om`n^\g` q\gp` _dmjf\s -53n5. v, -53n7. v, -53n:. v,
3Qlbc J<-P\mmdhb mj``_. 3Edmjf\s p\fo` \h_ _dmjf\s ohdn

MP9 S`ld`m
Ddnkg\t oc` k\nndib nk``_ ]òr`ì NM ja Edmjf\s p\fo` Edmjf\s ohdn ,-Pl`m^\f` p\fo`.
dikpo A \i_ NM ja dikpo B1 gg 3 m`^ 50444L
^g 3 m`^ 544L
KORF
MB
ET
X
B
7441E
CT
NJ
BUTO
MJ
N
DS
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N
Hlh1P
1E1ON OUT Y`f1NP
OUT
68V
E
fe.
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ED56u
R`_1
Clh1-C
Clh1-R
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P\mmdhb
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MB
ET
X
B
7441E
T_ppgke pmccb4Y5 D d y | Z |@ L-g. [
CT
NJ
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N
DS
NP
N
Hlh1P
1E1ON OUT Y`f1NP
OUT
68V
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fe.
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L
Cde1HN
ED56u
R`_1
Clh1-C
Clh1-R
1L1ON
-OV.
g 3 m`^
mj``_
g 3 gdh :4L
za = Scdn dn m`^dkmj^\g iph]`m ja oc` odh` eg 3 ciol 72:L
KORF
MB
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X
B
7441
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NJ
BUTO
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N
DS
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Hlh1P
1E1O OUT Y`f1N
OUT
68V
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N fe.
N `_.
ED56u
R`_1
Cde1H
Clh1-C
Clh1-R
-OV.
1L1O
]òr`ì NM ja dikpo A \i_ NM ja yEdmjf\s ohdn ia a\^nils _à\ofn>g3m`^ 1E1O OUT

68V
NE
N fe.
N `_.
ED56u
R`_1
Cde1H
Clh1-C
Clh1-R
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1L1O
Hlh1P
Y`f1N
OUT
NP
PN
7441
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DS
N
EET
NJ
B
KORF
X
MB
dikpo B1 3Tdg` ^c\ln S`hmil B S`hmil C

K = Sc` _dno\i^` ]òr`ì dikpo A \i_
Chjon B
dikpo BZh[
*= Om`n^\g` q\gp` Chjon C
n\
Iif_
dhjon n5 n6 n7 n8 n9 n: n;
5 5 5 5
Edmjf\s v, v, v, v,
n5 n6 n8 n;
n\ > Cn l`kodl`m gdh2 64gm ail l`nolh ndg`
3Qlbc J=-Ds^f`. 3Edmjf\s p\fo` \h_ _dmjf\s ohdn

Edmjf\s p\fo` Edmjf\s ohdn
Ddnkg\t oc` odh` amjh rcì dikpo A dn YND2UT PUT
KORFB
BUTON
JDS R
SFNSO
PIOTO
SFD MJN
WIT>S
CLF>OED56u68V
CRN>
CYS9441 TET6
NM oj oc` i`so NM1

===2==m`^2 ===2==gdh2
====2=m`^2 ====2=gdh2
Gvaic4X5 D q Ds^f` ==gdh2 9=2=m`^2 ==ciol 9=2=gdh2
SFNSPIOTO
KORFBUTONJDSOR
B
WIT>S
CRN>
CLF>OED56u68V
YND2UT PUT
TET6CYS9441
=ciol 9=gdh2
===ciol 9=gdh2
Pcini`f`^nld^ MP9
zo = L`\npm`hìo odh` Zn`^[ 9=m`^2
m`hmil S`ld`m
=====m`^2 =====gdh2
yS`n nc` _dmjf\s ohdn \n nc` -Tdg` ohdn. ia P\l\g`n`l 62
yEdmjf\s ohdn ia a\^nils _à\ofn>===2==m`^2
3Tdg` ^c\ln
Chjon B
n5 n6 n7 n8 n9 n:
Iif_
z dn ijo _dnkg\t`_ di LO8L07M/ dhjon
LO8L074/ LO8L0751 Edmjf\s n5 n7 n:

yn5 ni n: mciof_ ]` ip`l gdh2 64gm ail g`\moldhb2
G15=
Tripc4V_qc5 Qcqco
3Qlbc J>-P\mmdhb ndg`.
3Edmjf\s p\fo` \h_ _dmjf\s ohdn 4E5
Io _dnkg\tn oc` k\nn odh` ja ^`mo\di _dno\i^` Glrkqco
oj h`\npm` oc` odh` ]òr`ì NM \i_ oc`
SFD MJN
i`so NM ja Iikpo A1 ===2==m`^2 ===2==gdh2
4F5
P\mmdhb ====2=m`^2 ====2=gdh2
T_ppgke qgjc4pca5 D q y | Xgjco
ndg` ==gdh2 9=2=m`^2 ==ciol 9=2=gdh2
g [
^`Z
=ciol 9=gdh2 n\h
Z [
K,h- ===ciol 9=gdh2 Edm
,@ 9=m`^2 L> 4G5
Ljqdib _dno\i^` rdocdi 4kpgn` ^t^g`Zh[ MP9 Xcjm8
=====m`^2 =====gdh2 S`ld`m alkqoliico
zRò oc` _dnkg\t pido \o oc` ,Sdh` pido- ja O\m\hò`m 51
zo = L`\npm`hìo odh`Zn`^[ zDdnkg\t pido ja a\ôjmt _à\pgo=<<<1<<n`^1
K = C`mo\di _dno\i^`Zh[ 4H5
3Tdg` ^c\ln Tltco
z*= Om`n\g` q\gp` alkqoliico
Chjon B
n5 n6 n7 n8 n9 n:
4I5
T_kci
Iif_ jcqco
dhjon
z dn ijo _dnkg\t`_ di LO8L07M/
n7 v, n: v, 4J5
Edmjf\s n5 v,
LO8L074/ LO8L0751 X_afl9
Wmccb9
Tripc
jcqco
3Qlbc J?-Tdg` qd_nc. 3Edmjf\s p\fo` \h_ _dmjf\s ohdn
Edmjf\s ohdn MP9 S`ld`m 4K5
Edmjf\s p\fo`
Io _dnkg\tn oc` NM odh` ja dikpo A1 Hgpmi_v
SFD MJN yEdmjf\s ohdn ia a\^nils rkgq
mj`^dad^\ndih
===2==m`^2 ===2==gdh2
Xgjc tgbqf4X5 D q > ===2==m`^2
====2=m`^2 ====2=gdh2
KORF
MB
EET
X
4L5
B
7441
CT
NJ
BUTO
MJ
N
DS
NP
PN
Hlh1P
1E1O OUT Y`f1N
OUT
68V
NE
Cfe.
R`_.
ED56u
R`_1
Cde1H
N
Clh1-
N
-OV.
Clh1-
1L1O
Tdg` qd_nc ==gdh2 9=2=m`^2 ==ciol 9=2=gdh2 Wckplo
zo = NM h`\npm`hìo odh` ja dikpo AZn`^[ alkqoliico
=ciol 9=gdh2
===ciol 9=gdh2
9=m`^2
KORF
MB
EET
X
B
7441
CT
ONJ
MJ
BUT
N
DS
PNP
NPN
Hlh1
Y`f1
OUT
OUT
1L1 HNE u68V
-Cfe.
.
-R`_
R`_1
ON
ED56
Cde1
ON
Clh1
-OV.
1E1
Clh1
=====m`^2 =====gdh2 Minil 4M5
Sn\gj Wtgqafgke
zRò oc` _dnkg\t pido \o oc` ,Sdh` pido- ja O\m\hò`m 51 mltco
zDdnkg\t pido ja a\ôjmt _à\pgo=<<<1<<n`^1 prmmiv
3Tdg` ^c\ln
4N5
Tolugjgqv
Chjon B pckplo
n5 n\ n6 n\ n7
z dn ijo _dnkg\t`_ di LO8L07M/
4O5
LO8L074/ LO8L0751 Iif_ Tflql
dhjon cicaqoga
pckplo
Edmjf\s n5 n7
n\ > Cn l`kodl`m gdh2 64gm ail l`nolh ndg` 4P5
Tocpproc
pckplo
3Qlbc J@-Tdg` _daa`l`h^`. 3Edmjf\s p\fo` \h_ _dmjf\s ohdn MP9 S`ld`m
Io _dnkg\tn oc` odh` amjh dikpo A dn NM oj 4Q5
SFD MJN Vlq_ov
dikpo B dn NM1 ckalbco
===2==m`^2 ===2==gdh2
KORF
MB
EET
X
B
7441
CT
NJ
BUTO
MJ
N
DS
NP
N
Hlh1P
1E1O OUT Y`f1NP
OUT
68V
NE
N fe.
`_.
ED56u
R`_1
Cde1H
Clh1-C
Clh1-R
1L1ON
-OV.
KORF
MB
EET
X
B
7441
CT
NJ
BUTO
MJ
N
DS
NP
N
Hlh1P
1E1O OUT Y`f1NP
OUT
68V
NE
N fe.
`_.
ED56u
R`_1
Cde1H
Clh1-C
Clh1-R
1L1ON
-OV.
====2=m`^2 ====2=gdh2
Xgjc bgddcockac4X5 D q4X_xX`5 4R5
Tdg` dhn`lp\f ==gdh2 9=2=m`^2 ==ciol 9=2=gdh2 Wqcmmgke
jlqlo 3
=ciol 9=gdh2 ===ciol 9=gdh2 Hogsco 3
KORF
MB
EET
X
B
7441
CT
NJ
BUTO
MJ
N
DS
NP
PN
Hlh1P
1E1O OUT Y`f1N
OUT
68V
NE
Cfe.
R`_.
ED56u
R`_1
Cde1H
N
Clh1-
zo,S\ v S]- = Sc` h`\npm`_ odh` amjh dikpo

-OV.
Clh1-
1L1O
9=m`^2 Glkqoliico
KORF
MB
EET
X
B
7441
CT
NJ
BUTO
MJ
N
DS
NP
N
Hlh1P
1E1O OUT Y`f1NP
OUT
68V
NE
N fe.
`_.
ED56u
R`_1
Cde1H
Clh1-C
Clh1-R
1L1ON
-OV.
A dn NM oj dikpo B dn NMZn`^[ =====m`^2 =====gdh2 S`hmil B S`hmil C

zRò oc` _dnkg\t pido \o oc` ,Sdh` pido- ja O\m\hò`m 51 4S5
Ko_mfga
zDdnkg\t pido ja a\ôjmt _à\pgo=<<<1<<n`^1 m_kci
3Tdg` ^c\ln
4T5
Jgcib
Chjon B kcqtloh
bcsgac
Chjon C
n\ 4U5
Tolbraqglk
Iif_ pqlmm_ec
dhjon n5 n6 n7 n8 n9 n: n;
jlbcip 3
z dn ijo _dnkg\t`_ di LO8L07M/ ocmi_acjckq
LO8L074/ LO8L0751
Edmjf\s n5 n6 n8 n;
n\ > Cn l`kodl`m gdh2 64gm ail l`nolh ndg`
G164
3Qlbc JA-B]mifon` l\ndi.
Io _dnkg\tn cjr a\no jm g\o` Iikpo B ^jhk\mdib oj 3Edmjf\s p\fo` \h_ _dmjf\s ohdn
Iikpo A \n r`gg \n nk``_ jm \hjpio ja Iikpo/ \n Edmjf\s p\fo` Edmjf\s ohdn
\ k`m^ìo\b`1 ,
B]mifon` l\ndi
E`plirqc o_qgl D 4Mkmrq F 9 Mkmrq E5 y ;::2
B Gfiq g`n`l C Gfiq g`n`l
Jocnrckav ld gkmrq F]Lw^yF|
E`plirqc o_qgl D y ;::]2^
Jocnrckav ld gkmrq E]Lw^yE|
Ldkod_
3Tdg` ^c\ln
MP9 S`ld`m
zA*= Om`n^\g` ajm dikpo A
Chjon B
B*= Om`n^\g` ajm dikpo A aB
Gl`ko`h^s ia dhjon CZIt[vC,
Edmjf\s @ v544Z,[
Gl`ko`h^s ia dhjon BZIt[vB,
Chjon C
aC
zHjg_ = Hjg_ ndbi\g dn NM/ oc` _dnkg\t q\gp` rdgg ]` c`g_ piodg Hjg_ ndbi\g
dn NFF1
3Qlbc JB-Fllil l\ndi.

Io _dnkg\tn cjr a\no jm g\o` \n \ k`m^ìo\b`,+-
3Edmjf\s p\fo` \h_ _dmjf\s ohdn Dihp`s`l B
ajm dikpo B \b\dino dikpo A1
Edmjf\s p\fo` Edmjf\s ohdn Dihp`s`l C
Fllil l\ndi ,
Mkmrq F7Mkmrq E zA*= Om`n^\g` ajm dikpo A
Ioolo o_qglD y;::]2^
Mkmrq E B*= Om`n^\g` ajm dikpo B
MP9 S`ld`m
4Jocnrckav ld gkmrq F]Lw^yF|5 3Tdg` ^c\ln
74Jocnrckav ld gkmrq E]Lw^yE|5
Ioolo o_qglD y;::]2^
Jocnrckav ld gkmrq E]Lw^yE| Chjon B
aB
Chjon C
aC
zEmmjm m\odj hj_` dn ijo \q\dg\]g` di LO8L07M/
LO8L074/ LO8L075 hj_`gn1 dn NFF1
3Qlbc JC-E`hmdns.
3Edmjf\s p\fo` \h_ _dmjf\s ohdn
Io _dnkg\tn oc` _ìndot m\odj ja dikpo B \b\dino
ojo\g nph ja dikpo A \i_ dikpo B1 Edmjf\s p\fo` Edmjf\s ohdn
E`hmdns ,
Mkmrq F zA* =Om`n^\g` q\gp` ja dikpo A

HckpgqvD y;::]2^ B* =Om`n^\g` q\gp` ja dikpo B B Gfiq g`n`l C Gfiq g`n`l
Mkmrq E 6 Mkmrq F
Jocnrckav ld gkmrq F]Lw^yF| Ldkod_

HckpgqvD y;::]2^
4Jocnrckav ld gkmrq E]Lw^yE|5
64Jocnrckav ld gkmrq F]Lw^yF|5 MP9 S`ld`m
3Tdg` ^c\ln
Chjon B
aB
Chjon C
aC
dn NFF1
zF; hj_` dn \kkgd`_ oj LO8L07M/ LO8L074/
LO8L075 hj_`gn1
G165
Tripc4V_qc5 Qcqco
3Qlbc J;:-Fllil.
Io _dnkg\tn oc` `mmjm ]òr`ì no\i_\m_ dikpo A 3Edmjf\s p\fo` \h_ _dmjf\s ohdn Dihp`s`l B 4E5
Glrkqco
Dihp`s`l C
\i_ ^jhk\mdib dikpo B1 Edmjf\s p\fo` Edmjf\s ohdn
Fllil FNE Um`l m`nndhb ohdn
Ioolo D Mkmrq F 7 Mkmrq E zA*= Om`n^\g` q\gp` ja dikpo A 4F5

B*= Om`n^\g` q\gp` ja dikpo B Xgjco
Ioolo D 4Jocnrckav ld gkmrq F]Lw^ y F|5 MP9 S`ld`m
3Tdg` ^c\ln
7 4Jocnrckav ld gkmrq E]Lw^ y E|5
4G5
Chjon B Chjon C Xcjm8
aB aC alkqoliico
zSc`m` dn ij `mmjm hj_` di LO8L07M/
LO8L074/ LO8L075 hj_`gn1 zHjg_ = Hjg_ ndbi\g dn NM/ oc` _dnkg\t q\gp` rdgg ]` c`g_ piodg Hjg_
ndbi\g dn NFF1 4H5
Tltco
alkqoliico
3Qlbc J;;-L`hbnc g`\molg`hn.
KORF
MB
EET
X
B
7441
CT
ONJ
MJ
BUT
N
DS
PNP
NPN
Hlh1
Y`f1
OUT
OUT
1L1O HNE u68V
-Cfe.
Io _dnkg\tn oc` iph]`m ja dikpo A kpgn` rcdg`
.
-R`_
R`_1
ON
ED56
Cde1
N
Clh1
-OV.
1E1
Clh1
Edmjf\s p\fo` Edmjf\s ohdn 4I5
dikpo B dn NM1 B T_kci
Qo\hndnsZFB[ jcqco
L`hbnc gg
C
KORF
MB
4J5
X
1EE
B
Pckeqf jc_projckq ? O w *
CT
744
ONJ
MJ
BUT
N
DS
PNP
NPN
Hlh1
Y`f1
OUT
OUT
ON V
1E1 6u68
1L1 HNE
-Cfe.
.
-R`_
R`_1
g`\mol`g`hn ^g
Cde1
ED5
ON
Clh1
-OV.
Clh1
Pcini`f`^nld^ X_afl9
zO = Mph]`m ja dikpo A kpgn`/ m`hmil Wmccb9
g
Tripc
*= Om`n^\g` q\gp` zF\ôjmt _à\pgo,Tido-=Pp\iodotZEA[ MP9 S`ld`m jcqco
3Tdg` ^c\ln 4K5

5 6 7 8 9 : 5 6 5 6 7 8 Hgpmi_v
rkgq
Chjon B
Chjon C 4L5
zF< hj_` dn \kkgd`_ oj LO8L07M/ n\ n] Wckplo
LO8L074/ LO8L075 hj_`gn1 Iif_ alkqoliico
dhjon
Edmjf\s :v, 8v, 4M5
Wtgqafgke
zo\/ o] = Io m`lpdm`n hdi1 53hn ajm mòpmi odh`
mltco
prmmiv
3Qlbc J;<-Jhn`lp\f. 3Edmjf\s p\fo` \h_ _dmjf\s ohdn MP9 S`ld`m
Io _dnkg\tn oc` iph]`m ja dikpo A kpgn` amjh Edmjf\s p\fo` Edmjf\s ohdn
4N5
Tolugjgqv
dikpo B dn NM oj oc` odh` dikpo B dn NM i`so1 Qo\hndnsZFB[ pckplo
KORF
MB
T
X
1EE
B
CT
744
ONJ
MJ
BUT
N
DS
PNP
NPN
Hlh1
Y`f1
OUT
OUT
1L1 HNE u68V
-Cfe.
.
-R`_
R`_1
ON
ED56
Cde1
ON
Clh1
-OV.
1E1
Clh1
gg
Jhn`lp\f 4O5
Mkqcos_i D T y | ^g
Tflql
g cicaqoga
B pckplo
KORF
MB
ET
X
B
1E
CT
744
J
ON
MJ
BUT
N
DS
PNP
NPN
Hlh1
Y`f1
OUT
OUT
ON V
1E1 6u68
1L1 HNE
-Cfe.
zO = Mph]`m ja dikpo A kpgn`/

-R`_
R`_1
Cde1
ED5
ON
Clh1
-OV.
Clh1
zF\ôjmt _à\pgo,Tido-=Pp\iodotZEA[
*= Om`n^\g` q\gp` 3Tdg` ^c\ln C
Pcini`f`^nld^ m`hmil
4P5
Tocpproc
5 6 7 8 5 6 5 6 7 pckplo
Chjon B
Chjon C 4Q5
n\ n] Vlq_ov
Iif_ ckalbco
zF43 hj_` dn \kkgd`_ oj LO8L07M/ dhjon
4R5
LO8L074/ LO8L075 hj_`gn1 Edmjf\s 8 v, 7 v, Wqcmmgke
jlqlo 3
zo\ = Io m`lpdm`n hdi1 53hn ajm mòpmi odh` Hogsco 3
Glkqoliico
3Qlbc J;=-Mofndjfd^\ndih. WZMXG B KORF

TLSXS
N
HR
T
F
WI
K
MOE
UT
OUTP
V
2L
O
HHX7R CLE 4V
2E
O
N
FQW=::7 RF /ED56u68
4S5
NSFS
UO
T
Ko_mfga
Io _dnkg\tn oc` ^jpiodib q\gp` \b\dino kpgn`n m_kci
ja dikpo A1 Edmjf\s p\fo` Edmjf\s ohdn MP9
S`ld`m
Mofndjfd^\ndih Qo\hndnsZFB[
4T5
Jgcib
3Oj`l\ndih \h_ Tdg` ^c\ln kcqtloh
Qriqgmiga_qglk D T y| bcsgac
.Cn îohnm nc` hog]`l ia Jhjon B jofm`2
/Chjon C dm \h Fh\]f`3Edm\]f` dhjon mdbh\f0 qc`h Jhjon C dm ON0 g`n`l mnijm 4U5
zO = Opgn` iph]`m ja dikpo A/ nc` îohndhb \h_ _dmjf\s p\fo` ia Jhjon B0 qc`h Jhjon C dm OGG0 g`n`l îohnm Tolbraqglk
Jhjon B \b\dh2 pqlmm_ec
* = Om`n^\g` q\gp` 5 6 7 8 9 : 5 6 7 8 jlbcip 3
ocmi_acjckq
Chjon B
zL\s1 ^jpiodib nk``_ = 83f^kn
,n\h` rdoc h\s1 m`nkjin` am`lpì^t- Chjon C
RFSFT
zF44 hj_` dn \kkgd`_ oj LO8L07M/ dhjon
LO8L074/ LO8L075 hj_`gn1 Edmjf\s 4 5 6 7 8 9 : 4 5 6 7 8
y,@5 _dmjf\s p\fo`
G166
{Srqmrq jlbc
3R`g`ô jpokpo hj_` di ,jpokpo otk`- ja O\m\hò`m bmjpk 41
3LO8 n`md`n \m` 9 fdi_n ja jpokpo hj_`1 Sc`m` dn ij jpokpo hj_` di di_d^\ojm otk`/ LO8X076277278/ LO8L074 hj_`gn1
~ R,Ro\i_\m_- jpokpo hj_`/ H,Hdbc- jpokpo hj_`/ K,Kjr- jpokpo hj_`/ B,Bgj^f- jpokpo hj_`/ I,Ni` ncjo-jpokpo hj_`/
F,D`qd\odji-jpokpo hj_`1
3Ii jm_`m oj nò ^jhk\m\odq` q\gp`/ B jpokpo hj_` ncjpg_ ]` KK>K>H>HH/ joc`m R/ H/ K/ I jpokpo hj_`n jk`m\o`
di_dqd_p\ggt/ m`b\m_g`nn ja q\gp` ndu` ja ^jhk\m\odq` nòodib q\gp`1
,Sc`m` dn ij GN/ HH/ KK/ NTSOTS di LO8L075-
zW4Wq_kb_ob5 lrqmrq jlbc] ^ zM4Skc Wflq5 lrqmrq jlbc] ^
II II
Digj\l\ndp` I Digj\l\ndp` I
p\fo` L p\fo` L
LL LL
Ism
II
Ism
II
I I
Oonjon HO Oonjon HO
Ism 427m
L L
LL Ism LL
Edmjf\s p\fo` x Digj\l\ndp` p\fo` II ~ II ionjon ON Edmjf\s p\fo` xDigj\l\ndp` p\fo` II ~ II ionjon ON
Edmjf\s p\fo` x Digj\l\ndp` p\fo` I ~ I ionjon ON Digj\l\ndp` p\fo` II AEdmjf\s p\fo` xDigj\l\ndp` p\fo` I ~ I ionjon ON
Edmjf\s p\fo` w Digj\l\ndp` p\fo` L ~ L ionjon ON Digj\l\ndp` p\fo` I AEdmjf\s p\fo` xDigj\l\ndp` p\fo` L ~ L ionjon ON
Edmjf\s p\fo` w Digj\l\ndp` p\fo` LL ~ LL ionjon ON Digj\l\ndp` p\fo` L AEdmjf\s p\fo` xDigj\l\ndp` p\fo` LL ~ LL ionjon ON
HO ionjon > Wc`h nc`l` \l` hi II0 I0 L0 LL ionjon0
dn qdff ]` ON2 zSc`m` dn ij GN jpokpo di jpokpo hj_` I1
zNi` Rcjo, - jpokpo odh` c\n ]`ì ads`_ 316n`^1
zL4Lgef5 lrqmrq jlbc] ^ zSc`m` dn ij Htno`m`ndn di I,Ni` ncjo- ^jhk\m\odq` jpokpo hj_`1
II
zJ4Hcdicaqglk5 lrqmrq jlbc] ^
Digj\l\ndp` I
p\fo` Scdn apiôdji dn oj h`hjmdu` oc` nòodib q\gp` \i_ do jpokpon
L
LL rcì `s^``_ oc` _`qd\odji ja H/ K1
Ism 3L`hjmdu` oc` nòodib q\gp` = L`hjmdu` oc` ^pmmìo _dnkg\t
II q\gp` \n oc` nòodib q\gp` rdoc km`nndib, Q . | - f`t dn
Ism
I amjio1
Oonjon Ism 3Ddnkg\t oc` nòodib q\gp` = Cc`^f oc` h`hjmdu`_ oc` nòodib
L
q\gp` ]t , | - f`t1 ,Ddnkg\t oc` h`hjmdu`_ nòodib q\gp` ajm
Ism
LL km`nndib | f`t ^jiodipjpngt1-
HO 3D`qd\odji nòodib = Rò HZ [/ KZ [ _`qd\odji ]t
Edmjf\s p\fo` x Digj\l\ndp` p\fo` II ~ II ionjon ON nòodib q\gp`1 ,Sc` nò _`qd\odji rdgg ]` h`hjmdu`_ piodg nò
Edmjf\s p\fo` x Digj\l\ndp` p\fo` I ~ I ionjon ON oc` i`so _`qd\odji \b\di rcì kjr`m jaa1-
Edmjf\s p\fo` x Digj\l\ndp` p\fo` L ~ L ionjon ON
3D`qd\odji nòodib m\ib` = 313334 oj <<<<<,Sc` nòodib m\ib`
Edmjf\s p\fo` x Digj\l\ndp` p\fo` LL ~ LL ionjon ON
HO ionjon > Wc`h nc`l` \l` hi II0 I0 L0 LL ionjon0 rdgg ]` ^c\ib`_ ]t _`^dh\g kjdio nòodib k\m\hò`m1
dn qdff ]` ON2 Ia nòodib _`^dh\g kjdio \n 333313/ oc` nòodib m\ib` rdgg ]`
zP4Plt5 lrqmrq jlbc] ^ 314 oj <<<<1<1-
II
3Nk`m\odji = Ddnkg\t q\gp` x K Digj\l\ndp` p\fo` ~
Digj\l\ndp` I K Digj\l\ndp` jpokpo NM/
p\fo` L Ddnkg\t q\gp` y H Digj\l\ndp` p\fo` ~
LL H Digj\l\ndp` jpokpo NM
Pl`mm - Q / | . K`s ail
Ism g`gildtdhb nc` m`nndhb
II
Ism p\fo` \n nc` m\g` ndg`
I -Idbc1fdgdn.I _`pd\ndih
Oonjon L Ism
S`nndhb p\fo`
LL Ism
-Liq1fdgdn.L _`pd\ndih
HO
Edmjf\s p\fo` w Digj\l\ndp` p\fo` II ~ II ionjon ON
Edmjf\s p\fo` w Digj\l\ndp` p\fo` I ~ I ionjon ON
Edmjf\s p\fo` w Digj\l\ndp` p\fo` L ~ L ionjon ON Piq`l ON
Edmjf\s p\fo` w Digj\l\ndp` p\fo` LL ~ LL ionjon ON OGG
HO ionjon > Wc`h nc`l` \l` hi II0 I0 L0 LL ionjon0
dn qdff ]` ON2 S`nndhb p\fo` ON
zF4Filah5 lrqmrq jlbc] ^ g`gils OGG
II
Digj\l\ndp` L _`pd\ndih ON
I ionjon
p\fo` L OGG
-z5.
LL
Ism I _`pd\ndih ON
II ionjon OGG
Ism -z6.
I
Oonjon z,{4-Vcì n`g`ôdib oc` ^jhk\m\odq` jpokpo gdhdo apiôdji/
HO
Ism
Iidod\g jpokpo rdgg ijo ]` ^jh`1
L
z,{5-Sc` jpokpo ji oc` \]jq` dn ji oc` \nnphkodji oc\o oc`
LL Ism
kmdjm nòodib q\gp` ja h`hjmt ^\i ]` \q\dg\]g`1
Edmjf\s p\fo` xDigj\l\ndp` p\fo` II ~ II ionjon ON zSc`m` \m` ij HH/ GN/ KK jpokpon di F jpokpo hj_`1
Digj\l\ndp` p\fo` II +Edmjf\s p\fo` xDigj\l\ndp` p\fo` I ~ I ionjon ON zEqì ocjpbc/ nò oc` _`qd\odji \n *3,Y`mj-*/ do rdgg rjmf \n
Digj\l\ndp` p\fo` LL * Edmjf\s p\fo` wDigj\l\ndp` p\fo` L ~ L ionjon ON
Edmjf\s p\fo` w Digj\l\ndp` p\fo` LL ~ LL ionjon ON *_`qd\odji 4*1
HO ionjon > Wc`h nc`l` \l` hi II0 I0 L0 LL ionjon0 dn qdff ]` ON2
G167
Tripc4V_qc5 Qcqco
{Jrkaqglk
4E5
zWcicaqglk ld bgpmi_v gkqcos_i ,Wq_oqgke aloocaqglk qgjco drkaqglk Glrkqco
Io h`\npm`n \i_ _dnkg\tn m`^dkmj^\g iph]`m ja , hj_` ja O\m\hò`m bmjpk 4-

h`\npmdib odh` oj _ò`ô o\mbò1 L`\npmdib Scdn apiôdji dn oj dicd]do oc` jpokpo ^jh` ajm oc`
4F5
\^^pm\^t h\t ]` _mjkk`_ ]`^\pn` oc` h`\npmdib nòodib odh`1 ,Sdh` nòodib m\ib` 313 oj <<1<n`^1- Xgjco
odh` ja dio`mq\g dn ncjmo/ da oc` o\mbò dn m`qjgqdib Akkgd^\]g` jpokpo hj_` = R/ H/ K/ B/ I/ F hj_`
rdoc cdbc nk``_1 4G5
Xcjm8
Io dn \]g` oj ^c\ib` oc` _dnkg\t ^t^g` di m\ib` ja E`f\s ndg` ia gihdnildhb
alkqoliico
Digj\l\ndp`
313823182425272;n`^1- \i_ _dnkg\tn oc` \q`m\b` m`nndhb p\fo`
q\gp` ja h`\npmdib q\gp` ocì \]g` oj h\dio\di L0 LL
4H5
h`\npmdib \^^pm\^t rcì m`qjgqdib rdoc cdbc Tltco
alkqoliico
nk``_1 Ii ^\n` ja km`nò jpokpo otk`/ oc` m`nkjin`
^\i ]` _`g\t`_ rcì oc` h`\npmdib odh` dn gjib1 Oonjon Ni iojon
4I5
Sc`màjm`/ kg`\n` \_epno oc` h`\npmdib odh` -Gljm_o_qgsc lrqmrq igjgq drkaqglk T_kci
jcqco
kmjk`mgt1 , hj_` ja O\m\hò`m4 bmjpk-
Jhjon Scdn apiôdji dn oj gdhdo oc` KK/ K jpokpo ]àjm` H 4J5
X_afl9
S\gjfdhb jm HH jpokpo1 Wmccb9
Tripc
Akkgd^\]g` jpokpo hj_` = R/ B/ F hj_` jcqco
Jhh`l Diohndhb
zR`g`ô _dnkg\t n\hkgdib k`mdj_ di k\m\hò`m 51 3Xfc lrqmrq jlbc gp W lrqmrq jlbc 4K5
Hgpmi_v
4Mkgqg_i lmco_qglk _dqco prmmivgke mltco5 rkgq
zTocpa_ic drkaqglk II
Scdn km`n^\g` apiôdji \ggjrn oj hpgodkgt oc` Digj\l\ndp` I
4L5
p\fo`
iph]`m ja kpgn` jm kpgn` gìboc ]t \ q\md\]g`,W w L Wckplo
alkqoliico
43 t - ocì _dnkg\t nk`^dad^\odji ja h`\npm`hìo1 LL
Io rdgg _dnkg\t am`lpì^t jm QOL amjh km`n^\g` II 4M5

q\gp` ]t h`\npmdib oc` dikpo am`lpì^1 Fjm I
Wtgqafgke
mltco
`s\hkg`/ rc\o dn km`n^\g` q\gp` * rcì mkh dn HO prmmiv
Oonjon
_dnkg\t`_@ L
4N5
RPM @ av, Tolugjgqv
LL
@ av:4v-53 N. pckplo
MP9 Tcdm jidhn qc`l` nc` îgj\l\ndp`
S`ld`m @ av:4v-5 3 8. ionjon fdgdn aoh^ndih dm l`f`\m`_2
@ av:4v4269 4O5
zIidod\g K/ KK ^jhk\m\odq` jpokpo _j`n ijo jk`m\o` Tflql
@ av59
z a = Iikpo kpgn`,Fm`lpì^t- k`m n`^1 \ao`m npkkgtdib kjr`m1 cicaqoga
pckplo
z*= Om`n^\g` q\gp` zE\^ nòodib q\gp` ja HH/ H/ K/ KK dn ijo àa`ô`_
zM = Opgn` iph]`m k`m 4 m`qjgpodji ]t `\^c joc`m1 Sc`màjm`/ HH q\gp` h\t ]` `lp\g 4P5
3Om`n^\g` q\gp`,*?48- nòodib jm gjr`m oc\i KK q\gp`1 Tocpproc
pckplo
Rò Om`n^\g` q\gp`,*- \n ,W- \i_ ,t- n`k\m\o`gt di 3Xfc lrqmrq jlbc gp F lrqmrq jlbc
/ , / - ja O\m\hò`m bmjpk 51 4Mkgqg_i lmco_qglk _dqco prmmivgke mltco5 4Q5
Rò Om`n^\g`,*?48- \n ,W-=418333/ ,t-=43 4 Vlq_ov
II ckalbco
Io dn \gnj \]g` oj bò oc` n\h` _dnkg\t q\gp` I
Digj\l\ndp`
`qì ocjpbc nò \n W?314833/ t?43 5 p\fo` L 4R5
Wqcmmgke
W nòodib m\ib` = 313334v<1<<<< LL jlqlo 3
Hogsco 3
X nòodib m\ib` = 43 0< v43 < II Glkqoliico
zTc_h s_irc jlkgqlogke drkaqglk I

4S5
HO Ko_mfga
Io n\q`n Hdbc O`\f q\gp` jm Kjr O`\f q\gp` Oonjon m_kci
\b\dino _dnkg\t q\gp`1 L
3Io ^\i ^c`^f di k\m\hò`m bmjpk 3/ oc` Hdbc LL 4T5
Jgcib
O`\f, - q\gp` jm oc` Kjr O`\f, -q\gp` rdgg Tcdm jidhn qc`l` nc` îgj\l\ndp`
kcqtloh
ionjon fdgdn aoh^ndih dm l`f`\m`_2 bcsgac
]` ^jiodipjpngt n\q`_ _pmdib ^c`^fdib1
zIidod\g K/ KK ^jhk\m\odq` jpokpo _j`n ijo jk`m\o`
3Qà`m oj O\m\hò`m bmjpk 3 ajm Q`nò1 4U5
\ao`m npkkgtdib kjr`m1 Tolbraqglk
pqlmm_ec
zQlkgqlogke bci_v drkaqglk zE\^c nòodib q\gp` ja HH/ H/ K/ KK àa`ôn ji jlbcip 3
ocmi_acjckq
`\^c joc`m1 Sc`màjm`/ nòodib q\gp` ncjpg_ ]`
Io ^jiomjgn no\]gt oj gdhdo K/ KK jpokpo piodg ^`mo\di
KK>K>H>HH di n`lpì^`1
jpokpo dn _dnkg\t`_ jm \gg jpokpo piodg oc` `lpdkhìo
rdgg ]` di \ no\]g` no\opn \b\dino q\mdjpn ^c\ib` ja
dikpo np^c \n oc` no\mdib ^pmmìo rcì oc` hjojm dn
mpiidib \ao`m kjr`m ji1
G168
3Xfc lrqmrq jlbc gp J lrqmrq jlbc zPlah pcqqgke drkaqglk
4Mkgqg_i lmco_qglk _dqco prmmivgke mltco5 Scdn apiôdji dn oj nò oc` ì\]g` jm _dn\]g` ja `\^c
I _`pd\ndih O\m\hò`m1
Digj\l\ndp`
p\fo` S`nndhb p\fo` 3<:: = Ddn\]g` oj gj^f f`tn
L _`pd\ndih 3;<9 5 = Kj^f O3 v O6,Kj^f O\m\hò`m 3 v 6-
I 3;<9 6 = Kj^f O4 v O6,Kj^f O\m\hò`m 4 v 6-
Oonjon
L 3;<9 7 = Kj^f O5 v O6,Kj^f O\m\hò`m 5 v 6-
Tcdm jidhn qc`l` nc` îgj\l\ndp` 3;=9 8 = Kj^f O6,Kj^f O\m\hò`m 6 jigt-
ionjon fdgdn aoh^ndih dm l`f`\m`_2
zRò gj^f apiôdji di k\m\h`mo bmjpk 61
zIidod\g K ^jhk\m\odq` jpokpo _j`n ijo jk`m\o`
zMkkco f_obt_oc Plah pcqqgke drkaqglk
\ao`m npkkgtdib kjr`m1
Scdn apiôdji dn oj gj^f di O\m\hò`m bmjpk 6
zSc` ^jhk\m\odq` jpokpo gdhdo apiôdji rdgg ]`
]t Iii`m c\m_r\m` gj^f apiôdji di jm_`m oj km`qìo
m`g`\n`_ \o oc` nòodib q\gp`,Ro\i_\m_ nòodib-1
rmjib nòodib1
zLvpqcocpgp drkaqglk 3c3,H\m_r\m` Kj^f3-
Rò oc` Htno`m`ndn q\gp`,A- ajm ^jhk\m\odq` nòodib Io dn \]g` oj ^c`^f \i_ ^c\ib` hj_` di O\m\0
q\gp` di jm_`m oj km`qìo pino\]g` jk`m\odji _p` oj hò`m bmjpk 61
3c4,H\m_r\m` Kj^f4-
jpokpo dn NM2NFF am`lpìogt1
Io dn \]g` oj ^c`^f hj_` di O\m\hò`m bmjpk 6
R`nolh jidhn ia ionjon qc`h
Digj\l\ndp` nc`l` dm hi csmn`l`mdm p\fo` ]po/ pi\]g` oj ^c\ib`1
m`nndhb p\fo` 3 3c5,H\m_r\m` Kj^f5-
I0 II
Io dn pi\]g` oj ^c`^f \i_ ^c\ib` hj_` di O\m\
Digj\l\ndp`
m`nndhb p\fo` B
3
B
0hò`m bmjpk 6
L0 LL
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Oonjon I0 II ji1
3LO8R/ LO8X/ LO8V R`md`n
Oonjon L0 LL
B>Ismn`l`mdm p\fo`
EOT jimdndih S`nndhb l\hb`

44444 4444 u ==== c4 gi_` c5 gi_` c6 gi_`
444424 44424 u ===2= -G\^nils _à\ofn m`nndhb.
444244 44244 u ==2== zIii`m c\m_r\m` Kj^f nòodib kdi dn ji dii`m OCB1
442444 42444 u =2===
3LO8L R`md`n
424444 42444 u 42===
5 6 5 6 5 6 5 6
zIo dn \]g` oj nò *3* ]po rcì nò *3*/ oc` \ôp\g ON ON ON ON
jk`m\odji rdgg ]` \n *4*1 OGG OGG OGG OGG
zSc` didod\g nòodib q\gp` dn 33341 c4 gi_` c5 gi_`
c6 gi_`
-G\^nils _à\ofn m`nndhb.
zIo dn \]g` oj nò di * * hj_` ja O\m\hò`m bmjpk 41
zSc` kjndodji ja dii`m c\m_r\m` Kj^f nòodib
nrdo^c1
zErql7\col qgjc pcqqgke drkaqglk
Ia oc`m` dn ij kpgn` dikpo rdocdi nòodib odh`,Apoj0
NM
4 5
u`mj odh`-/ do m`b\m_n \n oc` dikpo ndbi\g dn ^po jaa 4 5

NM
ocì h\f` oc` q\gp` \n *33333* ajm^d]gt1 Mjo` oc\o
oc` Apoj0u`mj odh` nòodib ncjpg_ ]` gjib`m oc\i
zH_q_ `_kh ptgqafgke drkaqglk
oc` rd_`no dio`mq\g ja dikpo kpgn`1 Noc`mrdn` do h\t
Scdn dn \ apiôdji oj n\q` ^jhk\m\odq` nòodib q\gp`
]` _daad^pgo oj h\f` oc` _dnkg\t q\gp` \n *33333*1
\i_ km`n^\g` q\gp` di `\^c _\o\ ]\if,D\o\ B\if 4/
3Apoj0u`mj odh` nòodib m\ib`=314 v <<<<1<n`^
D\o\ B\if 5- di jm_`m oj h\f` `\nt oj pn`
,F\ôjmt _à\pgo nòodib = <<<<1<n`^-
i`^`nn\mt _\o\ n\q`_ di `\^c _\o\ ]\if1
3Vcì oc` _dnkg\t q\gp` dn *33333*/ `\^c jpokpo
3Vcì o`mhdi\g Mj16 \i_ 8 \m` jkì/ ^jhk\m\odq`
rdgg m`nkji_ oj cjr do r\n kmjbm\hh`_ ajm *3*1
q\gp` \i_ km`n^\g` q\gp` di D\o\ B\if 4 rdgg ]`
3Rò oc` odh` di * * \i_ * * hj_` ja k\m\0
\ôdq\o`_1
hò`m bmjpk 41
3Vcì o`mhdi\g Mj16 \i_ 8 \m` ncjmo`_/
^jhk\m\odq` q\gp` \i_ km`n^\g` q\gp` di D\o\ B\if
5 rdgg ]` \ôdq\o`_1
3Hjr oj n\q` ^jhk\m\odq` q\gp` \i_ km`n^\g` q\gp`
di `\^c D\o\ B\if = Eio`m dioj k\m\hò`m 5 bmjpk
\i_ n`g`ô oc` D\o\ B\if rc`m` tjp n\q`
oc` _\o\1 Scì/ n\q` `\^c ^jhk\m\odq` nòodib q\gp`
\i_ km`n^\g` q\gp`1
G169
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zXgjc rkgq pcicaqglk drkaqglk S B D T F D S B D T F D
T EM X T R T E M X T R 4E5
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3Sdh` pido n`g`ôdji apiôdji ^\i ]` nò di k\m\hò`m
MP9
5 bmjpk1 m`ld`m B S B D T F D
D T E M X T R
4F5
3Akkgd^\]g` hj_` = Lj_` F6 oj F9 K X R E T X D Xgjco
B C D
SFD MJN
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alkqoliico
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=ciol9=gdh9=m`^2 ===ciol9=gdh2 4H5
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5
54
4
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Di_` Di_` Di_` Di_` Di_` 4I5
oj F9 jk`m\odji hj_`1 T_kci
zSdh` m\ib` ja, - k\mo dn ijo _dnkg\t`_ di LO8L D\fôf\ndih l\hb` ia DRD Dc`ê Sog jcqco
n`md`n1 ,Ro\mo Cj_`

4J5
Io ncjrn oc` admno ja BKNCJ
zG_pc bcq_afjckq4HMT ptgqaf5 X_afl9
Wmccb9
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Og`\n` _ò\^c oc` ^\n` \ao`m opmidib jaa oc` kjr`m1 Tripc
rdgg ]` \__`_1 jcqco
3MP9W S`ld`m3MP9Y S`ld`m3MP9S18N
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. zOg`\n` km`nn \ kpgg ja rkgq
n`md`n \i_ \]g` oj nò rdocdi m\ib` ja 33 oj <<1
/ o`mhdi\g , \i_ kpgg do
,BCD ARCII-
ojr\m_ - _dm`ôdji1 4L5
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alkqoliico
. Io ncjrn Cjhh\i_ \n 5 \gkc\]òn \n ]`gjr1
3MP9M S`ld`m
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QD,Q`\_ m`nkjin`- } QZ85H[/ DZ77H[ Wtgqafgke
mltco
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4N5
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nlp`ù` \i_ kpgg ojr\m_ oc` jpond_`/ do _ò\^c`_1 2Q`nkjin`1 ,Qà`m oj ^jhh\i_ do`h-
4O5
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Io di_d^\o`n oc` ì_ ja BKNCJ1 ESW } Z36H[ cicaqoga
pckplo
{Gljjrkga_qglk lrqmrq 1CQC
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T`lgdh\ndhb R`mdmn\h^` kjgtijhdi\g ^j_`1 CQC dn ajm hjm` m`gd\]g` pckplo
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C-1. C-1.
MP9
om\inhdoo`m \i_ m`^d`q`m1 4Q5
m`ld`m Sc`m` \m` CQC0;/ CQC049 \i_ CQC065/ CQC0 Vlq_ov
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; c\n ]`ì \_jko`_ di LO8 n`md`n \^^jm_dib oj
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msmn`g Wqcmmgke
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S`ld`m S`ld`m S`ld`m
4 5 6 7 8 9 : ; < = B C D E F G
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8 4r8: 4r5< 4rGB 4rB8 4r6; 4r;= 4r=C 4rD9 4r<8 4rEB 4r7< 4r:: 4rF9 4rCC 4r9= 4r4; Jgcib
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9 4rEC 4r<9 4r:; 4r7= 4rCB 4rF8 4r4: 4r9< 4r5= 4r8; 4rB9 4rGC 4r;< 4r6: 4rD8 4r=B bcsgac
joc`m ntno`h-1 : 4r:9 4r7C 4rE= 4r<; 4r48 4r9B 4rC< 4rF: 4rB; 4rG= 4r5C 4r89 4rD: 4r=< 4r;B 4r68
51 Aao`m 7n`^1 ]`dib npkkgd`_ oc` kjr`m dioj ; 4rG< 4rB: 4r88 4r5B 4r== 4rD; 4r69 4r;C 4r7B 4r:8 4r<: 4rE< 4r9C 4r49 4rF; 4rC= 4U5
Tolbraqglk
pkk`m ntno`h/ ocì do no\mon oj ^jhhpid^\o`1 < 4r<D 4rE6 4r74 4r:F 4rFE 4rC7 4r95 4r4G 4r8F 4r54 4rG6 4rBD 4r6G 4r;5 4r=7 4rDE pqlmm_ec
= 4r55 4r8G 4rBE 4rG7 4r;4 4r6F 4rDD 4r=6 4rE7 4r<E 4r:G 4r75 4rC6 4rFD 4r4F 4r94 jlbcip 3
61 Iidod\g ^jhhpid^\odji rdgg ]` no\mo`_ ]t pkk`m ocmi_acjckq
B 4rBG 4rG5 4r57 4r8E 4rDF 4r=4 4r;6 4r6D 4r:E 4r77 4rE5 4r<G 4r4D 4r96 4rC4 4rFF
ntno`h1 Vcì Cjhh\i_ ndbi\g ^jh`n jpo amjh C 4r76 4r:D 4r<F 4rE4 4r97 4r4E 4rFG 4rC5 4rG4 4rBF 4r8D 4r56 4r=5 4rDG 4r6E 4r;7
pkk`m ntno`h ocì LO8 n`md`n rdgg m`nkjin`1 D 4rDB 4r=8 4r;: 4r6< 4rBC 4rG9 4r5; 4r8= 4r4< 4r9: 4rC8 4rFB 4r:= 4r7; 4rE9 4r<C
Ia oc`m` dn ij m`nkjin` \ao`m 6odh`n ja oc` E 4r9; 4r4= 4rFC 4rC9 4r7: 4r:< 4r<B 4rE8 4r=9 4rDC 4r6= 4r;; 4rG8 4rBB 4r8< 4r5:
F 4rF= 4rC; 4r99 4r4C 4r<< 4rE: 4r78 4r:B 4r6C 4r;9 4r=; 4rD= 4r8B 4r58 4rG: 4rB<
^jhh\i_ ndbi\g amjh pkk`m ntno`h/ `mmjm rdgg ]` G 4r;8 4r6B 4rD< 4r=: 4r59 4r8C 4rB= 4rG; 4rC: 4rF< 4r4B 4r98 4rE; 4r<= 4r:C 4r79
j^^pmm`_1
G16:
zGljjrkga_qglk Gljj_kb 51 Q`nkjin`,LO8 n`md`n-
3Tc` Dc\ld^n\ldmnd^-Nog]`l. \n + + dm BSDCC2 Vcì ^jhkgòdib oc` jk`m\odji \ao`m ijmh\g m`^`dq`1
Siln BDK STX B__l Digg\h_ C\he Di_` /31 54 9 54 8 54 7 54 6 545 54 4 EP FTX DRD BDK STX 4 5 W E 4 D 4 / 4 4 5 6 7 8 7 FTX DRD
l`mjihm` l`mko`mn l`mjihm` l`ko`mn
R`\_
46I +R+ +4+ +4+ +4+ +4+ +4+ +4+ +4+ 47I DRD E`^1
+X+ 7 6 5 4 Dc`ê
BDK Sn\ln B__l`mm Digg\h_ C\he Digg\h_ Ssg]if 54 9 54 8 54 54 54 54 dg\f Fh_ mog
jidhn
R`\_
4:I 46I +R+ +E+ 47I DRD

4:I 46I 74I 75I 9;I 88I 74I 87I 74I 6CI 74I 74I 75I 76I 77I 78I 79I 47I 7DI
61 CQC `mmjm = Sm\inhdo MAJZ48H[ jigt1

Wldn`
46I +W+ +X+ 47I DRD
,M``_ oj om\inhdo \b\di-

Wldn`
4:I 46I +W+ +E+ 47I DRD

71 Noc`m = Mj m`nkjin` ja ACJ2MAJ
P 4 Pli^`mm V\fo` ,Aao`m m`^`dqdib RSW/ oc` \__m`nn \m` ijo oc`
D 4 Digj\l\ndp` V\fo` II n\h`1
D 5 Digj\l\ndp` V\fo` I -Vcì m`^`dq` ]paa`m dn jq`magjri1
D 6 Digj\l\ndp` V\fo` L .Vcì oc` ]\p_ m\o` jm joc`m ^jhhpid^\odji
D 7 Digj\l\ndp` V\fo` LL nòodib q\gp` \m` ijo oc` n\h`1
K 4 P`\e V\fo` M\r2 81 Ia oc`m` dn ij m`nkjin` ja ACJ2MAJ
K 5 P`\e V\fo` Mdh2 ,Cc`^f oc` no\opn ja gdi`n
X 4 Pl`m^\fdhb V\fo` X2Bdh
-Cc`^f oc` ^jhhpid^\odji ^ji_dodji
X 5 Pl`m^\fdhb V\fo` X2Cdh
,Ròodib q\gp`-
Y 4 Pl`m^\fdhb V\fo` Y2Bdh
.Vcì oc` kmj]g`h dn j^^pmm`_ _p` oj ijdn`/ omt
Y 5 Pl`m^\fdhb V\fo` Y2Cdh
oj jk`m\o` ^jhhpid^\odji 6 odh`n hjm` piodg
R`m`n îhnlif ia g\rdgog3gdhdgog
R 4
p\fo`m m`^jq`mt
3R`\_ZRX[ ia g`\mol`g`hn > /Vcì ^jhhpid^\odji dn a\dg`_ am`lpìogt/ kg`\n`
B__l`mm 450 Digg\h_ RX \_epno oc` ^jhhpid^\odji nk``_1
41 Cjhh\i_,Tkk`m-
{Toca_rqglk dlo aljjrkga_qgke tgqf
,Cjhh\i_
-Akkgd^\odji = A__m`nn,34-/ H`\_`m ^j_`,QW-/ QT? pcogcp
Cpmmìo q\gp`,O3- ja B\if,3-/ 41 Io dn ijo kjnnd]g` oj hj_dat O\m\hò`m,B\p_ m\o`/
CQC Cc`^f nph,B8H- A__m`nn ò^-m`g\o`_ oj ^jhhpid^\odji ja LO8
STX 4 5 R X 4 P 4 / 4 4 4 4 4 4 4 FTX DRD n`md`n ji gdi` rdoc cdbc jm_`m ntno`hn np^c \n
E`^dg\f Dc`ê OC/ OKC ò^1 ,Emmjm rdgg ]` j^^pmm`_-
Sn\ln B__l`mm Digg\h_ C\he Digg\h_ Ssg]if 54 54 54 54 54 5 54 4 jidhn FNE mog
9 8 7 6
51 Fdmnogt h\f` ^jhhpid^\odji O\m\hò`m ja LO8

46I 74I 75I 96I 9<I 74I 94I 74I 6CI 74I 74I 74I 74I 74I 74I 74I 47I C9I
n`md`n \i_ cdbc jm_`m ntno`h \o ji`1
51 Q`nkjin`
61 Io dn ijo \ggjr oj nò jq`mg\kkdib ^jhhpid^\odji
,Mjmh\g m`^`dq` = A__dib ACJZ39H[ oj ^pmmìo
iph]`m \o oc` n\h` ^jhhpid^\odji gdi`1
q\gp` ja D\o\ om\inhdnndji B\if,3- dn .415671
,Emmjm rdgg ]` j^^pmm`_-
BDK STX 4 5 R E 4 P 4 / 4 4 5 6 7 8 7 FTX DRD
71 Og`\n` pn` Srdno k\dm rdm` ajm QR7;8 ^jhhp0
7 6 5
BDK Sn\ln B__l`mm Digg\h_ C\he Digg\h_ Ssg]if 54 9 54 8 54 54 54 54
4
E`^1 Dc`ê
dg\f Fh_ mog
id^\odji1
jidhn
81 Cjhhpid^\odji ^\]g` ^\i ]` `soì_`_ pk oj
4:I 46I 74I 75I 96I 88I 74I 94I 74I 6CI 74I 74I 75I 76I 77I 78I 77I 47I 67I
;33h/ \i_ h\sdhph 64 `lpdkhìon ^\i ]`
-Mjmh\g m`^`dq`= A__dib ACJZ39H[ oj ^pmmìo ^jii`ô`_1
q\gp` ja D\o\ om\inhdnndji B\if,3-dn 04891:1 91 Vcì ^jii`ô ^jhhpid^\odji ^\]g` ]òr`ì
BDK STX 4 5 R E 4 P 4 1 4 4 5 9 : ; 5 FTX DRD LO8 n`md`n \i_ cdbc jm_`m ntno`h/ oc` q`mod^\g
7 6 5 4
E`^1 Dc`ê m`ndno\i^`,433v533+- hpno ]` dino\gg`_ \o
BDK Sn\ln B__l`mm Digg\h_ C\he Digg\h_ Ssg]if 54 9 54 8 54 54 54 54 dg\f Fh_ mog
jidhn ]òr`ì ]joc ^jhhpid^\odji gdi`n1
4:I 46I 74I 75I 96I 88I 74I 94I 74I 6EI 74I 74I 75I 79I 7:I 7;I 75I 47I ;9I :1 Og`\n` ^c`^f O\m\hò`m m`g\o`_ oj ^jhhpid0
3Wldn`ZWX[ ia g`\mol`g`hn 3 m`nndhb p\fo` > ^\odji
B__l`mm 450 Digg\h_ WX ,Ro\mo ]do = 4]do,Fds-
41 CNLLAMD,Tkk`m- -Rojk ]do = 4]do,Fds-
,Cjhh\i_ .O\mdot ]do = Mji,Fds-
-Akkgd^\odji = A__m`nn,34-/ H`\_ Cj_`,VW-/ /D\o\ ]do = ;]do,Fds-
Sc` nòodib q\gp` dioj RU0HH 0B\p_ m\o` = 5733/ 7;33/ <933,Ròo\]g`-
,C3- ja BAMJ,3- dn .415671 1A__m`nn = 33 v <<,Ròo\]g`-
STX 4 5 W X 4 D 4 / 4 4 5 6 7 8 7 FTX DRD
E`^1 Dc`ê
Sn\ln B__l`mm Digg\h_ C\he Digg\h_ Ssg]if
7
54 54 8 54 54 54 54
9 6 5 4
dg\f Fh_ mog
jidhn
46I 74I 75I 9;I 9<I 74I 87I 74I 6CI 74I 74I 75I 76I 77I 78I 77I 47I 9EI
G16;
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.11 Accumulator
Hydraulic
Bladder Accumulator
Standard
1. Description 1.2. Design 1.2.2 Bladder material

The following elastomers are available as
1.1. Function seal cap valve protection standard:
Fluids are practically incompressible and gas valve cap zzNBR (acrylonitrile butadiene rubber,
cannot therefore store pressure energy. lock nut Perbunan),
shell bladder
The compressibility of a gas is utilised in zzIIR (butyl rubber),
hydraulic accumulators for storing fluids. zzFKM (fluoro rubber, Viton®),
HYDAC bladder accumulators are based
on this principle, using nitrogen as the zzECO (ethylene oxide epichlorohydrin
compressible medium. rubber).
A bladder accumulator consists of a fluid The material must be selected according
section and a gas section with the bladder to the particular operating fluid and
acting as the gas-proof screen. temperature.
The fluid around the bladder is connected When choosing the elastomer, allowances
to the hydraulic circuit so that the must be made for the fact that the gas
bladder accumulator draws in fluid when can cool down to below the permitted
the pressure increases and the gas is elastomer temperature if there are adverse
compressed. discharge conditions (high pressure ratio
When the pressure drops, the compressed p2/p0, high discharging velocity). This can
gas expands and forces the stored fluid cause cold cracking in the elastomer.
into the circuit. The gas temperature can be calculated
anti-extrusion
HYDAC bladder accumulators can be used
spacer
ring
using the HYDAC Accumulator Simulation
in a wide variety of applications, some of seal ring Program ASP.
lock nut
which are listed below: oil valve vent screw 1.2.3 Corrosion protection
zzenergy storage For operation with chemically aggressive
zzemergency operation media, the accumulator shell can be
1.2.1 Design supplied with corrosion protection, such as
zzforce equilibrium zzStandard Bladder Accumulator plastic coating on the inside or chemical
zzleakage compensation SB330/400/500/550 nickel-plating. If this is insufficient, then
HYDAC standard bladder accumulators stainless steel accumulators must be used.
zzvolume compensation consist of the pressure vessel, the
zzshock absorption flexible bladder with gas valve and the
zzvehicle suspension hydraulic connecction with check valve.
The pressure vessel is seamless and
zzpulsation damping manufactured from high tensile steel.
See catalogue section: zzBladder accumulator
zzHydraulic Dampers SB330N
The flow optimised design of the
No. 3.701 standard oil valve enables the maximum
possible operating fluid flow rate to
increase to 25 l/s on this accumulator
type.
zzHigh Flow bladder accumulator
SB330H
HYDAC high flow bladder accumulators,
type SB330H, are high performance
accumulators with a flow rate of up to
30 l/s. The fluid connection is enlarged to
allow higher flow rates.
E 3.201.25/04.09
17
1.3. MOUNTING POSITION 2. Technical 2.1.8 Gas charging
Always only charge with nitrogen class 4.5,
HYDAC bladder accumulators can be specifications filtered to < 3 µm.
installed vertically, horizontally and at a
slant. When installing vertically or at a 2.1. EXPLANATORY If other gases are to be used, please
contact HYDAC for advice.
slant, the oil valve must be at the bottom. NOTES
On certain applications listed below, Hydraulic accumulators must only be
particular positions are preferable: 2.1.1 Operating pressure charged with nitrogen.
See tables Never use other gases.
zzEnergy storage: (may differ from nominal pressure for Risk of explosion!
vertical, foreign test certificates)
zzPulsation damping: 2.1.9 Limits for gas pre-charge
any position from horizontal to vertical, 2.1.2 Nominal volume pressure
See tables p0 ≤ 0.9 • p1
zzMaintaining constant pressure:
any position from horizontal to vertical, 2.1.3 Effective gas volume with a permitted pressure ratio of:
zzVolume compensation: See tables p2 : p0 ≤ 4 : 1
vertical. based on nominal dimensions, this differs p2 = max. operating pressure
slightly from the nominal volume and must p0 = gas pre-charge pressure
If the mounting position is horizontal be used when calculating the effective
or at a slant, the effective volume and volume. 2.1.10 Certificate codes
the maximum permitted flow rate of the
2.1.4 Effective volume China A9
operating fluid are reduced.
Volume of fluid which is available between EU member states U 1)
the operating pressures p2 and p1. Japan P
1.4. TYPE OF MOUNTING 2.1.5 Max. flow rate of operating fluid Canada S1 2)
By using an appropriate adapter, HYDAC In order to achieve the max. flow rate given Switzerland U
accumulators, up to size 1 l, can be in the tables, the accumulator must be
mounted directly inline. mounted vertically. It must be remembered USA S
For strong vibrations and volumes above that a residual fluid volume of approx. 10% others on request
1 l, we recommend the use of HYDAC of the effective gas volume remains in the 1)
Alternative certificates possible
accumulator supports or the HYDAC accumulator. 2)
Approval required in the individual provinces
accumulator mounting set. 2.1.6 Fluids On no account must any welding, soldering
See catalogue sections: The following sealing and bladder or mechanical work be carried out on the
zzSupports for Hydraulic Accumulators materials are suitable for the fluids listed accumulator shell. After the hydraulic line
No. 3.502 below. has been connected it must be completely
vented.
zzACCUSET SB Material Fluids
No. 3.503 NBR20 Mineral oils (HL, HLP, Work on systems with hydraulic
HFA, HFB, HFC), water accumulators (repairs, connecting
pressure gauges etc) must only be carried
ECO Mineral oil
out once the pressure and the fluid have
IIR Phosphate ester been released.
FKM Chlorinated hydro-
carbons, petrol Please read the operating manual!
No. 3.201.CE
2.1.7 Permitted operating temperature Note:
The permitted operating temperatures are Application examples, accumulator sizing
dependent on the application limits of the and extracts from approvals regulations on
metallic materials and the bladders. hydraulic accumulators can be found in the
The standard valve bodies, gas valves following catalogue section:
and accumulator shells are suitable for zzAccumulators
temperatures from -10 °C ... +80 °C. No. 3.000
Outside these temperatures, special
material combinations must be used.
The following table shows the correlation
between bladder material and application
temperature.
Material Temperature ranges
NBR20 -15 °C ... + 80 °C
NBR21 -50 °C ... + 80 °C
NBR22 -30 °C ... + 80 °C
ECO -30 °C ... +120 °C
IIR -40 °C ... +100 °C
FKM -10 °C ... +150 °C
E 3.201.25/04.09
18
2.2. Model code
(also order example)
SB330 H – 32 A 1 / 112 U – 330 A 050
Series
Type
H = high flow
N = increased flow, standard oil valve dimensions
A = shock absorber
P = pulsation damper
S = suction flow stabiliser
B = bladder top-repairable
Combinations possible, e.g. HB - High flow with a top-repairable bladder
PH - pulsation damper with high flow rate.
No details = standard
Nominal volume [l]
Fluid connection
A = standard connection, thread with internal seal face
F = flange connection
C = valve mounting with screws on underside
E = sealing surfaces on front interface (e.g. on thread M50x1.5 - valve)
G = male thread
S = special connection, to customer specification
Gas side
1 = standard model 4)
2 = back-up model
3 = gas valve 7/8-14UNF with M8 female thread
4 = 5/8" gas valve
5 = gas valve M50x1.5 in accumulators smaller than 50 l
6 = 7/8-14UNF gas valve
7 = M28x1.5 gas valve
8 = M16x1.5 gas valve
9 = special gas valve, to customer specification
Material code 1)
Standard model = 112 for mineral oil
Depending on operating fluid
others on request
Fluid connection
1 = carbon steel
2 = high tensile steel
3 = stainless steel 3)
6 = low temperature steel
Accumulator shell
0 = plastic coated (internally)
1 = carbon steel
2 = chemically nickel-plated (internal coating)
4 = stainless steel 3)
6 = low temperature steel
Accumulator bladder 2)
2 = NBR20
3 = ECO
4 = IIR (butyl)
5 = NBR21 (low temperature)
6 = FKM
7 = other
9 = NBR22
Certification code
U = PED 97/23/EC
Permitted operating pressure [bar]
Connection
Thread, codes for fluid connections: A, C, E, G
A = Thread to ISO 228 (BSP)
B = Thread to DIN 13 or ISO 965/1 (metric)
C = Thread to ANSI B1.1 (UN..-2B seal SAE J 514)
D = Thread to ANSI B1.20.1 (NPT)
S = special thread, to customer specification
Flange, codes for fluid connection: F
A = DIN flange
B = flange ANSI B16.5
C = SAE flange 3000 psi
D = SAE flange 6000 psi
S = special flange, to customer specification
E 3.201.25/04.09
Pre-charge pressure p0 [bar] at 20 °C must be stated separately, if required!

1)
Not all combinations are possible
2)
When ordering spare bladders, please state smallest bladder connection port size
3)
Depending on type and pressure rating
4)
Gas valve type in SB < 50 l = 7/8 - 14 UNF, in SB ≥ 50 l = M50x1.5
19
3. DIMENSIONS AND SPARE PARTS Dimensions
3.1. DIMENSIONS
A B C ØD J Ø E SW Q 1)
Max. operating pressure

max. max. thread
Effective gas volume

Nominal volumes
(PED 97/23/EC)
Weight
Valve
ISO
[l] [bar] [l] [kg] [mm] [mm] [mm] [mm] 228 [mm] [mm] [l/s]
0.5 400 0.5 2.8 270 33.5 95.5
57 G 3/4 50 32
330 4.5 302 118 4
1 1.0
550 8.5 334 68 121 G1 45
330 2.4 10 531 63 118 G 1 1/4 50 10
2.5
550 2.5 13.5 539 68 121 G1 45 4
standard
330 11.5 58
4 3.7 419 63 173 G 1 1/4 67 50 10
400 15.5
5 550 4.9 23 867 68 121 G1 45 4
6 330 5.7 15 531 G 1 1/4
63 173 50 10
10 2)
330 9.3 25 728 G 1 1/4
standard 15
9.3 31.5 568 103 G2 103 70
N 330 229 25
58
10 H 9 34.5 603 138 G 2 1/2 125 90 30
400 9.3 37.5 572 103 233
standard G2 100 70 15
500 8.8 41 585 77 68 241
standard 15
43 660 103 G2 100 70
N 330 229 25
13 12 58
H 46 695 138 G 2 1/2 125 90 30
standard 400 49 666 103 233 G2 100 70 15
standard 15
18.4 50.5 896 103 G2 100 70 adapter
N 330 229 25
58 for
20 H 17.5 53.5 931 138 G 2 1/2 125 90 30 special
400 18.4 63.5 896 103 233 100 70 threads
standard G2 15
500 17 75.5 901 77 68 241 110 75
standard 15
23.6 69.0 1062 103 G2 100 70
24 N 330 58 229 25
H 24 72 1097 138 G 2 1/2 125 90 30
standard 15
33.9 87 1411 103 G2 100 70
N 330 229 25
58
32 H 32.5 90 1446 138 G 2 1/2 125 90 30
400 33.9 104.5 1411 103 233 100 70
standard G2 15
500 33.5 127 1446 77 68 241 110 75
15
117.5 1931 103 G2 100 70
N 330 229 25
47.5
50 H 120.5 1966 138 68 G 2 1/2 125 90 30
400 142 1931 103 233 70
standard G2 100 15
500 48.3 169 1951 77 241 75
60 60 182 1156
80 85 221 1406
356
100 105 255 1656
standard 330 138 68 G 2 1/2 125 90 30
130 133 305 1976
160 170 396 2006
406
200 201 485 2306
E 3.201.25/04.09
1)
Q = max. flow rate of pressure fluid
2)
slimline version, for confined spaces
20
3.2. Spare parts Description Item 3.3. REPAIR KITS
Bladder kit NBR, carbon steel
SB330/400/440/500/550 consisting of: Nom. volume: 0.5 ... 200 litres
SB330H / SB330N Standard gas valve
Bladder 2
Gas valve insert* 3 Nom. volume [l] Part no.
Lock nut 4 0.5 02128169
Seal cap 5 1 02106261
Valve protection cap 6 2.5 02106200
O-ring 7 4 02106204
Seal kit 5 02106208
consisting of: 6 02112100
O-ring 7 10 *) 03117512
Washer 15 10 02106212
O-ring 16 13 02106216
Vent screw 19 20 02106220
Support ring 23 24 02106224
O-ring 27 32 02106228
Repair kit 1) 50 02106252
consisting of: 60 03117513
Bladder kit (see above) 80 03117514
Seal kit (see above) 100 03117515
Anti-extrusion ring 14 130 03117516
Oil valve assembly 160 03117517
consisting of:
200 03117558
Valve assembly (items 9-13) 9
*) slimline version for confined spaces
Anti-extrusion ring 14 others on request
Washer 15
O-ring 16
Spacer 17
Lock nut 18
Vent screw 19
Support ring 23
* available separately
1)
When ordering please state smallest bladder
connection port size.
Item 1 not available as a spare part.
Item 19 for NBR/Carbon steel:
seal ring (item 20) included
Item 25 must be ordered as an accessory
(see Point 4).
Detail "X"
SB330/400 – 0.5 ... 6 l
SB330/400/500 – 10 ... 200 l and

SB330H – 10 ... 200 l
SB550 – 1 ... 5 l
E 3.201.25/04.09
21
4. ACCESSORIES FOR BLADDER 4.1.2 Pressure gauge model with shut-off valve
Gas side connection on the bladder accumulator for permanent
ACCUMULATORS monitoring of the pre-charge pressure with shut-off option.
4.1. ADAPTERS (gas side)
To monitor the accumulator pre-charge pressure, HYDAC offers a
selection of gas side adapters.
These must be ordered separately
4.1.1 Pressure gauge model:
Gas side connection on the bladder accumulator for permanent gauge Ø100
monitoring of the pre-charge pressure
pressure gauge
Ø63
gauge shut-off
valve
approx.
Gauge Gauge Adapter body* Adapter
indication range Part no. assembly
Part no. Part no.
– – 00366621
0 - 10 bar 00614420 02108416
0 - 60 bar 00606886 03093386
0 - 100 bar 00606887 00239275 02104778
0 - 160 bar 00606888 03032348
0 - 250 bar 00606889 02100217 Gauge Gauge Adapter body* Adapter
indication range Part no. assembly
0 - 400 bar 00606890 02102117
Part no. Part no.
* pmax= 400 bar
– – 02103381
0 - 25 bar 00631380 02105216
0 - 60 bar 00606771 02110059
0 - 100 bar 00606772 00363713 03139314
0 - 160 bar 00606773 03202970
0 - 250 bar 00606774 03194154
0 - 400 bar 00606775 02103226
* pmax= 400 bar
E 3.201.25/04.09
22
4.1.3 Remote monitoring of the pre-charge pressure 4.2. ADAPTERS FOR STANDARD BLADDER
To monitor the pre-charge pressure in hydraulic accumulators
remotely, gas side adapters with pressure gauge and mounting ACCUMULATORS (fluid side)
holes are available. to connect the bladder accumulator to pipe fittings. These are
In order to connect these adapters directly with the hydraulic available separately.
accumulator using appropriate lines, accumulator adapters are
also available for connection at the top (see diagram 1) or for
side-connection (see diagram 2).
O-ring
2 holes
pressure gauge
Ø63
approx.
Gauge Gauge Adapter body* Adapter D1 D2 D3 L1 L2 L3 SW O- Part no.

indication Part no. assembly Accum. ring
range Part no. Part no. conn.*
– – 03037666 NBR/
0 - 10 bar 00614420 03095818 (ISO228- Carbon
BSP) [mm] [mm] [mm] [mm] [mm] [mm] [mm] steel
0 - 60 bar 00606886 03095819
G 3/8 28 55 28 12 32 02104346
0 - 100 bar 00606887 02116746 03095820 G 3/4 17x3
G 1/2 28 60 28 14 36 02104348
0 - 160 bar 00606888 03095821
G 3/8 28 50 37 12 46 02116345
0 - 250 bar 00606889 03095822
G 1/2 34 50 37 14 46 02105232
0 - 400 bar 00606890 03095823 G 1 1/4 30x3
G 3/4 44 50 37 16 46 02104384
* pmax= 400 bar
G1 50 67 37 18 65 02110124
G 1/2 34 60 44 14 65 02104853
G 3/4 44 60 44 16 65 02104849
G2 48x3
G 1 1/4 60 60 44 20 65 02107113
G 1 1/2 68 80 44 22 70 02105905
* others on request
O-ring 11x2 5. NOTE

The information in this brochure relates to the operating
conditions and applications described. For applications and
operating conditions not described, please contact the relevant
technical department. Subject to technical modifications.
Diagram 1 Diagram 2
D1 D2 T Adapter Adapter Diag.

Threaded body* assembly
connection [mm] Part no. Part no.
00238709 02109481 1
ISO228- G 1/4 25
00241740 02102042 2
14 Technology GmbH
00355021 02109483 1 Industriegebiet
E 3.201.25/04.09
ISO228- G 3/8 28
03280414 00366607 2 D-66280 Sulzbach/Saar
02110594 02110636 1 Tel.: 0 68 97 / 509 - 01
ISO228- G 1/2 34 16 Fax: 0 68 97 / 509 - 464
00237884 00366608 2 Internet: www.hydac.com
* pmax= 400 bar E-Mail: speichertechnik@hydac.com
23
24
E 3.201.25/04.09
Operating and Installation
Instructions for HYDAC
Accumulators
1. General:
Prior to installation and during the operation of hydraulic accumulators, the regulations governing accumulators in the place of
installation must be observed. In the USA and Canada accumulators are subject to ASME Pressure Vessel Code. In addition,
HYDAC suggests a thorough inspection, including a pressure test, every 5 to 10 years depending upon the application.
HYDAC recommends the use of mounting components to minimize the risk of failure due to system vibrations; refer to HYDAC
Mounting Components brochure #02071834.
As part of the commissioning process, vent all air from the system piping once the hydraulics have been connected.
GAS CHARGING
! Pressurized Vessel -
Use Dry Nitrogen Only!
CAUTION
WARNING!
Hydraulic accumulators are pressurized vessels and only qualified technicians should perform repairs. Never weld, braze, or perform
any type of mechanical work on the accumulator shell. Never lift the accumulator by the gas valve. Always drain the fluid completely
from the accumulator before performing any work, such as recommended repairs (see Maintenance Instructions) or connecting pressure
gauges.
Always observe the maximum working pressure, operating temperature range, pressure ratio, recommended flow rate, and mounting
position. For details refer to specific HYDAC product literature. Never use car tire valve cores in accumulators. All defective parts
should be replaced with original HYDAC parts.
2. Precharging The Accumulator:
Precharge new or repaired accumulators with dry nitrogen gas to the proper gas precharge pressure (P0) prior to applying hydraulic
system pressure.
2.1 Recommended Gas Precharge Pressure (P0):
FOR ENERGY STORAGE P0 = 0.9 x P1
FOR SHOCK ABSORPTION P0 = (0.6 to 0.9) x Pm
FOR PULSATION DAMPENING P0 = (0.6 to 0.8) x Pm
P1 = minimum working pressure Pm = median working pressure
2.2 Procedure
Remove valve protection and valve seal caps (where applicable). Attach appropriate HYDAC charging and gauging unit (type FPS for
HYDAC gas valve version 4, type FPK for HYDAC gas valve version 1 and type FPK with adapter FPK/SB for top repairable bladder accumulators) to
the accumulator by following the instructions in the HYDAC Charging and Gauging Units brochure # 02071833. Once attached,
slowly open the shut-off valve on the commercially available nitrogen bottle and allow the gas to slowly enter the accumulator. The
first 20 to 25 PSI should take 2 to 3 minutes.
If gas precharge pressure is too low, continue charging; refer to HYDAC Charging and Gauging Units brochure #02071833.
If gas precharge is too high, it can be reduced by carefully opening the manual bleed valve and relieving some pressure.
Once the proper gas precharge pressure has been reached, disconnect the charging and gauging unit from the accumulator by
following the instructions in the HYDAC Charging and Gauging Units brochure. Check for leaks; NONE are permissible. Torque valve
seal cap (see torque requirements below) and hand tighten valve protection cap (where applicable).
Notes:
1) When using FPK unit DO NOT use the “T”-handle in the charging and gauging unit to loosen the socket head cap screw;
use a 6 mm Allen wrench.
2) HYDAC diaphragm accumulators with gas port version E2 are factory precharged and sealed with a welded steel plug. The gas
precharge pressure CANNOT be adjusted.
Torque Requirements:
Gas valve Version 1 - socket head cap screw - 20 Nm (15 lb-ft)
- valve protection cap - hand tighten (where applicable)
Gas Valve Version 4 - gas valve core - 0.5 Nm (0.4 lb-ft)
- valve seal cap - 30 Nm (22 lb-ft)
- valve protection cap - hand tighten (where applicable)
2.3 Temperature Effects:
To ensure that the recommended gas precharge pressure is maintained, even at relatively low or high operating temperatures,
the gas precharge pressure should be adjusted for temperature; refer to HYDAC Charging and Gauging Units brochure #02071833.
When adjusting an existing gas precharge pressure allow 5 to 10 minutes for the gas precharge pressure to reach equilibrium.
When precharging for the first time or after performing maintenance work, allow 20 to 30 minutes for the gas precharge pressure
to reach equilibrium.
3 Checking Gas Precharge Pressure:
The gas precharge pressure on gas port version E2 can only be checked using the method described in paragraph 3.2.
3.1 Measuring Gas Precharge Pressure on the Gas Side:
To check precharge pressure, attach HYDAC charging and gauging unit by following the instructions in the HYDAC Charging
and Gauging Units brochure #02071833. Once attached, turn “T” handle until pressure registers on gauge. Adjust gas precharge
pressure if necessary (refer to paragraph 2).
3.2 Measuring Gas Precharge Pressure on the Fluid Side:
This method requires that a pressure gauge be installed on the safety and shut-off block (fig. 1, item 2) or similar device, which
is connected directly to the accumulator. The procedure utilizing the SAB Block is as follows:
- Using hydraulic system pressure fill accumulator with fluid.
© Copyright 2005 HYDAC CORPORATION - Brochure - Operating & Installation Instructions for HYDAC Accumulators #02068196 / 2.05
- Close shut-off valve (fig. 1, item 3).
- Discharge fluid slowly, by opening the manual bleed valve (fig. 1, item 4).
- While draining the fluid, monitor the pressure gauge closely. The pressure in the gauge will suddenly drop to zero;
the pressure indicated immediately prior to this sudden drop is the gas precharge pressure.
3.3 Intervals Between Checking:
The gas precharge pressure should be checked at least once during the first week of operation. If there is no loss of gas
precharge pressure, it should be rechecked in 3 to 4 months. Thereafter, it should be checked at least once a year.
4 Safety Equipment
HYDAC recommends that the following safety equipment be used in conjunction with accumulators:
4.1 Safety and Shut-off Block:
The Hydac safety and shut-off block (see fig. 1) was designed to incorporate the following safety features:
- Pressure measurement device.
- Pressure relief device.
- Shut-off device.
- Bleed down device (manual or electric operation).
- Locking device
4.2 Thermal Fuse Cap:
In addition to the above, HYDAC also recommends the use of its Thermal Fuse Cap to release gas pressure in the event of a fire.
Fig. 1; Schematic of a HYDAC Safety and Shut-off Block:
6
2 5
4 1
1 - pressure relief valve

2 - pressure gauge (optional)
3 - shut-off valve
4 - manual bleed valve
5 - solenoid operated bleed valve (optional)
6 - thermal fuse cap (optional)
HYDAC CORPORATION • Accumulator Division

2280 City Line Road • Bethlehem, PA 18017
Phone (610) 266-0100 • Fax (610) 264-7529
www.hydacusa.com
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.12 Ball Valve
Series 16i Ball Valves
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.13 Check Valve
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.14 Pump Bypass Valve & Accumulator Drain Valve
VB16 Series Integral Bonnet Needle Valves
Pressure Rating up to 6000 psig Jan. 2004
Specification sheet # VB16-2
Features Temperature and Pressure Ratings

Two-piece chevron-style PTFE stem packing design Ratings are based on valves with PFA chevron packing.
with compensating disc springs Valve Stem Temperature Pressure Rating
z reduces packing friction wear Series Rating C (F) At 37 C (100 F)
z reduces valve operating torque Vee -53 to 232
z reduces load to seal VB16A Metal Seat (-65 to 450) 413 bar
VB16B PCTFE -53 to 93 (6000 psi)
Packing is supported by lower and upper Glands as well as Soft Seat (-65 to 200)
compensating disc springs
z reduces need for packing adjustment
Inline pattern Angle pattern
Material of Construction
No. Component Material
1 Body S316L
2 Stem S316L
3 Lower Gland S316L
4 Lower Packing PTFE
5 Upper Packing PTFE
6 Upper Gland S316L
7 Packing Springs 17-7PH
8 Gland Nut S316L
9 Bar Handle S316
10 Locking Pin S316
11 Set Screw S316
Ordering Information and Table of Dimensions Unit: mm (in.)

Valve End Connection Dimensions, mm (inch)
Ordering Number Inlet Outlet A A1 E B L L1 L2 C L3 D H
42.2 11.2 25.4 47.8 36.6 25.4
F-4N 1/4" Female NPT (1.66) (0.44) (1.00) (1.88)
23.9 (0.94)
(1.44) (1.00)
49.3
M-4N 1/4" Male NPT 24.6 (0.97)
VB16A- (1.94)
-
47.8 10.7
F-4R 1/4" Female ISO 7/1 (1.88)
23.9 (0.94)
(0.42)
Cv 0.21 41.7 44.4
(1.64) 26.2 48.5 24.6 23.9 36.6 25.4 (1.75)
Orifice: MF-4N 1/4" Male NPT 1/4" Female NPT
3.2mm (0.125 in.) (1.03) (1.91) (0.97) (0.94) (1.44) (1.00)
42.2 11.2 29.5 62.5
D-4T 1/4" Dk-Lok (1.66) (0.44) (1.16) (2.46)
31.2 (1.23)
39.9 28.7
25.4 (1.57) (1.13)
MD-4N4T 1/4" Male NPT 1/4" Dk-Lok (1.00)
- - - -
F-6N 3/8" Female NPT - - - -

35.8
58.7 16.8 35.8 52.3 (1.41)
F-8N 1/2" Female NPT
VB16B- (2.31) (0.66) (1.41) 71.4 (2.06)
31.8 (1.25)
(2.81) 31.8
F-8R 1/2" Female ISO 7/1 - - - -
(1.25)
Cv 0.73
Orifice: 31.0 b 35.8 16.8
MF-6N 3/8" Male NPT 3/8" Female NPT (1.22) (1.41) (0.66)
6.4mm (0.250 in.) 58.7 58.7 16.8 52.3 64.0
(2.31) (2.31) (0.66) 64.8 33.0 31.8 (2.06) 35.6 (2.52)
MF-8N 1/2" Male NPT 1/2" Female NPT 35.8 (2.55) (1.30) (1.25) (1.40)
(1.41) 63.5
MF-12N8N 3/4" Male NPT 1/2" Female NPT (2.50)
31.8 (1.25)
78.2
D-6T 3/8" Dk-Lok - -
(3.08)
39.1 (1.54) - -
83.8
D-8T 1/2" Dk-Lok (3.30)
41.9 (1.65)
Flow Data
Cv are measured at the valve. Therefore restrictions in end connections may reduce flow.
Factory Test
Every valve is tested with the nitrogen @68 bar (1000 psig) for leakage at the seat to
a maximum allowance leak rate of 0.1 scc/min. The stem packing is tested for no detectable leakage.
Dk Tech Corporation
www.dklok.com
www.dklokusa.com
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.15 Solenoid Valve
Pilot Operated 3/2
4 Quick Exhaust Solenoid Valves
Brass or Stainless Steel Bodies
SERIES
8317
1/4" and 3/8" NPT 8321
Features
3-WAY
• Designed for quick venting to 0 psi through the % ^ )
exhaust orifice
• Resilient seated poppets for tight shutoff
• Air is exhausted to quickly shift control valves
• Multi-industry applications
• Mountable in any position
Construction
Valve Parts in Contact with Fluids
Body Brass 304 Stainless Steel
Seals and Disc NBR (PA upper disc for 8317 Series)
Diaphragm CR (8317 Series only)
Core Tube 305 Stainless Steel
8317 8321
Core and Plugnut 430F Stainless Steel 2 A
NC
Core Springs 302 Stainless Steel and 17-7 PH Stainless Steel 34 1 E P
Shading Coil Copper Silver NO

Pilot Seat Cartridge and
CA (8321 Series only)
Disc-Holder
Piston Brass and 303 Stainless Steel (8321 only)
Electrical
Watt Rating and Power
Consumption Spare Coil Part Number
Standard
Coil and AC General Purpose Explosionproof
Class of DC VA VA
Insulation Watts Watts Holding Inrush AC DC AC DC
F 10.6 6.1 16 30 238210 238310 238214 238314
8317
F 11.6 10.1 25 50 238610 238710 238614 238714
Standard Voltages: 24, 120, 240, 480 volts AC, 60 Hz (or 110, 220 volts AC, 50 Hz).
6, 12, 24, 120, 240 volts DC. Must be specified when ordering.
Nominal Ambient Temp. Ranges
Other voltages available when required. AC: 32˚F to 125˚F (0˚C to 52˚C)
DC: 32˚F to 104˚F (0˚C to 40˚C)
Refer to Engineering Section for details.
Approvals
Solenoid Enclosures
CSA certified. UL listed General Purpose Valves.
Standard: Watertight, Types 1, 2, 3, 3S, 4, and 4X. Meets applicable CE directives.
Optional: Explosionproof and Watertight, Types 3, 3S, 4, 4X, 6, 6P, 7, and 9. Refer to Engineering Section for details.
(To order, add prefix “EF” to the catalog number.)
See Optional Features Section for other available options. Important
A Minimum Operating Pressure Differential must be
maintained between the pressure and exhaust ports.
Supply and exhaust piping must be full area, unrestricted.
ASCO flow controls and other similar components must
8317_8321R2 be installed in the cylinder lines only.
55
3/2
SERIES
8317
8321
4
Specifications (English units)
3-WAY
Orifice Cv Operating Pressure Max. Watt Rating/

Size Flow Differential (psi) Fluid Brass Body Stainless Steel Body Class of Coil
(ins.) Factor Max. AC Max. DC Temp. ˚F Insulation
Pipe
Size Air-Inert Lt. Oil Air-Inert Lt. Oil Catalog Const. Catalog Const.
(ins.) Press. Exh. Press. Exh. Min. Gas Water @45 SSU Gas Water @45 SSU AC DC Number Ref. Number Ref. AC DC
NORMALLY CLOSED (Pressure at Port 2) / NORMALLY OPEN (Pressure at Port 3)
1/4 3/32 1/4 .20 .73 5 80 50 50 40 30 15 180 104 8317G007 2 8317G008 4 10.1/F 11.6/F
NORMALLY CLOSED (Closed when de-energized)
1/4 3/32 1/4 .20 .73 5 150 150 95 75 55 30 180 104 8317G035 2 8317G036 4 10.1/F 11.6/F
1/4 9/32 11/32 .80 1.2 10 200 200 200 200 200 200 180 120 8321G001 3 - - 6.1/F 10.6/F
3/8 9/32 11/32 .80 1.2 10 200 200 200 200 200 200 180 120 8321G002 3 - - 6.1/F 10.6/F
NORMALLY CLOSED (Closed when de-energized), Air Only - Vents to Atmosphere
1/4 3/32 1/4 .20 .73 5 150 - - - - - 180 - 8317G023 1 8317G024 5 10.1/F -
NORMALLY OPEN (Open when de-energized)
1/4 3/32 1/4 .15 .73 5 160 160 95 75 45 25 180 104 8317G053 2 8317G054 4 10.1/F 11.6/F
1/4 9/32 11/32 .80 1.2 10 200 200 200 200 200 200 180 120 8321G003 3 - - 6.1/F 10.6/F
3/8 9/32 11/32 .80 1.2 10 200 200 200 200 200 200 180 120 8321G004 3 - - 6.1/F 10.6/F
Rating for 8321 valves established with 300 SSU light oil. Minimum Operating Pressure Differential on light oil is 10 psi.
On 50 hertz service, the watt rating for the 6.1/F solenoid is 8.1 watts.
Specifications (Metric units)

Orifice Kv Flow Operating Pressure Max. Watt Rating/
Size Factor Differential (bar) Fluid Brass Body Stainless Steel Body Class of Coil
(mm) (m3/h) Max. AC Max. DC Temp.°C Insulation
Pipe
Size Air-Inert Lt. Oil Air-Inert Lt. Oil Catalog Const. Catalog Const.
(ins.) Press. Exh. Press. Exh. Min. Gas Water @45 SSU Gas Water @45 SSU AC DC Number Ref. Number Ref. AC DC
NORMALLY CLOSED (Pressure at Port 2) / NORMALLY OPEN (Pressure at Port 3)
1/4 2 6 .17 .63 .3 6 3 3 2.7 2 1 82 40 8317G007 2 8317G008 4 10.1/F 11.6/F
NORMALLY CLOSED (Closed when de-energized)
1/4 2 6 .17 .63 .3 10 7 7 5 4 2 82 40 8317G035 2 8317G036 4 10.1/F 11.6/F
1/4 7 9 .69 1.0 .7 14 14 14 14 14 14 82 49 8321G001 3 - - 6.1/F 10.6/F
3/8 7 9 .69 1.0 .7 14 14 14 14 14 14 82 49 8321G002 3 - - 6.1/F 10.6/F
NORMALLY CLOSED (Closed when de-energized), Air Only - Vents to Atmosphere
1/4 2 6 .17 .63 .3 10 - - - - - 82 - 8317G023 1 8317G024 5 10.1/F -
NORMALLY OPEN (Open when de-energized)
1/4 2 6 .13 .63 .3 11 11 7 5 3 2 82 40 8317G053 2 8317G054 4 10.1/F 11.6/F
1/4 7 9 .69 1.0 .7 14 14 14 14 14 14 82 49 8321G003 3 - - 6.1/F 10.6/F
3/8 7 9 .69 1.0 .7 14 14 14 14 14 14 82 49 8321G004 3 - - 6.1/F 10.6/F
Rating for 8321 valves established with 300 SSU light oil. Minimum Operating Pressure Differential on light oil is .7 bar.
On 50 hertz service, the watt rating for the 6.1/F solenoid is 8.1 watts.
8317_8321R2
56
3/2
SERIES
4 8317
8321
Dimensions: inches (mm)
3-WAY
Const.
Ref. H K L P W
ins. 4.04 1.55 2.05 3.54 2.00
2
mm 103 39 52 90 51
ins. 4.02 1.53 2.02 3.52 2.00
4
mm 102 39 51 89 51
Const. Ref. 1, 5
Const. Ref. 2, 4
8317_8321R2
57
3/2
SERIES
8317
8321
4
Dimensions: inches (mm)
3-WAY
Const. Ref. 3
8317_8321R2
58
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.16 Air Breather
Tank Breather Filter
with Filler Strainer ELF
up to 5500 l/min
ELF 4 ELF 10 ELF 3 ELFL 3 ELF 30 ELF 7 ELF 72 ELF 5 ELF 52
1. TECHNICAL 1.3 FILTER SPECIFICATIONS

SPECIFICATIONS Temperature range -30 °C to +100 °C
1.1 FILTER HOUSING Material of housing Steel, zinc-plated/plastic coated
Construction (ELF 4, 3), steel (ELF 5, 52)
Tank breather filters size 4, 10, 3 and glass fibre reinforced synthetic material
30 consist of an air filter top, which is (ELF 10, 30, 7, 72)
connected to the mounting flange by a Material of filler strainer Synth. material: ELF 10, 4, 30, 3, 7, 72
bayonet plate or a threaded boss, and Metal: ELF 5, 52
a filler strainer.
Type of clogging indicator VMF (return line indicator)
Sizes 5 and 52 consist of a two-part
threaded air filter top, with built-in oil Pressure setting of clogging indicator 0.6 bar K pressure gauge
mist trap, one or two exchangeable 0.035 bar UBM indicator
filter element(s) and a filler strainer. (others on request)
Sizes 7 and 72 consist of a two-part
flanged filter top, an exchangeable 1.4 seals Biodegradable fluids
filter element and a filler strainer. NBR (= Perbunan) on filter ELF HTG HE HPG
1.2 FILTER ELEMENTs NBR/polyurethane on element PAG PRG
Cardboard on mounting flange all
Contamination retention capacities in g sizes + +
P
aper
1.5 special models and  
ELF 3 µm 10 µm accessories + suitable for all
 contact our Technical Sales Department
4 2.9 4.1 zzlockable model (only ELFL 3)
– not suitable
10 2.9 4.1 zzwith check/bypass valve to support the
3 6.2 8.7 suction characteristics of the pump zzHTG vegetable oil based hydraulic
30 6.2 8.7 Not 100% air-tight or leakage-free! fluids
7 26.1 36.7 (only ELF 10, 3, 30, 5 and 52)
72 52.2 73.4 zzHE ester-based synthetic hydraulic
5 85.1 119.6
zzwith anti-splash device fluids
52 170.2 239.2 (only ELF 10, 3, 30, 7, 72)
zzHPG polyglycol-based synthetic
zzwith connection for a clogging indicator
The filter elements are made from phenolic hydraulic fluids
resin impregnated paper and cannot (only ELF 7, 72)
therefore be cleaned! zzwith filler adaptor for automotive zzPAG sub-group HPG:
applications polyalkalene glycol
(only ELF 7 and 72) - see point 5. zzPEG sub-group HPG:
1.6 SPARE PARTS polyethylene glycol
See Original Spare Parts List
1.9 CHANGING INTERVALS
1.7 CERTIFICATES AND APPROVALS
On request The breather filter elements or filters
1.8 COMPATIBILITY WITH must be replaced as frequently as the
HYDRAULIC FLUIDS ISO 2943 fluid filters, but at least once a year.
The standard models are suitable for
use with mineral and lubrication oils.
For non-flam and biodegradable oils, Symbol
see tables:
Non-flam fluids
ELF HFA HFC HFD-R
4, 10, 3, 30 – – –
7, 72, 5, 52   – air filter
zzHFA oil in water emulsion

(H2O content ≥ 80%)
strainer
zzHFC water polyglycol solution
E 7.404.0/02.08
(H2O content 35-55%)

zzHFD-R synthetic, water free
phosphate ester
277
2. model code (also order example) 2.1.3 ELF 5 and 52
2.1 complete FILTER ELF P 52 G 3 W 2 . X /-RV0.4
2.1.1 ELF 4, 10, 3, 30 and ELFL 3 Filter type
ELF
ELF P 30 F 3 W 1 . X /-RV0.4
Filter type Filter material
ELF P Paper
ELFL (lockable) BN Betamicron®
Filter material
P Paper Size
Size ELF 5, 52
ELF 4, 10, 3, 30
ELFL 3 Type and size of connection
Type and size of connection Filter size
Filter size 5 52
4 10 3 30 G1 1/2  
F = Flange     G = Thread G2  
Filtration rating in µm G2 1/2  
P 3 (absolute) G3  
W no port for clogging indicator Filtration rating in µm
Type code P 3 (absolute)
Size Code ∆p [bar] BN 3 (absolute)
ELF 4 1.X -
ELF 10 1.X - Type of clogging indicator
ELF 3 1.X - W no port for clogging indicator
ELF 3.../-RV 4.X 0.4
ELF 3.../-RV 5.X 0.7 Type code
ELF 3.../-RV 6.X 0.2 Code Connection
ELF 3.../-RV 7.X 1.0 2.X G 2½
ELF 30 1.X - 3.X G3
Modification number 4.X G2
5.X G 1½
AS anti-splash without check/bypass valve (not ELF 3 & 4) Modification number
RV check/bypass valve (not ELF 4) X the latest version is always supplied
RV0.2 valve with relevant cracking pressure
RV0.4 (only ELF 10 and 30)
RV0.7 Supplementary details
SO148 metal filler strainer, 200 mm long (only ELF 3 and 30) RV0.4 check/bypass valve with 0.4 bar pressure setting
SO175 metal filler strainer, 100 mm long (only ELF 3 and 30)
2.1.2 ELF 7 and 72 2.2 REPLACEMENT ELEMENT

ELF P 72 F 3 W 1 . X /-SO148 0005 L 003 P
Filter type Size
ELF 0005 for ELF 5, 52
Filter material 0007 for ELF 7
P Paper 0072 for ELF 72
Size Type
ELF 7, 72 L
Type and size of connection
Filter size Filtration rating in µm
7 72 P 003
BN 003 (only for 0005)
F = Flange DIN 24557/Pt2  
Filtration rating in µm Filter material
P 3 (absolute) P Paper
BN Betamicron®
W no port for clogging indicator
K pressure gauge Replacement elements cannot be ordered for ELF 4, 10, 3, 30 and
(measuring range: -1 to +0.6 bar) ELFL 3. These filters are only available complete !
UBM visual/analogue vacuum gauge
with manual reset 2.3 REPLACEMENT CLOGGING INDICATOR
(pressure setting: -0.035 bar)
VMF 0.6 K . X
Type code
0 for type UBM Type
VMF Return line indicator
1 for types W and K
Modification number Pressure setting
X the latest version is always supplied 0.6 -1 to +0.6 bar
Supplementary details 0.035 -0.035 bar
AS anti-splash (only ELF 7, 72 without check/bypass valve) Type
SO148 metal filler strainer, 200 mm long (see point 2.1)
E 7.404.0/02.08
SO175 metal filler strainer, 100 mm long Modification number

SO394 ELF filter without strainer X the latest version is always supplied
278
3. FILTER CALCULATION / 3.3 SIZING GUIDELINES ELF 3
SIZING For ease of calculation, our Filter
Sizing Program is available on request
3.1 SINGLE PASS FILTRATION free of charge.
PERFORMANCE DATA FOR AIR
∆p [bar]
NEW: Sizing online at www.hydac.com
FILTER ELEMENTS The rate at which contamination
The following separation values were enters a hydraulic system can be
established under real-life simulated considerably reduced by using efficient
conditions. This means that the tank breather filtration.
selected velocity of the flow against NOTE:
the filter mesh was 20 cm/s and the Incorrectly sized breather filters can Q [l/min]
contamination added was 40 mg/m3 of place additional strain on the system
ISO MTD test dust. and reduce the service life of hydraulic ELF 30
Filtration Retention For particle Filter filter elements.
rating value d.. size material For optimum sizing the following
3 µm d 80 0.74 µm should therefore be observed:
d 100 2.64 µm Paper zzFiltration rating of air breather filter ≤
∆p [bar]
10 µm d 80 1.49 µm filtration rating of hydraulic filter
d 100 9.56 µm zzOnly use air breather filters with an
10 µm d 80 0.25 µm BN absolute retention rate (d100 ≤ x µm;
d 100 0.84 µm x = given filtration rating)
The d 80 value refers to the particle zzMax. permissible initial pressure loss:
size which is filtered out at a rate of 0.01 bar (with a clean filter element
and calculated air flow rate) Q [l/min]
80% during the retention test. The
particle size determined by this zzDetermination of the calculated air
flow rate: ELF 7
method is called the nominal filtration
rating of the air filter. The d 100 QA = f5 x Qp
value therefore refers to the particle QA = air flow rate for sizing purposes
size which is filtered out at a rate of in lN/min
∆p [bar]
100% during the single-pass test. f5 = factor for operating conditions
The particle size determined by this Qp = max. flow rate of the hydraulic
method is called the absolute filtration pump in l/min
rating of the air filter. Ambient conditions Factor f5
Table of average dust concentrations Low dust concentration;
in real life: filter fitted with clogging indicator; 1-2
Urban regions with 3-7 mg/m³ air continuous monitoring of the filter Q [l/min]
a low level of industry Average dust concentration;
General mechanical 9-23 mg/m³ air filter without clogging indicator; 3-6 ELF 72
engineering intermittent monitoring of the filter
Construction industry 8-35 mg/m³ air High dust concentration;
(wheeled vehicles) filter without clogging indicator; 7-10
infrequent or no monitoring of the
∆p [bar]
Construction industry 35-100 mg/m³ air

filter
(tracked vehicles)
Heavy industry 50-70 mg/m³ air
3.4 air flow rate
3.2 DIFFERENTIAL PRESSURE
ACROSS BREATHER FILTer ELF 4
The differential pressure (with clean
element) for the various filter sizes is Q [l/min]
shown in the graphs under point 3.4.
∆p [bar]
ELF 5
∆p [bar]
Q [l/min]
ELF 10
Q [l/min]
∆p [bar]
ELF 52
∆p [bar]
Q [l/min]
E 7.404.0/02.08
Q [l/min]
279
4. DIMENSIONS
ELF 4 ELF 10 ELF 3
M 5x12 DIN 7500
ELFL 3
Interface DIN 24557/Part 2
ELF 4... ELF 10... ELF 3.../ELFL 3...

d1 44 d1 54 d1 76
d2 50 d2 49 d2 83
d3 28 d3 28 d3 49
d4 41.3 d4 30 d4 73
d5 30 d5 41.3 d5 60
d6 4.5 d6 4.5 d6 4.5
h1 135 h1 158 d7 8
h2 81.5 h2 82 h1 159
h3 53.5 h3 76 h2 96.5
Weight 0.20 kg h4 38 h3 61.5
h5 6 h4 21
Weight 0.08 kg h5 31
E 7.404.0/02.08
l1 67.5
l2 57.5
Weight 0.25 kg
280
ELF 30 ELF 7 ELF 72
countersunk slotted
screw M5x16 DIN 963
countersunk
slotted screw M5x16
DIN 963
Interface to DIN 24557/Part 2 Interface to DIN 24557/Part 2 Interface to DIN 24557/Part 2
ELF 30... ELF 7... ELF 72...

d1 83 d1 116 d1 116
d2 83 d2 120 d2 120
d3 49 d3 47 d3 47
h1 185 d4 73 d6 M5
h2 100 d5 60 h1 236
h3 85 d6 M5 h2 97
h4 40 h1 181 h3 139
h5 5 h2 97 h4 60
Weight 0.23 kg h3 84 b1 44
h4 60 Weight 0.58 kg
b1 44
Weight 0.38 kg
E 7.404.0/02.08
281
5. filler adaptor
ELF 5 ELF 52 This adaptor can only be used on
ELF 7 and ELF 72 filters!
flange interface
to DIN 24557
ELF 5... ELF 5... ELF 52... ELF 52... These filler adaptors are available in
/-RV /-RV the following threaded connections:
d1 177 d1 177
d3 68 d3 68 zzAdaptor ELF /-FA12 (G ½)
...2.X G 2½ ...2.X G 2½ (Part No.: 03100932)
d8 ...3.X G 3 d8 ...3.X G 3
...4.X G 2 ...4.X G 2 zzAdaptor ELF /-FA34 (G ¾)
(Part No.: 03100933)
...5.X G 1½ ...5.X G 1½
h1 350 360 h1 416 438
zzAdaptor ELF /-FA1 (G 1)
h2 240 h2 240
(Part No.: 03100931)
h3 105 126 h3 176 198
h6 25 h6 25
h7 90 h7 125 112
SW 90 SW 90
...2.X 2.70 kg ...2.X 3.10 kg
Weight ...3.X 3.10 kg Weight ...3.X 3.50 kg
...4.X 2.70 kg ...4.X 3.10 kg
...5.X 2.60 kg ...5.X 3.00 kg

E 7.404.0/02.08
Tel.: 0 68 97 / 509-01
Fax: 0 68 97 / 509-300
282
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.17 Pressure Indicator
Mechanical
Pressure Measurement
Bourdon Tube Pressure Gauges

Stainless Steel Series
Model 232.50/233.50, without/with Liquid Filling
WIKA Data Sheet PM 02.02
Applications
 With liquid-filled case for applications with high dynamic

pressure pulsations or vibrations
 For gaseous and liquid aggressive media that are
not highly viscous or crystallising, also in aggressive
ambience
 Process industries: chemical/petro-chemical, power
stations, mining, on and offshore, environmental tech-
nology, machine building and plant construction
Special Features
 Excellent load-cycle stability and shock resistance

 All stainless steel construction
 German Lloyd, Gosstandart and DVGW approval
 Scale ranges up to 0 … 1600 bar
Bourdon Tube Pressure Gauge Model 232.50
Description Pressure limitation

NS 63: Steady: 3/4 x full scale value
Design Fluctuating: 2/3 x full scale value
EN 837-1 Short time: full scale value
Nominal size in mm NS 100, 160: Steady: full scale value
63, 100, 160 Fluctuating: 0.9 x full scale value
Short time: 1.3 x full scale value
Accuracy class
NG 63: 1.6 Operating temperature
NG 100, 160: 1.0 Ambient: -40 ... +60 °C without liquid filling
-20 ... +60 °C gauges with glycerine filling
Scale ranges
Medium: +200 °C maximum without liquid filling
NS 63: 0 ... 1 to 0 ... 1000 bar
+100 °C maximum with liquid filling
NS 100: 0 ... 0.6 to 0 ... 1000 bar
NS 160: 0 ... 0.6 to 0 ... 1600 bar Temperature effect
or all other equivalent vacuum or combined pressure and When the temperature of the measuring system deviates
vacuum ranges from the reference temperature (+20 °C):
max. ±0.4 %/10 K of full scale value
Ingress protection
IP 65 per EN 60 529 / lEC 529
WIKA Data Sheet PM 02.02 ·∙ 02/2009 Page 1 of 2
Data Sheets showing similar devices:

Stainless steel series; model 232.30; see data sheet PM 02.04
Standard version Options
Process connection  O ther process connection
Stainless steel 316L (NS 63: 1.4571),  A  ssembly on diaphragm seals see product review DS
lower mount (LM) or lower back mount (LBM) 1)  M  onel pressure system (model 26X.50, not with NS 160
NS 63: G ¼ B (male), 14 mm flats back connection)
NS 100, 160: G ½ B (male), 22 mm flats  Pressure system stainless steel 1.4571
 Surface or panel mounting flange, stainless steel
Pressure element  Panel mounting flange, stainless steel, polished
Stainless steel 316L,  Triangular bezel, stainless steel, polished, with clamp
< 100 bar: C-type  Ambient temperature -40 °C: silicon oil filling
≥≥ 100 bar: helical type  Switch contacts (see data sheet AC 08.01)
 Pressure gauge with electrical output signal,
Movement see Model PGT23.100/160, data sheet PV 12.04
Stainless steel  Version per ATEX Ex II 2 GD c
Dial
Standard version
Aluminium, white, black lettering,
NS 63 with pointer stop pin Lower mount (LM)
≤≤ 16 bar with compensating valve
> 16 bar without compensating valve
Pointer
Aluminium, black
1520806.03
Case
Stainless steel, with pressure relief in case top (NS 63) or in
case back (NS 100 and 160),
ranges ≤ 0 ... 16 bar with compensating valve to vent case
Window: Laminated safety glass (NS 63: Polycarbonate)
Bezel ring: Cam ring (bayonet type), stainless steel
Liquid filling (for Model 233.50): Glycerine 99.7 % Lower back mount (LBM) 1)
≤≤ 16 bar with compensating valve
1520814.03
> 16 bar without compensating valve
Special versions
Gauges for ammonia plants (NS 100 and 160)
With temperature scale for refrigerant R 717 (NH3) in °C,
scale ranges: -1 ... 0 ... 15 bar or -1 ... 0 ... 26 bar
Dimensions in mm
NS Dimensions in mm Weight in kg
a b b1 b2 D1 D2 e f G h±1 SW Model 232.50 Model 233.50
63 9.5 33 33 57 63 62 11.5 - 1) G¼B 54 14 0.16 0.20
100 15.5 49.5 49.5 83 101 99 17.5 30 G½B 87 22 0.60 0.90
160 15.5 49.5 3) 49.5 2) 83 2) 161 159 17.5 50 G½B 118 22 1.10 2.00
Process connection per EN 837-1 / 7.3 2) Plus 16 mm with pressure ranges ≥ 100 bar
1) NS 63: Centre back pressure entry (CBM) 3) Plus 16 mm with pressure range 1600 bar
Ordering information
Model / Nominal size / Scale range / Connection size / Connection location / Options
Modifications may take place and materials specified may be replaced by others without prior notice.
Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
9019723 02/2009 GB
Page 2 of 2 WIKA Data Sheet PM 02.02 ·∙ 02/2009
WIKA Alexander Wiegand GmbH & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Tel. (+49) 9372/132-0
Fax (+49) 9372/132-406
E-mail info@wika.de
www.wika.de
Operating 1. Safety device is fitted to a pressure gauge, it must
Instructions GB WARNING!
be protected against being blocked by debris
and dirt. With safety pressure gauges (see dial
Before installation, commission- symbol k) it must be ensured that the free space
ing and operation, ensure that the behind the blow-out back is at least 15 mm.
Pressure Gauges appropriate pressure gauge has After mounting, set the compen-
been selected in terms of measur- sating valve (if available) from
ing range, design and suitable wetted material CLOSE to OPEN.
(corrosion) for the specific measuring conditions. With models 4 and 7, do not open the flange
Examples: In order to guarantee the measuring accuracy mounting screws.
and long-term stability specified, the corre-
sponding load limits must be observed. Requirements for the installation point
Only qualified persons authorised by the plant If the line to the gauge is not sufficiently rigid for
manager are permitted to install, maintain and vibration-free mounting, a pipe-support bracket
service the pressure gauges. should be used to secure it (possibly via a flexi-
Model 732.14, ble capillary). If vibration cannot be prevented
Overpressure safety For hazardous media such as oxygen, acety-
through suitable installation, liquid-filled gauges
up to 400 bar lene, flammable or toxic gases or liquids, and
should be used. The instruments should be
Model 432.36, refrigeration plants, compressors, etc., in
protected against coarse dirt and wide fluctua-
Overpressure safety addition to all standard regulations, the appro-
tions in ambient temperature.
up to 400 bar priate existing codes or regulations must also be
followed.
Model 213.40 3. Permissible ambient and operating
After an external fire, pressure media can leak temperatures
out, particularly at soft solder joints. All gauges
must be checked and, if necessary, replaced When mounting the pressure gauge it must be
before recommissioning the plant. ensured that, taking into consideration the influ-
Non-observance of the respective regulations ence of convection and heat radiation, no devia-
Notes in accordance with Pressure Equipment can result in serious injury and/or damage to tion above or below the permissible ambient and
Directive 97/23/EC equipment. medium temperatures can occur. The influence
of temperature on the display accuracy must be
The pressure gauges are "pressure accessories"
2. Mechanical connection observed.
in accordance with Article 1, Paragraph 2.1.4
The volume of the pressure bearing housings of In accordance with the general technical regula-
WIKA pressure gauges is < 0.1 L 4. Storage
tions for pressure gauges (e.g. EN 837-2). When
The pressure gauges carry CE marking for Fluid screwing the gauges in the force required for
Group 1G in accordance with Annex 2, Table 1 The pressure gauge should be kept in its original
this must not be applied through the case or packing until installation. The gauge should be
when their permissible working pressure terminal box, rather only through the spanner
exceeds 200 bar protected from external damage during storage.
flats provided for this purpose (using a suitable Storage temperature range: -40 ... +70 °C.
Pressure gauges that do not carry the CE mark tool). Protect the gauges from humidity and dust.
are manufactured in accordance with Article 3,
Paragraph 3 "Sound engineering practice". Mounting with 5. Maintenance / Repairs
Applied standards spanner
EN 837-1 Bourdon tube pressure gauges, dimensions, The instruments are maintenance-free. Checks
metrology, requirements and testing should be carried out on a regular basis to
EN 837-2 Selection and installation recommendations Correct sealing of pressure gauge connections ensure the measuring accuracy of the pressure
for pressure gauges with parallel threads  must be made using gauge. The checks or recalibrations must be
EN 837-3 Diaphragm and capsule pressure gauges, suitable sealing rings, sealing washers or WIKA carried out by qualified skilled personnel with
dimensions, metrology, requirements and profile seals. The sealing of tapered threads (e.g. the appropriate equipment.
testing NPT threads) is made by providing the thread When dismounting, close the compensating
Specifications: see data sheet on www.wika.de  with additional sealing material such as, for valve (if available).
example, PTFE tape (EN 837-2).
Subject to technical modifications. WARNING!
© WIKA Alexander Wiegand SE & Co. KG 2009 Residual media in dismounted
Spanner flats Sealing by pressure gauges can result in a risk
2408976.03 02/2010
WIKA Alexander Wiegand SE & Co. KG the thread  to personnel, the environment and
Sealing face  equipment. Take sufficient precau-
63911 Klingenberg • Germany tionary measures.
Tel. (+49) 93 72/132-0 The torque depends on the seal used. Connect-
Fax (+49) 93 72/132-406 ing the gauge using a clamp socket or a union
E-Mail info@wika.de nut is recommended, so that it is easier to
www.wika.de orientate the gauge correctly. When a blow-out
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.18 Pressure Transmitter
<<Contents>> <<Index>>
General Model EJA510A and EJA530A

Specifications Absolute and Gauge Pressure
Transmitters
GS 01C21F01-00E [Style: S2]
The absolute and gauge pressure transmitter model

EJA510A and EJA530A can be used to measure
liquid, gas, or steam pressure. Both output a 4 to 20
mA DC signal corresponding to the measured pres-
sure, and also feature remote setup and monitoring
through communications with the BRAIN™ terminal
and CENTUM CS™ or µXL™ or HART® 275 host.
STANDARD SPECIFICATIONS
Refer to GS 01C22T02-00E for Fieldbus
communication type marked with “”.
PERFORMANCE SPECIFICATIONS
Zero-based calibrated span, linear output, wetted
parts material code ‘S’ and silicone oil.
Power Supply Effects “”
Reference Accuracy of Calibrated Span
0.005 % per Volt (from 21.6 to 32 V DC, 350 )
(including the effects of zero-based linearity, hyster-
esis, and repeatability, values are in absolute for FUNCTIONAL SPECIFICATIONS
EJA510A)
0.2 % of Span Span & Range Limits
(Values are in absolute for EJA510A)
0.075 % of Span, when/ HAC is specified
(EJA530A: A, B and C capsule) Measurement
Span and MPa psi (/D1) bar (/D3) kgf/cm2(/D4)
Range
0.12 % of Span, when/ HAC is specified
10 to 200 1.45 to 29
(EJA530A: D capsule) Span
kPa
0.1 to 2 0.1 to 2
A
Range 0 to 200 0 to 29 0 to 2 0 to 2
For spans below X, kPa
X Span 0.1 to 2 14.5 to 290 1 to 20 1 to 20
[0.050.15 ] % of Span B
Span Range 0 to 2 0 to 290 0 to 20 0 to 20
X Span 0.5 to 10 72.5 to 1450 5 to 100 5 to 100
[0.0250.05 ] % of span, when/ HAC is C
Span Range 0 to 10 0 to 1450 0 to 100 0 to 100
specified (EJA530A: A, B and C capsule) Span 5 to 50 720 to 7200 50 to 500 50 to 500
D
Range 0 to 50 0 to 7200 0 to 500 0 to 500
X
[0.030.09 ] % of span, when/ HAC is T01E.EPS
Span URL is defined as the Upper Range Limit from the
specified (EJA530A: D capsule) table above.
Where X equals:
Capsule X MPa {psi} Zero Adjustment Limits
A 20 kPa {2.9} Zero can be fully elevated or suppressed, within the
A with/ HAC 40 kPa {5.8} Lower and Upper Range Limits of the capsule.
B 0.2 {29} External Zero Adjustment “”
C 1 {145} External zero is continuously adjustable with 0.01 %
D 8 {1160} incremental resolution of span. Span may be
Ambient Temperature Effects adjusted locally using the digital indicator with range
Total Effects per 28 C (50 F) Change switch.
[0.15% Span 0.15% URL] Mounting Position Effect
Stability Rotation in diaphragm plane has no effect. Tilting up
0.1% of URL per 12 months to 90 will cause zero shift up to 0.27 kPa {1.1 inH2O}
which can be corrected by the zero adjustment.
Vibration Effects
0.1 % of URL Output “”
(5 to 15Hz; 4mm peak-to-peak constant displace- Two wire 4 to 20 mA DC output with digital communi-
ment, 15 to 150Hz; 2g, 150 to 2000Hz; 1g) cations. BRAIN or HART FSK protocol are superim-
posed on the 4 to 20 mA signal.
Yokogawa Electric Corporation GS 01C21F01-00E

2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 Japan ©Copyright Apr. 1999
Phone: 81-422-52-5690 Fax.: 81-422-52-2018 16th Edition Mar. 2006
<<Contents>> <<Index>> 2
Failure Alarm Minimum Pressure Limit
Output status at CPU failure and hardware error; See graph below.
Up-scale: 110%, 21.6 mA DC or more (standard)
Down-scale: -5%, 3.2 mA DC or less 100{750}
-2.5%, 3.6 mA DC or less (Optional
code /F1)
Note : Applicable for Output signal code D and E.
Damping Time Constant (1st order)
The sum of the amplifier and capsule damping time 10{75}
constant must be used for the overall time constant.
Amp damping time constant is adjustable from 0.2 to
64 seconds. 2.7{20}
Working
Capsule (Silicone Oil) A, B, C, and D pressure Applicable range
kPa abs 1{7.5}
Time Constant (approx. sec) 0.2 {mmHg abs}
Ambient Temperature Limits

(approval codes may affect limits) 0.13{1}
-40 to 85 C (-40 to 185 F) 0.1{0.75}
-30 to 80 C (-22 to 176 F) with LCD Display
Process Temperature Limits
(approval codes may affect limits)
-40 to 120 C (-40 to 248 F) 0.013{0.1}
0.01{0.075} -40 0 40 80 120 (248)
Ambient Humidity Limits
(-40) (32) (104) (176) 85
5 to 100 % RH @ 40 C (104 F)
(185)
Maximum Overpressure Process temperature C(F)
F01E.EPS
Capsule Figure 1. Working Pressure and Process Temperature

Capsule EJA510A EJA530A [For model EJA510A]
A 4 MPa abs{580 psia} 4 MPa {580 psig}
B 4 MPa abs{580 psia} 4 MPa {580 psig}
C 20 MPa abs{2900 psia} 20 MPa {2900 psig}
D 60 MPa abs{8500 psia} 60 MPa {8500 psig}
Supply & Load Requirements
(Safety approvals can affect electrical require-
Working Pressure Limits (Silicone Oil) ments, see graph below)
With 24 V DC supply, up to a 570 load can be
Maximum Pressure Limit
used.
Capsule
Capsule EJA510A EJA530A
A 200 kPa abs{29 psia} 200 kPa {29 psig}
B 2 MPa abs{290 psia} 2 MPa {290 psig} 600
D 50 MPa abs{7200 psia} 50 MPa {7200 psig} E-10.5
R=
0.0236 Digital
External Communication
load range
resistance
250
R ()
10.5 16.4 24.7 42

Power supply voltage E (V DC)
F02E.EPS
Figure 2. Relationship Between Power Supply Voltage

and External Load Resistance
All Rights Reserved. Copyright © 1999, Yokogawa Electric Corporation GS 01C21F01-00E Mar. 23, 2006-00
Supply Voltage “” PHYSICAL SPECIFICATIONS
10.5 to 42 V DC for general use and flameproof type
10.5 to 32 V DC for lightning protector (Optional Wetted Parts Materials:
code /A) Diaphragm and Process connector
10.5 to 30 V DC for intrinsically safe, Type n, Refer to ‘MODEL AND SUFFIX CODE.’
nonincendive, or non-sparking type Non-wetted Parts Materials:
Minimum voltage limited at 16.4 V DC for digital
communications, BRAIN and HART Housing
Low copper cast-aluminum alloy with polyurethane
Load (Output signal code D and E)
paint (Munsell 0.6GY3.1/2.0)
0 to 1335 for operation
250 to 600 for digital communication Degrees of Protection
IP67, NEMA4X, JIS C0920 immersion proof
EMC Conformity Standards: ,
Cover O-rings
EN61326, AS/NZS CISPR11 Buna-N
European Pressure Equipment Directive 97/23/EC Data plate and tag
Sound Engineering Practice SUS304
With option code /PE3 Fill Fluid
Silicone, Fluorinated oil (option)
Weight
Category III, Module H, Type of Equipment: Pressure
1.6 kg (3.5 lb) without integral indicator, mounting
Accessory-Vessel, Type of Fluid: Liquid and Gas,
bracket.
Group of Fluid: 1 and 2
Connections
Communication Requirements “”
Refer to the model code to specify the process and
BRAIN the electrical connection type.
Communication Distance
Up to 2 km (1.25 miles) when using CEV polyethyl- < Settings When Shipped > “”
ene-insulated PVC-sheathed cables. Communication
distance varies depending on type of cable used. Tag Number As specified in order *1
Output Mode ‘Linear’
Load Capacitance Display Mode ‘Linear’
0.22 F or less (see note) Operation ‘Normal’ unless otherwise specified in
Load Inductance Mode order
3.3 mH or less (see note) Damping Time ‘2 sec.’
Constant
Input Impedance of communicating device Calibration
10 k or more at 2.4 kHz. Range
Lower Range As specified in order
Value
Note : For general-use and Flameproof type.
Calibration
For Intrinsically safe type, please refer to Range
‘OPTIONAL SPECIFICATIONS.’ Higher Range As specified in order
Value
HART Selected from mmH2O, mmAq, mmWG,
Calibration mmHg, Torr, Pa, hPa, kPa, MPa, mbar,
Communication Distance Range Units bar, gf/cm2, kgf/cm2, inH2O, inHg, ftH2O,
Up to 1.5 km (1 mile) when using multiple twisted pair psi, or atm.(Only one unit can be specified)
T05E.EPS
cables. Communication distance varies depending on
type of cable used. *1: Up to 16 alphanumeric characters (including -
and · ) for Output Signal code D or up to 8
Use the following formula to determine cable length alphanumeric characters for Output Signal code
for specific applications: E will be entered in the amplifier memory.
65 x 106 (Cf + 10,000)

L= -
(R x C) C
Where:
L = length in meters or feet
R = resistance in (including barrier resistance)
C = cable capacitance in pF/m or pF/ft
Cf = maximum shunt capacitance of receiving devices
in pF/m or pF/ft
MODEL AND SUFFIX CODES
Model EJA510A and EJA530A
Model Suffix Codes Description

EJA510A . . . . . . . . . . . . . . . . . . . . Absolute pressure transmitter
EJA530A . . . . . . . . . . . . . . . . . . . . Gauge pressure transmitter
Output Signal -D . . . . . . . . . . . . . . . . . 4 to 20 mA DC with digital communication (BRAIN protocol)

-E . . . . . . . . . . . . . . . . . 4 to 20 mA DC with digital communication (HART protocol, refer to GS 01C22T01-00E)
-F . . . . . . . . . . . . . . . . . Digital communication (FOUNDATION Fieldbus protocol, refer to GS 01C22T02-00E)
Measurement span A . . . . . . . . . . . . . . . 10 to 200 kPa {0.1 to 2 kgf/cm2} {1.45 to 29 psi} {0.1 to 2 bar}
(capsule) B . . . . . . . . . . . . . . . 0.1 to 2 MPa {1 to 20 kgf/cm2} {14.5 to 290 psi} {1 to 20 bar}
C . . . . . . . . . . . . . . . 0.5 to 10 MPa {5 to 100 kgf/cm2} {72.5 to 1450 psi} {5 to 100 bar}
D . . . . . . . . . . . . . . . 5 to 50 MPa {50 to 500 kgf/cm2} {720 to 7200 psi} {50 to 500 bar}
Wetted parts [Process Connection] [Diaphragm]
material *2 S.............. SUS316L Hastelloy C-276 *3
H.............. Hastelloy C-276 *3 Hastelloy C-276 *3
Process connection 4............. 1/2 NPT female
7............. 1/2 NPT male
8............. G 1/2 DIN 16 288 male
9............. M201.5 DIN 16 288 male
N.......... Always N
-0 . . . . . . . . Always 0
Electrical connection 0 . . . . . . G1/2 female, one electrical connection
2 . . . . . . 1/2 NPT female, two electrical connections without blind plug
3 . . . . . . Pg 13.5 female, two electrical connections without blind plug
4 . . . . . . M20 female, two electrical connections without blind plug
5 . . . . . . G1/2 female, two electrical connections and a blind plug
7 . . . . . . 1/2 NPT female, two electrical connections and a blind plug
8 . . . . . . Pg 13.5 female, two electrical connections and a blind plug
9 . . . . . . M20 female, two electrical connections and a blind plug
Integral indicator D . . . Digital indicator
E . . . Digital indicator with the range setting switch *1
N . . . (None)
Mounting bracket E . . SECC Carbon steel 2-inch pipe mounting
F . . SUS304 2-inch pipe mounting
N . . (None)
Optional codes / Optional specification
T02E.EPS
The ‘’ marks indicate the most typical selection for each specification. Example: EJA530A-DAS4N-02NN/
*1: Not applicable for Output signal code F

*2: Users must consider the characteristics of selected wetted parts material and the influence of process fluids. The
use of inappropriate materials can result in the leakage of corrosive process fluids and cause injury to personnel
and/or damage to plant facilities. It is also possible that the diaphragm itself can be damaged and that material from
the broken diaphragm and the fill fluid can contaminate the user's process fluids.
Be very careful with highly corrosive process fluids such as hydrochloric acid, sulfuric acid, hydrogen sulfide,
sodium hypochlorite, and high-temperature steam (150°C [302°F] or above). Contact Yokogawa for detailed
information of the wetted parts material.
*3: Hastelloy C-276 or ASTM N10276.
OPTIONAL SPECIFICATIONS (For Explosion Protected types “”)
For FOUNDATION Fieldbus explosion protected type, see GS 01C22T02-00E.
Item Description Code

FM Explosionproof Approval *1 *3
Applicable standard: FM3600, FM3615, FM3810, ANSI/NEMA250
Explosionproof for Class I, Division 1, Groups B, C and D
Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G FF1
Hazardous (classified) locations, indoors and outdoors (NEMA 4X)
Temperature class: T6
Amb. Temp.: –40 to 60C (–40 to 140F)
FM Intrinsically safe Approval *1 *3
Applicable standard: FM3600, FM3610, FM3611, FM3810, ANSI/NEMA250
Factory Mutual (FM) Intrinsically Safe for Class I, Division 1, Groups A, B, C & D, Class II, Division 1,
Groups E, F & G and Class III, Division 1 Hazardous Locations.
Nonincendive for Class I, Division 2, Groups A, B, C & D, Class II, Division. 2,
Groups E, F & G, and Class III, Division 1 Hazardous Locations.
FS1
Enclosure: “NEMA 4X”, Temp. Class: T4, Amb. Temp.: –40 to 60C (–40 to 140F)
Intrinsically Safe Apparatus Parameters
[Groups A, B, C, D, E, F and G]
Vmax=30 V, Imax=165 mA, Pmax=0.9 W, Ci=22.5 nF, Li=730 H
[Groups C, D, E, F and G]
Combined FF1 and FS1 *1 *3 FU1
CENELEC ATEX (KEMA) Flameproof Approval *2 *3
Applicable standard: EN50014, EN50018, EN50281-1-1
Certificate: KEMA 02ATEX2148
II 2G EExd IIC T4, T5, T6 KF2
Amb. Temp.: T5; –40 to 80C ( –40 to 176F), T4 and T6; –40 to 75C ( –40 to 167F)
Max. process Temp.: T4; 120C (248F), T5; 100C (212F), T6; 85C (185F)
CENELEC ATEX (KEMA) Intrinsically safe Approval *2 *3
Applicable standard: EN50014, EN50020, EN500284, EN50281-1-1
Certificate: KEMA 02ATEX1030X KS2
CENELEC ATEX II 1G EEx ia IIC T4, Amb. Temp.: –40 to 60C (–40 to 140F)
Ui=30 V, Ii=165 mA, Pi=0.9 W, Ci=22.5 nF, Li=730 H
Combined KF2, KS2 and Type n *2 *3
Type n
Applicable standard: EN50021
II 3G Ex nL IIC T4, Amb. Temp.: –40 to 60°C (–40 to 140°F)
KU2
Ui=30 V DC, Ci=22.5 nF, Li=730 µH
Dust
II 1D maximum surface temperature T65°C (149F) {Tamb.: 40°C (104F)},
T85°C (185F) {Tamb.: 60°C (140F)}, T105°C (221F) {Tamb.: 80°C (176F)}
T03-1E.EPS
*1: Applicable for Electrical connection code 2 and 7 (1/2 NPT female).
*2: Applicable for Electrical connection code 2, 4, 7 and 9 (1/2 NPT and M20 female).
*3: Applicable for Output signal code D and E.
For intrinsically safe approval, use the safety barrier certified by the testing laboratories (BARD-400 is not applicable).
CSA Explosionproof Approval *1 *3
Applicable standard: C22.2 No. 0, No. 0.4, No. 25, No. 30, No. 94, No. 142
Certificate: 1089598
CF1
Dustignitionproof for Class II/III, Division 1, Groups E, F and G
Division2 ‘SEALS NOT REQUIRED’ , Temp. Class: T4, T5, T6 Encl Type 4x
Max. Process Temp.: T4; 120C (248F), T5; 100C (212F), T6; 85C (185F)
Amb. Temp.: –40 to 80C (–40 to 176F)
Canadian Standards
Association (CSA) CSA Intrinsically safe Approval *1 *3
Applicable standard: C22.2 No. 0, No. 0.4, No. 25, No. 30, No. 94, No. 142, No. 157,
No. 213
Certificate: 1053843 CS1
Class I, Groups A, B, C and D Class II and III, Groups E, F and G
Encl Type 4x, Temp. Class: T4, Amb. Temp.: –40 to 60C (–40 to 140F)
Combined CF1 and CS1 *1 *3 CU1
IECEx Intrinsically safe, type n and Flameproof Approval *2 *3
Intrinsically safe and type n
Applicable Standard: IEC 60079-0:2004, IEC 60079-11:1999, IEC 60079-15:2005,
IEC 60079-26:2005
Certificate: IECEx KEM 06.0007X
Ex ia IIC T4, Ex nL IIC T4 Enclosure: IP67
Amb. Temp.: –40 to 60C (–40 to 140F), Max. Process Temp.: 120C (248F)
IECEx Electrical Parameters: [Ex ia] Ui=30 V, Ii=165 mA, Pi=0.9 W, Ci=22.5 nF, Li=730 H
SU2
Scheme *4 [Ex nL] Ui=30 V, Ci=22.5 nF, Li=730 H
Flameproof
Applicable Standard: IEC 60079-0:2004, IEC60079-1:2003
Certificate: IECEx KEM 06.0005
Ex d IIC T6...T4 Enclosure: IP67
Max.Process Temp.: T4;120C (248F), T5;100C (212F), T6; 85C (185F)
Amb.Temp.: –40 to 75C (–40 to 167F) for T4, –40 to 80C (–40 to 176F) for T5,
–40 to 75C (–40 to 167F) for T6
T03-2E.EPS
For intrinsically safe approval, use the safety barrier certified by the testing laboratories (BARD-400 is not applicable).
*4: Applicable only for Australia and New Zealand area.
*5: Applicable for Electrical connection code 2, 4 and 7 (1/2 NPT and M20 female).
OPTIONAL SPECIFICATIONS
High accuracy type *11 High accuracy HAC
Amplifier cover only P
Color change
Painting *12 Amplifier cover and terminal cover, Munsell 7.5 R4/14 PR
Coating change Epoxy resin-baked coating *15 X1
Transmitter power supply voltage: 10.5 to 32 V DC (10.5 to 30 V DC for intrinsically
Lightning protector safe type, 9 to 32 V DC for Fieldbus communication type.) A
Allowable current: Max. 6000 A (140 s), Repeating 1000 A (140 s) 100 times
Degrease cleansing treatment *15 K1
Oil-prohibited use Degrease cleansing treatment and with fluorinated oil filled capsule.
Operating temperature 20 to 80C K2
P calibration (psi unit) D1

(See Table for Span and
Calibration units *1 bar calibration (bar unit) D3
Range Limits.)
M calibration (kgf/cm2 unit ) D4
Update time: 0.125 sec or less
Fast response *9 Amplifier damping time constant: 0.1 to 64 sec in 9 increments F1
Response time (with min. damping time constant): max. 0.3 sec
Failure alarm down-scale *2 Output status at CPU failure and hardware error is –5%, 3.2 mA or less. C1
Failure alarm down-scale: output status at CPU failure and
C2
Output signal limits: hardware error is –5%, 3.2 mA or less.
NAMUR NE43 compliant *2 *10 3.8 mA to 20.5 mA
Failure alarm up-scale: output status at CPU failure and
C3
hardware error is 110%, 21.6 mA or more.
Stainless steel amplifier Amplifier housing material; SCS14A stainless steel (equivalent to SUS316 cast
housing *3 stainless steel or ASTM CF-8M) E1
Stainless steel tag plate SUS304 stainless steel tag plate wired onto transmitter N4
PED 97/23/EC
European Pressure
Category: III, Module: H, Type of Equipment: Pressure Accessory-Vessel, PE3
Equipment Directive *14
Type of Fluid: Liquid and Gas, Group of Fluid: 1 and 2
Mill Certificate Process connector M15
Test Pressure: 200 kPa (2 kgf/cm2) *4 T05
Pressure test/Leak test Test Pressure: 2 MPa (20 kgf/cm2) *5 Nitrogen (N2) Gas or Water *8 T06
Certificate *13 Retention time: 10 minutes
Test Pressure: 10 MPa (100 kgf/cm2) *6 T07
Test Pressure: 50 MPa (500 kgf/cm2) *7 T08
T04E.EPS
*1: The unit of MWP (Max. working pressure) on the name plate of a housing is the same unit as specified by Option code
D1, D3 and D4.
*2: Applicable for Output signal code D and E. The hardware error indicates faulty amplifier or capsule.
When combining with Option code F1, output status for down-scale is –2.5%, 3.6 mA DC or less.
*3: Applicable for Electrical connection code 2, 3, 4, and 7. Not applicable for Option code P and X1.
*4: Applicable for Capsule code A.
*5: Applicable for Capsule code B.
*6: Applicable for Capsule code C.
*7: Applicable for Capsule code D.
*8: Pure nitrogen gas or pure water is used for oil-prohibited use (Option code K1 and K2)
*10: Not applicable for Option code C1.
*11: Applicable for EJA530A. Refer to GS 01C21F01-02E.
*12: Standard polyurethan painting can be used in acid atmosphere, whereas the epoxy resin-baked coating (Option code
X1) can be used in alkaline atmosphere. Anti-corrosion coating, the combination of polyurethan and epoxy resin-baked
coating, is available by special order as sea water, alkaline, and acid resistant.
*13: The unit on the certificate is always kPa or MPa regardless of selection of option code D1, D3, or D4.
*14: If compliance with category III is needed, specify this option code.
*15: Not applicable for color change option.
DIMENSIONS
With Process Connection code 7
Unit: mm(Approx. inch)
96(3.77) 41(1.61) 110(4.33)
Conduit connection 12 45
Ground
(0.47) (1.77) terminal
Shrouding bolt *2
(3.07)
78
127(5.0)
111(4.37)
170(6.69)
LOCK ZERO LOCK
Zero adjustment
Adapter
124(4.88)
Pipe(Open to atmosphere)*1
44(1.73)
(1.85)
47
2-inch pipe Mounting bracket

91(3.58)
(O. D. 60.5 mm)
*1: Applied to Model EJA530A with Measurement span code A, B, and C.

*2: Applicable only for ATEX and IECEx Flameproof type.
For Process Connection code 4

163(6.41)
For Process Connection code 8 and 9

20(0.78)
176(6.92)
6(0.23)
5(0.19)
F03E.EPS
● Terminal Configuration ● Terminal Wiring

+
SUPPLY Power supply and output terminal
–
CHECK + External indicator(ammeter) terminal*2

–
Communication Ground terminal

Terminals(BT200 etc.) SUPPLY CHECK CHECK METER
Connection hook*2 *2: When using an external indicator or a check meter,
Connection hook
the internal resistance must be 10 or less.
Not available for Fieldbus communication (Output
signal code F).
F04E.EPS
SELECTION GUIDE
Measurement Span Maximum Working Pressure
Application Type Model Capsule
kPa inH2O MPa psi
L 0.5 to 10 2 to 40 16*4 2250*4
Differential M 1 to 100 4 to 400 16 2250
Pressure Traditional-Mounting*1 EJA110A
H 5 to 500 20 to 2000 16 2250
V 0.14 to 14MPa 20 to 2000 psi 16 2250
L 1 to 10 4 to 40 3.5 500
Flow Integral Orifice EJA115 M 2 to 100 8 to 400 14 2000
H 20 to 210 80 to 830 14 2000
Differential Pressure Extended EJA118N M 2.5 to 100 10 to 400
& Liquid Level Flush EJA118W 25 to 500 Based on Flange Rating
H 100 to 2000
with Remote Seals Combination EJA118Y
Draft Range Traditional-Mounting*1 EJA120A E 0.1 to 1 0.4 to 4 50 kPa 7.25
Differential Pressure Traditional-Mounting*1 M 1 to 100 4 to 400 32 4500
& Liquid Level EJA130A
H 5 to 500 20 to 2000 32 4500
Liquid Level, Closed Flush EJA210A M 1 to 100 4 to 400
20 to 2000 Based on Flange Rating
or Open Tank Extended EJA220A H 5 to 500
L 0.67 to 10*2 2.67 to 40*2 10 kPa*2 40 in H2O*2
Absolute (vacuum) 130 kPa*2
Pressure Traditional-Mounting*1 EJA310A M 1.3 to 130*2 0.38 to 38 inHg*2 18.65*2
A 0.03 to 3 MPa*2 4.3 to 430 psi*2 3000 kPa*2 430*2
A 0.03 to 3 MPa 4.3 to 430 psi 3 430
Gauge Pressure Traditional-Mounting*1 EJA430A 0.14 to 14 MPa 20 to 2000 psi 14
B 2000
Gauge Pressure Extended EJA438N A 0.06 to 3 MPa 8.6 to 430 psi Based on Flange Rating
with Remote Seal B 0.46 to 7 MPa 66 to 1000 psi
Gauge Pressure A 0.06 to 3 MPa 8.6 to 430 psi
Flush EJA438W 66 to 2000 psi Based on Flange Rating
with Remote Seal B 0.46 to 14 MPa
C 5 to 32 MPa 720 to 4500 psi 32 4500
High Gauge Traditional-Mounting*1 EJA440A 5 to 50 MPa 720 to 7200 psi
D 50 7200
A 10 to 200 1.45 to 29 psi 200 kPa 29
Absolute & Gauge EJA510A B 0.1 to 2 MPa 14.5 to 290 psi 2 290
Direct-Mounting
Pressure*3 EJA530A C 0.5 to 10 MPa 72.5 to 1450 psi 10 1450
D 5 to 50 MPa 720 to 7200 psi 50 7200
T06E.EPS
*1: Traditional-mounting is 1/4 - 18 NPTF process connections ( 1/2 - 14 NPTF with process adapters ) on 2-1/8" centers.
*2: Measurement values in absolute.
*3: Measurement values in absolute for EJA510A.
*4: When combined with Wetted parts material code H, M, T, A, D, and B, the value is 3.5 MPa (500 psi).
< Ordering Information > “” < Related Instruments > “”
Specify the following when ordering Power Distributor: Refer to GS 01B04T01-02E or
1. Model, suffix codes, and optional codes GS 01B04T02-02E
2. Calibration range and units: BRAIN TERMINAL: Refer to GS 01C00A11-00E
1) Calibration range can be specified with range
value specifications up to 5 digits < Reference >
(excluding any decimal point) for low or high range 1. Teflon; Trademark of E.I. DuPont de Nemours & Co.
limits within the range of -32000 to 32000. 2. Hastelloy; Trademark of Haynes International Inc.
2) Specify only one unit from the table, ‘Settings 3. HART; Trademark of the HART Communication
when shipped.’ Foundation.
3. Select linear or square root for output mode and 4. FOUNDATION ; Trademark of Fieldbus Foundation.
display mode.
Note: If not specified, the instrument is shipped set for Material Cross Reference Table
linear mode. SUS316L AISI 316L
4. Select normal or reverse for operation mode SUS316 AISI 316
Note: If not specified, the instrument is shipped in SUS304 AISI 304
normal operation mode.
S25C AISI 1025
5. Display scale and units (for transmitters equipped
with integral indicator only) SCM435 AISI 4137
Specify either 0 to 100 % or engineering unit scale SUS630 ASTM630
and ‘Range and Unit’ for engineering units scale: SCS14A ASTM CF-8M
Scale range can be specified with range limit T07E.EPS
specifications up to 5 digits (excluding any decimal 5. Other company names and product names used in
point) for low or high range limits within the range of this material are registered trademarks or trademarks
-19999 to 19999. of their respective owners.
6. Tag Number (if required)
< Specification Conformance >
The model EJA510A and EJA530A maintain a
specification conformance to at least 3 .
Subject to change without notice.
User’s
Manual Model EJA510A and EJA530A
Absolute Pressure and
Gauge Pressure Transmitters
[Style: S2]
IM 01C21F01-01E
IM 01C21F01-01E
8th Edition
Yokogawa Electric Corporation
CONTENTS
CONTENTS
1. INTRODUCTION ............................................................................................ 1-1

Regarding This Manual ................................................................................. 1-1
1.1 For Safe Use of Product ........................................................................ 1-1
1.2 Warranty ................................................................................................ 1-2
1.3 ATEX Documentation ............................................................................ 1-3
2. HANDLING CAUTIONS ................................................................................ 2-1

2.1 Model and Specifications Check ......................................................... 2-1
2.2 Unpacking ........................................................................................... 2-1
2.3 Storage ................................................................................................ 2-1
2.4 Selecting the Installation Location ...................................................... 2-1
2.5 Pressure Connection ........................................................................... 2-2
2.6 Waterproofing of Cable Conduit Connections .................................... 2-2
2.7 Restrictions on Use of Radio Transceiver .......................................... 2-2
2.8 Insulation Resistance and Dielectric Strength Test ............................ 2-2
2.9 Installation of Explosion Protected Type ............................................ 2-3
2.9.1 FM Approval ................................................................................. 2-3
2.9.2 CSA Certification .......................................................................... 2-5
2.9.3 IECEx Certification ....................................................................... 2-6
2.9.4 CENELEC ATEX (KEMA) Certification ........................................ 2-8
2.10 EMC Conformity Standards .............................................................. 2-10
2.11 PED (Pressure Equipment Directive) ............................................... 2-10
2.12 Low Voltage Directive ....................................................................... 2-11
3. COMPONENT NAMES .................................................................................. 3-1
4. INSTALLATION ............................................................................................. 4-1

4.1 Precautions ......................................................................................... 4-1
4.2 Mounting .............................................................................................. 4-1
4.3 Rotating Transmitter Section .............................................................. 4-2
4.4 Changing the Direction of Integral Indicator ....................................... 4-2
5. INSTALLING IMPULSE PIPING ................................................................... 5-1

5.1 Impulse Piping Installation Precautions .............................................. 5-1
5.1.1 Connecting Impulse Piping to the Transmitter ............................. 5-1
5.1.2 Routing the Impulse Piping .......................................................... 5-1
5.2 Impulse Piping Connection Examples ................................................ 5-2
6. WIRING .......................................................................................................... 6-1

6.1 Wiring Precautions .............................................................................. 6-1
6.2 Selecting the Wiring Materials ............................................................ 6-1
6.3 Connections of External Wiring to Terminal Box ................................ 6-1
6.3.1 Power Supply Wiring Connection ................................................ 6-1
6.3.2 External Indicator Connection ...................................................... 6-1
6.3.3 BRAIN TERMINAL BT200 Connection ........................................ 6-1
6.3.4 Check Meter Connection .............................................................. 6-2
FD No. IM 01C21F01-01E i IM 01C21F01-01E

8th Edition: Oct. 2008(KP)
All Rights Reserved, Copyright © 1999, Yokogawa Electric Corporation
CONTENTS
6.4 Wiring .................................................................................................. 6-2

6.4.1 Loop Configuration ....................................................................... 6-2
(1) General-use Type and Flameproof Type ...................................... 6-2
(2) Intrinsically Safe Type ................................................................... 6-2
6.4.2 Wiring Installation ......................................................................... 6-2
(1) General-use Type and Intrinsically Safe Type .............................. 6-2
(2) Flameproof Type ........................................................................... 6-3
6.5 Grounding ............................................................................................ 6-3
6.6 Power Supply Voltage and Load Resistance ..................................... 6-3
7. OPERATION .................................................................................................. 7-1

7.1 Preparation for Starting Operation ...................................................... 7-1
7.2 Zero Point Adjustment ........................................................................ 7-2
7.2.1 When you can obtain Low Range Value from actual
measured value of 0% (0 kPa, atmospheric pressure); .............. 7-2
7.2.2 When you cannot obtain Low Range Value from actual
measured value of 0%; ................................................................ 7-3
7.3 Starting Operation ............................................................................... 7-3
7.4 Shutting Down Operation .................................................................... 7-3
7.5 Setting the Range Using the Range-setting Switch ........................... 7-4
8. BRAIN TERMINAL BT200 OPERATION ..................................................... 8-1

8.1 BT200 Operation Precautions ............................................................. 8-1
8.1.1 Connecting the BT200 ................................................................. 8-1
8.1.2 Conditions of Communication Line .............................................. 8-1
8.2 BT200 Operating Procedures ............................................................. 8-1
8.2.1 Key Layout and Screen Display ................................................... 8-1
8.2.2 Operating Key Functions .............................................................. 8-2
(1) Alphanumeric Keys and Shift Keys .............................................. 8-2
(2) Function Keys ............................................................................... 8-2
8.2.3 Calling Up Menu Addresses Using the Operating Keys .............. 8-3
8.3 Setting Parameters Using the BT200 ................................................. 8-4
8.3.1 Parameter Summary .................................................................... 8-4
8.3.2 Parameter Usage and Selection .................................................. 8-6
8.3.3 Setting Parameters ....................................................................... 8-7
(1) Tag No. Setup ............................................................................... 8-7
(2) Calibration Range Setup .............................................................. 8-7
(3) Damping Time Constant Setup ..................................................... 8-8
(4) Output Signal Low Cut Mode Setup ............................................. 8-9
(5) Change Output Limits ................................................................... 8-9
(6) Integral Indicator Scale Setup .................................................... 8-10
(7) Unit Setup for Displayed Temperature ........................................ 8-11
(8) Operation Mode Setup ............................................................... 8-12
(9) Output Status Display/Setup when a CPU Failure ..................... 8-12
(10)Output Status Setup when a Hardware Error Occurs ................. 8-12
(11)Range Change while Applying Actual Inputs .............................. 8-12
(12)Zero Point Adjustment ................................................................ 8-13
(13)Span Adjustment ........................................................................ 8-14
(14)Test Output Setup ....................................................................... 8-15
(15)User Memo Fields ...................................................................... 8-15
8.4 Displaying Data Using the BT200 ..................................................... 8-16
8.4.1 Displaying Measured Data ......................................................... 8-16
8.4.2 Display Transmitter Model and Specifications ........................... 8-16
ii IM 01C21F01-01E
CONTENTS
8.5 Self-Diagnostics ................................................................................ 8-16

8.5.1 Checking for Problems ............................................................... 8-16
(1) Identifying Problems with BT200 ................................................ 8-16
(2) Checking with Integral Indicator ................................................. 8-17
8.5.2 Errors and Countermeasures ..................................................... 8-18
9. MAINTENANCE ............................................................................................. 9-1

9.1 Overview ............................................................................................. 9-1
9.2 Calibration Instruments Selection ....................................................... 9-1
9.3 Calibration ........................................................................................... 9-1
9.4 Disassembly and Reassembly ............................................................ 9-3
9.4.1 Replacing the Integral Indicator ................................................... 9-3
9.4.2 Replacing the CPU Board Assembly ........................................... 9-4
9.4.3 Cleaning and Replacing the Capsule Assembly .......................... 9-5
9.5 Troubleshooting ................................................................................... 9-6
9.5.1 Basic Troubleshooting .................................................................. 9-6
9.5.2 Troubleshooting Flow Charts ....................................................... 9-6
10. GENERAL SPECIFICATIONS .................................................................... 10-1

10.1 Standard Specifications .................................................................... 10-1
10.2 Model and Suffix Codes .................................................................... 10-3
10.3 Optional Specifications ...................................................................... 10-4
10.4 Dimensions ........................................................................................ 10-7
Customer Maintenance Parts List

Model EJA510A and EJA530A Absolute and Gauge
Pressure Transmitter ....................................................... CMPL 01C21F01-01E
REVISION RECORD
iii IM 01C21F01-01E
1. INTRODUCTION
1. INTRODUCTION
Thank you for purchasing the DPharp electronic • The following safety symbol marks are used in this
pressure transmitter. manual:
The DPharp Pressure Transmitters are precisely
calibrated at the factory before shipment. To ensure WARNING
correct and efficient use of the instrument, please read
this manual thoroughly and fully understand how to Indicates a potentially hazardous situation which,
operate the instrument before operating it. if not avoided, could result in death or serious
injury.
Regarding This Manual
• This manual should be passed on to the end user.
• The contents of this manual are subject to change
CAUTION
without prior notice.
Indicates a potentially hazardous situation which,
• All rights reserved. No part of this manual may be
if not avoided, may result in minor or moderate
reproduced in any form without Yokogawa’s written
injury. It may also be used to alert against
permission.
unsafe practices.
• Yokogawa makes no warranty of any kind with
regard to this manual, including, but not limited to,
implied warranty of merchantability and fitness for a
particular purpose. IMPORTANT
• If any question arises or errors are found, or if any Indicates that operating the hardware or software
information is missing from this manual, please in this manner may damage it or lead to system
inform the nearest Yokogawa sales office. failure.
• The specifications covered by this manual are
limited to those for the standard type under the
specified model number break-down and do not
cover custom-made instruments. NOTE
• Please note that changes in the specifications, Draws attention to information essential for
construction, or component parts of the instrument understanding the operation and features.
may not immediately be reflected in this manual at
the time of change, provided that postponement of
revisions will not cause difficulty to the user from a Direct current
functional or performance standpoint.
• Yokogawa assumes no responsibilities for this 1.1 For Safe Use of Product
product except as stated in the warranty.
• If the customer or any third party is harmed by the For the protection and safety of the operator and the
use of this product, Yokogawa assumes no responsi- instrument or the system including the instrument,
bility for any such harm owing to any defects in the please be sure to follow the instructions on safety
product which were not predictable, or for any described in this manual when handling this instru-
indirect damages. ment. In case the instrument is handled in contradiction
to these instructions, Yokogawa does not guarantee
safety. Please give your attention to the followings.
NOTE
For FOUNDATION FieldbusTM, PROFIBUS PA and (a) Installation
HART protocol versions, please refer to IM • The instrument must be installed by an expert
01C22T02-01E, IM 01C22T03-00E and IM engineer or a skilled personnel. The procedures
01C22T01-01E respectively, in addition to this described about INSTALLATION are not permitted
manual. for operators.
1-1 IM 01C21F01-01E
1. INTRODUCTION
• In case of high process temperature, care should be (f) Modification

taken not to burn yourself because the surface of • Yokogawa will not be liable for malfunctions or
body and case reaches a high temperature. damage resulting from any modification made to this
instrument by the customer.
• The instrument installed in the process is under
pressure. Never loosen the process connector bolts to
avoid the dangerous spouting of process fluid. 1.2 Warranty
• During draining condensate from the pressure- • The warranty shall cover the period noted on the
detector section, take appropriate care to avoid quotation presented to the purchaser at the time of
contact with the skin, eyes or body, or inhalation of purchase. Problems occurred during the warranty
vapors, if the accumulated process fluid may be period shall basically be repaired free of charge.
toxic or otherwise harmful. • In case of problems, the customer should contact the
• When removing the instrument from hazardous Yokogawa representative from which the instrument
processes, avoid contact with the fluid and the was purchased, or the nearest Yokogawa office.
interior of the meter. • If a problem arises with this instrument, please
• All installation shall comply with local installation inform us of the nature of the problem and the
requirement and local electrical code. circumstances under which it developed, including
the model specification and serial number. Any
(b) Wiring diagrams, data and other information you can
• The instrument must be installed by an expert include in your communication will also be helpful.
engineer or a skilled personnel. The procedures • Responsible party for repair cost for the problems
described about WIRING are not permitted for shall be determined by Yokogawa based on our
operators. investigation.
• Please confirm that voltages between the power • The Purchaser shall bear the responsibility for repair
supply and the instrument before connecting the costs, even during the warranty period, if the
power cables and that the cables are not powered malfunction is due to:
before connecting.
- Improper and/or inadequate maintenance by the
(c) Operation purchaser.
• Wait 10 min. after power is turned off, before - Failure or damage due to improper handling, use or
opening the covers. storage which is out of design conditions.
- Use of the product in question in a location not
(d) Maintenance conforming to the standards specified by
• Please do not carry out except being written to a Yokogawa, or due to improper maintenance of the
maintenance descriptions. When these procedures installation location.
are needed, please contact nearest YOKOGAWA - Failure or damage due to modification or repair by
office. any party except Yokogawa or an approved
representative of Yokogawa.
• Care should be taken to prevent the build up of drift,
- Malfunction or damage from improper relocation
dust or other material on the display glass and
of the product in question after delivery.
name plate. In case of its maintenance, soft and dry
- Reason of force majeure such as fires, earthquakes,
cloth is used.
storms/floods, thunder/lightening, or other natural
disasters, or disturbances, riots, warfare, or
(e) Explosion Protected Type Instrument
radioactive contamination.
• Users of explosion proof instruments should refer
first to section 2.9 (Installation of an Explosion
Protected Instrument) of this manual.
• The use of this instrument is restricted to those who
have received appropriate training in the device.
• Take care not to create sparks when accessing the
instrument or peripheral devices in a hazardous
location.
1-2 IM 01C21F01-01E
1. INTRODUCTION
1.3 ATEX Documentation SF

This procedure is only applicable to the countries in
European Union. Kaikkien ATEX Ex -tyyppisten tuotteiden käyttöhjeet
ovat saatavilla englannin-, saksan- ja ranskankielisinä.
Mikäli tarvitsette Ex -tyyppisten tuotteiden ohjeita
GB omalla paikallisella kielellännne, ottakaa yhteyttä
lähimpään Yokogawa-toimistoon tai -edustajaan.
All instruction manuals for ATEX Ex related products
are available in English, German and French. Should
you require Ex related instructions in your local P
language, you are to contact your nearest Yokogawa
office or representative. Todos os manuais de instruções referentes aos produtos
Ex da ATEX estão disponíveis em Inglês, Alemão e
Francês. Se necessitar de instruções na sua língua
DK relacionadas com produtos Ex, deverá entrar em
contacto com a delegação mais próxima ou com um
Alle brugervejledninger for produkter relateret til representante da Yokogawa.
ATEX Ex er tilgængelige på engelsk, tysk og fransk.
Skulle De ønske yderligere oplysninger om håndtering
af Ex produkter på eget sprog, kan De rette F
henvendelse herom til den nærmeste Yokogawa
afdeling eller forhandler. Tous les manuels d’instruction des produits ATEX Ex
sont disponibles en langue anglaise, allemande et
française. Si vous nécessitez des instructions relatives
I aux produits Ex dans votre langue, veuillez bien
contacter votre représentant Yokogawa le plus proche.
Tutti i manuali operativi di prodotti ATEX
contrassegnati con Ex sono disponibili in inglese,
tedesco e francese. Se si desidera ricevere i manuali D
operativi di prodotti Ex in lingua locale, mettersi in
contatto con l’ufficio Yokogawa più vicino o con un Alle Betriebsanleitungen für ATEX Ex bezogene
rappresentante. Produkte stehen in den Sprachen Englisch, Deutsch
und Französisch zur Verfügung. Sollten Sie die
Betriebsanleitungen für Ex-Produkte in Ihrer
E Landessprache benötigen, setzen Sie sich bitte mit
Ihrem örtlichen Yokogawa-Vertreter in Verbindung.
Todos los manuales de instrucciones para los productos
antiexplosivos de ATEX están disponibles en inglés,
alemán y francés. Si desea solicitar las instrucciones de S
estos artículos antiexplosivos en su idioma local,
deberá ponerse en contacto con la oficina o el Alla instruktionsböcker för ATEX Ex (explosionssäkra)
representante de Yokogawa más cercano. produkter är tillgängliga på engelska, tyska och
franska. Om Ni behöver instruktioner för dessa
explosionssäkra produkter på annat språk, skall Ni
NL kontakta närmaste Yokogawakontor eller representant.
Alle handleidingen voor producten die te maken

hebben met ATEX explosiebeveiliging (Ex) zijn GR
verkrijgbaar in het Engels, Duits en Frans. Neem,
indien u aanwijzingen op het gebied van
ATEX Ex
explosiebeveiliging nodig hebt in uw eigen taal, contact
, .
op met de dichtstbijzijnde vestiging van Yokogawa of
Ex
met een vertegenwoordiger.
Yokogawa .
1-3 IM 01C21F01-01E
1. INTRODUCTION
SK PL
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1-4 IM 01C21F01-01E
2. HANDLING CAUTIONS
This chapter describes important cautions regarding
how to handle the transmitter. Read carefully before
2.3 Storage
using the transmitter. The following precautions must be observed when
storing the instrument, especially for a long period.
The EJA-A Series pressure transmitters are thoroughly
tested at the factory before shipment. When the (a) Select a storage area which meets the following
transmitter is delivered, visually check them to make conditions:
sure that no damage occurred during shipment. • It is not exposed to rain or water.
• It suffers minimum vibration and shock.
Also check that all transmitter mounting hardware
• It has an ambient temperature and relative
shown in Figure 2.1.1 is included. If the transmitter
humidity within the following ranges.
was ordered without the mounting bracket, the trans-
mitter mounting hardware is not included. After Ambient temperature:
checking the transmitter, repack it in the way it was –40 to 85°C without integral indicator
delivered until installation. –30 to 80°C with integral indicator
Mounting bracket Relative humidity:
U-bolt nut (S) (Flat type) 5% to 100% R.H. (at 40°C)
Plate
Preferred temperature and humidity:
Adapter
approx. 25°C and 65% R.H.
(b) When storing the transmitter, repack it as nearly
as possible to the way it was packed when
delivered from the factory.
(c) If storing a transmitter that has been used,
thoroughly clean the chambers inside the body, so
that no measured fluid remains in it. Also make
U-bolt (L) sure before storing that the transmitter assemblies
are securely mounted.
U-bolt (S)
U-bolt nut (L)

F0201.EPS
2.4 Selecting the Installation
Figure 2.1.1 Transmitter Mounting Hardware Location
2.1 Model and Specifications The transmitter is designed to withstand severe
environmental conditions. However, to ensure stable
Check and accurate operation for years, observe the follow-
The model name and specifications are indicated on the ing precautions when selecting an installation loca-
name plate attached to the case. If the reverse operat- tion.
ing mode was ordered (reverse signal), ‘REVERSE’ (a) Ambient Temperature
will be inscribed in field *1. Avoid locations subject to wide temperature
variations or a significant temperature gradient. If
the location is exposed to radiant heat from plant
equipments, provide adequate thermal insulation
and/or ventilation.
: Refer to USER'S MANUAL
F0202.EPS (b) Ambient Atmosphere

Figure 2.1.2 Name Plate Avoid installing the transmitter in a corrosive
atmosphere. If the transmitter must be installed in
2.2 Unpacking a corrosive atmosphere, there must be adequate
When moving the transmitter to the installation site, ventilation as well as measures to prevent
keep it in its original packaging. Then, unpack the intrusion or stagnation of rain water in conduits.
transmitter there to avoid damage on the way.
2-1 IM 01C21F01-01E
(c) Shock and Vibration by high frequency noise pickup. To test for such
Select an installation site suffering minimum shock effects, bring the transceiver in use slowly from a
and vibration (although the transmitter is designed distance of several meters from the transmitter,
to be relatively resistant to shock and vibration). and observe the measurement loop for noise
(d) Installation of Explosion-protected Transmitters effects. Thereafter, always use the transceiver
Explosion-protected transmitters can be installed in outside the area affected by noise.
hazardous areas according to the types of gases for
which they are certified. See Subsection 2.9
“Installation of Explosion Protected Type Transmit- 2.8 Insulation Resistance and
ters.” Dielectric Strength Test
Since the transmitter has undergone insulation resis-
2.5 Pressure Connection
tance and dielectric strength tests at the factory before
shipment, normally these tests are not required.
WARNING However, if required, observe the following precau-
tions in the test procedures.
• Instrument installed in the process is under
pressure. Never loosen the process connection (a) Do not perform such tests more frequently than is
part to avoid the dangerous spouting of process absolutely necessary. Even test voltages that do not
fluid. cause visible damage to the insulation may degrade
• During draining condensate from the capsule the insulation and reduce safety margins.
assembly, take appropriate care to avoid (b) Never apply a voltage exceeding 500 V DC (100 V
contact with the skin, eyes or body, or inhala- DC with an internal lightning protector) for the
tion of vapors, if the accumulated process fluid insulation resistance test, nor a voltage exceeding
may be toxic or otherwise harmful. 500 V AC (100 V AC with an internal lightning
protector) for the dielectric strength test.
The following precautions must be observed in order to (c) Before conducting these tests, disconnect all signal
safely operate the transmitter under pressure. lines from the transmitter terminals. Perform the
tests in the following procedure:
(a) Make sure that the process connection part is
tightened firmly. • Insulation Resistance Test
(b) Make sure that there are no leaks in the impulse 1) Short-circuit the + and – SUPPLY terminals in the
piping. terminal box.
(c) Never apply a pressure higher than the specified 2) Turn OFF the insulation tester. Then connect the
maximum working pressure. insulation tester plus (+) lead wire to the shorted
SUPPLY terminals and the minus (–) leadwire to
2.6 Waterproofing of Cable the grounding terminal.
3) Turn ON the insulation tester power and measure
Conduit Connections
the insulation resistance. The voltage should be
Apply a non-hardening sealant to the threads to applied short as possible to verify that the insula-
waterproof the transmitter cable conduit connections. tion resistance is at least 20 MΩ.
(See Figure 6.4.2a, 6.4.2b and 6.4.2c.) 4) After completing the test and being very careful not
to touch exposed conductors disconnect the
insulation tester and connect a 100 kΩ resistor
2.7 Restrictions on Use of Radio between the grounding terminal and the short-
Transceiver circuiting SUPPLY terminals. Leave this resistor
connected at least one second to discharge any
static potential. Do not touch the terminals while it
IMPORTANT is discharging.
Although the transmitter has been designed to • Dielectric Strength Test
resist high frequency electrical noise, if a radio 1) Short-circuit the + and – SUPPLY terminals in the
transceiver is used near the transmitter or its terminal box.
external wiring, the transmitter may be affected
2-2 IM 01C21F01-01E
2) Turn OFF the dielectric strength tester. Then

connect the tester between the shorted SUPPLY
WARNING
terminals and the grounding terminal. Be sure to To preserve the safety of explosionproof equip-
connect the grounding lead of the dielectric strength ment requires great care during mounting,
tester to the ground terminal. wiring, and piping. Safety requirements also
3) Set the current limit on the dielectric strength tester place restrictions on maintenance and repair
to 10 mA, then turn ON the power and gradually activities. Please read the following sections very
increase the test voltage from ‘0’ to the specified carefully.
voltage.
4) When the specified voltage is reached, hold it for 2.9.1 FM Approval
one minute.
5) After completing this test, slowly decrease the a. FM Intrinsically Safe Type
voltage to avoid any voltage surges. Caution for FM intrinsically safe type. (Following
contents refer “DOC. No. IFM012-A12 P.1 and 2.”)
2.9 Installation of Explosion Note 1. Model EJA Series pressure transmitters
Protected Type with optional code /FS1 are applicable for
use in hazardous locations.
In this section, further requirements and differences • Applicable Standard: FM3600, FM3610, FM3611,
and for explosionproof type instrument are described. FM3810, ANSI/NEMA250
For explosionproof type instrument, the description in
• Intrinsically Safe for Class I, Division 1, Groups A,
this chapter is prior to other description in this users
B, C & D. Class II, Division 1, Groups E, F & G
manual.
and Class III, Division 1 Hazardous Locations.
For the intrinsically safe equipment and explosionproof • Nonincendive for Class I, Division 2, Groups A, B,
equipment, in case the instrument is not restored to its C & D. Class II, Division 2, Groups E, F & G and
original condition after any repair or modification Class III, Division 1 Hazardous Locations.
undertaken by the customer, intrinsically safe • Outdoor hazardous locations, NEMA 4X.
construction or explosionproof construction is damaged • Temperature Class: T4
and may cause dangerous condition. Please contact • Ambient temperature: –40 to 60°C
Yokogawa for any repair or modification required to Note 2. Entity Parameters
the instrument. • Intrinsically Safe Apparatus Parameters
NOTE Vmax = 30 V Ci = 22.5 nF
Imax = 165 mA Li = 730 µH
For FOUNDATION Fieldbus and PROFIBUS PA
Pmax = 0.9 W
explosion protected type, please refer to IM
* Associated Apparatus Parameters
01C22T02-01E and IM 01C22T03-00E respec-
(FM approved barriers)
tively.
Voc ≤ 30 V Ca > 22.5 nF
Isc ≤ 165 mA La > 730 µH
Pmax ≤ 0.9W
CAUTION
• Intrinsically Safe Apparatus Parameters
This instrument is tested and certified as intrinsi- [Groups C, D, E, F and G]
cally safe type or explosionproof type. Please Vmax = 30 V Ci = 22.5 nF
note that the construction of the instrument, Imax = 225 mA Li = 730 µH
installation, external wiring, maintenance or Pmax = 0.9 W
repair is strictly restricted, and non-observance * Associated Apparatus Parameters
or negligence of this restriction would result in (FM approved barriers)
dangerous condition. Voc ≤ 30 V Ca > 22.5 nF
Isc ≤ 225 mA La > 730 µH
Pmax ≤ 0.9 W
2-3 IM 01C21F01-01E
• Entity Installation Requirements b. FM Explosionproof Type

Vmax ≥ Voc or Vt, Imax ≥ Isc or It, Caution for FM explosionproof type.
Pmax (IS Apparatus) ≥ Pmax (Barrier) Note 1. Model EJA Series differential, gauge,
Ca ≥ Ci + Ccable, La ≥ Li + Lcable and absolute pressure transmitters with
Note 3. Installation optional code /FF1 are applicable for
• Barrier must be installed in an enclosure that meets use in hazardous locations.
the requirements of ANSI/ISA S82.01. • Applicable Standard: FM3600, FM3615, FM3810,
• Control equipment connected to barrier must not use ANSI/NEMA250
or generate more than 250 V rms or V dc. • Explosionproof for Class I, Division 1, Groups B,
• Installation should be in accordance with ANSI/ISA C and D.
RP12.6 “Installation of Intrinsically Safe Systems for • Dust-ignitionproof for Class II/III, Division 1,
Hazardous (Classified) Locations” and the National Groups E, F and G.
Electric Code (ANSI/NFPA 70). • Outdoor hazardous locations, NEMA 4X.
• The configuration of associated apparatus must be • Temperature Class: T6
FMRC Approved. • Ambient Temperature: –40 to 60°C
• Dust-tight conduit seal must be used when installed • Supply Voltage: 42 V dc max.
in a Class II, III, Group E, F and G environments. • Output signal: 4 to 20 mA
• Associated apparatus manufacturer’s installation
Note 2. Wiring
drawing must be followed when installing this
• All wiring shall comply with National Electrical
apparatus.
Code ANSI/NEPA70 and Local Electrical Codes.
• The maximum power delivered from the barrier
• When installed in Division 1, “FACTORY
must not exceed 0.9 W.
SEALED, CONDUIT SEAL NOT REQUIRED.”
• Note a warning label worded “SUBSTITUTION OF
COMPONENTS MAY IMPAIR INTRINSIC Note 3. Operation
SAFETY,” and “INSTALL IN ACCORDANCE • Keep the “CAUTION” nameplate attached to the
WITH DOC. No. IFM012-A12 P.1 and 2.” transmitter.
CAUTION: OPEN CIRCUIT BEFORE REMOV-
Note 4. Maintenance and Repair
ING COVER. SEAL ALL CONDUITS WITHIN
• The instrument modification or parts replacement by
18 INCHES. WHEN INSTALLED IN DIV.1,
other than authorized representative of Yokogawa
“FACTORY SEALED, CONDUIT SEAL NOT
Electric Corporation is prohibited and will void
REQUIRED.” INSTALL IN ACCORDANCE
Factory Mutual Intrinsically safe and Nonincendive
WITH THE INSTRUCTION MANUAL IM 1C22.
Approval.
• Take care not to generate mechanical sparking
[Intrinsically Safe] when accessing to the instrument and peripheral
Hazardous Location Nonhazardous Location devices in a hazardous location.
Class I, II, III, Division 1, Note 4. Maintenance and Repair
Groups A, B, C, D, E, F, G General • The instrument modification or parts replacement
EJA Series Pressure Purpose
Transmitters Safety Barrier Equipment by other than authorized representative of
+ + + + Yokogawa Electric Corporation is prohibited and
Supply – – – – will void Factory Mutual Explosionproof Ap-
proval.
[Nonincendive] c. FM Intrinsically Safe Type/FM

Explosionproof Type
Hazardous Location Nonhazardous Location
Class I, II, Division 2,
Model EJA Series pressure transmitters with
Groups A, B, C, D, E, F, G optional code /FU1 can be selected the type
Class III, Division 1. General of protection (FM Intrinsically Safe or FM
Explosionproof) for use in hazardous loca-
Transmitters Equipment
tions.
+ +
Supply – –
Not Use
Safety Barrier
F0203.EPS
2-4 IM 01C21F01-01E
Note 1. For the installation of this transmitter, Corporation of America is prohibited and will void
once a particular type of protection is Canadian Standards Intrinsically safe and
selected, any other type of protection nonincendive Certification.
cannot be used. The installation must be [Intrinsically Safe]
in accordance with the description about
the type of protection in this instruction
Class I, II, III, Division 1,
manual. Groups A, B, C, D, E, F, G General
Note 2. In order to avoid confusion, unnecessary EJA Series Pressure Purpose
marking is crossed out on the label other Transmitters Safety Barrier Equipment
than the selected type of protection when + + + +
the transmitter is installed. Supply – – – –
2.9.2 CSA Certification F0204-1.EPS
[Nonincendive]
a. CSA Intrinsically Safe Type Hazardous Location Nonhazardous Location
Caution for CSA Intrinsically safe type. (Following Class I, II, Division 2,
contents refer to “DOC No. ICS003-A12 P.1-1 and Groups A, B, C, D, E, F, G
Class III, Division 1. General
P.1-2.”)
Note 1. Model EJA Series differential, gauge, and Transmitters Equipment
absolute pressure transmitters with + +
optional code /CS1 are applicable for use Supply – –
in hazardous locations Not Use
Certificate: 1053843 Safety Barrier
F0204-2.EPS
• Applicable Standard: C22.2 No.0, No.0.4, No.25,

No.30, No.94, No.142, No.157, No.213 b. CSA Explosionproof Type
• Intrinsically Safe for Class I, Division 1, Groups A,
Caution for CSA explosionproof type.
B, C & D. Class II, Division 1, Groups E, F & G
and Class III, Division 1 Hazardous Locations. Note 1. Model EJA Series differential, gauge, and
• Nonincendive for Class I, Division 2, Groups A, B, absolute pressure transmitters with
C & D, Class II, Division 2, Groups F & G, and optional code /CF1 are applicable for use
Class III, Hazardous Locations. (not use Safety in hazardous locations:
Barrier) Certificate: 1089598
• Encl. “Type 4X” • Applicable Standard: C22.2 No.0, No.0.4, No.25,
• Temperature Class: T4 No.30, No.94, No.142
• Ambient temperature: –40 to 60°C • Explosionproof for Class I, Division 1, Groups B,
• Process Temperature: 120°C max. C and D.
• Dust-ignitionproof for Class II/III, Division 1,
Note 2. Entity Parameters
Groups E, F and G.
• Intrinsically safe ratings are as follows:
• Encl “Type 4X”
Maximum Input Voltage (Vmax) = 30 V
• Temperature Class: T6, T5, and T4
Maximum Input Current (Imax) = 165 mA
• Process Temperature: 85°C (T6), 100°C (T5), and
Maximum Input Power (Pmax) = 0.9 W
120°C (T4)
Maximum Internal Capacitance (Ci) = 22.5 nF
• Ambient Temperature: –40 to 80°C
Maximum Internal Inductance (Li) = 730 µH
• Supply Voltage: 42 V dc max.
* Associated apparatus (CSA certified barriers)
• Output Signal: 4 to 20 mA
Maximum output voltage (Voc) ≤ 30 V
Maximum output current (Isc) ≤ 165 mA Note 2. Wiring
Maximum output power (Pmax) ≤ 0.9 W • All wiring shall comply with Canadian Electrical
Code Part I and Local Electrical Codes.
Note 3. Installation
• In hazardous location, wiring shall be in conduit as
• All wiring shall comply with Canadian Electrical
shown in the figure.
Code Part I and Local Electrical Codes.
CAUTION: SEAL ALL CONDUITS
• The instrument modification or parts replacement
WITHIN 50 cm OF THE ENCLOSURE.
by other than authorized representative of
UN SCELLEMENT DOIT ÊTRE
Yokogawa Electric Corporation and Yokogawa
INSTALLÉ À MOINS DE 50 cm DU
BÎTIER.
2-5 IM 01C21F01-01E
• When installed in Division 2, “SEALS NOT Note 2. In order to avoid confusion, unnecessary
REQUIRED.” marking is crossed out on the label other
Note 3. Operation than the selected type of protection when
• Keep the “CAUTION” label attached to the the transmitter is installed.
transmitter.
CAUTION: OPEN CIRCUIT BEFORE 2.9.3 IECEx Certification
REMOVING COVER. Model EJA Series differential, gauge, and
OUVRIR LE CIRCUIT AVANT absolute pressure transmitters with
DŃLEVER LE COUVERCLE. optional code /SU2 can be selected the type of
• Take care not to generate mechanical sparking protection (IECEx Intrinsically Safe/type n or
when accessing to the instrument and peripheral flameproof) for use in hazardous locations.
devices in a hazardous location. Note 1. For the installation of this transmitter,
Note 4. Maintenance and Repair once a particular type of protection is
• The instrument modification or parts replacement selected, any other type of protection
by other than authorized representative of cannot be used. The installation must be
Yokogawa Electric Corporation and Yokogawa in accordance with the description about
Corporation of America is prohibited and will void the type of protection in this instruction
Canadian Standards Explosionproof Certification. manual.
Note 2. In order to avoid confusion, unnecessary
Non-Hazardous Hazardous Locations Division 1
Locations marking is crossed out on the label other
Non-hazardous
than the selected type of protection when
Location the transmitter is installed.
Equipment 50 cm Max.
a. IECEx Intrinsically Safe Type / type n
Caution for IECEx Intrinsically safe and type n.
42 V DC Max. Conduit
Note 1. Model EJA Series differential, gauge, and
4 to 20 mA DC Sealing Fitting absolute pressure transmitters with
Signal
EJA Series optional code /SU2 are applicable for use
in hazardous locations.
Non-Hazardous Hazardous Locations Division 2
Locations • No. IECEx KEM 06.0007X
Non-hazardous • Applicable Standard: IEC 60079-0:2004,
Location IEC 60079-11:1999, IEC 60079-15:2005,
Equipment
IEC 60079-26:2004
• Type of Protection and Marking Code:
Ex ia IIC T4, Ex nL IIC T4
42 V DC Max.
4 to 20 mA DC Sealing Fitting • Ambient Temperature :–40 to 60°C
Signal • Max. Process Temp.: 120°C
EJA Series
• Enclosure: IP67
Note 2. Entity Parameters
F0205.EPS
• Intrinsically safe ratings are as follows:
c. CSA Intrinsically Safe Type/CSA Maximum Input Voltage (Ui) = 30 V
Explosionproof Type Maximum Input Current (Ii) = 165 mA
Model EJA Series pressure transmitters with Maximum Input Power (Pi) = 0.9 W
optional code /CU1 can be selected the type of Maximum Internal Capacitance (Ci) = 22.5 nF
protection (CSA Intrinsically Safe or CSA Maximum Internal Inductance (Li) = 730 µH
Explosionproof) for use in hazardous locations. • Type "n" ratings are as follows:
Note 1. For the installation of this transmitter, Maximum Input Voltage (Ui) = 30 V
once a particular type of protection is Maximum Internal Capacitance (Ci) = 22.5 nF
selected, any other type of protection Maximum Internal Inductance (Li) = 730 µH
cannot be used. The installation must be • Installation Requirements
in accordance with the description about Uo ≤ Ui, Io ≤ Ii, Po ≤ Pi,
the type of protection in this instruction Co ≥ Ci + Ccable, Lo ≥ Li + Lcable
manual. Uo, Io, Po, Co, and Lo are parameters of
barrier.
2-6 IM 01C21F01-01E
Note 3. Installation [type n]

• In any safety barreir used output current must be Hazardous Location Nonhazardous Location
limited by a resistor 'R' such that Io=Uo/R. Group IIC, Zone 2
• The safety barrier must be IECEx certified.
• Input voltage of the safety barrier must be less than EJA Series Pressure IECEx Certified
Transmitters Equipment [nL]
250 Vrms/Vdc.
+ +
• The instrument modification or parts replacement
Supply – –
by other than authorized representative of
Not Use
Yokogawa Electric Corporation and will void Safety Barrier
IECEx Intrinsically safe and type n certification. F0212.EPS
• The cable entry devices and blanking elements for

b. IECEx Flameproof Type
type n shall be of a certified type providing a level
of ingress protection of at least IP54, suitable for Caution for IECEx flameproof type.
the conditions of use and correctly installed. Note 1. Model EJA Series differential, gauge, and
• Electrical Connection: absolute pressure transmitters with
The type of electrical connection is stamped near optional code /SU2 are applicable for use
the electrical connection port according to the in hazardous locations:
following marking. • No. IECEx KEM 06.0005
• Applicable Standard: IEC60079-0:2004,
IEC60079-1:2003
T0202.EPS
Ex d IIC T6...T4
• Enclosure: IP67
• Maximum Process Temperature: 120°C (T4),
100°C (T5), 85°C (T6)
• Ambient Temperature: –40 to 75°C (T4), –40 to
Location of the marking 80°C (T5), –40 to 75°C (T6)
• Supply Voltage: 42 V dc max.
F0210.EPS
• Output Signal: 4 to 20 mA dc
Note 4. Operation Note 2. Wiring
• WARNING: • In hazardous locations, the cable entry devices shall
WHEN AMBIENT TEMPERATURE ≥ 55°C, be of a certified flameproof type, suitable for the
USE THE HEAT-RESISTING CABLES ≥ 90°C. conditions of use and correctly installed.
Note 5. Special Conditions for Safe Use • Unused apertures shall be closed with suitable
• WARNING: flameproof certified blanking elements. (The plug
IN THE CASE WHERE THE ENCLOSURE OF attached is certificated as the flame proof IP67 as a
THE PRESSURE TRANSMITTER IS MADE OF part of this apparatus.)
ALUMINUM, IF IT IS MOUNTED IN AN AREA • In case of ANSI 1/2 NPT plug, ANSI hexagonal
WHERE THE USE OF ZONE 0 IS REQUIRED, wrench should be applied to screw in.
IT MUST BE INSTALLED SUCH, THAT, EVEN Note 3. Operation
IN THE EVENT OF RARE INCIDENTS, IGNI- • WARNING:
TION SOURCES DUE TO IMPACT AND AFTER DE-ENERGIZING, DELAY 10 MINUTES
FRICTION SPARKS ARE EXCLUDED. BEFORE OPENING.
• WARNING:
[Intrinsically Safe]
WHEN AMBIENT TEMPERATURE ≥ 70°C,
USE THE HEAT-RESISTING CABLES ≥ 90°C.
Group I/IIC, Zone 0
when accessing to the instrument and peripheral
General
EJA Series Pressure IECEx certified Purpose devices in a hazardous location.
Transmitters Safety Barrier Equipment Note 4. Maintenance and Repair
+ + + + • The instrument modification or parts replacement
Supply – – – – by other than authorized representative of
Yokogawa Electric Corporation is prohibited and
F0211.EPS
will void IECEx Certification.
2-7 IM 01C21F01-01E
2.9.4 CENELEC ATEX (KEMA) [Installation Diagram]

Certification Hazardous Location Nonhazardous Location
(1) Technical Data

Transmitter
a. CENELEC ATEX (KEMA) Intrinsically Safe + +
Type Supply Safety Barrier *1
– –
Caution for CENELEC ATEX (KEMA) Intrinsi-
cally safe type.
Note 1. Model EJA Series differential, gauge, and
absolute pressure transmitters with F0208.EPS
optional code /KS2 for potentially explo- *1: In any safety barriers used the output current must be limited by
sive atmospheres: a resistor “R” such that Imaxout-Uz/R.
• No. KEMA 02ATEX1030 X
• Applicable Standard: EN50014:1997, b. CENELEC ATEX (KEMA) Flameproof Type
EN50020:1994, EN50284:1999 Caution for CENELEC ATEX (KEMA) flameproof
• Type of Protection and Marking code: type.
EEx ia IIC T4 Note 1. Model EJA Series differential, gauge, and
• Temperature Class: T4 absolute pressure transmitters with
• Enclosure: IP67 optional code /KF2 for potentially explo-
• Process Temperature: 120°C max. sive atmospheres:
• Ambient Temperature: –40 to 60°C • No. KEMA 02ATEX2148
Note 2. Electrical Data • Applicable Standard: EN50014:1997,
• In type of explosion protection intrinsic safety EEx EN50018:2000
ia IIC only for connection to a certified intrinsically • Type of Protection and Marking Code: EEx d IIC
safe circuit with following maximum values: T6···T4
Ui = 30 V • Temperature Class: T6, T5, and T4
Ii = 165 mA • Enclosure: IP67
Pi = 0.9 W • Maximum Process Temperature:
Effective internal capacitance; Ci = 22.5 nF 85°C (T6), 100°C (T5), and 120°C (T4)
Effective internal inductance; Li = 730 µH • Ambient Temperature: T4 and T6; –40 to 75°C,
Note 3. Installation T5; –40 to 80°C
• All wiring shall comply with local installation Note 2. Electrical Data
requirements. (Refer to the installation diagram) • Supply voltage: 42 V dc max.
Note 4. Maintenance and Repair • Output signal: 4 to 20 mA
• The instrument modification or parts replacement Note 3. Installation
by other than authorized representative of • All wiring shall comply with local installation
Yokogawa Electric Corporation is prohibited and requirement.
will void KEMA Intrinsically safe Certification. • The cable entry devices shall be of a certified
Note 5. Special Conditions for Safe Use flameproof type, suitable for the conditions of use.
• In the case where the enclosure of the Pressure Note 4. Operation
Transmitter is made of aluminium, if it is mounted • Keep the “CAUTION” label to the transmitter.
in an area where the use of category 1 G apparatus CAUTION: AFTER DE-ENERGIZING,
is required, it must be installed such, that, even in DELAY 10 MINUTES BEFORE
the event of rare incidents, ignition sources due to OPENING. WHEN THE AMBIENT
impact and friction sparks are excluded. TEMP.70°C, USE HEAT-RESISTING
CABLES90°C.
2-8 IM 01C21F01-01E
• Take care not to generate mechanical sparking Note 3. Maintenance and Repair
when accessing to the instrument and peripheral • The instrument modification or parts replacement
devices in a hazardous location. by other than authorized representative of
Note 5. Maintenance and Repair Yokogawa Electric Corporation is prohibited and
• The instrument modification or parts replacement will void Type of Protection “n”.
by other than authorized representative of [Installation Diagram]
will void KEMA Flameproof Certification. (Zone 2 only)
Transmitter
c. CENELEC ATEX (KEMA) Intrinsically Safe + +

Supply Power Supply
Type/CENELEC ATEX (KEMA) Flameproof – –
Type/ CENELEC ATEX Type n
Model EJA-A Series pressure transmitters with
optional code /KU2 can be selected the type of
F0209.EPS
protection CENELEC ATEX (KEMA) Intrinsically
Ratings of the Power Supply as follows;
Safe, Flameproof or CENELEC ATEX Type n Maximum Voltage: 30 V
for use in hazardous locations.
䊉 CENELEC ATEX Type of Protection “Dust”
Note 1. For the installation of this transmitter,
once a particular type of protection is selected, • Applicable Standard: EN50281-1-1:1997
any other type of protection cannot be used. • Type of Protection and Marking Code: II 1D
The installation must be in accordance with the • Maximum Surface Temperature:
description about the type of protection in this T65°C (Tamb.: 40°C), T85°C (Tamb.: 60°C), and
user’s manual. T105°C (Tamb.: 80°C)
Note 2. In order to avoid confusion, unnecessary Note 1. Installation instructions
marking is crossed out on the label other than The cable entry devices and blanking elements
the selected type of protection when the shall be of a certificated type providing a level
transmitter is installed. of ingress protection of at least IP6x, suitable
for the conditions of use and correctly installed.
䊉 CENELEC ATEX Type of Protection “n”
(2) Electrical Connection
The type of electrical connection is stamped near
WARNING the electrical connection port according to the
When using a power supply not having a non- following marking.
incendive circuit, please pay attention not to
ignite in the surrounding flammable atmosphere.
In such a case, we recommend using wiring
metal conduit in order to prevent the ignition.
• Applicable Standard: EN60079-15

• Referential Standard: IEC60079-0, IEC60079-11
Location of the marking
Ex nC IIL T4 F0200.EPS
• Temperature Class: T4
• Enclosure: IP67 (3) Installation
• Process Temperature: 120°C max.
• Ambient Temperature: –40 to 60°C WARNING
Note 1. Electrical Data
• All wiring shall comply with local installation
Ui = 30 V
requirement and local electrical code.
Effective internal capacitance; Ci = 22.5 nF
• There is no need of the conduit seal for both of
Effective internal inductance; Li = 730 µH
Division 1 and Division 2 hazardous locations
because this product is sealed at factory.
• In case of ANSI 1/2 NPT plug, ANSI hexagonal
requirements. (refer to the installation diagram)
wrench should be applied to screw in.
2-9 IM 01C21F01-01E
(4) Operation MWP: Maximum working pressure.

CAL RNG: Specified calibration range.
WARNING DISP MODE: Specified display mode.
OUTPUT MODE: Specified output mode.
• OPEN CIRCUIT BEFORE REMOVING NO.: Serial number and year of production*1.
COVER. INSTALL IN ACCORDANCE WITH TOKYO 180-8750 JAPAN:
THIS USER’S MANUAL The manufacturer name and the
• Take care not to generate mechanical sparking address*2.
when access to the instrument and peripheral *1: The third figure from the last shows the last one
devices in hazardous locations. figure of the year of production. For example, the
production year of the product engraved in “NO.”
column on the name plate as follows is 2001.
(5) Maintenance and Repair
12A819857 132
WARNING
The instrument modification or parts replacement The year 2001

by other than authorized Representative of *2: “180-8750” is a zip code which represents the
Yokogawa Electric Corporation is prohibited and following address.
will void the certification.
2-9-32 Nakacho, Musashino-shi, Tokyo Japan
(6) Name Plate

Name plate 2.10 EMC Conformity Standards
EN61326-1 Class A, Table 2 (For use in industrial
locations)
EN61326-2-3
: Refer to USER'S MANUAL
Tag plate for flameproof type CAUTION
This instrument is a Class A product, and it is

designed for use in the industrial environment.
Please use this instrument in the industrial
environment only.
Tag plate for intrinsically safe type
NOTE
YOKOGAWA recommends customer to apply
Tag plate for type n protection the Metal Conduit Wiring or to use the twisted
pair Shield Cable for signal wiring to conform the
requirement of EMC Regulation, when customer
installs the EJA Series Transmitters to the plant.
Tag plate for flameproof, intrinsically safe type,

type n protection, and Dust
2.11 PED (Pressure Equipment
D T65⬚C (Tamb.: 40⬚C), T85⬚C (Tamb.: 60⬚C),
and T105⬚C (Tamb.: 80⬚C)
Directive)
F0298.EPS
(1) General
MODEL: Specified model code. • EJA series of pressure transmitters are categorized
STYLE: Style code. as pressure accessories under the vessel section of
SUFFIX: Specified suffix code. this directive 97/23/EC, which corresponds to
SUPPLY: Supply voltage. Article 3, Paragraph 3 of PED, denoted as Sound
OUTPUT: Output signal. Engineering Practice (SEP).
2-10 IM 01C21F01-01E
• EJA130A, EJA440A, EJA510A, and EJA530A can (3) Operation

be used above 200 bar and therefore considered as
a part of a pressure retaining vessel where category CAUTION
lll, Module H applies. These models with option
code /PE3 conform to that category. • The temperature and pressure of fluid should
be applied under the normal operating condi-
(2) Technical Data tion.
• Models without /PE3 • The ambient temperature should be applied
Article 3, Paragraph 3 of PED, denoted as Sound under the normal operating condition.
Engineering Practice (SEP) . • Please pay attention to prevent the excessive
• Models with /PE3 pressure like water hammer, etc. When water
Module: H hammer is to be occurred, please take mea-
Type of Equipment: Pressure Accessory - Vessel sures to prevent the pressure from exceeding
Type of Fluid: Liquid and Gas PS by setting the safety valve, etc. at the
Group of Fluid: 1 and 2 system and the like.
• When external fire is to be occurred, please
Model PS(bar)*1 V(L) PS-V(bar-L) Category*2 take safety measures at the device or system
Article 3, paragraph 3 not to influence the transmitters.
EJA110A 160 0.01 1.6 (SEP)
Article 3, paragraph 3
EJA120A 0.5 0.01 0.005 (SEP)
EJA130A 420 0.01 4.2 (SEP) 2.12 Low Voltage Directive
EJA130A
With code /PE3 420 0.01 4.2 III Applicable standard : EN61010-1
EJA310A 160 0.01 1.6 (SEP) (1) Pollution Degree 2
EJA430A 160 0.01 1.6 (SEP)
"Pollution degree" describes the degree to which a
Article 3, paragraph 3 soild, liquid, or gas which deteriorates dielectric
EJA440A 500 0.01 50 (SEP) strength or surface resistivity is adhering. " 2 "
EJA440A
500 0.01 50 III
applies to normal indoor atmosphere. Normally,
With code /PE3
only non-conductive pollution occurs. Occasionally,
EJA510A 500 0.01 50 (SEP) however, temporary conductivity caused by
EJA510A condenstaion must be expected.
With code /PE3 500 0.01 50 III
(2) Installation Category I
EJA530A 500 0.01 50 (SEP) "Overvoltage category(Installation category)"
EJA530A
500 0.01 50 III
describes a number which defines a transient
With code /PE3
overvoltage condition. It implies the regulattion for
*1: PS is maximum allowable pressure for vessel itself.
*2: Referred to Table 1 covered by ANNEX II of EC Directive impulse withstand voltage. " I " applies to electrical
on Pressure Equipment Directive 97/23/EC T0299.EPS
equipment which is supplied from the circuit when
appropriate transient overvoltage control means
(interfaces) are provided.
2-11 IM 01C21F01-01E
3. COMPONENT NAMES
3. COMPONENT NAMES
External indicator Transmitter section
conduit connection (Note 1)
Terminal box cover
CPU assembly
Zero-adjustment screw
Integral
indicator (Note 1)
Mounting screw Pipe (Open to atmosphere)
(Note 3)
Setting pin (CN4) Capsule assembly
Range-setting
switch (Note 1)
(See Subsection 7.5)
Amplifier Cover Setting Pin (CN4) Burn-Out Output at

Position (Note 2) Direction Burn-Out
H
110% or
HIGH higher
L
H
-5% or
LOW lower
L
F0301.EPS
Note 1: See Subsection 10.2, “Model and Suffix Codes,” for

details.
Note 2: Insert the pin (CN4) as shown in the figure above to
set the burn-out direction. The pin is set to the H side
for delivery (unless option code /C1 is specified in the
order).
The setting can be confirmed by calling up parameter
D52 using the BRAIN TERMINAL. Refer to Subsection
8.3.3 (8).
Note 3: Applied to Model EJA530A with Measurement span
code A, B, and C.
Figure 3.1 Component Names
Table 3.1 Display Symbol

Display Symbol Meaning of Display Symbol
The output signal being zero-adjusted is increasing.
The output signal being zero-adjusted is decreasing.
%, Pa, kPa, MPa, kgf/cm2, gf/cm2, mbar, bar,
atm, mmHg, mmH2O, inH2O, inHg, ftH2O, psi, Torr Select one of these sixteen available engineering units for the display.
T0301.EPS
3-1 IM 01C21F01-01E
4. INSTALLATION
4. INSTALLATION
4.1 Precautions Vertical pipe mounting
Before installing the transmitter, read the cautionary

notes in Section 2.4, “Selecting the Installation Adapter
Location.” For additional information on the ambient
conditions allowed at the installation location, refer to U-bolt (S) Plate
Subsection 10.1 “Standard Specifications.” U-bolt nut (S)
IMPORTANT
• When welding piping during construction, take U-bolt nut (L)
care not to allow welding currents to flow
Mounting bracket
through the transmitter.
• Do not step on this instrument after installation. 50 mm(2-inch) pipe U-bolt (L)
Horizontal pipe mounting
4.2 Mounting Adapter

䊏 The impulse piping connection port of the transmit-
ter is covered with a plastic cap to protect against U-bolt (S) Plate
dust. This cap must be removed before connecting U-bolt nut (S)
the piping. (Be careful not to damage the threads
when removing these caps. Never insert a screw
driver or other tool between the cap and the port
threads to remove the cap.) U-bolt nut (L)
䊏 The transmitter can be mounted on a nominal 50 Mounting bracket

mm (2-inch) pipe using the mounting bracket
U-bolt (L)
supplied, as shown in Figure 4.2.1. 50 mm(2-inch) pipe
F0401.EPS
䊏 The user should prepare the mating gasket for the Figure 4.2.1 Transmitter Mounting
transmitters with Process connection code 8 and 9.
See Figure 4.2.2.
Gasket
F0402.EPS
Figure 4.2.2 Gasketing
4-1 IM 01C21F01-01E
4. INSTALLATION
IMPORTANT IMPORTANT
Tighten the hexagonal nut part of the capsule Do not rotate the transmitter section more than
assembly. See Figure 4.2.3. 180°.
Transmitter section Rotate 90° or 180° segments
Capsule assembly
Conduit connection
Zero-adjustment screw
Gasket
Pipe
Allen screw Capsule assembly

F0403.EPS
Figure 4.3 Rotating Transmitter Section

F0404.EPS
Figure 4.2.3 Tightening Transmitter

4.4 Changing the Direction of
4.3 Rotating Transmitter Section Integral Indicator
The DPharp transmitter section can be rotated in 90°
segments. IMPORTANT
1) Remove the two Allen screws that fasten the
Always turn OFF power, release pressure and
transmitter section and capsule assembly, using the
remove a transmitter to non-hazardous area
Allen wrench. Also, remove the pipe for the model
before disassembling and reassmbling an
EJA530A with Measurement span code A, B, and
indicator.
C, using the slotted screwdriver.
2) Rotate the transmitter section slowly in 90° seg-
ments. An integral indicator can be installed in the following
3) Tighten the two Allen screws to a torque of 5 N·m, three directions. Follow the instructions in section 9.4
and replace the pipe if applied. for removing and attaching the integral indicator.
F0405.EPS
Figure 4.4 Integral Indicator Direction
4-2 IM 01C21F01-01E
5. INSTALLING IMPULSE PIPING

5.1 Impulse Piping Installation 5.1.2 Routing the Impulse Piping
Precautions
(1) Process Pressure Tap Angles
5.1.1 Connecting Impulse Piping to the If condensate, gas, sediment or other extraneous
Transmitter material in the process piping gets into the impulse
piping, pressure measurement errors may result. To
prevent such problems, the process pressure taps must
IMPORTANT be angled as shown in Figure 5.1.2 according to the
kind of fluid being measured.
The transmitter can be installed in horizontal
impulse piping configuration, tilting the
transmitter's position up to 90°. When tilting,
NOTE
observe that the zero-adjustment screw and the
pipe (for Model EJA530A with Measurement • If the process fluid is a gas, the taps must be
span code A, B, and C) are positioned down- vertical or within 45° either side of vertical.
wards, as shown in Figure 5.1.1. • If the process fluid is a liquid, the taps must be
horizontal or below horizontal, but not more
than 45° below horizontal.
• If the process fluid is steam or other condens-
ing vapor, the taps must be horizontal or above
horizontal, but not more than 45° above hori-
zontal.
Pipe Zero-adjustment screw
[Gas] [Liquid] [Steam]
(Open to atmosphere)
F0503.EPS
45° 45°
Pressure
Figure 5.1.1 Horizontal Impulse Piping Connection taps 45° 45°
Process 45° 45°

piping
F0504.EPS
Figure 5.1.2 Process Pressure Tap Angle (For Horizontal

Piping)
5-1 IM 01C21F01-01E
(2) Position of Process Pressure Taps and 5.2 Impulse Piping Connection
Transmitter
Examples
If condensate (or gas) accumulates in the impulse
piping, it should be removed periodically by opening Figure 5.2 shows examples of typical impulse piping
the drain (or vent) plugs. However, this will generate a connections. Before connecting the transmitter to the
transient disturbance in the pressure measurement, and process, study the transmitter installation location, the
therefore it is necessary to position the taps and route process piping layout, and the characteristics of the
the impulse piping so that any extraneous liquid or gas process fluid (corrosiveness, toxicity, flammability,
generated in the leadlines returns naturally to the etc.), in order to make appropriate changes and
process piping. additions to the connection configurations.
• If the process fluid is a gas, then as a rule the Note the following points when referring to these
transmitter must be located higher than the process piping examples.
pressure taps. • If the impulse piping is long, bracing or supports
• If the process fluid is a liquid or steam, then as a should be provided to prevent vibration.
rule the transmitter must be located lower than the • The impulse piping material used must be compat-
process pressure taps. ible with the process pressure, temperature, and
(3) Impulse Piping Slope other conditions.
The impulse piping must be routed with only an • A variety of process pressure tap valves (main
upward or downward slope. Even for horizontal valves) are available according to the type of
routing, the impulse piping should have a slope of at connection (flanged, screwed, welded), construction
least 1/10 to prevent condensate (or gases) from (globe, gate, or ball valve), temperature and
accumulating in the pipes. pressure. Select the type of valve most appropriate
for the application.
(4) Preventing Freezing
If there is any risk that the process fluid in the impulse Tap valve
piping or transmitter could freeze, use a steam jacket or
heater to maintain the temperature of the fluid.
Union or flange
Stop valve
NOTE
After completing the connections, close the valves
on the process pressure taps (main valves), the Tee
valves at the transmitter (stop valves), and the Stop valve
impulse piping drain valves, so that condensate, Union or flange

sediment, dust and other extraneous material Drain valve
cannot enter the impulse piping. Drain plug
F0505.EPS
Figure 5.2 Impulse Piping Connection Examples
5-2 IM 01C21F01-01E
6. WIRING
6. WIRING
6.1 Wiring Precautions 6.3 Connections of External

Wiring to Terminal Box
IMPORTANT 6.3.1 Power Supply Wiring Connection
• Lay wiring as far as possible from electrical Connect the power supply wiring to the SUPPLY +
noise sources such as large capacity transform- and – terminals.
ers, motors, and power supplies.
• Remove electrical connection dust cap before Transmitter terminal box
+
wiring. Power supply
• All threaded parts must be treated with water- –
proofing sealant. (A non-hardening silicone
group sealant is recommended.) F0601.EPS
• To prevent noise pickup, do not pass signal

Figure 6.3.1 Power Supply Wiring Connection
and power cables through the same ducts.
• Explosion-protected instruments must be wired
in accordance with specific requirements (and,
6.3.2 External Indicator Connection
in certain countries, legal regulations) in order
to preserve the effectiveness of their explosion- Connect wiring for external indicators to the CHECK +
protected features. and – terminals.
• The terminal box cover is locked by an Allen (Note) Use a external indicator whose internal resistance is 10 Ω or
head bolt (a shrouding bolt) on CENELEC and less.
IECEx flameproof type transmitters. When the
External indicator
shrouding bolt is driven clockwise by an Allen Power supply
wrench, it is going in and cover lock is re- +
leased, and then the cover can be opened by –
hand. See Subsection 9.4 “Disassembly and

Reassembly” for details.
Transmitter terminal box
F0602.EPS
Figure 6.3.2 External Indicator Connection

6.2 Selecting the Wiring Materi-
als
6.3.3 BRAIN TERMINAL BT200 Connec-
(a) Use stranded leadwires or cables which are the tion
same as or better than 600 V grade PVC insulated
Connect the BT200 to the SUPPLY + and – terminals
wire (JIS C3307) or equivalent.
(Use hooks). The communication line requires a
(b) Use shielded wires in areas that are susceptible to
reception resistor of 250 to 600 Ω in series.
electrical noise.
(c) In areas with higher or lower ambient temperatures,
use appropriate wires or cables. +
(d) In environment where oils, solvents, corrosive gases Power supply
or liquids may be present, use wires or cables that –
are resistant to such substances. Ignore the polarity

since the BT200 is
(e) It is recommended that crimp-on solderless terminal AC-coupled to the
lugs (for 4 mm screws) with insulating sleeves be BT200 terminal box.
F0603.EPS
used for leadwire ends.
Figure 6.3.3 BT200 Connection
6-1 IM 01C21F01-01E
6. WIRING
6.3.4 Check Meter Connection (2) Intrinsically Safe Type

For intrinsically safe type, a safety barrier must be
Connect the check meter to the CHECK + and –
included in the loop.
terminals (use hooks).
• A 4 to 20 mA DC output signal from the CHECK + Hazardous Location Nonhazardous Location
and – terminals.
(Note) Use a check meter whose internal resistance is 10 Ω or less. Transmitter terminal box
Distributor
(Power supply unit)
Power supply
+
–
Receiver
instrument
+
–
Check meter
Transmitter terminal box F0604.EPS
Safety barrier F0606.EPS
Figure 6.3.4 Check Meter Connection

Figure 6.4.1b Connection between Transmitter and
Distributor
6.4 Wiring
6.4.2 Wiring Installation
6.4.1 Loop Configuration
(1) General-use Type and Intrinsically Safe
Since the DPharp uses a two-wire transmission system, Type
signal wiring is also used as power wiring. Make cable wiring using metallic conduit or water-
DC power is required for the transmitter loop. The proof glands.
transmitter and distributor are connected as shown • Apply a non-hardening sealant to the terminal box
below. connection port and to the threads on the flexible
For details of the power supply voltage and load metal conduit for waterproofing.
resistance, see Section 6.6; for communications line
Apply a non-hardening
requirements, see Subsection 8.1.2. sealant to the threads for
waterproofing.
(1) General-use Type and Flameproof Type
Wiring metal
Hazardous Location Nonhazardous Location conduit
Transmitter terminal box Tee

Distributor
(Power supply unit)
Drain plug
Receiver Flexible metal conduit

+
instrument
– F0607.EPS
F0605.EPS
Figure 6.4.2a Typical Wiring Using Flexible Metal Conduit
Figure 6.4.1a Connection between Transmitter and
Distributor
6-2 IM 01C21F01-01E
6. WIRING
(2) Flameproof Type 6.5 Grounding

Wire cables through a flameproof packing adapter, or
Grounding is always required for the proper operation
using a flameproof metal conduit.
of transmitters. Follow the domestic electrical require-
䊏 Wiring cable through flameproof packing adapter. ments as regulated in each country. For a transmitter
• Apply a nonhardening sealant to the terminal box with built-in lightning protector, grounding should
connection port and to the threads on the flameproof satisfy ground resistance of 10⍀ or less.
packing adapter for waterproofing.
Ground terminals are located on the inside and outside
Apply a non-hardening of the terminal box. Either of these terminals may be
sealant to the threads for used.
waterproofing.

Wiring metal
conduit
Ground terminal
Tee (Inside)
Drain plug
Flexible metal conduit
Flameproof packing adapter
Ground terminal
F0608.EPS
(Outside)
Figure 6.4.2b Typical Cable Wiring Using Flameproof
;;
Packing Adapter
F0610.EPS
䊏 Flameproof metal conduit wiring Figure 6.5 Ground Terminals

• A seal fitting must be installed near the terminal box
connection port for a sealed construction.
• Apply a non-hardening sealant to the threads of the
terminal box connection port, flexible metal conduit 6.6 Power Supply Voltage and
and seal fitting for waterproofing. Load Resistance
Non-hazardous area Gas sealing device When configuring the loop, make sure that the external
load resistance is within the range in the figure below.
Apply a non-hardening
(Note) In case of an intrinsically safe transmitter, external load
sealant to the threads of
these fittings for resistance includes safety barrier resistance.
Hazardous area waterproofing
600
Flameproof
heavy-gauge External E–10.5
R= Communication
steel conduit load 0.0236
applicable range
resistance BRAIN and HART
R (Ω)
Tee
Flameproof flexible
Drain plug 250
metal conduit
Seal fitting
After wiring, impregnate the fitting
with a compound to seal tubing.
F0609.EPS
Figure 6.4.2c Typical Wiring Using Flameproof Metal

Conduit 0 10.5 16.4 24.7 42
Power supply voltage E (V DC)
F0611.EPS
Figure 6.6 Relationship between Power Supply Voltage

and External Load Resistance
6-3 IM 01C21F01-01E
7. OPERATION
7. OPERATION
7.1 Preparation for Starting Confirming that Transmitter is Operating

Properly
Operation Using the BT200
This section describes the operation procedure for • If the wiring system is faulty, ‘communication error’
appears on the display.
measuring a pressure as shown in Figure 7.1.
• If the transmitter is faulty, ‘SELF CHECK ERROR’
appears on the display.
NOTE
PARAM
C60:SELF CHECK
Confirm that the process pressure tap valve, ERROR
drain valve, and stop valve are closed. communication error
(a) Introduce a process fluid into the impulse piping DATA DIAG PRNT ESC
and then to the transmitter in the following proce- Communication error Self-diagnostic error
dure: (Faulty wiring) (Faulty transmitter)
F0702.EPS
1) Open the tap valve (main valve) to fill the impulse
piping with process fluid. Using the integral indicator
2) Gradually open the stop valve to introduce process • If the wiring system is faulty, the display stays blank.
fluid into the transmitter pressure-detector section. • If the transmitter is faulty, an error code will appear
3) Confirm that there is no pressure leak in the on the display according to the nature of the error.
impulse piping, transmitter, or other components.
(b) Turn ON power and connect the BT200.
(c) Using the BT200, confirm that the transmitter is
operating properly. Check parameter values or
change the setpoints as necessary. See Chapter 8 for
BT200 operation. Self-diagnostic error on
the integral indicator
(Faulty transmitter)
Union or flange F0703.EPS
Vent plug (Fill plug)
Tap valve NOTE

If any of the error indications above appears on
the display of the integral indicator or BT200,
Stop valve
refer to Subsection 8.5.2 for corrective action.
Verify and Change Transmitter Parameter

Tee Setting and Values
The following parameters are the minimum settings
Union or flange
required for operation. The transmitter has been
Drain valve shipped with these parameters. To confirm or change
the values, see Subsection 8.3.3.
Drain plug
F0701.EPS
• Measuring range..........See Subsection 8.3.3 (2)
Figure 7.1 Liquid Flow Measurement (Gauge Pressure • Operation mode...........See Subsection 8.3.3 (7)
Transmitters)
7-1 IM 01C21F01-01E
7. OPERATION
7.2 Zero Point Adjustment 7.2.1 When you can obtain Low Range
Value from actual measured value
Adjust the zero point after operating preparation is of 0% (0 kPa, atmospheric pres-
completed. sure);
For pressure measurement using gauge pressure
transmitters, follow the step below before zero point
IMPORTANT
adjustment.
Do not turn off the power to the transmitter 1) Close the tap valve (main valve).
immediately after a zero adjustment. Powering 2) Loosen the fill plug so that the pressure applied to
off within 30 seconds after a zero adjustment will the transmitter is only the head of the seal liquid.
return the adjustment back to the previous 3) Adjust the zero point at this status.
settings. 4) After the adjustment, close the fill plug and then
gradually open the tap valve.
The zero point adjustment can be made in either way:

using the zero-adjustment screw of the transmitter or Using the Transmitter Zero-adjustment
Screw
the BT200 operation.
Before adjusting a screw, check that the parameter
For output signal checking, display the parameter A10: J20: EXT ZERO ADJ displays ENABLE. See
OUTPUT (%) in the BT200. Subsection 8.3.3 (11) for the setting procedure.
•BT200
• Use a slotted screwdriver to turn the zero-adjustment
screw. Turn the screw clockwise to increase the
PARAM Output signal (%) output or counterclockwise to decrease the output.
A10:OUTPUT(%) display The zero point adjustment can be made with a
0.0 %
A11:ENGR OUTPUT resolution of 0.01% of the setting range. Since the
A20:AMP TEMP degree of zero adjustments varies with the screw
turning speed, turn the screw slowly for fine adjust-
DATA DIAG PRNT ESC ment and quickly for coarse adjustment.
•Zero-adjustment Screw Using the BT200

Zero point can be adjusted by simple key operation of
the BT200.
Select parameter J10: ZERO ADJ, and press the
Zero-adjustment ENTER key twice. The zero point will be adjusted
screw
automatically to the output signal 0% (4 mA DC).
F0704.EPS Confirm that the setting value displayed for the
After reviewing this parameter you are prepared to parameter is ‘0.0%’ before pressing the ENTER key.
adjust the zero point. When making the zero adjust- See Subsection 8.3.3 (11) for BT200 operating proce-
ment on a pressure transmitter, the process pressure dures.
value does not have to be set to the low limit of the
measurement range (0%). In such case, adjust the SET
J10:ZERO ADJ Display when parameter
transmitter output signal to the actual measured value –0.0 %
J10 is selected.
+ 000.0
obtained from a high-accuracy pressure measuring
Press key
instrument.
twice for 0% output 4 mA DC.
CLR ESC
F0705.EPS
7-2 IM 01C21F01-01E
7. OPERATION
7.2.2 When you cannot obtain Low Range 7.3 Starting Operation
Value from actual measured value
of 0%; After completing the zero point adjustment, follow the
procedure below to start operation.
Convert the actual measured value obtained by a digital
manometer or a glass gauge into %. 1) Confirm the operating status. If the output signal
exhibits wide fluctuations (hunting) due to periodic
[Example] variation in the process pressure, use BT200 to
The measuring range of 50 to 250 kPa; the actual dampen the transmitter output signal. Confirm the
measured value of 130 kPa. hunting using a receiving instrument or the integral
indicator, and set the optimum damping time
130–50 constant. See Subsection 8.3.3 (3), “Damping Time
Actual measured value= x 100=40.0% Constant Setup.”
250–50
2) After confirming the operating status, perform the
Using the Transmitter Zero-Adjustment Screw following.
Turn the screw to match the output signal to the actual
measured value in %.
IMPORTANT
Using the BT200
• Remove the BT200 from the terminal box, and
Select the parameter J10: ZERO ADJ. Change the
confirm that none of the terminal screws are
set point (%) displayed for the parameter to the actual
loosened.
measured value (%), and press the ENTER key twice.
• Close the terminal box cover and the amplifier
See Subsection 8.3.3 (11) for operation details.
cover. Screw each cover in tightly until it will
not turn further.
SET Display at J10 • Two covers are required to be locked on the
J10:ZERO ADJ
–0.0 %
+ 000.0 CENELEC and IECEx Flameproof type trans-
mitters. An Allen head bolts (shrouding bolts)
are provided under edge of the each cover for
CLR ESC locking. When a shrouding bolts are driven
counterclockwise by an Allen wrench, it is
coming out and locks up a cover. (See page 9-
SET Change setting to the actually 4) After locking, the covers should be con-
J10:ZERO ADJ
–0.0 % measured value (40.0%). firmed not to be opened by hands.
+ 040.0
Press key twice • Tighten the zero-adjustment cover mounting
for 40% output 10.4 mA DC. screw to fix the cover in position.
CLR ESC
F0706.EPS
7.4 Shutting Down Operation

Shut down the transmitter operation as follows.
1) Turn off the power.
2) Close the stop valve.
3) Close the tap valve.
NOTE
Whenever shutting down the transmitter for a
long period, remove any process fluid from the
transmitter pressure-detector section.
7-3 IM 01C21F01-01E
7. OPERATION
7.5 Setting the Range Using the IMPORTANT

Range-setting Switch
• Do not turn off the power to the transmitter
With actual pressure being applied to the transmitter, immediately after completion of the change in
the range-setting switch (push-button) located on the the LRV and/or HRV setting(s). Note that
optional /E integral indicator plate and the external powering off within thirty seconds after setting
zero-adjustment screw allow users to change (re-range) will cause a return to the previous settings.
the low- and high-limit values for the measurement • Changing LRV automatically changes HRV to
range (LRV and HRV) without using BT200. How- the following value.
ever, other changes in the display settings (scale range
HRV = previous HRV + (new LRV – previous LRV)
and engineering unit) for the integral indicator requires
BT200. • If the range-setting push-button and external
zero-adjustment screw are not touched during a
Follow the procedure below to change the LRV and
range-change operation, the transmitter auto-
HRV settings.
matically switches back to the normal operation
[Example] mode.
Rerange LRV to 0 and HRV to 3 MPa.
Integral indicator
1) Connect the transmitter and apparatus as shown in
Figure 9.3.1 and warm up for at least five minutes. Note : Use a thin bal which
2) Press the range-setting push-button. has a blunt tip, e.g.,
a hexagonal wrench,
The integral indicator then displays “LSET.” to press the range-
3) Apply a pressure of 0 kPa (atmospheric pressure) to setting push-button
the transmitter. (Note 1)
4) Turn the external zero-adjustment screw in the
desired direction. The integral indicator displays the Range-setting switch
(Push-button)
output signal in %. (Note 2) F0707.EPS
5) Adjust the output signal to 0% (1 V DC) by rotating Figure 7.5 Range-setting Switch
the external zero-adjustment screw. Doing so
completes the LRV setting.
6) Press the range-setting push-button. The integral
indicator then displays “HSET.”
7) Apply a pressure of 3 MPa to the transmitter. (Note 1)
8) Turn the external zero-adjustment screw in the
desired direction. The integral indicator displays the
output signal in %. (Note 2)
9) Adjust the output signal to 100% (5 V DC) by
rotating the external zero-adjustment screw. Doing
so completes the HRV setting.
10) Press the range-setting push-button. The transmitter
then switches back to the normal operation mode
with the measurement range of 0 to 3 MPa.
Note 1: Wait until the pressure inside the pressure-detector section
has stabilized before proceeding to the next step.
Note 2: If the pressure applied to the transmitter exceeds the previous
LRV (or HRV), the integral indicator may display error
number “Er.07” (In this case, the output signal percent and
“Er.07” are displayed alternately every two seconds).
Although “Er.07” is displayed, you may proceed to the next
step. However, should any other error number be displayed,
take the appropriate measure in reference to Subsection
8.5.2, “Errors and Countermeasures.”
7-4 IM 01C21F01-01E
8. BRAIN TERMINAL BT200 OPERATION
8. BRAIN TERMINAL BT200

OPERATION
The DPharp is equipped with BRAIN communica- 8.2 BT200 Operating Procedures
tions capabilities, so that range changes, Tag No.
setup, monitoring of self-diagnostic results, and zero 8.2.1 Key Layout and Screen Display
point adjustment can be handled by remote control
via BT200 BRAIN TERMINAL or CENTUM CS Figure 8.2.1a shows the arrangement of the operating
console. This section describes procedures for setting keys on the BT200 keypad, and Figure 8.2.1b shows
parameters using the BT200. For details concerning the BT200 screen component.
the BT200, see IM 01C00A11-01E, “BT200 User’s
Manual.”
LCD
8.1 BT200 Operation Precau- (21 character × 8 lines)
tions
8.1.1 Connecting the BT200
The transmitter and the BT200 can be connected
either to the BT200 connection hooks in the transmit- Function keys
ter terminal box or to a relaying terminal board.
Movement keys
ENTER key
Control room Power ON/OFF key

Relaying
terminals Terminal board
Alphanumeric keys
Distributor
Shift keys
F0803.EPS
F0801.EPS
Figure 8.2.1a BT200 Key Layout
Figure 8.1.1 Connecting the BT200
MENU SCREEN
Messages
8.1.2 Conditions of Communication Line MENU BATTERY
A:DISPLAY
B:SENSOR TYPE
Menu choices
Cable resistance Rc Screen title
HOME SET ADJ ESC
Power PARAMETER SCREEN

cc
supply PARAM
A10:OUTPUT Function
100.0 %
Parameters A11:ENGR. OUTPUT commands
1000 mmH20
DPharp A20:AMP TEMP
Load Cable 23 deg C
resistance R resistance Rc DATA DI AG PRNT
F0804.EPS
Loop resistance = R + 2Rc
= 250 to 600 Ω Figure 8.2.1b BT200 Screen Component
Loop capacitance = 0.22 µF max. BT200
F0802.EPS
Figure 8.1.2 Conditions of Communication Line

8-1 IM 01C21F01-01E
8.2.2 Operating Key Functions Use the function key [F1] CODE to enter symbols.
The following symbols will appear in sequence, one
(1) Alphanumeric Keys and Shift Keys at a time, at the cursor each time you press [F1]
You can use the alphanumeric keys in conjunction CODE:
with the shift keys to enter symbols, as well as
/ . – , + * ) ( ’ & % $ # ” !
alphanumeric keys.
To enter characters next to these symbols, press [ > ]
to move the cursor.
Entry Key-in Sequence

Alphanumeric keys symbol command
l/m
(I) (/) (m)
T0803.EPS
Shift keys
F0805.EPS
(2) Function Keys

a. Entering Digits, Symbols, and Spaces The functions of the function keys depend on the
(0 to 9, ., 2, ) function commands on display.
Simply press the alphanumeric keys.
MENU
Entry Key-in Sequence A:DISPLAY
B:SENSOR TYPE
–4
0.3
HOME SET ADJ ESC Function commands
1 –9
T0801.EPS
Function keys
b. Entering Letters (A through Z) F0808.EPS
Press an alphanumeric key following a shift key to

enter the letter shown on that side which the shift key
represents. You must press the shift key before Function Command List
entering each letter. Command Function
ADJ Displays the ADJ menu
Left-side letter on the Right-side letter on CAPS/caps Selects uppercase or lowercase
alphanumeric key the alphanumeric key CODE Selects symbols
CLR Erases input data or deletes all data
F0806 .EPS
DATA Updates parameter data
Entry Key-in Sequence DEL Deletes one character
W DIAG Calls the self-check panel
IC ESC Returns to the most recent display

HOME Displays the menu panel
J. B
NO Quits setup and returns to the previous display
T0802.EPS
Use the function key [F2] to select between

CAPS OK Proceeds to the next panel
uppercase and lowercase (for letters only). The case PARM Enters the parameter number setup mode
toggles between uppercase and lowercase each time SET Displays the SET menu
you press [F2] CAPS. SLOT Returns to the slot selection panel
UTIL Calls the utility panel
Entering uppercase Entering lowercase *COPY Prints out parameters on display
CODE CAPS CLR ESC CODE caps CLR ESC *FEED Paper feed
*LIST Lists all parameters in the menu
*PON/POFF Automatic printout mode on or off
Entry Key-in Sequence *PRNT Changes to the print mode
to lower case *GO Starts printing
Boy *STOP Cancels printing
(B) (o) (y)
* Available on BT200-P00 (with printer).
F0807.EPS T0804.EPS
8-2 IM 01C21F01-01E
8.2.3 Calling Up Menu Addresses Using the Operating Keys
––WELCOME–– UTILITY The utility screen contains the

BRAIN TERMINAL 1.ID following items.
ID: BT200 2.SECURITY CODE
STARTUP 3.LANGUAGE SELECT 1. BT200 ID settings
SCREEN check connection 4.LCD CONTRAST 2. Security code settings
push ENTER key 5.PRINTER ADJUST
3. Switching language of messages
UTIL FEED esc (Japanese or English)
4. LCD contrast setting
5. Adjusting printout tone
(UTIL)
(BT200-P00 only)
PARAM
01:MODEL
EJA510A-DC
INITIAL 02:TAG NO. FUNC
DATA YOKOGAWA 1.MENU
SCREEN 03:SELF CHECK (ESC) 2.UPLOAD TO BT200
GOOD 3.DOWNLOAD TO INST
OK 4.PRINT ALL DATA
HOME SET ADJ ESC
(SET) (ADJ)
(HOME MENU SCREEN) (SET MENU SCREEN) (ADJ MENU SCREEN)
MENU MENU MENU
A.DISPLAY C.SETTING J.ADJUST
B.SENSOR TYPE D.AUX SET 1 K.TEST
MENU E.AUX SET 2 M.MEMO
SCREEN H:AUTO SET P:RECORD
HOME SET ADJ ESC HOME SET ADJ ESC HOME SET ADJ ESC
PARAM PARAM
A60:SELF CHECK C60:SELF CHECK
GOOD GOOD
PARAM PARAM PARAM

A21:CAPSULE TEMP C22:HIGH RANGE J60:SELF CHECK
PARA- 26.5 deg C 100 kPa GOOD
METER DATA DIAG PRNT ESC DATA DIAG PRNT ESC
SCREEN
PARAM PARAM PARAM
A10:OUTPUT(%) C10:TAG NO. J10:ZERO ADJ
50.0 % YOKOGAWA 0.0 %
DATA DIAG
A11:ENGR, PRNT
OUTPUT ESC DATA DIAG
C20:PRESS UNITPRNT ESC DATA DIAG
J11:ZERO DEV PRNT ESC
20.0 M kPa 22.2 %
A20:AMP TEMP C21:LOW RANGE J20:EXT. ZERO ADJ
24.5 deg C 0 kPa ENABLE
DATA DIAG PRNT ESC DATA DIAG PRNT ESC DATA DIAG PRNT ESC
SET See “BT200 Instruction Manual” for details

C10:TAG NO. concerning uploading and downloading parameters
SETUP YOKOGAWA
SCREEN YOKOGAWA and printouts (BT200-P00).
CODE CAPS CLR ESC

F0809.EPS
8-3 IM 01C21F01-01E
8.3 Setting Parameters Using the BT200

8.3.1 Parameter Summary
Instruments to which applicable:
F: Differential pressure transmitters EJA110A, EJA120A, and EJA130A
P: Pressure transmitters EJA310A, EJA430A, EJA440A, EJA510A, and EJA530A
L: Liquid level transmitters EJA210A and EJA220A
Applica-
Rewrita- bility
No. Item Description Remarks Default Value
bility F P L
01 MODEL Model+capsule type —
02 TAG NO. Tag number — 16 alphanumerics

03 SELF CHECK Self-diagnostic result — GOOD/ERROR
A DISPLAY Measured data display — Menu name
A10 OUTPUT (%) Output (in %) — –5 to 110%*3
A11 ENGR. Output (in engineering — –19999 to 19999
OUTPUT units)
A20 AMP TEMP Amplifier temperature — Unit specified in D30
A21 CAPSULE Capsule temperature — Unit specified in D30
TEMP
A30 STATIC Static pressure — Unit specified in D31*1 —
PRESS
A40 INPUT Input (indicated as the — –32000 to 32000
value after zeroing)
A60 SELF CHECK Self-diagnostic — GOOD/ERROR, CAP MODULE FAULT, AMP MODULE FAULT,
messages OUT OF RANGE, OUT OF SP RANGE*1, OVER TEMP (CAP),
OVER TEMP (AMP), OVER OUTPUT, OVER DISPLAY,
ILLEGAL LRV, ILLEGAL HRV, ILLEGAL SPAN, and
ZERO ADJ OVER
B SENSOR Sensor type — Menu name
TYPE
B10 MODEL Model+span — 16 uppercase alphanumerics
B11 STYLE NO.Style number —
B20 LRL Lower range-limit — –32000 to 32000

B21 URL Upper range-limit — –32000 to 32000
B30 MIN SPAN Minimum span — –32000 to 32000
B40 MAX STAT.P.
Maximum static — —
pressure*6
B60 SELF CHECK Self-diagnostic — Same as A60
messages
C SETTING Setting data — Menu name
C10 TAG. NO. Tag number 16 alphanumerics As specified when ordered.
C20 PRESS UNIT Measurement range Selected from mmH2O, mmAq, As specified when ordered.
units mmWG, mmHg, Torr, Pa, hPa, kPa,
MPa, mbar, bar, gf/cm2, kgf/cm2,
inH2O, inHg, ftH2O, psi, or atm
C21 LOW RANGE Measurement range, –32000 to 32000(but within As specified when ordered.
lower range value measurement range)
C22 HIGH Measurement range, –32000 to 32000(but within As specified when ordered.
RANGE higher range value measurement range)
C30 AMP Damping time constant Selected from 0.2*2, 0.5, 1.0, 2.0, 2.0 s
DAMPING 4.0, 8.0, 16.0, 32.0, or 64.0 sec.
C40 OUTPUT Output mode and Selected from OUT:LIN; DSP:LIN, As specified when ordered. — —
MODE integral indicator mode OUT:LIN; DSP:SQR, If not specified,

OUT:SQR; DSP:SQR OUT: LIN; DSP: LIN.
C60 SELF CHECK Self-diagnostic — Same as A60
messages
D AUX SET 1 Auxiliary setting data 1 — Menu name
D10 LOW CUT Low cut 0.0 to 20.0% 10.0%
D11 LOW CUT Low cut mode LINEAR/ZERO LINEAR
MODE
D15 OUT LIMIT(L) Lower output range-limit –5.0 to 110.0% –5.0%*1
D16 OUT LIMIT(H) Upper output range-limit –5.0 to 110.0% 110.0%
D20 DISP SELECT Display selection NORMAL %/USER SET, As specified when ordered.
USER & %/INP PRES, PRES & %
D21 DISP UNIT Engineering unit for 8 uppercase
display alphanumerics
D22 DISP LRV Engineering range, –19999 to 19999 As specified when ordered.
lower range value
D23 DISP HRV Engineering range, –19999 to 19999 As specified when ordered.
higher range value
D30 TEMP UNIT Temperature setting deg C/deg F deg C
units
*1: Unless otherwise specified by order. When optional code /F1 is specified, substitute the value –5 with –2.5.
T0805.EPS
8-4 IM 01C21F01-01E
Applica-
No. Item Description Rewrita- Remarks bility
Default Value
bility F P L
D AUX SET 1 Auxiliary setting data 1 — Menu name
D31 STAT. P. UNIT Static pressure setting Selected from mmH2O, mmAq, As specified when ordered. —
units mmWG, mmHg, Torr, Pa, hPa, kPa, If not specified, MPa.
MPa, mbar, bar, gf/cm2, kgf/cm2,
inH2O, inHg, ftH2O, psi, or atm
D40 REV OUTPUT Output reversal NORMAL/REVERSE If not specified, NORMAL.
D45 H/L SWAP Impulse piping NORMAL/REVERSE*4 NORMAL — —
accessing direction
D52 BURN OUT CPU error —
HIGH/LOW, –5 to 110%*3 HIGH
D53 ERROR OUT Hardware error HOLD/HIGH/LOW, –5 to 110%*3 HIGH
D60 SELF CHECK Self-diagnostic — Same as A60
messages
E AUX SET 2 Auxiliary setting data 2 — Menu name
E10 DFS MODE DFS mode OFF/ON*5 ON —
E14 TEMP Reference temperature AMP. TEMP/CAP. TEMP*5 CAP. TEMP —
SELECT sensor
E15 TEMP ZERO Zero shift 10.00*5 0.00 —
conpensation setup
E30 BI DIRE Bidirectional mode OFF/ON OFF — —
MODE
E50 AUTO Auto-recover from OFF/ON ON
RECOVER sensor error
E60 SELF CHECK Self-diagnostic — Same as A60
messages
H AUTO SET Automatic setup — Menu name
H10 AUTO LRV Automatic measure- –32000 to 32000 Displays the same data as
ment range lower C21.
range value setup
H11 AUTO HRV Automatic –32000 to 32000 Displays the same data as
measurement range C22.
higher range value
setup
H60 SELF CHECK Self-diagnostic — Same as A60
messages
J ADJUST Adjustment data — Menu name
J10 ZERO ADJ Automatic zero –5 to 110.0%*3
adjustment
J11 ZERO DEV. Manual zero
adjustment
J15 SPAN ADJ Manual span adjustment –10.00 to 10.00% 0.00%
J20 EXT. ZERO External zero- ENABLE/INHIBIT
ADJ adjustment screw
permission
J30 OUTPUT 4mA 4mA adjustment –10.00 to 10.00% 0.00%
J31 OUTPUT 20mA 20mA adjustment –10.00 to 10.00% 0.00%
J60 SELF CHECK Self-diagnostic — Same as A60
messages
K TEST Tests — Menu name
K10 OUTPUT in % Test output % setting –5 to 110.0%*3 Displays ‘ACTIVE’
while executing
K60 SELF CHECK Self-diagnostic — Same as A60
messages
M MEMO Memo — Menu name
M10 MEMO 1 Memo 8 uppercase alphanumerics
M60 SELF CHECK Self-diagnostic — Same as A60
messages
P RECORD History of the errors —
P10 ERROR REC 1 Last error Display the error

P11 ERROR REC 2 One time before Display the error
P12 ERROR REC 3 Two time before Display the error
P13 ERROR REC 4 Three time before Display the error
P60 SELF CHECK Self-diagnostic —
Same as A60
messages
*1: In case of Model EJA120A, static pressure cannot be measured. The display is always 0 MPa, but this is not a measured value.
*2: When Optional code /F1 is specified, substitute the value with 0.1.
*3: When Optional code /F1 is specified, substitute the value –5 with –2.5.
*4: Not applicable for Model EJA115.
*5: Applicable only for Model EJA118W, EJA118N, EJA118Y, EJA438W, and EJA438N.
*6: See MWP(max. working pressure) on the nameplate. B40 shows an approximate value of maximum pressure for the capsule.
T0806.EPS
8-5 IM 01C21F01-01E
8.3.2 Parameter Usage and Selection

IMPORTANT
Before describing the procedure for setting param-
eters, we present the following table showing how If the transmitter is turned off within 30 seconds
the parameters are used and in what case. after parameters have been set, the set data
will not be stored and the terminal returns to
previous settings.
Table 8.3.1 Parameter Usage and Selection

Setup Item Description
Tag No. setup Sets the Tag No. (using 16 alphanumeric characters).
P.8-7 Note: Up to 8 alphanumerics (upper case letters) can be used in the BT100.
Calibration range setup Sets the calibration range for 4 to 20 mA DC. Sets three data items: range unit, input value
P.8-7 at 4 mA DC (LRV), and input value at 20 mA DC (HRV).
Note: LRV and HRV can be specified with range value specifications up to 5 digits
(excluding any decimal point) within the range of –32000 to 32000.
Damping time constant setup Adjusts the output response speed for 4 to 20 mA DC.
P.8-8 Can be set in 9 increments from 0.2 to 64 s.
Output signal low cut mode setup Used mainly to stabilize output near 0% if output signal is the square root mode.
P.8-9 Two modes are available: forcing output to 0% for input below a specific value, or changing
to proportional output for input below a specific value.
Change the output limits Change the range of normal output.
P.8-9
Integral indicator scale range and Sets the following 5 types of integral indicator scale ranges and units:
unit setup % scale indicator, user set scale indicator, alternate indication of user set scale
P.8-10 and % scale, input pressure display, alternate indication of input pressure and % scale
When using the user set scale, 4 types of data can be set:
user set scale setting, unit (BT200 only), display value at 4 mA DC (LRV), and display
value at 20 mA DC (HRV).
Note: LRV and HRV can be specified with range value specifications up to 5
digits (excluding any decimal point) within the range of –19999 to 19999.
Unit setup for displayed temperature Sets a unit for temperatures displayed on the BT200.
P.8-11
Operation mode (normal/reverse Reverses the direction for 4 to 20 mA DC output relative to input.
signal) setup Reverse mode is used for applications in which safety requires that output be
P.8-12 driven toward 20 mA if input is lost.
Output status display/setup when Displays the status of 4 to 20 mA DC output when a CPU failure. The parameter
a CPU failure P.8-12 of the standard unit is fixed to the high limit value.
Output status setup when a hardware Sets the status of the 4 to 20 mA DC output when an abnormal status is detected
error occurs with the capsule or the amplifier as the result of self-diagnosis. One of the
P.8-12 following statuses; last held, high limit, and low limit values, can be selected.
Range change (while applying Range for 4 to 20 mA DC signal is set with actual input applied. Sets 20 mA DC output
actual inputs) precisely with respect to user’s reference instrument output. Note that DPharp is calibrated
P.8-12 with high accuracy before shipment, so span should be set using the normal range setup.
Zero point adjustment Adjusts zero point. This can be done either using the external zero-adjustment screw on
P.8-13 the transmitteror using the BT200.
Span adjustment Adjust the characterization curve. All the transmitters are calibrated at factory and this
P.8-14 adjustment is normally not necessary for most cases. Use for specific purposes.
Test output (fixed current output) Used for loop checks.
setup P.8-15 Output can be set freely from –5% to 110% in 1% steps.
User memo fields Allows user to enter up to 5 items of any desired text in up to 8 uppercase
P.8-15 alphanumeric characters per item.
T0807.EPS
8-6 IM 01C21F01-01E
8.3.3 Setting Parameters

SET This is the panel for confirming
C10:TAG NO.
Set or change the parameters as necessary. After YOKOGAWA
FIC-1a
set data. The set data items flash.
completing these, do not fail to use the “DIAG” key PRINTER OFF When all items have been confir-
F2:PRINTER ON
to confirm that “GOOD” is displayed for the self- FEED POFF NO
med, press the
diagnostic result at _60: SELF CHECK. again. (To go back to the setting
panel, press the (NO) key.
(1) Tag No. Setup (C10: TAG NO) SET The DPharp TAG NO. was
C10:TAG NO.
Use the procedure below to change the Tag No. Up FIC-1a overwritten.
to 16 alphanumeric characters can be entered. Press the (OK) key to
FEED NO OK
return to the parameter panel.
Press the (NO) key to
PARAM
• Example: Set a Tag No. to FIC-1a C10:TAG NO.
FIC-1a
return to the setting panel.
C20:PRESS UNIT
kPa
Press the key to turn on C21:LOW RANGE
the BT200. 0 kPa
DATA DIAG PRNT ESC
<When power is off>
F0811.EPS
––WELCOME–– Connect DPharp and BT200 using

BRAIN TERMINAL
ID: BT200 a communication cable and press
check connection the key. (2) Calibration Range Setup
push ENTER key
UTIL FEED a. Setting Calibration Range Unit

PARAM Displays the name of connected (C20: PRESS UNIT)
01:MODEL
EJA110A-DM DPharp model, TAG NO. and The unit is set at the factory before shipment if
02:TAG NO.
YOKOGAWA diagnostics information. Press the
03:SELF CHECK specified at the time of order. Follow the procedure
GOOD (OK) key after confirmation.
OK below to change the unit.
MENU Press the (SET) key to
A:DISPLAY
B:SENSOR TYPE display the SET menu panel. • Example: Change the unit from mmH2O to kPa.
SET Use the or
HOME SET ADJ ESC C20:PRESS UNIT
mmH20
< mmWG > key to select “kPa.”
MENU Select C: SETTING and press the < mmHG >
C:SETTING < Torr > Press the key twice
D:AUX SET 1 key. < kPa >
E:AUX SET 2
H:AUTO SET
ESC to enter the setting.
SET
HOME SET ADJ ESC C20:PRESS UNIT Press the (OK) key.
kPa
MENU Select C10: TAG NO. and press
C10:TAG NO.
YOKOGAWA the key.
C20:PRESS UNIT
kPa FEED NO OK
C21:LOW RANGE
0 kPa
DATA DIAG PRNT ESC mmH2O
SET Set the new TAG NO. (FIC-1a). mmAq
C10:TAG NO. mmWG
YOKOGAWA FOKOGAWA mmHg
YOKOGAWA
FIKOGAWA Torr
Pa
CODE CAPS CLR ESC FICOGAWA hPa
FIC-GAWA kPa
MPa
FIC-1AWA
mbar
bar
FIC-1aWA gf/cm2
FIC-1a kgf/cm2
inH2O
SET Set TAG NO. and press the inHg
C10:TAG NO. ftH2O
YOKOGAWA key. psi
FIC-1a _
atm
CODE caps CLE ESC F0812.EPS
When you have made an entry mistake, return

the cursor using the key, then reenter.
F0810.EPS
8-7 IM 01C21F01-01E
b. Setting Calibration Range Lower

Range Value and Higher Range Value • Example 2: With present settings of 0 to 30 kPa,
(C21: LOW RANGE, C22: HIGH set the Higher range value to10 kPa.
RANGE) SET
C22:HIGH RANGE
Set 10.
These range values are set as specified in the order 30 kPa Press the key twice
+ 10
before the instrument is shipped. Follow the proce- to enter the setting.
dure below to change the range. DEL CLR ESC
SET Press the (OK) key.

• The measurement span is determined by the high C22:HIGH RANGE
10 kPa
and low range limit values. In this instrument,
changing the low range value also automatically
FEED NO OK
changes the high range value, keeping the span
constant. PARAM The low range value is not
C20:PRESS UNIT
kPa changed, so the span changes.
C21:LOW RANGE
0 kPa
• Example 1: With present settings of 0 to 30 kPa, C22:HIGH RANGE
10 kPa
set the lower range value to 0.5 kPa. DATA DIAG PRNT ESC
SET Set 0.5. F0814.EPS

C21:LOW RANGE
0 kPa
+ 0.5 Press the key twice to
enter the setting.
(3) Damping Time Constant Setup
DEL CLR ESC (C30: AMP DAMPING)
SET When the instrument is shipped, the damping time
C21:LOW RANGE Press the (OK) key.
0.5 kPa constant is set at 2.0 seconds. Follow the procedure
below to change the time constant.
FEED NO OK
SET
C20:PRESS UNIT
The higher range value is changed • Example: Change from 2.0 sec to 4.0 sec.
kPa
C21:LOW RANGE while the span remains constant.
SET
0.5 kPa C30:AMP DAMPING Use the or key to
C22:HIGH RANGE 2.0 sec
30.5 kPa < 2.0 sec > select 4.0 sec.
DATA DIAG PRNT ESC < 4.0 sec >
< 8.0 sec > Press the key twice to
< 16.0 sec >
ESC enter the setting.
Span = Higher range value – Lower range value
SET
C30:AMP DAMPING Press the (OK) key.
F0813.EPS 4.0 sec
FEED NO OK
• Note, however, that changing the higher range value 0.2sec
does not cause the lower range value to change. 0.5sec
1.0sec
Thus, changing the higher range value also changes
2.0sec
the span.
4.0sec
• Calibration range can be specified with range value
8.0sec
specifications up to 5 digits (excluding any decimal 16.0sec
32.0sec
point) for low or high range limits within the range 64.0sec
of –32000 to 32000.
F0815.EPS
Note: The damping time constant set here is the damping time
constant for the amplifier assembly. The damping time
constant for the entire transmitter is the sum of the values for
the amplifier assembly and for the capsule assembly. For the
capsule assembly damping time constant (fixed), see the
“General Specifications” found at the end of this manual.
(See Chapter 10.)
8-8 IM 01C21F01-01E
(4) Output Signal Low Cut Mode Setup (5) Change Output Limits
(D10: LOW CUT, D11: LOW CUT MODE) (D15:OUT LIMIT(L), D16:OUT LIMIT(H))
Low cut mode can be used to stabilize the output The range of normal output is preset at factory from
signal near the zero point. The low cut point can be -5.0 to 110.0% unless otherwise specified, and the
set in a range from 0 to 20% of output. (Hysteresis of output is limited with these upper and lower values.
cut point: ±1%) This output range can be changed, for example, to
meet the requirements of NAMUR, etc. within the
LOW CUT at 10% settable range. Set the lower limit with D15:OUT
LIMIT(L) and upper limit with D16:OUT LIMIT(H).
50 Settable range : -5.0 to 110.0 (%)

Lower limit < Upper limit
Output(%)
10
0 10 50
Input(%)
F0816.EPS
• Example: Change the low cut setting range

from 5% to 10%, and the low
cut mode from LINEAR to ZERO.
SET Set “10.”
D10:LOW CUT
5.0 %
enter the setting.
CLR ESC

D10:LOW CUT
10.0 %
Next, the [D11: LOW CUT MODE]
setting panel is displayed.
FEED NO OK
SET Use the or key

D11:LOW CUT MODE
LINEAR
< LINEAR > to select ZERO.
< ZERO >
Press the key twice to
ESC
enter the setting.
D11:LOW CUT MODE
ZERO
FEED NO OK
PARAM
D10:LOW CUT
10.0 %
D11:LOW CUT MODE
ZERO
D20:DISP SELECT
NORMAL %
DATA DIAG PRNT ESC
F0817.EPS
8-9 IM 01C21F01-01E
(6) Integral Indicator Scale Setup

The following 5 displays are available for integral indicators.
D20: DISP SELECT Display Related Parameters Description

NORMAL % A10:OUTPUT (%) Indicates –5 to 110%
45.6 % range depending on the
Measurement range
(C21, C22).
USER SET A11:ENGR.OUTPUT Indicates values depending
20.0 M on the Engineering range
(D22, D23). (Note 1)
Units set using Engineering
unit (D21) are not indicated.
USER & % A10:OUTPUT (%) Indicates user set and %
45.6 % alternately in 3 second
A11:ENGR. OUTPUT intervals.
20.0 M
INP PRES A40:INPUT Indicates input

456 kPa pressure. (Note 2)
Indication limits –19999
to 19999.
PRES & % A10:OUTPUT (%) Indicates input pressure
45.6 % and % alternately in 3
A40:INPUT second intervals.
456 kPa
(Note 1) Scale range can be specified with range limit specifications up to 5 digits (excluding any
decimal point) for low or high range limits within the range of –19999 to 19999.
The range with decimals is available to the third decimal place.
(Note 2) It indicates the value after zeroing. T0808.EPS
See (a.) through (c.) for each setting procedure.
% indication and input User-set engineering unit display

pressure indication
D20: DISP SELECT D20: DISP SELECT

NORMAL % USER SET Set for user-set
INP PRES USER & % engineering unit display.
PRES & %
Transmitter is set D21: DISP UNIT Set a unit to be

for “% display” when displayed on the BT200.
shipped.
For % display, set this D22: DISP LRV Set a numeric value for
parameter only. engineering unit for 4 mA
output (LRV).
D23: DISP HRV Set a numeric value for

engineering unit for 20 mA
output (HRV).
F0818.EPS
8-10 IM 01C21F01-01E
a. Display Selection (D20: DISP SELECT) c. Lower and Higher Range Value Setup
Follow the instructions given to the below to change in Engineering Unit (D22: DISP LRV,
D23: DISP HRV)
the range of integral indication scales.
These parameter items are used to set the lower and
When USER SET is selected, the user set values of higher range values for the engineering unit display.
integral indication and A11: ENGR. OUTPUT
parameter are indicated. When the instrument is shipped, these are set as
specified in the order. Follow the procedure below to
change these settings. Note that these parameters
need not be set for % display.
• Example: Set the integral indicator scale to
engineering units display.
• Example: Set lower range value (LRV) to –50
SET Use the or key
D20:DISP SELECT
NORMAL %
and higher range value (HRV) to 50.
<NORMAL %> to select “USER SET.”
<USER SET>
<USER & %> Press the key twice to Setting LRV
<INP PRES> SET Set “–50.”
ESC enter the setting. D22:DISP LRV
0M
- 50 Press the key twice to
SET
D20:DISP SELECT Press the (OK) key. enter the setting.
USER SET
DEL CLR ESC
FEED NO OK Setting HRV

SET Set “50.”
D23:DISP HRV
100M
The “%” disappears from the + 50 Press the key twice to
integral indicator display. enter the setting.

DEL CLR ESC
F0819.EPS
D23:DISP HRV
50M
b. Setting User-set Engineering Unit

FEED NO OK
(D21: DISP UNIT)
This parameter allows entry of the engineering units PARAM
D21:DISP UNT
M
to be displayed on the BT200. When the instrument D22:DISP LRV
– 50M
is shipped, this is set as specified in the order. D23:DISP HRV
50M
DATA DIAG PRNT ESC
Follow the procedure below to change this setting.
F0821.EPS
This parameter need not be set for % display.
(7) Unit Setup for Displayed Temperature
(D30: TEMP UNIT)
• Example: Set an engineering unit M.
When the instrument is shipped, the temperature units
SET
D21:DISP UNIT
Set “M.” are set to degC. Follow the procedure below to
M_ Press the key twice to change this setting. Note that changing the unit here
enter the setting. changes the unit for A20: AMP TEMP (amplifier
CODE CAPS CLR ESC temperature) and A21: CAPSULE TEMP (capsule
temperature).
D21:DISP UNIT
M
• Example: Change the unit for the temperature

FEED NO OK
display.
F0820.EPS SET
D30:TEMP UNIT
Use the or key to
deg C
< deg C > select “deg F.”
< deg F >
ESC
enter the setting.
F0822.EPS
8-11 IM 01C21F01-01E
(8) Operation Mode Setup (a) HOLD; Outputs the last value held before the
(D40: REV OUTPUT) error occurred.
This parameter allows the direction of the 4 to 20 (b) HIGH; Outputs an output of 110% when an error
mA output to be reversed with respect to input. has occurred.
Follow the procedure below to make this change. (c) LOW; Outputs an output of –5% when an error
has occurred.
• Example: Change 4 to 20 mA output to 20 to Note: A hardware error means CAP MODULE FAULT of Er.01 or
4 mA output. AMP MODULE FAULT of Er. 02 which are shown in 8.5.2
“Errors and Countermeasures.”)
SET Use the or key
D40:REV OUTPUT
NORMAL
< NORMAL > to select REVERSE. • Example: Set the output status to LOW when
< REVERSE>
Press the key twice to a hardware error occurs.
ESC
enter the setting. SET
D53:ERROR OUT Use the or key
HIGH
F0823.EPS < HIGH> to select “LOW.”
< LOW>
< HOLD>
(9) Output Status Display/Setup when a CPU ESC
enter the setting.
Failure (D52: BURN OUT)
F0825.EPS
This parameter displays the status of 4 to 20 mA DC
output if a CPU failure occurs. In case of a failure, (11) Range Change while Applying Actual
communication is disabled. Inputs (H10: AUTO LRV, H11: AUTO
HRV)
Setting of HIGH or LOW is enabled. This is done
with the pin (CN4) on the CPU assembly. See This feature allows the lower and higher range values
Chapter 3 for details. to be set up automatically with the actual input
applied. If the lower and higher range values are set,
Standard specifications C21: LOW RANGE and C22: HIGH RANGE are
The parameter is set to HIGH. If a failure, the changed at this same time.
transmitter outputs the signal of 110% or higher. The
parameter D53: ERROR OUT is set to HIGH from Follow the procedure in the figure below.
the factory. The measurement span is determined by the higher
and lower range values. Changing the lower range
Optional code/C1 value results in the higher range value changing auto-
The parameter is set to LOW. If a failure, output matically, keeping the span constant.
which is –5% or lower is generated. The parameter
D53: ERROR OUT is set to LOW from the factory.
• Example 1: When changing the lower range
value to 0.5 kPa for the present
• Example: Standard specifications setting of 0 to 30 kPa, take the
D52: BURN OUT pin (CN4) position: H following action with input pressure
HIGH
of 0.5 kPa applied.
• Example: Optional code/C1 SET

H10:AUTO LRV
Press the key twice.
0 kPa
D52: BURN OUT pin (CN4) position: L + 0 The lower range value is changed
LOW
to 0.5 kPa.
ESC
F0824.EPS
H10:AUTO LRV
0.5000 kPa
(10) Output Status Setup when a Hardware
Error Occurs (D53: ERROR OUT)
This parameter allows the setting of the output status FEED NO OK
when a hardware error occurs. The following three PARAM The higher range value is changed
H10:AUTO LRV
selections are available. 0.5000 kPa
keeping the span constant.
H11:AUTO HRV
30.500 kPa
H60:SELF CHEC Parameters C21 and C22 are
GOOD
DATA DIAG PRNT ESC
changed at the same time.
F0826.EPS
8-12 IM 01C21F01-01E
Note that changing the higher range value does not (a) Follow the procedure below when setting the
cause the lower range value to change but does present output to 0% (4 mA).
change the span.
A10:OUTPUT (%) Output is 0.5%.

0.5 %
• Example 2: When the higher range value is to
be changed to 10 kPa with the
SET
Press the key twice.
present setting of 0 to 30 kPa, take J10:ZERO ADJ
0.0 %
+ 000.0
the following action with an input
pressure of 10 kPa applied.
CLR ESC
SET Press the key twice.
H11:AUTO HRV SET
30 kPa J10:ZERO ADJ Zero adjustment is completed.
+ 30 The higher range value is changed 0.0 %
Press the (OK) key.
to 10 kPa.
ESC
FEED NO OK
H11:AUTO HRV
10.000 kPa A10:OUTPUT (%) Output is 0%.
0.0 %
FEED NO OK
F0828.EPS
PARAM The lower range value is not

H10:AUTO LRV
0 kPa
H11:AUTO HRV changed, so the span changes. (b) In tank level measurement, if the actual level
10.000 kPa
H60:SELF CHECK Parameter C22 is changed at the cannot be brought to zero for zero adjustment,
GOOD
DATA DIAG PRNT ESC
same time. then the output can be adjusted to correspond to
the actual level obtained using another measuring
F0827.EPS
instrument such as a glass gauge.
(12) Zero Point Adjustment [Example]

(J10: ZERO ADJ, J11: ZERO DEV,
J20: EXT ZERO ADJ) Measurement range: 50 to 250 kPa, Actual value:
The DPharp supports several adjustment methods. 130 kPa.
Select the method best suited for the conditions of
Actual value
your application.
Actual = –Measurement range lower range value
Note that output signal can be checked by displaying x 100
value(%) Measurement range higher range value
parameter A10:OUTPUT (%) on the BT200. –Measurement range lower range value
130–50
= x 100=40.0%
Adjustment Method Description 250–50
Using the BT200 Set the present input to 0%.
Adjust for 0% output at input level of (b)-1 Follow the procedure below to use J10: ZERO
0%.
ADJ.
Adjust output to the reference value
obtained using other means.
If the input level cannot easily be A10:OUTPUT (%)
Present output is 41.0%.
made 0% (because of tank level, 41.0 %
etc.), adjust output to the reference
value obtained using other means, SET Enter the present actual level, 40%.
such as a sight glass. J10:ZERO ADJ
0.0 %
+ 040.0 Press the key twice.
Using the external Adjust zero point using the zero-
zero-adjustment adjustment screw on the transmitter.
screw P.8-14 This permits zero adjustment without CLR ESC
using the BT200. Accurately adjust

the output current to 4 mA DC or A10:OUTPUT (%) The output is changed to 40%.
40.0 %
other target output value using an
ammeter that accuratly reads output
F0829.EPS
currents.
T0809.EPS
8-13 IM 01C21F01-01E
(b)-2 Follow the procedure below to use J11: ZERO

• Example: Inhibiting zero adjustment by the
DEV.
external zero-adjustment screw
SET Use the or key to
A10:OUTPUT (%)
Present output is 41.0%. J20:EXIT ZERO ADJ
41.0 % ENABLE
Output error = 40.0 – 41.0 = –1.0%. < ENABLE > select “INHIBIT.”
< INHIBIT>
SET Since “J11: ZERO DEV.” contains ESC
J11:ZERO DEV. enter the setting.
2.50 %
0 the previous correction, obtain the
F0831.EPS
correction value by adding –1.0% to
ESC
it. 2.50% + (–1.0%) = 1.50% • Zero point adjustment using external zero-adjust-
ment screw on the transmitter
SET Set the correction value, 1.50.
J11:ZERO DEV.
2.50 % Turn the zero-adjustment screw on the outside of the
1.50 Press the key twice.
transmitter case using a slotted screwdriver. Turn the
ECS
screw to the right to increase the zero point or to the
left to decrease the zero output; the zero adjusts in
A10:OUTPUT (%) The output is changed to 40%. increments of 0.01% of the range setting.
40.0 %
Note that the amount of adjustment to the zero point
F0830.EPS changes according to the speed at which the screw is
turned. To make fine adjustments, turn the screw
When the zero point is adjusted, the displayed value slowly; to make coarse adjustments, turn the screw
of A40 is as follows. quickly.
[Example]
Note: When a zero point adjustment has been made, do not turn
When the zero point is shifted by 20 kPa for the off the transmitter less than 30 seconds after adjustment.
actual pressure, the parameter of A40 indicates 50
kPa.
(13) Span Adjustment
Each DPharp EJA series transmitter is factory
70 kPa
characterized according to the specification. Mount-
50 kPa ing position effects or zero shifts caused by static
pressure are typically compensated by a zero adjust-
Zero ment.
20 kPa adjustment
Zero adjustment
volume(J11) A span adjustment is a function to correct the slope
0 kPa 0 kPa
Actual differential Input value error from a zero point in characterizing 100% point
pressure/pressure of A40 F0839.EPS (HRV). This function can be used when span drifts
may be caused or characterization to the specific
(c) Zero Point Adjustment Using the External Zero
pressure standard is required.
Adjustment Screw
Therefore, the zero point adjustment should always
• Enabling/inhibiting of zero point adjustment using
be performed before the upper point adjustment in
the external zero-adjustment screw on the transmitter
order to maintain the pitch between zero and 100%
(J20: EXT ZERO ADJ)
points within the calibration range.
Follow the procedure below to enable or inhibit zero
You can manually perform the trimming procedure
point adjustment from the zero-adjustment screw on
by using J15: SPAN ADJ.
the transmitter.
This is set to “ENABLE” when the instrument is
shipped.
8-14 IM 01C21F01-01E
• Span adjustment value (14) Test Output Setup (K10: OUTPUT X%)
The span adjustment value is calculated as follows. This feature can be used to output a fixed current
from 3.2 mA (–5%) to 21.6 mA (110%) for loop
Span adjustment value (%) = P1 A40 100
checks.
P1
P1: Actual differential pressure/pressure value
A40: Input (indicated as the value after zeroing) • Example: Output 12 mA (50%) fixed current.
SET Set “50.0%.”
Measurement pressure K10:OUTPUT X %
0.0 %
output a fixed current at 50%.
ESC
A40
SET “Active” is displayed while this is
K10:OUTPUT X %
50.0 % ACTIVE
being executed.
Applied pressure
P1 Press the (OK) key to cancel
0 F0846.EPS
FEED NO OK
the fixed current output.
F0832.EPS
• Example: For the range of 0 to 30 kPa. IMPORTANT

A40: INPUT = 30.15 kPa
J15: SPAN ADJ = 0.15 % 1. Test output is held for approximately 10
minutes, and then released automatically after
Suppose that a standard pressure of 30 kPa is applied and
the value of the parameter of A40: INPUT is 30.15 kPa. the time has elapsed. Even if the BT200
Firstly, obtain the slope error for the span as follows; power supply is turned off or the communica-
tion cable is disconnected during test output,
P1 A40
Span adjustment value (%) = 100 it is held for approximately 10 minutes.
P1
2. Press the (OK) key to release test output
30.0030.15
100 = 0.5 (%) immediately.
30.00
Add 0.5% to 0.15% of the current value to calculate the

accumulated span adjustment value.
(15) User Memo Fields (M: MEMO)
0.15 (0.50) = 0.35
This feature provides 5 user memo fields, each
holding up to 8 alphanumeric characters. Up to 5
SET Set 0.35.
J15:SPAN ADJ
0.15 %
items such as inspection date, inspector, and other
- 0.35 Press key twice.
information can be saved in these fields.
DEL CLR ESC
SET
J15:SPAN ADJ
Press the (OK) key. • Example: Save an inspection date of January
-0.35 % 30, 1995.
PARAM Set “95.1.30” in the order of year,

FEED NO OK M10:MEMO 1
M20:MEMO 2 month, and day.

Note: Enter 0.00 to J15: SPAN ADJ to reset the M30:MEMO 3 Press the key twice to
span adjustment to the initial value at the DATA DIAG PRNT ESC
enter the setting.
shipment. SET
M10:MEMO 1
F0847.EPS 95.1.30_
ESC
F0833.EPS
8-15 IM 01C21F01-01E
8.4 Displaying Data Using the 8.5 Self-Diagnostics

BT200
8.5.1 Checking for Problems
8.4.1 Displaying Measured Data
(1) Identifying Problems with BT200
The BT200 can be used to display measured data. The following four areas can be checked.
The measured data is updated automatically every 7 (a) Whether connections are good.
seconds. In addition, the display can be updated to (b) Whether BT200 was properly operated.
the present data value at any time by pressing the (c) Whether settings were properly entered.
(DATA) key. For parameters associated with the (d) History of the errors.
display of measured data, see Subsection 8.3.1, See examples below.
“Parameter Summary.”
• Example 1: Connection errors
––WELCOME–– Press the key.
• Example: Display output. BRAIN TERMINAL
ID: BT200
When the panel shown on the left
MENU check connection
A:DISPLAY push ENTER key appears, press the key.
B:SENSOR TYPE
UTIL FEED
HOME SET ADJ ESC

Since communications will be
communication error unsuccessful if there is a problem
PARAM Display “A10: OUTPUT (%).”
A10:OUTPUT (%) in the connection to the BT200, the
XX.X %
A11:ENGR.OUTPUT ESC
YY.Y % display at the left will appear.
A20:AMP TEMP
ZZ deg C Recheck the connection.
DATA DIAG PRNT ESC
Data is updated automatically
Press the (OK) key.
PARAM communi
at 7-second intervals.
A10:OUTPUT (%)
A11:ENGR.OUTPUT
A20:AMP TEMP • Example 2: Setting entry errors

PARAM The initial data panel shows the
01:MODEL
EJA510A-DC
F0834.EPS
02:TAG NO. result of current transmitter
YOKOGAWA
03:SELF CHECK diagnostics.
ERROR
8.4.2 Display Transmitter Model and OK
Specifications
PARAM Press the (DIAG) key in the
C20:PRESS UNIT
The BT200 can be used to display the model and kPa
C21:LOW RANGE parameter panel to go to the
600 kPa
specifications of the transmitter. C22:HIGH RANGE diagnostics panel
600 kPa
DATA DIAG PRNT ESC
(C60: SELF CHECK).
• Example: View transmitter model name. DIAG An error message is displayed

C60:SELF CHECK
ERROR
< ERROR > when an error occurs in the
MENU Press . < ILLEGAL LRV >
A:DISPLAY diagnostics panel.
B:SENSOR TYPE
FEED PRNT ESC
F0836.EPS
HOME SET ADJ ESC
PARAM
B10:MODEL For the associated
EJA510A-DC parameters, see Subsection
B11:STYLE NO. 8.3.1, “Parameter Summary.”
S1.01
B20:LRL
– 98.07 kPa
DATA DIAG PRNT ESC
F0835.EPS
8-16 IM 01C21F01-01E
(2) Checking with Integral Indicator

• Example 3: Checking the history of the errors
MENU Connect the BT200 to the
J:ADJUST
K:TEST transmitter, and call item “P.”
NOTE
M:MEMO
P:RECORD
If an error is detected in the self-diagnostic, an
HOME SET ADJ ESC error number is displayed on the integral
PARAM indicator. If there is more than one error, the
P10:ERROR REC 1
ERROR error number changes at two-second intervals.
P11:ERROR REC 2
ERROR
P12:ERROR REC 3
See Table 8.5.1 regarding the error numbers.
GOOD
DATA DIAG PRNT ESC
P10: “ERROR REC 1” displays the last error.

P11: “ERROR REC 2” displays the error one time before
the last error occurred.
P12: “ERROR REC 3” displays the error two times before
P13: “ERROR REC 4” displays the error three times before
The history of up to four errors can be stored. When the 5th

error has occurred, it is stored in “P10”. The error stored in
“P13” will be deleted, and then, the error in “P12” will be
copied to “P13”. In this sequence, the history of the most
F0838.EPS
previously occurred error will be removed from memory.
“GOOD” will be displayed if there was no previous error. Figure 8.5.1 Identifying Problems Using the Integral
Indicator
SET Select P10: ERROR REC1 and
P10:ERROR REC 1
ERROR press the key to display
< ERROR >
< ILLEGAL LRV > the error message.
< ILLEGAL HRV >
ESC
<(a) SETUP PANEL>
For the details of the messages listed below, see Table

8.5.1 Error Message Summary.
CAP MODULE FAULT OVER TEMP (CAP) ILLEGAL LRV

AMP MODULE FAULT OVER TEMP (AMP) ILLEGAL HRV
OUT OF RANGE OVER OUTPUT ILLEGAL SPAN
OUT OF SP RANGE OVER DISPLAY ZERO ADJ OVER
Note 1: Press the key twice in the setting panel

(panel 1) to clear all error message (P10 to P13)
information.
Note 2: After two hours from when an error occurs, the error
message of that error will be recorded. Therefore,
if you switch off the transmitter within two hours from
when the error occurs, there is no history of that
error stored in the transmitter, and this function is
meaningless.
F0837.EPS
8-17 IM 01C21F01-01E
8.5.2 Errors and Countermeasures

The table below shows a summary of error messages.
Table 8.5.1 Error Message Summary
Integral
Output Operation
Indicator BT200 Display Cause Countermeasure
during Error
Display
None GOOD
---- ERROR
Er. 01 CAP MODULE Capsule problem.*1 Outputs the signal Replace the capsule
FAULT (Hold, High, or Low) when error keeps
set with parameter appearing even after
D53. restart.*2
Er. 02 AMP MODULE Amplifier problem. Outputs the signal Replace amplifier.
FAULT (Hold, High, or Low)
set with parameter
D53.
Er. 03 OUT OF RANGE Input is outside Outputs high range Check input.
measurement range limit value or low
limit of capsule. range limit value.
Er. 04 OUT OF SP Static pressure Displays present Check line pressure
RANGE exceeds specified output. (static pressure).
range.*3
Er. 05 OVER TEMP Capsule temperature Displays present Use heat insulation or
(CAP) is outside range output. make lagging to keep
(–50 to 130°C). temperature within
range.
Er. 06 OVER TEMP Amplifier temperature Displays present Use heat insulation or
(AMP) is outside range output. make lagging to keep
range.
Er. 07 OVER OUTPUT Output is outside high Outputs high or low Check input and range
or low range limit range limit value. setting, and change
value. them as needed.
Er. 08 OVER DISPLAY Displayed value is Displays high or low Check input and
outside high or low range limit value. display conditions and
range limit value. modify them as
needed.
Er. 09 ILLEGAL LRV LRV is outside setting Holds output Check LRV and
range. immediately before modify as needed.
error occurrence.
Er. 10 ILLEGAL HRV HRV is outside setting Holds output Check HRV and
error occurrence.
Er. 11 ILLEGAL SPAN SPAN is outside Holds output Check SPAN and
setting range. immediately before change as needed.
error occurrence.
Er. 12 ZERO ADJ OVER Zero adjustment is too Displays present Readjust zero point.
large. output.
*1: This error code appears at a capsule problem or when an illegal overpressure is applied to the
pressure sensor.
*2: If the normal pressure is regained, the Er.01 will disappear according to the setting of the parameter
of E50: AUTO RECOVER. When the E50: AUTO RECOVER is set to ON(defalut setting), the Er.01
will disappear automatically. When the E50: AUTO RECOVER is set to OFF, restart the transmitter
to cancel Er.01. If no error code appears then, perform necessary adjustment such as zero-adjust-
ment to continue the operation. If the error code still exists, replace the capsule assembly.
*3: For Model EJA120A, static pressure cannot be measured. The display is always 0 MPa, but this is
not a measured value.
T0810 .EPS
8-18 IM 01C21F01-01E
9. MAINTENANCE
9. MAINTENANCE
9.1 Overview 9.2 Calibration Instruments Se-

lection
WARNING Table 9.2.1 shows the instruments required for calibra-
tion. Select instruments that will enable the transmitter
Since the accumulated process fluid may be to be calibrated or adjusted to the required accuracy.
toxic or otherwise harmful, take appropriate care
to avoid contact with the body, or inhalation of The calibration instruments should be handled carefully
vapors even after dismounting the instrument so as to maintain the specified accuracy.
from the process line for maintenance.
9.3 Calibration
Maintenance of the transmitter is easy due to its
modular construction. This chapter describes the Use the procedure below to check instrument operation
procedures for calibration, adjustment, and the disas- and accuracy during periodic maintenance or trouble-
sembly and reassembly procedures required for shooting.
component replacement. 1) Connect the instruments as shown in Figure 9.3.1
Since the transmitters are precision instruments, and warm up the instruments for at least five
carefully and thoroughly read the following sections minutes.
for proper handling during maintenance.
IMPORTANT
IMPORTANT • To adjust the transmitter for highest accuracy,

make adjustments with the power supply
• As a rule, maintenance of this transmitter voltage and load resistance including leadwire
should be implemented in a maintenance resistances set close to the conditions under
service shop where the necessary tools are which the transmitter is installed.
provided. • If the measurement range 0% point is 0 kPa or
• The CPU assembly contains sensitive parts shifted in the positive direction (suppressed
that may be damaged by static electricity. zero), the reference pressure should be applied
Exercise care so as not to directly touch the as shown in the figure.
electronic parts or circuit patterns on the board, If the measurement range 0% point is shifted in
for example, by preventing static electrification the negative direction (elevated zero), the
by using grounded wrist straps when handling reference pressure should be applied using a
the assembly. Also take precautions such as vacuum pump.
placing a removed CPU assembly into a bag • Do not perform the calibration procedure until
with an antistatic coating. the transmitter is at room temperature.
2) Apply reference pressures of 0%, 50%, and 100% of

the measurement range to the transmitter. Calculate
the errors (differences between digital voltmeter
readings and reference pressures) as the pressure is
increased from 0% to 100% and is decreased from
100% to 0%, and confirm that the errors are within
the required accuracy.
9-1 IM 01C21F01-01E
9. MAINTENANCE
Table 9.2.1 Instruments Required for Calibration

Name Yokogawa-recommended Instrument Remarks
Power
supply Model SDBT or SDBS distributor 4 to 20 mA DC signal
Load Model 2792 standard resistor [250 Ω ±0.005%, 3 W]

resistor Load adjustment resistor [100 Ω ±1%, 1 W]
Model 2501 A digital multimeter
Voltmeter
Accuracy (10V DC range): ±(0.002% of rdg + 1 dgt)
Model MT220 precision digital manometer
1) For 10 kPa class
Accuracy: ±(0.015% of rdg + 0.015% of F.S.) . . . . . for 0 to 10 kPa
±(0.2% of rdg + 0.1% of F.S.) . . . . . . . . . for -10 to 0 kPa
2) For 130 kPa class
Accuracy: ±0.02% of rdg . . . . . . . . . . . . . . . . . . . . . . for 25 to 130 kPa
±5digits .......................... for 0 to 25 kPa
Digital ±(0.2% of rdg + 0.1% of F.S.) . . . . . . . . . for -80 to 0 kPa Select a manometer having
manometer 3) For 700 kPa class a pressure range close to
Accuracy: ±(0.02% of rdg + 3digits) . . . . . . . . . . . . . for 100 to 700 kPa that of the transmitter.
±5 digits ......................... for 0 to 100 kPa
4) For 3000 kPa class
Accuracy: ±(0.02% of rdg + 10 digits) . . . . . . . . . . . for 0 to 3000 kPa
5) For 130 kPa abs class
Accuracy: ±(0.03% of rdg + 6 digits) . . . . . . . . . . . . for 0 to 130 kPa abs
Model 7674 pneumatic pressure standard for 200 kPa {2 kgf/cm2}, 25 kPa {2500 mmH2O} Requires air pressure
Accuracy: ±0.05% of F.S. supply.
Pressure
generator Dead weight gauge tester 25 kPa {2500mmH2O} Select the one having a
Accuracy: ±0.03% of setting pressure range close to
that of the transmitter.
Model 6919 pressure regulator (pressure pump) Prepare the vacuum pump
Pressure
Pressure range: 0 to 133 kPa {1000 mmHg} for negative pressure
source
ranges.
T0901.EPS
Note: The above table contains the instruments capable of performing calibration to the 0.2% level. Since special maintenance and management
procedures involving traceability of each instrument to higher-level standards are required for calibration to the 0.1% level, there are
difficulties in calibration to this level in the field. For calibration to the 0.1% level, contact Yokogawa representatives from which the
instrument was purchased or the nearest Yokogawa office.
If a pressure generator If a pressure source and

is used: a manometer are combined:
Load resistance, Power Load resistance, Power

250 Ω supply 250 Ω supply
E E
Load Rc R Load Rc R
adjustment adjustment
resistance, V resistance, V
100 Ω Digital voltmeter 100 Ω Digital voltmeter
Reference pressure Reference pressure
P Model 7674 pneumatic P
pressure standards
Model MT220
precision digital manometer
Supply pressure Pressure source

F0901.EPS
Figure 9.3.1 Instrument Connections
9-2 IM 01C21F01-01E
9. MAINTENANCE
9.4 Disassembly and Reassem-

bly
Shrouding Bolt
CAUTION
Precautions for CENELEC and IECEx Flame- Shrouding Bolt
proof Type Transmitters F0902.EPS
• Flameproof type transmitters must be, as a

Figure 9.4 Shrouding Bolts
rule, removed to a non-hazardous area for
maintenance and be disassembled and reas-
sembled to the original state.
9.4.1 Replacing the Integral Indicator
• On the flameproof type transmitters the two
covers are locked, each by an Allen head bolt
(shrouding bolt). When a shrouding bolt is
CAUTION
driven clockwise by an Allen wrench, it is going
in and cover lock is released, and then the
cover can be opened by hand. Cautions for Flameproof Type Transmitters
When a cover is closed it should be locked by a Users are prohibited by law from modifying the
shrouding bolt without fail. Tighten the shroud- construction of a flameproof type transmitter.
ing bolt to a torque of 0.7 N·m. This would invalidate the agency approval and
the transmitter’s use in such rated area.
Thus the user is prohibited from using a flame-
This section describes procedures for disassembly and proof type transmitter with its integral indicator
reassembly for maintenance and component replace- removed, or from adding an integral indicator to
ment. a transmitter. If such modification is absolutely
Always turn OFF power and shut off and release required, contact Yokogawa.
pressures before disassembly. Use proper tools for all
operations. Table 9.4.1 shows the tools required. This subsection describes the procedure for replacing
Table 9.4.1 Tools for Disassembly and Reassembly an integral indicator. (See Figure 9.4.1)
Tool Quantity Remarks
Removing the Integral Indicator
Phillips screwdriver 1 JIS B4633, No. 2
1) Remove the cover.
Slotted screwdriver 1
2) Supporting the integral indicator by hand, loosen its
Allen wrenches 2 JIS B4648
two mounting screws.
One each, nominal 3 and
5 mm Allen wrenches 3) Dismount the LCD board assembly from the CPU
Wrench 1 Width across flats, 17 mm assembly.
Torque wrench 1 When doing this, carefully pull the LCD board
Adjustable wrench 1
assembly straight forward so as not to damage the
connector pins between it and the CPU assembly.
Socket wrench 1 Width across flats, 16 mm
Socket driver 1 Width across flats, 5.5 mm
Tweezers 1
T0902.EPS
9-3 IM 01C21F01-01E
9. MAINTENANCE
Attaching the Integral Indicator 3) Disconnect the output terminal cable (cable with
Integral indicator can be installed in the following three brown connector at the end). When doing this,
directions. lightly press the side of the CPU assembly connec-
tor and pull the cable connector to disengage.
4) Use a socket driver (width across flats, 5.5mm) to
loosen the two bosses.
5) Carefully pull the CPU assembly straight forward to
remove it.
6) Disconnect the flat cable (cable with black connec-
tor at the end) that connects the CPU assembly and
F0910.EPS the capsule.
Figure 9.4.1 Installation Direction of Indicator
NOTE
1) Align both the LCD board assembly and CPU
assembly connectors and engage them. Be careful not to apply excessive force to the
2) Insert and tighten the two mounting screws. CPU assembly when removing it.
3) Replace the cover.
Output terminal cable

Mounting the CPU Assembly
1) Connect the flat cable (with black connector)
CPU assembly between the CPU assembly and the capsule.
Press
Flat cable 2) Connect the output terminal cable (with brown
connector).
Boss
LCD board
assembly NOTE
Integral
indicator Make certain that the cables are free of pinching
Cover between the case and the CPU assembly edge.
3) Align and engage the zero-adjustment screw pin

Bracket Zero-adjustment
(for zero-adjustment screw pin
with the groove on the bracket on the CPU assem-
screw pin) bly. Then insert the CPU board assembly straight
onto the post in the amplifier case.
Mounting screw
4) Tighten the two bosses. If the transmitter is
F0903.EPS
equipped with an integral indicator, refer to Subsec-
tion 9.4.1 to mount the indicator.
Figure 9.4.2 Removing and Attaching LCD Board Assem-
bly and CPU Assembly
NOTE
Confirm that the zero-adjustment screw pin is
9.4.2 Replacing the CPU Board Assembly
placed properly in the groove on the bracket
This subsection describes the procedure for replacing prior to tightening the two bosses. If it is not, the
the CPU assembly. (See Figure 9.4.2) zero-adjustment mechanism will be damaged.
Removing the CPU Assembly

1) Remove the cover. If an integral indicator is 5) Replace the cover.
mounted, refer to Subsection 9.4.1 and remove the
indicator.
2) Turn the zero-adjustment screw to the position
(where the screw head slot is horizontal) as shown
in Figure 9.4.2.
9-4 IM 01C21F01-01E
9. MAINTENANCE
9.4.3 Cleaning and Replacing the 3) Separate the transmitter section and capsule assem-
Capsule Assembly bly.
4) Clean the capsule assembly or replace with a new
This subsection describes the procedures for cleaning
one.
and replacing the capsule assembly. (See Figure 9.4.3.)
Reassembling the Capsule Assembly
1) Insert the capsule assembly to the transmitter
CAUTION section. For the model EJA530A with Measurement
span code A, B, and C with the pipe (shown in
Cautions for Flameproof Type Transmitters Figure 9.4.3), insert the capsule assembly in a way
Users are prohibited by law from modifying the that the direction of the pipe screw thread matches
construction of a flameproof type transmitter. If to that of the zero-adjustment screw of the transmit-
you wish to replace the capsule assembly with ter section.
one of a different measurement range, contact 2) Tighten the two Allen screws to a torque of 5 N·m
Yokogawa. and the pipe with gasket if applied.
The user is permitted, however, to replace a 3) Install the CPU assembly according to Subsection
capsule assembly with another of the same 9.4.2.
measurement range. When doing so, be sure to 4) After completing reassembly, adjust the zero point
observe the following. and check the parameters.
• The replacement capsule assembly must have
the same part number as the one being re- Transmitter section
placed.
Allen screw
• The section connecting the transmitter and
capsule assembly is a critical element in
preservation of flameproof performance, and
must be checked to verify that it is free of Zero-adjustment
dents, scratches, and other defects. screw
• After completing maintenance, be sure to Allen screw
securely tighten the Allen screws that fasten
Gasket
the transmitter section and pressure-detector
section together.
Capsule name plate Pipe
Removing the Capsule Assembly Pipe screw thread

Capsule assembly
F0904.EPS
IMPORTANT
Figure 9.4.3 Removing and Mounting the Capsule
Exercise care as follows when cleaning the Assembly
capsule assembly.
• Handle the capsule assembly with care, and be
especially careful not to damage or distort the
diaphragms that contact the process fluid.
• Do not use a chlorinated or acidic solution for
cleaning.
• Rinse thoroughly with clean water and dry
thoroughly after cleaning.
1) Remove the CPU assembly as shown in Subsection

9.4.2.
2) Remove the two Allen screws and the pipe (shown
in Figure 9.4.3) for the model EJA530A with
Measurement span code A, B, and C, which connect
the transmitter section and capsule assembly.
9-5 IM 01C21F01-01E
9. MAINTENANCE
9.5 Troubleshooting 9.5.1 Basic Troubleshooting

First determine whether the process variable is actually
If any abnormality appears in the measured values, use
abnormal or a problem exists in the measurement
the troubleshooting flow chart below to isolate and
system.
remedy the problem. Since some problems have
complex causes, these flow charts may not identify all. If the problem is in the measurement system, isolate
If you have difficulty isolating or correcting a problem, the problem and decide what corrective action to take.
contact Yokogawa service personnel. This transmitter is equipped with a self-diagnostic
function which will be useful in troubleshooting; see
Section 8.5 for information on using this function.
Abnormalities appear in : Areas where self-diagnostic offers support

measurement.
Transmitter itself
Y Is process variable
itself abnormal? Check transmitter.
Inspect the N
process system. Measurement system problem Operating conditions
Isolate problem in Check/correct operating

measurement system. conditions.
Y Environmental conditions
Does problem exist in N Check/correct

Inspect receiver. receiving instrument? environmental conditions.
F0905.EPS
Figure 9.5.1 Basic Flow and Self-Diagnostics
9.5.2 Troubleshooting Flow Charts
Symptoms • There is no output signal.

• Output signal does not change although process variable is known to be varying.
• Output value is inconsistent with value inferred for process variable.
Connect BRAIN TERMINAL and check self-diagnostics.

Refer to error message summary in
YES Subsection 8.5.2 to take actions.
Does the self-diagnostic indicate problem location?
NO Refer to Section 6.3 to check/correct
NO polarity at each terminal from power
Is power supply polarity correct? supply to the terminal box.
YES
NO Refer to Section 6.6 for rated voltage
Are power supply voltage and load resistance correct?
and load resistance.
YES
NO Fully close equalizing valve, and fully
Are valves opened or closed correctly? open high pressure and low pressure
YES valves.
YES
Is there any pressure leak? Fix pressure leaks, paying particular
NO attention to connections for impulse
piping,pressure-detector section, etc.
Is there continuity through the transmitter loop wiring? NO
Do the loop numbers match? Find/correct broken conductor or wiring
error.
YES
Contact Yokogawa service personnel.

F0906.EPS
9-6 IM 01C21F01-01E
9. MAINTENANCE
Output travels beyond 0% or 100%.
YES
Does the self-diagnostic indicate problem location? Refer to error message summary in Subsection 8.5.2 to take
actions.
NO
NO Refer to Section 6.3 to check/correct polarity at each
Is power supply polarity correct? terminal from power supply to the terminal box.
YES
NO Fully close equalizing valve, and fully open high pressure
Are valves opened or closed correctly? and low pressure valves.
YES
YES Fix pressure leaks, paying particular attention to connections
Is there any pressure leak? for impulse piping, pressure-detector section, etc.
NO
NO Refer to individual model user manuals and connect piping
Is impulse piping to high pressure
and low pressure side correct? as appropriate for the measurement purpose.
YES
NO
Is zero point adjusted correctly? Adjust the zero point.
YES
F0907.EPS
Large output error.
YES Refer to error message summary in Subsection 8.5.2

Does the self-diagnostic indicate problem location?
to take actions.
NO
NO Fully close equalizing valve, and fully open high pressure
Are valves opened or closed correctly? and low pressure valves.
YES
NO Refer to individual model user manuals and connect piping
Is impulse piping connected correctly? as appropriate for the measurement purpose
YES
NO
Are power supply voltage and load resistance correct? Refer to Section 6.6 for rated voltage and load resistance.
YES
Is transmitter installed where there is YES
Provide lagging and/or cooling, or allow adequate ventilation
marked variation in temperature?
NO
NO
Were appropriate instruments used for calibration? Refer to Section 9.2 when selecting instruments for calibration.
YES
NO
Is output adjusted correctly? Adjust the output.
YES
F0908.EPS
9-7 IM 01C21F01-01E
10. GENERAL SPECIFICATIONS
10.1 Standard Specifications

Refer to IM 01C22T02-01E for FOUNDATION Damping Time Constant (1st order):
Fieldbus communication type and IM 01C22T03- The sum of the amplifier and capsule damping
time constant must be used for the overall time
00E for PROFIBUS PA communication type constant. Amp damping time constant is adjustable
marked with “”. from 0.2 to 64 seconds.
Capsule (Silicone Oil) A, B, C, and D
Performance Specifications
See General Specifications sheet, GS 01C21F01-E. Time Constant (approx. sec) 0.2
T1002.EPS
Functional Specifications
Ambient Temperature Limits:
Span & Range Limits * Safety approval codes may affect limits.
EJA510A and EJA530A: –40 to 85°C (–40 to 185°F),
–30 to 80°C (–22 to 176°F) with LCD Display
Measurement
Span and MPa psi (/D1) bar (/D3) kgf/cm2(/D4) Process Temperature Limits:
Range
10 to 200 1.45 to 29
* Safety approval codes may affect limits.
Span 0.1 to 2 0.1 to 2 –40 to 120°C (–40 to 248°F)
kPa
A
Range 0 to 200 0 to 29 0 to 2 0 to 2
kPa Maximum Overpressure:
Span 0.1 to 2 14.5 to 290 1 to 20 1 to 20
B Capsule
Range 0 to 2 0 to 290 0 to 20 0 to 20 Capsule EJA510A EJA530A
Span 0.5 to 10 72.5 to 1450 5 to 100 5 to 100 A 4 MPa abs{580 psia} 4 MPa {580 psig}
C B 4 MPa abs{580 psia} 4 MPa {580 psig}
Range 0 to 10 0 to 1450 0 to 100 0 to 100
Span 5 to 50 720 to 7200 50 to 500 50 to 500 D 60 MPa abs{8500 psia} 60 MPa {8500 psig}
D T1003.EPS
Range 0 to 50 0 to 7200 0 to 500 0 to 500
Values in absolute for EJA510A. T1001.EPS Working Pressure Limits (Silicone Oil)
Maximum Pressure Limit:
Zero Adjustment Limits:
Zero can be fully elevated or suppressed, within the Capsule
Capsule EJA510A EJA530A
Lower and Upper Range Limits of the capsule.
A 200 kPa abs{29 psia} 200 kPa {29 psig}
External Zero Adjustment “”: B 2 MPa abs{290 psia} 2 MPa {290 psig}
External zero is continuously adjustable with 0.01% C 10 MPa abs{1450 psia} 10 MPa {1450 psig}
incremental resolution of span. Span may be D 50 MPa abs{7200 psia} 50 MPa {7200 psig}
adjusted locally using the digital indicator with range T1004.EPS
switch.
Minimum Pressure Limit:
Output “”: EJA510A: 0.013 kPa abs
Two wire 4 to 20 mA DC output with digital commu- EJA530A: Lower limit of measurement range
nications, linear or square root programmable.
BRAIN or HART FSK protocol are superimposed on
the 4 to 20 mA signal. Installation
Supply & Load Requirements “”:
Failure Alarm: * Safety approvals can affect electrical requirements.
Output status at CPU failure and hardware error; See Section 6.6, ‘Power Supply Voltage and Load
Up-scale: 110%, 21.6 mA DC or more(standard) Resistance.’
Down-scale: -5%, 3.2 mA DC or less
-2.5%, 3.6 mA DC or less(Optional Supply Voltage “”:
code /F1) 10.5 to 42 V DC for general use and flameproof type
Note: Applicable for Output signal code D and E 10.5 to 32 V DC for lightning protector (Optional code /A)
10.5 to 30 V DC for intrinsically safe, Type n,
nonincendive, or non-sparking type
communications, BRAIN and HART
10-1 IM 01C21F01-01E
EMC Conformity Standards “”: , Physical Specifications

EN61326-1 Class A, Table 2 (For use in industrial Wetted Parts Materials:
lications) Diaphragm and Process connector;
EN61326-2-3 See ‘Model and Suffix Codes.’
Communication Requirements “”: Non-wetted Parts Materials:

BRAIN Housing;
Communication Distance; Low copper cast-aluminum alloy with polyurethane
Up to 2 km (1.25 miles) when using CEV polyethyl- paint (Munsell 0.6GY3.1/2.0)
ene-insulated PVC-sheathed cables. Degrees of Protection
Communication distance varies depending on type IP67, NEMA4X, JIS C0920 immersion proof
of cable used. Cover O-rings;
Load Capacitance; Buna-N
0.22 µF or less (see note) Data plate and tag;
Load Inductance; SUS304 or SUS316 (optional)
3.3 mH or less (see note) Fill Fluid;
Input Impedance of communicating device; Silicone or Fluorinated oil (optional)
10 kΩ or more at 2.4 kHz. Weight:
Note: For general-use and Flameproof type. 1.6 kg (3.5 lb) without integral indicator and
For Intrinsically safe type, please refer to mounting bracket.
‘Optional Specifications.’ Connections:
HART See ‘Model and Suffix Codes.’
Communication Distance;
Up to 1.5 km (1 mile) when using multiple twisted
pair cables. Communication distance varies
depending on type of cable used.
Use the following formula to determine cable
length for specific applications:
65 x 106 (Cf + 10,000)

L= -
(R x C) C
Where:
L = length in meters or feet
R = resistance in Ω (including barrier resistance)
C = cable capacitance in pF/m or pF/ft
Cf = maximum shunt capacitance of receiving
devices in pF/m or pF/ft
<Settings When Shipped> “”

Tag Number As specified in order *1 Calibration Range
Lower Range Value As specified in order
Output Mode ‘Linear’
Calibration Range As specified in order
Display Mode ‘Linear’ Higher Range Value
Operation Mode ‘Normal’ unless otherwise specified in order Selected from mmH2O, mmAq, mmWG,
Calibration Range mmHg, Torr, Pa, hPa, kPa, MPa, mbar,
Damping Time ‘2 sec.’ Units bar, gf/cm2, kgf/cm2, inH2O, inHg, ftH2O,
Constant psi, or atm.(Only one unit can be specified)
T05E.EPS
Note 1: If Tag No. is no more than 16 alphanumeric characters (including - and ·), it will be written into
the tag plate and amplifier memory settings.
10-2 IM 01C21F01-01E
10.2 Model and Suffix Codes

Model Suffix Codes Description

EJA510A . . . . . . . . . . . . . . . . . . . . Absolute pressure transmitter
EJA530A . . . . . . . . . . . . . . . . . . . . Gauge pressure transmitter
Output Signal -D . . . . . . . . . . . . . . . . . 4 to 20 mA DC with digital communication (BRAIN protocol)

-E . . . . . . . . . . . . . . . . . 4 to 20 mA DC with digital communication (HART protocol, see IM 01C22T01-01E)
-F . . . . . . . . . . . . . . . . . Digital communication (FOUNDATION Fieldbus protocol, see IM 01C22T02-01E)
-G . . . . . . . . . . . . . . . . . Digital communication (PROFIBUS PA protocol, see IM 01C22T03-00E)
Measurement span A . . . . . . . . . . . . . . . 10 to 200 kPa{0.1 to 2 kgf/cm2}
(capsule) B . . . . . . . . . . . . . . . 0.1 to 2 MPa{1 to 20 kgf/cm2}
C . . . . . . . . . . . . . . . 0.5 to 10 MPa{5 to 100 kgf/cm2}
D . . . . . . . . . . . . . . . 5 to 50 MPa{50 to 500 kgf/cm2}
Wetted parts material [Process Connection] [Diaphragm]
S.............. SUS316L Hastelloy C-276
H.............. Hastelloy C-276 Hastelloy C-276
Process connection 4............. 1/2 NPT female
7............. 1/2 NPT male
8............. G 1/2 DIN 16 288 male
9............. M20⫻1.5 DIN 16 288 male
N.......... Always N
-0 . . . . . . . . Always 0
Electrical connection 0 . . . . . . G1/2 female, one electrical connection
2 . . . . . . 1/2 NPT female, two electrical connections without blind plug
3 . . . . . . Pg 13.5 female, two electrical connections without blind plug
4 . . . . . . M20 female, two electrical connections without blind plug
5 . . . . . . G1/2 female, two electrical connections and a blind plug
7 . . . . . . 1/2 NPT female, two electrical connections and a blind plug
8 . . . . . . Pg 13.5 female, two electrical connections and a blind plug
9 . . . . . . M20 female, two electrical connections and a blind plug
A . . . . . . G1/2 female, two electrical connections and a SUS316 blind plug
C . . . . . . 1/2 NPT female, two electrical connections and a SUS316 blind plug
D . . . . . . M20 female, two electrical connections and a SUS316 blind plug
Integral indicator D . . . Digital indicator
E . . . Digital indicator with the range setting switch
N . . . (None)
Mounting bracket E . . SECC Carbon steel 2-inch pipe mounting
F . . SUS304 2-inch pipe mounting
L . . SUS316 2-inch pipe mounting
N . . (None)
Optional codes / Optional specification
T1006.EPS
10-3 IM 01C21F01-01E
10.3 Optional Specifications

For FOUNDATION Fieldbus explosion protected type, see IM 01C22T02-01E.
For PROFIBUS PA explosion protected type, see IM 01C22T03-00E.
FM Explosionproof Approval *1
Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G FF1
Hazardous (classified) locations, indoors and outdoors (NEMA 4X)
Temperature class: T6
Amb. Temp.: –40 to 60⬚C (–40 to 140⬚F)
FM Intrinsically safe Approval *1
Intrinsically Safe for Class I, Division 1, Groups A, B, C & D, Class II, Division 1,
Factory Mutual (FM) Groups E, F & G and Class III, Division 1 Hazardous Locations.
Nonincendive for Class I, Division 2, Groups A, B, C & D, Class II, Division. 2,
Groups E, F & G, and Class III, Division 1 Hazardous Locations.
Enclosure: “NEMA 4X”, Temp. Class: T4, Amb. Temp.: –40 to 60⬚C (–40 to 140⬚F) FS1
Intrinsically Safe Apparatus Parameters
Vmax=30 V, Imax=165 mA, Pmax=0.9 W, Ci=22.5 nF, Li=730 ␮H
[Groups C, D, E, F and G]
Combined FF1 and FS1 *1 FU1
CENELEC ATEX (KEMA) Flameproof Approval *2
II 2G EExd IIC T4, T5, T6 KF2
Amb. Temp.: T5; –40 to 80⬚C ( –40 to 176⬚F), T4 and T6; –40 to 75⬚C ( –40 to 167⬚F)
Max. process Temp.: T4; 120⬚C (248⬚F), T5; 100⬚C (212⬚F), T6; 85⬚C (185⬚F)
CENELEC ATEX (KEMA) Intrinsically safe Approval *2
Certificate: KEMA 02ATEX1030X
II 1G EEx ia IIC T4, Amb. Temp.: –40 to 60⬚C (–40 to 140⬚F) KS2
CENELEC ATEX
Ui=30 V, Ii=165 mA, Pi=0.9 W, Ci=22.5 nF, Li=730 ␮H
Combined KF2, KS2 and Type n *2
Type n
II 3G Ex nL IIC T4, Amb. Temp.: –40 to 60°C (–40 to 140°F)
Ui=30 V DC, Ci=22.5 nF, Li=730 µH KU2
Dust
II 1D maximum surface temperature T65°C (149⬚F) {Tamb.: 40°C (104⬚F)},
T85°C (185⬚F) {Tamb.: 60°C (140⬚F)}, T105°C (221⬚F) {Tamb.: 80°C (176⬚F)}
T1007-1.EPS
10-4 IM 01C21F01-01E

CSA Explosionproof Approval *1
Dustignitionproof for Class II/III, Division 1, Groups E, F and G
Division2 ‘SEALS NOT REQUIRED’ , Temp. Class: T4, T5, T6 Encl Type 4x
Max. Process Temp.: T4; 120⬚C (248⬚F), T5; 100⬚C (212⬚F), T6; 85⬚C (185⬚F) CF1
Amb. Temp.: –40 to 80⬚C (–40 to 176⬚F)
Process Sealing Certification
Dual Seal Certified by CSA to the requirement of ANSI/ISA 12.27.01
No additional sealing required. Primary seal failure annunciation: at the zero
adjustment screw
Canadian Standards
Association (CSA) CSA Intrinsically safe Approval *1
Intrinsically Safe for Class I, Groups A, B, C and D Class II and III, Groups E, F and G
Nonincendive for Class I, Division 2, Groups A, B, C and D Class II, Division 2,
Groups F and G and Class III (not use Safety Barrier)
Encl Type 4x, Temp. Class: T4, Amb. Temp.: –40 to 60⬚C (–40 to 140⬚F) CS1
Process Sealing Certification
Dual Seal Certified by CSA to the requirement of ANSI/ISA 12.27.01
No additional sealing required. Primary seal failure annunciation: at the zero
adjustment screw
Combined CF1 and CS1 *1 CU1
IECEx Intrinsically safe, type n and Flameproof Approval *2
Intrinsically safe and type n
Certificate: IECEx KEM 06.0007X
Ex ia IIC T4, Ex nL IIC T4 Enclosure: IP67
Amb. Temp.: –40 to 60⬚C (–40 to 140⬚F), Max. Process Temp.: 120⬚C (248⬚F)
IECEx Electrical Parameters: [Ex ia] Ui=30 V, Ii=165 mA, Pi=0.9 W, Ci=22.5 nF, Li=730 ␮H
[Ex nL] Ui=30 V, Ci=22.5 nF, Li=730 ␮H SU2
Scheme
Flameproof
Ex d IIC T6...T4 Enclosure: IP67
Max.Process Temp.: T4;120⬚C (248⬚F), T5;100⬚C (212⬚F), T6; 85⬚C (185⬚F)
Amb.Temp.: –40 to 75⬚C (–40 to 167⬚F) for T4, –40 to 80⬚C (–40 to 176⬚F) for T5,
–40 to 75⬚C (–40 to 167⬚F) for T6
T1007-2.EPS
*2: Applicable for Electrical connection code 2, 4 and 7 (1/2 NPT and M20 female).
10-5 IM 01C21F01-01E

Amplifier cover only P
Color change
Painting Amplifier cover and terminal cover, Munsell 7.5 R4/14 PR
Coating change Epoxy resin-baked coating X1
Exterior parts on the amplifier housing (name plates, tag plate, zero-adjustment screw,
316 SST exterior parts HC
stopper screw) will become 316 or 316L SST.
Transmitter power supply voltage: 10.5 to 32 V DC (10.5 to 30 V DC for intrinsically safe
Lightning protector type, 9 to 32 V DC for FOUNDATION Fieldbus and PROFIBUS PA communication type.) A
Allowable current: Max. 6000 A (1⫻40 ␮s), Repeating 1000 A (1⫻40 ␮s) 100 times
Degrease cleansing treatment K1
Oil-prohibited use Degrease cleansing treatment with fluorinated oil filled capsule.
Operating temperature: –20 to 80°C K2
P calibration (psi unit) D1

bar calibration (bar unit) (See Table for Span and
Calibration units D3
Range Limits.)
M calibration (kgf/cm2 unit) D4
Fast response *2 Update time: 0.125 sec or less, see GS for the response time. F1
Failure alarm down-scale *1 Output status at CPU failure and hardware error is –5%, 3.2 mA or less. C1
hardware error is –5%, 3.2 mA or less. C2
Output signal limits:
NAMUR NE43 compliant *1 3.8 mA to 20.5 mA
C3
hardware error is 110%, 21.6 mA or more.
Stainless steel amplifier Amplifier housing material; SCS14A stainless steel (equivalent to SUS316 cast stainless
E1
housing steel or ASTM CF-8M)
Stainless steel tag plate JIS SUS304 stainless steel tag plate wired onto transmitter N4
High Accuracy type High Accuracy (Applicable only for Model EJA530A) HAC
PED 97/23/EC
European Pressure CATEGORY: III, Module: H, Type of Equipment: Pressure Accessory - Vessel,
PE3
Equipment Directive Type of Fluid: Liquid and Gas,
Group of Fluid: 1 and 2
Mill Certificate Process connector M15
Test Pressure: 200 kPa (2 kgf/cm2) T05
Pressure test/ Test Pressure: 2 MPa (20 kgf/cm2) Nitrogen (N2) Gas T06
Leak test Certificate Retention time: 10 minutes
Test Pressure: 10 MPa (100 kgf/cm2) T07
Test Pressure: 50 MPa (500 kgf/cm2) T08
T1008.EPS
*1: Applicable for Output signal code D and E. The hardware error indicates faulty amplifier or
capsule. When combining with Optional code F1, output status for down-scale is –2.5%,
3.6 mA DC or less.
*2: Applicable for Output signal code D and E. Write protection switch is attached for Output code E.
10-6 IM 01C21F01-01E
10.4 Dimensions
Model EJA510A and EJA530A [Style: S2]
With Process Connection code 7

Unit: mm(Approx. inch)
96(3.77) 41(1.61) 110(4.33)
Conduit connection 12 45
Ground
(0.47) (1.77) terminal
Shrouding bolt *2
(3.07)
␾78
127(5.0)
111(4.37)
170(6.69)
LOCK ZERO LOCK
Zero adjustment
Adapter
124(4.88)
Pipe(Open to atmosphere)*1
44(1.73)
(1.85)
47
2-inch pipe Mounting bracket

91(3.58)
(O. D. 60.5 mm)
*1: Applied to Model EJA530A with Measurement span code A, B, and C.

*2: Applicable only for ATEX and IECEx Flameproof type.
For Process Connection code 4

163(6.41)
For Process Connection code 8 and 9

20(0.78)
176(6.92)
␾6(0.23)
5(0.19)
F1001.EPS
10-7 IM 01C21F01-01E
Customer Model EJA510A and EJA530A
Maintenance Absolute and Gauge
Pressure Transmitter
Parts List
2 5
4
11
A 10
12
13 1
2 2
1
14
A
6
7-2
7-1 5
8 9
18
17
15 15
16
15
Process connection Process connection

code 4 code 8 and 9
Process connection
code 7
21
19
22
24
20 23
All Rights Reserved, Copyright © 1999, Yokogawa Electric Corporation. CMPL 01C21F01-01E
6th Edition: Oct. 2008(KP)
2
Item Part No. Qty Description
1 Bellow 2 Cover
F9341RA Cast-aluminum alloy
F9341RJ SCS14A stainless steel
2 F9341JP 2 O-ring
3 Below 1 Case Assembly (Note 1)
F9341AA Cast-aluminum alloy for G1/2

F9341AC Cast-aluminum alloy for G1/2 (two electrical connections)
F9341AE Cast-aluminum alloy for 1/2 NPT (two electrical connections)
F9341AH Cast-aluminum alloy for M20 (two electrical connections)
F9341AJ Cast-aluminum alloy for Pg13.5 (two electrical connections)
F9341AR SCS14A stainless steel for 1/2 NPT (two electrical connections)
4 F9341KA 1 Name Plate
5 Bellow 4 Screw
F9900RG For cast-aluminum alloy case assembly
F9900RR For SCS14A stainless steel case assembly
6 F9341KL 1 Tag Plate

7-1 Below 1 CPU Assembly
F9342AB For BRAIN protocol version
F9342AL For HART protocol version
F9342AF For BRAIN protocol version (Optional code /F1)
F9342AM For HART protocol version with write protection switch (Optional code /F1)
7-2 F9342BF 1 For FOUNDATION Fieldbus protocol version
F9342BG For FOUNDATION Fieldbus protocol version with PID/LM function (Optional code /LC1)
8 F9900RP 2 Cap Screw
9 Y9612YU 2 Screw
10 Below 1 Plug
F9340NW For Pg13.5
F9340NX For M20
G9330DK For G1/2
G9612EB For 1/2 NPT
11 Bellow 1 Cover Assembly

F9341FM Cast-aluminum alloy
F9341FJ SCS14A stainless steel
12 Below 1 LCD Board Assembly
F9342BL Without range-setting switch For integral indicator
F9342BM With range-setting switch

13 F9342MK 2 Mounting Screw
14 F9300PB 2 Label
15 1 Capsule Assembly (See Table 1.)(Note 2)
16 F9300AJ 1 O-ring
17 Below 1 Pipe (for EJA530A with Measurement Span code A, B, and C)

F9385XK Polypropylene resin
F9385XM SUS316 Stainless Steel (Optional code /E1)
18 F9385XL 1 O-ring (for EJA530A with Measurement Span code A, B, and C)
19 F9385XZ 1 Plate, SUS304 Stainless Steel
20 Below 1 Bracket Assembly

F9385XV SECC carbon steel
F9385XT SECC carbon steel (for epoxy resin-baked coating)
F9385XU SUS304 stainless steel
21 D0117XL-A 1 U-bolt/Nut Assembly (L), SUS304 Stainless Steel
22 Below 1 Bracket
F9270AX SECC carbon steel
F9300TN SECC carbon steel (for epoxy resin-baked coating)
F9300TE SUS304 Stainless Steel
23 F9385XW 1 U-bolt/Nut Assembly (S), SUS304 Stainless Steel
24 F9385XY 1 Adapter, SUS304 Stainless Steel
(Note 1) Applicable for BRAIN and HART protocol versions (Output signal code D and E).
For FOUNDATION Fieldbus protocol version (Output signal code F), consult Yokogawa local office.
(Note 2) In case of Degrease cleansing treatment (Optional code /K1), consult Yokogawa local office.
Table 1. Capsule Assembly Part Number (Item 15)

Process Capsule EJA510A EJA530A
connection Code S(*1) S, /K2(*2) H(*1) H, /K2(*2) S(*1) S, K2(*2) H(*1) H, K2(*2)
A F9421AB F9421AP F9421NB F9421NP F9420AB F9420AP F9420NB F9420NP
B F9421BB F9421BP F9421PB F9421PP F9420BB F9420BP F9420PB F9420PP
1/2 NPT female
C F9421CB F9421CP F9421QB F9421QP F9420CB F9420CP F9420QB F9420QP
D F9421DB F9421DP F9421RB F9421RP F9420DB F9420DP F9420RB F9420RP
A F9421AD F9421AR F9421ND F9421NR F9420AD F9420AR F9420ND F9420NR
B F9421BD F9421BR F9421PD F9421PR F9420BD F9420BR F9420PD F9420PR
1/2 NPT male
C F9421CD F9421CR F9421QD F9421QR F9420CD F9420CR F9420QD F9420QR
D F9421DD F9421DR F9421RD F9421RR F9420DD F9420DR F9420RD F9420RR
A F9421AE F9421AS F9421NE F9421NS F9420AE F9420AS F9420NE F9420NS
B F9421BE F9421BS F9421PE F9421PS F9420BE F9420BS F9420PE F9420PS
G1/2 male (DIN)
C F9421CE F9421CS F9421QE F9421QS F9420CE F9420CS F9420QE F9420QS
D F9421DE F9421DS F9421RE F9421RS F9420DE F9420DS F9420RE F9420RS
A F9421AF F9421AT F9421NF F9421NT F9420AF F9420AT F9420NF F9420NT
B F9421BF F9421BT F9421PF F9421PT F9420BF F9420BT F9420PF F9420PT
M20⫻1.5 male
C F9421CF F9421CT F9421QF F9421QT F9420CF F9420CT F9420QF F9420QT
D F9421DF F9421DT F9421RF F9421RT F9420DF F9420DT F9420RF F9420RT
*1: Silicone oil filled capsule (Standard)
*2: Fluorinated oil filled capsule (for oil-prohibited use: Optional code /K2)
Jan. 2008 CMPL 01C21F01-01E

Subject to change without notice. Printed in Japan.
REVISION RECORD
Title: Model EJA510A and EJA530A Absolute Pressure and Gauge Pressure
Transmitter
Manual No.: IM 01C21F01-01E
Edition Date Page Revised Item
1st June 1999 – New publication
2nd June 2000 CONTENTS Page 3 • Add REVISION RECORD.
2-8 2.9.4 b.• Add maximum process temperature of –40 to 75°C for KEMA
Flameproof type T6.
• Change wating period when opening terminal cover after power
off from 1 min. to 10 min.
• Add note for using heat-resisting cables.
8-4 8.3.1 • Add footnote *2 for amp. damping time constant when Optional
code /F1 is specified.
8-5 • Add footnote *3 for low side output status at failure alarm when
Optional code /F1 is specified.
10-4 10.3 • Change explosion protected type Optional code from /1 to
/11.
• Add maximum process temperature of –40 to 75°C for KEMA
Flameproof type T6.
10-5 • Add Optional code /F1 and /N4.
CMPL CMPL 1C21F1-01E 1st 2nd
Page 2 • Change Part No. on Item 7, CPU Assembly.
F9342BP F9342AB
F9342BQ F9342AL
• Add Part No. on Item 7, CPU Assembly.
F9342AF for BRAIN protocol, Optional code /F1
F9342AM for HART protocol, Optional code /F1
3rd Aug. 2001 – • Style change from S1 to S2.
2-8 2.10 • Change EMC Conformity number.
8-4, 8-5 8.3.1 • Add footnote (*4) to B40, Maximum static pressure in Parameter
Summary.
10-1 10.1 • Change Maximum Over pressure for Capsule code A from
400 kPa to 4 MPa.
10-4 10.3 • Change explosion protected type Optional code from /11 to
/1.
10-6 10.4 • Change dimensions.
CMPL CMPL 1C21F1-01E 2nd CMPL 01C21F01-01E 3rd
• Change Part No. on Item 15, Capsule Assembly and followings.
• Item 17; F9374MS F9385XK, F9385XM
• Item 18; F9374MU F9385XL
• Item 19; F9374NZ F9385XZ
• Item 20; F9374MX F9385XV, F9374NX F9385XT,
F9374MW F9385XU
• Item 23; F9374MY F9385XW
• Item 24; F9374NY F9385XY
4th May 2002 1-2 1.1 • Add “1.1 For Safety Using.”
2-7 2.9.4 • Add descriptions based on ATEX directive.
10-4 10.3 • Add Optional code K2.
10-5 • Add Optional code C2 and C3.
5th Apr. 2003 2-8 2.9.4 • Add Option code KU2

2-10 2.11 • Add PED (Pressure Equipment Directive)
10-3 10.2 • Add Output Signal code F.
10-4 10.3 • Add Option code KU2.
10-5 10.3 • Add Option code HAC and PE3.
CMPL CMPL 01C21F01-01E 3rd 4th
• Add part No. on Item 7-2, CPU Assembly for fieldbus protocol.
REVISION RECORD.EPS
IM 01C21F01-01E
6th Apr. 2006 1-2 1.1 • Add (e) Explosion Protected Type Instrument and (f) Modification
1-3 1.3 • Add “1.3 ATEX Document”
2-6 2.9.3 • Add “IECEx Certification” and delete “SAA Certification”
2-11 2.12 • Add Low Voltage Directive
10-4, 10-5 10.3 • Add Certificate numbers and Applicable standards
10-5 • Add option code /SU2 and delete option code /SU1
10-6 • Add option code /PR
7th Jan. 2008 1-1 • Add direct current symbol.

1-4 • Add 11 European languages for ATEX documentation.
2-3+ 2.9.1 • Add applicable standard and certificate number for appovals.
2-10 2.10 • Add EMC caution note.
4-2 4.4 • Add section of changing the direction of integral indicator.
8-14 8.3.3 (11) • Add figure for A40.
9-4 9.4.1 • Add figure of integral indicator direction.
10-1+ 10.1, 10.2 • Add PROFIBUS PA communication type.
10-4, -5 10.3 • Delete applicable standard from the table.
CMPL CMPL 01C21F01-01E 4th CMPL 01C21F01-01E 5th
• Delete logo from the tag plate.
8th Oct. 2008 2-9 2.9.4 Change explosion protection marking for type n from EEx to Ex.
2-10 2.10 Update EMC conformity standards.
8-4 and 8-5 8.3.1 Add new parameters.
8-6 8.3.2 Add items in table 8.3.1.
8-9 and later 8.3.3 Add (5) Change Output Limit and (13) Span Adjustment.
Re-number the items.
8-18 8.5.2 Modify descriptions and notes for Er.01.
9-1 9.3 Add a note for calibration.
9-5 9.4.3 Add a note for cleaning.
10-3 10.2 Add new suffix codes.
10-5, 10-6 10.3 Add Sealing statement for CSA.standards., Add /HC.
CMPL CMPL 01C21F01-01E 7th 8th
Change part No .of item 5 and 8.
REVISION RECORD2.EPS
IM 01C21F01-01E
User’s
Manual Model EJA Series
HART Protocol
IM 01C22T01-01E
IM 01C22T01-01E
8th Edition
CONTENTS
CONTENTS
PRELIMINARY ........................................................................................................ ii
1. ZERO POINT ADJUSTMENT ....................................................................... 1-1
1.1 Zero Point Adjustment ........................................................................ 1-1
1.1.1 Using the HART Communicator ................................................... 1-2
1.1.2 Using the Transmitter Zero-adjustment Screw ............................ 1-2
1.2 Auto LRV (Change Low Range Value) ............................................... 1-3
1.2.1 Using Model 275 — Apply Values ............................................... 1-3
1.2.2 Setting the Range Using the Range-setting Switch .................... 1-3
2. HART COMMUNICATOR OPERATION ....................................................... 2-1

2.1 Conditions of Communication Line ..................................................... 2-1
2.1.1 Interconnection Between DPharp and HART Communicator ...... 2-1
2.1.2 Communication Line Requirements ............................................. 2-1
2.2 Basic Operation of the HART Communicator (Model 275) ................ 2-2
2.2.1 Keys and Functions ...................................................................... 2-2
2.2.2 Display .......................................................................................... 2-3
2.2.3 Calling Up Menu Addresses ........................................................ 2-3
2.2.4 Entering, Setting, and Sending Data ........................................... 2-4
2.3 Parameters .......................................................................................... 2-5
2.3.1 Parameter Usage and Selection .................................................. 2-5
2.3.2 Menu Tree .................................................................................... 2-6
2.3.3 Setting Parameters ....................................................................... 2-7
(1) Tag No. ........................................................................................ 2-7
(2) Unit .............................................................................................. 2-7
(3) Range Change ............................................................................ 2-7
(4) Output Mode (Linear/Sq root) ..................................................... 2-8
(5) Damping Time Constants ............................................................ 2-9
(6) Output Signal Low Cut Mode Setup ............................................ 2-9
(7) Bi-directional Flow Measurement .............................................. 2-10
(8) Change Output Limits ............................................................... 2-10
(9) Integral Indicator Display Mode ................................................. 2-10
(10) Integral Indicator Scale ............................................................. 2-10
(11) Unit for Displayed Temperature ................................................. 2-12
(12) Unit for Displayed Static Pressure ............................................ 2-12
(13) Test Output ................................................................................ 2-13
(14) Sensor Trim ............................................................................... 2-13
(15) Trim Analog Output ................................................................... 2-14
(16) Burst Mode ................................................................................ 2-16
(17) Multidrop Mode ......................................................................... 2-17
(18) External Switch Mode ............................................................... 2-17
(19) Software Write Protect .............................................................. 2-18
(20) Hardware Write Protect and Burnout Direction
(with Optional code /F1) ............................................................ 2-19
(21) H2O Unit Select ......................................................................... 2-19
(1) Identify Problems with HART Communicator ............................ 2-20
(2) Checking with Integral Indicator ................................................ 2-21
3. PARAMETER LISTS ..................................................................................... 3-1
REVISION RECORD
FD No. IM 01C22T01-01E
8th Edition: Oct. 2008(YK)
All Rights Reserved, Copyright © 1995, Yokogawa Electric Corporation i IM 01C22T01-01E
PRELIMINARY
PRELIMINARY
This manual describes the function, performance, and
operating procedures of the DPharp EJA Series with CAUTION
HART protocol. The DPharp EJA Series with HART
Matching of communicator DD and instrument DD
protocol uses the same pressure sensing element as in
Before using model 275 HART communicator,
DPharp EJA with BRAIN protocol. Therefore, this
check that the DD(Device Description) installed in
manual describes only the functions unique to HART
the communicator matches to that of instruments
Communicator operating procedures which are not
to set up. To check the DD in the instrument or
covered in the DPharp EJA with BRAIN protocol
the HART communicator, follow the steps below.
instruction manual. For the items listed below which
If the correct DD is not installed in the communi-
are common to both the HART protocol and BRAIN
cator, you must upgrade the DD at the HART
protocol, see the applicable user’s manuals listed in
official programming sites. For communication
Table 1.
tools other than Model 275 HART communicator,
contact vendors of each for upgrade information.
Contents of Individual User’s Manuals
• INTRODUCTION
1. Checking the DD in the instrument
• HANDLING CAUTIONS 1) Connect the communicator to the instrument
• COMPONENT NAMES to set up.
• INSTALLATION
• INSTALLING IMPULSE PIPING 2) Call "Device setup" and press [→] .
• WIRING 3) Call "Review" and press [→] .
• OPERATION 4) By pressing [NEXT] or [PREV], find "Fld dev
— Zero Point Adjustment
(For BRAIN Protocol) rev" to show the DD of the instrument.
• BRAIN TERMINAL BT200 OPERATION
(For BRAIN Protocol) [Example]
• MAINTENANCE EJA:
Review
• PARAMETER SUMMARY Fld dev rev
2
(For BRAIN Protocol)
• GENERAL SPECIFICATIONS "The instrument DD is
HELP PREV NEXT EXIT
Version 2."
F02.EPS
Contents of this User’s Manual for HART Protocol
—IM 01C22T01-01E—
2. Checking the DD in Model 275 HART commu-
• ZERO POINT ADJUSTMENT
nicator
• HART Communicator OPERATION
• PARAMETER LISTS 1) Turn on the communicator alone.
F01.EPS 2) Call "Utility" from main menu and press [→] .
3) Call "Simulation" and press [→] .
Figure 1. Relationship between Individual Manuals and
HART Manual Contents 4) Select "YOKOGAWA" from manufacturers
list by pressing [ ↓ ] and press [→] .
5) Select the model name of the instrument(i.e.
Table 1. Individual User’s Manuals
EJA) by pressing [ ↓ ] and press [→] to
show the DD of the communicator.
Model Manual No.
[Example]
EJA110A, EJA120A, EJA130A IM 01C21B01-01E HART Communicator
EJA210A, EJA220A IM 01C21C01-01E Fld dev rev Version 1 and 2.
1 Dev v1, DD v2
EJA310A, EJA430A, EJA440A IM 01C21D01-01E 2 Dev v2, DD v1
EJA510A, EJA530A IM 01C21F01-01E "The communicator DD
EJA110, EJA120 IM 01C22B01-01E supports Version 1 and 2."
EJA210, EJA220 IM 01C22C01-01E F03.EPS
EJA310, EJA430 IM 01C22D01-01E
EJA118W, EJA118N, EJA118Y IM 01C22H01-01E
EJA438W, EJA438N IM 01C22J01-01E
EJA115 IM 01C22K01-01E
T01.EPS
ii IM 01C22T01-01E
1. ZERO POINT ADJUSTMENT

After operating preparation is completed, adjust the 䊏 Using the HART Communicator
zero point. The zero point adjustment can be made Zero point can be adjusted by simple key operation of
using either of the following two methods. the HART Communicator.
For output signal checking, display the parameter % Select parameter Zero Trim, and press the OK (F4)
rnge in the HART Communicator. key twice. The zero point will be adjusted automati-
cally to the output signal 0% (4 mA DC). Confirm that
the setting value displayed for the parameter % rnge
EJA:
Process variable is 0.0% before pressing the OK (F4) key. See Subsec-
1 Pres 0.012nnH2O HART Communication
2 % range 0.00% display tion for HART Communicator operating procedures.
3 A01 Out 4.002mA
4 Snsr temp 38.1C
5 Static pres
1.1 Zero Point Adjustment
HELP DIAG HOME ESC
The DPharp supports several adjustment methods.
Select the method best suited for conditions matching
the state of the site.
Note that output signal can be checked by HART
Zero-adjustment Communicator.
screw
Adjustment Method Description
F0101.EPS Zero adjustment Set the present Adjust for 0% output
using the HART input to 0%. at input level of 0%.
Communicator P.1-2 ‘Zero trim’
䊏 Using the Transmitter Zero-adjustment
Screw Adjust output to If the input level
the reference cannot easily be
Before using the zero-adjustment screw outside the value obtained made 0% (because of
transmitter case, confirm the following. using other tank level, etc.),
means. adjust output to the
• Ext SW mode must be ENABLE. See Subsection P.1-2 ‘Lower reference value
2.3.3 (17) for the setting procedure. sensor trim’ obtained using other
means, such as a
• Use a slotted screwdriver to turn the zero-adjustment glass gauge.
screw. Turn the screw clockwise to increase the
Zero adjustment Adjust zero point using the zero-
output or counterclockwise to decrease the output, using the adjustment screw on the transmitter.
the zero point adjustment can be adjusted with a external zero- This permits zero adjustment without
resolution of 0.01% of the setting range. adjustment using the HART Communicator.
screw Accurately adjust the output current to
The degree of zero adjustments varies with the 4mA DC or other target output value
screw turning speed. Therefore, turn the screw using an ammeter that accurately reads
slowly for fine adjustment and quickly for coarse output currents.
T0101.EPS
adjustment.
CAUTION
Do not turn off the power to the transmitter

immediately after a zero adjustment. Powering
off within 30 seconds after a zero adjustment will
return the adjustment back to the previous
settings.
1-1 IM 01C22T01-01E
1.1.1 Using the HART Communicator 1. Device setup

2. Diag/Service
(1) Zeroing — Zero trim
3. Calibration
3. Sensor trim
NOTE
2. Lower Sensor Trim
Zero trim carries out the zero adjustment and
1
sets the input values at present, equal to 0
EJA:
mmH2O. Use this setting to set LRV = 0 mmH2O. Apply low pressure
(OK)
1. Device setup Check the tank level at present, and

ABORT OK
press OK (F4).
2. Diag/Service
2
3. Calibration EJA:
Press OK when
pressure is stable
3. Sensor trim
(OK)
1. Zero trim
Press OK (F4).
ABORT OK
1
EJA: 3 ‘1 3 5 0’
WARN-LOOP should be
removed from EJA:
automatic control ENTER applied
(OK) Pressure Value
0.000 mmH2O
(ENTER)
Press OK (F4). 0.000
ABORT OK
Enter the value of the actual level
HELP DEL ABORT ENTER
(1350 mmH2O), and press ENTER
2
(F4).
EJA:
WARN-This will affect F0104.EPS
sensor calibration
(OK)
Press OK (F4).
ABORT OK
NOTE
3
EJA:
Lower Sensor trim adjusts the input value at
Apply O input to
sensor present. See Fine Input Adjustment for detail.
(OK)
A pressure of 0 mmH2O is applied.

ABORT OK
Press OK (F4) after the pressure 1.1.2 Using the Transmitter Zero-adjust-
has become stable. ment Screw
F0102.EPS
Turn the zero-adjustment screw on the outside of the
(2) Arbitrary Level Adjustment — Lower transmitter case using a slotted screwdriver. Turn the
Sensor Trim screw to the right to increase the zero point or to the
This zero adjustment applies to tank level measure- left to decrease the zero output; the zero adjusts in
ments, etc. where the actual tank level cannot be set to increments of 0.01% of the range setting.
zero. For this adjustment, use the actual tank level Note that the amount of adjustment to the zero point
obtained with a glass gauge or the like to meet the changes according to the speed at which the screw is
DPharp output. turned. To make fine adjustments, turn the screw
slowly; to make coarse adjustments, turn the screw
quickly.
DPharp span: 0 to 2500 mmH2O Note: When a zero point adjustment has been made do not turn of
Actual level: 1350 mmH2O the transmitter less than 30 seconds after adjustment.
Transmitter output: 1383 mmH2O
2500 mmH2O
Actual level
1350 mmH2O
DPharp
0 mmH2O
F0103.EPS
1-2 IM 01C22T01-01E
1.2 Auto LRV (Change Low 1.2.2 Setting the Range Using the Range-
Range Value) setting Switch
With actual pressure(s) being applied to the transmitter,
1.2.1 Using Model 275 — Apply Values the range-setting switch (push-button) attached to the
Display the Apply Values display, and adjust the zero integral indicator plate and the external zero-adjust-
point as follows: ment screw allow users to change the lower- and
upper-range values for the measurement range (LRV
and URV) without the use of a HART Communicator.
1. Device setup
However, a change in the display settings (scale range
3. Basic setup and engineering unit) for the integral indicator requires
3. Re-range a HART Communicator.
2. Apply values Follow the procedure below to change the LRV and
1 URV settings.
EJA:
WARN-LOOP should be
removed from
Example: Rerange LRV to 0 and HRV to 20 kPa.
automatic control
(OK) 1) Connect the transmitter and allow them to warm up
Press OK (F4). for at least five minutes.
ABORT OK
2) Press the range-setting push-button.
2 The integral indicator then displays LSET.
EJA:
Set the:
3) Apply a pressure of 0 kPa (atmospheric pressure) to
1 4mA
2 20mA the high-pressure side of the transmitter. (Note 1)
3 Exit (ENTER)
4) Turn the external zero-adjustment screw (either in
Select 4 mA, and press ENTER
ABORT ENTER
(F4).
the output-increase or -decrease direction).
The integral indicator displays the output signal (in
3
EJA:
%). (Note 2)
Apply New 4ma input 5) Adjust the output signal to 0% (1 V DC) by
(OK) rotating the external zero-adjustment screw. Doing
Apply a pressure corresponding to so completes the LRV setting.
ABORT OK
0% of the measurement range. 6) Press the range-setting pushbutton.
‘Pressure stabilizing’
The integral indicator then displays USET.
4
7) Apply a pressure of 20 kPa to the high-pressure
EJA:
Current applied
Process value:
side of the transmitter. (Note 1)
0.06 mmH2O
1 Set as 4mA value (ENTER) 8) Turn the external zero-adjustment screw (either in
2 Read new value
3 Leave as found LRV (0%) is read as –0.06 mmH2O. the output-increase or -decrease direction).
ABORT ENTER
Select Set as 4mA value, and The integral indicator displays the output signal (in
press ENTER (F4).
%). (Note 2)
F0105.EPS
9) Adjust the output signal to 100% (5 V DC) by
rotating the external zero-adjustment screw. Doing
so completes the URV setting.
10)Press the range-setting pushbutton.
The transmitter then switches back to the normal
operation mode while maintaining the measurement
range at 0 to 20 kPa.
Note 1: Wait until the pressure inside the pressure-detector section
has stabilized before proceeding to the next step.
Note 2: If the pressure applied to the transmitter exceeds the
previous LRV (or URV) , the integral indicator may display
error number “Er.07” (In this case, the output signal percent
and “Er.07” are displayed alternately every two seconds).
Although “Er.07” is displayed, there is no need to worry and
you may proceed to the next step. However, should any
other error number be displayed, take the appropriate
measure in reference to Section 2.4 Self-Diagnostics,
“Errors Messages.”
1-3 IM 01C22T01-01E
IMPORTANT
1. Do not turn off the power to the transmitter

immediately after completion of the change in
the LRV (and/or URV) setting(s). Note that
powering off within thirty seconds after setting
will ca use a return to the previous settings.
2. Changing LRV automatically changes URV to
the following value.
URV previous URV (new LRV previous LRV)
3. If the range-setting push-button and external
zero-adjustment screw are not touched during
a range-change operation, the transmitter
automatically switches back to the normal
operation mode.
Integral indicator
Range-setting switch
(Push-button)
Note: Use a thin bar which has a blunt tip, e.g.,

a hexagonal wrench, to press the range-
setting push-button.
F0106.EPS
Figure 1.2.1 Range-setting Switch
1-4 IM 01C22T01-01E
2. HART COMMUNICATOR OPERATION

2.1 Conditions of Communica- 2.1.2 Communication Line Requirements
tion Line
Specifications for Communication Line:
2.1.1 Interconnection Between DPharp Supply voltage(general use type); 16.4 to 42 V DC
and HART Communicator Load resistance; 250 to 600 W (Including cable
resistance)
The HART Communicator can interface with the Minimum cable size; 24 AWG, (0.51 mm diameter)
transmitter from the control room, the transmitter site, Cable type; Single pair shielded or multiple pair with
or any other wiring termination point in the loop, overall shield
provided there is a minimum of 250 Ω between the Maximum twisted-pair length; 10,000 ft (3,048 m)
connection and the power supply. To communicate, it Maximum multiple twisted-pair length; 5,000 ft
must be connected in parallel with the transmitter; the (1,524 m)
connections are non-polarized. Figure 2.1.1 illustrates Use the following formula to determine cable length
the wiring connections for direct interface at the for a specific application;
transmitter site for the DPharp. The HART Communi-
cator can be used for remote access from any terminal 65×106 (C +10,000)
L= – f
strip as well. (R×C) C
Where: L = length in feet or meters.

Control room
R = resistance in ohms, current sense
Relaying Terminal
terminals board resistance plus barrier resistance.
C = cable capacitance in pF/ft, or pF/m.
Cf = Maximum shunt capacitance of field
Distributor
devices in pF.
DPharp
HART
communicator
HART communicator
F0201.EPS
Figure 2.1.1 Interconnection Diagram
2-1 IM 01C22T01-01E
2.2 Basic Operation of the HART Communicator (Model 275)

2.2.1 Keys and Functions
Communication Cable
LCD (Liquid crystal display)

(21 characters×8 lines)
Function keys
Functions of the keys are indicated on the
display.
Pressing (HOME) when the display is
EJA:YOKOGAWA
as shown changes the display to “Online”
Process variables menu. (See 2.2.2 “Display”.)
1 Pres 0.00 mmH2O
2 % rnge 0.00 %
3 A01 Out 4.000mA Moves the highlighting cursor on the display to
4 Snsr temp 37.0C
5 Static Pres select the desired item.
HELP HOME
Hot key
Call up setting menu
1. Keypad Input
2. Enable Write
3. New Password
Power ON/OFF
1. Changes the display contents.
2. Moves the position where a number or
character is to be entered.
Pressing calls up the display
corresponding to the item pointed with the
highlighting cursor.
Pressing returns to the previous
display. (See 2.2.3.)
Alphanumeric keys
1. Enters numbers and characters.
2. Selects the desired menu item with the
corresponding number. (See 2.2.4.)
Pressing single key enters the number.
Pressing the key with shift key enters the
alphabetic character.
(Press) (ENTER)
To enter “7”, “7”

Shift keys
To enter “C”, “C”
Use to enter alphabetic characters.
F0202.EPS
Figure 2.2.1 The HART Communicator
2-2 IM 01C22T01-01E
2.2.2 Display Function Key Labels

The HART communicator searches for a transmitter on F1 F2 F3 F4
the 4 to 20mA loop when it is turned on. When the HELP ON/OFF ABORT OK
HART communicator is connected to the transmitter, access on-line activates or terminate acknowledge
help deactivates a current task information on
Online menu (Top menu) is started automatically and binary variable screen
the following display appears. If no transmitter is RETRY DEL ESC ENTER
found, you select Online menu. try to re- delete current leave value accept user-
establish character or Hot unchanged entered data
communication Key Menu item
Manufacturer’s EXIT SEND QUIT NEXT
transmitter type Tag (8 Characters) leave the send data to terminate session leave the
<a>
current menu device, or mark because of a current menu
data to send comunication
error
EJA :YOKOGAWA YES PGUP PGDN NO
Online answer to move up one move down one answer to
 1 Device setup yes/no question help screen help screen yes/no question
2 Pres 0.13 mmH2O ALL PREV NEXT SKIP
<c>
3 A01 Out 4.001 mA include current go to previous go to next do not mark
<d> 4 LRV 0.00 mmH2O Hot Key item on message in a message in the variable to be
5 URV 3000.00 mmH2O Hot Key Menu list of messages list of messages sent in off-line
<e> for all devices configuration
HOME ONE
go to the top include Hot Key
SAVE EDIT menu in the item for one
save information edit a variable device device
to value description
communicator
BACK
SEND ADD go back to
Function keys send data to add current item menu from
device, or mark to Hot Key which HOME
data to send Menu was pressed
The highlighting cursor
F0204.EPS
Pressing one of the SHIFT keys makes the arrow

mark corresponding to the pressed key appear. Key Operation
Appears when the voltage level of the battery is low. There are two choices to select the desired menu item.
F0203.EPS
1. Use the or key to select the desired item,
Figure 2.2.2 Display
and then press the key.
2. Press the number displayed for the desired item.
<a> appears and flashes during communication • To return to the previous display, press the key.
between the HART communicator and the * If ABORT , ESC and EXIT are displayed,
transmitter. At Burst mode, appears. press the desired function key.
 The menu items selected from the previous menu.
<c> The items to be used from the menu of . Example: Call up the Tag item, to change the tag.
<d> or appears when the item is scrolled out of
Check to see where item Tag is located in the menu
the display.
configuration. Then, call up Tag item on the display
<e> The labels of function corresponding to each
according to the menu configuration.
function key appears. These labels reflect cur-
rently available choices.
Device setup Process variables
Pres Diag/Service
2.2.3 Calling Up Menu Addresses P01 Out Basic Setup
LRV Detailed Setup
Subsection 2.3.2 shows the configuration of all menu URV Review
items available with the HART communicator. The
desired item can be displayed with ease by understand- Tag EJA:YOKOGAWA
Tag
ing the menu configuration. Unit YOKOGAWA
Re-range YOKOGAWA
When the HART communicator is connected to the Device information

.
transmitter, Online menu will be displayed after power . HELP DEL ESC ENTER
.
is turned on. Call up the desired item as follows:
2-3 IM 01C22T01-01E
Display Operation
When the setting display shown above appears, enter
1
the data as follows:
EJA:YOKOGAWA
Online or Character to Operation Display
1 Device setup
2 Pres be entered
3 A01 Out
4 LRV
5 URV Display 1 appears when the F F O K O G A W A
DEL SET ESC ENTER
HART Communicator is turned on.
Select Device setup.
I F I K O G A W A
2
EJA:YOKOGAWA
Device setup ×2
1 Process Varlables
2 Diag/Service C F I C O G A W A
3 Basic Setup or
4 Detailed Setup
5 Review
DEL SAVE HOME ENTER
- F I C - G A W A
Select Basic setup.
3 1 F I C - 1 A W A
EJA:YOKOGAWA
Basic Setup
1 Tag
2 Unit
3 Re-range A F I C - 1 A W A
4 Device information
5 Xfer fnctn Select Tag.
HELP
DEL SAVE HOME ENTER Deletes
characters. F I C - 1 A
4
(DEL)
EJA:YOKOGAWA The display for Tag setting appears.
Tag
YOKOGAWA F0207.EPS
YOKOGAWA
DEL
HELP DEL ESC ENTER
Display Operation
F0205.EPS
5
EJA:YOKOGAWA
Tag
YOKOGAWA
FIC-IA
(ENTER)
2.2.4 Entering, Setting, and Sending Data HELP DEL ESC ENTER
After entering the data, set the
HART communicator with the data
The data input using the keys are set in the HART entered by pressing ENTER (F4).
communicator by pressing ENTER (F4). Then, by 6
pressing SEND (F2), the data is sent to the transmitter. EJA:YOKOGAWA
Basic setup
1 Tag
Note that the data is not set in the transmitter if SEND 2 Unit
3 Re-range (SEND)
(F2) is not pressed. All the data set with the HART 4 Device information
5 Xfer fncth
Send the data to the transmitter by
communicator is held in memory unless power is HELP SEND HOME ENTER
pressing SEND (F2).
turned off, every data can be sent to the transmitter at
7
once.
EJA:FIC-1A
Basic Setup
* is flashed during communica-
1 Tag tion.
Operation 2 Unit
3 Re-range SEND disappears, and the
Entering data on the Tag setting display. 4 Device information
5 Xfer fncth
transmission is complete.
HELP SAVE HOME ENTER
F0208.EPS
Example: To change from Tag YOKOGAWA to FIC-1A.
Call up the Tag setting display.
1. Device setup
3. Basic setup
1. Tag
EJA:YOKOGAWA
Tag
YOKOGAWA
YOKOGAWA
HELP DEL ESC ENTER
F0206.EPS
2-4 IM 01C22T01-01E
2.3 Parameters
NOTE
2.3.1 Parameter Usage and Selection Do not turn off the transmitter as soon as HART
Before describing the procedure for setting parameters, Communicator settings (sending) have been
we present the following table showing how the made. If the transmitter is turned of less than 30
prameters are used and in what case. seconds after parameters have been set, the set
data will not be stored and the terminal returns
to previous settings.
Table 2.3.1 Parameter Usage and Selection

Item HART Communicator Description Page
Memory Tag Tag number, Up to 8 characters

Descriptor Up to 16 characters
Message Up to 32 characters
P.2-7
Date xx/yy/zz
Transmitter Engineering unit Unit inH2O, inHG, ftH2O, mmH2O, mmHG, psi, bar, mbar, g/cm2, kg/cm2, Pa, kPa, MPa, torr, atm
Range LRV/URV Set the calibration range by the keypad
Apply values Range for 4 to 20 mA DC signal is set with actual input applied.
Sets mode for output signal to “linear mode” (proportional to input differential pressure) P.2-8
Output mode Xfer fnctn
or to “Square root mode” (proportional to flow).
Damping time constant Damp Adjust the output response speed for 4 to 20 mA DC. 0.2, 0.5, 1, 1.5, 2, 4, 6, 8, 16, 32
(sec)
Output signal low cut Low cut Used mainly to stabilize output near 0 if output signal is the square root mode. Two
mode are available: forcing output to 0% for input below a specific value, or changing to P.2-9
mode
proportional output for input below a specific value.
Cut mode Linear or Zero
Bi-direction flow Bi-dire mode Used to measure bi-directional flows.
measurement mode P.2-10
H2O unit selection H2O Unit select at 4°C (39.2°F)/at 20°C (68°F) P.2-19
Unit for displayed Snsr temp unit Sets a unit for temperature displayed on the model 275.
temperature
P.2-12
Unit for displayed static Static pres unit Sets a unit for static pressure displayed on the model 275.
pressure
Display Integral indicator display Display fnctn Sets mode for integral indicator to “linear mode” (proportional to input differential
P.2-10
mode pressure) or to “Square root mode” (proportional to flow).
Display mode Set the following 5 types of integral indicator scale ranges and unit: “% scale indicator”,
“use set scale indicator”, “alternate indication of user set scale and % scale”, “input P.2-11
pressure display” and “alternate indication of input pressure and % scale.
Integral indicator scale Engr disp range Engr unit/Engr disp LRV/Engr disp URV/Engr disp point. P.2-10
HART output Burst mode Burst option Selection of the data to be sent continuously (Pres/% rnge/A01 out).
Burst mode ON/OFF switching of burst mode.
P.2-16
Multi-drop mode Poll addr Setting the polling address (1 to 15).
Auto poll ON/OFF switching of multi-drop mode.
Monitoring Pres Pressure variable
% rnge % output variable
A01 out 4 to 20 mA output variable
—
Snsr temp Sensor temperature
Static pres Static pressure
Engr display Displays output as on an LCD. settable in the engr disp range.
Maintenance Test output Loop test Used for loop checks. Output can be set freely from –5% to 110% in 1% step. P.2-12
Self-diagnostics Self test Check using the self-test command. If an error is detected, the corresponding message
is displayed. P.2-19
Status Display of the result of self-test, calibration of transmitter.
Output when CPU error A01 Alarm typ Display the status of 4 to 20 mA DC output when a failure —
has occurred
External volume Ext SW mode Display/set the external volume protect/permit for LRV (URV) setting.
protect/permit
Software Write Protect Write protect Displays the permit/protect status of setting changes depending on communications. P.2-17
Enable write Write protect status is released for 10 minutes when the password is entered.
New password Setting a new password.
Adjustment Zeroing Zero trim Set the current input value to 0 kPa. P.1-2
Sensor trim Lower/Upper sensor trim Adjust only measured pressure variable. P.2-13
Analog output trim D/A trim, Scaled D/A trim Adjust the output value at the points of 4 mA and 20 mA. P.2-14
T0201.EPS
2-5 IM 01C22T01-01E
2.3.2 Menu Tree
1 PROCESS 1 Pressure Hot Key 1 Keypad Input 1 LRV

VARIABLES 2 Percent Range 2 URV
3 Analog Output 3 Unit
4 Sensor Temperature 4 LSL
5 Static Pressure 5 USL
6 Engineering Unit 6 Min Span
7 Engineering Display
2 Wrt protect menu 1 Write protect
2 Enable wrt 10 min
2 DIAGNOSTICS 1 TEST/STATUS 1 Self Test 3 New password
AND SERVICE 2 Status 4 Software seal
2 Loop Test
1 RERANGE 1 Keypad Input
2 Apply Values
3 CALIBRATION
1 Digital-to-Analog Trim
2 TRIM ANALOG 2 Scaled Digital-to-Analog Trim
OUTPUT
1 Tag 1 Zero Trim
3 SENSOR TRIM 2 Pressure
2 Unit 3 Lower Sensor Trim
4 Upper Sensor Trim
3 BASIC SETUP 3 RERANGE 1 Keypad Input 5 Sensor Trim Points
2 Apply Values 6 Clear snsr trim
4 DEVICE INFO 1 Date

2 Descriptor 1 Zero Trim
Online Menu 5 Transfer Function 3 Message 2 Pressure
4 Write Protect 3 Lower Sensor Trim
1 DEVICE SETUP 6 Damp 1 Percent Range
2 Pres 2 Pressure 4 Upper Sensor Trim
3 A01 Out 7 Low Cut 3 Unit 5 Sensor Trim Point
4 LRV 1 Pressure Sensor 4 Sensor Trim 6 Clear snsr trim
5 URV 8 Cut Mode
2 Temperature 1 Snsr temp
1 SENSORS Sensor 2 Amp temp
3 Sensor temp Unit
3 Static Pressure 1 Static Pressure

4 DETAILED 2 Static Pressure Unit
SETUP Sensor
2 SIGNAL 1 PROCESS 1 Pressure
CONDITION VARIABLES 2 Percent Range
3 Sensor Temperature
2 RERANGE 1 Keypad Input

3 Unit 2 Apply Values
4 Transfer Function
5 Damp 1 Pressure
6 Low Cut 2 Percent Range
7 Cut Mode 3 Analog Output
8 Bi-dir Mode 4 Sensor Temperature
9 H2O Unit Select 5 Static Pressure
6 Engineering Unit
3 OUTPUT 1 PROCESS 7 Engineering Display
CONDITION VARIABLES
1 Loop Test
2 Digital-to-Analog Trim
2 ANALOG 3 Scaled D/A Trim
OUTPUT 4 Auto recover
5 AO lower limit %
3 Analog Output 6 AO upper limit %
Alarm
1 Poll Address
4 HART OUTPUT 2 Number of Request Preambles
3 Burst Mode
4 Burst Option
4 DISPLAY 1 Display Mode 1 Engineering Unit

CONDITION 2 Display Function 2 Engineering Display LRV
3 Engineering 3 Engineering Display URV
Display Range 4 Engineering Display Point
5 REVIEW 5 DEVICE
INFORMATION 1 Field Device Info
2 Sensor Info
3 Self Test
F0209.EPS
2-6 IM 01C22T01-01E
2.3.3 Setting Parameters 4

EJA:
keypad input
(1) Tag No. 1 LRV
2 URV
0.00
3000.00
mmH2O
mmH2O
3 Unit inH2O (SEND)
To change the Tag No., see section 2.2.4 Entering, 4 LSL -3500 mmH2O
5 USL 3500 mmH2O
Setting, and Sending Data. DEL
HELP SEND ESC ENTER Press SEND (F2) to send the new
unit to the transmitter memory.
Up to 8 characters can be set with Tag. The maximum
5
number of characters to be set for other items is as EJA: Check that SEND disappears.
shown below. With Option code /CA, the Descriptor is keypad input
1 LRV 0.00 inH2O
2 URV 118.000 inH2O
filled in at the factory as specified in the order. 3 Unit inH2O
4 LSL -140.0 inH2O
5 USL 140.0 inH2O
Item The Number of Characters DEL
HELP SEND ESC ENTER
Tag 8
Descriptor 16 F02111.EPS
Message 32
Date 2/2/2
T0202.EPS
(3) Range Change
Ranges are factory-set as specified by the customer.
Example: To change from Tag YOKOGAWA to FIC-1A. To rerange, change the settings as follows:
Call up the Tag setting display. (a) Keypad — LRV, URV

1. Device setup EJA:YOKOGAWA
Tag
YOKOGAWA
Example: To change the range from 0 to 2500 mmH2O to
3. Basic setup YOKOGAWA 500 to 3500 mmH2O
1. Tag
HELP DEL ESC ENTER 1
EJA:
F0210.EPS Online
1 Device setup
2 Pres
See Section 2.2.4. 3 A01 Out
4 LRV
5 URV Select the 4. LRV item.
DEL SET ESC ENTER
(2) Unit
2
The unit is set at the factory before shipment if EJA:
specified at the time of order. Follow the procedure 1 LRV
2 URV
0.0 mmH2O
2500 mmH2O
below to change the unit.
To set the Lower Range Valve,
HELP SAVE HOME ENTER select the LRV item.
Example: To change the unit from mmH2O to inH2O 3
EJA: ‘5 0 0’
LRV
1 0.0 mmH2O
0.0
EJA:
Hot Key
1 Keypad input (ENTER)
2 Enable Write HELP DEL ESC ENTER
3 New Password Enter 500, and press ENTER (F4).
4
DEL SET ESC ENTER
Press Hot key and call up Range EJA:
1 LRV 500 mmH2O
2 values. 2 URV 3000.0 mmH2O
EJA:
keypad input
1 LRV 0.00 mmH2O To change the Upper Range Valve,
2 URV 3000.00 mmH2O
3 Unit mmH2O DEL
HELP SEND HOME ENTER select the URV item.
4 LSL -3500 mmH2O Select the Press Unit item to set
5 USL -3500 mmH2O 5
HELP SAVE HOME ENTER the units of pressure.
EJA: ‘3 5 0 0’
URV
3 2500.0 mmH2O
2500.0
EJA:
Pressure unit ×3
mmH2O (ENTER)
mmH2O
mmHg HELP DEL ESC ENTER Enter 3500, and press ENTER (F4).
psi
bar 6
HELP
DEL SAVE ESC ENTER (ENTER)
EJA:
Select the desired engineering unit 1 LRV 500.0 mmH2O
2 URV 3500.0 mmH2O
and press ENTER (F4).
F0211.EPS (SEND)
Press SEND (F2) to send the

HELP SEND HOME ENTER
changed data to the transmitter.
Check that SEND disappears.
F0212.EPS
2-7 IM 01C22T01-01E
NOTE 4
EJA:
It is possible to set LRV URV. This setting Current applied
process value:
500.01 mmH2O
reverses the 4 to 20 mA output signal. 1 Set as 4mA value (ENTER)
2 Read new value
Conditions: LSL LRV USL 3 Leave as found The LRV to be changed is 500.01
HELP
DEL SEND ABORT ENTER mmH2O.
LSL URV USL • Selecting item 1 sets LRV to
|URV LRV| Min. Span 500.01 mmH2O.
The 4 to 20 mA output does not correspond to • Selecting item 2 reads LRV again.
To set LRV = 500.01, select item 1
the scale of the indicator under the following 5 and press ENTER (F4).
conditions in which; EJA:
Set the ×2
• the equipment with standard specification is 1 4mA
2 20mA
used with the setting changed to the above 3 Exit
setting. HELP DEL ABORT ENTER (ENTER)

• the customer specified equipment (with the Select Exit and press ENTER (F4).
above factory-setting) is used with the setting Check the value after completing
the range change with URV and
changed to the normal (standard) setting.
LRV.
In the cases above, replace the scale with one * The span is maintained the same
which corresponds correctly to the 4 to 20 mA. as when changing LRV with Apply
values. In this case, if LRV is
changed from 0 to 500, URV is
changed automatically to 3000.
(b) Changing the Ranges While Applying an F02131.EPS
Actual Input — Apply values

This feature allows the lower and upper range values to (4) Output Mode (Linear/Sq root)
be setup automatically with the actual input applied. If The output mode has already been set to a Linear
the upper and lower range values are set, “URV” and output (Linear). Follow the procedure below to
“LRV” are changed at the same time. change the mode.
The measurement span is determined by the upper and
lower range valves. Changing the lower range value Example: To change the mode from Linear to Sq root.
results in the upper range value change automatically,
keeping the span constant. Call up the Xfer fnctn display.
Example: To change the range from 0 to 2500 mmH2O to 1. Device setup

500 to 3000 mmH2O
3. Basic setup
Call up the Apply Values display. 5. Xfer fnctn
1. Device setup
1
3. Basic setup EJA:
Transfer function
Linear
3. Re-range Linear
Sq root
2. Apply values
1 DEL SET ESC ENTER (ENTER)
EJA:
WARN-Loop should be
removed from
automatic control
(OK) (SEND)
Press OK (F4). [1] Select Sq root, and press
DEL SET ABORT OK
ENTER (F4).
2 [2] Press SEND (F2) to send the
EJA: data to the transmitter, then
Set the:
1 4mA check to confirm that SEND
2 20mA
3 Exit (ENTER) disappears.
To set the lower range value, select F0214.EPS
HELP SAVE ABORT ENTER 4mA and press ENTER (F4).
3
The output mode is set as specified in the order when
EJA: the instrument is shipped.
Apply new 4ma input
(OK)
If the instrument is equipped with an integral indicator
Apply the pressure of 500mmH2O. and Transfer function is sq root, “ ” is displayed on
HELP DEL ABORT OK After obtaining a stable pressure, the integral indicator.
press OK (F4). F0213.EPS
2-8 IM 01C22T01-01E
(5) Damping Time Constants (6) Output Signal Low Cut Mode Setup
The damping constant is set to 2.0 seconds at the Low cut can be used on the output signal to stabilize
factory. When changing the damping constant, proceed the output near the zero point.
as follows:
The low cut point can be set in a range from 0 to 20%
of output. (Hysteresis of cut point: ±1%)
Example: To change from 2.0 seconds to 0.2 seconds
Either LINEAR or ZERO can be selected as the low
Call up the Damp display. cut mode.
Unless otherwise specified, the cut mode is set to
1. Device setup
LINEAR at the factory.
3. Basic setup
6. Damp
Example: To set the low cut range to 20% and the cut mode
1 to ZERO, proceed as follows:
EJA: ‘0 . 2’
Damping
2.00 s
2.00
(%) (%)
(ENTER) 50 50
HELP DEL ESC ENTER
Enter 0.2 and press ENTER (F4).
Output
Output
2
EJA:
Basic Setup 20 20
1 Unit kPa
2 Re-range
4 Xfer fncfn Linear
5 Damp 0.20s Press SEND (F2) to send the data
to the transmitter. 0 50 0 50
Input (%) Input (%)
3
EJA:
Set to nearest For low cut in linear mode For low cut in zero mode
possible value
occurred writing Pres F0216.EPS
damping (OK)
Press OK...
A confirmation display appears. Figure 2.2.2 Low Cut Mode
DEL SET ESC OK
Press OK (F4), then check to
confirm that SEND disappears.
1. Device setup
F0215.EPS
3. Basic setup
7. Low Cut, 8. Cut mode
NOTE EJA: ‘2 0’
Low cut
1. Only the damping constants listed in Table 2 10.00%
10.00
are available. When a value not listed in (ENTER)
Table 2 is entered, the value in Table 2 HELP DEL ESC ENTER
Call up the Low cut, and set to
nearest the entered value is set. 20%.
2. The damping constant set with the procedure
EJA:
here is of the damping constant in the trans- Cut mode
Linear
Linear
mission part (electric circuit). The damping Zero
constant of the capsule assembly shall be

HELP SEND ESC ENTER (ENTER)
added to obtain the overall damping constant
of the transmitter. Select the Cut mode, and set to
Zero.
EJA:
Table 2 Basic Setup
5 Xfer fnctn Linear
0.2 Sec 6 Damp 0.50s (SEND)
0.5 Sec 7 Low cut 20.00 %
1.0 Sec
8 Cut mode Zero Press SEND (F2) to send the date,
DEL SEND HOME OK
2.0 Sec then check to confirm that SEND
4.0 Sec disappears.
8.0 Sec F0217.EPS
16.0 Sec
32.0 Sec
64.0 Sec
T0203.EPS
2-9 IM 01C22T01-01E
(7) Bi-directional Flow Measurement (8) Change Output Limits

(a) Bi-dir mode enables selection of 50% output at an The range of normal ouput is preset at factory from
input of 0 mmH2O. 5.0 to 110.0% unless otherwise specified or condi-
tioned, and the output is limited with these upper and
Example: If measurement range is 0 to 3000mmH2O lower values. This output range can be changed, for
(LRV = 0 mmH2O, URV = 3000 mmH2O)
example, to meet the requirements of NAMUR, within
the settable range. Set the lower limit with AO lower
1. Device setup
limit % and upper limit with AO Upper Limit %.
4. Detailed setup
Settable range : 5.0 to 110.0 (%),
2. Signal condition
8. Bi-dir mode Upper limit > Lower limit

EJA:
Bi-dir mode (9) Integral Indicator Display Mode
OFF
off
on
Example: Change from Linear to Sq root
1. Device setup
4. Detailed setup
(SEND)
Call up the Bi-dir mode Display 4. Display condition

Select on, and press ENTER (F4).
2. Display fnctn
Press SEND (F2) to send the data
to the transmitter, then check to EJA:
confirm that SEND disappears. Display fnctn
Linear
Linear
Note: The measurement range changes to –3000 to 0 to Square Root
3000mmH2O (output 0% to 50% to 100%).

Note that LRV and URV are not changed. HELP SEND ESC ENTER (ENTER)
F0218.EPS
(b) Combining Bi-dir mode with Xfer fnctn provides (SEND)

a square root output computed independently for Select Square Root and press
0% to 50% output and for 50% to 100% output. ENTER (F4).
Press SEND (F2) to send data.
20 mA (100% display) F0220.EPS
LRV HRV
4 mA (–100% display)
Output mode “LINEAR”
20 mA (100% display)
Low Cut
LRV HRV
4 mA (–100% display)
Output mode “SQUARE ROOT”

F0219.EPS
2-10 IM 01C22T01-01E
(10) Integral Indicator Scale Example: Set the integral indicator scale to engineering units
Display Related display
Mode Display Parameters Description
NORMAL % % rnge 45.6% Indicates –5 to 1. Device setup

110% range
depending on the 4. Detailed setup
set range (LRV,
URV). 4. Display condition
USER SET Engr disp range Displays values 1. Display mode

20.0M depending on
engr disp LRV EJA:
and engr disp Display mode
Normal %
URV Units set Normal %
using engr disp User set
User set & %
unit are not Input press
indicated. HELP SEND ESC ENTER (ENTER)
USER & % % rnge Indicates user set
45.6% and % alternately
Engr disp range in 3 second
(SEND)
20.0M intervals.
Select User set and press ENTER
(F4).
Press SEND (F2) to send the data
INP PRES Pres 456 kPa Indicates input to the transmitter.
pressure. F0222.EPS
PRES & % % rnge 45.6% Indicates input

(b) Setting User-set Engineering Unit
Pres 456 kPa pressure and % Engr unit allows entry of the engineering units to
alternately in 3
second intervals. be displayed on the HART communicator. When
the instrument is shipped, this is set as specified in
the order. Follow the procedure below to change
* The number of lines displayed on the LCD is determined by the
this setting.
number of LRV and URV lines set on the brain terminal. Since these units are not displayed on the integral
T0204.EPS
See (a) through (c) for each setting procedure. indicator, use the adhesive labels provided Engr
unit need not be set for % display.
% indication and input User-set engineering Example: Set an engineering unit M.

pressure indication unit display
Normal % User set Set for user-set 1. Device setup

Input press User set & % engineering unit
Input press & % display. 4. Detailed setup
4. Display condition
Transmitter is set Engr disp unit Set a unit to be 3. Engr disp range
for “NORMAL %” displayed on 1. Engr unit
when shipped. the HART Com-
munication. EJA:
Engr unit
For % display, set Set a numeric

this parameter value for engi-
Engr disp LRV neering unit for HELP DEL ESC ENTER (ENTER)
only.
4 mA output
(LRV).
(SEND)
Set a numeric
value for engi- Set M, and press ENTER (F4).
Engr disp URV neering unit for
F0223.EPS
20 mA output
(HRV).
F0221.EPS (c) Lower and Upper Range Value Setup in
Engineering Unit
(a) Display Mode Engr disp LRV and Engr disp URV are used to
Follow the instructions given to the below to set the lower and higher range values for the
change the range of integral indication scale. engineering unit display. When the instrument is
When USER SET is selected, the user set values shipped, these are set as specified in the order.
of integral indication. Note that these items need not be set for % display.
2-11 IM 01C22T01-01E
Example: Set low range value (LRV) to –50 and upper range
(11) Unit for Displayed Temperature
value (URV) to 50. When the instrument is shipped, the temperature units
are set to C (Centigrade). Follow the procedure below
1. Device setup to change this setting.
4. Detailed setup
The unit changed here corresponds the unit for Snsr
4. Display condition temp.
3. Engr disp range
2. Engr disp LRV, 3. Engr disp URV Example: Change the unit for the temperature display.
EJA: ‘– 5 0’
Engr disp LRV
0.0 1. Device setup
0.0
(ENTER) 4. Detailed setup

DEL DEL ESC ENTER 1. Sensors
Set –50, and press ENTER (F4).
2. Temp sensor
EJA:
Engr disp range
1 Engr unit 2. Snsr temp unit
2 Engr disp LRV
3 Engr disp URV
4 Engr disp point EJA:
Press to select engr disp URV. Snsr temp unit
C
HELP SEND HOME ENTER C
F
EJA: ‘–5 0’ HELP SEND ESC ENTER

Engr disp URV (ENTER)
0.0
0.0
Select F (Fahrenheit), and Press
(ENTER) ENTER (F4).
DEL
HELP DEL ESC ENTER
F0225.EPS
(SEND)
(12) Unit for Displayed Static Pressure
Set 50, and press ENTER (F4). Follow the procedure to change the static pressure unit.
F0224.EPS Changing this parameter also changes the unit for the
static pressure display.
Example: Change the static pressure unit from mmH2O to

kPa.
1. Device setup
4. Detailed setup
1. Sensors
3. Static Pres sensor
2. Static Pres unit

EJA:
Static Pres unit
mmH2O
mmH2O
mmHg
psi
bar
inH2O
inHg
ftH2O (SEND)
mmH2O Select kPa and Press ENTER (F4).
mmHg
Select SEND (F2) to send the data.
psi
bar
mbar
g/cm2
kg/cm2
Pa
kPa
torr
atm
F0226.EPS
2-12 IM 01C22T01-01E
(13) Test Output

This feature can be used to output a fixed current from CAUTION
3.2 mA (–5%) to 21.6 mA (110%) for loop checks.
1. Test output is held for approximately 10
minutes, and then released automatically
Example: To output 12 mA (50%) after the time has elapsed. Even if the HART
Communicator power supply is turned off or
1. Device setup the communication cable is disconnected
2. Diag/Service during test output, it is held for approximately
2. Loop test 10 minutes.
2. Press the (OK) key to release test output
1
EJA: immediately.
WARN-loop should be
removed from
automatic control
(OK)
Set the control loop in manual (14) Sensor Trim
DEL SET ABORT OK
mode, and press OK (F4).
Each DPharp EJA Series Transmitter is factory
2
characterized. Factory characterization is the process of
EJA:
Choose analog output
level
×2 comparing a known pressure input with the output of
1 4mA
2 20mA
each transmitter sensor module over the entire pressure
3 Other
4 End and temperature operating range. During the character-
DEL SET ABORT ENTER (ENTER) ization process, this comparison information is stored
Select Other, and press ENTER in the transmitter EEPROM. In operation, the transmit-
(F4).
Supplementary explanation.
ter uses this factory-stored curve to produce a process
1. 4 mA: variable output (PV), in engineering units, dependent
Outputs a 4 mA current signal on the pressure input. The sensor trim calibration
2. 20 mA:
Outputs a 20 mA current signal procedure allows you to make corrections to the
3. Other: calculated process variable.
Sets a desired output using the
alphanumeric keys There are two ways to trim the sensor: full sensor trim
4. End: Exits and zero trim. A full sensor trim is a two point process,
3
in which two accurate end-point pressures are applied
EJA: ‘1 2’
Output (equal to or greater than the range values), and all
4.000
output is linearized between them. A zero trim is a
(ENTER) one-point adjustment typically used to compensate for
Enter 12, and press ENTER (F4). mounting position effects or zero shifts caused by static
A fixed current of 12 mA is output.
pressure. (See section 1.1.1)
4
EJA:
Fld dev output is
fixed at 12.000 mA Example 1: For the range of 1000 to 3000 mmH2O
(OK)
1. Device setup
DEL
HELP SEND ABORT OK Press OK (F4).
2. Diag/Service
5 3. Calibration
EJA:
Choose analog output ×3 3. Sensor Trim
level
1 4mA
2 20mA 1
3 Other EJA:
4 End Sensor trim
DEL
HELP SEND ABORT ENTER (ENTER) 1 Zero trim
2 Pres
3 Lower sensor trim
To finish the loop test, select End, 4 Upper sensor trim Select the Lower Sensor trim.
5 Sensor trim points
6
and press ENTER (F4). HELP SET HOME OK
EJA: 2
NOTE-loop may be
returned to automatic EJA:
control Apply low pressure
(OK)
(OK)
DEL
HELP SEND ESC OK Press OK (F4). Apply a standard pressure of 1000
F0227.EPS DEL SET ABORT OK mmH2O to the transmitter. After
obtaining a stable pressure, press
OK (F4).
F02281.EPS
2-13 IM 01C22T01-01E
3 (15) Trim Analog Output

EJA:
Press OK when
Fine output adjustment is carried out with D/A trim or
pressure is stable Scaled D/A trim.
(OK)
• D/A Trim
HELP DEL ABORT OK Press OK (F4).
D/A trim is to be carried out if the calibration
4 digital ammeter does not read 4.000 mA and 20.000
EJA: ‘1 0 0 0’
Enter applied mA exactly with the output signal of 0% and 100%.
pressure value
0.00 mmH2O • Scaled D/A Trim
0.00
(ENTER) Scaled D/A trim is to be carried out if the output
HELP DEL ABORT ENTER Enter 1000, and press ENTER (F4). is adjusted using a voltmeter or other types of
Remove pressure appears for a meters or using a meter whose the scale unit is 0 to
while.
Fine input adjustment (0%) is 100%.
complete.
F02282.EPS Example 1: For the adjustment using an ammeter (±1µA is
measurable)
SPAN adjustment shall be carried out with Upper
Sensor trim. After selecting Upper Sensor trim, 1. Device setup
apply a pressure of 3000 mmH2O (corresponding to 2 Diag/Service
100% of the measurement range). Then, proceed the
3. Calibration
same as for the operations for Lower Sensor trim.
2. Trim analog output
1
1
EJA:
EJA: Trim analog output
Sensor trim 1 D/A trim
1 Zero Trim 2 Scaled D/A trim
2 Pres
3 Lower sensor trim
4 Upper sensor trim Select the D/A trim item.
5 Sensor trim points Select the Upper Sensor trim item. HELP SET HOME OK
HELP SET HOME OK
2
2
EJA:
EJA: WARN-LOOP should be
Apply hi pressure removed from
automatic control
(OK)
(OK)
Press OK (F4).
Apply a standard pressure of 300 DEL SET ABORT OK
DEL SET ABORT OK
mmH2O to the transmitter. After
obtaining a stable pressure, press 3
OK (F4). EJA:
Connect reference
3 meter
EJA: (OK)
Press OK when
pressure is stable
Connect the ammeter (±1µA is
(OK) HELP DEL ABORT OK
measurable), and press OK (F4).
HELP DEL ABORT OK Press OK (F4). 4
EJA:
Setting fld dev
4 output to 4mA
EJA: ‘3 0 0 0’ (OK)
Enter applied
Pressure value Press OK (F4), and the transmitter
0.00 mmH2O HELP DEL ABORT OK
0.00 outputs the output signal of 0%.
(OK)
5
HELP DEL ABORT ENTER Enter 3000, and press ENTER (F4). ‘4 . 1 1 5’
EJA:
Remove pressure appears for a Enter meter value
while. 4.000
Fine input adjustment (100%) is
(ENTER)
complete.
HELP DEL ESC ENTER
Ammeter reading: 4.115
F0229.EPS
Enter the read value 4.115 of the
ammeter, and press ENTER (F4).
(The output of the transmitter
changes.)
F0230.EPS
2-14 IM 01C22T01-01E
6 Example 2: To adjust using a voltmeter

EJA:
Fld dev output 4.000
mA equal to reference
meter? 1
1 Yes (ENTER)
2 No EJA:
Trim analog output
HELP SET ABORT ENTER Ammeter reading: 4.000 1 D/A trim
2 Scaled D/A trim
Because the reading on the
ammeter is 4.000 mA, select YES Select the Scaled D/A trim item.
HELP SET HOME OK
and press ENTER (F4).
If the reading is not 4.000 mA, 2
select item 2. NO. Repeat steps 4
EJA:
and 5 until the ammeter reads WARN-Loop should be
removed from
7 4.000 mA. automatic control
(OK)
EJA:
Setting fld dev Press OK (F4).
output to 20mA DEL SET ABORT OK
(OK)
3
Press OK (F4), and the transmitter
DEL SET ABORT OK EJA:
outputs the output signal of 100%. Trim will be scaled
from 4.000 to 20.000
8 1 Proceed
2 Change
EJA: ‘1 9.0 5 0‘
Enter meter value Select Change, and press ENTER
20.000 (F4).
The same operations as for D/A
(ENTER)
trim are required when selecting
Ammeter reading: 19.050 item 3. Proceed.
4
Carry out the same procedures as ‘1’
EJA:
those described under 4 and 5 . Set scale- Lo output
9 value
4
EJA: 4
Fld dev output 20.000 (ENTER)
mA equal to reference
meter? HELP DEL ABORT ENTER
1 Yes (ENTER) Enter the value read on the meter
2 No
when the signal is 4 mA. In this
HELP DEL ABORT ENTER Ammeter reading: 20.000 case, Enter the value of the voltage
Returning fld dev to original across a 250 Ω resistor (1 V), and
output appears. press ENTER (F4).
10 5
EJA: EJA: ‘5’
NOTE-Loop may be Set scale- Hi output
returned to automatic value
control 20
(OK) 20
(ENTER)
HELP DEL ESC OK Press OK (F4). HELP DEL ABORT ENTER Enter the value read on the meter
when the signal is 20 mA. Then,
F0231.EPS
enter 5, and press ENTER (F4).
6
EJA:
Trim will be scaled
from 1.000 to 5.000
1 Proceed
2 Change (ENTER)
Select Proceed and press ENTER
HELP SET ABORT ENTER
(F4).
7
EJA:
Connect reference
meter
(OK)
Connect the voltmeter, and press
DEL SET ABORT OK
OK (F4).
8
EJA:
Setting fld dev
output to 4mA
(OK)
Press OK (F4). The output signal of

HELP DEL ABORT OK
0% is output.
F0232.EPS
2-15 IM 01C22T01-01E
9
(16) Burst Mode
EJA: ‘1 . 0 1’ The transmitter continuously sends the data stored in it
Enter meter value
1.000
when the burst mode is set on. Either one of measured
(ENTER) pressure variable, % output value, or 4 to 20 mA
HELP DEL ABORT ENTER output value can be selected and sent. The data is sent
Voltmeter reading: 1.010
intermittently as a digital signal at 75 ms intervals
Enter the reading of the voltmeter
when the transmitter is set in the burst mode. There-
(1.010), and press ENTER (F4).
(The output of the transmitter fore, communication by the HART simultaneous
changes.) communicator is also possible.
10
EJA:
Scaled output: 1.000
equal readout Setting of Burst Mode
device?
1 Yes (ENTER)
2 No
1. Device setup
HELP DEL ABORT ENTER Voltmeter reading: 1.000
4. Detailed setup
Because the reading on the
voltmeter is 1.000, select Yes and 3. Output condition
press ENTER (F4).
If the reading is not 1.000, select 4. HART output
No. Repeat steps 8 and 9 until 3. Burst mode, 4. Burst option
the voltmeter reads 1.000 V.
11 EJA:
Burst option
EJA: ********
Setting fld dev PV
output to 20mA % range/current (ENTER)
Process vars/crnt
(OK)
HELP DEL ESC ENTER
Call up the Burst option, and set
Press OK (F4). The output signal of the data to be sent.
HELP SET ABORT OK
100% is output. • Pressure variable (PV)
12 • % output value (% range/current)
‘5 . 2 1’
EJA:
• 4 to 20 mA output value (Process
Enter meter value vars/crnt)
5.000 EJA:
(ENTER) Burst mode
Off
On
HELP DEL ABORT ENTER Voltmeter reading: 5.210 Off
Enter the reading of the voltmeter

DEL
HELP DEL ESC ENTER (ENTER)
(5.210), and press ENTER (F4).
13
EJA:
Scaled output: 5.000 (SEND)
equal readout
device?
1 Yes (ENTER) Call up the Burst mode and set to
2 No
On.
HELP DEL ABORT ENTER Voltmeter reading: 5.000 Then, Press SEND (F2).
“Returning fid dev to Select Yes and press ENTER (F4). F0234.EPS
original output”
14 To Release from the Burst Mode:

EJA:
NOTE-Loop may be
Call up the Burst mode display, and set to OFF.
returned to automatic
control
(OK)
Press OK (F4).
HELP DEL ABORT OK
F0233.EPS
2-16 IM 01C22T01-01E
(17) Multidrop Mode Example: Communication when set in the multi-drop mode
“Multidropping” transmitters refers to the connection
of several transmitters to a single communications 1
transmission line. Up to 15 transmitters can be con- HART Communicator (1) The HART communicator
Online
nected when set in the multidrop mode. To activate 1 EJA110-1 searches for the transmitter that
2 EJA110-2
3 EJA110-3 is set in the multi-drop mode
multidrop communication, the transmitter address must when the HART communicator
be changed to a number from 1 to 15. This change HELP SET HOME OK is turned on.
deactivates the 4 to 20 mA analog output, sending it to When the HART communicator
2 is connected to the transmitter,
4 mA. The alarm current also is disabled. the manufacturer’s x’ter type
EJA:EJA110-1:
Online
1 Device setup
code and the tag will be
Setting of Multidrop Mode 2 Pres 0.00 mmH2O displayed (display 1 ).
3 A01 Out .000 mA
4 LRV 0.00 mmH2O (2) Select the desired transmitter.
5 URM 3500.00 mmH2O After that, normal
1. Device setup DEL SET ABORT OK
communication to the selected
4. Detailed Setup transmitter is possible. However,
3
the communication speed is
HART Communicator
3. Output condition 1 Offline slow in this case (display 2 ).
2 Online (3) To communicate with another
3 Transfer
4. HART Output 4 Frequency Device transmitter, turn off the power
5 Utility
once and then turn on it again,
1. Poll addr HELP DEL ABORT OK or call up display 3 , and select
EJA: Call up the Poll addr and set the Online.
Poll addr
O polling address. (a number from 1 to (4) Display 1 will appear. Select
0
15) the desired transmitter.
And press SEND (F2) to send the F0236.EPS
HELP DEL ESC ENTER data.

To Release the Multi-drop Mode:
Online Follow the procedure below.
Utility
1. Call up the Poll addr display, and set the address
Auto Poll to 0.
HART Communicator
Auto Poll 2. Call up the Auto Poll display, and set to No.
No
No
Yes (18) External Switch Mode
DEL
HELP DEL ESC ENTER
• Enabling/inhibiting zero point adjustment using the
(ENTER)
external zero-adjustment screw on the transmitter.
Call up the Auto Poll and set to
Yes.
Follow the procedure below to enable or inhibit zero
point adjustment from the zero-adjustment screw on
F0235.EPS
the transmitter.
This is set to ENABLE when the instrument is
shipped.
NOTE
1. When the address is set and the multi-drop Example: Inhibiting zero adjustment by the external zero-
adjustment screw
mode is set to “No” at the same time, Online
menus cannot be called up and displayed. Be 1. Device setup
sure to turn the multidrop mode to “Yes” after
4. Detailed setup
setting the address with “Poll addr.”
5. Device information
2. When the same polling address is set for two
or more transmitters in multidrop mode, 1. Field device info
communication with these transmitters is 7. Ext SW mode
disabled. EJA:
Ext SW mode
Enable
Enable
Inhibit
(SEND)
Select Inhibit and press ENTER
(F4).
Press SEND (F2) to send the data.
F0237.EPS
2-17 IM 01C22T01-01E
(19) Software Write Protect (b) Changing the Password

EJA configured data is saved by the write protect
function. Write protect status is set to YES when 8 Example: To change the password from 1 2 3 4 1 2 3 4
to 6 7 8 9 A B C D
alphanumerics are entered in the New password
field and transferred to the transmitter. In write protect
EJA:
YES status, the transmitter does not accept parameter Input password
********
********
changes. When the 8 alphanumeric string entered in the
12341234
New password field is also entered in the Enable
write field and transferred to the transmitter, it will be
(ENTER)
possible to change transmitter parameters during a 10
Press Hot key and call up Enable
minute period.
Write.
Enter the password and press
To change the transmitter from Write protect YES
ENTER (F4).
status back to Write protect NO status, enter 8 spaces
EJA:
in the New password field after Write protect has been Write enable in 10
minutes
released using enable write. (OK)
Press OK (F4).
HELP DEL ABORT OK Write protect status is released for
(a) Setting Password
10 minutes.
Example: Set the password to 1 2 3 4 1 2 3 4 EJA:

Method Aborted
(OK)
EJA:
Hot key
1 keypad input Press ENTER (F4).
2 Enable Write HELP DEL ABORT OK
3 New password
EJA:
HELP SEND ESC ENTER Hot key
Press Hot key. 1 keypad input
2 Enable write
Select the New password. 3 New password
EJA: Select the New password.

Enter New Password HELP DEL ABPRT OK
********
********
(ENTER) EJA: 6789ABCD
Enter New Password
Set 1 2 3 4 1 2 3 4 and press ********
HELP DEL ABORT ENTER ENTER (F4). ********
(ENTER)
HELP DEL ABORT ENTER Set 6 7 8 9 A B C D.
EJA:
Re-Enter New
Password
EJA: 6789ABCD
Re-Enter New 6789ABCD (OK)
Password
12341234 Press ENTER (F4).
12341234 (ENTER) HELP DEL ABORT ENTER
Press ENTER (F4).
HELP DEL ABORT ENTER EJA:
Set New Password OK
EJA:
Set New Password OK (OK)
(OK)
HELP DEL ABORT OK
Press OK (F4).
HELP DEL ABORT OK Write Protect status changes from EJA:
NO to YES. Method Aborted
EJA: (OK)
Method Aborted
Press OK (F4).
(OK) HELP DEL ABORT OK
Press OK (F4). F0239.EPS

HELP DEL ABORT OK
F0238.EPS
2-18 IM 01C22T01-01E
CPU assembly
NOTE Slide switch Burnout direction switch
1. Enable Wrt 10 min releases Write Protect L H

status for 10 minutes. While Write Protect Y N
status is released, enter a new password in
Write protection switch
the New Password field.
It will not be possible to set a new password Hardware write protection switch
when 10 minutes have elapsed.
2. To release Write Protect status completely, Write Protection L H L H
Switch Position Y N Y N
enter 8 spaces in the New Password field
according to the instructions given in (b),
Write Protection NO YES
Changing the Password. This causes Write
Protect status to change from YES to NO. Burnout direction switch
EJA:
Enter New Password 8 Burnout Direction L H L H
******** Switch Position
******** Y N Y N
HELP DEL ABORT ENTER (ENTER)

Burnout Direction HIGH LOW
F02F1.EPS
EJA:
Re-Enter New
Password
1 (ENTER)
(21) H2O Unit Select
When mmH2O, inH2O or ftH2O is set, the pressure
varies with the standard temperature definition. The
* "Joker password" and "Software Seal" Yokogawa default setting for the standard temperature
When you lose the password that has been registered, it is
possible to release the mode for 10 minutes by using a is 4°C (39.2°F). Use the procedure described below
joker password. Enter "YOKOGAWA" to release Write when a standard temperature of 20°C (68°F) is re-
protect status for 10 minutes. If this joker password is quired.
used, the status shown in the parameter "Software seal" is
changed from "Keep" to "Break." Press Hot key and select Call up the H2O Unit select.
"2. Wrt Protect menu." Current status is shown in "4.
Software seal." This status will be returned from "Break" to
"Keep" by registering a new password.
F0240.EPS
1. Device setup
4. Detailed setup
(20) Hardware Write Protect and Burnout 2. Signal condition

Direction(with Optional code /F1) 9. H2O Unit select
This function prohibits parameter changes through a EJA:
H2O Unit select
slide switch on a CPU assembly board. In the case the @4C
@4C
hardware write protection switch is set to YES, none of @20C(68F)
the communication method including the handheld HELP SEND ESC ENTER (ENTER)
terminal such as model 275 is allowed for the alter-
ation of parameters. The write protection switch is
factory set to NO(N position in the figure below). (SEND)
Select @20C (68F) and press

ENTER (F4).
F0241.EPS
2-19 IM 01C22T01-01E
2.4 Self-Diagnostics • Error Messages — HART Communicator

Error Message Probable Cause Countermeasure
2.4.1 Checking for Problems Pressure sensor Capsule problem Replace capsule
error when error keeps
(1) Identify Problems with HART Communica- Temp (Cap) sensor appearing even
after restart.
tor error
Self-diagnostics of the transmitter and check of EEPROM (Cap)
failure
incorrect data setting can be carried out with the
Sensor board not
HART communicator. There are two methods for self-
initialized
diagnosis of the transmitter, self-diagnosis for every Temp (Amp) sensor Amplifier problem Replace
transmission and manually executing the SELF TEST error amplifier.
command. When an error message appears, follow EEPROM (Amp)
“ERROR MESSAGES”. failure
Dev id not entered
Diagnostic by “self test” CPU board not
initialized
1. Device setup Invalid Selection Change the
setting.
2. Diag/Service Parameter Too High Set value is too high.
1. Test/Status Parameter Too Low Set value is too low.

Incorrect Byte Count —
1
In Write Protect Operation is set in the —
EJA:
Test/status Mode Write Protect mode.
1 Self test
2 Status Set to Nearest Value is set to a —
Possible Value nearest possible value.
Call up the Test/Status, and select
HELP SET HOME OK
Self test. Lower Range Value LRV set point is too Change the
too High high. range.
2
Lower Range Value LRV set point is too
EJA: If there is no error detected, Self too Low low.
Self test OK
test OK will be displayed.
When an error occurs, an error Upper Range Value URV set point is too
message appears, and the results too High high.
DEL SET ABORT OK of self-diagnosis appear in the Upper Range Value URV set point is too
Status item. too Low low.
Span too Small Set span is too small.
1
EJA: Applied Process Applied pressure is Adjust the
Test/status
Value too High too high. applied pressure.
1 Self test
2 Status
Applied process Applied pressure is
Value too Low too low.
Call up the Status item.
HELP SET HOME OK The shift of URV Change the
New LRV pushed
URV Over Sensor according to the new setting within the
2 LRV setting exceeds range of USL.
Limit
EJA: USL.
Status
Field device not
installed Excess Correction Amount of correction Adjust the amount
OFF (NEXT)
Attempted is too much. of correction.
If there is no error, the result of
DEL PREV NEXT EXIT In Proper Current The fixed current Set in the fixed
diagnostics is indicated as OFF. If
Mode mode is desired but current mode.
ON is indicated, a countermeasure
not set in that mode.
for that error is necessary.
F0242.EPS
In Multidrop Mode Operation is set in —
the multi-drop mode.
T0205.EPS
2-20 IM 01C22T01-01E
(2) Checking with Integral Indicator

If an error is detected in the self-diagnostic, an error
number is displayed on the integral indicator. If there is
more than one error, the error number changes at two-
second intervals.
See Table 2.4.1 regarding the error numbers.
F0243.EPS
Figure 2.4.1 Identifying Problems Using the Integral

Indicator
• Error Messages — DPharp Integral Indicator
Integral
Output Operation
Indicator Description Cause Countermeasure
during Error
Display
None GOOD
---- ERROR
Er. 01 CAP MODULE Capsule problem*1 Outputs the signal Replace capsu
capsule
FAULT according to status of when error keeps
burnout direction appearing even after
switch (High or Low). resart.*1
Er. 02 AMP MODULE Amplifier problem Outputs the signal Replace amplifier.
FAULT according to status of
burnout direction
switch (High or Low).
Er. 03 OUT OF RANGE Input is outside Outputs high range Check input.
measurement range limit value or low
limit of capsule. range limit value.
Er. 04 OUT OF SP Static pressure Displays present Check line pressure
RANGE exceeds specified output. (static pressure).
range.
Er. 05 OVER TEMP Capsule temperature Displays present Use heat insulation or
(CAP) is outside range output. make lagging to keep
range.
Er. 06 OVER TEMP Amplifier temperature Displays present Use heat insulation or
(AMP) is outside range output. make lagging to keep
range.
Er. 07 OVER OUTPUT Output is outside high Outputs high or low Check input and range
or low range limit range limit value. setting, and change
value. them as needed.
Er. 08 OVER DISPLAY Displayed value is Displays high or low Check input and
outside high or low range limit value. display conditions and
range limit value. modify them as
needed.
Er. 09 ILLEGAL LRV LRV is outside setting Holds output Check LRV and
error occurrence.
Er. 10 ILLEGAL URV URV is outside setting Holds output Check URV and
error occurrence.
Er. 11 ILLEGAL SPAN SPAN is outside Holds output Check SPAN and
setting range. immediately before change as needed.
error occurrence.
Er. 12 ZERO ADJ OVER Zero adjustment is too Displays present Readjust zero point.
large. output.
*1 : This error code appears at capsule problem or when an illiegal overpressure is applied to the
pressure sensor.
*2 : If the normal pressure is regained, the Er.01 will disappear according to the setting of the parameter
of Auto recover. When the Auto recover is set to ON(default setting), the Er.01 will disappear auto-
matically. When the Auto recover is set to OFF, restart the transmitter to cancel Er.01. If no error
code appears then, perform necessary adjustments such as zero-adjustment to continue the
operation. If the error code still appears. replace the capsule assembly.
T0206.EPS
2-21 IM 01C22T01-01E
3. PARAMETER LISTS
3. PARAMETER LISTS
Item UHI Description Remarks
Tag Tag number Tag number, Up to 8 characters
Descriptor Descriptor Up to 16 characters
Message Message Up to 32 characters
Date Date xx/yy/zz
Transmitter Unit Unit inH2O, inHg, ftH2O, mmH2O, mmHg, psi, bar, mbar, g/cm2,
kg/cm2, Pa, kPa, MPa, torr, atm
LRV Lower range value Set the calibration range by the keypad
URV Lower range value
Apply values Apply values Range for 4 to 20 mA DC signal is set with actual input applied.
Damp Damping time constant 0.2, 0.5, 1, 1.5, 2, 4, 6, 8, 16, 32 sec
Xfer fnctn Transfer function linear/Square root
Low cut Low cut 0 to 20 %
Cut mode Cut mode Linear/Zero
Bi-dire mode Bi-directional mode On/Off
H2O Unit select H2O Unit select @4°C/@20°C (68°F)
Snsr temp unit Sensor temperature unit °C/°F
AO lower limit % Analog output upper and lower –5.0% to 110.0%
AO upper limit % limits
Auto recover Auto recover mode ON/OFF
Static pres unit Static pressure unit inH2O, inHg, ftH2O, mmH2O, mmHg, psi, bar, mbar, g/cm2,
Display
kg/cm2, Pa, kPa, torr, atm
Display mode Display mode Normal % , User set , User set & % , Inp pres , Pres & %
Display fnctn Display fnctn linear/Square root
Engr unit Engineering unit Up to 8 characters
Engr disp LRV Engineering display LRV –19999 to 19999
Engr disp URV Engineering display URV –19999 to 19999
Engr disp point Engineering display decimal point 0, 1, 2, 3
Poll addr Polling address 1 to 15
HART output
Auto poll Auto poll No/Yes
Burst option Burst mode option Pres , % rnge , A01 out
Burst mode Burst mode ON/OFF
Monitoring Pres Pressure variable
% rnge % output variable –3.2 mA to 21.6 mA
A01 out 4 to 20 mA output variable –5.0% to 110.0%
Snsr temp Sensor temperature
Static pres Static pressure
Engr display Output (in Engr unit) –19999 to 19999
Mainenance Loop test Test output % setting –5.0% to 110.0%
Self test Self test Check using the self-test command.
Status Status Display of the result of self-test, calibration of transmitter.
A01 Alarm typ Status of analog output alarm High/Low
Write Protect Write Protect Yes/No
Enable Write Enable Write 8 characters
New password New password 8 characters
Ext SW mode Ext SW mode Enable/Inhibit
Software seal Software seal Keep/Break
T0301.EPS
3-1 IM 01C22T01-01E
3. PARAMETER LISTS
Item UHI Description Remarks

Adjustment Zero trim Zero trim Set the current input value to 0 kPa.
Lower sensor trim Lower sensor trim Adjust only measured pressure variable.
Upper sensor trim Upper sensor trim
D/A trim Digital/Analog output trim Adjust the output value at the points of 4 mA and 20 mA.
Scaled D/A trim Scaled D/A trim
Sensor Isoltr matl Isolator material Hast-C, Tantalum, 316L, Unknown, Special
information Fill fluid Fill fluid Silicone oil, F oil, Unknown, Special
Gasket matl gasket material PTFE, 316L, Unknown, Special
Flange matl Flange material Carbon Steel, Hast-C, 316L, Unknown, Special
Drain vent matl Drain vent material 316SST, Hast-C, 316L, None, Unknown, Special
Flange type Flange type Conventional, Remote seal, Level, Unknown, Special
RS isoltr matl Remote seal isolator material 316 SST, Hast-C, Monel, Tantalum, 316L, Unknown, Special
Flange size Flange size ANSI 150, ANSI 300, ANSI 600, None, Unknown, Special
Num remote seal Number of remote seal One seal, Two seal, None, Unknown
RS fill fluid Remote seal fill fluid Silicone oil, SH704, SH705, Ethy Gly/H2O, Prop Gly/H2O,
None, Unknown, Special
RS type Remote seal type Wafer, Nozzle, HTV-W, HTV-N, None, Unknown, Special
Additional Distributor Distributor YOKOGAWA
information Dev type Device type EJA
Dev ID Device ID
Final asmbly num Final assembly number
Universal rev Universal revision
Fld dev rev Fld dev revision
Software rev Software revision
Model Model
Style Style
LSL Lower range limit
USL Upper range limit
MIN SPAN Minimum span
Manufacturer Manufacturer
Lo snsr trim pt Lower snsr trim pt
Up snsr trim pt Upper snsr trim pt
Serial No. Serial Number
T0302.EPS
3-2 IM 01C22T01-01E
REVISION RECORD
Title: Model EJA Series HART Protocol
Manual No.: IM 01C22T01-01E
1st Nov. 1995 – New publication
2nd Mar. 1998 1 • Add EJA-A Series IM numbers to Table 1.
3 • Add REVISION RECORD
2-1 2.1.1 • Change the figure of terminal configuration
3rd Mar. 2000 – Revised a book in a new format.
The location of contents and the associated page numbers may
not coincide with the one in old edition.
2-19 2.3.3(19) • Add Hardware Write Protect and Burnout Direction(with optional
code /F1).
4th July 2000 ii • Add Caution for matching communicator DD and instrument DD.
2-6 2.3.2 • Add Software seal parameter.
2-18 2.3.3 • Change NOTE for Write Protect.
3-1 3 • Add software seal
5th Oct. 2000 2-5 2.3.1 • Add "MPa" to engineering unit.
2-21 • Correct the description of Output Operation during Error for
Er.01 and Er. 02.
6th Apr. 2003 2-7 2.3.3 • Add Option code /CA.
7th Jan. 2008 – Miscellaneous corrections.
8th Oct. 2008 2-6 2.3.2 • Add parameters AO upper/lower limits and Auto recover.
2-10 2.3.3 • Add (8) Change Output Limits.
2-18 2.3.3 • Change the example for a password.
2-21 2.4.1 • Add descriptions for Er.01 and Auto recover function.
3-1 3 • Add parameters AO upper/lowerr limits and Auto recover.
REVISION RECORD.EPS
IM 01C22T01-01E
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.19 Pressure Switch
B-Series Switches – Pressure, Differential
Pressure, Temperature & Hydraulic
FEATURES Thermowells
B-Series switches have proven reliable Thermowells must be used on any appli-
in such harsh environments as: cation where the stem of the temperature
switch may be exposed to pressure, cor-
• Offshore oil rigs rosive fluids or high velocity. Additionally,
• Chemical and petrochemical plants the use of a thermowell permits instrument
interchange or calibration check without
• Pulp and paper mills
disturbing or closing down the process.
• Steel mills Ashcroft temperature switches have
• Power plants bulb diameters to match 3⁄8˝ nominal bore
• Water and sewage-treatment plants thermowells. The bulbs have a sensitive
portion length of 2˝ which can be used
• Other corrosive environments with 21⁄2˝ “U” dimensioned thermowells or
longer. For maximum accuracy, a thermo-
Ashcroft Inc. supplies highly reliable
well’s “U” dimension should be selected
Ashcroft® switches and controls for indus-
to permit complete immersion of the sen-
trial and process applications. We begin
sitive portion plus 1˝ when measuring the
with rock-solid designs, matching the most
temperature of liquids; an extra 3˝ should
appropriate technology with the safety and
be allowed when measuring the temper-
reliability requirements of the applications.
ature of gases.
The materials of construction are specified
Thermowell bushings should be used
to Ashcroft’s exacting standards, and prod-
with remote mount temperature switches.
uct is built to last in the toughest applica-
We recommend the standard 3˝ bulb and
tions. Our modern, responsive manufactur-
code 69 Series bushings for use with any
ing facility is supported by an extensive
thermowell “U” dimension. A split rubber
network of stocking distributors and factory
grommet allows easy installation and “S”
sales offices located in virtually every part
dimension adjustment.
of the world. Special application assistance
is always just a telephone call away.
The Ashcroft B-Series switch line is
designed to satisfy most switch require-
ments. Materials of construction have been
selected for long life. A wide variety of pre-
cision switch elements are available to
meet every application requirement,
including hermetically sealed contacts for
added reliability and safety. The actuators
we use have been proven in more than 20
years of service in the world’s plants and
mills. Special designs are available for fire
safety, NACE, limit control and other more
stringent requirements. Simplicity and
ease of use are stressed to improve relia-
bility of the installation.
Applications include: pumps, compres-
sors, washers, filters, degreasers, evapora-
tors, recovery systems, food processing,
ground support equipment, reverse osmo-
sis systems, heat exchangers, hydraulic
systems, lubrication systems, marine
equipment, textile machinery, heating and
air conditioning equipment.
All specifications are subject to change without notice. Ashcroft Inc., 250 East Main Street, Stratford, CT 06614 USA
All sales subject to standard terms and conditions. Tel: 203-378-8281 • Fax: 203-385-0408
BULLETIN SW10 © Ashcroft Inc. 2007 10/08 email: info@ashcroft.com • www.ashcroft.com
B-Series Switches – Pressure, Differential Pressure,
Temperature & Hydraulic
Temperature Switches ship that exists between temperature and span setpoint repeatability with very high
B-Series temperature switches feature pressure according to the vapor pressure overtemperature ratings.
a SAMA Class II vapor pressure thermal laws. A wide selection of sensing bulb These standard designs perform well
system. This system provides quick, and armored capillary lengths is avail- in applications where shock and vibra-
accurate response to process tempera- able. The vapor pressure system design tion could be a problem and should be
ture changes with negligible ambient features small bulb sizes, making instal- used with Ashcroft thermowells for bulb
temperature effects. This is inherent in lation easy and cost-effective. protection and ease of installation and
the design due to the precise relation- All models feature ±1.0% percent of maintenance.
STANDARD TEMPERATURE RANGE SELECTION

Maximum
Nominal Range(1) Approximate Deadband(1) Switch Element
Temperature
°F °C °F 20, 26, 27 21, 24, 31 50 22 32, 42
–40 to 60 –40 to 160 400 1.0-2.0 3.0-8.0 1.5-5.5 1.4-6.0 8.0-16.0
0 to 100 –20 to 400 400 1.5-3.0 5.0-12.0 2.2-8.5 1.5-7.5 9.0-20.0
75 to 205 20 to 95 400 1.5-3.5 8.0-16.0 2.5-12.0 2.0-9.0 10.0-24.0
150 to 260 65 to 125 400 1.5-3.0 5.0-12.0 2.2-8.5 2.0-9.0 10.0-24.0
235 to 375 110 to 190 500 1.5-3.5 5.0-12.0 2.5-8.5 2.0-9.0 10.0-24.0
350 to 525(3) 175 to 275 700 2.0-4.5 8.0-16.0 3.2-12.0 2.5-10.0 15.0-34.0
500 to 750(2) 260 to 400 900 4.0-8.0 16.0-30.0 7.2-24.0 5.0-23.0 30.0-50.0
NOTES: 1 All deadbands given in °F. 4 Dual switch element multiply single switch element value by 1.6 for
2 Available with remote mount thermal systems only. approximate deadband.
3 Not available with 23⁄4˝ stem. 5 Set and reset points must fall within the adjustable range.
Pressure & Differential Pressure Switches
B-Series pressure, differential pressure and of construction. maximum reliability. This design is available in
vacuum switches use two different actuators All standard models feature ±1 percent of 316 SS or Monel. Differential pressure models
depending on setpoint require-ments. For set- range setpoint repeatability and a minimum of use a unique, dual diaphragm-sealed piston
points between 2 and 3000 psi, the simple, 400 percent of range proof pressures. design that features very high static operating
rugged diaphragm-sealed piston actuator is These standard designs perform well in appli- pressures and small size.
used. This design features high reliability and cations where shock and vibration could be a For setpoints between 4.5 and 150 inches of
choice of actuator seal materials for virtually problem and may be used in conjunction with H2O, a large diaphragm is used for increased
every application. An optional welded design is Ashcroft diaphragm seals in extreme services sensitivity in both pressure and differential
also available for setpoints up to 1000 psi for such as slurries or abrasive process fluids. pressure designs with good choice of materials
PRESSURE/VACUUM SWITCHES
Overpressure Ratings Approximate Deadband(2) Switch Element
Nominal Range(1) Proof psi Burst psi 20, 26, 27 21, 24, 31 50 22 32, 42
Vacuum
–30˝ Hg –760mm Hg -100 kPa 250 400 0.3-0.7 1.5-3.0 0.5-2.2 0.4-1.5 2.1-4.2
Compound
–15˝ H2O/ –375mm H2O/ –3.7 kPa/ 20 35 0.15-.75/ 1.5-2.5/ 0.45-2.0/ 0.5-1.2/ 2.1-3.5/
15˝ H2O 375mm H2O 3.7 kPa 0.15-.75 1.5-2.5 0.45-2.0 0.5-1.2 2.1-3.5
–30˝ H2O/ –760mm H2O/ –7.5 kPa/ 20 35 0.30-.60/ 1.5-2.5/ 0.45-2.0/ 0.5-1.5/ 2.1-3.5/
30˝ H2O 760mm H2O 7.5 kPa 0.30-.60 1.5-2.5 0.45-2.0 0.5-1.5 2.1-3.5
–30˝ Hg/ –760mm Hg/ –100 kPa/ 0.5-1.0/ 2.0-3.0/ 0.75-2.5/ 0.7-1.8/ 2.8-4.2/
15 psi 1.0 kg/cm2 100 kPa 250 400 0.3-0.7 0.5-1.5 0 .5-1.0 0.7-1.4 0.7-2.1
–30˝ Hg/ –760mm Hg/ –100 kPa/ 1.0-1.5/ 3.0-6.0/ 1.2-4.5/ 1.4-2.4 4.2-8.4/
30 psi 2.0 kg/cm2 200 kPa 250 400 0.3-0.8 1.0-2.0 0.7-1.5 0.4-1.3 1.4-2.8
–30˝ Hg/ –760mm Hg/ –100 kPa/ 2.0-3.0/ 5.0-9.0/ 2.5-7.0/ 2.8-4.5 7.0-12.0/
60 psi 4.0 kg/cm2 400 kPa 250 400 0.7-1.5 3.0-5.0 1.1-4.0 1.0-2.3 4.2-7.0
Pressure
10˝ H2O 250mm H2O 2.5 kPa 20 35 0.2-0.5 1.0-2.0 0.35-1.5 0.4-1.0 1.4-2.8
30˝ H2O 750mm H2O 7.5 kPa 20 35 0.3-0.6 1.5-2.5 0.45-2.0 0.5-2.0 2.1-3.5
60˝ H2O 1500mm H2O 15 kPa 20 35 0.5-1.3 1.5-3.5 0.9-2.5 0.7-3.0 2.1-5.0
100˝ H2O 2500mm H2O 25 kPa 20 35 0.6-1.6 2.5-5.5 1.1-4.0 1.0-4.0 3.5-7.7
150˝ H2O 3750mm H2O 37 kPa 20 35 1.0-2.5 4.5-8.5 1.7-6.5 2.0-6.0 6.0-12.0
15 psi 1.0 kg/cm2 100 kPa 500 1500 0.1-0.35 0.5-1.5 0.2-1.0 0.4-1.0 0.7-2.1
30 psi 2.0 kg/cm2 200 kPa 500 1500 0.1-0.50 0.5-1.5 0.3-1.0 0.4-1.0 0.7-2.1
60 psi 4.0 kg/cm2 400 kPa 500 1500 0.3-1.0 1.0-3.5 0.7-2.5 0.6-2.0 1.4-5.0
100 psi 7.0 kg/cm2 700 kPa 1000 3000 0.5-1.7 1.5-5.0 1.1-3.5 1.0-4.5 2.1-7.0
200 psi 14 kg/cm2 1400 kPa 1000 3000 1-3 5-13 2-9 3.0-7.5 7.0-18.2
400 psi 28 kg/cm2 2800 kPa 2400 3000 4-7.5 5-24 5.5-15 4.0-11.0 7.0-33.6
600 psi 42 kg/cm2 4200 kPa 2400 3000 4-11 9-30 7-20 5.0-23.0 12.6-42
1000 psi 70 kg/cm2 7000 kPa 12000 18000 7-30 30-110 18-70 15-80 42-154
3000 psi 210 kg/cm2 2100 kPa 12000 18000 15-60 80-235 37-160 30.0-230 112-329
DIFFERENTIAL PRESSURE SWITCHES

Pressure Ratings Approximate Deadband(2) Switch Element
Static Work-
Nominal Range(1) ing Pressure Proof psi 20, 26, 27 21, 24, 31 50 22 32, 42
30˝ H2O 750mm H2O 7.5 kPa 5.4 21.6 0.3-0.6 1.5-2.5 0.45-2.0 0.5-2.0 2.1-3.5
60˝ H2O 1500mm H2O 15 kPa 5.4 21.6 0.5-1.3 1.5-3.5 0.9-2.5 0.7-3.0 2.1-5.0
100˝ H2O 2500mm H2O 25 kPa 5.4 21.6 0.6-1.6 2.5-5.5 1.1-4.0 1.0-4.0 3.5-7.7
150˝ H2O 3750mm H2O 37 kPa 5.4 21.6 1.0-2.5 4.5-8.5 1.8-6.5 2.0-6.0 6.3-12.0
15 psid 1.0 kg/cm2 100 kPa 500 2000 0.5-1.0 2.0-5.0 0.7-3.5 0.7-1.4 2.8-7.0
30 psid 2.0 kg/cm2 200 kPa 500 2000 1.0-2.0 2.0-5.0 1.5-3.5 1.4-2.8 2.8-7.0
60 psid 4.0 kg/cm2 400 kPa 500 2000 2.0-4.0 3.0-6.0 3.0-4.5 2.8-5.6 4.2-8.5
100 psid 7.0 kg/cm2 700 kPa 1000 4000 4.0-10.0 11.0-20.0 7.0-15.0 6.0-14.0 16.0-28.0
200 psid 14.0 kg/cm2 1400 kPa 1000 4000 5.0-15.0 12.0-40.0 10.0-26.0 7.0-21.0 17.0-56.0
400 psid 28.0 kg/cm2 2800 kPa 1000 8000 10.0-20.0 20.0-60.0 15.0-40.0 14.0-28.0 28.0-84.0
600 psid 42 0 kg/cm2 4200 kPa 1000 8000 20.0-40.0 80.0-150.0 30.0-115.0 30.0-56.0 112.0-210.0
Values shown are for zero static working pressure.
NOTES: 1 Switches may generally be set between 15% and 100% of nominal range Viton: Multiply Buna N value by 1.4
on increasing pressure. Consult factory for applications where setpoints Teflon: Multiply Buna N value by 1.2
must be lower. Stainless Steel: Multiply Buna N value by 1.7
2 All deadbands are given in English units as shown in the nominal range Monel: Multiply Buna N value by 1.7
column. Deadbands shown are for switches with Buna N diaphragm. Dual Switch Element: Multiply single switch element value by 1.6
Approximate deadbands for optional diaphragms: for approximate deadband.
B-SERIES PRESSURE AND DIFFERENTIAL PRESSURE SWITCH MODEL NUMBER:
To specify the exact switch desired, select entries from appropriate tables as shown in example below.
1 2 3 4 5
B 4 2 0 B X P K 600 PSI
1 – ENCLOSURE 2 – SWITCH ELEMENT SELECTION
Pressure switch, Type 400, watertight enclosure Order Switch Elements
B4
meets NEMA 3, 4, 4X, 13 and IP66 requirements. Code UL/CSA Listed SPDT
Pressure switch, Type 700, explosion-proof 20(7) Narrow deadband ac 15A, 125/250 Vac
B7 enclosure meets Div. 1 & 2, NEMA 7, 9 and IP66 21 Ammonia service 5A, 125/250 Vac
requirements. 22(6) Hermetically sealed switch, 5A, 125/250 Vac
Differential pressure switch, Type 400, water- narrow deadband
D4 tight enclosure meets NEMA 3, 4, 4X, 13 and 23 Heavy duty ac 22A, 125/250 Vac
IP66 requirements. 24(1) General purpose 15A, 125/250/480 Vac
Differential pressure switch, Type 700, explosion- 1⁄2A, 125 Vdc
D7 proof enclosure meets Div. 1 & 2, NEMA 7, 9 and 1⁄4A, 250 Vdc; 6A, 30 Vdc
IP66 requirements. 25(2) Heavy duty dc 10A, 125 Vac or dc,
1⁄8 HP, 125 Vac or dc
26(7) Sealed environment proof 15A, 125/250 Vac

3 – ACTUATOR SEAL 27 High temperature 300°F 15A, 125/250 Vac
Range 28(5) Manual reset trip on 15A, 125/250 Vac
Code Process increasing
and Temperature Vac. 0-600 1000 3000 29(5) Manual reset trip on 15A, 125/250 Vac
Material Limits °F(9) ˝ H2O psi psi psi decreasing
B – Buna-N 0 to 150 • • • • 31 Low level (gold) contacts 1A, 125 Vac
V – Viton 20 to 300 • • • 32 Hermetically sealed switch, 11A, 125/250 Vac
T – Teflon 0 to 150 • • • • general purpose 5A, 30 Vdc
42 Hermetically sealed switch, 1A, 125 Vac
S – 316L(8) 0 to 300 • •
gold contacts
P – Monel(8) 0 to 300 • • 50 Variable deadband 15A, 125/250 Vac
UL/CSA Listed Dual (2 SPDT)
4 – OPTIONS 5 – RANGE 61(7) Dual narrow deadband 15A, 125/250 Vac
Use table from page 6 Select from table on page 4 62(7) Dual sealed environment 15A, 125/250 Vac
proof
63 Dual high temp. 300°F 15A, 125/250 Vac
NOTES: 64 Dual general purpose 15A, 125/250/480 Vac
1⁄2A, 125 Vdc
1 Standard switch.
1⁄4A, 250 Vdc
2 Not available with psid ranges.
3 Dual switches are 2 SPDT snap-action switches, not independently 65 Dual ammonia service 5A, 125/250 Vac
adjustable.
4 Wires cannot be terminated inside B400 switch enclosure. 67(4,6) Dual hermetically sealed 5A, 125/250 Vac
5 Not available with type 700 enclosure. switch, narrow deadband
6 Estimated dc. rating, 2.5A, 28 Vdc (not 68(4) Dual hermetically sealed 11A, 125/250 Vac
UL listed).
7 Estimated dc rating, 0.4A, 120 Vdc (not UL listed). switch, general purpose 5A, 30 Vdc
8 Available on pressure only. 70 Dual low level gold contacts 1A, 125 Vac
9 Ambient operating temperature limits –20 to 150°F, all styles, setpoint 71(4) Dual hermetically sealed 1A, 125 Vac
shift of ±1% of range per 50°F temperature change is normal.
Switches are calibrated at 70°F reference. switch, gold contacts
B-SERIES TEMPERATURE SWITCH MODEL NUMBER:
1 2 3 4 5 6
T 4 2 0 T 0 5 030 X N H 150° to 260°F

1 – ENCLOSURE 3 – THERMAL SYSTEM SELECTION
Temperature switch, Type 400, watertight enclosure Direct Mount
T4
meets NEMA 3, 4, 4X, 13 and IP66 requirements. Order Code System Material Style
Temperature switch, Type 700, explosion-proof TS 3l6 SS Rigid
T7 enclosure meets Div. 1 & 2, NEMA 7, 9 and IP66 Remote Mount
requirements. Order Code System Material Line Length Style(9)
T05 316 SS 5´ Capillary
2 – SWITCH ELEMENT SELECTION T10 316 SS 10´ with
Order Switch Elements T15 316 SS 15´ 302 SS
Code UL/CSA Listed SPDT T20 316 SS 20´ Spring
20(7) Narrow deadband ac 15A, 125/250 Vac T25 316 SS 25´ Armor
21 Ammonia service 5A, 125/250 Vac
22(6) Hermetically sealed switch, 5A, 125/250 Vac 4 – BULB LENGTH SELECTION
narrow deadband Direct Mount
23 Heavy duty ac 22A, 125/250 Vac Minimum
24(1) General purpose 15A, 125/250/480 Vac Order “S” Thermowell
1
⁄2A, 125 Vdc Code Dimension “U” Dimension
1
⁄4A, 250 Vdc; 6A, 30 Vdc 027(8) 23⁄4˝ –
25 Heavy duty dc 10A, 125 Vac or dc, 040 4˝ 21⁄2˝
1
⁄8 HP, 125 Vac or dc 060 6˝ 41⁄2˝
26(7) Sealed environment proof 15A, 125/250 Vac 090 9˝ 71⁄2˝
27 High temperature 300°F 15A, 125/250 Vac 120 12˝ 101⁄2˝
28(5) Manual reset trip on 15A, 125/250 Vac Remote Mount
increasing 030(9) 3˝ 21⁄2˝
29(5) Manual reset trip on 15A, 125/250 Vac
decreasing 5 – OPTIONS
31 Low level (gold) contacts 1A, 125 Vac
32 Hermetically sealed switch, 11A, 125/250 Vac Use table on page 7
general purpose 5A, 30 Vdc
42 Hermetically sealed gold 1A, 125 Vac
contacts 6 – STANDARD TEMPERATURE
50 Variable deadband 15A, 125/250 Vac
RANGE SELECTION
Adjustable Range
°F °C
61(7) Dual narrow deadband 15A, 125/250 Vac
–40 to 600 –40 to 160
62(7) Dual sealed environment 15A, 125/250 Vac
proof 0 to 100 –40 to 400
63 Dual high temp. 300°F 15A, 125/250 Vac 75 to 205 20 to 95
64 Dual general purpose 15A, 125/250/480 Vac 150 to 260 65 to 125
1
⁄2A, 125 Vdc 235 to 375 110 to 190
1
⁄4A, 250 Vdc 350 to 525 175 to 275
65 Dual ammonia service 5A, 125/250 Vac 500 to 750(2) 260 to 400
67(4,6) Dual hermetically sealed 5A, 125/250 Vac NOTES:
switch, narrow deadband 1 Standard switch.
2 Available with remote mount thermal systems only.
68(4) Dual hermetically sealed 11A, 125/250 Vac 3 Dual switches are 2 SPDT snap-action switches, not independently
adjustable.
switch, general purpose 5A, 30 Vdc 4 Wires cannot be terminated inside T400 switch enclosure.
70 Dual low level gold contacts 1A, 125 Vac 5 Not available with Type 700 enclosure.
6 Estimated dc rating, 2.5A, 28 Vdc (not UL listed).
71(4) Dual hermetically sealed 1A, 125 Vac 7 Estimated dc rating, 0.4A, 120 Vdc (not UL listed).
8 Not available on 350 to 525°F.
switch, gold contacts 9 Consult factory on remote mount for bulb lengths other than 3.̋
B-SERIES HYDRAULIC PRESSURE SWITCH MODEL NUMBER:
1 2 3 4 5
H 4 2 4 V X F S 3000 PSI
1 – ENCLOSURE 3 – ACTUATOR SEAL
Hydraulic pressure switch, Type 400, watertight Code Process
H4 enclosure meets NEMA 3, 4, 4X, 13 and IP66 and Temperature
requirements. Material Limits °F(4)
Viton O-Ring,
V – Viton 20 to 300
2 – SWITCH ELEMENT SELECTION Stainless Steel
Pressure
Order Switch Elements Connection
Code UL/CSA Listed SPDT
20(3) Narrow deadband ac 15A, 125/250 Vac
21 Ammonia service 5A, 125/250 Vac 4 – OPTIONS
22 Hermetically sealed switch, 5A, 125/250 Vac Use table from page 7
narrow deadband
23 Heavy duty ac 22A, 125/250 Vac 5 – STANDARD
24(1) General purpose 15A, 125/250/480 Vac PRESSURE RANGE
1⁄2A, 125 Vdc
1⁄4A, 250 Vdc; 6A, 30 Vdc Adjustable Proof
Range Setpoint Pressure
25 Heavy duty dc 10A, 125 Vac or dc, psi Limits psi psi
1⁄8 HP, 125 Vac or dc
1000 150-1000 12,000
26(3) Sealed environment proof 15A, 125/250 Vac
27 High temperature 300°F 15A, 125/250 Vac 2000 300-2000 12,000
28 Manual reset trip on 15A, 125/250 Vac 3000 450-3000 12,000
increasing 5000 750-5000 10,000
29 Manual reset trip on 15A, 125/250 Vac 7500 1125-7500 100,000
decreasing
32 Hermetically sealed switch, 11A, 125/250 Vac
general purpose 5A, 30 Vdc
42 Hermetically sealed switch, 1A, 125 Vac
gold contacts
61(3) Dual narrow deadband 15A, 125/250 Vac
NOTES:
62(3) Dual sealed environment 15A, 125/250 Vac
proof 1 Standard switch.
2 Dual switches are 2 SPDT snap-action switches, not
63 Dual high temp. 300°F 15A, 125/250 Vac independently adjustable.
3 Estimated dc rating, 0.4A, 120 Vdc (not UL listed).
64 Dual general purpose 15A, 125/250/480 Vac 4 Ambient operating temperature limits –20 to 150°F, all
1⁄2A, 125 Vdc
styles, setpoint shift of ±1% of range per 50°F temperature
1⁄4A, 250 Vdc change is normal. Switches are calibrated at 70° F reference.
65 Dual ammonia service 5A, 125/250 Vac

70 Dual low level, gold contacts 1A, 125 Vac
B-Series Switches – Pressure, Differential
Pressure, Temperature & Hydraulic
OPTIONAL FEATURES AND ACCESSORIES
NOTES:
B-SERIES SWITCH OPTIONS 1 Buna N and Viton diaphragm.
Appicable Switch Series 2 Advise static or working pressure for differential pressure switches.
3 Buna N cannot be cleaned for oxygen service.
Differential Temp- 4 N/A on 700 Series.
Pressure Pressure erature H 5 Standard with 1000 and 3000 psi ranges. Bottom connection only
on DP in H2O ranges.
All 6 Terminal Blocks standard with 700 dual switches.
7 Stainless steel diaphragm only.
Code Description (psi) (in. H2O) (psi) (in. H2O) Ranges Notes 8 Pressure connection 1⁄4 NPTF.
9 Standard on 700 Series. N/A with DPDT element on 400 Series.
XBP Wall Mounting Bracket in. H2O • • 10 N/A with Monel diaphragm.
1 11 Standard on 400 Series.
XBX ⁄2˝ Male NPT Bushing • 12 N/A on 3000 psi range. Available with Teflon diaphragm only.
XCH Chained Cover • • • • • • 13 SS diaphragm required. Teflon diaphragm is the backup.
NEMA 7 only.
XC8 CSA Approval • • • • • 11 14 Available in ranges vacuum to 600 psi. Not available with stainless
steel or Monel diaphragm.
XCN ATEX Directive 94/9/EC EEx d IIC T6 • • • • • 15 Buna N and Viton diaphragm – 15#D & 30#D only.
16 24, 32, 64 or 68 element only.
XFM FM Approval – Single Element • • • • 17 17 N/A on all combinations.
18 700 Series only.
FM Approval – Dual Element • • • • 17
XFP Fungus Proofing • • • • • •
XFS Factory Adjusted Setpoint • • • • • • 2
XG3 Belleville Actuator • 16,17
XG5 UL Limit Control to 150˝ H2O • 1, 17
XG6 UL Limit Control to 600 psi • 1, 17
XG7 Secondary Chamber with Vent • 13
XG8 Steam Limit Control to 300 psi • 7
XG9 Fire Safe Welded Actuator • 7
XHS High Static Differential Pressure • 15
High Pressure, 40 psi, (static) d/p only
XHX 160 psi (proof) d/p only • •
100 psi (proof) pressure only (˝ H2O)
XJK Left Conduit Connection • • • • • • 9
XJL 3⁄4˝ to 1⁄2˝ Reducing Bushing • • • • • •
XJM Metric Electrical Conduit Connection
M20 x 1.5 • • • • • •
XK3 Terminal Block (700 Series only) • • • • • 6
XLE 6 foot Leads on the Micro Switch • • • • • •
XNH Tagging Stainless Steel • • • • • •
XNN Paper Tag • • • • • •
XPK Pilot Light(s) Top Mounted • • • • • • 4
XPM 3⁄4˝ Sealed Conduit Connection
with 16˝ Lead Wires • • • • • •
XTA 316 Stainless Steel Pressure • •
Connection for in. H2O Range
XTM 2˝ Pipe Mounting Bracket • • • • •
XUD 316 Stainless Steel Pressure Conn. •
Pressure Connection:
X06 1⁄2 NPT Male, 1⁄4 NPT Female • • • • 5
316 Stainless Steel (Combination)
X07 1⁄2 NPTF Press. Conn., 316 SS • • • • 10
X6B Cleaned for Oxygen Service • • • 3
Diaphragm Seal • • • •
Dimensions – 400 Series
Ø 0.28 X 3 HOLES 2.27

Pressure switch – psi ranges Pressure switch – inches of (7)
water ranges (58)
0.22 4.03
(6) (102)
1.25
Ø 0.28 X 3 HOLES (32)
(7)
4.03
(102) 2.27
0.22 (58)
(6) 0.25
(6)
1.25
(32) 3.32 2.77
(84) 3.26 (70)
(83)
5.95
0.25 (151)
(6) 2.84
1.25
2.77 (32) 3/4 NPT (72)
3.32 (70)
(84)
5.68 5.11
(144) (130) Ø 0.34
2 HOLES
2.50 0.36
(64) (9)
3/4 NPT 0.14 1.39 3.06
(4) (35) (78)
2.78 5.62
0.50 (71) (143)
Ø 2.31 (13)
(59) 3.50
3.26 (89)
(83) 1/4 NPT BRACKET WHEN
FEMALE REQURIED “XBP”
Ø 5.12 VARIATION
(130)
Differential pressure switch – Differential pressure switch –

psi differential ranges inches of water ranges
2.27 (58)
2.27
0.22 4.03 Ø 0.28 X 3 HOLES
(58) (6) (102)
(7) 1.25
4.03 1.25 (32)
0.22
(6) (102) (32)
0.25
0.25 (6)
Ø 0.28 X 3 HOLES
(6) 3.32
3.32 (7) 2.77 2.77
(84) 3.26
(84) (70) (70)
(83)
6.07 (154)
2.99 7.16 3/4 NPT 2.96 (75)

(76) (182) 1.57 (40)
3/4 NPT
Ø 0.34
H L 2 HOLES
1.55 1/4 NPT
(39) FEMALE
0.50 (13) 0.36 (9)
1.39 3.06
3.26 (35) (78)
(83) 2.78 (71) 5.62
1/4 NPT 1/4 NPT
FEMALE HIGH FEMALE LOW Ø 2.31 (143)
PRESSURE PORT PRESSURE PORT (59) 3.50 (89)
BRACKET WHEN
REQURIED “XBP” VARIATION
Ø 5.12 (130)
Temperature switch – direct mount Temperature switch – remote mount

2.27 2.27
Ø 0.28 (7) X 3 HOLES (58) (58)
0.22 4.03 (102) 1.25 Ø 0.28 (7) X 3 HOLES
(6) (32) 1.25
0.22 (6) 4.03 (102) (32)
0.25
(6) 0.25
(6)
3.32
(84) 2.77 3.32
(84) 2.77
(70) (70)
4.61
(117) 4.61
(117)
2.00 2.00
(51) (51)
3/4 NPT
3/4 NPT
7/8 HEX
Ø2.31 (59) 1/2 NPT MALE 2.50
2.31 (64)
“L”
“S” (59)
1.31 Ø2.31 (59)
3.26 (83) (33) ACTIVE BULB
LENGTH
2.31 3.26 (83) Ø 0.37 3.00

(59) Ø 0.37 (9) (76)
ACTIVE BULB (9)
LENGTH
Dimensions – 700 Series
Pressure switch – psi ranges Pressure switch – inches of water ranges

Ø 0.28 x 3 HOLES 3.58
(7) 3.58 Ø 0.28 x 3 HOLES 5.20 (91)
5.20 (132)
(132) (91) (7)
1.22 2.18 1.22 (31)

2.18 (55) 0.03
(31) (1)
(55) 0.03
(1) 0.32
(8)
0.32
(8)
3.62 1.37
(92) (35)
3.62 Ø 3.90
(99)
(92) Ø 3.90 6.43
(99) 163
5.73
(146) 1.93 0.31 (8)
0.31 1.11 4.37 (49)
(8) (28) (111)
3/4 NPT
1.37 2 HOLES
(35)
3/4 NPT 2 HOLES Ø 0.34 X 2 HOLES
(9)
1.93 1.39 0.36
(49) 2.31 (35) (9)
1/4 NPT FEMALE (59) 0.36
(9) 3.06
0.50 2.78 (78)
(13) 5.62
4.37 (71) (143)
(111) 3.50
(89) 1/4 NPT FEMALE BRACKET WHEN
REQUIRED "XBP"
Ø 5.12 VARIATION
(130)
Differential pressure switch – Differential pressure switch –

psi differential ranges inches of water ranges
5.20 5.20 (132) 3.58 (91)

(132) 3.58
Ø 0.28 x 3 HOLES (91)
(7) Ø 0.28 x 3 HOLES (7) 2.18
0.03 (55) 1.22 (31) 0.03
2.18 (1) (1)
(55)
0.32
0.32 (8)
(8)
0.31 3.62 1.37
(8) (92) (35)
3.62 Ø 3.90
(92) (99)
Ø 3.90 6.43
(99) (163) 0.31 (8)
4.37
3.09 (111)
1.93 3/4 NPT 2 HOLES
1.37 (78) 7.78
(35) (49)
(198)
H L
3/4 NPT Ø 0.34 X 2 HOLES (9)
2 HOLES 3.06
1/4 NPT FEMALE 0.36 1.39 (78)
HIGH PRESSURE PORT 1.55 (9) (35) 1.11
1/4 NPT FEMALE (39) 0.36 (9) (28)
1.43
LOW PRESSURE PORT (36) 0.50 2.78 (71) 5.62
Ø 2.31 (13) (143)
(59) 3.50 (89)
1.93 1/4 NPT FEMALE Ø 5.12 (130) 1/4 NPT FEMALE BRACKET WHEN
(49) LOW PRESSURE PORT HIGH PRESSURE PORT REQUIRED "XBP" VARIATION
4.37
(111)
Temperature switch – direct mount Temperature switch – remote mount
Ø 0.28 x 3 HOLES 5.20 3.58 3.58

(7) (132) (91) (91)
2.18
(55) 1.22 5.20
(31) 0.03
(1) (132) 1.22 (31)
0.32
(8) 0.03
(1)
Ø 0.28 x 3 HOLES 2.18
(7) (55)
3.60 (91)
0.32
5.23 Ø 3.90 (8)
(133) (99)
0.31
(8)
3.61 Ø 3.90
1.37 (92) (99)
(35)
5.23
3/4 NPT 2 HOLES (133) 0.31 (8)
1.93 7/8 HEX

(49) 1/2 NPT MALE 1.37
1.31 (35)
2.31 (33) “S”
(59)
3/4 NPT 2 HOLES
1.93 2.50
(64) “L”
2.31 (49)
4.37 (59) 0.37 3.00
(111) (9) 2.31 (76)
ACTIVE BULB 2.31
LENGTH (59) (59)
ACTIVE BULB
LENGTH Ø 0.37
4.37 (9)
(111)
215
Product Selection Information
PRESSURE, TEMPERATURE AND Optional stainless steel pressure connections are 2. Enclosure
DIFFERENTIAL PRESSURE SWITCH available (option XTA). The enclosure protects the switch element and
SELECTION mechanism from the environment and has provi-
For High Differential Pressure Actuator Ranges,
sions for mounting and wiring. All Ashcroft
3-15 to 60-600 psid, a Dual Diaphragm-Sealed
Before making your selection, consider the switch enclosures are epoxy-coated aluminum or
Piston Actuator is used. This actuator is designed
following: stainless steel for maximum corrosion resistance.
to for high static-pressure applications. The stan-
Choose between watertight NEMA 4, 4X for most
1. Actuator dard pressure connections are nickel-plated
industrial applications and explosion-proof NEMA
The actuator responds to changes in pressure, brass. Diaphragms are available in Viton, Buna N
7/9 for most process applications.
temperature or differential pressure and operates and Teflon. Always review process temperature
the switch element in response to these changes. limits before making seal selections. Optional Ashcroft enclosures include watertight cover gas-
stainless steel pressure connections are available kets, external mounting holes and one or two 3/4
The actuator is normally exposed to process fluid (option XUD). NPT electrical conduit holes for ease of installa-
and must therefore be chemically compatible tion. Pressure switches may also be mounted
with it. The following may be used to help select For all temperature ranges the standard
directly to the process by means of the standard
actuator type: Ashcroft® temperature actuator operates on the 1
/4 NPTF or optional 1/2 NPT pressure connection.
vapor pressure principle: the vapor pressure in a
For nominal pressure ranges 0-15 psi through sealed thermal system is applied to a sensing Note: When installing Ashcroft switches, refer to
0-3000 psi, the standard actuator is a diaphragm- element, which in turn actuates a switch. This is instruction sheets included with each switch, the
sealed piston. In this actuator, process pressure known as a SAMA Class II system. Various filling National Electrical Code, and any other local
acting on the piston area causes it to overcome materials are used, including Propane, Butane, codes or requirements to assure safety.
the adjustment spring force and actuate a snap- Methyl Alcohol, N Propyl Alcohol and Xylene.
action switch. A diaphragm and O-ring seal the 3. The Switching Function
High overtemperature capability is possible with
process media from this mechanism. These are Next, consider the switching function. Most appli-
this type of system. The interface between liquid
available in various materials, i.e.: Buna N, Teflon cations for alarm and shutdown are satisfied by
and vapor is the point at which sensing occurs.
and Viton. The standard process connection is single setpoint, fixed deadband models. For high/
This is the “sensitive” portion of the bulb. Bulb
stainless steel. Optional monel pressure connec- low or alarm and shutdown, the dual setpoint
extensions and capillary are normally filled with
tion is available. models may be selected. For pump, compressor,
vapor, and have little effect on the setpoint,
level and other control applications, an adjustable
For ˝ H2O Pressure and Differential Pressure regardless of ambient temperature variations;
deadband model is often the best choice.
Ranges, a diaphragm actuator is used. In this therefore, no ambient compensation is required.
design, the standard pressure connections are For best results, the bulb should be mounted 4. The Switch Element
carbon steel. Diaphragms are available in Viton, within 60 degrees of vertical to assure the liquid Finally, the electrical switching element must be
Buna N and Teflon. Always review process tem- remains in the bulb. compatible with the electrical load being
perature limits before making seal selections. switched. For ease of selection, all electrical
Consult factory for guidance in product selection

Phone (203) 385-0217, Fax (203) 385-0602 or
visit our web site at www.ashcroft.com
216
Product Selection Information
switching elements are snap acting, SPDT (single Explosion Proof – A term commonly used in Overpressure Rating(s) – A nonspecific term
pole-double throw), or 2 (SPDT). Select a switch industry referring to enclosures capable of with- that could refer to either burst or proof pressure,
element with electrical rating that exceeds the standing an internal explosion of a specified gas or both.
electrical rating of the device being controlled by without igniting surrounding gases. Strict instal-
Proof Pressure – The maximum pressure which
the switch. For better reliability and safety, lation practices in accordance with the national
may be applied without causing damage. This is
optional Hermetically Sealed switching elements electrical code are also required for safety.
determined under strict laboratory conditions
may be specified. Fixed Deadband – The difference between the including controlled rate of change and tem-
ADDITIONAL SWITCH TERMINOLOGY setpoint and the reset point of a pressure or temperature: This value is for reference only. Consult
perature switch. It further signifies that this dead- factory for applications where switch must oper-
Accuracy – (See repeatability) Accuracy normally band is a fixed function of the pressure switch ate at pressures above nominal range or refer-
refers to conformity of an indicated value to an and not adjustable. ence temperature (70°F).
accepted standard value. There is no indication in
switch products; thus, instead, the term repeat- Hermetically Sealed Switch – A switch element Repeatability (Accuracy) – The closeness of
ability is used as the key performance measure. whose contacts are completely sealed from the agreement among a number of consecutive mea-
Ashcroft switch accuracy is 1% of nominal environment to provide additional safety and reli- surements of the output setpoint for the same
range. ability. Contact arc cannot cause an explosion value of the input under the same operating con-
and atmospheric corrosive elements cannot ditions, approaching from the same direction, for
Automatic Reset Switch – Switch which returns affect the contacts. full-range traverses. Ashcroft switch repeatabil-
to normal state when actuating variable (Pres-
Manual Reset Switch – Pressure or Tempera- ity is 1% of nominal range.
sure or Temperature) is reduced.
ture switch in which contacts remain actuated Note: It is usually measured as nonrepeatabil-ity
Adjustable or Operating Range – That part of even after the actuating variable returns to and expressed as repeatability in percent of span
the nominal range over which the switch setpoint normal. On Ashcroft manual reset switches, a or nominal range. It does not include hysteresis
may be adjusted. Normally about 15% to 100% button must be pushed to reset the contacts. or deadband.
of the nominal range for pressure and differential
National Electrical Manufacturers Association
pressure switches and the full span for tempera- Reset Point – The reset point is the Pressure,
(NEMA) – This group has defined several catego-
ture switches. Temperature or Differential Pressure Value where
ries of enclosures, usually referred to as “types.”
the electrical switch contacts will return to their
Burst Pressure – The maximum pressure that Further, they designate certain features and capa-
original or normal position after the switch has
may be applied to a pressure switch without bilities each type must include. For example,
activated.
causing leakage or rupture. This is normally at among other features, a NEMA 4 enclosure must
least 400% of nominal range for Ashcroft include a threaded conduit connector, external Setpoint – The setpoint is the Pressure, Tem-
switches. Switches subjected to pressures above mounting provision and cover gaskets. When perature or Differential Pressure value at which
the nominal range can be permanently damaged. selecting a NEMA 4 enclosure from any manu- the electrical circuit of a switch will change state
facturer, a buyer is assured of receiving these or actuate. It should be specified either on
Deadband – The difference between the setpoint features. increase or decrease of that variable. (See also
and the reset point, normally expressed in units
NEMA 4 – Watertight and dusttight enclosures reset point.)
of the actuating variable. Sometimes referred to
as differential. intended for use indoors or outdoors to pro- Single-Pole Double Throw (SPDT) Switching
tect the equipment against splashing, falling Element – A SPDT switching element has one
Division 1 – A National Electrical Code Classifica- or hose-directed water, external condensation normally open, one normally closed, and one
tion of hazardous locations. In Division 1 loca- and water seepage. They are also sleet-resistant. common terminal. The switch can be wired with
tions, hazardous concentrations of flammable
NEMA 4X – Watertight, dusttight and corrosion- the circuit either normally open (N/O) or normally
gases or vapors exist continuously, intermittently
resistant enclosures with same qualifications as closed (N/C). SPDT is standard with most
or periodically under normal conditions; fre-
NEMA 4, but with added corrosion resistance. Ashcroft pressure and temperature switches.
quently because of repair or maintenance
operation/leakage or due to breakdown or faulty NEMA 7 – Enclosures for indoor Class I, Division Snap Action – In switch terminology, snap action
operation of equipment or processes which 1 hazardous locations with gas or vapor generally refers to the action of contacts in the
might also cause simultaneous failure of electri- atmospheres. switch element. These contacts open and close
cal equipment. Explosion-proof NEMA 7/9 enclo- quickly and snap closed with sufficient pressure
NEMA 9 – Enclosures for indoor Class II, Division
sures are required in Division 1 locations. to firmly establish an electrical circuit. The term
1 hazardous locations with combustible dust
distinguishes products from mercury bottle
Division 2 – A National Electrical Code Classifica- atmospheres.
types that were subject to vibration problems.
tion of Hazardous locations. In Division 2 hazard- Normal Switch Position – Contact position
ous locations, flammable or volatile liquid or before actuating pressure (or variable) is applied. Static Pressure – For differential pressure
flammable gases are handled, processed or Normally closed contacts open when the switch switches, static pressure refers to the lower of
used, but will normally be confined within closed is actuated. Normally open contacts close when the two pressures applied to the actuator.
containers or closed systems from which they the switch is actuated.
can escape only in case of accidental rupture or
breakdown or in case of abnormal operation of Normally Closed – Refers to switch contacts
equipment. Either Nema 7/9 explosion-proof that are closed in the normal switch state or posi-
enclosures or any enclosure with hermetically tion (unactuated). A pressure change opens the
sealed switch contacts may be used in Division contacts.
2 locations. Normally Open Switch – Refers to the contacts
that are open in the normal switch state or posi-
tion (unactuated). A pressure change closes the
contacts.
Consult factory for guidance in product selection

Phone (203) 385-0217, Fax (203) 385-0602 or
visit our web site at www.ashcroft.com
Installation and Maintenance Instructions for
B400 & B700 ASHCROFT® Snap Action
Switches for Pressure Control
Ø 0.28 X 3 HOLES
B400 (7)
4.03
Ø 0.28 X 3 HOLES 2.27 (102) 2.27
(7) (58) 0.22 (58)
0.22 4.03 (6)
(6) (102) 1.25
1.25
(32) (32)
0.25 0.25
(6) (6)
3.32 2.77 3.32 2.77
(84) 3.26 (70) (84) (70)
(83) 5.68 5.11
(144) (130)
5.95
(151)
2.84 2.50
1.25 (64)
(32) 3/4 NPT (72)
3/4 NPT
Ø 0.34
2 HOLES
0.36 Ø 2.31
(9) (59)
3.26
0.14 1.39 3.06 (83)
(4) (35) (78)
2.78 5.62
0.50 (71) (143)
(13) STANDARD RANGES 1.8 lb
3.50
(89) BRACKET WHEN 15, 30, 60, 100, 200, 400, 600 psi
1/4 NPT (.81 kg)
Ø 5.12 FEMALE REQURIED “XBP” 1000, 3000 psi
VARIATION
(130) 30˝Hg vac.-0
STANDARD RANGES 2.7 lb

10, 30, 60, 100, 150 ˝H2O
15˝H2O vac.-15˝H2O (1.2 kg)
B700
Ø 0.28 x 3 HOLES
(7) 5.20 3.58
3.58 (132) (91)
Ø 0.28 x 3 HOLES 5.20 (91)
(7) (132)
1.22
2.18 (31)
2.18 1.22 (31) (55) 0.03
(55) 0.03 (1)
(1)
0.32 0.32
(8) (8)
3.62 1.37
(92) (35) 3.62
(92) Ø 3.90
Ø 3.90
(99) (99)
5.73
6.43 (146)
163 0.31
1.93 0.31 (8) (8)
1.11 4.37 (49)
(111) 1.37
(28) (35)
3/4 NPT
2 HOLES 3/4 NPT 2 HOLES
Ø 0.34 X 2 HOLES
(9) 1.93
(49) 2.31
1.39 0.36 1/4 NPT FEMALE (59)
(35) (9)
0.36 4.37
(9) 3.06
0.50 2.78 (78) (111)
(13) 5.62
(71) (143)
3.50
(89) 1/4 NPT FEMALE BRACKET WHEN
REQUIRED "XBP" 2.7 lb
Ø 5.12 VARIATION
(130)
(1.2 kg)
3.6 lb
(1.6 kg)
INTRODUCTION available with various electrical characteristics. Two SPDT switch

The Ashcroft pressure switch is a precision built agency elements mounted together are available except on variable
approved control device which features a mechanical snap Deadband and manual reset types. Various wetted material con-
action switch. Controllers are available for operation on pressure structions for compatibility with a range of pressure media may
or vacuum with fixed or variable differential. Also manual reset be obtained.
types for operation on increasing or decreasing pressure. The The Ashcroft snap action pressure switch is furnished in the
manual reset types remain tripped until reset by pressing a but- standard NEMA 4 and explosion-proof NEMA 7 & 9 enclosure
ton on top of the enclosure. Standard electrical switch is SPDT, styles. Both enclosures are epoxy coated aluminum castings.
© 2007 Ashcroft Inc., 250 East Main Street, Stratford, CT 06614-5145, USA, Tel: 203-378-8281, Fax: 203-385-0499, www.ashcroft.com
All sales subject to standard terms and conditions of sale. I&M009-10008-10/00 (250-2246E) AMR 12/07
Installation and Maintenance Instructions for
B400 & B700 ASHCROFT® Snap Action
Switches for Pressure Control
INSTALLATION When hermetically sealed switch elements(s) are supplied, the

These controls are precision instruments and should never be lead color coding is as follows:
left with internal components exposed. During installation insure Common – White
that covers are in place and conduit openings are closed except Normally Closed – Red
when actually working on the control. Normally Open – Blue
MOUNTING B400 AND B700 SERIES B700 SERIES

Three holes external to the enclosure for surface mounting. SPDT – Wire directly to the switch according to circuit requirements.
Location of these holes is shown on the general dimension 2 SPDT – Wire to front switch terminal block (left) and rear
drawing. They may also be mounted directly on pressure line switch terminal block (right) as marked. Strip insulation 5⁄16˝,
using the pressure connection. When tightening control to pres- insert in proper terminal connector and tighten clamping screw
sure line, always use the wrench flats or hex on the lower housing. to secure.
ELECTRICAL CONNECTIONS ADJUSTMENT OF SETPOINT

Remove cover B400 & B700 Series – A single setpoint adjustment nut (7⁄8˝) is
B400 Series – two screws hold cover to enclosure located centrally at the bottom on the inside of the enclosure.
B700 Series – cover unscrews For accurate setpoint calibration, mount the switch on a cali-
bration stand, a pump or catalog No.1305 deadweight gauge
TERMINAL BLOCK tester. A suitable reference standard such as an Ashcroft
SWITCH A Duragauge or Test Gauge is necessary to observe convenient
3
2 TERMINAL BLOCK
changes in pressure.
As received, the pressure switch will normally be set to
1
SWITCH B
approximately 90% of the indicated range. Pressurize the
1
2 system to required setpoint and turn the adjustment nut until

C
3
switch changes mode. Direction of turning is indicated on a label

NO
affixed to the inside of the control enclosure. When setpoint has
NC
NC been achieved raise and lower pressure to insure that setpoint
NO
is correct.
C After installation of the control replace cover to insure electri-
cal safety and to protect internal parts from the environment.
CONDUIT CONNECTIONS
Note – It is recommended that Teflon tape or other sealant be B450 and B750 VARIABLE DEADBAND SWITCHES
used on conduit, bushing or plug threads to ensure integrity of Deadband is varied by rotating the wheel on the precision
the enclosure. switch. When viewed from the front of the enclosure, rotation to
the left increases deadband – rotation to the right decreases
B400 Series standard – one 3⁄4˝ NPT conduit hole right side. deadband. Letters on the wheel may be used as a reference.
B700 Series standard – two 3⁄4˝ N PT conduit holes with one Deadbands obtainable will vary from 0.5% to 9% of pressure
permanent plug. NEMA 7 & 9 enclosures require proper conduit range depending on range segment and type of diaphragm.
seals and breathers as per the National Electrical Code.
ADJUSTMENT OF SETPOINT
B400 & B700 Series – XJL variation – two 3⁄4˝ NPT conduit As received, the pressure switch will normally be set to approxi-
holes with two 3⁄4˝ to 1⁄2˝ NPT reducing bushings. mately 90% of range. Rotate the wheel on the MICRO SWITCH
B400 Series – XJK variation – two 3⁄4˝ NPT conduit holes. all the way to the right; this will provide smallest deadband.
Pressurize the system to the required setpoint and turn the
B400 SERIES adjustment nut until the switch changes mode. Lower the
SPDT – Wire directly to the switch according to circuit require- pressure to reset the switch. Rotate the wheel on the MICRO
ments. On controls with pilot lights wire lights according to circuit SWITCH until the desired deadband is obtained. The upper
diagram on inside of cover. See special wiring instruction tag for setpoint will be changing upward with this adjustment. Lower the
single switches with two pilot lights and dual switches with one pressure to reset the switch. Then increase the pressure to the
or more lights. desired setpoint and turn the adjusting nut until the switch
changes mode. Lower the pressure and check resetpoint and
2 SPDT – Dual switching elements consist of two SPDT switches deadband.
mounted together in a bracket. Switches are calibrated to have
simultaneous operation within 1% of range either on increasing Note – As indicated above, adjustment of setpoint is made by
or decreasing pressure but not in both directions. Wire directly to use of 7⁄8˝ nut. Precision switch element mounting screws
the front and rear switch according to circuit requirements. and bracket adjusting screw are factory sealed and
Leads are provided on rear switch color coded as follows: should not be tampered with.
Common – White Note – Since vacuum models are already above setpoint at
Normally Closed – Red atmosphere, the Normally Open (NO) circuit will be
Normally Open – Blue closed as received.
See SPDT instructions for pilot light hook-up.
© 2007 Ashcroft Inc., 250 East Main Street, Stratford, CT 06614-5145, USA, Tel: 203-378-8281, Fax: 203-385-0499, www.ashcroft.com
All sales subject to standard terms and conditions of sale. I&M009-10008-10/00 (250-2246E) AMR 1/07
B400-Series
Wiring Diagram
Switch Element
RED BLUE WHITE SINGLE

SWITCH
BLUE
RED WHITE NC
NO
C
FRONT
BLUE WHITE
SWITCH
REAR
RED SWITCH
NC
NO
C NC
NO
C
SWITCH ELEMENT
WIRING DIAGRAM
B4, D4, T4, B7, D7, T7
B400-Series Wiring Diagram Dim. Dwg. © Ashcroft Inc 2006., 250 East Main St., Stratford, CT 06614-5145 USA, Tel: 203-378-8281, Fax: 203-385-0499, www.ashcroft.com
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.20 Temperature Indicator
Mechanical
Temperature Measurement
Bimetal Thermometers
Process Industry Series, Model 55
WIKA Data Sheet TM 55.01
Applications
 Chemical industry, petrochemical industry, process

technology and food industry
 For aggressive medium
Special Features
 Universal application
 Case and stem material stainless steel
Description
This series of thermometers is designed for installation in

Fig. left: Bimetal Thermometer Model R5502
pipes, tanks, plants and machinery.
Fig. right: Bimetal Thermometer, Adjustable Stem and
Dial Model S5550
The stem and the case of the instrument are made of
stainless steel. Various insertion lengths and process
connections are available to match the requirements of any
process optimally. Due to their high ingress protection
(IP 65) and liquid damping these thermometers can be used
in applications with extreme vibrations.
WIKA Data Sheet TM 55.01 ∙ 03/2009 Page 1 of 6
Data Sheets showing similar devices:

Electrical Alarm Contacts; Model 8xx; see Data Sheet AC 08.01
Standard version Dial
Aluminium white, lettering black
Temperature element
Bimetal helix Window
Instrument glass
Nominal size in mm
63, 100, 160 Pointer
Aluminium, black, micro adjustable pointer
Design of connection
S Standard (male thread connection) Zero adjustment
1 Plain stem (without thread) on case back side, external only adjustable stem/dial (option)
2 Male nut
3 Union nut Pressure rating of stem
4 Compression fitting (sliding on stem) max. 25 bar, static
5 Union nut with fitting
Ambient temperature limit at the case
Location of stem +60 °C max. (others on request)
A55XX centre back (axial)
R55XX bottom (radial) Ingress protection
S55XX centre back, adjustable stem and dial IP 65 per EN 60 529
Accuracy class
DIN EN 13 190
Options
Working range
 Scale range °F, °C / °F (dual scale)
Normal (1 year): Measuring range (DIN EN 13 190)
 Liquid damping to 250 °C max. (at stem)
Short time (24 h max.): Scale range (DIN EN 13 190)
 Window of laminated safety glass or acrylic plastic
Case and cam ring (bayonet type)  Stem diameter 6, 8, 10 mm
Stainless steel  Ingress protection IP 66
 Thermometers with switch contacts (data sheet TV 25.01)
Stem and process connection  Special temperature range or dial printing to customer
Stainless steel 1.4571 specifications (on request)
Scale range, measuring range 1), error limit (DIN EN 13 190)

Scale graduation per WIKA standard
Scale range Scale spacing Measuring range 1) Error limit
in °C in °C in °C in °C
-70 ... +30 1 -60 ... +20 1
-50 ... +50 1 -40 ... +40 1
-30 ... +50 1 -20 ... +40 1
-20 ... +60 1 -10 ... +50 1
0 ... 60 1 10 ... 50 1
0 ... 80 1 10 ... 70 1
0 ... 100 1 10 ... 90 1
0 ... 120 2 10 ... 110 2
0 ... 160 2 20 ... 150 2
0 ... 200 2 20 ... 180 2
0 ... 250 5 30 ... 220 2.5
0 ... 300 5 30 ... 270 5
0 ... 400 5 50 ... 350 5
0 ... 500 5 40 ... 450 5
0 ... 600 10 100 ... 500 10
1) The measuring range is limited by two triangular marks on the dial. Within this range the specified error limit applies per DIN EN 13 190.
Models
Version Nominal size Design
63 100 160 S 1 2 3 4 5
Model 55 axial, lower back A5525 A5500 A5501 x x x x x x
radial, bottom R5526 R5502 R5503 x x x x x x
Model 55 adjustable stem/dial - S5550 S5551 - x x x x x
Page of 6 WIKA Data Sheet TM 55.01 ∙ 03/2009

Design of connection
3073050U
Design standard
Connection, male: G ½ B, G ¾ B, ½ NPT, ¾ NPT
Stem lengths: l1 = 63, 100, 160, 200, 250 mm
Nominal size Process connection Dimensions in mm
NS G i SW d4 Ød
63, 100, 160 G½B 14 27 26 8 Legend:
G¾B 16 32 32 8 G Male thread
½ NPT 19 22 - 8 i Thread length
¾ NPT 20 30 - 8 Ø d4 Diameter of the sealing collar
SW Flats
Ø d Stem diameter
Design 1, plain stem (without thread)

Stem lengths: I = 140, 200, 240, 290 mm
3073050V
Nominal size Dimensions in mm
NS d1 Ød
63 14 8
100, 160 18 8
Legend:
Ø d1 Plain diameter
Ø d Stem diameter
Design 2, male nut

Stem lengths: l1 = 80, 140, 180, 230 mm
3073050W
NS G i SW Ød
63, 100, 160 G½B 20 27 8
Legend:
G Male thread
i Thread length incl. plain
SW Flats
Ø d Stem diameter
Design 3, union nut

Stem lengths: l1 = 89, 126, 186, 226, 276 mm
3073050X

NS G1 i SW Ød
63, 100, 160 G½ 8.5 27 8
G¾ 10.5 32 8
M24 x 1.5 13.5 32 8
Legend:
G1 Female thread
i Thread length
SW Flats
Ø d Stem diameter

Design 4, compression fitting (sliding on stem)
Minimum insertion depth lmin approx. 60 mm
3073050Y
Standard stem lengths: l1 = 63, 100, 160, 200, 250 mm
Lenghts L = l1 + 40 mm
NS G i SW d4 Ød
63, 100, 160 G½B 14 27 26 8
G¾B 16 32 32 8
Sealing ring
M18 x 1.5 12 24 23 8
½ NPT 19 22 - 8
¾ NPT 20 30 - 8
Legend:
G Male thread
i Thread length
Ø d4 Diameter of the sealing collar
SW Flats
Ø d Stem diameter
Design 5, union nut with fitting

G ½ B, G ¾ B, M18 x 1.5 as well as ½ NPT, ¾ NPT
3073050Z
Minimum insertion depth lmin approx. 60 mm
Stem lengths l1 = variable
Lengths L = l1 + 40 mm
Stainless steel 1.4571
NS G i SW d4 Ød
63, 100, 160 G½B 14 27 26 8 Legend:
G¾B 16 32 32 8 G Male thread
M18 x 1.5 12 24 23 8 i Thread length
Ø d4 Diameter of the sealing collar
½ NPT 19 22 - 8
SW Flats
¾ NPT 20 30 - 8
Ø d Stem diameter

Dimensions in mm
Centre back Radial bottom
3073068
3073076
b b1 d 1) d4 Ø D1 Ø D2 F G SW Model A55xx Model R55xx
63 35 60 8 26 64 62 57 G½B 27 0.25 0.25
100 50 83 8 26 101 99 83 G½B 27 0.8 0.8
160 50 83 8 26 161 159 113 G½B 27 1.1 1.1
1) Option: Stem diameter 6, 10, 12 mm

Adjustable stem and dial
3073084
b b1 d 1) Ø D1 Ø D2 F Model S55xx
100 25 68 8 101 99 68 0.5

160 25 68 8 161 159 68 0.7
1) Option: Stem diameter 6, 10, 12 mm
Ordering information
Model / Nominal size / Scale range / Connection size / Connection location / Options
Modifications may take place and materials specified may be replaced by others without prior notice.
Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
9019227 03/2009 GB
WIKA Alexander Wiegand GmbH & Co. KG

63911 Klingenberg/Germany
Tel. (+49) 9372/132-0
Fax (+49) 9372/132-406
E-mail info@wika.de
www.wika.de
INSTRUCTIONS FOR THE INSTALLATION AND
USE OF WIKA BIMETAL DIAL THERMOMETERS
GENERAL ADJUSTMENT
When removing the thermometer from the packing box, If it is necessary to make an adjustment to the thermom-
handle it by the case assembly or the fitting. Do not eter, proceed as follows:
handle the thermometer by the stem. Do not bend the For thermometers with an external adjustment, use a small
stem this will cause misalignment of the internal parts, wrench, screwdriver or coin to turn the slotted hexagonal
resulting in permanent damage. RESET adjustment in the back of the case until the
pointer indicates the proper temperature on the dial. All
INSTALLATION OF THERMOMETERS adjustments must be made using a well agitated tempera-
The thermometer should be mounted at any convenient ture bath operating at a known temperature. Instruments
location where it will be subjected to the average tempera- used to monitor the temperature bath must have an
ture variations to be indicated. accuracy greater than the thermometer being adjusted.
Avoid bending the stem, as this will cause misalignment of MAINTENANCE OF DIAL THERMOETERS
the internal parts, resulting in permanent damage. Aside from occasional testing, little or no maintenance is
To tighten the thermometer to the apparatus use a wrench required.
applied to the hexagon head of the threaded connection
located just outside of the case. Be sure that the gasketed glass window is on the case at
all times, as moisture and dirt inside the case will eventu-
INSTALLATION ally cause the thermometer to loose its accuracy (see
Locate the free end stem so that at least the last two to caution note below).
three inches of the free end will be subjected to the
average temperature to be measured. If the thermometer is used for measuring the temperature
Do not expose the stem to a temperature in excess of the of a material that may harden and build up an insulating
maximum dial reading. layer on the stem, the thermometer should be removed
from the apparatus occasionally and the stem cleaned.
The thermometer is normally provided with a threaded Observe this precaution to insure the sensitivity of the
connection. To tighten the thermometer to the apparatus instrument.
or into a thermowell, use an open-end wrench applied to
the hexagonal head of the threaded connection. Turn until FILLED THERMOEMTER POLICY
reasonably tight, the tighten still further in the same WIKA does not recommend use of filled instruments for
manner as a pipe elbow or similar pipe fitting until the continual use at operating temperatures above 400° F
scale is in the desired position for reading. DO NOT (204° C) or below 100° F (-70° C). Under no circum-
TIGHTEN BY TURNING THE THERMOMETER CASE. stances will an instrument warrant apply or will WIKA
Install the thermometer so that the maximum case tem- assume any liability for use above these temperatures
perature is kept below 200° F at all times.
CAUTION: Bimetal Thermometers operating below freezing
When a thermometer is equipped with a thermowell, the must have a perfectly tight case to prevent entrance of
thermowell should be installed onto the apparatus first. moisture, which eventually will condense and freeze inside
The stem of the thermometer should then be coated with a the stem. This condition shows up as a failure of the
thermometer to read accurately below 32° F or 0° C. For this
heat-conducting medium (a mixture of glycerin and
reason it is important to avoid damage of the glass window,
graphite or any other heavy lubricant may be used), after while the stem temperature is at freezing or below.
which the thermometer stem is inserted and tightened into
the thermowell.
CAUTION: Thermowells should be used for all process

systems where pressure, velocity, or viscous, abrasive,
or corrosive material are present individually or in
combination to protect the thermometer stem from
corrosion or physical damage, and to facilitate removal
of the thermometer without disturbing the process.
TESTING
WIKA Bimetal Dial Thermometers are carefully calibrated
at the factory and under most operating conditions will
retain their accuracy indefinitely. However, as in the case
of all instruments, it is beneficial to make periodic checks
for accuracy against known standards.
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.21 Temperature Transmitter
<<Contents>> <<Index>>
General Model YTA110

Specifications Temperature Transmitter
GS 01C50B01-00E [Style: S3]
The YTA110 is the high performance temperature

transmitter that accepts Thermocouple, RTD, ohms or
DC milivolts inputs and converts it to a 4 to 20 mA DC
signal for transmission. The YTA110 supports either
BRAIN or HART communication protocol.
The YTA110 in it standard configuration is certified by
TÜ V as complying with SIL2 for safety requirement.
■ FEATURES
High performance
Microprocesser-based sensing technology ensures T/C:
long-term accuracy and high reliability. 0.1% of reading or 0.1°C per year,
whichever is greater at 232°C.
High reliability 5 Year Stability
Dual-compartment housing realizes high resistance RTD:
capability to harsh environments, and YTA110 has 0.2% of reading or 0.2°C,
SIL2 capability for safety requirement. whichever is greater at 232°C.
T/sC:
Variety of sensor inputs 0.4% of reading or 0.4°C,
The type of sensor input is user-selectable from whichever is greater at 232°C.
thermocouples (T/C), RTDs, ohms, or DC milivolts. RFI Effect
Tested per EN 50082-2, field intensity up to 10 V/m.
Digital communication
Power Supply Effect
BRAIN or HART® communication protocol is avail-
±0.005 % of calibration span per volt
able. The insturment configuration can be changed
by the user with using the BT200 or HART communi- Vibration Effect
cator. 10 to 60 Hz 0.21 mm peak displacement
60 to 2000 Hz 3G
Self-diagnostics function Position Effect
Continuous self-diagnostics capability ensures long- None
term performance and lower cost of ownership.
FUNCTIONAL SPECIFICATIONS
LCD display with bargraph
Input
The LCD display provides both a digital readout and
percent bargraph simultaneously. Input type is selectable: Thermocouples, 2-, 3-, and
4-wire RTDs, ohms and DC milivolts. See Table 1.
on page 3.
■ STANDARD SPECIFICATIONS Span & Range Limits
See Table 1. on page 3.
PERFORMANCE SPECIFICATIONS
Input signal source resistance (for T/C, mV)
Accuracy 1 k or lower
(A/D accuracy/span + D/A accuracy) or 0.1 % of
Input lead wire resistance (for RTD, ohm)
calibrated span, whichever is greater.
See Table 1. on page 3. 10 per wire or lower
Cold Junction Compensation Accuracy Output
(For T/C only) Two wire 4 to 20 mA DC. Output range: 3.68 mA to
± 0.5˚C (± 0.9 ˚F) 20.8 mA
BRAIN or HART ® protocol is superimposed on the
Ambient Temperature Effect (per 10 ˚C change) 4 to 20 mA signal.
± 0.1 % or ± (Temperature Coefficient /span), Any single value from the followings can be selected
whichever is greater. See Table 2. for Temperature as the analog output signal.
Coefficient. Sensor 1, Terminal Temperature.
Stability Also, up to three of the above values can be dis-
RTD: played on LCD display or read via communication.
0.1% of reading or 0.1°C per 2 years, Isolation
whichever is greater at 232°C. Input/Output/GND isolated to 500 V DC
Yokogawa Electric Corporation GS 01C50B01-00E

2-9-32 Nakacho, Musashino-shi, Tokyo, 180-8750 Japan ©Copyright June 1998
Phone: 81-422-52-5690 Fax.: 81-422-52-2018 15th Edition Feb. 2008
Sensor Burnout Communication Requirements
High (21.6 mA DC) or Low (3.6 mA DC), BRAIN:
userselectable.
Communication Distance
Output in Transmitter Failure Up to 2 km (1.25 miles) when using CEV polyethyl-
Up-scale: 110%, 21.6 mA DC or more (Standard or ene-insulated PVC-sheathed cables. Communication
Optional code /C3) distance varies depending on type of cable used.
Down-scale: –5%, 3.2 mA DC or less (Optional code
/C1 or /C2) Load Capacitance
0.22 F or less
Update Time
Approximately 0.5 seconds Load Inductance
3.3 mH or less
Turn-on Time
Approximately 5 seconds Input Impedance of communicating device
10 k or more at 2.4 kHz.
Damping Time Constant
Selectable from 0 to 99 seconds PHYSICAL SPECIFICATIONS
Ambient Temperature Limits
Enclosure
Option code may affect limits.
-40 to 85 ˚C (-40 to 185 ˚F) Material
-30 to 80 ˚C (-22 to 176 ˚F) with Integral Indicator Low copper cast-aluminum alloy
Ambient Humidity Limits Coating
5 to 100 % RH at 40 ˚C (104 ˚F) Polyurethan resin baked finish
Color: Deep-sea moss green (Munsell 0.6GY3.1/2.0)
EMC Conformity Standards , Degrees of Protection
EN61326, AS/NZS CISPR11 IP67, NEMA4X, JIS C0920 immersion proof
SIL Certification Data and tag plate
YTA110 temperature transmitter is certified by TÜ V SUS304 Stainless steel
NORD CERT GmbH in compliance with the following Mounting
standards; Optional mounting brackets can be used either for
IEC 61508: 2000; Part1 to Part 7 Functional Safety of two-inch pipe or flat panel mounting.
Electrical/electronic/programmable electronic related Terminal Screws
systems; M4 screws
SIL 2 capability for single transmitter use, SIL 3
capability for dual transmitter use. Integral Indicator
Optional LCD digital indicator includes 5-digit numeri-
Self-calibration cal dispaly with ˚C, K, ˚F,˚R, % and mV, 0 to 100 %
The analog-to-digital measurement circuitry automati- bargraph and dot-matrix display.
cally self-calibrates for temperature update by
comparing the dynamic measurement to extremely Weight
stable and accurate internal reference elements. 1.2 kg(2.6 lb) without Integral indicator and Mounting
bracket. Integral indicator weights 0.2 kg(0.4 lb).
Self-diagnostics
Loss of input error, ambient temperature error, Electrical Connections
EEPROM error, and CPU error. Up to four error Refer to ‘MODEL AND SUFFIX CODES’ on page 5.
history can be stored in the memory.
Manual Output Function
The output value can be set manually.
Supply & Load Requirements
Supply Voltage
10.5 to 42 V DC for general use and flameproof type
10.5 to 32 CV DC for lightning protector (Optional
code /A)
10.5 to 30 V DC for intrinsically safe, Type n,
nonincendive, or non-sparking type
communications, BRAIN and HART®
protocols
Load
0 to 1335 for operation
250 to 600 for digital communication
See Figure 1. on page 4.
All Rights Reserved. Copyright © 1998, Yokogawa Electric Corporation GS 01C50B01-00E Apr. 20, 2007-00
Table 1. Sensor type, measurement range, and accuracy.
Accuracy
Reference Measurement Range Minimum Span
Sensor Type Input range A/D Accuracy D/A
Standard (Recommended)
C F C F C F Accuracy
100 to 300 212 to 572 ± 3.0 ± 5.4
B 100 to 1820 212 to 3308 300 to 400 572 to 752 ± 1.0 ± 1.8
400 to 1820 752 to 3308 ± 0.75 ± 1.35
-200 to -50 -328 to -58 ± 0.35 ± 0.63
E -200 to 1000 -328 to 1832
-50 to 1000 -58 to 1832 ± 0.16 ± 0.29
-200 to -50 -328 to -58 ± 0.40 ± 0.72
J -200 to 1200 -328 to 2192
-50 to 1200 -58 to 2192 ± 0.20 ± 0.36
-200 to -50 -328 to -58 ± 0.50 ± 0.90
K -200 to 1372 -328 to 2502
-50 to 1372 -58 to 2502 ± 0.25 ± 0.45
IEC584 -200 to -50 -328 to -58 ± 0.80 ± 1.44
N -200 to 1300 -328 to 2372
-50 to 1300 -58 to 2372 ± 0.35 ± 0.63
-50 to 0 -58 to 32 ± 1.0 ± 1.8
0 to 100 32 to 212 ± 0.80 ± 1.44
R -50 to 1768 -58 to 3214
100 to 600 212 to 1112 ± 0.60 ± 1.08
600 to 1768 1112 to 3214 ± 0.40 ± 0.72
25 C
T/C -50 to 0 -58 to 32 ± 1.0 ± 1.8
(45 F)
0 to 100 32 to 212 ± 0.80 ± 1.44
S -50 to 1768 -58 to 3214
100 to 600 212 to 1112 ± 0.60 ± 1.08
600 to 1768 1112 to 3214 ± 0.40 ± 0.72
-200 to -50 -328 to -58 ± 0.25 ± 0.45 ± 0.02%
T -200 to 400 -328 to 752
-50 to 400 -58 to 752 ± 0.14 ± 0.25 of span
0 to 400 32 to 752 ± 0.80 ± 1.44
400 to 1400 752 to 2552 ± 0.50 ± 0.90
W3 0 to 2300 32 to 4172
1400 to 2000 2552 to 3632 ± 0.60 ± 1.08
ASTM 2000 to 2300 3632 to 4172 ± 0.90 ± 1.62
E988 0 to 400 32 to 752 ± 0.70 ± 1.26
400 to 1400 752 to 2552 ± 0.50 ± 0.90
W5 0 to 2300 32 to 4172
1400 to 2000 2552 to 3632 ± 0.70 ± 1.26
2000 to 2300 3632 to 4172 ± 0.90 ± 1.62
-200 to -50 -328 to -58 ± 0.30 ± 0.54
L -200 to 900 -328 to 1652
-50 to 900 -58 to 1652 ± 0.20 ± 0.36
DIN43710
-200 to -50 -328 to -58 ± 0.50 ± 0.90
U -200 to 600 -328 to 1112
-50 to 600 -58 to 1112 ± 0.25 ± 0.45
Pt100 -200 to 850 -328 to 1562 -200 to 850 -328 to 1562 ± 0.14 ± 0.25
Pt200 IEC751 -200 to 850 -328 to 1562 -200 to 850 -328 to 1562 ± 0.30 ± 0.54
Pt500 -200 to 850 -328 to 1562 10 C -200 to 850 -328 to 1562 ± 0.20 ± 0.36
RTD
JPt100 JIS C1604 -200 to 500 -328 to 932 (18 F) -200 to 500 -328 to 932 ± 0.16 ± 0.29
SAMA -70 to -40 -94 to -40 ± 1.35 ± 2.43
Cu -70 to 150 -94 to 302
RC21-4 -40 to 150 -40 to 302 ± 1.0 ± 1.8
Ni120 -70 to 320 -94 to 608 -70 to 320 -94 to 608 ± 0.11 ± 0.19
mV -10 to 100 [mV] 3 [mV] ± 12 [µ V]
ohm 0 to 2000 [Ω] 20 [Ω] ± 0.35 [Ω]
T01E.EPS
Total Accuracy = (A/D Accuracy / Span + D/A Accuracy) or (± 0.1% of calibrated span), whichever is greater.
For T/C input, add Cold Junction Compensation Accuracy (± 0.5 C) to the total accuracy.
Example; when selecting Pt100 with measurement range of 0 to 200 C.
0.14C 100% of span +0.02% of span = 0.09% of span
200C
Since the value is smaller than ± 0.1% of span, the total accuracy is ± 0.1%.
All Rights Reserved. Copyright © 1998, Yokogawa Electric Corporation GS 01C50B01-00E Aug. 11, 2006-00
Table 2. Temperature Coefficient
Sensor Type Temperature Coefficient
Thermocouples E,J,K,N,T,L,U 0.08C + 0.02% of abs.reading
Thermocouples R,S,W3,W5 0.25C + 0.02% of abs.reading
100C Reading < 300C 1C + 0.02% of abs.reading
T/C B
300C Reading 0.5C + 0.02% of abs.reading
RTD 0.08C + 0.02% of abs.reading
mV 0.002 mV + 0.02% of abs.reading
ohm 0.1 Ω + 0.02% of abs.reading
T02E.EPS
Note1: Ambient Temperature Effect per 10°C change is 0.1% or

(temperature coefficient/span), whichever is greater.
Note2: The “abs.reading” on Table2 means the absolute value of the reading in °C.
Example of abs reading;
When the temperature value is 250 Kelvin, abs reading is 23.15, absolute (250273.15).
Example of Ambient Temperature Effect;
Conditions;
1) Input Sensor: Pt100
2) Calibration Range: 100 to 100°C
3) Reading value: 50°C
Ambient Temperature Effect per 10°C;
Temperature Coefficient/Span=(0.08°C0.02/100|50°C|)/{100°C(100°C)}= 0.00045
→ 0.045%
Therefore, Ambient Temperature Effect is 0.1%/10°C
600
E-10.5
R=
0.0236 Digital
External Communication
load range
resistance BRAIN and HART
250
R () F02E.EPS
Figure 2. Integral Indicator Display Example.
10.5 16.4 24.7 42

Power supply voltage E (V DC) F01E.EPS
Figure 1. Relationship Between Power Supply Voltage

and External Load Resistance.
■ MODEL AND SUFFIX CODES
Model Suffix Codes Descriptions
YTA110 ••••••••••••••••••••••••• Temperature Transmitter

Output Signal -D •••••••••••••••••••••• 4 to 20mA DC with digital commnuication (BRAIN protocol)
-E •••••••••••••••••••••• 4 to 20mA DC with digital communication (HART protocol, refer to GS 01C50T01-00E)
A ••••••••••••••••• Always A
Electrical Connection 0 ••••••••••••• G1/2 female
2 ••••••••••••• 1/2 NPT female
3 ••••••••••••• Pg 13.5 female
4 ••••••••••••• M20 female
Integral Indicator D •••••••• with digital indicator
N •••••••• None
Mounting Bracket B •••• SUS304 Stainless steel 2-inch horizontal pipe mounting *1
D •••• SUS304 Stainless steel 2-inch vertical pipe mounting *1
N •••• None
Optional Codes / Optional Specifications
*1: For flat-panel mounting, please prepare bolts and nuts. T03E.EPS
■ OPTIONAL SPECIFICATIONS
Item Descriptions Code
Lightning protector Power supply voltage: 10.5 to 32 V DC

A
Allowable current: Max. 6000A(140s), repeating 1000A(140s) 100 times
Coating change Epoxy resin coating X1
Munsell code: N1.5 Black P1
Painting
Color change Amplifier cover only Munsell code: 7.5BG4/1.5, Jade green P2
Metallic silver P7
Amplifier and terminal Covers Munsell code: 7.5 R4/14 Red PR
Calibration Unit Degree F/Degree R unit D2
Output signal low-side in Output signal low-side: -5%, 3.2 mA DC or less. C1
Transmitter failure Sensor burnout is also set to 'LOW': -2.5%, 3.6 mA DC.

hardware error is -5%, 3.2 mA or less. C2
Sensor burnout is also set to LOW: -2.5%, 3.6 mA DC.
Output signal limits:
NAMUR NE43 Compliant
3.8 mA to 20.5 mA
hardware error is 110%, 21.6 mA or more. C3
In this case Sensor burnout is High: 110%, 21.6 mA DC.
Description into “Descriptor” parameter of HART protocol
Data Configuration CA
(max. 16 characters)
Housing Material: SCS14A stainless steel (equivalent to SUS316 cast stainless E1

Stainless steel housing *1
steel and ASTM CF-8M)
T04E.EPS
*1: Not applicable for optional code JF3, G11, G12, P1, P2, P7, PR, and X1.
■ OPTIONAL SPECIFICATIONS (For Explosion Protected Types)
CENELEC ATEX (KEMA) Intrinsically safe, Flameproof approval and Type n combination
[Intrinsically safe approval]
Applicable standard: EN 50014, EN 50020, EN 50284 Certificate: KEMA 02ATEX1026X
II 1G EEx ia IIC T4,T5 Ambient Temerature: -40 to 70°C for T4, -40 to 50°C for T5
Supply/Output circuit: Ui=30V, Ii=165mA, Pi=900mW, Ci=20nF, Li=660H
Input circuit: Uo=8.6V, Io=30mA, Po=70mW, Co=3F, Lo=20mH
Electrical Connection: 1/2 NPT female and M20 female*1
[Flameproof and Dust Ignition Proof Approval]
Applicable Standard: EN 60079-0, IEC 60079-1, EN 61241-0, EN 61241-1
CENELEC ATEX Certificate: KEMA 07ATEX0130
II 2G Ex d IIC T6/T5, II 2D Ex tD A21 IP67 T70°C, T90°C KU2
(KEMA)
Ambient Temperature for Gas Atmospheres: -40 to 75°C for T6, -40 to 80°C for T5
Ambient Temperature for Dust Atmospheres: -40 to 65°C for T70°C, -40 to 80°C for T90°C
Enclosure: IP67
[Type n approval]
Applicable standard: EN60079-15 Referential standard: IEC60079-0, IEC60079-11
II 3G EEx nL llC T4, T5 Ambient Temperature: -40 to 70C for T4, -40 to 50C for T5
Supply/Output circuit: Ui=30V, Ci=20nF, Li=660H
CSA Intrinsically safe, non-incendive and Explosionproof approval combination
[Intrinsically safe/non-incendive approval]
Applicable standard: C22.2 No0, C22.2 No0.4, C22.2 No25, C22.2 No94, C22.2 No142,
C22.2 No157, C22.2 No213 Certificate: 172608-0001053837
Intrinsically safe for Class I, Division 1, Groups A, B, C and D; Class II, Division 1, Groups
E, F and G; Class III, Division 1:
Non-incendive for Class I, Division 2, Groups A, B, C and D; Class II, Division 2, Groups E,
F and G; Class III, Division 1:
Enclosure Type 4X Temperature Class: T4, Ambient Temperature: -40 to 60C,
Canadian Standards Supply: Vmax=30V, Imax=165mA, Pmax=0.9W, Ci=18nF, Li=730H CU1
Association (CSA) Sensor input: Voc=9V, Isc=40mA, Po=0.09W, Ca=1F, La=10mH
Electrical Connection: 1/2 NPT female*1
[Explosionproof approval]
C22.2 No142, C22.2 No157, C22.2 No213, C22.2 No1010.1 Certificate: 1089576
Explosionproof Class I, Div.1, Groups B, C and D, Class II, Groups E, F and G, Class III.
For Class I, Div.2 Locations “FACTORY SEALED, CONDUIT SEAL NOT REQUIRED”
Enclosure Type 4X Temperature Class: T6 Ambient Temperature: -40 to 60C
FM Intrinsically safe, non-incendive and Explosionproof approval combination
Applicable standard: FM 3600, FM 3610, FM 3611, FM 3810
Intrinsically safe for Class I, II, III Division 1 Groups A, B, C, D, E, F and G.
Non-incendive for Class I, II, Division 2 Groups A, B, C, D, F and G Class III, Division 1.
Enclosure Type: 4X Temperature Class: T4 Ambient Temperature: -40 to 60C (-40 to 140F)
Supply: Vmax=30V, Imax=165mA, Pmax=0.9W, Ci=18nF, Li=730H
Sensor: Voc=9V, Isc=40mA, Po=90Mw, Ca=1F, La=10mH FU1
Applicable standard: FM 3600, FM 3615, FM 3810, NEMA250
Class I, Division 1, Groups A, B, C and D.;
Factory Mutual (FM) Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G.
"FACTORY SEALD, CONDUIT SEAL NOT REQUIRED." Enclosure Ratings: NEMA4X
Temperature Class: T6 Ambient Temperature: -40 to 60C (-40 to 140F)
Electrical Connection: 1/2NPT female*2
FM Explosionproof approval
Explosionproof Class I, Division 1, Groups A, B, C and D;
Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G. FF1
“FACTORY SEALED, CONDUIT SEAL NOT REQUIRED.” Enclosure Rating: NEMA 4X
T05E-1.EPS
*1 : Applicable for Electrical Connection Code 2 and 4.
*2 : Applicable for Electrical Connection Code 2.
All Rights Reserved. Copyright © 1998, Yokogawa Electric Corporation GS 01C50B01-00E Feb. 01, 2008-00

SAA Int rinsically safe, non-sparking and Flameproof approval combination
[Intrinsically safe and non-sparking]
Applicable standard: AS2380.1, AS2380.7, AS2380.9 Certificate: AUS Ex 3652X
Ex ia IIC T4 (Tamb=70C) IP66/67, Ex n IIC T4 (Tamb=70C), IP66/67
Standards
Input parameters: Ui=30V, Ii=165mA, Pi=0.9W
Association of SU1
Output parameters: Uo=8.6V, Io=30mA, Po=62mW, Co=1F
Australia (SAA)
[Flameproof approval]
Applicable standard: AS2380.1, AS2380.2 Certificate: AUS Ex 3640
Ex d IIC T6 (Tamb=75C) IP66/67
Electrical connection: 1/2 NPT female, Pg13.5 female and M20 female*4
Japanese Industrial TIIS Flameproof approval
JF3
Standards (TIIS) Ex ds IIC T6 X Amb. Temp.: -20 to 60C
Attached flameproof Electrical connection: G1/2 female 1 pc. G11
packing adapter*3 Applicable cable: O.D. 8.5 to 11 mm 2 pc. G12
IECEx Flameproof and Dust ignition proof Approval
Applicable Standard: IEC 60079-0, IEC 60079-1, IEC 61241-0, IEC 61241-1
Ex d IIC T6/T5, Ex tD A21 IP67 T70°C, T90°C
Ambient Temperature for Gas Atmospheres: -40 to 75°C (-40 to 167°F) for T6,
IECEx Scheme*5 SF2
-40 to 80°C (-40 to 176°F) for T5
Ambient Temperature for Dust Atmospheres: -40 to 65°C (-40 to 149°F) for T70°C,
-40 to 80°C (-40 to 176°F) for T90°C
Enclosure: IP67
Electrical Connection: 1/2 NPT female and M20 female
T05E-2.EPS
*3 : If cable wiring is to be used to a TIIS flameproof type transmitter, do not fail to add the YOKOGAWA-assured flameproof packing adapter.
*4 : Applicable for Electrical connection code 2, 3 and 4.
*5 : Applicable only for Australia, New Zealand area.
■ DIMENSIONS
Unit: mm (Approx. inch)
2-inch horizontal pipe mounting
65.4(2.57)
111(4.37) 46(1.81) 65(2.56)

Electrical Connection 18.5
(Input signal) Terminal Cover
(0.73)
Electrical Connection
(Output signal) With Indicator
(Optional)
ø93
102 (3.66)
(4.02)
164
(6.46)
Shrouding Bolt Ground Terminal

40
(For Explosionproof type) (1.57) 25
(0.98) Tag Plate
Horizontal Pipe Mounting Bracket

(Optional)
56(2.21)
2-inch pipe, ø60.5(ø2.38)
70(2.76)
90(3.54)
2-inch vertical pipe mounting 65.4(2.57)
46(1.81) 65(2.56)
111(4.37) Electrical Connection 18.5
(0.73)
(Output signal)
With Indicator
(Optional)
ø93
Shrouding Bolt (3.66)
(For Explosionproof type)
209.5
(8.25)
191.5 Ground Terminal
(7.54)
Tag Plate
Vertical Pipe Mounting Bracket
(Optional)
46(1.81)
2-inch pipe, ø60.5(ø2.38) 64(2.52)

101(3.98)
98(3.86)
F03E.EPS
Terminals
Terminal Configuration
Power Supply and output terminal
Communication
External Indicator (ammeter) terminal *1
Terminals (BT200 etc.)
Connection hook
Ground terminal
*1: When using an external indicator or check meter,

CHECK METER
the internal resistance must be 10Ω or less.
Connection hook *1
This hook is not available for Fieldbus communi-
M101.5 12-deep female cation type(output signal code F).
for mounting bracket F04.EPS
Input Wiring
Single input (YTA110)

(A) (A) (A)
1 1 1 1
(+) (B) (A)
2 2 2 2
(B) (B) (B)
3 (–)
3 3 3
(B)
4 4 4 4
5 5 5 5
T/C or DC milivolts two-wire three-wire four-wire

RTD or ohm RTD or ohm RTD
F05E.EPS
Table A. Settings upon shipment.

< Ordering Information >
Specify the following when ordering Input sensor type Pt100 three-wire system, or as specified
Calibration range lower limit "0" or as specified
Model, suffix codes, and optional codes
Calibration range upper limit "100" or as specified
The instrument is shipped with the settings shown in Calibration unit "C" or as specified
Table A. Specify the following when necessary. Damping time constant 2 seconds
Sensor burnout *1 High (110%, 21.6 mA DC)
1. Sensor type. Output in Transmitter failure *1 High (110%, 21.6 mA DC or more)
For RTD and resistance input, specify the number of Integral Indicator *2 PV
wire as well. Output type Sensor 1
(Example; Pt200 3-wire system)
Tag number As specified in order
2. Calibration range and unit T07E.EPS
1) Calibration range can be specified within the *1: Except when Optional code C1 or C2 is specified.
*2: When Integral indicator is specified.
measurement range shown in Table 1. on page 3.
2) Specify one range from C, K, F or R for tempera-
ture input. F and R are available when Optional < Related Instruments >
code D2 is specified. It is not necessary to specify Power Distributor: Refer to GS 01B04T01-02E or
the unit of mV and ohm inputs, for these units GS 01B04T02-00E
automatically will be mV or Ω. BRAIN TERMINAL: Refer to GS 01C00A11-00E
3. Tag Number
4. Other Items related with options < Reference >
/CA option allows specifying the setting Descriptor for
HART protocol type at factory. HART; Trademark of The HART Communiation
Specify upto 16 characters to be entered in the Foundation. (USA)
Descriptor parameter. Material Cross Reference Table
SUS304 AISI 304
T08E.EPS
Subject to change without notice.
User's
Manual YTA Series
Temperature Transmitters
(Hardware)
[Style: S3]
IM 01C50B01-01E
IM 01C50B01-01E
12th Edition
CONTENTS
CONTENTS
1. PREFACE ...................................................................................................... 1-1

Notes on the User’s Manual .......................................................................... 1-1
Notes on Safety and Modifications ................................................................ 1-1
For Safe Use of Product ................................................................................ 1-1
Warranty ........................................................................................................ 1-2
Trademarks .................................................................................................... 1-2
ATEX Documentation .................................................................................... 1-3
2. NOTES ON HANDLING ................................................................................ 2-1

2.1 Nameplate ........................................................................................... 2-1
2.2 Transport ............................................................................................. 2-1
2.3 Storage ................................................................................................ 2-1
2.4 Choosing the Installation Location ...................................................... 2-1
2.5 Use of a Transceiver ........................................................................... 2-2
2.6 Insulation Resistance Test and Withstand Voltage Test .................... 2-2
2.6.1 Insulation resistance test procedure ............................................ 2-2
2.6.2 Withstand voltage test procedure ................................................ 2-3
2.7 Installation of Explosion Protected Type Transmitters ....................... 2-3
2.7.1 CSA Certification .......................................................................... 2-3
2.7.2 CENELEC ATEX (KEMA) Certification ........................................ 2-5
2.7.3 FM Certification ............................................................................ 2-8
2.7.4 TIIS Certification ........................................................................... 2-9
2.7.5 SAA Certification ........................................................................ 2-10
2.7.6 IECEx Certification ..................................................................... 2-11
2.8 EMC Conformity Standards .............................................................. 2-11
2.9 Low Voltage Directive ....................................................................... 2-11
3. PART NAMES AND FUNCTIONS ................................................................ 3-1

3.1 Part Names ......................................................................................... 3-1
3.2 Setting the Hardware Error Burnout Change-over Switch ................. 3-2
3.3 Built-in Indicator Display Function ...................................................... 3-2
4. INSTALLATION ............................................................................................. 4-1
5. WIRING .......................................................................................................... 5-1

5.1 Notes on Wiring .................................................................................. 5-1
5.2 Loop Construction ............................................................................... 5-1
5.3 Cable Selection ................................................................................... 5-2
5.3.1 Input signal Cable Selection ........................................................ 5-2
5.3.2 Output Signal Cable Selection ..................................................... 5-2
5.4 Cable and Terminal Connections ....................................................... 5-2
5.4.1 Input Terminal Connections ......................................................... 5-2
5.4.2 Output Terminal Connection ........................................................ 5-3
5.5 Wiring Cautions ................................................................................... 5-4
5.6 Grounding ............................................................................................ 5-5
FD No. IM 01C50B01-01E i IM 01C50B01-01E

12th Edition: Nov. 2007(KP)
All Rights Reserved, Copyright © 1998, Yokogawa Electric Corporation
CONTENTS
6. MAINTENANCE ............................................................................................. 6-1

6.1 General ................................................................................................ 6-1
6.2 Calibration ........................................................................................... 6-1
6.2.1 Selection of Equipment for Calibration ........................................ 6-1
6.2.2 Calibration Procedure ................................................................... 6-1
6.3 Disassembly and Assembly ................................................................ 6-2
6.3.1 Replacement of Built-in Indicator ................................................. 6-3
6.3.2 Replacement of CPU Assembly ................................................... 6-3
6.4 Troubleshooting ................................................................................... 6-4
6.4.1 Basic Troubleshooting Flow ......................................................... 6-4
6.4.2 Example of Troubleshooting Flow ................................................ 6-4
6.5 Integral Indicator and Error Display .................................................... 6-6
7. GENERAL SPECIFICATIONS ...................................................................... 7-1

7.1 Standard Specifications ...................................................................... 7-1
7.2 Model and Suffix Codes ...................................................................... 7-5
7.3 Optional Specifications ........................................................................ 7-5
7.4 Dimensions .......................................................................................... 7-8
INSTALLATION AND OPERATING PRECAUTIONS FOR JIS FLAMEPROOF

EQUIPMENT ........................................................................................ EX-B03E
Customer Maintenance Parts List ..................................... CMPL 01C50B01-02E
REVISION RECORD
ii IM 01C50B01-01E
1. PREFACE
1. PREFACE
The YTA temperature transmitter is fully factory-tested • No maintenance should be performed on explosion-
according to the specifications indicated on the order. proof type temperature transmitters while the
equipment is energized. If maintenance is required
In order for the YTA temperature transmitter to be
with the cover open, always first use a gas detector
fully functional and to operate in an efficient manner,
to check that no explosive gases are present.
the manual must be carefully read to become familiar
• If the user attempts to repair or modify an
with the functions, operation, and handling of the
explosionproof type transmitter and is unable to
YTA.
restore it to its original condition, damage to the
This manual gives instructions on handling, wiring and explosionproof features result, leading to dangerous
maintenance of YTA110, YTA310 and YTA320 conditions. Contact your authorized Yokogawa
temperature transmitters. Changing the parameter Electric Corporation representative for repairs or
settings requires a terminal dedicated to the HART modifications of an explosionproof type transmitter.
protocol or the BRAIN protocol. For details on how to
set the parameters of these transmitters, refer to the
For Safe Use of Product
“BRAIN Protocol” IM 0lC50T03-01E or “HART
Please give your attention to the followings.
Protocol” IM 01C50T01-01E.
For FOUNDATION Fieldbus communication type, (a) Installation
please refer to IM 01C50T02-01E in addition to this • The instrument must be installed by an expert
manual. engineer or a skilled personnel. The procedures
described about INSTALLATION are not permitted
Notes on the User’s Manual for operators.
• This manual should be delivered to the end user.
• In case of high process temperature, care should be
• The information contained in this manual is subject
taken not to burn yourself because the surface of the
to change without prior notice.
case reaches a high temperature.
• The information contained in this manual, in whole
or part, shall not be transcribed or copied without • All installation shall comply with local installation
notice. requirement and local electrical code.
• In no case does this manual guarantee the merchant
ability of the transmitter or its adaptability to a (b) Wiring
specific client need. • The instrument must be installed by an expert
• Should any doubt or error be found in this manual, engineer or a skilled personnel. The procedures
submit inquiries to your local dealer. described about WIRING are not permitted for
• No special specifications are contained in this operators.
manual.
• Please confirm that voltages between the power
• Changes to specifications, structure, and components
supply and the instrument before connecting the
used may not lead to the revision of this manual
power cables and that the cables are not powered
unless such changes affect the function and perfor-
before connecting.
mance of the transmitter.
(c) Maintenance
Notes on Safety and Modifications • Please do not carry out except being written to a
• Before handling the YTA, it is absolutely imperative maintenance descriptions. When these procedures
that users of this equipment read and observe the are needed, please contact nearest YOKOGAWA
safety instructions mentioned in each section of the office.
manual in order to ensure the protection and safety • Care should be taken to prevent the build up of drift,
of operators, the YTA itself and the system contain- dust or other material on the display glass and
ing the transmitter. We are not liable for any name plate. In case of its maintenance, soft and dry
accidents arising out of handling that does not cloth is used.
adhere to the guidelines established in the safety
instructions.
1-1 IM 01C50B01-01E
1. PREFACE
(d) Modification Warranty

• Yokogawa will not be liable for malfunctions or • The warranty period of the instrument is written on
damage resulting from any modification made to this the estimate sheet that is included with your pur-
instrument by the customer. chase. Any trouble arising during the warranty
period shall be repaired free of charge.
• Inquiries with regard to problems with the instru-
Symbols used in this manual ment shall be accepted by the sales outlet or our
The YTA temperature transmitter and this manual use local dealer representative.
the following safety related symbols and signals. • Should the instrument be found to be defective,
inform us of the model name and the serial number
of the instrument together with a detailed description
WARNING of nonconformance and a progress report. Outline
drawings or related data will also be helpful for
Contains precautions to protect against the
repair.
chance of explosion or electric shock which, if
• Whether or not the defective instrument is repaired
not observed, could lead to death or serious
free of charge depends on the result of our inspec-
injury.
tion.
Conditions not eligible for charge-exempt

CAUTION repair.
• Problems caused by improper or insufficient
Contains precautions to protect against danger,
maintenance on the part of the customer.
which, if not observed, could lead to personal
• Trouble or damage caused by mishandling, misus-
injury or damage to the instrument.
age, or storage that exceeds the design or specifica-
tion requirements.
• Problems caused by improper installation location or
by maintenance conducted in a non-conforming
IMPORTANT
location.
Contains precautions to be observed to protect • Trouble or damage was caused by modification or
against adverse conditions that may lead to repair that was handled by a party or parties other
damage to the instrument or a system failure. than our consigned agent.
• Trouble or damage was caused by inappropriate
relocation following delivery.
• Trouble or damage was caused by fire, earthquake,
NOTE wind or flood damage, lightning strikes or other acts
of God that are not directly a result of problems with
Contains precautions to be observed with regard
this instrument.
to understanding operation and functions.
Some of the diagrams in this manual are partially Trademarks

omitted, described in writing, or simplified for ease of • HART is a trademark of the HART Communication
explanation. The screen drawings contained in the Foundation.
instruction manual may have a display position or • Registered trademarks or trademarks appearing in
characters (upper/lower case) that differ slightly from this manual are not designated by a TM or ®
the full-scale screen to an extent that does not hinder symbol.
the understanding of functions or monitoring of • Other company names and product names used in
operation. this manual are the registered trademarks or trade-
marks of their respective owners.
1-2 IM 01C50B01-01E
1. PREFACE
ATEX Documentation
This procedure is only applicable to the countries in SF
European Union.
Kaikkien ATEX Ex -tyyppisten tuotteiden käyttöhjeet
GB Mikäli tarvitsette Ex -tyyppisten tuotteiden ohjeita
omalla paikallisella kielellännne, ottakaa yhteyttä
All instruction manuals for ATEX Ex related products lähimpään Yokogawa-toimistoon tai -edustajaan.
you require Ex related instructions in your local
language, you are to contact your nearest Yokogawa P
office or representative.
Todos os manuais de instruções referentes aos produtos
DK Francês. Se necessitar de instruções na sua língua
relacionadas com produtos Ex, deverá entrar em
Alle brugervejledninger for produkter relateret til contacto com a delegação mais próxima ou com um
ATEX Ex er tilgængelige på engelsk, tysk og fransk. representante da Yokogawa.
af Ex produkter på eget sprog, kan De rette
henvendelse herom til den nærmeste Yokogawa F
afdeling eller forhandler.
Tous les manuels d’instruction des produits ATEX Ex
I française. Si vous nécessitez des instructions relatives
aux produits Ex dans votre langue, veuillez bien
Tutti i manuali operativi di prodotti ATEX contacter votre représentant Yokogawa le plus proche.
tedesco e francese. Se si desidera ricevere i manuali
operativi di prodotti Ex in lingua locale, mettersi in D
contatto con l’ufficio Yokogawa più vicino o con un
Alle Betriebsanleitungen für ATEX Ex bezogene
rappresentante.
Produkte stehen in den Sprachen Englisch, Deutsch
E Betriebsanleitungen für Ex-Produkte in Ihrer
Landessprache benötigen, setzen Sie sich bitte mit
Todos los manuales de instrucciones para los productos Ihrem örtlichen Yokogawa-Vertreter in Verbindung.
alemán y francés. Si desea solicitar las instrucciones de
estos artículos antiexplosivos en su idioma local, S
deberá ponerse en contacto con la oficina o el
Alla instruktionsböcker för ATEX Ex (explosionssäkra)
representante de Yokogawa más cercano.
produkter är tillgängliga på engelska, tyska och
NL explosionssäkra produkter på annat språk, skall Ni
kontakta närmaste Yokogawakontor eller representant.
hebben met ATEX explosiebeveiliging (Ex) zijn
verkrijgbaar in het Engels, Duits en Frans. Neem, GR
ATEX Ex
, .
Ex

Yokogawa .
1-3 IM 01C50B01-01E
1. PREFACE
SK PL
CZ
SLO
LT H
BG
LV
EST RO
1-4 IM 01C50B01-01E
2. NOTES ON HANDLING
The YTA temperature transmitter is fully factory- 2.2 Transport
tested upon shipment. When the YTA is delivered,
check the appearance for damage, and also check that To prevent damage while in transit, leave the transmit-
the transmitter mounting parts shown in Figure 2.1 are ter in the original shipping container until it reaches
included with your shipment. If “No Mounting the installation site.
Bracket” is indicated, no transmitter mounting bracket
is included. 2.3 Storage
When an extended storage period is expected, observe
the following precautions:
Bracket 1. If at all possible, store the transmitter in factory-
fastening bolt shipped condition, that is, in the original shipping
U-bolt nut container.
2. Choose a storage location that satisfies the follow-
Horizontal ing requirements.
Spring pipe mounting
Vertical pipe washer bracket • A location that is not exposed to rain or water.
mounting • A location subject to a minimum of vibration or
bracket
impact.
Transmitter • The following temperature and humidity range is
Spring fastening bolt
washer recommended. Ordinary temperature and humidity
U-bolt
(25°C, 65%) are preferable.
Temperature: No Integral indicator –40 to 85°C
Bracket U-bolt nut
fastening nut With Integral indicator –30 to 80°C
F0201.EPS
Humidity: 5 to 100% RH (at 40°C)
Figure 2.1 Transmitter mounting parts
3. The performance of the transmitter may be im-
2.1 Nameplate paired if stored in an area exposed to direct rain and
water. To avoid damage to the transmitter, install it
The model name and configuration are indicated on immediately after removal from shipping container.
the nameplate. Verify that the configuration indicated Follow wiring instructions in Chapter 5.
in the “Model and Suffix Code” in Chapter 7 is in
compliance with the specifications written on the order 2.4 Choosing the Installation
sheet.
Location
Model name
Specification code Serial No. Although the temperature transmitter is designed to
TEMPERATURE
operate in a vigorous environment, to maintain
TRANSMITTER 420 mA DC
YTA stability and accuracy, the following is recommended:
10.530 (42) V DC
:Refer to USER’S MANUAL.
(1) Ambient Temperature
TOKYO 180-8750 JAPAN
It is preferable to not to expose the instrument to

Style code Factory-shipped range and unit
F0202.EPS extreme temperatures or temperature fluctuations. If
the instrument is exposed to radiation heat a thermal
Figure 2.2 Name plate
protection system and appropriate ventilation is
recommended.
(2) Environmental Requirements
Do not allow the instrument to be installed in a
location that is exposed to corrosive atmospheric
conditions. When using the instrument in a corrosive
environment, ensure the location is well ventilated.
The unit and its wiring should be protected from
exposure to rainwater.
2-1 IM 01C50B01-01E
(3) Impact and Vibration 4. Turn the power of the insulation resistance meter
It is recommended that the instrument be installed in a ON and measure the insulation resistance. The
location that is subject to a minimum amount of impact duration of the applied voltage must be the period
and vibration. during which 100M or more is confirmed (or
20M if the unit is equipped with a built-in
2.5 Use of a Transceiver arrester).
5. Upon completion of the test, remove the insulation
Although the temperature transmitter is designed to resistance meter, connect a 100K resistor between
resist influence from high frequency noise; use of a the transition wiring, and allow the electricity to
transceiver in the vicinity of installation may cause discharge. Do not touch the terminal with your bare
problems. Installing the transmitter in an area free from hands while the electricity is discharging for more
high frequency noise (RFI) is recommended. than 1 second.
Testing between the output terminal and
2.6 Insulation Resistance Test grounding terminal
and Withstand Voltage Test 1. Lay transition wiring between the + terminal, the -
terminal, and the check terminal of the terminal box,
then connect an insulation resistance meter (with the
CAUTION power turned OFF) between the transition wiring
and the grounding terminal. The polarity of the
(1) Overvoltage of the test voltage that is so transition wiring must be positive and that of the
small that it does not cause an dielectric grounding terminal must be negative.
breakdown may in fact deteriorate insulation 2. Turn the power of the insulation resistance meter
and lower the safety performance; to prevent ON and measure the insulation resistance. The
this it is recommended that the amount of duration of the applied voltage must be the period
testing be kept to a minimum. during which 100M or more is confirmed (or
(2) The voltage for the insulation resistance test 20M if the unit is equipped with a built-in
must be 500 VAC or lower, and the voltage arrester).
for the withstand voltage test must be 500 3. Upon completion of the test, remove the insulation
VAC or lower. Failure to heed these guide- resistance meter, connect a 100K resistor between
lines may cause faulty operation. the transition wiring and the grounding terminal, and
(3) Where a built-in arrester is provided (suffix allow the electricity to discharge. Do not touch the
code: /A), the voltage for the insulation terminal with your bare hands while the electricity is
resistance test must be 100 VDC or lower, discharging for more than 1 second.
and the voltage for the withstand voltage test
Testing between the input terminal and
must be 100 VAC or lower. Failure to heed grounding terminal
these guidelines may cause faulty operation. 1. Lay transition wiring between terminals 1, 2, 3, 4
and 5 of the terminal box, and connect the insulation
Follow the steps below to perform the test, the wiring resistor (with the power turned OFF) between the
of the transmission line must be removed before transition wiring and the grounding terminal. The
initiating testing. polarity of the transition wiring must be positive and
that of the grounding terminal must be negative.
2.6.1 Insulation resistance test procedure 2. Turn the power of the insulation resistance meter
ON and measure the insulation resistance. The
Testing between the output terminal and duration of the applied voltage must be the period
input terminal during which 100M or more is confirmed (or
1. Lay transition wiring between the + terminal, the - 20M if the unit is equipped with a built-in
terminal, and the check terminal of the terminal box. arrester).
2. Lay wiring across terminals 1, 2, 3, and 4 of the 3. Upon completion of the test, remove the insulation
terminal box. resistance meter, connect a 100K resistor between
3. Connect the insulation resistance meter (with the the transition wiring and the grounding terminal, and
power turned OFF) between the transition wiring of allow the electricity to discharge. Do not touch the
Steps 1 and 2 above. The polarity of the input terminal with your bare hands while the electricity is
terminals must be positive and that of the output discharging for more than 1 second.
terminals must be negative.
2-2 IM 01C50B01-01E
2.6.2 Withstand voltage test procedure 2.7 Installation of Explosion

Testing between the output terminal and the Protected Type Transmitters
input terminal
In this section, further requirements and differences
1. Lay transition wiring between the + terminal, the –
and for explosionproof type instrument are described.
terminal, and the check terminal of the terminal box.
For explosionproof type instrument, the description in
2. Lay transition wiring between terminals 1, 2, 3, 4
this chapter is prior to other description in this users
and 5 of the terminal box.
manual.
3. Connect the withstand voltage tester (with the power
turned OFF) between the transition wiring shown in
Steps 1 and 2 above. CAUTION
4. After setting the current limit value of the withstand
voltage tester to 10mA, turn the power ON, and To preserve the safety of explosionproof equip-
carefully increase the impressed voltage from 0V to ment requires great care during mounting,
the specified value. wiring, and piping. Safety requirements also
5. The voltage at the specified value must remain for a place restrictions on maintenance and repair
duration of one minute. activities. Please read the following sections very
6. Upon completion of the test, carefully reduce the carefully.
voltage so that no voltage surge occurs.
Testing between the output terminal and the
grounding terminal 2.7.1 CSA Certification
1. Lay the transition wiring between the + terminal, the
Model YTA110/CU1, YTA310/CU1 and YTA320/CU1
- terminal and the check terminal of the terminal
temperature transmitters can be selected the type of
box, and connect the withstand voltage tester (with
protection (CSA Intrinsically Safe, Non-incendive, or
the power turned OFF) between the transition wiring
Explosionproof) for use in hazardous locations.
and the grounding terminal. Connect the grounding
side of the withstand voltage tester to the grounding
once a particular type of protection is
terminal.
selected, any other type of protection
cannot be used. The installation must be
voltage tester to 10mA, turn the power ON, and
gradually increase the impressed voltage from 0V to
the specified value.
manual.
3. The voltage at the specified value must remain for a
duration of one minute.
marking is crossed out on the label other
4. Upon completion of the test, carefully reduce the
the transmitter is installed.
Testing between the input terminal and the
a) CSA Intrinsically Safe Type/Non-incendive
grounding terminal
Type
1. Lay the transition wiring across terminals 1, 2, 3, 4,
Caution for CSA Intrinsically safe type. (Following
and 5 of the terminal box and connect the withstand
contents refers “DOC No. ICS008-A13 P.1-1 and P.1-
voltage tester (with the power turned OFF) between
2”)
the transition wiring and the grounding terminal.
Note 1. Model YTA110/CU1, YTA310/CU1 and
Connect the grounding side of the withstand voltage
YTA320/CU1 temperature transmitters
tester to the grounding terminal.
are applicable for use in hazardous
locations:
voltage tester to 10mA, turn the power ON, and
Certificate 172608-0001053837
gradually increase the impressed voltage from 0V to
[For CSA C22.2]
the specified value.
• Applicable Standard: C22.2 No.0, C22.2 No.0.4,
3. The voltage at the specified value must remain for a
C22.2 No.25, C22.2 No.94, C22.2 No.142, C22.2
duration of one minute.
No.157, C22.2 No.213
4. Upon completion of the test, carefully reduce the
• Intrinsically Safe for Class I, II, III, Division 1,
Groups A, B, C, D, E, F & G.
• Non-incendive for Class I, II, Division 2, Groups A,
B, C, D, E, F & G, Class III, Division 1.
2-3 IM 01C50B01-01E
• Encl. “Type 4X” b) CSA Explosionproof Type

• Temperature Class: T4 Caution for CSA Explosionproof type
• Ambient temperature: –40 to 60°C Note 1. Model YTA110/CU1, YTA310/CU1 and
Note 2. Entity Parameters (Electrical/Non- YTA320/CU1 temperature transmitters
incendive field wiring parameters) are applicable for use in hazardous
• [Supply Circuit] locations:
Vmax = 30 V, Imax = 165 mA, Pmax = 0.9 W Certificate 1089576
Ci = 18 nF, Li = 730 µH [For CSA C22.2]
• [Associated apparatus] • Applicable Standard: C22.2 No.0, C22.2 No.0.4,
Voc ≤ 30 V, Isc ≤ 165 mA, Pmax ≤ 0.9 W C22.2 No.25, C22.2 No.30, C22.2 No.94, C22.2
• [Sensor Circuit] No.142, C22.2 No.157, C22.2 No.213, C22.2
Voc = 9 V, Isc = 40 mA, Po = 90 mW, No.1010.1
Ca = 1 µF, La = 10 mH • Explosionproof for Class I, Division 1, Groups B,
Note 3. Installation C and D.
• All wiring shall comply with Canadian Electrical • Dust-ignitionproof for Class II, Groups E, F and G,
Code Part I and Local Electrical Codes. Class III.
• For the sensor circuitry, the above parameters for • Encl “Type 4X”
sensor circuit must be taken into account. • Temperature Class: T6
• Dust-tight conduit seal must be used when installed in • Ambient Temperature: –40 to 60°C
class II and III environments. • Supply Voltage: 42 V dc max.
• In any used safety barrier, output current must be • Output Signal: 4 to 20 mA
limited by a resistor 'R' such that Isc=Voc/R. Note 2. Wiring
• The safety barrier must be CSA certified, and the • All wiring shall comply with Canadian Electrical
input voltage of the barrier must be less than Code Part I and Local Electrical Codes.
250Vrms/Vdc. • In hazardous location, wiring shall be in conduit as
• For non-incendive type, general purpose equipment shown in the figure.
must be CSA certified and the equipment which have WARNING: A SEAL SHALL BE INSTALLED
non-incendive field wiring parameters. WITHIN 50 cm OF THE ENCLO-
• The instrument modification or parts replacement by SURE. UN SCELLEMENT DOIT
other than authorized representative of Yokogawa ÊTRE INSTALLÉ À MOINS DE
Electric Corporation is prohibited and will void 50 cm DU BOÎTIER.
Canadian Standards Intrinsically safe and • When installed in Division 2, “FACTORY
nonincendive Certification. SEALED, CONDUIT SEAL NOT REQUIRED”.
Note 3. Operation
[Intrinsically Safe]
• Keep strictly the “WARNING” on the label
Hazardous Nonhazardous
Location Location attached on the transmitter.
YTA Series General WARNING: OPEN CIRCUIT BEFORE RE-
Temperature Purpose MOVING COVER. OUVRIR LE
Transmitter Safety Barrier Equipment
1 + + + +
CIRCUIT AVANT DÉNLEVER LE
2 Supply COUVERCLE.
3 – – – – • Take care not to generate mechanical spark when
4 Sensor
5
access to the instrument and peripheral devices in
hazardous location.
[Non-incendive] • The instrument modification or parts replacement
Hazardous Nonhazardous by other than authorized representative of
Location Location
YTA Series General
Temperature Purpose will void Canadian Standards Explosionproof
Transmitter Equipment
Certification.
1 + +
2 Supply
3 – –
4 Sensor Not Use
5 Safety Barrier
F0204.EPS
2-4 IM 01C50B01-01E
HAZARDOUS LOCATIONS DIVISION 1 NON-HAZARDOUS

LOCATIONS
50 cm Max. YTA Series 50 cm Max.
Non-hazardous
Sensor Location
Equipment
42 V DC Max.
Sealing Fitting Conduit Sealing Fitting 4 to 20 mA DC
Signal
Certified/Listed Temperature Sensor

Explosionproof Class I, Groups C and D
Dustignitionproof Class II, Groups E, F and G, Class III
Wiring method shall be suitable for the specified hazardous locations.
HAZARDOUS LOCATIONS DIVISION 2 NON-HAZARDOUS

LOCATIONS
YTA Series
Non-hazardous
Sensor Location
Equipment
42 V DC Max.
Conduit Sealing Fitting 4 to 20 mA DC
Signal
Certified/Listed Temperature Sensor

Explosionproof Class I, Groups C and D
Dustignitionproof Class II, Groups E, F and G, Class III
Wiring method shall be suitable for the specified hazardous locations.
F0203.EPS
2.7.2 CENELEC ATEX (KEMA) Certification • Applicable Standard: EN 50014, EN 50020, EN

50284
Model YTA110/KU2, YTA310/KU2 and YTA320/
• Type of Protection and Marking code: II 1G EEx ia
KU2 temperature transmitters can be selected the type
IIC T5, T4
of protection (CENELEC ATEX(KEMA) Intrinsically
• Temperature Class: T5, T4
Safe or CENELEC ATEX(KEMA) Flameproof or
• Ambient Temperature: –40 to 70°C for T4, –40 to
CENELEC ATEX Type of Protection “n”) for use in
50°C for T5
hazardous locations.
• Enclosure: IP67
Note 2. Electrical Data
once a particular type of protection is
• In type of explosion protection intrinsic safety II 1G
EEx ia IIC only for connection to a certified
intrinsically safe circuit with following maximum
values:
• [Supply circuit]
manual.
Ui = 30 V Ii = 165 mA
Pi = 900 mW
marking is crossed out on the label other
Effective internal capacitance, Ci = 20 nF
Effective internal inductance, Li = 660 µH
• [Sensor circuit]
Uo = 8.6 V Io = 30 mA
(1) Technical Data Po = 70 mW
a) CENELEC ATEX (KEMA) Intrinsically Safe Max. allowed external capacitance, Co = 3 µF
Type Max. allowed external inductance, Lo = 20 mH
Caution for CENELEC ATEX (KEMA) Intrinsically Note 3. Installation
safe type • All wiring shall comply with local installation
Note 1. Model YTA110/KU2, YTA310/KU2 and requirements. (Refer to the installation diagram)
YTA320/KU2 temperature transmitters for Note 4. Maintenance and Repair
potentially explosive atmospheres: • The instrument modification or parts replacement by
• No. KEMA 02ATEX1026X other than authorized representative of Yokogawa
KEMA Intrinsically safe Certification.
2-5 IM 01C50B01-01E
Note 5. Special condition for safe use WARNING: AFTER DE-ENERGIZING, DELAY
• Because the enclosure of the Temperature Transmit- 5 MINUTES BEFORE OPENING.
ter is made of aluminium, if it is mounted in an area WHEN THE AMBIENT TEMP.
where the use of category 1G apparatus is required, 70C, USE THE HEATRESISTING
it must be installed such, that, even in the event of CABLES OF HIGHER THAN 90C.
rare incidents, ignition source due to impact and • Take care not to generate mechanical spark when
friction sparks are excluded. access to the instrument and peripheral devices in
hazardous location.
[Installation Diagram]
Location Location • The instrument modification or parts replacement by
other than authorized representative of Yokogawa
Transmitter Safety Barrier *1 Electric Corporation is prohibited and will void
1 + + KEMA Flameproof Certification.
2 Supply
3 – –
4 Sensor
5
c) CENELEC ATEX Type of Protection “n”
F0208.EPS
WARNING
*1: In any safety barriers used the output current must be limited by When using a power supply not having a non-
a resistor “R” such that Imaxout-Uz/R.
incendive circuit, please pay attention not to
ignite in the surrounding flammable atmosphere.
b) CENELEC ATEX (KEMA) Flameproof Type In such a case, we recommend using wiring
and Dust Ignition Proof Type metal conduit in order to prevent the ignition.
Caution for CENELEC ATEX (KEMA) Flameproof
Type and Dust Ignition Proof Type Caution for CENELEC ATEX Type of Protection “n”
Note 1. Model YTA110/KU2, YTA310/KU2 and Note 1. Model YTA110/KU2, YTA310/KU2 and
YTA320/KU2 temperature transmitters YTA320/KU2 temperature transmitters for
are applicable for use in hazardous potentially explosive atmospheres:
locations: • Applicable standard: EN60079-15:2003
• No. KEMA 07ATEX0130 • Referential standard: IEC60079-0:1998,
• Applicable Standard: EN 60079-0, IEC 60079-1, IEC60079-11:1999
EN 61241-0, EN 61241-1 • Type of Protection and Marking Code: II 3G EEx
• Type of Protection and Marking Code: II 2G Ex d nL IIC T5, T4
IIC T6/T5, II 2D Ex tD A21 IP67 T70°C, T90°C • Temperature Class: T5, T4
• Ambient Temperature for Gas Atmospheres: • Ambient Temperature: –40 to 50°C for T5, –40 to
–40 to 75°C (T6), –40 to 80°C (T5) 70°C for T4
• Ambient Temperature for Dust Atmospheres: • Enclosure: IP67
–40 to 65°C (T70°C), –40 to 80°C (T90°C) Note 2. Electrical Data
• Enclosure: IP67 [Supply circuit]
Note 2. Electrical Data Ui = 30 V
• Supply voltage: 42 V dc max. Effective internal capacitance, Ci = 20 nF
• Output signal: 4 to 20 mA Effective internal inductance, Li = 660 µH
Note 3. Installation [Sensor circuit]
• All wiring shall comply with local installation Uo= 8.6 V Io = 30 mA Po = 70 mW
requirement. Max. allowed external capacitance, Co = 3 µF
• The cable entry devices shall be of a certified Max. allowed external inductance, Lo = 20 mH
flameproof type, suitable for the conditions of use. Note 3. Installation
Note 4. Operation • All wiring shall comply with local installation
• Keep strictly the “WARNING” on the label on the requirements. (refer to the installation diagram)
transmitter.
2-6 IM 01C50B01-01E
Note 4. Maintenance and Repair (5) Maintenance and Repair

other than authorized representative of Yokogawa WARNING
Type of Protection “n” Certification. The instrument modification or parts replacement
by other than authorized Representative of
[Installation Diagram]
Location Location
will void the certification.
(Zone 2 only)
Temperature (6) Name Plate
Transmitter Power Supply
+ + Name plate for KU2
Suppry II 1G II 2G II 3G
TEMPERATURE No. KEMA 02ATEX1026 X No. KEMA 02ATEX2155 EEx nL IIC T5
– – TRANSMITTER
YTA
420 mA DC
EEx ia IIC T5
Tamb -40 TO 50C
EEx ia IIC T4
Tamb -40 TO 70C
EEx d IIC T6
Tamb -40 TO 75C
EEx d IIC T5
Tamb -40 TO 80C
Tamb -40 TO 50C
EEx nL IIC T4
Tamb -40 TO 70C
ENCLOSURE: IP67
ENCLOSURE: IP67 ENCLOSURE: IP67 SUPPLY INPUT
SUPPLY INPUT WARNING Ui=30V
Ui=30V, Ii=165mA, Pi=900mV Ci=20nF, Li=660H
AFTER DE-ENERGIZING, DELAY SENSOR OUTPUT
Ci=20nF, Li=660H
5 MINUTES BEFORE OPENING.
SENSOR OUTPUT Uo=8.6V, Io=30mA
WHEN THE AMBIENT TEMP.70C,
0344 Uo=8.6V, Io=30mA, Po=70mW
USE THE HEAT-RESISTING
Po=70mW, Co=3F
10.530 (42) V DC Co=3F, Lo=20mH
CABLES90C.
Lo=20mH
:Refer to USER’S MANUAL. Cross out unnecessary marking other than the selected type
TOKYO 180-8750 JAPAN of protection. When II 3G is selected, cross out 0344.
F0212.EPS
F0298.EPS
Ratings of the Power Supply are as follows:
Maximum Voltage: 30 V MODEL: Specified model code.
(2) Electrical Connection SUFFIX: Specified suffix code.
STYLE: Style code.
The type of electrical connection is stamped near
SUPPLY: Supply voltage.
the electrical connection port according to the
NO.: Serial number and year of production*1.
following marking.
OUTPUT: Output signal.
FACTORY CAL: Specified calibration range.
TOKYO 180-8750 JAPAN:
The manufacturer name and the
address*2.
*1: The third figure from the left shows the production
year. The relationship between the production year
Location of the marking and the third figure is shown below.
F0200.EPS
The third figure F G H J K L M
(3) Installation The year of
2006 2007 2008 2009 2010 2011 2012
Production
T0202.EPS
WARNING For example, the production year of the product
engraved in “NO.” column on the name plate as
All wiring shall comply with local installation follows is 2006.
requirement and local electrical code.
C2F616294
(4) Operation
The year 2006
WARNING *2: “180-8750” is a postal code which represents the
following address.
• OPEN CIRCUIT BEFORE REMOVING
COVER. INSTALL IN ACCORDANCE WITH 2-9-32 Nakacho, Musashino-shi, Tokyo Japan
THIS USER’S MANUAL
when access to the instrument and peripheral
devices in hazardous locations.
2-7 IM 01C50B01-01E
2.7.3 FM Certification [Intrinsically Safe]

a) FM Intrinsically Safe Type Location Location
Caution for FM Intrinsically safe type. General
Note 1. Model YTA /FU1 temperature transmitter Purpose
Equipment
is applicable for use in hazardous Class I, II, III, Division 1,
Groups A, B, C, D, E, F and G
locations
• Applicable Standard: FM 3600, FM 3610, FM 3611, + –
FM 3810 Intrinsically
Safe Sensor
• Intrinsically Safe for Class I, Division 1, Groups A, or Simple Temperature
B, C & D. Apparatus Transmitter Safety Barrier
Class II, Division 1, Groups E, F & G and Class III, 1 + + +
Division 1 Hazardous Locations. 2 Supply
3 – – –
• Outdoor hazardous locations, NEMA 4X. 4 Sensor
C
• Temperature Class: T4 5
• Ambient temperature: –40 to 60°C
Note 2. Entity Parameters of the temperature F0210.EPS
transmitter:
• Supply Circuit (+ and –) • Sensor Circuit ( 1 to 5 ) b) FM Non-incendive Type
Vmax : 30 V Voc/Vt : 9 V Caution for FM Non-incendive type.
Imax : 165 mA Isc/It : 40 mA Note 1. Model YTA /FU1 temperature transmitter
Pmax : 0.9 W Ca : 1 µF is applicable for use in hazardous
Ci : 18 nF La : 10 mH locations
Li : 730 µH • Applicable Standard: FM 3600, FM 3610, FM 3611,
• For the sensor input circuitry, these entity parameters FM 3810
must be taken into account when installed. • Non-incendive for Class I, Division 2, Groups A, B,
• Installation Requirements between temperature C & D.
transmitter and safety barrier: Class II, Division 2, Groups E, F & G and Class III,
Voc ≤ Vmax, Isc ≤ Imax, Ca ≥ Ci + Ccable, La ≥ Division 1 Hazardous Locations.
Li + Lcable • Outdoor hazardous locations, NEMA 4X.
Voc, Isc, Ca and La are parameters of the safety • Temperature Class: T4
barrier. • Ambient temperature: –40 to 60°C
Note 3. Installation Note 2. Non-incendive field wiring Parameters of
• The safety barrier must be FM approved. the temperature transmitter:
• Input voltage of the safety barrier must be less than • Supply Circuit (+ and -) • Sensor Circuit ( 1 to 5 )
250 Vrms/Vdc. Vmax : 30 V Voc/Vt : 9 V
• Installation should be in accordance with ANSI/ISA Imax : 165 mA Isc/It : 40 mA
RP12.6 “Installation of Intrinsically Safe Systems Pmax : 0.9 W Ca : 1 µF
for Hazardous (Classified) Locations” and the Ci : 18 nF La : 10 mH
National Electric Code (ANSI/NFPA 70). Li : 730 µH
• Intrinsically safe sensor must be FMRC Approved or • For the sensor input circuitry, these non-incendive
be simple apparatus (a device which will neither parameters must be taken into account when
generate nor store more than 1.2 V, 0.1 A, 25 mW installed.
or 20 µJ, ex. switches, thermocouples, LED’s or • Installation Requirements between temperature
RTD’s). transmitter and general purpose equipment:
• Dust-tight conduit seal must be used when installed Voc ≤ Vmax, Isc ≤ Imax, Ca ≥ Ci + Ccable, La ≥
in a Class II and III environments. Li + Lcable
Note 4. Maintenance and Repair Voc , Isc, Ca and La are non-incendive field wiring
• The instrument modification or parts replacement by parameters of general purpose equipment.
other than authorized representative of Yokogawa Note 3. Installation
Electric Corporation is prohibited and will void • The general purpose equipment must be FM ap-
Factory Mutual Intrinsically safe and Nonincendive proved which have non-incendive field wiring
Approval. parameters.
2-8 IM 01C50B01-01E
• Installation should be in accordance with ANSI/ISA Note 3. Operation

RP12.6 “Installation of Intrinsically Safe Systems • Keep strictly the “WARNING” on the nameplate
for Hazardous (Classified) Locations” and the attached on the transmitter.
National Electric Code (ANSI/NFPA 70). WARNING: OPEN CIRCUIT BEFORE RE-
• non-incendive sensor must be FMRC Approved or MOVING COVER. “FACTORY
be simple apparatus (a device which will neither SEALED, CONDUIT SEAL NOT
generate nor store more than 1.2 V, 0.1 A, 25 mW REQUIRED”. INSTALL IN ACCOR-
or 20 µJ, ex. switches, thermocouples, LED’s or DANCE WITH THE INSTRUCTION
RTD’s). MANUAL IM 1C50B1.
• Dust-tight conduit seal must be used when installed • Take care not to generate mechanical spark when
in a Class II and III environments. access to the instrument and peripheral devices in
Note 4. Maintenance and Repair hazardous location.
• The instrument modification or parts replacement by Note 4. Maintenance and Repair
other than authorized representative of Yokogawa • The instrument modification or parts replacement by
Electric Corporation is prohibited and will void other than authorized representative of Yokogawa
Factory Mutual Intrinsically safe and Nonincendive Electric Corporation is prohibited and will void
Approval. Factory Mutual Explosionproof Approval.
[Nonincendive]
Hazardous Nonhazardous 2.7.4 TIIS Certification
Location Location
Class I, II, Division 2, a) TIIS Flameproof Type
Groups A, B, C, D, E, F and G The model YTA /JF3 temperature transmitter, which
Class III, Division 1.
has obtained certification according to technical criteria
Non-incendive
Sensor General for explosion-protected construction of electric machin-
or Simple Temperature Purpose ery and equipment (Standards Notification No.556
Apparatus Transmitter Equipment
from the Japanese Ministry of Labor) conforming to
1 + +
2 Supply
IEC standards, is designed for hazardous areas where
3 – – explosive gases and/or inflammable vapors may be
4 Sensor
C present. (This allows installation in Division 1 and 2
5
areas)
F0211.EPS To preserve the safety of flameproof equipment
requires great care during mounting, wiring, and
c) FM Explosionproof Type piping. Safety requirements also place restrictions on
Caution for FM Explosionproof type maintenance and repair activities. Users absolutely
Note 1. Model YTA /FU1 and YTA /FF1 tempera- must read “Installation and Operating Precautions for
ture transmitters are applicable for use in TIIS Flameproof Equipment” at the end of this manual.
hazardous locations:
• Applicable Standard: FM 3600, FM 3615, FM 3810,
NEMA 250 WARNING
• Explosionproof for Class I, Division 1, Groups A, B, The terminal cover should not be opened at
C, and D. least for three minutes after the power is turned
• Dust-ignitionproof for Class II/III, Division 1, off.
Groups E, F and G. The terminal section of the flameproof YTA
• Enclosure rating: NEMA 4X. series is made of resin-filled, explosion-protected
• Temperature Class: T6 construction. The technical standards for this
• Ambient Temperature: –40 to 60°C flameproof construction require that the possibil-
• Supply Voltage: 42 V dc max. ity of explosion resulting from a prospective
• Output signal: 4 to 20 mA short-circuit current*1 of up to 4000 A be pre-
Note 2. Wiring vented even for cases when external power
• All wiring shall comply with National Electrical supply circuits are short-circuited accidentally.
Code ANSI/NEPA70 and Local Electrical Codes. Install a fuse or a circuit breaker having a
• “FACTORY SEALED, CONDUIT SEAL NOT breaking capacity of at least 4000 A in the
REQUIRED”. higher-order power line connected to the YTA
2-9 IM 01C50B01-01E
series. The breaking capacity refers to the upper [Output parameters (terminals 1 to 5)]
limit of current that can be cut off. Normally, a Maximum Output Voltage(Uo) = 8.6 V
fuse or a circuit breaker having a breaking Maximum Output Current(Io) = 30 mA
capacity of greater than 5000 A is used in power Maximum Output Power(Po) = 62 mW
Maximum External Capacitance = 1 µF
supply circuits. Confirm that this is true with your
Maximum External Inductance = 20 mH
factory. No extra measures need be taken after Maximum External Connected L/R = 0.5mH/
the confirmation. Note 3. Installation
Note that the rated current of the YTA series in • All wiring shall comply with Australian Standards.
terms of explosion protection is 4 to 20 mA; • The input and output cables are to be installed either
keep the input current of the YTA series within as seperate cables or as seperate screened circuits.
the appropriate range. • Certified IP66/67 glands or plugs must be used on
the enclosure cable entries.
*1: Refers to a current that flows when a fuse in a circuit is Note 4. Maintenance and Repair
substituted with a connecting metal piece having virtually no • The instrument modification or parts replacement by other
impedance and the circuit is then shorted. For AC circuits, this
current is represented by a root-mean-square value (JIS C6575).
than authorized representative of Yokogawa Electric
Corporation is prohibited and will void SAA Certification.
2.7.5 SAA Certification [Installation Diagram for intrinsically safe type]
Model YTA110/SU1, YTA310/SU1 and YTA320/SU1 Hazardous Location Nonhazardous Location
(Zone 0)
temperature transmitters can be selected the type of
Transmitter Safety Barrier *1
protection (SAA Intrinsically Safe, Type of Protection 1 + +
“n” or Flameproof) for use in hazardous locations. 2 Supply
Note 1. For the installation of this transmitter, 3 – –
4 Sensor
once a particular type of protection is 5
in accordance with the description about [ Installation Diagram for Type n ]
the type of protection in this instruction Hazardous Location Nonhazardous Location
(Zone 2)
manual.
Transmitter
Note 2. In order to avoid confusion, cross out + +
unnecessary marking on the label other Suppry Power Supply
than the selected type of protection when – –
a) SAA Intrinsically Safe/Type N Type F2013.EPS
Caution for SAA Intrinsically safe/Type n type *1: In any safety barriers used the output current must be limited by
Note 1. Model YTA110/SU1, YTA310/SU1 and a resistor “R” such that Imaxout-Uz/R.
YTA320/SU1 temperature transmitters for b) SAA Flameproof Type

potentially explosive atmospheres: Caution for SAA Flameproof Type
• Certificate: AUS Ex 3652X Note 1. Model YTA110/SU1, YTA310/SU1 and
• Applicable Standard: AS2380.1, AS2380.7, YTA320/SU1 temperature transmitters for
AS2380.9 potentially explosive atmospheres:
• Type of Protection and Marking code: • Certificate: AUS Ex 3640
Ex ia IIC T4 (Tamb=70°C) IP66/67 Zone 0 • Applicable Standard: AS2380.1, AS2380.2
Ex n IIC T4 (Tamb=70°C) IP66/67 Zone 2 • Type of Protection and Marking Code:
• Ambient Temperature: –40 to 70°C Ex d IIC T6(Tamb 75°C) IP66/67 Zone 1
Note 2. Entity Parameter • Ambient Temperature: –40 to 75°C
• In type of explosion protection only for connection Note 2.Electrical Data
to a certified intrinsically safe/type n circuit with • Supply voltage: 42 V dc max.
following maximum values: • Output signal: 4 to 20 mA
[Input parameters (terminals +&-/C)] Note 3. Installation
Maximum Input Voltage(Ui) = 30 V • All wiring shall comply with Australian Standards.
Maximum Input Current(Ii) = 165 mA • The cable entry devices shall be of a certified
Maximum Input Power(Pi) = 0.9 W
flameproof type, suitable for the conditions of use.
Maximum Internal Capacitance(Ci) = 30.2 nF
Maximum Internal Inductance(Li) = 738 µH
2-10 IM 01C50B01-01E
Note 4. Operation WARNING: AFTER DE-ENERGIZING, DELAY

• Keep strictly the “WARNING” on the label on the 5 MINUTES BEFORE OPENING.
transmitter. WHEN THE AMBIENT TEMP.
WARNING: WAIT 5 MIN. AFTER POWER- 70°C, USE THE HEATRESISTING
DISCONNECTION, BEFORE CABLES OF HIGHER THAN 90°C.
OPENING THE ENCLOSURE. • Take care not to generate mechanical spark when
WHEN THE AMBIENT TEMP. access to the instrument and peripheral devices in
70C, USE THE HEATRESIST- hazardous location.
ING CABLES OF HIGHER THAN Note 5. Maintenance and Repair
90C • The instrument modification or parts replacement by
• Take care not to generate mechanical spark when other than authorized representative of Yokogawa
access to the instrument and peripheral devices in Electric Corporation is prohibited and will void
hazardous location. IECEx Flameproof Certification.
other than authorized representative of Yokogawa 2.8 EMC Conformity Standards
Electric Corporation is prohibited and will void SAA
Certification. EN61326, AS/NZS CISPR11
2.7.6 IECEx Certification

NOTE
a) IECEx Flameproof Type and Dust Ignition YOKOGAWA recommends customer to apply
Proof Type
the Metal Conduit Wiring or to use the twisted
Caution for IECEx flameproof type and Dust Ignition
pair Shield Cable for signal wiring to conform the
Proof Type requirement of EMC Regulation, when customer
Note 1. Model YTA110/SF2, YTA310/SF2, and installs the YTA Series Transmitters to the plant.
YTA320/SF2 temperature transmitters
are applicable for use in hazardous
locations:
• No. IECEx KEM 07.0044 2.9 Low Voltage Directive
• Applicable Standard: IEC 60079-0, IEC 60079-1,
IEC 61241-0, IEC 61241-1 Applicable standard: EN61010-1
Ex d IIC T6/T5, Ex tD A21 IP67 T70°C, T90°C (1) Pollution Degree 2
• Ambient Temperature for Gas Atmospheres: “Pollution degree” describes the degree to which a
–40 to 75°C (T6), –40 to 80°C (T5) soild, liquid, or gas which deteriorates dielectric
• Ambient Temperature for Dust Atmospheres: strength or surface resistivity is adhering. “ 2 ”
–40 to 65°C (T70°C), –40 to 80°C (T90°C) applies to normal indoor atmosphere. Normally,
• Enclosure: IP67 only non-conductive pollution occurs. Occasionally,
Note 2. Electrical Data however, temporary conductivity caused by
• Supply voltage: 42 V dc max. condenstaion must be expected.
• Output signal: 4 to 20 mA
(2) Installation Category I
“Overvoltage category(Installation category)”
requirement. describes a number which defines a transient
• The cable entry devices shall be of a certified overvoltage condition. It implies the regulattion for
impulse withstand voltage. “ I ” applies to electrical
flameproof type, suitable for the conditions of use.
Note 4. Operation equipment which is supplied from the circuit when
• Keep strictly the “WARNING” on the label on the appropriate transient overvoltage control means
(interfaces) are provided.
transmitter.
2-11 IM 01C50B01-01E
3. PART NAMES AND FUNCTIONS
3.1 Part Names
Burn out output direction

setting pin upon hardware failure
Name plate
Stud bolt
CPU assembly
Terminal cover
LCD assembly
(with indicator)
Grounding
Amp. cover terminal
Tag plate
Grounding
terminal
Lock screw
(for CENELEC, SAA and Wiring connector
TIIS flameproof type) (output signal side)
Wiring connector
(input signal side)
Built-in indicator display Output signal terminal Input signal terminal
F0301.EPS
Figure 3.1 Part Names
3-1 IM 01C50B01-01E
(1)Output bar chart display

3.2 Setting the Hardware Error
The output value is displayed in a bar chart. Resolution
Burnout Change-over Switch of the bar chart is to the extent of 32 divisions (each
increment is about 3.125%). If the output exceeds 0%
The temperature transmitter is equipped with a hard-
or 100%, is lit. The bar chart can be toggled ON/
ware error burnout function used to set the output
OFF using the bar chart display parameter.
direction upon hardware error, and a sensor burnout
function that sets the direction of the output in the (2) Communication protocol display
event of burnout of the temperature sensor. When The indicator is on in accordance with each communi-
factory-shipped under normal conditions, the output of cation protocol.
both hardware error burnout and sensor burnout are set
to HIGH, but if suffix code /C1 is specified, the (3)Operation mode display
hardware error burnout is set to LOW (-5%) output, Lit when each operation mode is activated.
and sensor burnout is set to LOW (-2.5%) output,
respectively. The setting of the direction of output from M.D.: Lit when the multidrop mode of HART commu-
burnout can be changed. nication specification is activated.
To change the direction of output arising from burnout, B.M.: Lit during burst mode transfer of HART commu-
switch the setting pin on the CPU assembly (see Figure nication specification.
3.1 and Table 3.1). To change the direction of output F.O.: Lit when manual mode is active.
arising out of sensor burnout, a dedicated hand-held
terminal is required to rewrite the parameters within W.P.: Lit when write protect status is active.
the transmitter. For details, refer to the separate
(4)Input display
instruction manual, IM 01C50T01-01E “HART
Indicates the type of input in accordance with the value
Protocol” or IM 01C50T03-01E “BRAIN Protocol”.
shown in the column in Item (5).
Table 3.1 Output Direction Setting Pins for Hardware
Error Burnout Sns1: Meant to show the process variable allocated to
Pin Hardware error Hardware error Remark
Sensor 1.
position burnout burnout
direction output Sns2: Meant to show the process variable allocated to
H HIGH 110% or more Set to HIGH upon Sensor 2. (Can be displayed only with the
(21.6 mA DC) shipment from the YTA320.) .
L factory
H LOW -5% or less Set to LOW when Term: Meant to show the temperature of the terminal
(3.2 mA DC) suffix code /C1 box of the temperature transmitter.
L is provided
T0301.EPS Avg: Meant to show the average of the process
variable allocated to Sensor1 and Sensor2. (Can
3.3 Built-in Indicator Display be displayed only with the YTA320.).
Function Dif: Meant to show the difference of the process

variable allocated to Sensor1 and Sensor2. (Can
be displayed only with the YTA320.)
Communication protocol display
Output bar chart display (5)Process variable display
Operation mode Displays the process variable or output value. The
display value is displayed down to the second decimal position
if the integer part is less than three digits, or down to
Input display the first decimal position if the integer part is 4 digits.
Process variable display If the value is negative, the minus () sign is lit. For
process variables, the indicators for each item specified
Unit display in the column of input display in Item (4) and the unit
Display of sensor type and column in Item (6) are lit. For output value, % or mA
number of wire connections F0302.EPS in the unit column in Item (6) is lit. When burnout of
the temperature sensor is identified, or the temperature
Figure 3.2 Built-in Indicator Display Function
transmitter is found abnormal, an error code flashes.
For a list of error codes, refer to “Error code table” in
Section 6.4.
3-2 IM 01C50B01-01E
(6)Unit display Upon shipment from the factory, the indicator is set as
The unit specified as the unit of process in the process follows.
variable display column in Item (5) is lit. The output Table 3.2 Setting of Indicator upon Shipment from the
display is fixed to mA or %. Factory
Display location Contents

(7)Display of sensor type and number of wire
connections Output bar chart display Output bar chart display is on.
Displays process variable/output items, the number of Input display Sns1 is lit.
sensor wiring connections and the multidrop address in Process variable display PV value and output value
dot matrix (only applies to HART communication). In (mA) are alternately displayed.
the event of hardware error, “FAIL” is displayed. Unit display The unit specified upon
shipped from factory and mA
Process variable: To display the process variable are lit.
value in the process variable Display of sensor type and “PV” and “OUT” are displayed
display in Item (5), display the type number of wire connections alternately.
T0302.EPS
of applicable process variable
(“PV”, “SV”, “TV”).
Output display: To display the output value in the
process variable display in Item
(5), display “OUT”. During the
output of sensor burnout, “Abn”
and “OUT” are alternately dis
played.
WIRE: Displays the number of wiring
connections. There are two wiring
connections for thermocouple
input, while there are two to four
connections for thermometer
resistor; these are displayed
alternately with the sensor type.
The display can be hidden by
setting an applicable parameter.
Note that the DIF and AVG display
does not allow the sensor type to
be displayed.
TYPE: Displays the type of sensor. Note
that the DIF and AVG display does
not allow the sensor type to be
displayed. If the sensor is custom-
ordered, “Z1” and “Z2” are
displayed.
Multidrop address: If the multidrop address is 1
through 15 in HART communica-
tion, the output display brings up
these addresses instead of display
ing “OUT”.
3-3 IM 01C50B01-01E
4. INSTALLATION
4. INSTALLATION
• For details of choosing the installation location, refer

IMPORTANT
to the guidelines outlined in Section 2.4, “Choosing
• When performing on-site pipe fitting work that the installation location”.
involves welding, use care to prevent outflow • The mounting bracket shown in Figure 4.1 is used
of the welding current into the transmitter. for the transmitter and is installed on 50A (2B) pipe.
• Do not use the transmitter as a foothold for It can be installed either on a horizontal pipe and a
installation. vertical pipe or on a wall.
• To install the mounting bracket on the transmitter,
torque the transmitter lock screw (1) to about 20 to
30Nm.
Horizontal Pipe Mounting Vertical Pipe Mounting
• When using a horizontal pipe mounting bracket
U-bolt nut
Horizontal pipe
mounting bracket
Spring washer
Transmitter
fastening bolt
U-bolt
• When using a vertical pipe mounting bracket

Wall Mounting
Bracket
fastening bolt
Vertical pipe Spring washer

mounting Note: Wall mounting bolts are user-
bracket Transmitter
supplied.
fastening bolt
U-bolt nut
Spring washer
Bracket
U-bolt fastening nut
F0401.EPS
Figure 4.1 Mounting the Transmitter

4-1 IM 01C50B01-01E
5. WIRING
5. WIRING
5.1 Notes on Wiring <Hazardous location> <Nonhazardous location>
Input signal
(thermocouple,
Distributor
RTD, mV, etc.) (power supply unit) Receiver
IMPORTANT +
–
• Apply a waterproofing sealant to the
threads of the connection port. (It is recom-
mended that you use non-hardening sealant
Output signal
made of silicon resin for waterproofing.)
F0501.EPS
• Lay wiring as far away as possible from
electrical noise sources such as large trans- Figure 5.1 Loop Construction (for General-use Type and
Flameproof Type)
formers, motors and power supplies.
• Remove the wiring connection dust-caps <Hazardous location> <Nonhazardous location>
before wiring. Input signal
• To prevent electrical noise, the signal cable (thermocouple, Distributor
RTD, mV, etc.) (power supply unit) Receiver
and the power cable must not be housed in
+ Output signal
the same conduit.
–
• The terminal box cover is locked by an Allen
Safety
head bolt (a shrouding bolt) on CENELEC, barrier
SAA and TIIS flameproof type transmitters.
When the shrouding bolt is driven clockwise
F0502.EPS
by an Allen wrench, it is going in and cover
lock is released, and then the cove can be Figure 5.2 Loop Construction (for Intrinsically Safe
Type)
opened by hands. See Subsection 6.3
“Disassembly and Reassembly” for details.
600
External R= E–10.5
0.0236 Communication
load
5.2 Loop Construction resistance applicable range
BRAIN and HART
The YTA is a two-wire temperature transmitter that R 250
uses the output power supply wiring and signal wiring ()
alternately.
The transmission loop requires DC power. Connect the 10.5 16.4 24.7 42
transmitter with the distributor as shown in Figure 5.1 Power supply voltage E (V DC)
or Figure 5.2. F0503.EPS
Figure 5.3 Relation between Power Supply Voltage and

For the transmission loop, the load resistance of the Load Resistance
distributor or other instrument to be installed in the Note: For intrinsic safe explosion-proof type units, the internal
loop and the lead wire must be within the range shown resistance of the safety barrier is also included in the load
in Figure 5.3. resistance.
For details of communication requirements, refer to the

additional reference materials, IM 01C50T03-01E “YTA
Series BRAIN Communication”, and IM 01C50T01-01E
“YTA Series HART Communication”.
5-1 IM 01C50B01-01E
5. WIRING
5.3 Cable Selection

CAUTION
5.3.1 Input signal Cable Selection
When wiring, pay attention not to damage the
A dedicated cable is used for connection between the cable and cores. All the cores of the cable must
temperature sensor and the temperature transmitter. have the sufficient insulation around them.
When a thermocouple is used as the temperature
sensor, a compensation wire must be used that it
appropriate for the type of thermocouple (refer to STEP 1
compensating cables for JIS C 1610/IEC584-3 thermo- (1)
couples). When a resistance temperature sensor (RTD)
is used as the temperature sensor, 2-core/3-core/4-core
cable must be used (refer to resistance thermometer
sensor JIS C 1604/IEC751). The terminal of the
dedicated cable is a 4 mm screw.
5.3.2 Output Signal Cable Selection

• With regard to the type of wire to be used for
wiring, use twisted wires or cables with perfor- a. Cable connection to thermometer resistor(RTD),
3-wire
mance equivalent of 600V vinyl insulated cable
(JIS C3307).
• For wiring in areas susceptible to electrical noise, STEP 2
(2)
use shielded wires.
• For wiring in high or low temperature areas, use
wires or cables suitable for such temperatures.
• For use in an atmosphere where harmful gases or
liquids, oil, or solvents are present, use wires or
cables made of materials resistant to those sub-
stances.
• It is recommended that a self-sealing terminal with
insulation sleeve (4-mm screw) be used for lead
wire ends. b. Power supply cable connection F0504.EPS
Figure 5.4 Terminal Connection Pro cedure
WARNING
If the YTA is TIIS flameproof and the ambient The temperature sensor is to be connected
temperature is 50°C or more, use an external as shown in Figures 5.6 and 5.7.
cable having a maximum allowable heat resis-
tance of at least 70°C in consideration of the
instrument’s generation of heat or the cable’s
self-heating.
5.4 Cable and Terminal Connec-

tions
5.4.1 Input Terminal Connections
F0505.EPS
Figure 5.5 Terminal diagram

NOTE
It is recommended that the terminals be con-

nected in the order of input terminal (1) and
output terminal (2).
5-2 IM 01C50B01-01E
5. WIRING
Sensor1(YTA110, YTA310) 5.4.2 Output Terminal Connection

(A)
1 1
2
(+)
2 (1) Connection of output signal/power supply
3 (–)
3
(B)
cable
4 4 Connect the output signal cable (shared with the
5 5
power supply cable) to the – terminal and the +
Thermocouple and RTD and resistance
DC voltage (2-wire)
terminal. For details, refer to Figure 5.2, “Loop
(A) (A)
construction”.
1 1
(B)
2 2
(A)
(2) Connection of wiring for field indicator
(B) (B)
3 3 Connect the lead wire for the field indicator with
(B)
4 4
5 5 the – terminal and the C terminal.
Note: Use a field indicator with an internal resistance of 10W or less.
RTD and resistance RTD
(3-wire) (4-wire) Field indicator
F0506.EPS
Figure 5.6 YTA110 and YTA310 Input Terminal Wire

Connection Diagram
Power
supply – +
1 input (YTA320) +
(A)
1 1 –
(+)
2 2 F0508.EPS
(B)
3 (–)
3
Figure 5.8 Connection to Field Indicator
4 4
5 5
DC voltage (2-wire) (3) Connection of check meter
1
(A)
1
(A) Connect the check meter with the – terminal and
(B) (A)
2 2 the C terminal.
(B) (B)
3 3 The current signal of output signal 4 to 20 mA DC
(B)
4 4
5 5 is output from the – terminal and the C terminal.
Note: Use a check meter with internal resistance of 10 or less.
RTD and resistance RTD
(3-wire) (4-wire) Check meter
2 input (YTA320)
(A1)
1 (+) 1 (B1) Power
2 2 (B1) supply
3 (–) 3 +
(B2)
4 4 (B2)
5 (+)
5 –
(A2) F0509.EPS
DC voltage (3-wire) Figure 5.9 Check Meter Connection
(A1)
1 (+) 1
(B1)
2 (–) 2
3 (B) 3
(B2)
4 (B) 4
(A2)
5 (A) 5
Thermocouple + RTD and resistance
RTD and resistance (2-wire)
(3-wire)
Figure 5.7 YTA320 Input Terminal Wire Connection

Diagram
5-3 IM 01C50B01-01E
5. WIRING
5.5 Wiring Cautions Table 5.1 Flameproof Packing and Appropriate Cable
Outer Diameters
(1) General-use Type and Intrinsically Safe Wiring Port Appropriate Identifying Part
Type Thread Cable Outer Mark Number
Use metal conduit wiring or a waterproof gland Diameter Diameter (mm)
(metal wiring conduit JIS F 8801) for cable wiring. G1/2
8 -10 16 8-10
G9601AM
• Apply nonhardening sealant to the threads of the 10.1-12 16 10-12
wiring tap and a flexible fitting for secure water- T0501.EPS
proofing. Figure 5.10 shows an example of wiring Follow the procedure below to install the flameproof
on the output side. This example also applies to the packing adapter.
wiring on the input side.
1. Screw the flameproof packing adapter into the
Flexible fitting terminal box until the O-ring touches the terminal
Wiring conduit
box wiring port (at least 6 full turns), and tighten the
lock nut.
2. Insert the cable through the union cover, the union
coupling, the gland the clamp nut, the clamp ring,
one washer, the rubber packing, and the packing
Tee box, in that order.
Apply a nonhardening
sealant to the threads for
3. Insert the end of the cable into the terminal box.
waterproofing. Drain plug 4. Tighten the union cover to grip the cable. When
F0510.EPS tightening the union cover, tighten approximately
Figure 5.10 Example of Wiring Using a Wiring Conduit one turn past the point where the cable will no
longer move up and down. Proper tightening is
important. If it is too tight, a circuit break in the
(2) TIIS Flameproof Type
cable may occur; if not tight enough, the flameproof
Wire cables through a flameproof packing adapter,
effectiveness will be compromised.
or using a flameproof metal conduit.
Wiring cable through flameproof packing
adapter for only TIIS flameproof type (see CAUTION
Figure 5.11)
• Use only flameproof packing adapters approved by Tighten the union cover approximately one turn
Yokogawa. after the point where you can no longer shift the
• Apply a nonhardening sealant to the terminal box cable up and down by hand. Take great care in
connection port and to the threads on the flame- this step, since proper tightening is very important.
proof packing adapter for waterproofing.
Flexible fitting
5. Fasten the cable with tightening the clamp nut.
6. Tighten the lock nut on the union cover.
Wiring conduit
7. Connect the cable wires to each terminal.
Union coupling
Lock nut
Clamp nut
Clamp ring
Grand
Tee Washer
Cable Rubber packing
sealant to the threads for
waterproofing. Drain plug
Packing box
F0510.EPS
Union cover
Lock nut
Figure 5.11 Typical Cable Wiring Using Flameproof Adapter body
Packing Adapter
O-ring
• Measure the cable outer diameter in two directions CAUTION
to within 0.1mm. Be sure to apply non-
hardening sealant to
• Calculate the average of the two diameters, and use the threads for water
packing with an internal diameter nearest to this proofing.
F0512.EPS
value from among the three provided (see
Figure 5.12 Flameproof Gland Packing Adapter
Table5.1). lnstallation
5-4 IM 01C50B01-01E
5. WIRING
Flameproof metal conduit wiring 5.6 Grounding

• A seal fitting must be installed near the terminal
Grounding is always required for the proper operation
box connection port for a sealed construction.
of transmitters. Follow the domestic electrical require-
• Apply a nonhardening sealant to the threads of the
ments as regulated in each country. For a transmitter
terminal box connection port, flexible metal conduit
with built-in lightning protector, grounding should
and seal fitting for waterproofing.
satisfy ground resistance of 10 or less.
Flameproof flexible Non-hazardous Ground terminals are located on the inside and outside
metal conduit area
of the terminal box. Either of these terminals may be
used.
Gas sealing Hazardous

device area
WARNING
Flameproof
heavy-gauge For TIIS flameproof type and intrinsically safe,
steel conduit grounding should satisfy Class D requirements
sealant to the threads of
Tee
(grounding resistance, 100 or less).
these fittings for
waterproofing Drain plug
Seal fitting
After wiring, impregnate the fitting Grounding
with a compound to seal tubing. F0513.EPS terminal
(Inside)
Figure 5.13 Typical Wiring Using Flameproof Metal
Conduit
Grounding
F0511.EPS
terminal
(Outside)
Figure 5.14 Grounding Terminal
5-5 IM 01C50B01-01E
6. MAINTENANCE
6. MAINTENANCE
6.1 General Table 6.1 Calibration Equipment List
Name Recommended Remark

Each component of this instrument is configured in
Power supply SDBT, SDBS 4 to 20mA DC
units to make maintenance easier. type distributor (Output voltage:
26.5±1.5V, drop by
This chapter contains disassembly and assembly internal 250
procedures associated with calibration, adjustment and resistance included)
part replacement required for maintenance of the Load resistance 2792 type standard For 4 to 20mA DC
affected instrument. resistor
(250 ±0.005%)
Voltmeter Model 1271 digital For 4 to 20mA DC
multimeter signal
IMPORTANT (accuracy: ±0.002%)
Universal Model 9100 type For calibration of
1. Maintenance of this instrument should be calibrator DC voltage and
performed in a service shop where the neces- thermocouple
sary tools are provided. Variable resistor 279301 type 6-dial For calibration of
2. Handling the CPU assembly variable resistor thermometer resistor
Some of the parts contained in the CPU (accuracy: ±0.001% (RTD) input
±2m)
assembly are susceptible to static electricity
T0601 EPS
damage. Before performing maintenance, use
a ground wrist band or other antistatic mea
a. Wiring of power supply and output
sures, and avoid touching the electronic + Output signal
components and circuits with bare hands.
When removed from the instrument, keep the – Load
resistance
CPU assembly in an antistatic bag.
Voltmeter
6.2 Calibration b. Example of wiring for thermocouple

or DC voltage input
This instrument is fully factory-tested and is guaran- (when 1 input type is used)
teed for the intended accuracy, eliminating the need for 1
2 (+)
calibration. When calibration needs to be varified, the 3 (–)
following equipment and calibration procedure is 4
5 DC voltage generator
recommended.
c. Example of wiring for thermometer
6.2.1 Selection of Equipment for Calibra- resistor 4-core type
(when 1 input type is used)
tion (A)
1 (A)
Table 6.1 lists the equipment required for calibration. 2 (B)
3 (B)
The calibration equipment traceable to a verifying 4
agency standard should be used. 5 Variable resistor
F0601.EPS
6.2.2 Calibration Procedure Figure 6.1 Example of Wiring for Calibration Equipment
To conduct calibration required to evaluate the uncer-

tainty while using the instrument, follow the steps 2. For DC voltage input
below: With a voltage generator, deliver input signals
corresponding to 0, 25, 75, or 100% of the input
1. In accordance with the example wiring shown in
span to the temperature transmitter. Measure the
Figure 6.1, connect each equipment and initiate
resulting input signal with the voltmeter (digital
warm up. Lay wiring on the input side according to
multimeter) and check the output value relative to
the sensor to be used.
the input value.
6-1 IM 01C50B01-01E
6. MAINTENANCE
3. For thermocouple input Table 6.2 Tools for Disassembly and Assembly
Since this instrument is equipped with a reference Tool name Quantity Remark
junction compensating function, use a reference Phillips screwdriver 1
junction compensating function in universal Standard screwdriver 1
calibrator in order to compensate for this function Hexagonal wrench 1
Crescent wrench 1
upon calibration. According to the reference Torque wrench 1
milivolt table for thermocouple, obtain milivolt Box wrench 1 For M10 screw
corresponding to 0, 25, 50, 75, or 100% of the Box screwdriver 1
Forceps 1
span, and use that power as the input value, then
T0602.EPS
deliver it from the universal calibrator to the
temperature transmitter. Measure the resulting
output signal with the voltage meter (digital CAUTION
multimeter) and check the output value relative to
Precautions for CENELEC, SAA and TIIS
the input value.
Flameproof Type Transmitters
4. Thermometer resistor (RTD)
• For a withstand flameproof type transmitter, as
Using a thermometer resistor as input, calibration of
a rule, move the transmitter to a non-hazardous
the temperature transmitter is carried out via a 4-
location, then proceed with maintenance and
core wire connection.
restore the instrument to the original condition.
As defined the reference resistor value table of the
• For a withstand CENELEC, SAA and TIIS
thermometer resistor (RTD), obtain resistance
flameproof type transmitter, turn the lock bolt
values corresponding to 0, 25, 50, 75 or 100% of
(hexagon socket bolt) clockwise with a wrench
the span, and use the obtained resistance as the
for hexagon head, unlock and remove the
input value, then deliver it to the temperature
cover. When installing the cover, it is the must
transmitter by means of a variable resistor. Measure
to turn the lock bolt counterclockwise and lock
the resulting output signal with the voltmeter
the cover (locked to a torque of 0.7 Nm).
(digital multimeter) and check the output value
• For a withstand flameproof type transmitter, in
relative to the input value.
no case should the user be allowed to modify
5. In Steps 2 through 4, if the output signal deviates
the transmitter. Therefore, no user is allowed to
from the given range of accuracy when a given
add a built-in indicator, or use the transmitter
input signal is delivered, adjust the output using the
with the indicator removed. Contact us for any
handheld terminal. For details of how to adjust the
modification.
output, refer to the additional references, “BRAIN
Protocol” IM 01C50T03-01E or “HART Protocol”
IM 01C50T01-01E and the instruction manual for
each terminal.
Terminal cover
6.3 Disassembly and Assembly

CPU assembly
This section details the procedure for part replacement LCD board
or disassembly and assembly of each component (with indicator)
depending on the maintenance process.
Amp. Cover
Before starting disassembly and assembly work, turn
off the power, and use a tool suited to the associated
work.
Lock bolt
Table 6.2 lists the tools required for disassembly and
Stud bolt
assembly of the instrument.
Mounting screw
F0602.EPS
Figure 6.3 Mounting and Removal of Built-in Indicator

and CPU Assembly
6-2 IM 01C50B01-01E
6. MAINTENANCE
6.3.1 Replacement of Built-in Indicator 6.3.2 Replacement of CPU Assembly
Removal of built-in indicator Removal of CPU assembly

1. Remove the cover. 1. Remove the cover.
2. Loosen two mounting screws while using your hand 2. Use a Phillips screwdriver to loosen the two screws.
to support the built-in indicator. 3. For a CPU assembly with a built-in indicator,
3. Remove the LCD assembly from the CPU assem- remove it as described in Section 6.3.1. Next loosen
bly. At this time, straighten and pull the LCD the two stud bolts.
assembly forward so that the connector connecting 4. Pull the CPU assembly directly toward you.
the CPU assembly and the LCD assembly is not 5. Remove the cable (with a brown connector attached
damaged. at the head).
Mounting the built-in indicator
Integral Indicator can be installed in the following NOTE
three directions.
Use care not to apply excessive force to the
CPU assembly during removal.
Mounting the CPU assembly

1. Connect the cable with the CPU assembly.
2. Align the pin on the base board with the connector
(black) of the CPU assembly, and insert the CPU
assembly straight into the board.
IMPORTANT
Use care not to pinch the cable under the cover,

and fully insert the cable into the case.
3. Loosen the two screws. If the unit includes a built-

in indicator, install it as described in Section 6.3.1.
4. Mount the cover.
F0603.EPS
Figure 6.4 Installation Direction of Indicator
1. Place the LCD assembly in desired direction over

the CPU assembly.
2. Align the mounting hole of the LCD assembly with
the stud bolt hole, and carefully insert the indicator
into the connector in a straight manner so that the
connector is not damaged.
3. Tighten the two mounting screws that secure the
indicator.
4. Install the cover.
6-3 IM 01C50B01-01E
6. MAINTENANCE
6.4 Troubleshooting 6.4.2 Example of Troubleshooting Flow

When the measured value is found abnormal, follow
the troubleshooting flowchart below. If the complex The following phenomena indicate that this
instrument may be out of operation.
nature of the trouble means that the cause cannot be [Example]
identified using the following flowchart, refer the • No output signal is delivered.
matter to our service personnel. • Process variable changes but the output
signal remains unchanged.
• The assessed value of the process variable
6.4.1 Basic Troubleshooting Flow and the output are not coincident.
When the process measurement is found to be abnor-

mal, it is necessary to determine whether the input • If a built-in indicator is attached, check the
display of the error code.
temperature is out of range, the sensor has failed or
• Connect a hand-held terminal and check
being damaged, or the unit has been improperly wired. self-diagnosis.
If it is suspected that the measurement system is the
source of the problem, use the flowchart to identify the
affected area and determine how to proceed. Was a faulty YES
area found with self-
In these troubleshooting steps, the self diagnostic diagnosis?
function provides helpful solutions to the problem,
refer to the instructions in Section 6.5 for details. NO Refer to the error message list and
check for recovery measures.
: Part supported
by self-diagnosis
Is the polarity NO
of the power supply
Measured value correct?
is found faulty
YES Check the polarity between the
power supply and terminal box and
YES correct it.
Error in process
variable?
Error in measurement
Inspect the process NO system Are the power
NO
Faulty supply voltage and load
area in measurement resistance correct?
system
YES Refer to Section 5.2 and set

the specified voltage and load
YES resistance.
Receiver error
Inspect receiver NO Is the sensor NO

correctly connected?
Environmental condition Transmitter

YES Check the sensor connection and
correct it.
Environmental condition: Check the transmitter
check, study, correction
Operating requirements
Is there a
disconnection in the loop? NO
Operating requirements: Do the loop numbers
check, study, correction correspond to the
counterpart?
F0604.EPS
Check for disconnection or faulty
wiring and take corrective
Figure 6.5 Basic Flow and Self-diagnosis YES measures.
Refer to our service personnel for details.

F0605.EPS
Figure 6.6 Example of Troubleshooting Flow
6-4 IM 01C50B01-01E
6. MAINTENANCE
Table 6.3 Problems, Causes and Countermeasures

Related Parameter
Observed Problems Possible Cause Countermeasure
(BRAIN protocol) (HART protocol)
Output fluctuates Span is too narrow. Check the range, and change the F10:LRV PV LRV (4)
greatly. settings to make the span larger. F20:URV PV URV (5)
Input adjustment by user was Clear the user adjustment (Sensor J05:SNSR1 CLR Snsr1 Trim Act (123312)
not corrctly done. trim) value or set it to off. K05:SNSR2 CLR Snsr2 Trim Act (123322)
Output adjustment by user Clear the user adjustment (output L05:OUT CLR D/A Clr to Default
was not correctly done. trim) value or set it to off. (12343)
Transmitter outputs The transmitter is in manual Release manual mode. (Make the G10:OUTPUT MODE Loop test (122)
fixed current. (test output) mode. transmitter return to Automatic
Mode)
Input adjustment by user was Clear the user adjustment (Sensor J05:SNSR1 CLR Snsr1 Trim Act (123312)
not corrctly done. trim) value or set it to off. K05:SNSR2 CLR Snsr2 Trim Act (123322)
Output adjustment by user Clear the user adjustment (output L05:OUT CLR D/A Clr to Default
was not correctly done. trim) value or set it to off. (12343)
Output is reversed. LRV is greater than URV. Set the correct value to URV and F10:LRV PV LRV (4)
(See note 1) LRV. F20:URV PV URV (5)
The transmitter is set to Set the transmitter to normal H10:REVERSE OUT

reversed output mode. output mode.
Parameters cannot The transmitter is in write Release write protect. H40:WRITE PROTCT Chng wrt Protect
be changed. protect status. (Hot key)
Sensor backup Settings of Process Variables Set Sensor1 as PV and Sensor2 B10:PV is PV is (11211)
function doesn’t work are not correct. as SV. B20:SV is SV is (11212)
correctly. Configuration of Sensor1 and • Check the type and wire D10:SENSOR1 TYPE Snsr1 config (134)
Sensor2 is not correct. settings for Sensor1 and E10:SENSOR2 TYPE Snsr2 config (135)
Sensor2.
• Check the connection of
Sensor1 and Sensor2.
Sensor Burnout is set to “off.” Check the Sensor Burnout setting. F40:BURN OUT Sensor barnout (14315)
Sensor backup mode is not Change the Sensor Backup H20:SNSR BACKUP Snsr backup (14141)
enabled. function to “enable.”
Output damping Damping time constant is set Set correct value. B12:PV DAMPING PV damp (1322)
doesn’t work. to “0 second.”
Setting for “PV damping point” If output fluctuation is great, set a B13:DMP POINT PV damp point (1323)
is too small. greater value for PV damping
point than current setting. (Initial
setting is “2%” of output)
T0603.EPS
Note 1: If the reversed output is desired and necessary setting was done by user, it is not considered as a problem.
6-5 IM 01C50B01-01E
6. MAINTENANCE
6.5 Integral Indicator and Error

Display
For temperature transmitters equipped with an integral
indicator, errors in the temperature sensor or the
transmitter cause an integral indicator to call up the
applicable error code. Table 6.4 lists the error codes
and the associated corrective actions.
Table 6.4 List of Error Codes
Indicator BT200 display Cause Output operation upon error Action

N/A Good
Er-01 Output Too Low Input value is lower than the Output goes to minimum Check the LRV setting and
PV low range value. value(–2.0%). adjust.
Er-02 Output Too High Input value is higher than the Output goes to maximum Check the URV setting and
PV upper range value. value(105%). adjust.
Er-03 Sensor1 Failure Sensor1 fails or disconnects If sensor1 is set as PV, the • Check sensor for damage.
from the terminal block. burnout value is output. • Check terminal connection.
When sensor backup mode • If sensor backup mode is set,
is set in YTA320, sensor2 refer to “Er-09”.
input is used as output.
Er-04 Sensor2 Failure Sensor2 fails or disconnects If sensor2 is set as PV, or • Check sensor for damage.
(YTA320 only) from the terminal block. sensor backup mode is in • Check terminal connection.
effect, sensor burnout value • If sensor backup mode is set,
is output. repair wiring or replace
damaged sensors.
Er-05 S1 Signal Error Sensor1 input value greatly Output goes to minimum • Check sensor connections.
exceeds the sensor value(–2.0%) or maximum • Check the sensor type
measurement range. Sensor value(105%). selected.
type setting or connection
polarity may be incorrect.
(YTA320 only) exceeds sensor value(–2.0%) or maximum • Check sensor type selected.
measurement range. Sensor value(105%).
Er-07 Amb Temp Low The ambient temperature Continues to operate and Use a heater to raise the
exceeds the lower ambient output. ambient temperature, or reset to
temp limit and the specified a higher level.
accuracy cannot be
achieved.
Er-08 Amb Temp High The ambient temperature Continues to operate and Take enough distance from the
exceeds the upper ambient output. source of heat, or reset to a
temp limit and the specified lower level.
accuracy cannot be
achieved.
Er-09 Sns Backup Start Sensor backup mode is in Sensor2 input is used as Restore the status of sensor1 to
(YTA320 only) effect. output. If sensor2 also fails, normal and Enable sensor1
the transmitter operate with return parameters, or turn the
burnout settings. power ON again.
Er-10 Illegal PV MAP There is a problem with the Output status immediately Check the setting for PV
PV mapping settings. before error is retained mapping and correct the setting.
(HOLD).
Er-11 Term Sns Failure Terminal block temperature Operation and output Contact our service personnel.
sensor failed. continues.
Er-12 EEPROM Failure EEPROM failed. The output goes to the Contact our service personnel.
value set by the hardware
failure mode jumper.
Er-13 CPU Failure Output side hardware failure. The output goes to the Contact our service personnel.
Er-14 AD Conv Failure Input circuit hardware failure. The output goes to the Contact our service personnel.
Er-15 Reverse Cal Fail Confirmation Calculation The output goes to the Contact our service personnel.
result is bad. value set by the hardware
T0604.EPS
6-6 IM 01C50B01-01E
7.1 Standard Specifications Spacing to power line;

Output signal line; 15 cm or longer (avoid
For the specifications of Fieldbus communication type parallel wiring)
marked with (), refer to IM 01C50T02-01E. Input signal line; 100 cm or longer (avoid
parallel wiring)
Input signal: Input impedance of receiver connected to
Input points: YTA110; 1, YTA310; 1, receiver resistance; 10 k or higher (at 2.4 kHz)
YTA320; 2
Thermocouple: J, K, E, T, R, S, B, N Accuracy():
(T/C) (JIS/IEC584), L, U YTA110;
(DIN43710), W3, W5 A/C conversion accuracy + D/A conversion
(ASTM988) accuracy (Refer to Table 7.1) or ±0.1%,
Thermometer resistor: Pt100, Pt200, Pt500 whichever is greater. For thermocouple input,
(RTD) (IEC751), JPt100(JIS), above plus reference junction compensation
Cu, Ni120 accuracy.
2/3/4-wire YTA310, YTA320;
DC voltage: mV A/C conversion accuracy + D/A conversion
Resistance: Resistor 2/3-wire accuracy (Refer to Table 7.1) For thermocouple
input, above plus reference junction compensa-
Input signal source resistance: tion accuracy.
1k or lower (at thermocouple, DC voltage
input) Reference junction compensation accuracy:
±0.5°C (±0.9°F)
Input lead wire resistance:
10/1-core or less (with thermometer resistor, Ambient temperature:
resistance input) –40 to 85°C (–40 to 185°F) . . . general type
–30 to 80°C (–1 to 176°F) . . . . with Integral
Output(): indicator
Two wire 4 to 20 mA DC
Output range: 3.68 mA to 20.8 mA Ambient temperature effect per 10°C change() :
YTA110;
Measuring range: ± 0.1% or ± (Temperature Coefficient/span),
Refer to Table 7.1. whichever is greater (refer to Table 7.2)
Power supply voltage(): YTA310, YTA320;
For general use type; A/D conversion temperature factor + D/A
10.5 to 42 VDC conversion temperature factor (refer to Table
With lightning protection (Optional code A); 7.3)
10.5 to 32 VDC Stability
For intrinsically safe, Type n, non-incendive or RTD:
non-sparking type; !0.1% of reading or !0.1°C per 2 years,
10.5 to 30 VDC whichever is greater at 23!2°C.
Communication line conditions(): T/C:
Power supply voltage; 16.4 to 42 VDC !0.1% of reading or !0.1°C per year,
Load resistance; 250 to 600 (including cable whichever is greater at 23!2°C.
resistance) 5 Year Stability
For relation between power supply voltage and RTD:
load resistance, refer to Figure 5.3. !0.2% of reading or !0.2°C,
Maximum line length; 2 km when CEV cable is whichever is greater at 23!2°C.
used. T/C:
Load resistance; 0.22 µF or less !0.4% of reading or !0.4°C,
Load inductance; 3.3 mH or less whichever is greater at 23!2°C.
7-1 IM 01C50B01-01E
Ambient humidity:
5 to 100%RH at 40°C (104°F)
Effect of supply voltage fluctuation:
±0.005%/V
Insulation:
Input/output insulated at 500 V DC
Mounting:
Mounted on 2B pipes and wall
Degrees of Protection:
IP67, NEMA 4X, JIS C0920 immersion proof
Electrical connection:
Refer to “Model and Specification Codes”.
Case and cover:
Aluminum alloy casting
Painting:
Polyurethane resin baked finish
Deep sea moss green (equivalent of Munsell
0.6GY3.1/2.0)
Integral indicator (option):
LCD digital indicator (5-digit display)
Output bar graph; 0 to 100% display
Damping constant:
0 to 99 seconds (integer range that can be set)
Sensor burnout (Output Signal Code D&E) :
High (110%, 21.6 mA DC) or Low (–2.5%, 3.6
mA DC)
Weight:
1.2 kg; without built-in indicator (without mount-
ing bracket)
1.4 kg; with Integral indicator (without mounting
bracket)
EMC compliant standard: ,
EN61326, AS/NZS CISPR11
7-2 IM 01C50B01-01E
Table 7.1 Input Type, Measurement Range and Accuracy

Accuracy
Reference Measurement Range Minimum Span
Sensor Type Input range A/D Accuracy D/A
Standard (Recommended)
C F C F C F Accuracy
100 to 300 212 to 572 ± 3.0 ± 5.4
B 100 to 1820 212 to 3308 300 to 400 572 to 752 ± 1.0 ± 1.8
400 to 1820 752 to 3308 ± 0.75 ± 1.35
-200 to -50 -328 to -58 ± 0.35 ± 0.63
E -200 to 1000 -328 to 1832
-50 to 1000 -58 to 1832 ± 0.16 ± 0.29
-200 to -50 -328 to -58 ± 0.40 ± 0.72
J -200 to 1200 -328 to 2192
-50 to 1200 -58 to 2192 ± 0.20 ± 0.36
-200 to -50 -328 to -58 ± 0.50 ± 0.90
K -200 to 1372 -328 to 2502
-50 to 1372 -58 to 2502 ± 0.25 ± 0.45
IEC584 -200 to -50 -328 to -58 ± 0.80 ± 1.44
N -200 to 1300 -328 to 2372
-50 to 1300 -58 to 2372 ± 0.35 ± 0.63
-50 to 0 -58 to 32 ± 1.0 ± 1.8
0 to 100 32 to 212 ± 0.80 ± 1.44
R -50 to 1768 -58 to 3214
100 to 600 212 to 1112 ± 0.60 ± 1.08
600 to 1768 1112 to 3214 ± 0.40 ± 0.72
25 C
T/C -50 to 0 -58 to 32 ± 1.0 ± 1.8
(45 F)
0 to 100 32 to 212 ± 0.80 ± 1.44
S -50 to 1768 -58 to 3214
100 to 600 212 to 1112 ± 0.60 ± 1.08
600 to 1768 1112 to 3214 ± 0.40 ± 0.72
-200 to -50 -328 to -58 ± 0.25 ± 0.45 ± 0.02%
T -200 to 400 -328 to 752
-50 to 400 -58 to 752 ± 0.14 ± 0.25 of span
0 to 400 32 to 752 ± 0.80 ± 1.44
400 to 1400 752 to 2552 ± 0.50 ± 0.90
W3 0 to 2300 32 to 4172
1400 to 2000 2552 to 3632 ± 0.60 ± 1.08
ASTM 2000 to 2300 3632 to 4172 ± 0.90 ± 1.62
E988 0 to 400 32 to 752 ± 0.70 ± 1.26
400 to 1400 752 to 2552 ± 0.50 ± 0.90
W5 0 to 2300 32 to 4172
1400 to 2000 2552 to 3632 ± 0.70 ± 1.26
2000 to 2300 3632 to 4172 ± 0.90 ± 1.62
-200 to -50 -328 to -58 ± 0.30 ± 0.54
L -200 to 900 -328 to 1652
-50 to 900 -58 to 1652 ± 0.20 ± 0.36
DIN43710
-200 to -50 -328 to -58 ± 0.50 ± 0.90
U -200 to 600 -328 to 1112
-50 to 600 -58 to 1112 ± 0.25 ± 0.45
Pt100 -200 to 850 -328 to 1562 -200 to 850 -328 to 1562 ± 0.14 ± 0.25
Pt200 IEC751 -200 to 850 -328 to 1562 -200 to 850 -328 to 1562 ± 0.30 ± 0.54
Pt500 -200 to 850 -328 to 1562 10 C -200 to 850 -328 to 1562 ± 0.20 ± 0.36
RTD
JPt100 JIS C1604 -200 to 500 -328 to 932 (18 F) -200 to 500 -328 to 932 ± 0.16 ± 0.29
SAMA -70 to -40 -94 to -40 ± 1.35 ± 2.43
Cu RC21-4 -70 to 150 -94 to 302
-40 to 150 -40 to 302 ± 1.0 ± 1.8
Ni120 -70 to 320 -94 to 608 -70 to 320 -94 to 608 ± 0.11 ± 0.19
mV -10 to 100 [mV] 3 [mV] ± 12 [µ V]
ohm 0 to 2000 [Ω] 20 [Ω] ± 0.35 [Ω]
T0701.EPS
Table 7.2 YTA110 Effect of Ambient Temperature

Sensor Type Temperature Coefficient Note1: Ambient Temperature Effect per 10°C change is !0.1% or
Thermocouples E, J, K, N, T, L, U 0.08C + 0.02% of abs.reading !(temperature coefficient/span), whichever is greater.
Thermocouples R, S, W3, W5
Note2: The “abs.reading” on Table7.2 means the absolute value of
0.25C + 0.02% of abs.reading
the reading in °C.
100C " Reading < 300C 1C + 0.02% of abs.reading
T/C B Example of abs reading;
300C " Reading 0.5C + 0.02% of abs.reading When the temperature value is 250 Kelvin, abs reading is
RTD 0.08C + 0.02% of abs.reading 23.15, absolute (250273.15).
mV 0.002 mV + 0.02% of abs.reading Example of Ambient Temperature Effect;
ohm 0.1 + 0.02% of abs.reading Conditions;
1) Input Sensor:Pt100 2) Calibration Range:100 to 100°C
T07021.EPS
3) Reading value: 50°C
Ambient Temperature Effect per 10°C;
Temperature Coefficient/Span
=(0.08°C#0.02/100$|50°C|)/{100°C(100°C)}= 0.00045
→ 0.045%
Therefore, Ambient Temperature Effect is !0.1%/10°C
7-3 IM 01C50B01-01E
Table 7.3 YTA310, YTA320 Effect of Ambient Temperature

Input Range
Sensor Type A/D Coefficient D/A Coeffieicient
C F
100 to 300 212 to 572 ± (0.530 C0.080 % of reading)
B 300 to 1000 572 to 1832 ± (0.350 C0.021 % of reading )
1000 to 1820 1832 to 3308 ± (0.140 C)
E -200 to 1000 -328 to 1832 ± (0.035 C#0.042 % of abs.reading)
-200 to 0 -328 to 32 ± (0.039 C#0.020 % of abs.reading)
J
0 to 1200 32 to 2192 ± (0.039 C#0.0029 % of reading)
K
0 to 1372 32 to 2502 ± (0.046 C#0.0054 % of reading)
N
0 to 1300 32 to 2372 ± (0.054 C#0.0036 % of reading)
-50 to 200 -58 to 392 ± (0.210 C0.032 % of abs.reading)
R
200 to 1768 392 to 3214 ± (0.150 C)
T/C
-50 to 200 -58 to 392 ± (0.210 C0.032 % of abs.reading)
S
200 to 1768 392 to 3214 ± (0.150 C)
-200 to 0 -328 to 32 ± (0.046 C0.036 % of abs.reading) ± {0.0088% of span#0.007% of (readingLRV)}
T
0 to 400 32 to 752 ± (0.046 C)
0 to 1400 32 to 2552 ± (0.100 C#0.0040 % of reading)
W3
1400 to 2300 2552 to 4172 ± ( -0.130C#0.020 % of reading)
0 to 1400 32 to 2552 ± (0.100 C#0.0040 % of reading)
W5
1400 to 2300 2552 to 4172 ± ( -0.120C#0.020 % of reading)
L
0 to 900 32 to 1652 ± (0.039 C#0.0029 % of reading)
U
0 to 600 32 to 1112 ± (0.046 C)
Pt100 -200 to 850 -328 to 1562 ± ( 0.047 C#0.009 % of reading)
RTD
JPt100 -200 to 500 -328 to 932 ± ( 0.047 C#0.009 % of reading)
Cu -70 to 150 -94 to 302 ± ( 0.320 C#0.120 % of reading)
Ni120 -70 to 320 -94 to 608 ± ( 0.016 C#0.007 % of reading)
mV ± (0.001mV#0.0043 % of abs.reading)
ohm ± (0.040 #0.0088 % of reading)
T07022.EPS
Note: Temperature Effect = A/D coeffieicnt + D/A coefficient (The data in the table is the coeffcient per 10C change.)
Example 1; Pt100, 0 to 200C calibration range, 50C reading
(0.047C # 50C $ 0.009%) # [200C $ 0.0088% # (50 0) $ 0.007%]
= (0.047C # 0.0045C) # (0.0176C # 0.0035C )
= ± 0.0726C [ per 10C change ]
Example 2; T T/C, 100 to 100C calibration range, 250C reading
(0.046C # | 250C | $ 0.036%) # {200C $ 0.0088% # [250 (100)] $ 0.007%}
= (0.046C # 0.018C) # (0.0176C # 0.0035C )
= ± 0.0851C [ per 10C change ]
Terminals
Terminal Configuration
Power Supply and output terminal
Communication
External Indicator (ammeter) terminal *2
Terminals (BT200 etc.)
Connection hook
Ground terminal
*2: When using an external indicator or check meter,

CHECK METER
the internal resistance must be 10Ω or less.
Connection hook *2
The hook is not available for Fieldbus communi-
M10$1.5 12-deep female cation type(output signal code F).
for mounting bracket
F0702.EPS
7-4 IM 01C50B01-01E
Factory setting ()

Tag No. Left blank if not specified in order
Input sensor type “Pt100, 3-wire” if not specified in order
Lower bound of calibration range “0” if not specified in order
Upper bound of calibration range “100” if not specified in order
Unit of calibration range “°C” if not specified in order
Damping constant 2 seconds
Sensor burnout High side (110%, 21.6 mA DC) *1
Output when transmitter fails High side (110%, 21.6 mA DC) *2
T0705.EPS
*1: When option code C1 is specified, Low takes effect (–2.5%, 3.6mADC).
*2: When option code C1 is specified, Low takes effect (–5%, 3.2mADC or less).
7.2 Model and Suffix Codes

Model Basic Specification Codes Description
YTA110 . . . . . . . . . . . . . . . . . . . . . . Temperature transmitter (1 input type)
YTA310 . . . . . . . . . . . . . . . . . . . . . . High precision temperature transmitter (1 input type)
YTA320 . . . . . . . . . . . . . . . . . . . . . . High precision temperature transmitter (2 input type)
Output –D . . . . . . . . . . . . . . . . . . . . 4 to 20mA DC output, BRAIN communication type
signal –E . . . . . . . . . . . . . . . . . . . . 4 to 20mA DC output, HART communication type
–F . . . . . . . . . . . . . . . . . . . . FOUNDATION Fieldbus communication type *1
— A................. Always A
Electrical 0............... G1/2 female
connection 2............... 1/2 NPT female
3............... Pg13.5 female
4............... M20 female
Built-in indicator D............ Digital indicator
N............ None
Mounting bracket B . . . . . . . . . SUS304 Stainless steel 2-inch horizontal pipe mounting *2
D . . . . . . . . . SUS304 Stainless steel 2-inch vertical pipe mounting *2
N . . . . . . . . . None
Additional specifications / Additional specifications
T0703.EPS
*1: Applicable for YTA320 only.
*2: Use bolts for wall mounting.
7.3 Optional Specifications

YTA110
YTA310
YTA320
Power supply voltage: 10.5 to 32 V DC

Lightning protector Allowable current: Max. 6000A(1$40s), A
repeating 1000A(1$40s) 100 times
Coating change Epoxy resin coating X1
Munsell renotation code: NI1.5 Black P1
Painting
Color change Amplifier cover only Munsell renotation code: 7.5BG4/1.5, Jade green P2
Metallic silver P7
Amplifier and Terminal covers Munsell renotation code: 7.5R4/14 Red PR
Stainless Steel Housing*1 Housing Material: SCS14A Stainless steel E1
Calibration Unit Addition of Degree F and Degree R unit D2
Output signal low-side in Output signal low-side: –5 %, 3.2 mA DC or less. C1
Transmitter failure*2 Sensor burnout is also set to ‘Low’: –2.5 %, 3.6 mA DC
Failure alarm down-scale: output status at CPU
failure and hardware error is –5%, 3.2 mA or less. C2
NAMUR NE43 Output signal limits: Sensor burnout is also set to ‘Low’: –2.5%, 3.6 mA
compliant*2 3.8 mA to 20.5 mA
Failure alarm up-scale: output status at CPU failure
and hardware error is 110%, 21.6 mA or more. C3
Sensor burnout is also set to ‘High’: 110%, 21.6 mA
Data Configuration*2 Description into “Descriptor” parameter of HART protocol. CA
(max. 16 characters)
Sensor matching function*2 RTD Sensor matching function CM1 $
T0704.EPS
*1 : Not applicable with other option codes, except for A, C1, D2 and CM1.
*2 : Not applicable for output signal code F.
7-5 IM 01C50B01-01E
[For Explosion Protected Types]

For FOUNDATION Fieldbus explosion protected type, see IM 01C50T02-01E.
CENELEC ATEX (KEMA) Intrinsically safe, Flameproof approval and Type n combination
[Intrinsically safe approval]
Applicable standard: EN 50014, EN 50020, EN 50284 Certificate: KEMA 02ATEX1026X
II 1G EEx ia IIC T4,T5 Ambient Temerature: -40 to 70°C for T4, -40 to 50°C for T5
Supply/Output circuit: Ui=30V, Ii=165mA, Pi=900mW, Ci=20nF, Li=660H
[Flameproof and Dust Ignition Proof Approval]
Applicable Standard: EN 60079-0, IEC 60079-1, EN 61241-0, EN 61241-1 KU2
CENELEC ATEX
II 2G Ex d IIC T6/T5, II 2D Ex tD A21 IP67 T70°C, T90°C
(KEMA)
Ambient Temperature for Gas Atmospheres: -40 to 75°C for T6, -40 to 80°C for T5
Ambient Temperature for Dust Atmospheres: -40 to 65°C for T70°C, -40 to 80°C for T90°C
Enclosure: IP67
[Type n approval]
Applicable standard: EN60079-15 Referential standard: IEC60079-0, IEC60079-11
II 3G EEx nL llC T4, T5 Ambient Temperature: -40 to 70C for T4, -40 to 50C for T5
Supply/Output circuit: Ui=30V, Ci=20nF, Li=660H
CSA Intrinsically safe, non-incendive and Explosionproof approval combination*3
C22.2 No157, C22.2 No213 Certificate: 172608-0001053837
Intrinsically safe for Class I, Division 1, Groups A, B, C and D; Class II, Division 1, Groups
E, F and G; Class III, Division 1:
Non-incendive for Class I, Division 2, Groups A, B, C and D; Class II, Division 2, Groups E,
F and G; Class III, Division 1:
Enclosure Type 4X Temperature Class: T4, Ambient Temperature: -40 to 60C,
Canadian Standards
Supply: Vmax=30V, Imax=165mA, Pmax=0.9W, Ci=18nF, Li=730H CU1
Association (CSA)
Sensor input: Voc=9V, Isc=40mA, Po=0.09W, Ca=1F, La=10mH
C22.2 No142, C22.2 No157, C22.2 No213, C22.2 No1010.1 Certificate: 1089576
Explosionproof Class I, Div.1, Groups B, C and D, Class II, Groups E, F and G, Class III. For
Class I, Div.2 Locations “FACTORY SEALED, CONDUIT SEAL NOT REQUIRED”
Enclosure Type 4X Temperature Class: T4 Ambient Temperature: -40 to 60C
FM Explosionproof approval
Explosionproof Class I, Division 1, Groups A, B, C and D;
Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G. FF1
“FACTORY SEALED, CONDUIT SEAL NOT REQUIRED.” Enclosure Rating: NEMA 4X
FM Intrinsically safe, non-incendive and Explosionproof approval combination*3
Applicable standard: FM 3600, FM 3610, FM 3611, FM 3810
Intrinsically safe for Class I, II, III Division 1 Groups A, B, C, D, E, F and G.
Factory Mutual (FM)
Non-incendive for Class I, II, Division 2 Groups A, B, C, D, E, F and G Class III, Division 1.
Enclosure Type: 4X Temperature Class: T4 Ambient Temperature: -40 to 60C (-40 to 140F)
Supply: Vmax=30V, Imax=165mA, Pmax=0.9W, Ci=18nF, Li=730H
Sensor: Voc=9V, Isc=40mA, Po=90Mw, Ca=1F, La=10mH FU1
Class I, Division 1, Groups A, B, C and D.;
Dust-ignitionproof for Class II/III, Division 1, Groups E, F and G.
"FACTORY SEALD, CONDUIT SEAL NOT REQUIRED." Enclosure Ratings: NEMA4X
Electrical Connection: 1/2NPT female*2
T0706-1.EPS
*1 : Applicable for Electrical Connection Code 2 and 4.
*2 : Applicable for Electrical Connection Code 2.
*3 : Not applicable for Output Signal Code F.
7-6 IM 01C50B01-01E

SAA Intrinsically safe, non-sparking and Flameproof approval combination
[Intrinsically safe and non-sparking]
Applicable standard: AS2380.1, AS2380.7, AS2380.9 Certificate: AUS Ex 3652X
Ex ia IIC T4 (Tamb=70C) IP66/67, Ex n IIC T4 (Tamb=70C), IP66/67
Standards
Input parameters: Ui=30V, Ii=165mA, Pi=0.9W
Association of SU1
Output parameters: Uo=8.6V, Io=30mA, Po=62mW, Co=1F
Australia (SAA)
[Flameproof approval]
Applicable standard: AS2380.1, AS2380.2 Certificate: AUS Ex 3640
Ex d IIC T6 (Tamb=75C) IP66/67
Electrical connection: 1/2 NPT female, Pg13.5 female and M20 female*5
Japanese Industrial TIIS Flameproof approval
JF3
Standards (TIIS) Ex ds IIC T6 X Amb. Temp.: -20 to 60C
Attached flameproof Electrical connection: G1/2 female 1 pc. G11
packing adapter*4 Applicable cable: O.D. 8.5 to 11 mm 2 pc. G12
ECEx Flameproof and Dust ignition proof Approval
Applicable Standard: IEC 60079-0, IEC 60079-1, IEC 61241-0, OEC 61241-1
Ex d IIC T6/T5, Ex tD A21 IP67 T70°C, T90°C
IECEx Scheme*6 Ambient Temperature for Gas Atmospheres: -40 to 75°C (-40 to 167°F) for T6, SF2
-40 to 80°C (-40 to 176°F) for T5
Ambient Temperature for Dust Atmospheres: -40 to 65°C (-40 to 149°F) for T70°C,
-40 to 80°C (-40 to 176°F) for T90°C
Enclosure: IP67
Electrical Connection: 1/2 NPT female and M20 female
T0706-2.EPS
*4 : If cable wiring is to be used to a TIIS flameproof type transmitter, do not fail to add the YOKOGAWA-assured flameproof packing adapter.
*5 : Applicable for Electrical connection code 2, 3 and 4.
*6 : Applicable only for Australia, New Zealand area.
7-7 IM 01C50B01-01E
7.4 Dimensions
Unit: mm (Approx. inch)
2-inch horizontal pipe mounting
65.4(2.57)
111(4.37) 46(1.81) 65(2.56)

Electrical Connection 18.5
(0.73)
(Output signal) With Indicator
(Optional)
ø93
102 (3.66)
(4.02)
164
(6.46)
Shrouding Bolt Ground Terminal

40
(For Explosionproof type) (1.57) 25
(0.98) Tag Plate
Horizontal Pipe Mounting Bracket

(Optional)
56(2.21)
2-inch pipe, ø60.5(ø2.38)
70(2.76)
90(3.54)
2-inch vertical pipe mounting 65.4(2.57)
46(1.81) 65(2.56)
111(4.37) Electrical Connection 18.5
(0.73)
(Output signal)
With Indicator
(Optional)
ø93
Shrouding Bolt (3.66)
(For Explosionproof type)
209.5
(8.25)
191.5 Ground Terminal
(7.54)
Tag Plate
Vertical Pipe Mounting Bracket
(Optional)
46(1.81)
2-inch pipe, ø60.5(ø2.38) 64(2.52)

101(3.98)
98(3.86)
F0701.EPS
7-8 IM 01C50B01-01E
INSTALLATION AND OPERATING PRECAUTIONS FOR TIIS FLAMEPROOF EQUIPMENT
INSTALLATION AND OPERATING PRECAUTIONS FOR

TIIS FLAMEPROOF EQUIPMENT
Apparatus Certified Under Technical Criteria

(IEC-compatible Standards)
1. General construction is of completely enclosed type and its enclosure

shall endure explosive pressures in cases where explosive
The following describes precautions on electrical apparatus gases or vapours entering the enclosure cause explosion. In
of flameproof construction (hereinafter referred to as addition, the enclosure construction shall be such that flame
flameproof apparatus) in explosion-protected apparatus. caused by explosion does not ignite gases or vapours outside
Following the Labour Safety and Health Laws of Japan, the enclosure.
flameproof apparatus is subjected to type tests to meet either In this manual, the word "flameproof" is applied to the
the technical criteria for explosionproof electrical machinery flameproof equipment combined with the types of protection
and equipment (standards notification no. 556 from the "e", "o", "i", and "d" as well as flameproof equipment.
Japanese Ministry of Labour) (hereinafter referred to as
technical criteria), in conformity with the IEC Standards, or
the “Recommended Practice for Explosion-Protected 3. Terminology
Electrical Installations in General Industries,” published in
1979. These certified apparatus can be used in hazardous (1) Enclosure
locations where explosive or inflammable gases or vapours An outer shell of an electrical apparatus, which encloses live
may be present. parts and thus is needed to configure explosion-protected
construction.
Certified apparatus includes a certification label and an
equipment nameplate with the specifications necessary for (2) Shroud
explosion requirements as well as precautions on explosion
A component part which is so designed that the fastening of
protection. Please confirm these precautionary items and use
joint surfaces cannot be loosened unless a special tool is
them to meet specification requirements.
used.
For electrical wiring and maintenance servicing, please refer
to “Internal Wiring Rules” in the Electrical Installation (3) Enclosure internal volume
Technical Standards as well as “USER’S GUIDELINES for This is indicated by:— the total internal volume of the
Electrical Installations for Explosive Gas Atmospheres in flameproof enclosure minus the volume of the internal
General Industry,” published in 1994. components essential to equipment functions.
To meet flameproof requirements, equipment that can be (4) Path length of joint surface
termed “flameproof” must: On a joint surface, the length of the shortest path through
(1) Be certified by a Japanese public authority in accordance which flame flows from the inside to outside of the
with the Labour Safety and Health Laws of Japan and flameproof enclosure. This definition cannot be applied to
have a certification label in an appropriate location on its threaded joints.
case, and
(5) Gaps between joint surfaces
(2) Be used in compliance with the specifications marked on
its certification label, equipment nameplate and The physical distance between two mating surfaces, or
precautionary information furnished. differences in diameters if the mating surfaces are cylindrical.
2. Electrical Apparatus of Flame- Note: The permissible sizes of gaps between joint surfaces, the path
length of a joint surface and the number of joint threads are
proof Type of Explosion-Pro- determined by such factors as the enclosure’s internal
tected Construction volume, joint and mating surface construction, and the
explosion classification of the specified gases and vapours.
Electrical apparatus which is of flameproof construction is
subjected to a type test and certified by the Japanese Ministry
of Labour aiming at preventing explosion caused by electrical
apparatus in a factory or any location where inflammable
gases or vapours may be present. The flameproof
1 EX-B03E
4. Installation of Flameproof Ap- • Specific cables shall be used as recommended by the

paratus “USER’S GUIDELINES for Electrical Installations for
Explosive Gas Atmospheres in General Industry,”
(1) Installation Area published in 1994.
Flameproof apparatus may be installed, in accordance with • In necessary, appropriate protective pipes (conduit or
applicable gases, in a hazardous area in Zone 1 or 2, where flexible pipes), ducts or trays shall be used for
the specified gases are present. Those apparatus shall not be preventing the cable run (outside the cable glands) from
installed in a hazardous area in Zone 0. damage.
• To prevent explosive atmosphere from being propagated
Note: Hazardous areas are classified in zones based upon the
form Zone 1 or 2 hazardous location to any different
frequency of the appearance and the duration of an explosive
gas atmosphere as follows: location or non-hazardous location through the protective
Zone 0: An area in which an explosive gas atmosphere is pipe or duct, apply sealing of the protective pipes in the
present continuously or is present for long periods. vicinity of individual boundaries, or fill the ducts with
Zone 1: An area in which an explosive gas atmosphere is
sand appropriately.
likely to occur in normal operation.
Zone 2: An area in which an explosive gas atmosphere is not • When branch connections of cables, or cable connections
likely to occur in normal operation and if it does with insulated cables inside the conduit pipes are made,
occur it will exist for a short period only. a flameproof or increased-safety connection box shall be
(2) Environmental Conditions used. In this case, flameproof or increased-safety cable
The standard environmental condition for the installation of glands meeting the type of connection box must be used
flameproof apparatus is limited to an ambient temperature for cable connections to the box.
range from –20°C to +40°C (for products certified under (2) Flameproof Metal Conduit Wiring
Technical Criteria). However, some field-mounted • For the flameproof metal conduit wiring or insulated
instruments may be certified at an ambient temperature up to wires shall be used as recommended by the USER’S
+60°C as indicated on the instrument nameplates. If the GUIDELINES for Electrical Installations for Explosive
flameproof apparatus are exposed to direct sunshine or Gas Atmospheres in General Industry, published in
radiant heat from plant facilities, appropriate thermal 1994.
protection measures shall be taken. • For conduit pipes, heavy-gauge steel conduits
conforming to JIS C 8305 Standard shall be used.
• Flameproof sealing fittings shall be used in the vicinity
5. External Wiring for Flameproof
of the wiring connections, and those fittings shall be
Apparatus filled with sealing compounds to complete sealing of the
Flameproof apparatus require cable wiring or flameproof apparatus. In addition, to prevent explosive gases,
metal conduits for their electrical connections. For cable moisture, or flame caused by explosion form being
wiring, cable glands (cable entry devices for flameproof type) propagated through the conduit, always provide sealing
to wiring connections shall be attached. For metal conduits, fittings to complete sealing of the conduit in the
attach sealing fittings as close to wiring connections as following locations:
possible and completely seal the apparatus. All non-live (a) In the boundaries between the hazardous and non-
metal parts such as the enclosure shall be securely grounded. hazardous locations.
For details, see the “USER’S GUIDELINES for Electrical (b) In the boundaries where there is a different
Installations for Explosive Gas Atmospheres in General classification of hazardous location.
Industry,” published in 1994. • For the connections of the apparatus with a conduit pipe
or its associated accessories, G-type parallel pipe threads
(1) Cable Wiring (JIS B 0202) shall be used to provide a minimum of
• For cable wiring, cable glands (cable entry devices for five-thread engagement to complete tightness. In
flameproof type) specified or supplied with the apparatus addition, since these parallel threads do not have sealing
shall be directly attached to the wiring connections to property, nonhardening sealant such as liquid gaskets
complete sealing of the apparatus. shall thus be applied to those threads for ensuring
• Screws that connect cable glands to the apparatus are waterproofness.
those for G-type parallel pipe threads (JIS B 0202) with • If metal conduits need flexibility, use flameproof flexible
no sealing property. To protect the apparatus from fittings.
corrosive gases or moisture, apply nonhardening sealant
such as liquid gaskets to those threads for waterproofing.
2 EX-B03E
6. Maintenance of Flameproof requirements for flameproof apparatus (however, bear in

Apparatus mind that the apparatus must always be restored to its
original condition). If you attempt to repair the
To maintain the flameproof apparatus, do the following. (For flameproof apparatus, company-specified components
details, see Chapter 10 “MAINTENANCE OF EXPLOSION- shall be used.
PROTECTED ELECTRICAL INSTALLATION” in the (d) Before starting to service the apparatus, be sure to check
USER’S GUIDELINES for Electrical Installations for all parts necessary for retaining the requirements for
Explosive Gas Atmospheres in General Industry.) flameproof apparatus. For this, check that all screws,
bolts, nuts, and threaded connections have properly been
(1) Maintenance servicing with the power on. tightened.
Flameproof apparatus shall not be maintenance-serviced with
(3) Prohibition of specification changes and
its power turned on. However, in cases where maintenance
modifications
servicing is to be conducted with the power turned on, with
Do not attempt to change specifications or make modifica-
the equipment cover removed, always use a gas detector to
tions involving addition of or changes in external wiring
check that there is no explosive gas in that location. If it
connections.
cannot be checked whether an explosive gas is present or not,
maintenance servicing shall be limited to the following two
items: 7. Selection of Cable Entry De-
(a) Visual inspection vices for Flameproof Type
Visually inspect the flameproof apparatus, metal
conduits, and cables for damage or corrosion, and other
mechanical and structural defects. IMPORTANT
(b) Zero and span adjustments
These adjustments should be made only to the extent The cable glands (cable entry devices for flameproof
that they can be conducted from the outside without type) conforming to IEC Standards are certified in
opening the equipment cover. In doing this, great care combination with the flameproof apparatus. So,
must be taken not to cause mechanical sparks with tools. Yokogawa-specified cable entry devices for flameproof
type shall be used to meet this demand.
(2) Repair
If the flameproof apparatus requires repair, turn off the power
and transport it to a safety (non-hazardous) location. Observe References:
the following points before attempting to repair the
(1) Type Certificate Guide for Explosion-Protected Con-
apparatus.
struction Electrical Machinery and Equipment (relating
(a) Make only such electrical and mechanical repairs as will to Technical Standards Conforming to International
restore the apparatus to its original condition. For the Standards), issued by the Technical Institution of
flameproof apparatus, the gaps and path lengths of joints Industrial Safety, Japan
and mating surfaces, and mechanical strength of (2) USER’S GUIDELINES for Electrical Installations for
enclosures are critical factors in explosion protection. Explosive Gas Atmospheres in General Industry (1994),
Exercise great care not to damage the joints or shock the issued by the Japanese Ministry of Labour, the Research
enclosure. Institute of Industrial Safet
(b) If any damage occurs in threads, joints or mating
surfaces, inspection windows, connections between the
transmitter and terminal box, shrouds or clamps, or
external wiring connections which are essential in
flameproofness, contact Yokogawa Electric Corporation.
CAUTION
Do not attempt to re-process threaded connections or

refinish joints or mating surfaces.
(c) Unless otherwise specified, the electrical circuitry and

internal mechanisms may be repaired by component
replacement, as this will not directly affect the
3 EX-B03E
Customer YTA Series
Maintenance Temperature Transmitter
Parts List [ Style : S3 ]
7
8
2
1
13
12
20
2
11
5
3 9
10
18
6
4
3
2
1
17
29
16
28 14 15
For FOUNDATION Fieldbus Type

27
12 24
30
31 25
21
15 26
19
23 6
22
YTA_CMPL.EPS
All Rights Reserved, Copyright © 1998, Yokogawa Electric Corporation.

CMPL 01C50B01-02E
12th Edition: Nov. 2007 (KP)
2
Item Part No. Qty Description
1 F9165EA 2 Cover
2 B1000ER 2 O-Ring
3 Y9406JB 2 Screw Machine
4 See Table 1 1 CPU Assembly for BRAIN or HART Communication type
5 B1002BT 2 Stud Bolt
6 F9342MW 1 Connector Assembly

7 — 1 Name Plate
8 F9300AG 2 Screw
9 F9165DF 1 Tag Plate
10 F9300AG 2 Screw
11 F9165FA 1 Cover Assembly

12 F9167DA 1 LCD Assembly
13 B1001BT 2 Stud Bolt
14 Y9016NU 1 Bolt Hexagon
15 D0117XL-A 1 U-bolt Assembly
16 Y9100SU 1 Washer Spring

17 F9165CY 1 Bracket
18 Y9406ZU 2 Screw (for CENELEC, SAA and TIIS flameproof type)
19 Below 1 Cable Grand Assembly (for JIS Flameproof; option code: /JF3)
G9601AM For Electrical Connection: G 1/2 female (option code: /G11)
20 — 1 Case Assembly for BRAIN or HART Communication type

21 — 1 Case Assembly for Fieldbus Communication type
22 — 1 CPU Assembly for Fieldbus Communication type
23 Y9420JB 2 Screw Machine
24 F9165KA 2 Screw
25 F9165KF 2 Nut
26 F9165KD 2 Stud Bolt
27 F9284NZ 1 Bracket
28 F9165QB 1 Bracket
29 Y9616NU 4 Screw
30 Y9600SU 4 Washer
31 Y9601BU 4 Nut
Table 1. CPU Assembly (for BRAIN and HART)

Communication Without With CPU Assembly is shipped with
Model the setting shown in Table 2.
protocol /CM1 /CM1
-D (BRAIN) F9167BJ
YTA110
-E (HART) F9167BM
-D (BRAIN) F9167BK F9167BU
YTA310
-E (HART) F9167BN F9167BW
-D (BRAIN) F9167BL F9167BV
YTA320
-E (HART) F9167BP F9167BX
Table 2. Setting upon shipment

Input sensor type Pt100 three-wire system
Calibration range lower limit “0”
Calibration range upper limit “100”
Calibration unit “°C”
Sensor burnout High (110%, 21.6mA DC)
Nov. 2007
Subject to change without notice. Printed in Japan.
CMPL 01C50B01-02E
REVISION RECORD
Title: Model YTA series Temperature Transmitter (Hardware) [Style: S3]
Manual No.: IM 01C50B01-01E
Edition Date Page Revised item
1st Sep. 1998 — New Publication
2nd Nov. 1998 2-5 2.7.1 Add subsection 2.7.1 CSA certification.
2-7 2.7.2 Add subsection 2.7.2 CENELEC(KEMA) certificated.
2-9 2.8 Add subsection 2.8 EMC Conformity Standards.
5-5 5.5 Add wiring cautions for intrinsically safe type and flameproof type.
7-2 to 7-3 7.1 Correct errors.
3rd Jan. 1999 2-9 2.7.3 Add subsection 2.7.3 FM certification.

5-3 5.4 Delete resistance 4-wire type. (Figure 5.6 &5.7)
6-2 6.2.2 Delete resistance 4-wire type. (Figure 6.1)
6-7 6.4. Add HART parameter.
6-9 6.5 Correct errors. (Er-05 & Er-06 in Table 6.4)
7-1 7.1 Delete resistance 4-wire type
7-5 7.3 Add optional code /FF1.
7-6 7.4 Add Terminal dimensions.
CMPL CMPL 1C50B1-02E 1st to 2nd
Page 1 Correct dimensions
4th June 1999 Contents Add Ex-B02E 'Installation and Operating Precautions for JIS Flameproof
Equipment'.
2-1 2.1 Add C-tick mark.
2-7 2.7.2 Add IEC (KEMA) Type of protection 'n'
2-10 2.7.3 Add FM Intrinsically Safe Type
2-12 2.7.4 Add JIS Flameproof Type
2-13 2.8 Add C-tick mark
5-1 5.1 Add 'IMPORTANT' for JIS Flameproof type.
5-3 5.3.2 Add 'WARNING' for JIS Flameproof type.
5-6 5.5(2) Add cable wiring procedure using Flameproof Packing adapter.
6-3 6.3 Add Figure 6.3.
7-4 7.3 Add optional code /CM1, /FU1, /JF3, /G11, and /G12.
Ex-B02E Add Ex-B02E 'Installation and Operating Precautions for JIS Flameproof
Equipment'.
CMPL Add item 18, 19, 20, and 21.
5th July 2000
6th July 2000 Cover Add Style code

Contents Add 2.7.5
2-13 Add '2.7.5 SAA Certification'
7-1 7.1 Correct Description of Ambient temperature effect
7-3 Add Table 7.2 YTA110 Effect of Ambient Temperature'
7-4 7.4 Add Stainless steel housing
CMPL Change Item 4
7th July 2001 2-15 2-15 Change referred standard

7-1 7. Add Notes for Fieldbus type, change EMC standard.
7-4 to 7-6 7.1 Add codes and notes for Fieldbus type.
EX-B03E EX-B02E superseded to EX-B03E.
CMPL CMPL 4th to 5th edition (Adding Fieldbus related parts)
8th May 2002 1-1 Add “■ For Safety Using.”

2-5 2.7.2 Add descriptions based on ATEX directive.
7-6 7.3 Add Optional code KU2.
CMPL CMPL 6th to 7th edition (Fieldbus Type Part No. correction)
1. Item 5, B1002BT to Item 26, F9165KD
2. Item 23, F9165KA (Screw) to Y9420JB (Screw machine)
3. Item 24, Y9420JB (Screw machine) to F9165KA (Screw)
CMPL 1C50B1-02E 7th to CMPL 01C50B01-02E 8th
Rev.1.EPS
IM 01C50B01-01E
9th Apr. 2003 2-1 Add Vertical pipe mounting bracket.
4-1 Add Vertical pipe mounting bracket.
7-5 7.2 Add mounting bracket code D.
7-7 7.4 Change Dimensions.
CMPL CMPL 01C50B01-02E 8th to 9th
Add Part No.
Item Part No.
27 F9284NZ
28 F9165QB
29 F9616NU
30 Y9600SU
31 Y9601BU
10th Dec. 2004 — Change Title of Flameproof (JIS → TIIS)

Contents Add ‘ATEX Documentation.’
1-2 1. Add Attention on Maintenance.
1-3 1. Add ATEX Documentation.
2-6 2.7.2 Correct errors.
3-1 3.1 Add Notes for Lock screw.
6-2 6.3 Add Description about SAA to CAUTION.
7-5 7.3 Add C2, C3 Options.
CMPL CMPL 9th to 10th edition.
Delete Part Number of Name Plate.
Add Note for Lock screw.
Add Ports Number of CPU Assembly for /KS25.
11th Sep. 2006 Cover Change Style Code

Contents Add 2.9 Low Voltage Directive
2-3, 2-4
2-5, 2-6 2. Add Certificate Number and Applicable Standard for Explosion
2-8, 2-9 Protected Types.
2-10
2-11 2.9 Add 2.9 Low Voltage Directive.
6-6 6.5 Add Error code.
7-1 7.1 Add Stability Specifications.
7-3 7.1 Add Note for YTA110 Ambient Temperature Effect.
7-5 7.3 Add Optional Code CA.
7-6, 7-7 7.3 Add Certificate Number and Applicable Standard for Explosion
Protected Types.
12th Nov. 2007 2-6, 7-6 2.7.2 Change Applicable standards and add Dust Ignition Proof for KU2.
2-11, 7-7 2.7.6 Add IECEx Certification.
7-5 7.3 Add Option PR.
CMPL CMPL Add setting upon shipment for CPU Assembly.
Rev.2.EPS
IM 01C50B01-01E
User’s YTA series
Manual Temperature Transmitter
(HART Protocol)
IM 01C50T01-01E
IM 01C50T01-01E
5th Edition
Blank Page
CONTENTS
CONTENTS
1. INTRODUCTION .......................................................................................... 1-1

Regarding This Manual ................................................................................. 1-1
For Safe Use of Product ............................................................................... 1-2
Warranty ........................................................................................................ 1-2
ATEX Documentation.................................................................................... 1-3
1.1 Matching of DD and Instruments ........................................................ 1-4
2. HART COMMUNICATOR OPERATION ..................................................... 2-1

2.1 Conditions of Communication Line ..................................................... 2-1
2.1.1 Interconnection Between YTA and HART Communicator ........... 2-1
2.1.2 Communication Line Requirements ............................................. 2-1
2.2 Basic Operation of the HART Communicator (Model 275) ................ 2-2
2.2.1 Keys and Functions ...................................................................... 2-2
2.2.2 Display .......................................................................................... 2-3
2.2.3 Calling Up Menu Addresses ........................................................ 2-3
2.2.4 Entering, Setting and Sending Data ............................................ 2-4
3. OPERATION ................................................................................................ 3-1

3.1 Parameter Description ........................................................................ 3-1
3.2 Menu Tree ........................................................................................... 3-4
3.3 Review ................................................................................................. 3-5
3.4 Basic Setup ......................................................................................... 3-5
3.4.1 Sensor Configuration .................................................................... 3-5
3.4.2 Process Variable Mapping ........................................................... 3-6
3.4.3 Unit ............................................................................................... 3-8
3.4.4 PV Range ..................................................................................... 3-9
3.4.5 Damping Time Constant ............................................................ 3-10
3.4.6 Tag No. ....................................................................................... 3-11
3.5 Detailed Setup ................................................................................... 3-11
3.5.1 Device Information ..................................................................... 3-11
3.5.2 Test Output ................................................................................. 3-11
3.5.3 Burnout Function ........................................................................ 3-11
3.5.4 Integral Indicator Display Mode ................................................. 3-12
3.5.5 Write Protect ............................................................................... 3-13
3.5.6 Sensor Trim ................................................................................ 3-14
3.5.7 Analog Output Trim .................................................................... 3-15
3.5.8 Sensor Backup (For Model YTA320 only) ................................. 3-16
3.5.9 Burst Mode ................................................................................. 3-16
3.5.10 Multi Drop ................................................................................... 3-17
3.5.11 Sensor Matching Function ......................................................... 3-17
3.5.12 CJC Selection ............................................................................ 3-18
3.6.2 Warnings .................................................................................... 3-22
3.6.3 Logging Functions ...................................................................... 3-22
4. PARAMETERS LISTS ................................................................................. 4-1
FD No. IM 01C50T01-01E
5th Edition: Sep. 2006 (KP)
All Rights Reserved, Copyright © 1998, Yokogawa Electric Corporation i IM 01C50T01-01E
CONTENTS
APPENDIX A. SAFETY INSTRUMENTED SYSTEMS INSTALLATION ......... A-1

A.1 Scope and Purpose ............................................................................ A-1
A.2 Using the YTA for an SIS Application ................................................ A-1
A.2.1 Safety Accuracy ........................................................................... A-1
A.2.2 Diagnostic Response Time .......................................................... A-1
A.2.3 Setup ............................................................................................ A-1
A.2.4 Required Parameter Settings ....................................................... A-1
A.2.5 Proof Testing ................................................................................ A-1
A.2.6 Repair and Replacement ............................................................. A-2
A.2.7 Startup Time ................................................................................. A-2
A.2.8 Firmware Update .......................................................................... A-2
A.2.9 Reliability Data ............................................................................. A-3
A.2.10 Lifetime Limits .............................................................................. A-3
A.2.11 Environmental Limits .................................................................... A-3
A.2.12 Application Limits ......................................................................... A-3
A.3 Terms and Definitions ......................................................................... A-3
REVISION RECORD
ii IM 01C50T01-01E
1. INTRODUCTION
1. INTRODUCTION
Thank you for purchasing the YTA series Temperature

Transmitter. WARNING
The YTA series Temperature Transmitters are correctly Indicates a potentially hazardous situation which,
calibrated at the factory before shipment. To ensure if not avoided, could result in death or serious
correct and efficient use of the instrument, please read injury.
this manual thoroughly and fully understand how to
operate the instrument before operating it.
This manual describes that communication function of
YTA series conforms to HART protocol and offers CAUTION
instruction for setting parameters for models YTA110,
Indicates a potentially hazardous situation which,
YTA310 and YTA320 Temperature Transmitters via
if not avoided, may result in minor or moderate
HART 275 handheld terminal. In regards to the
injury. It may also be used to alert against
installation, wiring and maintenance of the YTA series
unsafe practices.
Temperature Transmitters, please refer to the Instruc-
tion Manual “YTA series Temperature Transmitters
Hardware Manual IM 01C50B01-01E.”
IMPORTANT
䊏 Regarding This Manual
Indicates that operating the hardware or software
• This manual should be passed on to the end user. in this manner may damage it or lead to system
• The contents of this manual are subject to change failure.
without prior notice.
• All rights reserved. No part of this manual may be
reproduced in any form without Yokogawa’s written
permission.
• Yokogawa makes no warranty of any kind with NOTE
regard to this manual, including, but not limited to, Draws attention to information essential for
implied warranty of merchantability and fitness for a understanding the operation and features.
particular purpose.
• If any question arises or errors are found, or if any
information is missing from this manual, please
inform the nearest Yokogawa sales office.
• The specifications covered by this manual are
limited to those for the standard type under the
specified model number break-down and do not
cover custom-made instrument.
• Please note that changes in the specifications,
construction, or component parts of the instrument
may not immediately be reflected in this manual at
the time of change, provided that postponement of
revisions will not cause difficulty to the user from a
functional or performance standpoint.
• The following safety symbol marks are used in this
Manual:
1-1 IM 01C50T01-01E
1. INTRODUCTION
䊏 For Safe Use of Product 䊏 Warranty

For the protection and safety of the operator and the • The warranty shall cover the period noted on the
instrument or the system including the instrument, quotation presented to the purchaser at the time of
please be sure to follow the instructions on safety purchase. Problems occurred during the warranty
described in this manual when handling this instru- period shall basically be repaired free of charge.
ment. In case the instrument is handled in contradiction • In case of problems, the customer should contact the
to these instructions, Yokogawa does not guarantee Yokogawa representative from which the instrument
safety. Please give your attention to the followings. was purchased, or the nearest Yokogawa office.
• If a problem arises with this instrument, please
(a) Installation inform us of the nature of the problem and the
• The instrument must be installed by an expert circumstances under which it developed, including
engineer or a skilled personnel. The procedures the model specification and serial number. Any
described about INSTALLATION are not permitted diagrams, data and other information you can
for operators. include in your communication will also be helpful.
• Responsible party for repair cost for the problems
• In case of high process temperature, care should be
shall be determined by Yokogawa based on our
taken not to burn yourself because the surface of the
investigation.
case reaches a high temperature.
• The Purchaser shall bear the responsibility for repair
• All installation shall comply with local installation costs, even during the warranty period, if the
requirement and local electrical code. malfunction is due to:
(b) Wiring - Improper and/or inadequate maintenance by the

purchaser.
• The instrument must be installed by an expert
- Failure or damage due to improper handling, use
engineer or a skilled personnel. The procedures
or storage which is out of design conditions.
described about WIRING are not permitted for
- Use of the product in question in a location not
operators.
conforming to the standards specified by
• Please confirm that voltages between the power Yokogawa, or due to improper maintenance of
supply and the instrument before connecting the the installation location.
power cables and that the cables are not powered - Failure or damage due to modification or repair
before connecting. by any party except Yokogawa or an approved
representative of Yokogawa.
(c) Maintenance - Malfunction or damage from improper relocation
• Please do not carry out except being written to a of the product in question after delivery.
maintenance descriptions. When these procedures - Reason of force majeure such as fires, earth-
are needed, please contact nearest YOKOGAWA quakes, storms/floods, thunder/lightening, or
office. other natural disasters, or disturbances, riots,
• Care should be taken to prevent the build up of drift, warfare, or radioactive contamination.
dust or other material on the display glass and
name plate. In case of its maintenance, soft and dry
cloth is used.
(d) Modification
• Yokogawa will not be liable for malfunctions or
damage resulting from any modification made to
this instrument by the customer.
1-2 IM 01C50T01-01E
1. INTRODUCTION
䊏 ATEX Documentation SF
This procedure is only applicable to the countries in
European Union. Kaikkien ATEX Ex -tyyppisten tuotteiden käyttöhjeet
Mikäli tarvitsette Ex -tyyppisten tuotteiden ohjeita
GB omalla paikallisella kielellännne, ottakaa yhteyttä
lähimpään Yokogawa-toimistoon tai -edustajaan.
All instruction manuals for ATEX Ex related products
you require Ex related instructions in your local P
language, you are to contact your nearest Yokogawa
office or representative. Todos os manuais de instruções referentes aos produtos
Francês. Se necessitar de instruções na sua língua
DK relacionadas com produtos Ex, deverá entrar em
contacto com a delegação mais próxima ou com um
Alle brugervejledninger for produkter relateret til representante da Yokogawa.
ATEX Ex er tilgængelige på engelsk, tysk og fransk.
af Ex produkter på eget sprog, kan De rette F
henvendelse herom til den nærmeste Yokogawa
afdeling eller forhandler. Tous les manuels d’instruction des produits ATEX Ex
française. Si vous nécessitez des instructions relatives
I aux produits Ex dans votre langue, veuillez bien
contacter votre représentant Yokogawa le plus proche.
Tutti i manuali operativi di prodotti ATEX
tedesco e francese. Se si desidera ricevere i manuali D
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1-3 IM 01C50T01-01E
1. INTRODUCTION
1.1 Matching of DD and Instru-

ments
To setup the YTA via HART handheld communicator,
it is necessary that the correct version of DD(Device
Description) is installed in the communicator. The
matching of the instrument and the DD in the commu-
nicator can be checked by the following procedures. If
the correct DD is not installed in your communicator,
contact your nearest official programming site for
HART Communicator and ask for an update.
For the instruments or software other than the HART
handheld communicator, contact a vendor of each
instrument / software and ask for information.
1. Check the revision of the instrument.

1) Connect the communicator with the instrument.
2) Call "Review" display, and find the parameter
"Fld dev rev" there. The device revision of the
instrument is shown in it.
2. Check the revision of DD
1) Turn on the communictor without connecting
with the instrument.
2) Call "Simulation" display. [ Menu → 4.Utility →
Simulation ]
3) The list of the manufaturers is shown. Find
YOKOGAWA and select it.1
4) The list of the devices is shown. Find YTA and
check if the dev rev number shown there matches
the number confirmed in the step 1.
1-4 IM 01C50T01-01E
2.1 Conditions of Communica- Maximum twisted-pair length; 10,000 ft

(3,048 m)
tion Line Maximum multiple twisted-pair length;
5,000 ft (1,524 m)
2.1.1 Interconnection Between YTA Use the following formula to determine cable length
and HART Communicator for a specific application;
The HART communicator can interface with the
transmitter from the control room, the transmitter site, 65×106 (Cf+10,000)
or any other wiring termination point in the loop, L= –
(R×C) C
provided there is a minimum of 250W between the
connection and the power supply. To communicate, it where: L = length in feet or meters.
must be connected in parallel with the transmitter; the R = resistance in ohms, current sense
connections are non-polarized. Figure 2.1 illustrates the resistance plus barrier resistance.
wiring connections for direct interface at the transmit- C = cable capacitance in pF/ft or pF/m.
ter site for the YTA. The HART communicator can be Cf = Maximum shunt capacitance of field
used for remote access from any terminal strip as well. devices in pF.
Control room
Relaying
terminals Terminal board
Distributor
YTA
HART
communicator
HART communicator
F0201.EPS
Figure 2.1 Interconnection Diagram
2.1.2 Communication Line

Requirements
Specifications for Communication Line:
Supply voltage
General use type; 16.4 to 42 V DC
Load resistance; 250 to 600Ω
(Including cable resistance)
Minimum cable size; 24 AWG,
(0.51 mm diameter)
Cable type; Single pair shielded or
multiple pair with overall shield
2-1 IM 01C50T01-01E
2.2 Basic Operation of the HART Communicator (Model 275)

2.2.1 Keys and Functions
Communication Cable
LCD (Liquid crystal display)

(21 characters×8 lines)
Function keys
Functions of the keys are indicated on the
display.
Pressing (HOME) when the display is
YTA :
as shown changes the display to “Online”
Online menu. (See 2.2.2 “Display”.)
1 Device setup
2 PV 0.00 degC
3 PV AO 4.001 mA Moves the highlighting cursor on the display to
4 PV LRV 0.00 degC
5 PV URV 100.00 degC select the desired item.
Hot key
Call up setting menu
1. Range values
2. Chng Wrt Protect
Power ON/OFF
1. Changes the display contents.
2. Moves the position where a number or
character is to be entered.
Pressing calls up the display
corresponding to the item pointed with the
highlighting cursor.
Pressing returns to the previous
display. (See 2.2.3.)
Alphanumeric keys
1. Enters numbers and characters.
2. Selects the desired menu item with the
corresponding number. (See 2.2.4.)
Pressing single key enters the number.
Pressing the key with shift key enters the
alphabetic character.
(Press) (ENTER)
To enter “7”, ‘7’

Shift keys
To enter “C”, ‘C’
Use to enter alphabetic characters.
F0202.EPS
Figure 2.2 The HART Communicator
2-2 IM 01C50T01-01E
2.2.2 Display Function Key Labels
The HART communicator searches for transmitter on F1 F2 F3 F4

the 4 to 20 mA loop when it is turned on. When the HELP ON/OFF ABORT OK
HART communicator is connected to the transmitter, access on-line activates or terminate acknowledge
help deactivates a current task information on
“Online” menu (Top menu) is started automatically bianry variable screen
and the following display appears. If no transmitter is RETRY DEL ESC ENTER
found, you select “Online” menu. try to re- delete current leave value accept user-
establish character or Hot unchanged entered data
communication Key Menu item
Manufacturer’s transmitter type Tag (8 Characters) <a> EXIT SEND QUIT NEXT
leave the send data to terminate session leave the
current menu device, or mark because of a current menu
data to send comunication
YTA :YOKOGAWA error
 Online YES PGUP PGDN NO
1 Device setup answer to move up one move down one answer to
<c> 2 PV 0.00 degC yes/no question help screen help screen yes/no question
3 PV AO 4.001 mA ALL PREV NEXT ONE
4 PV LRV 0.00 degC include current go to previous go to next include Hot Key
<d> Hot Key item on message in a message in the item for one
5 PV URV 100.00 degC
Hot Key Menu list of messages list of messages device
<e> for all devices
NEXT SAVE HOME
go to the next save information go to the top
variable in to memory menu in the
offline edit module or data device
pack description
FILTR MARK BACK
Function keys opens toggles marked go back to
customization configuration menu from
menu to sort variables for which HOME
The highlighting cursor
configurations sending to field was pressed
Pressing one of the SHIFT keys makes the arrow device
mark corresponding to the pressed key appear. XPAND EDIT
opens detailed edit a variable
Appears when the voltage level of the battery is low configuration value
F0203.EPS information
CMPRS ADD
Figure 2.3 Display closes detailed add current item
configuration to Hot Key
information Menu
<a> appears and flashes during communication F0303.EPS
between the HART communicator and the Figure 2.4 Function Key Labels
transmitter. In Burst mode, appears.
 The menu items selected from the previous menu. 2.2.3 Calling Up Menu Addresses
<c> The items to be used from the menu of .
Clause 3.2 shows the configuration of all menu items
<d> or appears when the item is scrolled out of
available with the HART communicator. The desired
the display.
item can be displayed with ease by understanding the
<e> The labels of function corresponding to each menu configuration.
function key appears. These labels reflect cur-
rently available choices. When the HART communicator is connected to the
transmitter, “Online” menu will be displayed after
power is turned on (See Figure 2.2). Call up the
desired item as follows:
Key operation
There are two choices to select the desired menu item.
1. Use the or key to select the desired item,
and then press the key.
2. Press the number key displayed for the desired
item.
2-3 IM 01C50T01-01E
• To return to the previous display, press the key. 2.2.4 Entering, Setting and Sending
* If ABORT , ESC and EXIT are displayed, press the Data
desired function key.
The data input using the keys are stored in the HART
communicator by pressing ENTER (F4). Then, by
Example: Call up the “Tag” to change the tag.
pressing SEND (F2), the data is sent to the transmitter.
Note that the data is not stored in the transmitter if
Check to see where item “Tag” is located in the menu SEND (F2) is not pressed. All the data stored with the
configuration. Then, call up “Tag” item on the display HART communicator is held in memory unless power
according to the menu configuration. is turned off, all data can be sent to the transmitter at
once.
Device setup Process variables Tag
PV Diag/Service PV Unit&Damp Operation
PV AO Basic setup Range values
PV LRV Detailed setup . Entering data on the “Tag” setting display.
.
PV URV Review .
YTA :YOKOGAWA
Tag
Example: To change from Tag “YOKOGAWA” to “FIC-1A”.
YOKOGAWA
YOKOGAWA
Call up the “Tag” setting display.

HELP DEL ESC ENTER
1. Device setup
Display Operation
1 3. Basic setup
YTA :YOKOGAWA
Online or
1 Device setup
1. Tag
2 PV
3 PV AO
4 PV LRV YTA :YOKOGAWA
5 PV URV Display 1 appears when the HART Tag
YOKOGAWA
DEL SET ESC ENTER
Communicator is turned on. YOKOGAWA
Select “Device setup”.
2 HELP DEL ESC ENTER
YTA :YOKOGAWA
Device setup ×2
1 Process variables
2 Diag/Service
3 Basic setup
or When the setting display shown above appears,
4 Detailed setup
5 Review enter the data as follows:
DEL SAVE HOME ENTER
Select “Basic setup”.

Character to Operation Display
3 be entered
YTA :YOKOGAWA
Basic Setup or F F O K O G A W A
1 Tag YOKOGAWA
2 PV Unit&Damp
3 Range values
4 Snsr 1 config
5 Snsr 2 config
HELP SAVE HOME ENTER I F I K O G A W A
Select “Tag”.
C F I C O G A W A
4
YTA :YOKOGAWA The display for Tag setting appears.
Tag
YOKOGAWA - F I C - G A W A
YOKOGAWA
HELP DEL ESC ENTER 1 F I C - 1 A W A
A F I C - 1 A W A
Deletes
characters. 2 F I C - 1 A
(DEL)
2-4 IM 01C50T01-01E
Display Operation
5
YTA :YOKOGAWA
Tag
YOKOGAWA
FIC-1A
(ENTER)
After entering the data, set the
HELP DEL ESC ENTER
HART communicator with the data
entered by pressing ENTER (F4).
6
YTA :YOKOGAWA
Basic setup
1 Tag FIC-1A
2 PV Unit&Damp
3 Range values
4 Snsr 1 config (SEND)
5 Snsr 2 config
HELP SEND HOME ENTER Send the data to the transmitter by
pressing SEND (F2).
7
YTA :FIC-1A
Basic setup
* is flashed during communica-
1 Tag FIC-1A tion.
2 PV Unit&Damp
3 Range values
4 Snsr 1 config SEND disappears, and the
5 Snsr 2 config transmission is complete.
2-5 IM 01C50T01-01E
3. OPERATION
3. OPERATION
• Tag No., Message, Descriptor (→ 3.4.6 ,
IMPORTANT 3.5.1)
Setting data in Tag, Message, and Descriptor
Do not turn off the power to the transmitter parameters.
immediately after transfer of the data from HART • Test Output (→ 3.5.2)
Communicator. If the transmitter is turned off in Make the transmitter output a fixed current from -2.5
less than 30 seconds after parameters has been through 110 % in 0.1% increments for loop checks.
set, the setting data will not be stored and the • Sensor Burnout (→ 3.5.3)
transmitter will return to the previous settings. Configure the current output value in sensor failure.
Selectable from High, Low and User setting value.
• Integral Indicator Display Mode (→ 3.5.4)
To change items to be displayed on the Integral
NOTE Indicator.
Parameters and functions in regards to Sensor2 • Write Protection (→ 3.5.5)
are offered only for Model YTA320, and not To enable / disable write protection of parameters.
available with YTA110/YTA310. • Sensor Backup Function (→ 3.5.8)
To configure a transmitter to automatically transfer
the input from Sensor1 to Sensor2 when Sensor1
fails.
3.1 Parameter Description • Burst Mode (→ 3.5.9)
The followings outline the functions of the HART In the burst mode, a transmitter continuously sends a
parameters for YTA. Table 3.1 shows the name, usage selected set of data.
and selection of each parameter. • Sensor trim (→ 3.5.6)
The trim adjustment function allows the user to add a
• Review Configuration Data (→ 3.3)
compensation to the factory set characterization
• Sensor Configuration (→ 3.4.1)
curve to more closely match the input signal.
When changing the sensor type from the current
• Output trim (→ 3.5.7)
setting to another, it is necessary to change some
Adjust the output value. See “IM01C50B01-01E 6.
parameter settings.
Calibration” also.
• Process variable mapping (→ 3.4.2)
Process variable is to be assigned as primary(PV),
secondary(SV), tertiary(TV) and fourth(4V) Variable
and can be monitored on the Integral indicator or
Handheld terminal. Primary variable(PV) is output as
the 4 to 20mA analog signal.
• Unit Setting (→ 3.4.3)
Choose the engineering unit for the process variables
assigned as PV,SV, TV and 4V from °C, Kelvin, °F
and °R . When mV or ohm is specified as an input
type, the unit is automatically set as mV or ohm.
• Range setting (→ 3.4.4 )
Changing the range of PV to be output as the 4 to
20mA DC. There’s two ways to set the range value.
<a> Setting by keypad
 Setting by applying value
• Damping time constant (→ 3.4.5)
Setting the response time of the transmitter smooths
the output with rapid changes in input.
3-1 IM 01C50T01-01E
3. OPERATION
Table 3.1 Parameters list
HART
Item Description Page
Communicator
Memory Tag Tag number, up to 8 characters 3-11
Tag Ex Extension of Tag, up to 8 characters 3-11
Descriptor Up to 16 characters 3-11
Message Up to 32 characters 3-11
Date mm/dd/yy 3-11
Sensor1(2) To describe a serial number of sensor. —
snsr s/n 0 to 16777215
Process Variable Engineering Unit PV units °C, K, °F, °R (Note 1) 3-8
(SV,TV,4V)
Range LRV/URV Set the calibration range using the keypad. 3-9
Apply values Value for 4 and 20 mA signal is set with actual input applied. 3-10
Damping time PV Damp Adjust the output response speed of the 4 to 20 mA DC. 3-10
constant (SV,TV,4V) Enter integer value from 0 to 99 seconds.
PV damping PV damp point Set the % of PV where the damping function is disabled.
3-10
holding point When PV exceeds this value, the damping is disabled and
the output follows the PV.
Variable PV is Specify the value to be used as PV from: “Sensor1”,
mapping (SV,TV,4V) “Terminal Temperature(Term)” and “Sensor1-Term”. The SV, 3-6
TV and 4V can also be specified and monitored from the
HART communicator or Integral Indicator.
The YTA320 variables include above plus: “Sensor2”,
“Sensor2-Term”, “Average” and “Differential temperature”.
Differential Diff direction When using differential value, select whichever is desired;
Direciton (YTA320 only) Sensor1-Sensor2 or Sensor2-Sensor1. 3-8
Sensor1 Sensor1 type Snsr1 Type Specify input type. 3-5

Configuration Sensor1 wire Snsr1 Wire Specify the number of wire for RTD or ohm input. 3-5
Sensor1 unit Snsr1 unit Select a unit from °C, K, °F, or °R. (See note 1). This unit is
automatically referred as a PV, SV, TV or 4V unit when 3-5
Sensor1 is mapped.
Sensor matching Snsr1 Match Enable / disable sensor matching function. When it is set to
function (Note 2) Enbl “enable”, sensor coefficient parameter can be entered. 3-17
Snsr1 Match Sensors specific co-efficients (by Callender vanDusen or 3-17
coefs IEC)
Terminal Terminal Temp. Term unit Select a unit from °C, K, °F, or °R. (See note 1). This unit is
automatically referred as a PV, SV, TV or 4V unit when —
Temperature unit
Terminal Temperature is mapped.
CJC Function CJC Select Select CJC function 3-18
CNST CJC Specify constant value to be used for CJC function. 3-18
Temp
Sensor2 Sensor2 type Snsr2 Type Specify input type. 3-5
Configuration Sensor2 wire Snsr2 Wire Specify the number of wires. 3-5
(YTA320 only)
Sensor2 unit Snsr2 unit Select a unit from °C, K, °F, or °R. (See note 1). This unit is
automatically referred as a PV, SV, TV or 4V unit when 3-5
Sensor2 is mapped.
Sensor matching Snsr2 Match Enable/disable sensor matching function. When it is set to
3-17
function (Note 2) Enbl “enable”, sensor coefficient parameter can be set.
Snsr2 Match Sensors specific co-efficients (by Callender vanDusen or 3-17
coefs IEC)
Sensor Back-up Enbl Snsr Bkup Enables/disables sensor back-up mode. 3-16
Function Bkup state Shows the back-up status. 3-16
(YTA320 only) Bkup Return Enables the recovery from Sensor2 to sensor1 in back-up 3-16
Snsr1 operation.
Note 1: °F and °R are available only when option code /D2 is specified. T0301_1.EPS
Note 2: The parameters are available only when option code /CM1 is specified with YTA310/YTA320.
3-2 IM 01C50T01-01E
3. OPERATION
HART
Item Description Page
Communicator
Sensor burn-out Select the output direction/value upon Sensor failure from 3-11
Output Snsr burnout type
Output Low, High, off or user-setting value (mA or %).
Output in CPU AO Alrm typ Show the current setting of the output direction in CPU failure 3-11
failure which is set by hardware switch on a CPU assembly.
Burst mode Burst option Select a set of data to be continuously sent; (1)PV, (2)output
3-16
in % range & current, (3)PV and output in current.
Burst mode Enable/disable the burst mode. 3-16
Multi-drop mode Poll addr Setting the polling address (0 to 15). 3-17
Display Display select Process Disp, Select variables/information to be displayed on an integral

(Note 3) %/mA Disp, indicator.
3-12
Err-No Disp,
Bar graph,
Matrix Disp
Display update Disp update Select the update period form fast, normal, and slow. 3-13
period
Process Variable PV,SV,TV,4V Process variables. —
Monitoring
Output in % PV % rnge % Output variable —
Output in mA PV AO 4 to 20 mA Output variable —
Terminal Term Terminal temperature variable —
Temperature
Maintenance Test Output Loop test Used for loop checks. Output can be set from 4, 20 mA or the 3-11
designated value within 3.6 to 21.6 mA.
Self-diagnostics Self test Check the transmitter status. If an error is detected, the 3-19
corresponding message is displayed.
Master test Reset the CPU of the transmitter and check the status. —
Status Display of the result of self-test. 3-19
Set warning enbl Show/not show warning messages. 3-22
Error log view Up to 4 error histories are stored in EEPROM. 3-22
Max/Min log Maximum and Minimum value of PV, SV, TV, 4V and Terminal 3-22
Temperature during the operation.
Operate Time Operation time from last power-up. 3-22
Power Check Unintentional power-loss during operation may be detected. 3-22

Write Protect Write protect Displays the permit/protect status for setting changes. 3-13
Enable wrt Write protect status is released for 10 minutes when the
3-14
10 min password is entered.
New password Setting a new password. 3-14
Software Seal Shows if the “joker” password has been used during the 3-14
operation.
Sensor trim Input trimming Select input trimming mode. The mode depends on the kind 3-14
Adjustment mode of calibration device and the number of calibration points.
(Sensor1/2)
Snsr1(2) trim act Select the action type of input trimming. 3-14
S1(2) Input an additional compensation to the factory set
trim zero/gain characterization curve stored in the transmitter. 3-14
Analog output D/A trim, Scaled Adjust the 4 mA to 20 mA output.

3-15
trim D/A trim
Referential Distributor Yokogawa
Information Model YTA110/YTA310/YTA320
Dev.id
—
Final asmbly num
Universal rev
Fld dev rev
Software rev
PV LSL Lower Limit for PV.
PV USL Upper Limit for PV.
Snsr1(2) LSL Lower Limit for Sensor 1(2) input.
Snsr1(2) USL Upper Limit for Sensor 1(2) input.
Snsr1(2) snsr serial number information
Term LSL Lower Limit for terminal temperature.
Term USL Upper Limit for terminal temperature.
T0301_2.EPS
Note 3: Appears only when Integral Indicator is specified.
3-3 IM 01C50T01-01E
3. OPERATION
3.2 Menu Tree

(Device setup) (Process Variables)
1.Process variables 1.Variable view 1.PV 1.PV is
2.PV % rnge 2.SV is
3.PV AO 1.Variable map 3.TV is
4.SV 4.4V is 1.PV Unit
5.TV 2.PV Damp
6.4V 2.Diff direction 1.PV Unit&Damp 3.PV damp point
7.Term
1.SV Unit
2.Variable setting 2.SV Unit&Damp
3.Unit&Damp 2.SV Damp
3.Max/Min log 1.PV max/min log 3.TV Unit&Damp 1.TV Unit
2.SV max/min log 2.TV Damp
3.TV max/min log
4.4V max/min log 4.4V Unit&Damp 1.4V Unit
5.Term max/min log 2.4V Damp
6.Max/Min log Clear 5.Term Unit
(Diag/Service)
2.Diag/Service 1.Test device 1.Status 1.Status group 1
2.Status group 2
2.Self test 3.Status group 3
3.Master test 4.Status group 4
5.Status group 5
4.Set waming enbl 6.Status group 6
1.Apply values
1.PV LRV
2.Loop test 2.PV URV
2.Range values
3.PV Unit 1.Snsr1
4.PV LSL 2.Input Triming Mode
3.Calibration 5.PV USL 3.Sns1 Trim Act
Online Menu
1.Snsr 1 inp trim 4.S1 Trim Zero/Gain
1.Device setup 3.Sensor Trim
1.Snsr2
2.Snsr 2 inp trim 2.Input Triming Mode
2.PV
1.D/A trim 3.Sns2 Trim Act
2.Scaled D/A trim 4.S2 Trim Zero/Gain
3.PV AO 4.AO D/A Trim
3.D/A Clr to Default
4.PV LRV 4.Error log 1.Error log view
2.Error log clear
5.PV URV
5.Power monitoring 1.Power Check
2.Operate Time
(Basic Setup)
1.Tag 1.PV Unit
3.Basic setup
2.PV Damp
2.PV Unit&Damp 3.PV damp point 1.PV LRV
2.PV URV
3.Range values
3.PV Unit
1.Snsr1 Type 4.PV LSL
4.Snsr 1 config 2.Snsr1 Wire 5.PV USL
3.Snsr1 unit
4.Snsr1 Match Enbl
5.Snsr 2 config 1.Snsr2 Type
1.Snsr1
2.Snsr2 Wire
2.Snsr 1 config
6.Snsr1 sensor s/n 3.Snsr2 unit 1.Snsr1 snsr s/n
3.Snsr 1 inp trim
7.Snsr2 sensor s/n 4.Snsr2 Match Enbl 2.Snsr1 LSL
4.Snsr 1 info. 3.Snsr1 USL
1.Process sensor 1
1.Snsr2
2.Snsr 2 config
2.Process sensor 2
3.Snsr 2 inp trim
1.Snsr2 snsr s/n
4.Snsr 2 info. 2.Snsr2 LSL
(Detailed setup) 3.Snsr2 USL
1.Sensors 1.Term
4.Detailed setup
3.Term temp sensor 2.Term Unit
3.Term temp Limits 1.Term LSL
4. CJC Select 2.Term USL
5. CNST CJC Temp
4.Snsr Backup
1.Snsr Bkup
1.PV % rnge 2.Bkup State
2.Signal condition
2.PV LRV 3. Bkup Return Snsr1
3.PV URV
4.PV Unit&Damp
5.Apply values 1.AO
6.PV LSL 2.AO Alrm typ
7.PV USL 3.Loop test
8.PV Min span 4.AO D/A Trim
1.Analog output 5.Snsr burnout 1.Snsr burnout type
3.Output condition
2.Snsr burnout val
2.HART output 1.Poll addr
2.Num req preams
3.Burst mode
4.Burst option 1.Process Disp
2.%/mA Disp
3.Meter output 1.Display select 3.Err-No Disp
4.Bar graph
1.Tag 2.Disp Update 5.Matrix Disp
4.Device information
2.Tag Ex
3.Descriptor <Hot key>
4.Message
1.Sensor 1 Review 5.Date 1.Range values
5.Review 6.Final asmbly num 2.Wrt protect menu
2.Sensor 2 Review 7.Distributor
8.Model
3.Term temp Review 9.Dev id
Write protect 1.Universal rev
Note :
2.Fld dev rev
Some parameters may appear or
4.Out&Meter Review disappear depending on the model,
Revision #’s 3.Software rev
5.Device Review
suffix, option codes and setting of
parameters.
Figure 3.1 Menu Tree
3-4 IM 01C50T01-01E
3. OPERATION
3.3 Review
Before starting operation, review all the configuration
of the transmitter to confirm that it meets the current
application.
1. Device setup Call up “Review” display.

Parameters are grouped by type
and listed in review display of each
group.
5. Review
YTA : Call up each review display, and
Review
1. Sensor 1 Review scroll through the list to check each
2. Term temp Review
3. Out & Meter Review variable.
ENTER
4. Device Review If a change is necessary, refer to the
HELP SAVE HOME “3.4 Basic Setup” in this manual.
3.4 Basic Setup

3.4.1 Sensor Configuration
When changing sensor type, it is necessary to change
the parameters related to the sensor type.
Figure 3.1 diagram shows the wire connections to the
input terminals of the transmitter and sensor type
selections for the parameters in each connection case.
Note that TCs and mV are categorized as Group A and
RTDs and ohm as Group B.
Check the connections between the input terminals and
temperature sensors and set the correct sensor type and
the number of wire connections for the parameters.
1-input model YTA110, YTA310, and YTA320 2-input model YTA320 Group A
TYPE B (IEC584)
Thermocouple and DC voltage (TC & mV) Thermocouple and DC voltage (TC & mV) TYPE W3 (ASTM988)
TYPE W5 (ASTM988)
1 (+) 1 TYPE E (IEC584)
(+) TYPE J (IEC584
2 2 Sensor1
Sensor1 Group A Group A TYPE K (IEC584)
(–)
3 (–) 3 TYPE L (DIN43710)
4 4 TYPE N (IEC584)
(+) Sensor2 Group A TYPE R (IEC584)
5 5 TYPE S (IEC584)
TYPE T (IEC584)
Resistance thermometer(RTD) and resistance (2-wire type) TYPE U (DIN43710)
Resistance thermometer(RTD) and resistance (2-wire type) Pt100 (IEC751)
(A) (A1) Pt200 (IEC751)
1 1
(B1) Pt500 (IEC751)
2 Sensor1 Group B 2 Sensor1 Group B JPt100 (JIS)
(B)
3 3 Ni120 (STI INC)
(B2) Cu (SAMA RC21-4)
4 4 Sensor2 Group B ohm
(A2)
5 5 mV
Resistance thermometer(RTD) and resistance (3-wire type) Resistance thermometer(RTD) and resistance (3-wire type) Group B
(A) (A1) TYPE B (IEC584)
1 1 TYPE W3 (ASTM988)
(B) (B1)
2 Sensor1 Group B (B1)
2 Sensor1 Group B TYPE W5 (ASTM988)
(B)
3 3 TYPE E (IEC584)
(B2) TYPE J (IEC584
4 (B2)
4 Sensor2 Group B TYPE K (IEC584)
5 (A2)
5 TYPE L (DIN43710)
TYPE N (IEC584)
TYPE R (IEC584)
Resistance thermometer(RTD) (4-wire type) Thermocouple(TC) & TYPE S (IEC584)
(A)
1 Resistance thermometer(RTD) and resistance (3-wire type) TYPE T (IEC584)
(A)
TYPE U (DIN43710)
2 (+) 1 Pt100 (IEC751)
(B)
3
Sensor1 Group B* (–) 2
Pt200 (IEC751)
(B) Sensor1 Group A Pt500 (IEC751)
4 * : Without ohm (B) 3 JPt100 (JIS)
5 4 Sensor2 Ni120 (STI INC)
(B) Group B Cu (SAMA RC21-4)
(A) 5 ohm [* Only for 2 or 3-wire type]
mV
F0303.EPS
3-5 IM 01C50T01-01E
3. OPERATION
3
Example: To set Pt100, 4-wire sensor as “Sensor1” input. YTA :
Snsr 1 config
Also set a unit for Sensor1 as “°C”. 1. Snsr1 Type
2. Snsr1 Wire 3 Wire
3. Snsr1 unit deg C
1. Device setup Call up the “Snsr 1 config” display.
HELP HOME ENTER Enter “2” to call up “Snsr1 Wire”
3. Basic setup setting display.
4
4. Snsr 1 config
YTA :
Snsr1 Wire
1 3 Wire
YTA : 2 Wire
Snsr 1 config 3 Wire
1. Snsr1 Type 4 Wire
3. Snsr1 unit deg C HELP SEND ESC ENTER
Press down key until designated
HELP SAVE HOME ENTER Press “1” to call up “Snsr1 Type” wire number is high-lighted. Press
display. ENTER[F4].
5
YTA :
2 Snsr 1 config
YTA : 1. Snsr1 Type
Snsr1 type 2. Snsr1 Wire 4 Wire
Pt100(IEC751) 3. Snsr1 unit deg C
PT100(IEC751)
PT200(IEC751)
PT500(IEC751) HELP SEND HOME ENTER Select “3.Snsr1 unit” to set the unit
JPt100(JIS)
HELP SEND ABORT ENTER
for Sensor1.
Scroll with the up/down key until 6
designated sensor type is high- YTA :
lightened. Press ENTER[F4] to set Sensor1 unit
degC
the type. degC
Kelvin
Use key to scroll the list
HELP DEK ESC ENTER until designated unit is highlighted.
Press ENTER[F4].
When selecting input type from T/C or mV, the
7
number of the wires is automatically set to “2 Wire”. It
YTA :
is not necessary to change the setting in “Snsr1 Wire”. Snsr 1 config
1. Snsr1 Type
3. Snsr1 unit deg C
Press SEND[F2] to transfer the
data to the transmitter.
Check that SEND disappears.
3.4.2 Process Variable Mapping

Process variable can be assigned as primary(PV),
secondary(SV), tertiary(TV) or fourth(4V) Variable
and can be monitored on Integral indicator or Handheld
terminal. The primary variable(PV) is output as a 4 to
20mA analog signal, and thus it is necessary to map
the variable as PV. Other variable can be left as “Not
Used” when they are not required.
Configuration of Sensor 1 (and Sensor 2 for YTA320)
must be done before changing the process variable
mapping. (See 3.4.1)
3-6 IM 01C50T01-01E
3. OPERATION
1. Device setup Calling up the “Variable map” NOTE

display.
1. Process Variables Sensor type “Non-sntandard 1” “Non-standard 2”
2. Variable setting are always shown, but cannot be used unless a
necessary function is pre-installed in the trans-
1. Variable map mitters upon shipment.
1
YTA :
PV is Snsr1
SV is Term
TV is Not used
NOTE
4V is Not used
Pressing 'OK' to change The display in the left shows the 1. When SV, TV or 4V are not required, it is
them.
HELP SAVE ABORT OK current setting of the map.
Press OK[F4]. recommended to leave them as “Not used”
to improve the performance.
2
2. Each process variable, for example “Sensor1”,
YTA :
PV is
Snsr1
can be assigned to only one variable. If
Snsr1
Snsr1-Term “Sensor1” is already set as PV, it cannot be
Term
set as SV, TV or 4V simultaneously.
4. When “Diff”, “Avg”, “Snsr1-Trem”, or “Snsr2-
Trem” are selected, the sensor types to be
Scroll with the up/down key until set for Sensor1 and Sensor2 should be
the designated sensor type is high- selected from any one of the following three
lightened. Press ENTER[F4] to groups; Temperature sensor(T/C and RTD),
set the type. The selection is as
DC voltage or resistance. The combination(for
follows.
[For YTA110, YTA310] example, temperature sensor and DC voltage
Sensor1 input) would cause an incorrect computation
Sensor1 - Terminal Temperature due to the different unit system and is not
Terminal Temperature
allowed.
[For YTA320]
Above plus ; 5. When “Snsr1-Trem” or “Snsr2-Trem” are
Sensor2 selected, DC voltage and resistance input
Sensor2 - Terminal Temperature should not be set for Sensor1 or Sensor2.
Diff : Sensor2-Sensor1 or
Sensor1-Sensor2
Average : (Sensor1+Sensor2)/2
3
YTA :
SV is
Not used
Snsr1
Snsr1-Term
Term Follow the same procedures for
Not used
HELP SEND ABORT ENTER SV, TV and 4V. When you want to
leave the setting as it is, just press
ENTER [F4] to move to the next
variable display. Pressing
ABORT[F3] will cancel all the
previous procedures for mapping.
4
YTA :
PV is Snsr1
SV is Term
TV is Not used
4V is Not used
Pressing 'OK' will
send them.
HELP SEND ABORT OK Press OK[F4] to send the new
setting to the transmitter.
3-7 IM 01C50T01-01E
3. OPERATION
— Differential Direction — (For YTA320) 3.4.3 Unit

If “Diff” is selected as Process variables, it is necessary
The unit for PV is set at the factory before shipment.
to set which is designated; Sensor1-Sensor2 or Sen-
When Sensor1(or Sensor2) or Terminal temperature is
sor2-Sensor1.
mapped as PV, SV, TV or 4V, the unit that is selected
for Sensor1(orSensor2) or Terminal temperature is
1 automatically referred as a unit for these process
YTA :
Variable setting variables. (See 3.4.1 Sensor Configuration) When
1 Variable map
2 Diff direction
3 Unit&Damp
another value is mapped as PV, SV, TV or 4V, it is
possible to set an independent unit for those variables.
Eneter “2” to select Differential
direction.
Example: To change the PV unit from “°C” to “°F”.
2 * “F” degree appears only when /D2 code is specified.
YTA :
Diff direction
Snsr1-Snsr2
Snsr1-Snsr2 1
Snsr2-Snsr1 YTA :
Press up/down key to select the Hot key
differentical direction.Press 1. Range values
HELP SEND ESC ENTER 2. Chng Wrt Protect
ENTER[F4].
HELP DEL ESC ENTER

3
Press Hot key and select “1. Range
YTA :
Variable setting values”.
1 Variable map 2
2 Diff direction
3 Unit&Damp YTA :
Press SEND[F2] to transfer the Range values
1 PV LRV 0.00 degC
data to the transmitter. 2 PV URV 100.00 degC
Check that SEND disappears. 3 PV Unit degC
4 PV LSL -200.00 degC
5 PV USL 850.00 degC
HELP DEL ESC ENTER
Select the “3. PV Unit” to set the
unit.
3
YTA :
Snsr1 unit
degC
degC
degF
degR
Kelvin
HELP DEL ESC ENTER
Select designated unit and press

ENTER[F4].
4
YTA :
Range values
1 PV LRV 0.00 degC
3 PV Unit degF
4 PV LSL -200.00 degC
HELP SEND ESC ENTER
Press SEND[F2] to send the new
setting to the transmitter.
5
YTA : Check that SEND dissappears.
Hot key
1 PV LRV 32.00 degF
2 PV URV 212.00 degF
3 PV Unit degF
4 PV LSL -328 degF
5 PV USL 1562 degF
HELP SEND ESC ENTER
The unit for SV, TV and 4V can be changed in

“Unit&Damping” display. Call up “Unit&Damp”
display. (1. Device setup → 1. Process variables → 2.
Variable setting → Unit&Damp.)
3-8 IM 01C50T01-01E
3. OPERATION
3.4.4 PV Range
NOTE
The range for PV corresponding to the 4 to 20mA
output signal is set at the factory before shipment. It is possible to set LRV>URV. This setting
Following are the procedures to change the range. reverses the 4 to 20 mA output signal.
Setting Conditions: LSL <= LRV <= USL
Example: To change the range from “0 to 100 °C” to LSL <= URV <= USL
“50 to 200 °C”. |URV – LRV| >= Recom
mended Min. span
(1) Changing the range with Keypad
– LRV, URV –
1
YTA :
Hot key
1. Range values
2. Chng Wrt Protect
HELP SAVE ESC ENTER

Press Hot key and call up “Range
values”.
2
YTA :
Range values
1 PV LRV 0.00 degC
3 PV Unit degC
4 PV LSL -200.00 degC Select the “1. PV LRV” to set the
HELP DEL ESC ENTER
Lower Range Value.
Setting limit dependig on the
selected sensor type is shown as
“4. PV LSL.” And “5. PV USL”.
3
YTA :
LRV
0.0 degC
50.0
HELP DEL ESC ENTER

Enter “50”, and press ENTER[F4].
4
YTA :
Range values
1 PV LRV 50.00 degC
3 PV Unit degC
4 PV LSL -200.00 degC To set the Upper Range Value,
HELP SEND ESC ENTER
select the “2 PV URV”.
Setting limit is shown as “4 PV
LSL” and “5 PV USL”.
5
YTA :
URV
100.00 degC
200
HELP DEL ESC ENTER

Enter “200” , and press ENTER[F4].
6
YTA :
Range values
1 PV LRV 50.00 degC
3 PV Unit degC
4 PV LSL -200.00 degC Press SEND[F2] to send the new
HELP SEND
range value to the transmitter.
Confirm that SEND disappears.
3-9 IM 01C50T01-01E
3. OPERATION
(2) Changing the range while applying an 3.4.5 Damping Time Constant
actual input – Apply values –
Setting the response time of each Process Variable to
This feature allows the lower and upper range
make it vary slowly with a rapid change in input. Set
values to be setup automatically with the actual
the value from 0 to 99 seconds.
input applied.
If the time constant is set to 2 seconds, Transmitter
1. Device setup Call up “Apply Values” display. calculates a reading every cycle time using the damp-
2. Diag/Service
ing equation, to make the output 63 percent of the
input range after 2 seconds.
3. Calibration
This damping time constant is normally set to work
1. Apply values when the temperature makes a step change within 2
1 percent of the output range. The damping can be
YTA:
WARN-Loop should be changed using the “PV damp point” parameter .
removed from
automatic control
Press OK[F4] to make the control Example: To set the damping time constant for PV to “5”
HELP SAVE ABORT OK
loop manual. seconds.
2 1. Device setup Call up “PV Unit&Damp” display.

YTA :
Set
1
the:
4mA
1. Process variables
2 20mA
3 Exit
2. Variable setting
To set the lower range value, select
“1. 4mA” and press ENTER[F4]. Unit & Damp
1. PV Unit&Damp
3
YTA : 1
Apply new 4ma input
YTA :
PV Unit&Damp
1 PV Unit degC
Apply the input which corresponds 2 PV Damp 2 s
3 PV damp point 2 %
HELP SEND ABORT OK
to 4mA. After obtaining stable input,
press OK[F4]. HELP SAVE HOME ENTER
Enter “2” to call up “PV damp”
display.
4
YTA : 2
Current applied
process value:50.10 degC YTA :
1 Set as 4mA value Snsr1 damp
2 Read new value 2 s
3 Leave as found The LRV to be changed is 50.10 5

degC.
• Selecting item 1 sets LRV to HELP SAVE ABORT ENTER
50.10degC. Enter new value, and press
• Selecting item 2 reads LRV ENTER[F4].
again. 3
To set LRV to “50.10”, select item 1 YTA :
PV Unit&Damp
5
and press ENTER[F4]. 1 PV Unit degC
2 PV Damp 5 s
YTA : 3 PV damp point 2 %
Set the: Press SEND[F2] to send the
1 4mA
2 20mA HELP SEND HOME ENTER setting to the transmitter.
3 Exit Check that SEND disappears.
# When necessary, change the
Select “2. 20mA” and press
setting of “PV damp point”.
ENTER[F4]. Apply the value which
corresponding to 20mA and enter it
as URV. (Refer to procedures 3
and 4 .)
After completing the range change,

select “3.Exit” and press ENTER[F4].
3-10 IM 01C50T01-01E
3. OPERATION
3.4.6 Tag No.

CAUTION
To change the Tag, see section 2.2.4 “Entering, setting
and Sending Data”. 1. Test output is held for approximately 10
minutes, and then released automatically
Up to 8 characters can be set with “Tag”. after the time has elapsed. If the HART
communicator power supply is turned off or
Example: To change from Tag “YOKOGAWA” to “FIC-1A.” communication connector is disconnected
during the test output operation, it is held for
1. Device setup Call up the “Tag” setting display. approximately 10 minutes.
2. Press the key to release the test output
3. Basic Setup
immediately.
1. Tag
YTA :YOKOGAWA
Tag No.
Enter new setting and press
YOKOGAWA ENTER[F4].
YOKOGAWA
NOTE
HELP DEL ESC ENTER
If the transmitter is equipped with the integral
See Section 2.2.4. indicator, the LCD displays F.O.
"F.O." lit on.

3.5 Detailed Setup
3.5.1 Device Information
F0304.EPS
Following Device information can be entered.

3.5.3 Burnout Function
Tag : Up to 8 characters.
Tag Extension: Extension of Tag description. Up a) Sensor burnout
to 8 characters.
Configure the burnout mode in the case of sensor
Descriptor: Up to 16 characters
failure or disconnection.
Message: Up to 32 characters
Call up the “Snsr burnout type” display. [1.Device
Date: mm/dd/yy mm:month, dd:day,
setup → 4.Detailed setup → 3.Output condition →
yy:year
1.Analog output → 5.Snsr burnout ]
Call up the “Device Information” display. [1.Device When the sensor failure is detected, the transmitter
setup → 4.Detailed setup → 4.Device information] outputs one of the following values.
Low: Outputs 3.6mA
3.5.2 Test Output High: Outputs 21.6mA
User(mA): Outputs user set value in mA. Settable
This feature can be used to output a fixed current from
within 3.6 to 21.6 mA.
3.6 mA (-2.5%) to 21.6 mA (110%) for loop checks.
User(%): Outputs user set value in %. Settable
Call up the “Loop test ” display. [1.Device setup.→ within -2.5 to 110 %.
2.Diag/Service → 2.Loop test] Off: The burn out output is NOT defined
Put the control loop in manual mode by pressing
OK[F4]. The following output selections are offered.
NOTE
4mA: Outputs 4 mA current
20 mA: Outputs 20 mA current When sensor burnout is set to “off”, the
Other: Sets a desired output in mA using transmitter's output will go undefined at sensor
alphanumeric keys. failure. It is necessary to understand this point
End: Exits well when setting “off”.
3-11 IM 01C50T01-01E
3. OPERATION
During sensor burn out time, the Sensor1 failure or the process variable is lit. If
Sensor2 failure error message is generated. (See “Inhibit” is selected, no process
Section 3.6.1 for details.) variable is displayed.
If the transmitter is equipped with the integral indica-
(b) % /mA Disp
tor, the LCD displays “Abn.” as shown in Figure 3.2.
To Specify output value to be
shown on the digital display.
Select from following;
mA
%
Displays output value. mA, %
Displays "Abn." F0306.EPS
Inhibit
Figure 3.2 Integral Indicator Display in Sensor If two values are selected, they
Burn Out
will appear on the display one
after another. Process variables
F03542 and output value(see (a)) is
b) Burnout in hardware failure
shown on the digital display in
The output status of the transmitter in hardware
turn. The unit corresponding to
failure is set using a jumper on the CPU assembly.
each output value is lit. If
The current setting can be checked in parameter
“Inhibit” is selected, no ourput
“AO Alrm type”.
value will be displayed.
Call up the “AO Alrm type parameter” display.
[1.Device setup → 4.Detailed setup → 3.Output (c) Err-No Disp
condition → 1.Analog output → 2.AO Alrm typ]. To Select whether error codes
are shown on the digital display
3.5.4 Integral Indicator Display Mode or not when an error occurs.
When “Show” is selected, error
When an integral indicator is specified with the
code will be shown on the
transmitter, the display items and update speed can be
digital display. When “Inhibit”
configured.
is selected, no error code will
Call up the”Meter output” display [1.Device setup → Displays bar graph. be shown on the digital display.
4.Detailed setup → 3.Output condition → 3.Meter
(d) Bar graph
output ]
To select whether the output
1) Display selection bar-graph display is lit or not.
Displays PV value.
When “Show” is selected, The
(a) Process Disp F03542
output value is shown in a 32-
To Specify process variables to
segment bar-graph. If “Inhibit”
be shown on the digital display.
is selected, the bar-graph is off.
Process variables and output
F03541
value(see (b)) are shown on the (e) Matrix Disp
digital display in turn. Select- To select information to be
able from followings; shown on the dot matrix
PV display.
Displays PV value and
SV sensor type Process:Display name of the
TV process variable shown on
4V the digital display. (Ex.
PV, SV PV)
PV, SV, TV Type:
PV, SV, TV, 4V F03543
Display type of the input
Inhibit sensor
If two or more variables are Wire:
specified, each value appears Display the number of
one after another in order. The wires of the input sensor.
unit corresponding to each
3-12 IM 01C50T01-01E
3. OPERATION
Process, Type: 3.5.5.2 Hardware Write Protect Function

Display Process Variable Hardware write protect function is set up by Switch
name and Sensor Type in (SW2) on the CPU assembly.
turn.
Type, Wire:
Pin position of SW2 Write Protect Status
Display Sensor Type and
the number of wires in WP
turn Y
No
SW2
Inhibit: Display none. N
2) Disp Update WP
Update period of the display is Y
Yes
SW2
selected from Normal, Fast and N
Slow.
SW1
Burnout output direction
NOTE upon hardware failure
When the transmitter is used at temperatures

SW2
under -10 °C, the response speed of the display Hardware Write Protect
may become slow. It is recommended to set the
display speed to normal or slow in such case.
CPU Assembly
3.5.5 Write Protect F0355.EPS
The write protect function is used to prevent unautho- Figure 3.3 SW2 setting
rized configuration data changes in the transmitter.
There are two ways to set this function; by hardwared
NOTE
and by software, and hardware write protect function is
given priority. 1. Turn off the power supply before changing
Press Hot key and select “2. Wrt protect menu.” the setting of SW2.
Current status is shown in “1. Write protect.” 2. To change the SW2, it is necessary to
remove the LCD assembly with LCD model.
3.5.5.1 Write Protect Status Refer to “ 6.3 Disassembly and Assembly” in
“YTA series Hardware Instruction Manual”
Press Hot key and select “2.Wrt protect menu.”
about the procedures.
Current status is shown in “1.Write protect.”
Yes: Hardware or software write protect function
is activated. Under this status, any change
operation is denied with the message. [ In
write protect mode ] .
No : Neither protect function is activated.
3-13 IM 01C50T01-01E
3. OPERATION
3.5.5.3 Software Write Protect Function 3.5.6 Sensor Trim

Each YTA transmitter is factory-characterized based on
● To activate write protect function
the standard sensor curve, and uses this information to
1. Press Hot key and select “2. Wrt protect menu”.
2. Select “3.New password”. produce a process variable output. The sensor trim
3. Enter up to 8 alphanumeric string from key-pads. function is used to make an adjustment to the internal
interpretation of the input signal and the factory
Press ENTER[F4].
characterization in the transmitter. (See Figure 3.4)
4. Re enter the strings and press ENTER[F4].
5. Press OK[F4] to set the password. The status is Since the factory characterization is kept even after
changed to “Write protect YES”. applying the trim operation, it is possible to ignore the
trim function when the original settings are recovered.
● To change the password or to release the
write protect mode
1. Press Hot key and select “2. Wrt protect menu” .
2. Select “2. Enable wrt 10 min”. Enter the password. GAIN
Output
Output
ZERO ZERO
By this operation, the write protection is released
for 10 minutes. It is possible to change the
paramters.
3. Select “3.New password”.
4. To change the password, enter new password and Input Input
press ENTER[F4]. One point trim Two point trim
To release the write protect mode, enter 8 spaces in F0307.EPS
the new password field and press ENTER[F4]. Figure 3.4 Trim function images
5. Press OK[F4] to set the new password or to release
● The Procedures (For Sensor 1)
the write protect mode.
Before performing the sensor trim, complete the
configuration of the sensor input. (See 3.4.1-2)
NOTE 1. Connect the calibration device to the transmitter.
a. Wiring of power supply and output
1. “Enable Wrt 10 min” releases write protect
+ Output signal
status for 10 minutes. While write protect is
released, enter a new password in the “New –
Password” field. It will not be possible to set a Load resistance
new password after 10 minutes have elapsed.
2. “Joker Password” and “Software Seal”
When you foget the password that has been
registered, it is possible to release the mode Voltmeter
for 10 minutes by using a joker password. b. Example of wiring of thermocouple
or DC voltage input (1-input type)
Enter YOKOGAWA to release write protect
1
status for 10 minutes. If this joker password is 2 (+)
used, the status shown in the parameter 3 (–)
4
“Software seal” is changed from “Keep” to 5 DC voltage generator or
“Break”. Press Hot key and select “2. Wrt thermocouple
Protect menu” . Current status is shown in “4.
c. Example of wiring of thermometer resistor
Software seal”. This status will be returned 4-wire type (1-input type)
from “Break” to “Keep” by registering a new (A)
1
password. 2
(A)
(B)
3 (B)
4
5 Variable resistor or
thermometer resistor F0305.EPS
Figure 3.5 Example of wiring for calibration

equipment
3-14 IM 01C50T01-01E
3. OPERATION
2. Call up the “Snsr1 inp trim” display. [1.Device Perform the following steps when the input trim-
setup → 2. Diag/Service → 3.Calibration → ming mode is “V.R. / ZERO&GAIN” or “Temp /
3.Sensor Trim → 1.Snsr 1 inp trim] ZERO&GAIN”.
3. Select “2.Input Trimming Mode”. The following 8. Perform gain-point adjustment.
selections are offered. (a) When the input trimming mode is “V.R. /
V.R. / ZERO&GAIN ZERO&GAIN”, apply the value for the gain-point
V.R. / ZERO shown in the table 3.2 depending on the specified
Temp / ZERO&GAIN sensor type. Wait until the input from the calibra-
Temp / ZERO tion device becomes stable.
Select “V.R. / ZERO&GAIN” or “V.R. / ZERO” (b) When the input trimming mode is “Temp /
when the calibration device is DC voltage generator ZERO&GAIN”, expose the temperature sensor to
or Variable resistor or select “TEMP / calibration temperature for the gain-point. Wait
ZERO&GAIN” or “TEMP / ZERO” when the until the input from the temperature sensor becomes
device is Temperature sensor. stable.
4. Enable the user trim. Select “3. Snsr1 Trim Act”. 9. Press OK[F4].
The following selections are offered. 10. Enter Gain trim reference value from key pad, and
On: Use User trim value press ENTER[F4].
Off: Ignore User trim value, and return to the
factory setting. Follow outlined procedures to perform Sensor2 trim.
Clear: Clear User trim value and return to the
factory setting. 3.5.7 Analog Output Trim
Select “On” to enable trim function and Press Fine output adjustment is performed with “D/A trim”
ENTER[F4]. or “Scaled D/A trim”.
5. Perform zero-adjustment. Call up the “4. S1 Trim
Zero/Gain”. ● D/A Trim
(a) When the input trimming mode is “V.R. / D/A trim is to be performed if the digital ammeter used
ZERO&GAIN” or “V.R. / ZERO”, apply the value for calibration does not read 4.000mA and 20.000mA
for the zero-point shown in the table 3.2 depending exactly when the output signal is 0% and 100%.
on the specified sensor type. Wait until the input
from the calibration device becomes stable. Procedures
(b) When the input trimming mode is “TEMP / 1. Call up the “D/A trim” display. [1.Device setup →
ZERO&GAIN” or “TEMP / ZERO”, expose the 2. Diag/Service → 3.Calibration → 4.AO D/A Trim
temperature sensor to calibration temperature for → 1.D/A trim]
the zero-point. Wait until the input from the 2. Press OK[F4] to set the transmitter to manual
temperature sensor becomes stable. mode.
3. Connect the ammeter(±1µA is measurable) and
Table 3.2 press OK[F4].
Sensor type Zero-point value 4. Press OK[F4] to make the transmitter output 4
B,R,S,T 0 mV mA(0%) . Check the reading of the ammeter, and
TC, mV
E,J,K,N,W3,W5,L,U,mV 0 mV enter this value using the key pad and Press
Pt100, JPt100, Ni120, Cu 40 Ω ENTER[F4].
RTD, ohm 5. Next, press OK[F4] to make the transmitter output
Pt200, Pt500, ohm 40 Ω
20 mA (100%) . Check the reading on the ammeter,
Sensor type Gain-point value and enter this value using the key pad.
B,R,S,T 25 mV 6. After completing the above steps, return the
TC, mV transmitter to automatic control.
E,J,K,N,W3,W5,L,U,mV 75 mV
Pt100, JPt100, Ni120, Cu 330 Ω ● Scaled D/A trim
RTD, ohm
Pt200, Pt500, ohm 1600 Ω
T0302.EPS
6. Press OK[F4].
7. Enter Zero trim reference value from key pad, and
press ENTER[F4].
3-15 IM 01C50T01-01E
3. OPERATION
● To enable Sensor backup function

Example: To adjust using a voltmeter.
1. Set the sensor type, wire and unit for Sensor1 and
2. (See 3.4.1)
Procedures Any Sensor type except “Non-connection” can be
1. Call up the “Scaled D/A trim” display. [1.Device selected.
setup → 2.Diag/Service → 3.Calibration → 4.AO 2. Map Sensor1 as PV, and Sensor2 as SV. (See
D/A Trim → 2.Scaled D/A trim] 3.4.2)
2. Press OK[F4] to set the transmitter to manual mode . TV and 4V can be set to any designated value
3. Select “2. Change” and press ENTER[F4]. except for “Sensor1” and “Sensor2” from the
4. Enter the value read on the meter when the signal is selection. Sets damping time constant and unit for
4 mA. In this case, enter the value of the voltage each process variable.
across the 250Ω resistor (1V) and press 3. Set the sensor burnout type to High, Low or user
ENTER[F4]. setting value.
5. Enter the value read on the meter when the signal is If the sensor burnout type is set to "off", the sensor
20 mA. In this case, enter the value of the voltage failure will not be detected and the backup function
across the 250Ω resistor (5V) and press will not act.
ENTER[F4]. 4. Send all the setting data to a transmitter.
6. Select “1. Proceed” and press ENTER[F4]. 5. Call up the “Snsr Backup” display. [1.Device setup
7. Connect voltmeter and press ENTER[F4]. → 4.Detailed Setup → 1.Sensors → 4.Snsr Backup
8. Press OK[F4] to make the transmitter output 4 → 1.Snsr Bkup]
mA(0%) . Check the reading on the voltmeter, and 6. Select Sensor Backup “Enable”. Press ENTER[F4] .
enter this value using the key pad.
● To make the transmitter return to using
9. Next, press OK[F4] to make the transmitter output
Sensor1 in Backup Operation
20 mA (100%) . Check the reading on the voltme-
1. Confirm that the Sensor1 is recovered
ter, and enter this value using the key pad.
2. Call up the “Bkup Return Snsr1” parameter.
10. After completing the above steps, return the
[1.Device setup → 4.Detailed Setup → 1.Sensors
transmitter to automatic control.
→ 4.Snsr Backup → 3.Bkup Return Snsr1]
3. Press OK[F4]. Backup status returns to “Waiting.”
3.5.8 Sensor Backup (For Model
YTA320 only)
NOTE
The sensor backup command sets the transmitter to
automatically use Sensor2 as output if Sensor1 fails. Don’t change the sensor type, wire and setting
When the sensor backup mode is activated, the of PV and SV while Sensor Backup mode is
transmitter will output the Sensor1 which is mapped as “Enable.” When the change is necessary, turn
PV. Sensor2 is mapped as SV. If sensor1 fails, the Sensor Backup mode “Disable” before changing.
transmitter starts Sensor Backup operation and
Sensor2(SV) is output in place of PV. There’s no
disruption in 4 to 20 mA output. The Error code for 3.5.9 Burst Mode
sensor1 failure is shown on an Integral Indicator, if it
The transmitter continuously sends the data stored in it
is specified. Error message is sent to the HART
when the burst mode is set ON. The data is sent
communicator that the sensor1 failed and the sensor
intermittently as a digital signal with 75ms intervals
backup mode has started. In backup operation, even if
when the transmitter is set in the burst mode. There-
the Sensor1 recovers, the transmitter will continue to
fore, communications with the HART communicator is
use Sensor2 until the backup operation is reset by
also possible.
parameter or power is turned off. If Sensor2 fails
during backup operation, the transmitter will send an Any one of the following values can be selected.
error code for Sensor2 failure to the Integral Indicator PV
and HART communicator and output the “Sensor % range/current: Output in % and mA
burnout” value. Process vars/ crnt: Output in mA and Process
variables (PV, SV, TV and
4V)
3-16 IM 01C50T01-01E
3. OPERATION
1. Call up the “HART output” display. [1.Device 3.5.11 Sensor Matching Function
This function is available only when optional specifica-
2.HART output]
tion /CM1 is specified with YTA310 or YTA320.
2. Select “4. Burst option”. Select a set of data to be
sent. Siginificant temperature measurement accuracy
3. Return to “HART output” display and select “3. improvement can be obtained using a temperature
Burst mode”. Select “On” to start the burst option. sensor that is matched to a transmitter. This matching
Press SEND[F2] to send the setting. To release the process entails teaching the transmitter the relationship
burst mode, select “Off” in this display. between resistance and temperature for a specific RTD
sensor. This relationship, approximated by the
If the transmitter is equipped with the integral indica- Callender-van Dusen equation, is described as follow-
tor, the LCD displays “B.M.” ing :
Rt = R0 {1 + α (1+0.01δ ) t - αδ / 104 t2 - αβ / 108
3.5.10 Multi Drop
(t -100 ) t3 }
“Multi dropping” transmitters refers to the connection
where : Rt = Resistance (ohms) at
of several transmitters to a single communication
Tempearature t (oC)
transmission line. Up to 15 transmitters can be con-
R0 = Sensor -specific constant
nected when set in the multidrop mode. To activate
(Resistance at t=0 oC)
multi drop communication, the transmitter address
α (alpha) = Sensor-specific constant
must be changed to a number from 1 to 15. This
δ (delta) = Sensor-specific constant
change deactivates the 4 to 20 mA analog output,
β (beta) = Sensor-specific constant
sending it to 4mA . The alarm current is also disabled.
(0 at t>0 oC)
● Setting of Multi drop
Call up the “HART output” display. [1.Device Although the sensor curve is standardized, the exact
setup → 4.Detailed setup → 3.Output condition → values for R0, α, δ and β are specific to each RTD
2.HART output] sensor and are obtained by testing each individual
Select “1. Poll addr” and set the polling address.(a sensor at various temperatures. These constants are
number from 1 to 15). known as Callender-van Dusen constants.
Press SEND[F2] to send the setting.
Generally, the constants R0, A, B, and C are also used
as the characteristic coefficients of the RTD instead of
If the transmitter is equipped with the integral indica-
R0, α, δ and β. These are derived from IEC Standard
tor, the LCD displays “M.D.” and "F.O."
Curve and the relationship is described as followings ;
Rt = R0 {1 + At - Bt2 + C (t -100) t3 }
NOTE where : Rt = Resistance (ohms) at
Tempearature t (oC)
1. When the identical address is set for two or
R0 = Sensor-specific constant
more transmitters in multidrop mode, commu-
(Resistance at t=0 oC)
nication with these transmitters is disabled.
A = Sensor-specific constant
2. Multi drop mode and Burst mode should not
B = Sensor-specific constant
be operated together at the same time.
C =Sensor-specific constant
(0 at t > 0 oC)
● Releasing the Multidrop mode
First, call up the “HART output” display. [1.Device
These two equations are equivalent. A model YTA
can cope with either case as above-mentioned.
2.HART output]
Select “1. Poll addr” and set the polling address to
“0”. Press SEND[F2].
3-17 IM 01C50T01-01E
3. OPERATION
● For Setting up two sensors (For model

NOTE YTA320 )
If using two sensors with a model YTA320, repeat the
1. This function is effective only in three kinds of
procedures for the Sensor2. [1. Device setup
sensors; Pt100, Pt200 and Pt500.
→ 3. Basic setup → 5. Snsr 2 config ]
2. Input relations between the sensor type and
the value of R0 properly. When Pt100 is Table 3-3
specified as an input type, the value close to Item Initial Setting Value
100 must be set to R0. When Pt500 is R0 100
specified as an input type, the value close to 3.9083 E-3
A
500 must be set to R0.
IEC B -5.775 E-7
3. When the sensor type is changed, the sensor
C -4.183 E-12
matching function must be set up again or set
α 3.8506 E-3
to “Disable”. Callender
vanDusen δ 1.4998
β 1.0863 E-1
● Setting the Sensor Matching Function (by -3
Note : “E-3” stands for 10
using alpha delta and beta co-effieicent) T0303.EPS
1. Set the designated sensor type and the number of

wires. (Refer to “3.4.1 Sensor Configuration” in 3.5.12 CJC Selection
this manual. ) For thermocouple input, the terminal temperature
2. Call up the “Snsr1 Match Enbl” display. measured by an internal sensor is used for Cold
[1.Device setup → 3. Basic setup Junction Compensation function. In YTA, constant
→ 4. Snsr1 config → 4. Snsr1 Match Enbl ] value set by users can be used for the compensation
3. Select “Enable” and press ENTER[F4]. function in place of the measured terminal temperature.
4. Call up the “Snsr1 Match coefs” display. If the constant value is set to “0”, compensation will
[1. Device setup → 3. Basic setup → 4. Snsr1 config not be applied.
→ 5. Snsr1 Match coefs ]
1. Call up the parameter “CJC Select” . [1.Device
5. Select “2. alpha delta beta” and press ENTER[F4] .
setup → 4. Detailed setup → 1. Sensors → 3. Term
6. The display shows the current setting of the R0,
temp sensor → 4. CJC Select ]
alpha, delta, and beta values. Press OK[F4] .
2. Select “Constant CJC” and press ENTER[F4].
7. The communicator prompts you to enter R0, alpha,
3. Call up the parameter “CNST CJC Temp” .
delta and beta value successively. Enter the R0,
[1.Device setup → 4. Detailed setup → 1. Sensors
alpha, delta and beta values and press ENTER[F4]
→ 3. Term temp sensor → 5. CNST CJC Temp
accordingly.
4. Enter temperature value in constant and press
8. Press OK[F4] to confirm the new values.
ENTER[F4].
9. Press SEND[F2] to transfer the data to the trans-
mitter. Check that [SEND] dissappears.
3.6 Self-Diagnostics
When “Disable” is selected in the above step 3,
temperature is calculated by using the default value of 3.6.1 Checking for Problems
R0, alpha, delta and beta.
(1) Identifying Problems with the HART Com-
● Setting up the Sensor Matching Function municator
(by using A,B and C co-effieicent) Self diagnostics of the transmitter and check of
If using the R0, A,B and C parameters in place of incorrect data settings can be carried out with the
alpha delta and bata co-efficients, replace “2. alpha HART communicator. There are two methods for self-
delta beta” with “1. A B C” in the step 5 in the above. diagnosis of the transmitter; self-diagnosis for every
transmission and manually executing the Self test
command.
In YTA series, there're two classes to show the result
of diagnostices; errors and warnings. Errors are the
serious status for operation which must be corrected
3-18 IM 01C50T01-01E
3. OPERATION
iimmediately. Warnings are the light errors and

indication of the status which is important for opera-
tion.
When an error message appears, see table 3.4 “List of
Errors” for details. If warning messages are set be
shown, the warning status will also be shown on the
HART communicator. See table 3.5 “List of Warnings”
for details.
1. Device setup Diagnostic by “Self test”
2. Diag/Service
1. Test device
1
YTA : Call up the “Test device” display,
Test device
1 Status and select “Self test”.
2 Self test
3 Master test
4 Set warning enbl
2
YTA : OK
Self test OK
If there is no error detected, “Self
test OK” will be displayed. When an
error occurs, an error message
HELP SAVE ABORT OK
appears, and the results of self-
diagnosis appears in the Status item.
3
YTA : Call up the “1. Status”.
Test device
1 Status
2 Self test
3 Master test
4 Set warning enbl
The Error status is in groups 1 and
HELP SAVE HOME ENTER 2.
The Warning status is in groups 3
through 6. Highlight the group to
4
show the status Errors. If Error is
YTA :
Status not detected, the result of
1 Status group 1
2 Status group 2 diagnostics is indicated as “OFF”.
3 Status group 3
4 Status group 4 If “ON” is indicated, a
5 Status group 5 countermeasure for that error is
necessary.
NOTE
Note that if the Set warning enbl is set to “OFF

(not display)”, the status in this display remains
“ OFF ” even when the warning status occurs.
(See 3.6.2)
3-19 IM 01C50T01-01E
3. OPERATION
Table 3.4 List of Errors
Indicator HART display Cause Output operation upon error Action

N/A Good
Er-01 Output Too Low Input value is lower than the Output goes to minimum Check the LRV setting and
PV low range value. value(–2.0%). adjust.
Er-02 Output Too High Input value is higher than the Output goes to maximum Check the URV setting and
PV upper range value. value(105%). adjust.
Er-03 Sensor1 Failure Sensor1 fails or disconnects If sensor1 is set as PV, the • Check sensor for damage.
from the terminal block. burnout value is output. • Check terminal connection.
When sensor backup mode • If sensor backup mode is set,
is set in YTA320, sensor2 refer to “Er-09”.
input is used as output.
Er-04 Sensor2 Failure Sensor2 fails or disconnects If sensor2 is set as PV, or • Check sensor for damage.
(YTA320 only) from the terminal block. the sensor backup mode is • Check terminal connection.
in effect, sensor burnout • If sensor backup mode is set,
value is output. repair wiring or replace
damaged sensors.
exceeds the sensor value(–2.0%) or maximum • Check the sensor type
measurement range. Sensor value(105%). selected.
(YTA320 only) exceeds sensor value(–2.0%) or maximum • Check sensor type selected.
measurement range. Sensor value(105%).
Er-07 Amb Temp Low The ambient temperature Continues to operate and Use a heater to raise the
exceeds the lower ambient output. ambient temperature, or reset to
temp limit and the specified a higher level.
accuracy cannot be
achieved.
Er-08 Amb Temp High The ambient temperature Continues to operate and Take enough distance from the
exceeds the upper ambient output. source of heat, or reset to a
temp limit and the specified lower level.
accuracy cannot be
achieved.
Er-09 Snsr Backup Start Sensor backup mode is in Sensor2 input is used as Repair or replace the sensor1.
(YTA320 only) effect. output. If sensor2 also fails, Then enable sensor1 return
the transmitter operate with parameter, or turn the power
burnout settings. OFF and repower it.
Er-10 Illegal PV MAP There is a problem with the Output status immediately Check the setting for PV
PV mapping settings. before error is retained mapping and correct the setting.
(HOLD).
Er-11 Term Sns Failure Terminal block temperature Operation and output Contact service personnel.
sensor failed. continues.
Er-12 EEPROM Failure EEPROM failure. The output goes to the Contact service personnel.
Er-13 CPU Failure Output side hardware failure. The output goes to the Contact service personnel.
Er-14 AD Conv Failure Input circuit hardware failure. The output goes to the Contact service personnel.
Er-15 Reverse Cal Fail Confirmation calculation The output goes to the Contact service personnel.
result is bad. value set by the hardware
T0304.EPS
3-20 IM 01C50T01-01E
3. OPERATION
Table 3.5 List of Warnings
Group(note) Parameter Status Countermeasure

LRV Too Low The LRV setting is lower than the Check the LRV setting.
temperature range (GS guaranteed value).
LRV Too High The LRV setting is higher than the Check the LRV setting.
URV Too Low The URV setting is lower than the Check the URV setting.
group1 URV Too High The URV setting is higher than the Check the URV setting.
Span Too Small The setting is lower than the recommended Set URV-LRV to be greater than recommended
minimum span. minimum span.
Snsr1 Temp Low Sensor 1 input temperature is lower than Check process: Verify correct sensor selection for
the measurement range of YTA series. temperature range.
Snsr1 Temp High Sensor 1 input temperature is higher than Check process: Verify correct sensor selection for
Sns2 Temp Low Sensor 2 input temperature is lower than Check process: Verify correct sensor selection for
Snsr2 Temp High Sensor 2 input temperature is higher than Check process: Verify correct sensor selection for
Illegal SV Map There is a problem with input (setting Correct SV mapping.
status) specified to SV map.
Illegal TV Map There is a problem with input (setting Correct TV mapping.
group2 status) specified to TV map.
Illegal 4V Map There is a problem with input (setting Correct 4V mapping.
status) specified to 4V map.
Fixed Current Fixed current value is output now. The transmitter is now in Test output mode or
multi-drop mode. Return to normal operation, if
desired.
Snsr Backup Set The sensor backup mode is set. Turn the sensor backup mode OFF.
Soft Not Protect The software write protection is not set. Set the protect parameter to Yes to enable the
Unexpected write cannot be prevented. write protect mode and prevent unexpected
changes.
group3
Last Sum Area The EEPROM checksum field is using the There is no problem with current operation;
spare 4 (the last area). This means there is however, if EEPROM is damaged, EEPROM
no spare area for writing the EEPROM FAILURE will be indicated.
checksum.
Hard Not Protect The hardware write protection is not set. Set the jumper(SW2) on the CPU assembly to
group4
Unexpected write cannot be prevented. “Y” to prevent unexpected parameter changes.
Note: Group in “Set warning enbl.” See 3.6.2 T0305.EPS
(2) Checking with the Integral Indicator

If an error is detected in the self-diagnostic, an error
code is displayed on the digital indicator. If there is
more than one error, the error codes appear in turns.
Refer to “List of Errors” to check the error contents
and the countermeasure.
F0302.EPS
Figure 3.6 Example of Error Code Display
3-21 IM 01C50T01-01E
3. OPERATION
3.6.2 Warnings 3. To clear the logged data for Process variables,

return the “Max/Min log” display and select “Max/
When non-fatal errors or unusual status such as invalid
Min log Clear”. Select “Execute” and press
setting of parameters has happened, it can be detected
ENTER[F4]. Even after this operation, the logged
and shown on the HART commnuicator as a warning
data for terminal temperature shall remain.
message. Whether displaying each warning message or
not can be configured by parameters. (3) Power Check
This parameter is always reset at power-off.
Therefore, by setting this parameter to “start” after
1. Device setup
power-on, the transmitter can be checked if a
2. Diag/Service temporary loss of power has occured.
1. Test device
Call up the “Power Check” display. [1.Device setup
→ 2.Diag/Service → 5.Power monitoring →
1
YTA : Call up the “Test device” display, 1.Power Check]. Select “Start” and press
Test device
1 Status and select “4. Set warning enbl”. ENTER[F4]. If the parameters is changed to
2 Self Test
3 Master Test “STOP” during the normal operation, the transmit-
4 Set warning enbl
ter may have experienced a loss of power.
(4) Operate Time

2 Transmitter’s operation time from the last power-on
YTA :
Set warning enbl
Select group, and select is counted. This parameter is reset at every power
1 Warn enbl group 1 “ON”(Display) or “OFF”(Not display) off. Call up the “Operate Time” display to check
2 Warn enbl group 2
for each warning message to
the time. [1.Device setup → 2. Diag/Service →
3 Warn enbl group 3
4 Warn enbl group 4
decide whether the message
should appear on the HART 5.Power monitoring → 2.Operate Time].
communicator when a warning
status occurs.
YTA :
Warn enbl group1
LRV Too Low ON
LRV Too High OFF
URV Too Low OFF
URV Too High OFF
Span Too Small OFF
HELP OFF ESC ENTER
3.6.3 Logging Functions

The YTA series have the capability to store the data
useful for diagnosis of the problems.
(1) Error log

Up to four error histories are stored in the transmit-
ter memory, and can be seen using the following
procedures.
1. Call up the “ Error log” display. [1.Device setup →
2.Diag/Service → 4.Error log]
2. Select “1. Error log view” to show logged errors.
3. To clear the logged errors, return to the “Error log”
display and select “2. Error log Clear”
(2) Max/Min log
Minimum value and Maximum value of the Process
variables during the operation from the last Power-
up are stored in the transmitter memory and can be
checked. The logged data for Process Variables
except for terminal temperature shall be reset at
every Power-off.
1. Call up the “ Max/Min log” display. [1.Device
setup → 1.Process variables → 3.Max/Min log]
2. Enter the log display for each process variable.
3-22 IM 01C50T01-01E
4. PARAMETERS LISTS
4. PARAMETERS LISTS
Initial setting value marked with “ * ” is as of specified upon ordering.
HART
Item Selection/ Setting Range Initial Setting
Communicator
Memory Tag Up to 8 characters —*
Tag Ex Up to 8 characters —
Descriptor Up to 16 characters —
Message Up to 32 characters —
Date mm/dd/yy —
Snsr1(2) 0 to 16777215 —
snsr s/n
Process Engineering Unit PV unit °C, K,°F, or °R (see note 1) °C*
Variable (SV,TV,4V)
Range LRV/URV Set the calibration range using the keypad. LRV:0*
URV:100*
Apply values Value for 4 and 20 mA signal is set with actual input —
applied.
Damping time PV Damp 0 to 99 seconds. 2s
constant (SV,TV,4V)
Damping holding PV Damp point 0 to 99%. 2%
point
Variable PV is “Sensor1”, “Terminal Temperature(term)” or “Sensor1- PV:
mapping (SV,TV,4V) Term”. Sensor1
For YTA320, above plus “Sensor2”, “Sensor2-Term”, SV(YTA320):
“Average” or “Differential” temperature. Sensor2
Differential Diff direction Sensor1-Sensor2 or Sensor2-Sensor1. Sensor1-Sensor2
Direciton (YTA320 only)
Sensor1 Sensor1 type Snsr1 Type Specify input type. Pt100*
Configuration Sensor1 wire Snsr1 Wire 2, 3 or 4 wire. 3 wire*
Sensor1 unit Snsr1 unit °C, K, °F, or °R. (See note 1). °C*
Enable sensor Snsr1 Match Enable or disable disable
match function Enbl (Note 3)
Terminal Terminal Temp. Term Unit °C, K, °F, or °R. (See note 1). °C*
Temperature unit
CJC Function CJC Select Internal CJC, Constant CJC Internal CJC
CNST CJC -10000 to 10000 0

Temp
Sensor2 Sensor2 type Snsr2 Type Specify input type. Pt100*
Configuration Sensor2 wire Snsr2 Wire 2, 3 or 4 wire. 3 wire*
(YTA320 only)
Sensor2 unit Snsr2 unit °C, K, °F, or °R. (See note 1). °C*
Enable sensor Snsr2 Match Enable or disable disable
match function Enbl (Note 2)
Sensor Backup Snsr Bkup Enables/disables sensor backup mode. disable
Function Shows the backup status. (Waiting or Start.) —
Bkup state&Cntl
Bkup Return Enables the recovery to sensor1 during backup —
Snsr1 operation.
T0401_1.EPS
Note 1: °F and °R are available only when option code /D2 is specified.
Note 2: Appears only when Sensor Matching Function(/CM1) is specified.
4-1 IM 01C50T01-01E
4. PARAMETERS LISTS
HART
Item Selection / Setting Range Initial Setting
Communicator
Display Display select Process Disp (1)PV (2)SV (3)TV (4)4V (5)PV,SV (6)PV,SV,TV
(7)PV,SV,TV,4V (8)Inhibit PV
(see note 3)
%/mA Disp (1)mA (2)% (3)mA,% (4)Inhibit mA
Error-No Disp Show or Inhibit Show
Bar graph Show or Inhibit Show
Matrix Disp (1)Process (2)Type (3)Wire (4)Process,Type Process
(5)Type,Wire (6)Inhibit
Display update Disp update
period Fast, normal, or slow. Normal
Output Sensor burn-out Snsr burnout type

Low, High, off, or user-setting value (mA or %). High*
Output
Output in CPU AO Alrm typ Show the current setting of the output direction in
failure hardware failure which is set using jumper on a CPU High*
assembly.
Burst mode Burst option (1)PV, (2)output in % range & current, (3)PV and output —
in current.
Burst mode Enable/disable the burst mode. disable
Multi-drop mode Poll addr 0 to 15. 0
Monitoring Process Variable PV,SV,TV,4V Process variables. —
Output in % PV % rnge % Output variable —
Output in mA PV AO 4 to 20 mA Output variable —
Terminal Term Terminal temperature variable —
Temperature
Maintenance Test Output Loop test Output can be set from 4, 20 mA or the designated —
value within 3.6 to 21.6 mA.
Self-diagnostics Self test Check the transmitters’s status. If an error is detected, —
the corresponsing message is displayed.
Master test Reset the CPU and check the transmitters’s status. —
Status Display of the result of self-test transmitter. —
Set warning enbl Show/not show warning messages. OFF or ON. All OFF
Error log view Up to 4 error histories are stored in EEPROM. —
Max/Min log Maximum and Minimum value of PV, SV, TV, 4V and —
Terminal Temperature during the operation.
Operate Time Operation time from last power-on. —
Power Check Un-intentional loss of during the operation may be STOP
detected. START or STOP.
Write Protect Write protect Displays the permit/protect status for setting changes. NO
Enable wrt Write protect status is released for 10 minutes when the —
10 min password is entered.
New password Setting a new password. 8 alpha numeric characters. —
Software seal Show the status if the joker password was used. —
Keep(not used), Break(used)
Adjustment Sensor trim Input trimming (1)V.R. / ZERO&GAIN (2)V.R. / ZERO (3)Temp /
—
(Sensor1/2) mode ZERO&GAIN (4)Temp / ZERO
Snsr1(2) trim act (1)On (2)Off (3)Clear —
S1(2) Give correction to the interpretation of a temperature
—
trim zero/gain input to the characterization curve stored in a transmitter.
Analog output D/A trim, Scaled Adjust the output points of 4 mA and 20 mA.
trim D/A trim
Referential Destributor Yokogawa
Information Model YTA110/YTA310/YTA320
Dev.id
Final asmbly num
Universal rev
Fld dev rev
Software rev
PV LSL Lower Limit for PV setting.
PV USL Upper Limit for PV setting.
Snsr1(2) LSL Lower Limit for Sensor 1(2)
Snsr1(2) USL Upper Limit for Sensor 1(2)
Snsr1(2) Snsr s/n Sensor1(2) serial number information
Note 3: Appears only when Integral Indicator is specified. T0401_2.EPS
4-2 IM 01C50T01-01E
APPENDIX A. SAFETY INSTRUMENTED SYSTEMS INSTALLATION
APPENDIX A. SAFETY INSTRUMENTED

SYSTEMS INSTALLATION
The calibration of the transmitter must be performed

WARNING
after parameters are set.
The contents of this appendix are cited from
exida.com safety manual on the YTA series A.2.4 Required Parameter Settings
pressure transmitters specifically observed for The following parameters need to be set in order to
the safety transmitter purpose. When using the maintain the designed safety integrity.
YTA for Safety Instrumented Systems (SIS)
Table A.2.4 Required Parameter Settings
application, the instructions and procedures in
this section must be strictly followed in order to Item Description
preserve the transmitter for that safety level. Burnout direction To specify if the output should go 21.6
switch mA or higher or 3.6 mA or lower upon
detection of an internal failure.
Write protection The write function should be disabled.
A.1 Scope and Purpose switch
TA0101.EPS
This section provides an overview of the user responsi- A.2.5 Proof Testing
bilities for installation and operation of the YTA in
order to maintain the designed safety level for Safety The objective of proof testing is to detect failures
Instrumented Systems (SIS) applications. Items that within the transmitter that are not detected by the
will be addressed are proof testing, repair and replace- diagnostics of the transmitter. Of main concern are
ment of the transmitter, reliability data, lifetime, undetected failures that prevent the safety instrumented
environmental and application limits, and parameter function from performing its intended function. See
settings. table A2.5 for proof testing method.
The frequency of the proof tests (or the proof test
A.2 Using the YTA for an SIS interval) is to be determined in the reliability calcula-
tions for the safety instrumented functions for which
Application the YTA is applied. The actual proof tests must be
performed more frequently or as frequently as specified
A.2.1 Safety Accuracy
in the calculation in order to maintain required safety
The YTA has a specified safety accuracy of 2%. This integrity of the safety instrumented function.
means that the internal component failures are listed in
The following tests need to be specifically executed
the device failure rate if they will cause an error of 2%
when a proof test is performed. The results of the proof
or greater.
test need to be documented and this documentation
should be part of a plant safety management system.
A.2.2 Diagnostic Response Time
Failures that are detected should be reported to
The YTA will report an internal failure within 8 Yokogawa.
seconds of the fault occurrence.
The personnel performing the proof test of the trans-
A.2.3 Setup mitter should be trained in SIS operations including
bypass procedures, YTA temperature transmitter
During installation the transmitter must be setup with maintenance, and company management of change
engineering units parameters. This is typically done procedures.
with a handheld terminal. These parameters must be
verified during the installation to insure that the correct
parameters are in the transmitter. Engineering range
parameters can be verified by reading these parameters
from the optional local display or by checking actual
calibration of the transmitter.
A-1 IM 01C50T01-01E
Table A.2.5 Proof Testing
Testing method Tools required Expected outcome Remarks
Analog Output Loop Test: Handheld terminal Proof Test Coverage The output needs to
1. Bypass the safety PLC or take =61% be monitored to assure
other appropriate action to avoid that the transmitter
a false trip. communicates the
correct signal.
2. Send a HART or BRAIN
command to the transmitter to
go to the high alarm current
output and verify that the analog
current reaches that value.
3. Send a HART or BRAIN
command to the transmitter to
go to the low alarm current
output and verify that the analog
current reaches that value.
4. Use the HART or BRAIN
communicator to view detailed
device status to ensure no
alarms or warnings are present
in the transmitter.
5. Perform reasonability check on
the sensor value(s) versus an
independent estimate (i.e. from
direct monitoring of BPCS value)
to show current reading is good.
6. Restore the loop to full
operation.
7. Remove the bypass from the
safety PLC or otherwise restore
normal operation.
Analog Output Loop Test and Handheld terminal Proof Test Coverage The output needs to be
Temperature Spot Check: =96% monitored to assure
1. Bypass the safety PLC or take that the transmitter
other appropriate action to avoid communicates the
a false trip. correct signal.
2. Perform Analog Output Loop

Test.
3. Verify the measurement for two
temperature points.
4. Perform reasonability check of
the housing temperature.
5. Restore the loop to full operation.
6. Remove the bypass from the
safety PLC or otherwise restore
normal operation.
TA0102.EPS
A.2.6 Repair and Replacement A.2.7 Startup Time

If repair is to be performed with the process online, the The YTA generates a valid signal within 5 seconds of
YTA will need to be bypassed during the repair. The power-on startup.
user should setup appropriate bypass procedures.
A.2.8 Firmware Update
In the unlikely event that the YTA has a failure, the
failures that are detected should be reported to In case firmware updates are required, they will be
Yokogawa. performed at factory. The replacement responsibilities
are then in place. The user will not be required to
When replacing the YTA, the procedure in the installa-
perform any firmware updates.
tion manual should be followed.
The personnel performing the repair or replacement of
the YTA should have a sufficient skill level.
A-2 IM 01C50T01-01E
A.2.9 Reliability Data A SIS is composed of any

combination of sensor(s), logic
A detailed Failure Mode, Effects, and Diagnostics
solver(s), and final element(s).
Analysis (FMEDA) report is available from Yokogawa
with all failure rates and failure modes. SLC Safety Lifecycle
The YTA is certified up to SIL2 for use in a simplex Safety Freedom from unacceptable risk
(1oo1) configuration, depending on the PFDavg of harm
respectively PFH calculation of the entire Safety
Functional Safety The ability of a system to carry
Instrumented Function.
out the actions necessary to
The development process of the YTA is certified up to achieve or to maintain a defined
SIL3, allowing redundant use of the transmitter up to safe state for the equipment /
this Safety Integrity Level, depending the PFDavg machinery / plant / apparatus
respectively PFH calculation of the entire Safety under control of the system
Instrumented Function.
Basic Safety The equipment must be designed
When using the transmitter in a redundant configura- and manufactured such that it
tion, the use of a common cause factor (-factor) of protects against risk of damage to
5% is suggested. If the owner-operator of the plant persons by electrical shock and
would institute common cause failure training and other hazards and against resulting
more detailed maintenance procedures for avoiding fire and explosion. The protection
common cause failure, a beta factor of 2% would be must be effective under all
applicable. conditions of the nominal
operation and under single fault
A.2.10 Lifetime Limits condition
The expected lifetime of the YTA is 50 years. The Verification The demonstration for each phase
reliability data listed in the FMEDA report is only of the life-cycle that the (output)
valid for this period. The failure rates of the YTA may deliverables of the phase meet the
increase sometime after this period. Reliability objectives and requirements
calculations based on the data listed in the FMEDA specified by the inputs to the
report for YTA lifetimes beyond 50 years may yield phase. The verification is usually
results that are too optimistic, i.e. the calculated Safety executed by analysis and / or
Integrity Level will not be achieved. testing
A.2.11 Environmental Limits Validation The demonstration that the safety-

related system(s) or the
The environmental limits of the YTA are specified in combination of safety-related
the user’s manual IM 01C50B01-01E. system(s) and external risk
reduction facilities meet, in all
A.2.12 Application Limits respects, the Safety Requirements
The application limits of the YTA are specified in the Specification. The validation is
user’s manual IM 01C50B01-01E. If the transmitter is usually executed by testing.
used outside of the application limits, the reliability Safety Assessment The investigation to arrive at a
data listed in A.2.9 becomes invalid. judgment - based on evidence - of
the safety achieved by safety-
A.3 Terms and Definitions related systems
FMEDA Failure Mode Effect and Further definitions of terms used for safety techniques
Diagnostic Analysis and measures and the description of safety related
systems are given in IEC 61508-4.
SIF Safety Instrumented Function
SIL Safety Integrity Level
SIS Safety Instrumented System –
Implementation of one or more
Safety Instrumented Functions.
A-3 IM 01C50T01-01E
◆ Revision Record
● Manual No. : IM 01C50T01-01E
● Title : YTA series Temperature Transmitter (HART Protocol)

1st Sep. 1998 — New Publication
2nd Jan. 1999 — Error Correction
3rd Jun. 1999 3-3, 3-5, Add parameters related to Sensor matching function.
4-1
3-23 Add “3.5.11 Sensor Matching Function”.
4th July 2000 Cover Add style code

CONTENTS Add “1.1 Matching of DD and instruments”, “3.5.12 CJC Selection”
1-3 Add “1.1 Matching of DD and instruments”
3-3, 3-4 Add parameters
3-5 Add parameters
3-9 Add Notes for Non-standard sensor
3-18 Add hardware write protect function
3-23 Add “Notes item 2”
3-28 Add parameters
4-1, 4-2 Add parameters
5th Sep. 2006 Cover Remove style code

CONTENTS Add APPENDIX A
1-1 to 1-4 Change Introduction and add ATEX documentation
3-3, 3-4, 4-2 Add a parameter
3-15 Change Sensor Trim procedure
3-20 Add an error item
A-1 to A-3 New Publication
Written by Product Marketing Dept.

Transmitters Center
Industrial Automation Systems Business Div.
Published by Yokogawa Electric Corporation

2-9-32 Nakacho, Musashino-shi, Tokyo 180,
JAPAN
Blank Page
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.22 Temperature Element
Publication No.1354
RESISTANCE BULB
MICA TYPE RTD
山里産業株式会社 RESIMIC
SHEATHED TYPE RTD
Head Office : 1-5-4, Mishimae, Takatsuki-shi,
Osaka 569-0835, Japan RESISLIM
Tel :+81-6-6441-4897 Fax:+81-6-6441-3516 STEM TYPE RTD
Takatsuki Factory : 1-5-4, Mishimae, Takatsuki-shi,

Osaka 569-0835, Japan
THERMOWELL
THERMOWELL
Tel:+81-72-678-1313 Fax:+81-72-679-2006
Subsidiary
in Canada : M.I. CableTechnologies, Inc. (MICT)
Tel:+1-403-571-8266 Fax:+1-403-571-8267
URL:http://www.mict.ab.ca
in Singapore : Thermosensor Technologies Pte. Ltd. (TST)

Tel:+65-628-0090 Fax:+65-6262-0013
URL:http://www.thermosensor.com
2004.DEC.1000.○
K
CONTENTS
Resistance Temperature Detectors Page
What is Resistance Temperature Detector? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LINE OF BUSINESS Its Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Structure and Measuring Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
Precautions in Practical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Characteristics and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Temperature Sensors: Other products and lmported Calibration Services for Nominal Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Equipment: Temperature Sensors by JCSS Operating Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Metal Sheathed Thermocouple, THERMIC Metal Sheathed Heat Tracing Cable and Laboratory: Temperature Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Beaded Type Thermocouple with Micro Heater Assembly Precision calibration using Triple Point of Class and Rated Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Protection Tube Dissolved Oxygen Sensor for Molten Water and Mercury. Fixed Point Temperature/Resistance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Metal Sheathed Resistance Temperature Copper Bath, METAL-OX Standards of pure metals and Standard
Detector, RESIMIC AM・FM Turbine Blade Tip Clearance Platinum Resistance Thermometer Types of RTD Element .......................................................... 6
Resistance Temperature Detector with Measuring System traceable to National Standard. RESIMICA (Mica Type Platinum RTD Element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Protection Tube ISOTECH Precision Temperature Comparison Calibration with Standard RESICERAM® (Ceramic Type Platinum RTD Element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fine Diameter Resistance Temperature Calibration Apparatus and Standard Platinum Resistance Thermometer and RESIGLASS (Glass Sealed Type Platinum RTD Element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Element, RESICERAM Thermometers Standard Thermocouple using Liquid
Tubular Stem Type Resistance Turbine Blade and Aircraft Wing Models Baths, Fluidized Bed Alumina powder Mica Type RTD (Model: RE)
Temperature Detector, RESISLIM for Wind-Tunnel Experiment Bath, and Electric Furnace. A Certified
Special Thermocouple for Ultra-High Computerized Two & Three Dimensional What is Mica Type RTD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Calibration Report shall be issued.
Temperature, HT-THERMIC Fine Traverser Its Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special Thermocouple for Temperature Total, Static and YAW Probes for high Vibration & Shock Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Measurement of Tube Skin temperatures Low Temperature Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Multi-Point Thermocouple Temperature Transmitters Standard Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Characteristics of Insulating Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Characteristics of Metal Protection Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Standard Dimensions of Protection Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Surface Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Standard Assemblies of Mica Type RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Terminal Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ISO 9001
ACCREDITATIONS OF QUALITY ASSURANCE, Since 1995, we maintain leading position
RESIMIC® Sheathed RTD (Model:RM)
SAFETY AND P.L. WARRANTY as one of the reliable manufacturers of
various temperature sensors under rigid What is RESIMIC? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
quality assurance system to ISO 9001 Its Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
which has compatibility with the Types and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
qualification marks and logos (left). Sheathed Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ISO 14001
Beginning in July, 2004, a key objective of RESISLIM Stem Type RTD (Model:RS)
ISO 14001 all of Yamari's business operations has What is RESISLIM?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
been to reduce industrial pollution and
JQA-0797 JQA-EM4107 Its Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
minimize damage to the environment.
Head Office / Takatsuki Factory Takatsuki Factory The environmental protection programs Types and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tokyo / Nagoya / Fukuoka Inner Lead Material to Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
we have now established form part of our
commitment to continual improvement, Types of RESISLIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ISO 9001：2000／JIS Q 9001：2000 subject to a strict environmental Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ISO 14001：1996／JIS Q 14001：1996 management system meeting all the Standard Assemblies of RESIMIC ® and RESISLIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
requirements of ISO 14001.
Standard Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
JCSS:
In order to certify accuracy and reliability Types of Lead Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
of the temperature sensors, we obtained
an accreditation by IA Japan (International
Accreditation Japan) in 1994 as a qualified
Thermowell (Model:WL)
symbolizes the traceability system in accordance with the measurement law.
temperature calibration service laboratory Bores and Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
The Calibration results may be accepted internationally through ILAC/APLAC MRA.
through an established traceability with Standard Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
the National Standard. JCSS (Japan Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Calibration Service System) is in Standard Thermowells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
conformity with ISO/IEC 17025 to
provide measurement standards and Inspections and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
measured quantities, i.e., an authorized
certification of the temperature figures.
Temperature Calibration Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2000-T163
2000-T164 P.L.
Our products are fully inspected to
Chemical Resistance of Protection Tube Material . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CENELEC(KEMA) assure quality and proper functions, but
for warranty to the customers, sufficient OVERSEAS AFFILIATED COMPANY
amount of P.L. Insurance is being M.I. Cable Technologies, Inc.(MICT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
covered. Thermosensor Technologies Pte. Ltd.(TST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
RESISTANCE TEMPERATURE DETECTORS Characteristics and Standards
JIS C 1604-1997 BS EN60751-1996
JIS C 1604-1989 (JPt 100) DIN EN60751-1996
What is Resistance Temperature Detector (RTD)? IEC 751-1986 (Amd. '95)
Generally, electrical resistance of any metallic conductor

varies according to temperature changes. The sensor for
Nominal Resistance Operating Temperature Range
Resistance Value Resistance Ratio Code Application Operating Temperature
measurement of temperature by utilizing this phenomenon Code (Ω at 0℃) R100/R0
is called “Resistance Thermometer”or“RTD”and can L low temperature −200∼＋100
Pt 100 100 1.3851
measure temperatures more precisely than other tempera- M medium temperature 0∼350
ture sensors. (JPt 100) 100 1.3916 H high temperature 0∼650 ★
R100 is resistance value at 100℃.

R0 is resistance value at 0℃. S ★★
extra-high temperature 0∼850
★ This shall be 500℃ for sheathed type RTD
★★ Not applicable for sheathed type RTD
Its Features
Resistance temperature detectors for industrial applica-
tions have the following features. Temperature Tolerance
1. Good sensitivity. Measuring
−200 −100 0 100 200 300 400 500 600 650
Temp.(℃)
2. Excellent stability and reproducibility.
Tolerance(℃)
3. High accuracy.
Class A ±0.55 ±0.35 ±0.15 ±0.35 ±0.55 ±0.75 ±0.95 ±1.15 ±1.35 ±1.45
Class B ±1.3 ±0.8 ±0.3 ±0.8 ±1.3 ±1.8 ±2.3 ±2.8 ±3.3 ±3.6
Structure and Measuring Methods
Structure:
Metal wire that changes its electric resistance to changes
in temperature are utilized is called“Resistance Wire”. Class and Rated Current
This resistance wire, normally of platinum, is used to Code Class Tolerance(℃) Rated Current(mA)
manufacture a temperature sensor called“Resistance
Temperature Detector(RTD)Element”. Generally speaking, Pt 100 A ±(0.15＋0.002│t│) 0.5, 1, 2
RTD is composed of RTD element, lead wires, protection A (JPt 100) B ±(0.3 ＋0.005│t│) 0.5, 1, 2, (5)
tube and terminals. R │ t│means the measurement temperature expressed
by a temperature (℃) unrelated to signs ＋, −.
Measuring Methods: B
2-Wires Connection: Type W
2-wires (Type W)
RTD element is connected to respective two wire leads.
Although it is less expensive than other types, it is not Temperature/Resistance Table
recommendable for high precision measurement of temper- Std. Std. Std. Std. Std.
ature because it is susceptible to lead resistance and pro- A Pt100 JPt100 Pt100 JPt100 Pt100 JPt100 Pt100 JPt100 Pt100
℃ ℃ ℃ ℃ ℃
duces error. R B −200 18.52 17.14 0 100.00 100.00 200 175.86 177.13 400 247.09 249.56 600 313.71
3-Wires Connection: Type X
B −190 22.83 21.46 10 103.90 103.97 210 179.53 180.86 410 250.53 253.06 610 316.92
One end of RTD element is connected to two wire leads −180 27.10 25.80 20 107.79 107.93 220 183.19 184.58 420 253.96 256.55 620 320.12
3-wires (Type X)
and the other end connected to single lead to eliminate the −170 31.34 30.12 30 111.67 111.88 230 186.84 188.29 430 257.38 260.02 630 323.30
effect from lead resistance. This type is most widely used −160 35.54 34.42 40 115.54 115.81 240 190.47 191.99 440 260.78 263.49 640 326.48
as a reliable method in industrial applications. A −150 39.72 38.68 50 119.40 119.73 250 194.10 195.67 450 264.18 266.94 650 329.64
4-Wires Connection: Type Y A −140 43.88 42.91 60 123.24 123.64 260 197.71 199.35 460 267.56 270.38 660 332.79
RTD element is connected to respective two wire leads to R B −130 48.00 47.11 70 127.08 127.54 270 201.31 203.01 470 270.93 273.80
remove the effect from lead resistance. This connection −120 52.11 51.29 80 130.90 131.42 280 204.90 206.66 480 274.29 277.22
cancels lead resistance effect and is especially recom- B −110 56.19 55.44 90 134.71 135.30 290 208.48 210.30 490 277.64 280.63
mendable for high precision measurement of temperature 4-wires (Type Y) −100 60.26 59.57 100 138.51 139.16 300 212.05 213.93 500 280.98 284.02
but somewhat expensive than other types. R = RTD element. = Terminal. − 90 64.30 63.68 110 142.29 143.01 310 215.61 217.54 510 284.30 287.40
- = lead wire. − 80 68.33 67.77 120 146.07 146.85 320 219.15 221.15 520 287.62
− 70 72.33 71.85 130 149.83 150.67 330 222.68 224.74 530 290.92
A or B = Code for terminal
− 60 76.33 75.91 140 153.58 154.49 340 226.21 228.32 540 294.21
Precautions in Practical Applications − 50 80.31 79.96 150 157.33 158.29 350 229.72 231.89 550 297.49
Selection of proper RTD suitable for the application is the most important factor. For precision measurement − 40 84.27 83.99 160 161.05 162.08 360 233.21 235.45 560 300.75
of temperature, consideration should be given to selection of RTD element, protection tube, structure and − 30 88.22 88.01 170 164.77 165.86 370 236.70 238.99 570 304.01
fitting (location) according to the respective resistance to heat, corrosion, mechanical shock and other environ- − 20 92.16 92.02 180 168.48 169.63 380 240.18 242.53 580 307.25
− 10 96.09 96.02 190 172.17 173.38 390 243.64 246.05 590 310.49
mental conditions.
−4− −5−
®
Types of RTD Element
Ceramic Type Platinum RTD Element

RESICERAM® is composed of a coil-formed high
purity platinum wire inserted into bores of a fine polished
Mica Type Platinum RTD Element Pt wire Lead wire
recrystallized Alumina ceramic body and fixed on its bottom
by special heat resistant frit. As approximately 80% of the
Mica type Platinum RTD element is composed of a φ
resistance wire is free of heat strain from temperature D
mica plate wound with a high purity platinum wire and
change, drift in resistivity is minimized and its reproducibility
sandwiched in between two mica plates for insulation
and long term stability are superior to any of conventional L
and, again, sandwiched in between two stainless steel
core-wound elements.
plate springs and, then, fixed tightly by stainless steel
Pt wire Lead wire
wires.
Because of ease in handling and rigid structure, it is Types
W
being used widely in industrial applications. Resistance Nom. Dimensions(mm) Operating Temp. Rated Current
Nominal
Type Ratio Class
L
Resistance(Ω) R100/R0 Length(L) O. D. (D) (℃) (mA)
C100 / 0715S 100 15 0.75
C100 / 0915S 100 15 0.9 Below 1
S.S. spring C100 / 1210S 100 1.3851 10 1.2
A
C100 / 1615S 100 JIS 15 1.6
C100 / 2815S 100 IEC 15 2.8
Below 2
Types C100 / 3025S
C100 / 4530S
100
100
DIN
BS
25
30
3.0
4.5
Resistance Nom. Dimensions(mm) I.D. of Protection Operating Temp. Rated Current −200∼500
Nominal CJ100/0715S 100 15 0.75
Type Ratio Class
Resistance(Ω) R100/R0 Length(L) Width(W) Tube (mm) (℃) (mA) CJ100/0915S 100 15 0.9 Below 2
CJ100/1210S 100 1.3916 10 1.2
M100/ 40S 100 50 4.0 5.0
CJ100/1615S 100 15 1.6 B
M100/ 50S 100 CJ100/2815S 100 15 2.8
50 5.0 6.0 Below 5
M100/ 50D 100×2 CJ100/3025S 100 Old JIS 25 3.0
M100/ 60S 100 50 CJ100/4530S 100 30 4.5
(75) 6.0 7.0 On order for dual element, put suffix D instead of S. Other special sizes are also available.
M100/ 60D 100×2 For high temperature use (0-650℃) put suffix-H after S or D on element Types. Example −“C100/2815S-H”.
M100/ 70S 100 50
(75) 7.0 8.0
M100/ 70D 100×2 1.3851 Below 2
M100/ 80S 100 50
(75) 8.0 9.0
M100/ 80D 100×2
M100/ 90S 100 JIS 50
IEC (75) 9.0 10.0
M100/ 90D 100×2
DIN
Glass-sealed Platinum RTD Element
M100/100S 100 BS 50
(75) 10.0∼ 11.0∼16.0 A It is composed of a high purity platinum wire wound
M100/100D 100×2
−200∼250 non-inductively around a special glass body, of which Pt wire Lead wire
MJ100/40S 100 50 4.0 5.0 B resistivity at 0℃ is adjusted to fall within the respective
MJ100/50S 100 standard ranges, inserted into another special glass
50 5.0 6.0 φ
D
MJ100/50D 100×2 tube and heat sealed overall. Quick response and
MJ100/60S 100 50 excellent in insulation, withstand voltage, vibration, and
(75) 6.0 7.0 high resistance to liquid, chemicals and gases. L
MJ100/60D 100×2
MJ100/70S 100 50 Below 2
7.0 8.0
MJ100/70D 100×2 1.3916 (75) Types
MJ100/80S 100 50 Below 5
Nominal Resistance Nom. Dimensions(mm) Operating Temp. Rated Current
(75) 8.0 9.0 Type Ratio Class
MJ100/80D 100×2 Resistance(Ω) R100/R0 Length(L) O. D. (D) (℃) (mA)
MJ100/90S 100 50 G100 / 2025S 100 1.3851 2.0
9.0 10.0 Below 1 A
MJ100/90D 100×2 (75) G100 / 3025S 100 JIS, IEC. 25 3.0
Old JIS Below 2
MJ100/100S 100 G100 / 4025S 100 DIN, BS 4.0
50 −200∼350
(75) 10.0∼ 11.0∼16.0 GJ100/2025S 100 1.3916 2.0
MJ100/100D 100×2 Below 2
GJ100/3025S 100 25 3.0 B
In the Nominal Resistance column, × 2 means dual elements. Old JIS Below 5
GJ100/4025S 100 4.0
Other sizes and nominal resistance values (500Ω, 1000Ω) are also available upon request.
Other sizes are also available.
−6− −7−
Properties of lnsulating Tubes
Operating Maximum
Material Code Temp. Temp. Properties
(MODEL:RE) Ceramic 1 PS1 1400℃ 1600℃ Highest insulation among insulation materials. Solid.
Teflon FEP 180℃ 200℃ Excellent resistance to heat, chemicals, etc. Flexible.
Mica Type RTD Polyimid PM 220℃ − Characteristics similar to FEP but tougher and thin-wall thickness.
Terminal
Properties of Metal Protection Tubes
What is Mica Type RTD? Material Code Operating Temp. Properties
This is the most typical resistance temperature detector Copper CU 250℃ Good heat conductivity and excellent corrosion-resistance.
using RESIMICA (Mica type RTD element) as shown in
Brass BS Oxidizing400℃ Reducing 150℃ Similar to Copper and good workability.
the right picture.
Terminal Box 304S. S. 304 980℃ High resistance to heat and corrosion.
316S. S. 316 980℃ Excellent resistance to heat, acids and alkalis.
Features 316L.S. S. 316L 980℃ Excellent resistance to grain boundary corrosion.
1) The use of high purity platinum resistance wire Titanium TI Oxidizing250℃ Reducing1000℃ Excellent resistance to corrosion at low temp. but easily oxidized and
embrittled at high temperature.
ensures precision measurement.
Monel MN Oxidizing500℃ Reducing 600℃ Excellent resistance to heat, high pressure and corrosion.
2) Excellent in stability and reproducibility. Other special tubes are also available. Operating and maximum temperatures vary depending on atmosheres.
Vibration & Shock Resistance

For the use under high flow-velocity, vibration or mechani- Standard Dimensions of Protection Tubes (○＝Available)
cal shock, RTD element and inner lead wires are protect- Regular Type Regular Type Shock Proof Type Shock Proof Type
single double single double
ed by shock-resistant stainless steel inner tube support. Protection Tube material
size(mm)
304 316 316L 304 316 316L 304 316 316L 304 316 316L Remarks
Low Temperature Treatment 7 × 5 ○

8 × 6 ○ ○
Low temperatures often cause dew condensation in a
protection tube that results in deterioration of insulation 9 × 7 ○ ○
Inner lead wires
resistance. For use at sub-zero temperature, please 10 × 8 ○ ○ ○ ○ ○ ○ ○ ○ ○
specify“Low Temperature Treatment”that makes the 11 × 9 ○ ○ ○ ○
sensing tip of RTD element covered with silicon or 12 × 9 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
paraffin coating to protect from dewing. RTD Element 13 × 9 ○ ○ ○ ○
13.8× 9.4 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 8A SCH.40
Structure of RTD Assembly 15 × 11 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Standard Specifications 16 × 12 ○ ○ ○ ○
17.3×12.7 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 10A SCH.40
Nominal Resistance (at 0℃) Code No. of Element Code
20 × 16 ○ ○ ○ ○
Pt 100Ω 100 1 (Single) S
21.7×16.1 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 15A SCH.40
JPt 100Ω J100 2 (Double) D
Lend Connection Code Rated Current Code

2-wires W 0.5 mA 005
SURFACE COATINGS
3-wires X 1 mA 01 Corrosion Resistant Lining & Coating
4-wires Y 2 mA 02 Thickness Max Oper.
Coating Material (mm) Structure Temp. Characteristics
5 mA ※ 05 Good protection against oxidation and gas penetration
Glass-lining 1∼1.2 Steel＋Glass 450℃ but poor thermal shock resistance.
※: 5 mA for JPt100
Lead Wires to Applications Suitable in concentrated 2HCl, H2SO4 and HNO3 and
Teflon(FEP)coating 0.3 Metal＋FEP 120℃ most of chemicals but depending on temperature
conditions.
Application Code Operating Temperature Inner Lead Wires
Low Temperature L −200∼100℃ Silver
Mid. Temperature M 0∼250℃ Silver
For Abrasion Resistance. . . . . . . . Stellite, Colmonoy, Tungsten and other materials can be
processed to improve abrasion resistance of metal protec-
High Temperature H 0∼400℃ Nickel tion tubes. For further details, please consult factory.
−8− −9−
Standard Assemblies of Mica Type RTD Terminal Boxes
(MODEL:RE) Other entry threads of R, NPT or Metrics can be specified.
RE01 Insulator Threaded Type Weather Proof Wall Mount Plastics Molded
Order : RE01 Type
M 100 S X 02 L KN KW KP
Code Type Inner Resist- No.of Lead Rated Length
Leads ance Element Connection Current
Ref Page : P8 P8 Material: Al-alloy diecast Al-alloy diecast Phenolic Resin
11 KN Conduit Dia: G1／2・G3／4 G1／2・G3／4 G1／2
Applicable tube I.D. Term.
Box
P6 P11 No. of Terminals: 2, 3, 4, 6 2, 3, 4, 6 2, 3, 4
L Terminal Block: Ceramic Ceramic Ceramic
RE12 Metal Protection Tube Type Surface Finish: Melamin baked Melamin baked −
Order : RE12 M J100 S X 02 L KN
Code Type Inner Resist- No.of Lead Rated Length Term.
Surface Color: Metallic Silver Metallic Silver Black
Leads ance Element Connection Current Box
Ref Page : P8 P8 P11
G1 2 , G 3 4 G1 2 , G 3 4 G1 2 , G 3 4 G1 2
15 316
Dimensions of Material
(86)
Prot. Tube
94
φ71
45
P9 P9
L Dimensions
2−φ6.5
RE13 Metal Protection Tube Type (Screwed) Order : RE13 (87) 75
55
94
M 100 S X 02 L U 104 G1 2
Code Type Inner Resist- No.of Lead Rated Length Insert 50
Leads ance Element Connection Current Length
Ref Page : P8 P8
Flame Proof ＊ Two Way Cable Entry Dual Cable Entry
KN 15 316 R1
2 316 Type
Term. Dimensions of Material Thread Std Material
KG (d2G4,Exd IIC T6) KR KF
Box Prot. Tube
U P11 P9 P9 Al-alloy diecast,

L Material: Stainless Steel Al-alloy diecast Al-alloy diecast
Conduit Dia: M16, 20, 25 G1／2 ×2 G1／2 ×2
RE14 Metal Protection Tube Type (Flanged) Order : RE14 M 100 S X 02 L U KN No. of Terminals: 2, 3, 4, 6 4, 6 4, 6
Code Type Inner Resist- No.of Type of Rated Length Insert Term.
Leads ance Element Lead Current Length Box Terminal Block: Bakelite Ceramic Ceramic
Surface Finish: Melamin baked Melamin baked Melamin baked
15 316 JIS10K25ARF 316
Dimensions of
Prot. Tube
Material Flange Rating Material Surface Color: Metallic Silver Metallic Silver Metallic Silver
P9 P9 P21
U G1 2 , G 3 4
L G1 2 , G 3 4
G1 2 , G 3 4
24
Shock Proof Models
98
≒116
90
Dimensions
RE51 Basic Type without Protection Tube
Order : RE51 M 100 S X 02 L ≒123
105
Code Type Inner Resist- No.of Type of Rated Length
80 50 65 2− G 1 2
Leads ance Element Lead Current 75
Ref Page : P8 P8
11 KN ＊Approved by KEMA for“II2G EEx d IIC T6”to CENELEC EN 50018.
Applicable tube I.D. Term.
Box Two way entry model also available.
P6 P11
L
RE52 Metal Protection Tube Type Order : RE52 M 100 S X 02 L

Code Type Inner Resist- No.of Type of Rated Length
Leads ance Element Lead Current
Ref Page : P8 P8
KN 15 316
Term. Dimensions of Material
Box Prot. Tube
P11 P9 P9
L
RE53 Metal Protection Tube Type (Screwed) Order : RE53 M 100 S X 02 L U

Code Type Inner Resist- No.of Type of Rated Length Insert
Leads ance Element Lead Current Length
Ref Page : P8 P8
1
KN 15 316 R 2 316
Term. Dimensions of Material Thread Std Material
Box Prot. Tube
P11 P9 P9
U
L
RE54 Metal Protection Tube Type (Flanged) Order : RE54 M J100 S X 02 L U KN

Code Type Inner Resist- No.of Type of Rated Length Insert Term.
Leads ance Element Lead Current Length Box
15 316 JIS10K25ARF 316
Dimensions of Material Flange Rating Material
Prot. Tube
P9 P9 P21
U
L
In case of JPt (R100/R0=1.3916), put a suffix-J, Example see code RE 12 and RE 54.
− 10 − − 11 −
®
RESIMIC® Types and Codes
(MODEL:RM) Nominal Resistance (at 0℃) Code Number of Element Code
Pt 100Ω 100 1 (single) S
JPt 100Ω J100 2 (double) D
Sheathed Type RTD
Rated Current Code
Lead Connection Code 0.5 mA 005
3 wires X 1 mA 01
®
RESIMIC What is RESIMIC? 4 wires Y 2 mA 02
5 mA ※ 05
RESIMIC ® is a registered trade name of YAMARI's
metal sheathed RTD that has a monolithic structure com-
prising of RESICERAM® element and MI cable (MgO RESIMIC® Sheathed Leads
compacted, metel sheathed lead wires). This newly deve-
loped RTD has very quick response, longer service life Sheath O. D. Conductor Dia. Lead Resistance Sheath Sheath Max Length
(mm) (mm) (Ω/m at 20℃) Wall(mm) Material (m )
and high accuracy under critical conditions. sheath
Ni Conductor
3.2 0.33 1.106 0.30 316 SS 150
MgO
4.8 0.51 0.467 0.43 316 SS 60
®
RESIMIC Its Features 6.4 0.66 0.276 0.58 316 SS 30
8.0 0.81 0.177 0.74 316 SS 15
1) Quick Response:
Since RESIMIC® sensing part is filled with high 4.8 0.51 0.467 0.43 316 SS 60
purity alumina powder and protected by a metal 6.4 0.66 0.276 0.58 316 SS 30
sheath, it has much faster response than those of
8.0 0.81 0.177 0.74 316 SS 15
ordinary RTD's and can follow any slight change in
temperature.
2) High Flexibility: RESIMIC® Response Time

Except for the sensing part of up to 60mm from the
tip, it can be bent to the radius equal to 2 times of the The“τ”Constants (63.2%) when RESIMIC® is immersed into 100℃ (boiling water) from 0℃ (ice bath).
sheath O.D. φ3.2 less than 2 sec.
φ4.8 less than 4 sec.
3) High Accuracy: φ6.4 less than 6 sec.
Since high purity platinum resistance wire is used, it φ8.0 less than 11 sec.
has high accuracy falling within the class of A or B
100
stipulated by JIS C1604-1997, or other internationally
known Standards.
4) Wide Variety of Specifications:

Outer diameters from 3.2mm to 8.0mm and total φ8.0
length up to 150 meters are available.

63.2
Temperature (℃)
5) Wide Range of Measuring Temperatures:
φ6.4
From cryogenic (−200℃) to high temperature
(＋500℃) can be measured although it may vary
depending on surrounding atmospheres. φ4.8
φ3.2
0 5 10 15 20 25 30 35 40 45 50 55 60
Time (sec)
− 12 − − 13 −
RESISLIM Types
(MODEL:RS) Nominal Nom. O.D. Manufacturable Range to Operating Temp. Maximum
Resistance (at 0℃) (mm) −200∼250℃ 250∼650℃※ Length (mm)
Stem Type RTD 1.0 ○ 200
1.2 ○ 〃
1.6 ○ 1,000
2.0 ○ 〃
RESISLIM What is RESISLIM? Pt 100Ω 2.5 ○ 〃
JPt 100Ω 3.2 ○ ○ 2,000
RESISLIM is a newly developed RTD assembly that is composed of a fine diameter metal protection tube in
which high purity Al2O3 powder is tightly compacted and sealed around RESICERAM® element. 4.0 ○ ○ 〃
4.8 ○ ○※ 〃
6.4 ○ ○※ 〃
8.0 ○ ○※ 〃
RESISLIM Its Features 3.2 ○ 2,000
4.0 ○ 〃
Pt 100Ω × 2
1) Due to small mass of heat and finer diameter, it is possible to measure temperatures in such places where 4.8 ○ ○ 〃
conventional types are not accessible. JPt 100Ω × 2
6.4 ○ ○※ 〃
8.0 ○ ○※ 〃
2) It has quicker response than Mica type RTD or RESIMIC®.
※High temperature models of up to 650℃ are available upon request.
3) It has accuracies of class A or B stipulated by JIS C1604-1997, or other internationally known standards due
to use of RESICERAM® elements.
RESISLIM Response Time
4) It has wide range of operating temperatures from −200℃ to ＋650℃ depending on surrounding
The“τ”Constants (63.2%) when RESISLIM is immersed into 100℃ (boiling water) from 0℃ (ice bath).
atmospheres as in the case of RESIMIC®.
RESISLIM Types and Codes
Nominal Resistance (at 0℃) Code Number. of Element Code 100
Pt 100Ω 100 1 (single) S

φ3.2
JPt 100Ω J100 2 (double) D
φ6.4
φ4.8
φ8.0
Lead Connection Code Rated Current Code
63.2
Temperature (℃)
3-wires X 0.5 mA 005
4-wires Y 1 mA 01
2 mA 02
5 mA ※ 05
Inner Lead Material to Operating Temperature

Application Code Operating Temperature Lead Material
Mid. Temperature M −200∼250℃ Silver
High Temperature H 0∼650℃※ Nickel 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
※: Operating temperature of Old JIS JPt is up to 500℃. Time (sec)
− 14 − − 15 −
RESIMIC ® (MODEL:RM)
Standard Assemblies of
RESISLIM (MODEL:RS)
RM RM RM
RS A Basic Type RS N RS UN Screwed Type
Order : RMA M 100 S X 02 32 With Union Order : RMN M 100 S X 02 48
Code Type Inner Resist- No.of Lead Rated O.D.
Code Inner Resist- No.of Lead Rated O.D.
P13,P15
RMUN Leads ance Element Connection Current
P13,P14 Type P13,P14 P13,P15
L L U KN R1 2 304
Length Insert Term. Thread Std Material
Length
Length Box
L 50 U P11
L
RM RM RM
RS B Flexible Lead Type RS NB RS UNB Screwed Type
Order : RMB M 100 S X 02 32 With Union Order : RMNB M 100 S X 02 48
P13,P15
RMUNB Leads ance Element Connection Current
P13,P14 Type P13,P14 P13,P15
L WR13 ( A ) L U KN R1 2 304
Length Lead Lead Length Length Insert Term. Thread Std Material
70 Length Box
L 55 A
P19 U P11
L
RM RM RM
RS BF Armoured Lead Type RS NS RS UNS Spring-Loaded Type
Order : RMBF M 100 S X 02 With Union Order : RMNS M J100 S X 02 48
Code Type Inner Resist- No.of Lead Rated
Leads ance Element Connection Current RMUNS Leads ance Element Connection Current
P13,P14 Type P13,P14 P13,P15
≒10 Spring
48 L WR 13 A Return L U KN R1 2 304
O.D. Length Lead Insert Length Insert Term. Thread Std Material
70 Length Length Box
L 55 A P13,P15 P19 U P11
L
RM BYS RM RM
RS Bayonet Mount Type RS NBS RS UNBS Spring-Loaded Type
Order : RMBYS M 100 S X 02 With Union Order : RMNBS M J100 S X 02 48
Leads ance Element Connection Current RMUNBS Leads ance Element Connection Current
P13,P14 Type P13,P14 P13,P15
≒10 Spring
48 L WR 13 A Return L U KN R1 2 304
E O.D. Length Lead Insert Length Insert Term. Thread Std Material
70 Length Length Box
L 55 A P13,P15 P19 U P11
L
RM RM
RS ES Metal Connector Type RS P Metal Protection Tube Type
Order : RMES M 100 S X 02
Order : RMP M 100 S X 02 48
Leads ance Element Connection Current Leads ance Element Connection Current
P13,P14 P13,P14 P13,P15
48 L WR 13 A L KN 15 304
70 O.D. Length Lead Insert Length Term. Dimensions of Material
Length Box Prot. Tube
L 81 A P13,P15 P19
P11 P9
L
RM RM Order : RMPB M 100 S X 02 48

RS H Basic Type with Terminal Box RS PB Metal Protection Tube Type (Screwed) Code Type Inner Resist- No.of Lead Rated
O.D.
1
Order : RMH M 100 S X 02 48 P13,P14 P13,P15
NPT
2
P13,P15 L U KN 15 304
P13,P14 Insert Term. Dimensions of Material
Length
L KN NPT 1 2 BU P11 P9
Length Term. Bushing
Box
U R12 304
P11
L L Thread Std Material
RM RM Order : RMPF M 100 S X 02 48

RS NF Flanged Type RS PF Metal Protection Tube Type (Flanged) Code Type Inner Resist- No.of Lead Rated
O.D.
Order : RMNF M 100 S X 02 48 P13,P14 P13,P15
P13,P15 L U KN 15 304
P13,P14 Insert Term. Dimensions of Material
Length
L U KN JIS10K25ARF 304 P11 P9
Length Insert Term. Flange Rating Material
U
Length Box JIS10K25ARF 304
P11 P21 U Flange Rating Material
L L
P21
In case of JPt (R100/R0=1.3916), put suffix-J. Example see code RMNF and RMNS.
− 16 − − 17 −
Optional Accessories Types of Lead Wires
Unit : mm
1. Fixed Type Bushing 304SS φD TYPE S1 S2 A B Appearance Type Color Dimensions Covering Application
Coding
1.0 BN 101 R 1／8 − 10 16
S1 1.6 BN 161 R 1／8 − 10 16 Conductor
Black
2.2 BN 221 R 1／8 − 10 16 0.4/7 Outer: PVC insulating
(Red,
BN 321 R 1
／8 − 10 16 WR12 sheath. General
White,
Nom. O.D. Inner: Copper shield
3.2 BN 322 R 1／4 − 12 20 Blue)
φ
φ9.0mm
1
D BN 324 R ／2 − 20 35
1
／8
BN 481 R − 10 16 Conductor
Grey Outer: Stainless Steel
BN 482 R 1／4 − 12 20 0.18/20
4.8 (Red, shield. High
BN 484 R 1／2 − 20 35 WR13
White, Inner: Glass braided Temp.
BN 486 R 3／4 − 20 35 Nom. O.D.
White) insulating sheath.
Weld φ5.0mm
BN 642 R 1／4 − 12 20
A 6.4 BN 644 R 1／2 − 20 35
Conductor
3
／4
BN 646 R − 20 35 Grey 0.18/20
B
BN 802 R 1／4 − 12 20 WR13D (R,W,W) 〃〃
1
／2 (R,W,W) Nom. O.D.
8.0 BN 804 R − 20 35
BN 806 R 3／4 − 20 35 φ6.6mm
1
2. Compression Fitting 304SS 1.0 CF 101 R ／8 − 10 33
1 Conductor
CF 151 R ／8 − 10 33
1.5 Grey 0.18/20 Outer: Heat-resistant
CF 152 R 1／4 − 12 35 WR15A PVC insulating sheath. General
(R,W,W)
CF 161 R 1／8 − 10 33 Nom. O.D. Inner: Copper shield.
1.6
CF 162 R 1／4 − 12 35 φ5.0mm
1
S1 CF 201 R ／8 − 10 33
2.0 Conductor
φ
CF 202 R 1／4 − 12 35
D Grey 0.18/20
1
／8
CF 221 R − 10 33
2.2 WR15D (R,W,W) 〃〃
CF 222 R 1／4 − 12 35
(R,W,W) Nom. O.D.
CF 301 R 1／8 − 10 33 φ6.8mm
3.0
CF 302 R 1／4 − 12 35
A 1
CF 321 R ／8 − 10 33 Conductor
3.2
B CF 322 R 1
／4 − 12 35 Grey 0.18/20 Outer: Silicon insula-
High
CF 451 R ／81
− 10 33 WR16 ting sheath.
(R,W,W) Temp.
4.5 Nom. O.D. Inner: Copper shield.
CF 452 R 1／4 − 12 35
φ5.8mm
CF 481 R 1／8 − 10 33
4.8 1
CF 482 R ／4 − 12 35 Conductor
Outer: Stainless Steel
6.0 CF 602 R 1／4 − 12 35 0.18/12
White shield.
Note:The standard cotter is Stainless Steel 6.4 CF 642 R 1／4 − 12 35 WR17 〃
(R,W,W) Inner: Glass insulating
but Teflon cotter (Type TCF) is also available. 8.0 CF 802 R 1／4 − 12 35 Nom. O.D. sheath.
3 1 φ4.0mm
3. Compression Fitting with Bushing CF 323 R ／8 R ／8 15 54
304SS 3.2 CF 324 R 1／2 R 1／8 20 59
Conductor
3 1
CF 326 R ／4 R ／8 20 59 White 0.18/12
S1 CF 483 R 3／8 R 1／8 15 54 WR17D (R,W,W) 〃〃
1
φ
D 4.8 CF 484 R ／2 R 1／8 20 59 (R,W,W) Nom. O.D.
CF 486 R 3／4 R 1／8 20 59 φ5.0mm
R 3
／8 R 1／4
CF 643 15 54
1 1 Conductor
6.4 CF 644 R ／2 R ／4 20 59
S2 Grey 0.18/7
A
CF 646 R 3／4 R 1／4 20 59 Heat-resistant PVC
WR18 General
(R,W,W) insulating sheath.
B CF 803 R 3／8 R 1／4 15 54 Nom. O.D.
8.0 CF 804 R 1／2 R 1／4 20 59 φ3.5mm
3 1
CF 806 R ／4 R ／4 20 59 Other special types are also available. (R=Red, W=White)
− 18 − − 19 −
Flanges
(MODEL:WL) JIS Flange
Flat Face (FF) Raised Face (RF)
Hole Hole
THERMOWELL (Drilled Bar Stock Type Protection Tube) is usually being used to ensure longer service life
t
t
under critical conditions such as very corrosive gases or liquids, high temperature, high pressure, vibration, g
f
C
C
shock or high flow velocity. D D
At YAMARI, various THERMOWELLs durable under these conditions are manufactured. Fig.1 Fig.2
Dimensional Specifications Unit : mm

No. of Hole Nom.
THERMOWELL Bores & Depths Flange Rating Size A
15
Size B
1/2
D
80 9
t f
1
g
44 60
C f
1
Bolt Holes
4
Dia.
12
Bolt Size
M10
Weight(kg)
0.32
20 3/4 85 10 1 49 65 1 4 12 M10 0.41
Max.Depth
Bore (mm) (mm)
JIS 5K 25 1 95 10 1 59 75 1 4 12 M10 0.52
32 11/4 115 12 2 70 90 2 4 15 M12 0.91
4.0 500 40 11/2 120 12 2 75 95 2 4 15 M12 0.99
15 1/2 95 12 1 51 70 1 4 15 M12 0.63
5.5 700 20 3/4 100 14 1 56 75 1 4 15 M12 0.78
JIS 10K 25 1 125 14 1 67 90 1 4 19 M16 1.22
7.0 800 32 11/4 135 16 2 76 100 2 4 19 M16 1.66
40 11/2 140 16 2 81 105 2 4 19 M16 1.80
8.5 1,000
10.0 1,200
ANSI Flange
11.0 1,200 Raised Face (RF) Ring Joint (RTJ)
Hole Hole
12.0 1,200
t
t
16.0 1,200
P
6.4
g
E
f
K
C C
D Fig.3 D Fig.4
THERMOWELL Raw Material Sizes
Raised Face (RF) Ring Joint (RTJ)
Round Bar (O.D.): mm
X X Hole
25, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, Hole
50, 55
Y
Y
t
t
Hexagonal Bar: mm P
6.4
g
E
f
K
26, 29, 32, 35, 38, 41 C C
D Fig.5 D Fig.6
THERMOWELL Standard Materials Dimensional Specifications Unit : mm
304 SS, 316 SS, 316L SS, 310S SS, 321 SS, Inconel, Flange Size A Size B D Min.t f g C No. of Hole Bolt Size Nom. Hub RTJ
Bolt Holes Dia. (inch) Weight(kg) X Y Min.K P E
Hastelloy B, Hastelloy C, Hastelloy X, Monel,
15 1/2 89 11.5 1.6 35.1 60.5 4 15.8 1/2 0.43 30.2 16.0 -- -- --
Nickel and its alloys, 50Co-30Cr, Titanium and its 20 3/4 99 13.0 1.6 42.9 69.9 4 15.8 1/2 0.62 38.1 16.0 -- -- --
alloys. Other special materials are also available ANSI 150lbs 25 1 108 14.5 1.6 50.8 79.2 4 15.8 1/2 0.87 49.5 18.0 63.5 74.62 6.4
upon request. 32 11/4 117 16.0 1.6 63.5 88.9 4 15.8 1/2 1.16 58.7 21.0 73.5 57.15 6.4
40 11/2 127 18.0 1.6 73.2 98.6 4 15.8 1/2 1.54 65.1 22.4 83.0 65.07 6.4
15 1/2 95 14.5 1.6 35.1 66.5 4 15.8 1/2 0.65 38.1 22.4 51.0 34.14 6.4
20 3/4 117 16.0 1.6 42.9 82.5 4 19.0 5/8 1.09 48.0 25.4 63.5 42.88 6.4
ANSI 300lbs 25 1 124 18.0 1.6 50.8 88.9 4 19.0 5/8 1.38 54.0 27.0 70.0 50.80 6.4
32 11/4 133 19.5 1.6 63.5 98.6 4 19.0 5/8 1.82 63.5 27.0 63.5 60.32 6.4
40 11/2 155 21.0 1.6 73.2 114.5 4 22.4 3/4 2.70 70.0 30.3 90.5 68.28 6.4
15 1/2 95 14.5 6.4 35.1 66.5 4 15.8 1/2 0.76 38.1 22.4 51.0 34.14 6.4
ANSI 400lbs 20 3/4 117 16.0 6.4 42.9 82.6 4 19.0 5/8 1.27 48.0 25.4 63.5 42.88 6.4
& 25 1 124 18.0 6.4 50.8 88.9 4 19.0 5/8 1.59 54.0 27.0 70.0 50.80 6.4
600lbs 32 11/4 133 21.0 6.4 63.5 98.5 4 19.0 5/8 2.24 63.5 28.5 79.5 60.32 6.4
40 11/2 155 22.5 6.4 73.2 114.5 4 22.4 3/4 3.30 70.0 32.0 90.5 68.28 6.4
15 1/2 121 22.5 6.4 35.1 82.5 4 22.4 3/4 1.79 38.1 32.0 60.5 39.67 6.4
ANSI 900lbs 20 3/4 130 25.5 6.4 42.9 88.9 4 22.4 3/4 2.40 44.5 35.1 67.0 44.45 6.4
& 25 1 149 28.5 6.4 50.8 101.6 4 25.4 7/8 3.44 52.5 41.2 71.5 50.80 6.4
1,500lbs 32 11/4 159 28.5 6.4 63.5 111.3 4 25.4 7/8 3.95 63.5 41.2 81.5 60.32 6.4
40 11/2 178 32.0 6.4 73.2 124.0 4 28.5 1 5.41 70.0 44.5 92.0 68.28 6.4
− 20 − − 21 −
Standard Thermowells
(MODEL:WL)
WL･01 Hexagonal Screwed-in WL･05 Flanged (Screwed-in) Type
Type
Order : WL･01 316 250 R 1
9 15 Order : WL･05
※ Thread Allowance Code 2 304 500 R3 4 JIS10K20ARF 304
P Model No. Material “U” “P”Thread “B” “D2 ” Code Model No. Material “U” “P”Thread Flange Rating Material
316SS Length Std. Bore Dia 304SS Length Std. 304SS
D1
D2 B S N
D1 ※
D2 B S 18 45 20 29 33.5Hex Rc 1 2 5 11 17 21 50 28 Rc 1 2
“D1 ”Dia Factory Standerd “S”Thread P 17 “B” “D2 ” Neck
5 For Tapered Unless Otherwise Specified Std.
“D1 ”Dia “S”Thread
Bore Dia For Tapered Dimmension Std.
※20 17 Well Only Well Only Length×“N”
U 45 Hex U 50
WL･11 Hexagonal Screwed-in WL･06 Flanged (Weld) Type

Type
Order : WL･11 304 300 R 3
8.5 65 Order : WL･06
※ Thread Allowance Code 4 316 1250 JIS10K20ARF 316
B2 P Model No. Material “U” “P”Thread “B”× Length Code Model No. Material “U”Length Flange Rating Material
304SS Length Std. Bore Size 316SS 316SS
D2 B D1
D1 S
D2 B S 11 17 21 45 ※
20 35 40.4Hex Rc 1 2 5 9 15 18 50 28 Rc 1 2
5 “B2 ” “D2 ” “D1 ”Dia Factory Standerd “S”Thread 17 “B” “D2 ” “D1 ”Dia Neck “S”Thread
65 Dia Dia For Tapered Unless Otherwise Specified Std. Bore Dia For Tapered Dimension Std.
※20 17 Well Only Well Only Length×“N”
U 45 Hex U 50
WL･12 Hexagonal Lagging WL･61 Flanged (Weld) Type

Extension Type
Order : WL･12 310 450 R1 11 17 Order : WL･61
※ Thread Allowance Code 310 600 ANSI1"600LBRF 310
P Model No. Material “U” “P”Thread “B” “D2 ” B2 Code Model No. Material “U”Length Flange Rating Material
310SS Length Std. Bore Dia 310SS 310SS
D1 S
D1 D2 B N
※
D2 B S 26 75 25 38 43.9Hex Rc 1 2 5 8.5 65 11 17 26 50 34 1
2Rc
5 “D1 ”Dia “T” Factory Standerd “S”Thread 17 “B”× Length “B2 ” “D2 ” “D1 ”Dia Neck “S”Thread
For Tapered Length Unless Otherwise Specified Std. 65 Bore Size Dia Dia For Tapered Dimension Std.
17 Well Only Well Only Length×“N”
U ※25 T Hex 50
WL･02 Hexagonal Lagging WL･07 Plain Weld Type

Extension Type
Order : WL･02 321 300 R1 11 Order : WL･07
※ Thread Allowance Code 304 300 9 17
P Model No. Material “U” “P”Thread “B” Code Model No. Material “U”Length “B” “D2 ”
321SS Length Std. Bore 304SS Bore Dia
D2 B S N
D1 N ※
D2 B S 17 26 75 34 25 34 41 47.3Hex Rc 1 2 75 38 Rc 1 2
5 “D2 ” “D1 ”Dia “T” “N” Factory Standerd “S”Thread 17 Neck “S”Thread
Dia For Tapered Length Unless Otherwise Specified Std. 5 Dimension Std.
20 Well Only U T Length×“N”
U ※25 T Hex
T45
WL･21 Hexagonal Heavy Duty WL･08 Weld Type

Type
Order : WL･21 321 350 65 R1 1 2 11 Order : WL･08
※ Thread Allowance Code 321 500 11 22 25
P Model No. Material “U” “P”Thread “B” Code Model No. Material “U”Length “B” “D2 ” “D1 ”Dia
321SS Length Std. Bore 321SS Bore Dia For Tapered
D1 D1 Well Only
D2 B S N
N ※
D2 B S 17 26 34 50 25 50 57.7Hex Rc 1 2 5 50 41 Rc 1 2
5 “D2 ” “D1 ”Dia “N” Factory Standerd “S”Thread Neck “S”Thread
Dia For Tapered Unless Otherwise Specified Std. 17 Dimension
65 ※25 17 Well Only U 50
Std.
Length×“N”
U 50 Hex
WL･22 Hexagonal Heavy Duty WL･09 Ball Joint Type

Type
Order : WL･22 316 400 65 R1 7 65 11 Order : WL･09
※ Thread Allowance Code T 316 1300 25.4R 34.9D 3.2T
B2 P Model No. Material “U” “P”Thread “B”× Length “B” 35° Code Model No. Material “U”Length Ball Joint Dimension
316SS Length Std. Bore Size Dia. 316SS “R”×“D”×“T”
D D1 R
D1 D2 B SN
N 17 26 34 50 ※
25 35 40.4Hex Rc 1 2
D2 B S
5
R 10 14.3 19 75 26.6 Rc 1 2
“D2 ” “D1 ”Dia “N” Factory Standerd “S”Thread “B” “D2 ” “D1 ”Dia Neck “S”Thread
5 Dia For Tapered Unless Otherwise Specified Std. 17 For Tapered Dimension
Bore Dia Std.
65 ※25 17 Well Only Well Only Length×“N”
75
U 50 Hex
WL･04 Screwed-in Weld Type WL･10 Van Stone Type

Order : WL･04 304 300 R34 11 17 Order : WL･10
※ Thread Allowance Code 304 250 50 6.5 11
P 20
Model No. Material “U” “P”Thread “B” “D2 ” Code Model No. Material “U”Length Raised Face “B”
304SS Length Std. Bore Dia 304SS “D”×“Q” Bore
D D1
D1 D2 B S N
D2 B S N 21 75 28 ※
20 Rc 1 2 17 26 65 34 Rc 1 2
5
5 “D1 ”Dia “T” “N” “S”Thread “D2 ” “D1 ”Dia Neck “S”Thread
For Tapered Length Std. Dia For Tapered Dimension Std.
17 Well Only Q 17 Well Only Length×“N”
U ※20 T w
U 65
Other special types are also available upon request. Other special types are also available upon request.
− 22 − − 23 −
Inspections and Tests Temperature Calibration Services
At YAMARI, all products (Mica Type, RESIMIC ®, Traceability System of Temperature Laboratory
RESISLIM and Thermowell) are inspected and tested
before delivery in accordance with the following in-
spection procedures.
J A P A N
U.S.A U.K.
1. Check on Appearance and Structure: (Japan Calibration Service System, JCSS)
Visual inspection is made on joints, junctions, welds,
name plate and other parts. Primary Standards
Color penetration check also made on welds. National Institute of Advanced Industrial
NIST NPL
Science and Technology (AIST)
2. Dimensional Check:
Dimensions specified in the drawing are checked by a
Primary Sub Standards
scale or calipers.
Unless otherwise specified, dimensional check is made Japan Electric Meters Inspection Corporation (JEMIC) UKAS(NAMAS)
according to the tables below. ISOTECH,U.K.
Length of Mica Type RTD Unit:mm Length of RESIMIC ® and RESISLIM Unit:mm
Yamari Standard Laboratory
Nominal Length Tolerance Nominal Length Tolerance
JCSS Accreditation No. 0037
Under 1,000 ±3.0 Under 250 ±3.0
Secondary Standards
1,000∼2,000 ±5.0 250∼1,000 ±5.0
Water Triple Standard PT Standard Digital Standard Standard PT Standard
Above 2,000 ±7.0 Above 1,000 ±1.0%
Point Resistance Resistor Voltmeter Thermocouple Resistance Thermocouple
Note : For those assembled with protection tube or thermowell, Apparatus Thermometer Type“R” Thermometer Type“S”
the length within the range of giving no functional trouble
is regard as passed. WTP:0.3mK Hg,TP:1mK 1Ω : 1ppm 10mV:0.3μV 0∼1,100℃: N2,BP:10mK Au,MP:1K
(2σ) In,FP:1.6mK 10Ω : 1ppm (2σ) 0.4K Al,FP:10mK Pd,MP:2K
3. Insulation Resistance Inspection Sn,FP:1.7mK 100Ω : 1ppm (2σ) Ag,FP:40mK (2σ)
Insulation resistance is checked at room temperature by a DC 100V or 500V megohmeter in accordance with Zn,FP:2.9mK (2σ) (2σ)
the following table. (2σ)
Voltage Insulation
Type of RTD Applied Resistance Working Standards Working Standards Working Standards
Mica Type RTD 500V D.C. Above 10MΩ
RESIMIC®,RESISLIM (＜φ2.0) 100V D.C. Above 20MΩ Fixed Point Standards

Fixed Point Standards
(In, Sn, Zn, Al, Ag, Cu)
RESIMIC®,RESISLIM 500V D.C. Above 100MΩ (WTP, Hg, Ga, In, Sn, Zn) Otherd
Standard PT Resistance
Standard PT Resistance Thermometer
Thermometer (Type R)
4. Temperature Resistance Calibration
Each product is calibrated on resistance value at ice point (0℃) and/or boiling point of water (100℃). Com-
parison test in the range of −50℃ to ＋500℃ or the fixed point test at respective freezing points of Indium,
Tin, Cadmium or Zinc are also conducted upon request. Temperature sensor requested for calibration by the customers
Freezing Temp. Accuracy

Metal ITS-90(℃) (℃)
Indium (In) 156.5985 ※ AIST : National Institute of Advanced Industrial Science
and Technology
Tin (Sn) 231.928 ±0.01 NIST : National Institute of Standards and Technology
NPL : National Physical Laboratory
Cadmium (Cd) 321.069 ※
UKAS : United Kingdam Accreditation Service
Zinc (Zn) 419.527 ±0.001 NAMAS : National Measurement Accreditation Service
JEMIC : Japan Electric Meters Inspection Corporation
※＝ Accuracy varies depending on respective purities of the metals refined.
JCSS : Japan Calibration Service System
5. Others Tests
Voltage Withstand Test, X-Ray Test, Vibration Test, Pressure Test, Helium Leak Test, etc. are also performed
upon request.
− 24 − − 25 −
Chemical Resistance of Protection Tube Material
OVERSEAS AFFILIATED COMPANIES
Hastelloy C-276
Haynes alloy 25
Common steel
Concentration
Carpenter 20
Cupro-nickel
Inconel 600
Hastelloy B
Hastelloy X
50Co-30Cr
Temp. (℃)
Aluminium
316J1LSS
Zirconium
Tantalum
310S SS
Corrosives
Titanium
Nimonic
316LSS
Copper
304SS
321SS
316SS
347SS
Teflon
Monel
Nickel
Brass
Lead
PVC
M.I. CABLE TECHNOLOGIES, INC. (MICT)
5％ B 30 B B B B B B A B B A A B B A A B A B A B C C A C A
One of the Hastelloy series and excellent in heat resistance.
Cobalt-base alloy and excellent in heat and abrasion resistance.

〃 C B.P C C C C C C B C C A B C C A C A C C C C A C B Establishment : October 1995
10％ B 30 B B B B B B A B B A A B B A A B B A B C C A C A Annual Turnover : CA$6,100,000
〃 C B.P C C C C C C A C C A B C C A C B C C C A C B Address : Bay6, 5905-11th Street S.E. Calgary Alberta Canada T2H2A6
H2SO4
50％ C 30 C C C C C C A B B A A B B A A B B A B C C A C A
TEL: 403-571-8266 FAX: 403-571-8267
〃 C B.P C C C C C C A C C A B C C A C B C C C B C B
90％ B 30 B B B B B B A B B A A B B A A B B B A B C C A C A http://www.mict.ab.ca
〃 C B.P C C C C C C A C C A C C A C B B C C C B C B CA$1,350,000.00
5％ C 30 C C C C C C B B B A A A B A A B B A C C C B C B Capital : 33
〃 C B.P C C C C C C C B B A A B B A C C C B C C Number of Employees : Manufacturing and Sales of Various Kinds of MI Thermocouple Cable,
10％ C 30 C C C C C C B B B A A A B A A B B A C C C B C B
2HCl Major Businesses : MI Extension Cable, MI Heat Tracing Cable
〃 C B.P C C C C C C C B B A A B B A C C C B C C
20％ C 30 C C C C C C B B B A A A B A A B B A C C C B C B
〃 C B.P C C C C C C C B B A A B B A C C C B C C
20％ A 30 A A A A A A A A A C A A C A B C C B C B C C C B
〃 A B.P A A A A A A A A A C A A C A C C C C C C C C
40％ A 30 A A A A A A A A A C A A C A A C C B C B C C C B
HNO3
75％ A 30 A A A A A A A A A C A A C A A C C B C B C C C B
10％ A 30 A A A A A A A A A A A A A A A B A B A B A B B C A
〃 A B.P A A A A A A A A A A A A B A A B A B B B B B C A
50％ A 30 A A A A A A A A A A A A B A A B A B A B A B B C A
CH3CO2H
〃 B B.P A A A A A A A B A A A A B A A B A B B B C B C A
80％ B 30 A A A A A A A B A A A A B A A B A B A B A C B C A
〃 B B.P A A A A A A A B A A A A B A A B A B B B C B C A
5％ A 30 A A A A A A A A A A A A A A A B A B A B C C B A A
〃 B B.P B A A A A A A B A A A A A A A B A B B C C B A A
50％ B 30 B B B B B B A A A A A A A A A B A B A B C C B A A
H3PO4
〃 B B.P B B B B B B A B B A A A B A A B A B C C C B A B
85％ B 30 B B B B B B A B B A A A A A A B A B A B C C B A B
〃 B B.P B B B B B B A B B A A A B A A B A B C C C B A B
30％ C 30 C C C C C C C A A A C A A A A C C B B C C
H2F2 〃 C B.P C C C C C C C B C C C B C C C C C B C C
70％ C B.P C C C C C C C B C C C B C C C C C C C C
B 30 B B B B B B B B B A A A A A A
THERMOSENSOR TECHNOLOGIES PTE. LTD. (TST)
HCl B 200 B B B B B B B B B A A A A A A Establishment : November 1997
B 400 B B B B B B B B B A A A A B
A 30 A A A A A A A A A A A A A A A B A A A A B B B B
Annual Turnover : S$4,500,000
10％
〃 A B.P A A A A A A A A A A A A A A B A A A B B B B Address : 61 Tuas View Walk 2 Westlink Techpark Singapore 637630
50％ A 30 A A A A A A A A A A A A A A A B A A A A B B B B TEL: 065-268-0090 FAX: 065-262-0013
NaOH
〃 B B.P B B B B B B A A A A A A A A B A A B B B B B http://www.thermosensor.com
70％ A 30 A A A A A A A A A A A A A A A B A A A B B B B B Capital : S$800,000.00
〃 B B.P B B B B B B A A A A A A A A B A A B B B B B
Number of Employees : 33
25％ A B.P A A A A A A A A A A A C A C C A B B C C B B
KOH
50％ B B.P B B B B B B A A A A A C A C C A B B C C B B
Major Businesses : Manufacturing and Sales of Thermocouples, Resistance Temperature
HCl (dry) C 30 C C C C C C A A A A A A A A A C B C A Detectors and Thermowells
〃 (wet) C 30 C C C C C C C C C A A A C C C C B C A Sales Area : Southeast Asia except P.R.China, Taiwan, Korea
HCl vapor C C C C C C C B A C C B C
HF C C C C C C C A C B C A B A C C C B C C
H2 (SiF6) 5％ 20 C C C C C C C A A A A B C A C A C C C B C
F 10％ 30 C C C C C C C A A A A B C A C A C C C B C
10％ B.P B A A A A A A A A A C C B C
NaOH
75％ 100 B A A A A A A A A A C C B C
CO2 10％ 200 A A A A A A A A A A A A A
SO2 A A A A A A A A A A A A A A C C
Na5P3O10 10％ 30 B B B B B B B B C C C A C C B C C C
CHCl 30 C C C C C C C C C B C C C
AlF3 50％ 30 B B B A B A C
Fatty Acids 100 A A A A A A A
A A A A
A A A A A
NH3 A A A A A A A A A
NaCl A A A A A A A A B A A A C B B
CrO4 A A
H2O4 A A A A A A A A A A A A A A
S (liguid) A A A A A A A A A A A A A
CaCl2 A A A A A A A A A A A A A A B A A A B B
Note: A = Almost no corrosion in critical conditions. B = Small corrosion but permissible in general use other than specific parts.
C = Heavy corrosion and unsuitable.
− 26 − − 27 −
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.23 Level Indicator
Fluid Level Gauge
Fluid Level Sensor
Temperature Switch
FSA / FSK / TSE
E 5.050.11/05.04
up to size 381
up to PN 0.5 bar
up to T = 80 °C
1. DESCRIPTION 1.2. FUNCTION OF THE FSA 1.3. APPLICATION
1.1. GENERAL By using a HYDAC FSA, the fluid HYDAC fluid level gauges FSA,
level can be easily seen on the fluid level sensors FSK and
HYDAC fluid level gauges FSA, outside of the tank. The fluid temperature switches TSE are
fluid level sensors FSK and enters the unit via the lower used to monitor and control levels
temperature switches TSE are connection bore and is clearly of operating fluid.
units which serve to monitor and visible in the tube. Selection of
control the level of operating fluid. Areas of application are
the correct size allows the for example:
The flexible product range means respective level of the fluid to be
that many combinations are Machine tools, system
monitored.
possible: engineering, hydraulic oil,
FUNCTION OF THE FSK lubricating oil and cutting oil tanks
– FSA: five sizes. By using a HYDAC FSK, the fluid as well as gearboxes.
Visual thermometer with level is monitored via an electrical 1.4. NOTES
°C and °F scale. switching signal. This switching
signal can be used as an warning The upper viscosity limit is
Temperature gauge which records 2,000 mm²/s.
the temperature of the operating message or to regulate the fluid
fluid in the tank; display in °C. level. The fluid enters the unit via It is not possible to combine a
Dual scale in °C and °F is the lower connection bore and temperature switch TSE with an
available on request. pushes up a float in the tube. FT temperature gauge.
The float now shows the level of To ensure correct functioning,
Simple, standardised mounting
the fluid in the tank. If the level of pressure, viscosity and
conditions (FSA/K).
fluid drops again, the float temperature specifications must
– FSK: four sizes. activates a switching contact. be observed.
Switching contact can be either On type C the circuit is then FSA/FSK
type O (opens when fluid is at low closed and on type O the circuit Not suitable for use with glycol or
level) or type C (closes when is then open. fluids containing glycol.
fluid is at low level) or type W
The special dual switching model FSK
(dual switching unit)
(type W) offers two possibilities. Depending on the fluid level of the
Temperature gauge which records It can either be used to close on tank the following switching logic
the temperature of the operating contact or to open on contact. applies.
fluid in the tank; display in °C.
FUNCTION OF THE TSE
Dual scale in °C and °F is
available on request. The HYDAC TSE is a very useful
additional option to the FSA and
Simple, standardised mounting Tank fluid level
FSK products. However, it also
conditions (FSA/K).
has a useful application as a
– TSE: three nominal temperatures separate build-on unit on
possible: 60 °C, 70 °C and 80 °C. systems.
Can be easily fitted into the FSA The temperature sensor of the
and FSK. (opens on
TSE, when fitted, is surrounded
contact)
Simple, standardised mounting by operating fluid. When the
conditions (FSA/K). nominal temperature is reached,
Non-corroding surfaces. a contact opens and the circuit is
broken. Tank fluid level
This switching process can be

used either as a warning
message or to monitor the
temperature.
When the temperature of the fluid (closes on
contact)
drops by approx. 25 K, the circuit
closes again.
In the FSK type O the switching

contact opens when the fluid level
drops below the switching level.
Correspondingly, in the FSK type
C, the switching contact closes
when the fluid level drops below
the switching level.
E 5.050.11/05.04
2
2. TECHNICAL 2.1.2 Model code for FSA
SPECIFICATIONS (also order example)
2.1. GENERAL FSA - 076 - 2 . X / FT200 / 12
2.1.1 Designation and symbol
Fluid level gauge
Fluid level gauge FSA
Size
≅ centre distance of bolts
076
127
176
254
381
Material of seals
2 = Viton (FKM)
1 = Perbunan (NBR)
Series
(determined by manufacturer)
Additional thermometer function
– = no additional function
Fluid level sensor FSK T = thermometer in display tube
FT 200 = temperature gauge 200 mm
TSE 60 = temperature switch nominal temperature 60 °C
Mounting
Banjo bolt thread
O - N/C contact M 12 (standard)
M 10 (not on TSE)
Model code for FSK

FSK - 127 - 2 . X / O / FT200 / 12 / ...
C - N/O contact Fluid level sensor

Size
≅ centre distance of bolts
127
176
254
381
Material of seals
W - N/O or 2 = Viton (FKM)
N/C contact Series
(determined by manufacturer)
Temperature switch TSE Switching function
O = opens at the switching level
C = closes at the switching level
W = opens or closes at the switching level
(Hirschmann plug = standard)
Additional thermometer function
– = no additional function
Mounting
Banjo bolt thread
M 12 (standard)
M 10 (not on TSE)
E 5.050.11/05.04
Plug
No details = 3 pole MPM (standard)
Z4 = 4 pole Hirschmann
SEW = 4 pole M12x1 (sensor technology plug)
3
2.1.4 Type of construction
Model code for TSE
The units are designed to be
mounted directly on to the
TSE - 70 / X / 12 operating fluid tank.
2.1.5 Type of connection
Temperature switch FSA / FSK
TSE – temperature switch (for FSA) The unit is mounted using two
TSE-L – temperature switch long (for FSK) banjo bolts. The connection
Nominal temperature bores can either be threaded
60 °C holes or clearance holes
70 °C (Ø 13, Ø 11).
80 °C TSE
Series The temperature switch can be
(determined by manufacturer) fitted to the FSA / FSK in place
of the lower banjo bolt.
Banjo bolt thread
2.1.6 Mounting position
M 12
FSA – vertically
on the tank wall
2.1.3 Standard models FSK – vertically
on the tank wall
Type Size Order no. = Weight (connection plug at
≅ centre distance of bolts stock no. [kg] the bottom of the tank)
FSA - 076 - 1.X/-/12 76 700 000 0.17 TSE – instead of
FSA - 076 - 2.X/-/12 76 700 002 0.17 lower banjo bolt
FSA - 127 - 1.X/-/12 127 700 036 0.19 M12 (FSA)
FSA - 127 - 2.X/-/12 127 700 038 0.19 TSE-L – instead of
FSA - 176 - 1.X/-/12 176 700 113 0.22 lower banjo bolt
M12 (FSK)
FSA - 176 - 2.X/-/12 176 700 137 0.22
2.1.7 Weight
FSA - 254 - 1.X/-/12 254 700 072 0.24 (See table 2.1.3)
FSA - 254 - 2.X/-/12 254 700 074 0.24 2.1.8 Flow direction
FSA - 381 - 1.X/-/12 381 700 095 0.29 Optional
FSA - 381 - 2.X/-/12 381 700 160 0.29 2.1.9 Ambient temperature
- 20 °C to + 80 °C
TSE - 60 /X/12 – 703 724 0.11 2.1.10 Materials
TSE - 70 /X/12 – 703 714 0.11 FSA / FSK
TSE - 80 /X/12 – 551 481 0.11 – End caps and tube in high quality
synthetic material
FSK - 127 - 2.X/O/-/12 127 3 070 285 0.21 – Housing in aluminium
FSK - 127 - 2.X/C/-/12 127 3 112 276 0.21 – Soft seals in Viton (FKM) or
Perbunan (NBR)
FSK - 127 - 2.X/W/-/12/Z4 127 3 112 298 0.21
– Bolts, nuts and washers in steel
FSK - 127 - 2.X/O/-/12/SEW 127 3 136 130 0.21 (plated)
FSK - 176 - 2.X/O/-/12 176 3 112 231 0.23 – Plug connections in high quality
FSK - 176 - 2.X/C/-/12 176 3 112 299 0.23 synthetic material (FSK)
FSK - 176 - 2.X/W/-/12/Z4 176 3 112 301 0.23 TSE / TSE-L
FSK - 254 - 2.X/O/-/12 254 3 112 302 0.26 – Housing with temperature sensor,
FSK - 254 - 2.X/C/-/12 254 3 112 303 0.26 washer and nut in steel
(zinc-plated)
FSK - 254 - 2.X/W/-/12/Z4 254 3 112 305 0.26
– Plug connections in high quality
FSK - 381 - 2.X/O/-/12 381 3 112 306 0.30
synthetic material
FSK - 381 - 2.X/C/-/12 381 3 112 307 0.30
FSK - 381 - 2.X/W/-/12/Z4 381 3 112 309 0.30
TSE-L - 60 /X/12 – 3 148 887 0.13

TSE-L - 70 /X/12 – 3 148 886 0.13
TSE-L - 80 /X/12 – 3 148 885 0.13
FT 200 0 - 100 °C / M12 200 700 154 0.03

FT 300 0 - 100 °C / M12 300 700 155 0.04
E 5.050.11/05.04
4
2.2. HYDRAULIC DETAILS 2.3.2 Contact load
2.3. ELECTRICAL DETAILS
2.2.1 Nominal pressure Max. 8 W
OF FSK
Max. 0.5 bar 2.3.1 Electrical functions 2.3.3 Switching voltage
2.2.2 Operating fluids 50 V AC / DC
Type O (Standard)
Mineral oil to DIN 51524, Part 1 Opens when fluid at 2.3.4 Switching current
and 2, water-oil emulsions and switching level 0.2 A
synthetic fluids, such as hydraulic
fluids based on phosphate ester 2.4. ELECTRICAL DETAILS
(NOT water glycol). OF TSE / TSE-L
For water glycol, glass tubes are 2.4.1 Electrical function
available.
For other fluids, please contact opens on contact
our technical sales department. Type O
2.2.3 Temperature of operating fluid (Hirschmann plug - Z4)
Opens when fluid at
- 20 °C to + 80 °C switching level
2.2.4 Scale range of thermometer
FSA / FSK
Thermometer T for FSA:
+ 20 °C to + 80 °C
Thermometer FT for FSA / FSK:
0 °C to + 100 °C
2.4.2 Switching power

2.5 A/50 V -
Type O 10,000 switching operations
(Sensor technology plug - SEW)
Opens when fluid at 0.5 A/50 V -
switching level 100,000 switching operations
2.4.3 Minimum switching current
50 mA
2.4.4 Switching tolerance
±5K
2.4.5 Switching hysteresis
approx. 25 K
Type C (Standard)
Closes when fluid at
switching level
Type W (Standard)
(Hirschmann plug - Z4)
Dual switching unit
Type W
(Sensor technology plug - SEW)
Dual switching unit
E 5.050.11/05.04
5
3. DIMENSIONS
3.1. FLUID LEVEL GAUGE FSA
FSA Standard FSA with thermometer
torque value
8-10 Nm
torque value
8-10 Nm
FSA with temperature switch TSE
torque value
8-10 Nm
FSA / FSK with temperature gauge
torque value
8-10 Nm
Size =
centre distance of bolts L0 L1 L2
76 107 37 76
E 5.050.11/05.04
127 158 88 127

176 207 137 176
254 285 215 254
381 412 342 381
6
3.2. FLUID LEVEL SENSOR FSK
FSK Standard
torque value
8-10 Nm
switching level
torque value
8-10 Nm
fitting dimension
FSK Hirschmann plug Z4
torque value
8-10 Nm
switching level
torque value
8-10 Nm
fitting dimension
Size =
centre distance of bolts L1 L2 L3 L4
E 5.050.11/05.04
127 88 127 215 219

176 137 176 264 268
254 215 254 347 351
381 342 381 474 478
7
FSK Sensor technology plug M12x1
torque value
8-10 Nm
switching level
torque value
8-10 Nm
FSK with temperature switch TSE-L
torque value
8-10 Nm
Size =
centre distance of bolts L1 L2 L5
127 88 127 188
176 137 176 237
254 215 254 320
381 342 381 447
3.3 TEMPERATURE SWITCH

TSE / TSE-L
see FSA with TSE fitted
see FSK with TSE-L fitted
E 5.050.11/05.04
8
4. SPARE PARTS 5. NOTE
The information in this
4.1. SEAL KIT brochure relates to the
operating conditions
and applications
described.
For applications or
operating conditions
not described, please
contact the relevant
technical department.
Subject to technical
modifications.
Seal kit Order no. = Stock no.

FSA - 76 - 381 - 1.X 704 616
FSA - 76 - 381 - 2.X 704 627
E 5.050.11/05.04
9
16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.24 Unitrol 1000 Automatic Voltage Regulator
ABB
UNITROL® 1000-15 User Manual
Automatic Voltage Regulator
Compact voltage regulator for synchronous machines
up to 15 A exciter current
Product Release
Control: 5.010
Panel: 5.003
CMT1000: 5.001
Document No.: 3BHS262681 E80 Rev.-

Document Revision date: 04 / 2010
© ABB Switzerland Ltd. All Rights Reserved.

ABB
ABB reserves all rights to this document and to the information and
topics contained in it. This also applies to any possible claims to
copyright or patents. Forwarding and/or the duplicating of this document
without the express permission of ABB is forbidden.
This document has been prepared and checked with great care. If
however it still contains errors, please report them to ABB.
ii 3BHS262681 E80 Rev.A UNITROL 1000 User Manual

ABB
Table of Contents
Table of Contents ...............................................................................................................iii
Terms and Abbreviations .................................................................................................vii
Chapter 1 - Introduction .................................................................................................1-1

1.1 General ..........................................................................................................................1-1
1.2 Field of Application ........................................................................................................1-2
1.3 Contents of this Manual .................................................................................................1-3
1.4 Manufacturer’s Address.................................................................................................1-4
Chapter 2 - Safety Instructions ......................................................................................2-1

2.1 General ..........................................................................................................................2-1
2.2 Intended Audience.........................................................................................................2-1
2.3 Qualifications and Responsibilities ................................................................................2-1
2.3.1 Qualifications and Responsibilities ......................................................................................... 2-1
2.3.2 Consequences of Non-compliance......................................................................................... 2-2
2.4 Safety Concept ..............................................................................................................2-2
2.4.1 General ................................................................................................................................... 2-2
2.4.2 Safety Rules............................................................................................................................ 2-2
2.5 Safety Regulations.........................................................................................................2-3
2.5.1 Structure of Safety Instructions............................................................................................... 2-3
2.5.2 Pacemaker.............................................................................................................................. 2-4
2.6 Danger signs..................................................................................................................2-4
Chapter 3 - Device Overview..........................................................................................3-1

3.1 General ..........................................................................................................................3-1
3.2 Description of the Excitation System .............................................................................3-1
3.2.1 Introduction ............................................................................................................................. 3-1
3.3 Hardware .......................................................................................................................3-2
3.3.1 Connection diagram................................................................................................................ 3-2
3.3.2 Control Interfaces.................................................................................................................... 3-3
3.3.3 Overview of the Device Connections...................................................................................... 3-5
3.3.4 Device connections................................................................................................................. 3-6
3.3.5 Digital Inputs ........................................................................................................................... 3-9
3.3.6 Digital Outputs ...................................................................................................................... 3-11
3.3.7 Analog Inputs ........................................................................................................................ 3-12
3.3.8 Analog Outputs ..................................................................................................................... 3-14
3.3.9 Communication ports ............................................................................................................ 3-15
3.4 Software.......................................................................................................................3-21
3.4.1 Operating modes .................................................................................................................. 3-23
3.4.2 Channel Follow-up ................................................................................................................ 3-24
3.4.3 Voltage droop compensation (VDC) ..................................................................................... 3-24
3.4.4 Synchronization (SYNC) ....................................................................................................... 3-26
3.4.5 Voltage matching (VM) ......................................................................................................... 3-29
3.4.6 Rotating Diode Monitoring (RDM)......................................................................................... 3-30
3.4.7 Power system stabilizer (PSS) ............................................................................................. 3-31
3.4.8 Double Channel (DCH) ......................................................................................................... 3-33
UNITROL 1000 User Manual 3BHS262681 E80 Rev.A iii

ABB
3.4.9 Remote Access ..................................................................................................................... 3-42
3.4.10 Access Levels ....................................................................................................................... 3-43
3.4.11 Description of parameters ..................................................................................................... 3-45
Chapter 4 - Installation and Storage ............................................................................. 4-1

4.1 General ......................................................................................................................... 4-1
4.2 Safety Regulations........................................................................................................ 4-1
4.3 Unpacking ..................................................................................................................... 4-1
4.4 Mechanical Installation.................................................................................................. 4-2
4.5 Electrical Installation ..................................................................................................... 4-3
4.6 Storage ......................................................................................................................... 4-3
4.6.1 Storage Conditions.................................................................................................................. 4-3
4.6.2 Disposal................................................................................................................................... 4-3
Chapter 5 - Commissioning........................................................................................... 5-1

5.1 General ......................................................................................................................... 5-1
5.3 Setting Aids................................................................................................................... 5-2
5.3.1 Setting aids ............................................................................................................................. 5-2
5.4 Work carried out while Machine is at Standstill............................................................. 5-7
5.5 Work carried out while Machine is Running .................................................................. 5-8
5.5.1 No-load tests (nominal speed, not synchronized)................................................................... 5-8
5.5.2 Tests under load ..................................................................................................................... 5-8
5.5.3 Synchronization....................................................................................................................... 5-8
5.6 Concluding Work after Commissioning ......................................................................... 5-9
Chapter 6 - Operation..................................................................................................... 6-1

6.1 General ......................................................................................................................... 6-1
6.3 Panel Operation ............................................................................................................ 6-2
6.3.1 Panel start-up.......................................................................................................................... 6-2
6.3.2 Keypad operation .................................................................................................................... 6-4
6.3.3 Example of parameter setting ................................................................................................. 6-4
6.3.4 Menu structure ........................................................................................................................ 6-6
6.3.5 Limiters and Alarms .............................................................................................................. 6-13
6.3.6 Fault messages..................................................................................................................... 6-14
6.4 PC Software tool ......................................................................................................... 6-15
6.4.1 System requirements for CMT1000 release 5 ...................................................................... 6-15
6.4.2 Installing CMT1000 software................................................................................................. 6-15
6.4.3 Starting with CMT1000.......................................................................................................... 6-15
6.4.4 Menu structure of CMT 1000 ................................................................................................ 6-19
6.4.5 Tune Menu ............................................................................................................................ 6-45
6.4.6 Save parameter file ............................................................................................................... 6-47
Chapter 7 - Preventive Maintenance ............................................................................. 7-1

7.1 General ......................................................................................................................... 7-1
7.3 Standard Procedures for Maintenance ......................................................................... 7-1
Chapter 8 - Troubleshooting ......................................................................................... 8-1

8.1 General ......................................................................................................................... 8-1
iv 3BHS262681 E80 Rev.A UNITROL 1000 User Manual

ABB
8.2 Safety Regulations.........................................................................................................8-1
8.3 List of Possible Faults....................................................................................................8-1
8.4 Repair ............................................................................................................................8-4
8.5 Compatibility ..................................................................................................................8-4
Chapter 9 - Technical data .............................................................................................9-1

9.1 General ..........................................................................................................................9-1
9.1.1 Ordering information ............................................................................................................... 9-1
9.1.2 Mechanical data...................................................................................................................... 9-1
9.1.3 Climatic stability ...................................................................................................................... 9-1
9.1.4 Electrical data ......................................................................................................................... 9-1
9.1.5 Relevant standards, CE conformity ........................................................................................ 9-2
9.1.6 Ordering information connection cable ................................................................................... 9-2
9.1.7 Reliability................................................................................................................................. 9-2
9.2 Settings record for UNITROL 1000................................................................................9-2
9.3 Parameter Settings, default values................................................................................9-3
UNITROL® 1000 User Manual 3BHS262681 E80 Rev.A v

ABB
Terms and Abbreviations
AC Alternating Current
AIO Analog Input and Output
AUTO Automatic Voltage Regulation
(Auto Mode)
AVR Automatic Voltage Regulator
Bat Battery
CB Circuit Breaker
MAIN Main Channel in double channel systems.
REDUNDANT Redundant (Backup) Channel in double channel systems.
CT Current Transformer
DC Direct Current
DIO Digital Input and Output
DSP Digital Signal Processor: referred as the main controller of the
AVR, responsible of regulation, control and communication.
ESD Electrostatic Discharge
EXC Excitation
FCB Field Circuit Breaker
GEN Generator
GFR Ground Fault Relay (Rotor Ground Fault Protection)
HW Hardware
IGBT Insulated Gate Bipolar Transistor
MANUAL Field Current Regulation
(Manual Mode)
PC Personal Computer
PCB Printed Circuit Board
PDF Portable Document Format
PE Protective Earth (Protective Ground)
PF Power Factor
PPE Personal Protective Equipment
PS Power Supply
PT Potential Transformer
Q Reactive Power
SW Software
V/Hz Volt per Hertz (-Limiter)
VDC Voltage Droop Compensation
UNITROL 1000 User Manual 3BHS262681 E80 Rev.A vii

ABB
Chapter 1 - Introduction
1.1 General
The User Manual provides detailed information on the

• description of the product,
• installation,
• operation,
• maintenance and troubleshooting
of the excitation system, including detailed descriptions of the functions and
the hardware of the device. Technical data is included as well.
Our experience has shown that, if the information and recommendations
contained in this User Manual are observed, the best possible reliability of
our products is assured.
The data contained herein purports solely to describe the product and is not
a warranty of performance or characteristics. It is with the best interest of
our customers in mind that we constantly strive to improve our products
and keep them abreast of advances in technology. This document has
been carefully prepared and reviewed, however should in spite of this the
reader find an error, he is requested to inform us at his earliest
convenience.
It is hardly possible to cover every eventuality in the operating instructions
for technical equipment, which can occur in practice. We would therefore
request you to notify us or our agent in the case of any unusual behavior
that does not appear to be covered by these operating instructions.
It is pointed out that all local regulations must be observed when
connecting and commissioning this equipment in addition to these
operating instructions. We cannot accept any responsibility for damage
incurred as a result of mishandling the equipment regardless of whether
particular reference is made in these operating instructions or not. We lay
particular stress on the fact that only genuine spare parts should be used
for replacements.
All rights with respect to this document, including applications for patent
and registration of other industrial property rights, are reserved.
Unauthorized use, in particular reproduction or disclosure to third parties, is
prohibited.
Each person involved in the installation, operation, maintenance and repair
of the excitation system must have read and fully understood the
corresponding chapters in this Operating Instructions Manual and in
particular Chapter 2 - Safety Instructions.
UNITROL 1000 User Manual 3BHS262681 E80 Rev.A 1-1

Chapter 1 - Introduction ABB
1.2 Field of Application
This advanced-design automatic voltage regulator is used for the excitation of indirectly
excited synchronous machines. This unit is only suitable for this area of application. The
regulator can also be switched over to function as a reactive power-, power factor- or field
current regulator.
SM = Synchronous Machine
Back-up Channel
E = Exciter
PMG = Permanent Magnet Abb UNITROL 1000
Abb UNITROL 1000
R R
Batt.
Generator
Shunt excitation with:

- short-circuit support (Boost)
Optional:
- Power System Stabilizer (PSS)
SM E
- Synchronization unit
- Diode monitoring
- Changeover to a back-up unit.
- Others
Abb UNITROL 1000

R
Generator or motor excitation with

PMG or external supply.
PMG
SM E
Abb UNITROL 1000

R
Replacement of voltage regulators

for generators or motors with direct-
current excitation machines.
SM =
1-2 3BHS262681 E80 Rev.A UNITROL 1000 User Manual

ABB Chapter 1 - Introduction
1.3 Contents of this Manual
Chapter 1 - Introduction describes the contents of the User Manual and

provides the manufacturer’s information.
Chapter 2 - Safety Instructions explains the safety instruction levels and
provides general instructions on safety, which need to be strictly observed.
Chapter 3 - Device Overview outlines the description of the device,
operation modes, hardware capabilities and software features.
Chapter 4 - Installation and Storage provides information on environmental
conditions to be maintained during transportation and storage, information
on disposal and recycling of materials.
Chapter 5 - Commissioning provides information on preparing the device
for commissioning.
Chapter 6 - Operation describes the instructions how to operate the device.
Chapter 7 - Preventive Maintenance contains the maintenance schedule
and step-by-step instructions for specific maintenance tasks to be carried
out by the customer.
Chapter 8 -Troubleshooting provides instructions on how to proceed when
encountering problems.
Chapter 9 - Technical data describes the technical data from the device,
ordering number and parameter list.

Chapter 1 - Introduction ABB
1.4 Manufacturer’s Address
If any questions arise, consult the local ABB representative or the

manufacturer:
IMPORTANT!
When calling ABB, please leave your name, department and phone
number. This will allow the responsible ABB representative to call back
without delay.
ABB Switzerland Ltd

Static Excitation Systems, Voltage Regulators
and Synchronizing Equipment
CH-5300 Turgi / Switzerland
Telephone: +41 58 589 24 86
Fax: +41 58 589 23 33
Email: pes@ch.abb.com
Internet: http://www.abb.com/unitrol
24 h – Hotline for urgent service inquiries: +41 844 845 845

Email contact for service inquiries: unitrol.supportline@ch.abb.com
ABB is constantly striving for the best product and service offerings for our
customers. Therefore ABB appreciates your valuable feedback or
suggestions for improvements of UNITROL products.
Please send your comments to "unitrol.feedback@ch.abb.com". Your
information will be forwarded to the responsible persons in order to improve
ABB’s future offerings.

ABB
Chapter 2 - Safety Instructions
2.1 General
Chapter 2 - Safety Instructions includes the safety instructions that must

be followed during installation, operation and maintenance of the
excitation system. Please read all instructions carefully before operating
the device and keep this manual for future reference.
2.2 Intended Audience
The User Manual addresses the following target groups:

• Installation personnel
• Operators
• Maintenance and repair personnel
2.3 Qualifications and Responsibilities
2.3.1 Qualifications and Responsibilities
Personnel involved in installation work and commissioning of the

UNITROL 1000 must be familiar, specially instructed and informed about
the residual danger areas according to the regulations currently in force.
Operating personnel is not permitted to work at the control system.
Specially instructed personnel must only carry out maintenance and
repair work.
The maintenance personnel must be informed about the emergency
shutdown measures and must be capable of turning off the system in
case of emergency.
The maintenance personnel must be familiar with the accident prevention
measures at their workplace and must be instructed in first aid and fire
fighting.
It is the owner’s responsibility to ensure that each person involved in the
installation and commissioning of the UNITROL 1000 has received the
appropriate training or instructions and has thoroughly read and clearly
understood the safety instructions in this chapter.

Chapter 2 - Safety Instructions ABB
2.3.2 Consequences of Non-compliance
Failure to comply with the safety instructions increases the risk of electric
shock and damage to the equipment. Third parties who approach the
installation are also at risk.
If the scheduled maintenance activities are performed only partially or not
at all, damage may occur with associated expensive repair costs.
2.4 Safety Concept
2.4.1 General
The safety regulations in this chapter generally apply when working on

the excitation system. You will find additional instructions and warnings
related to particular topics or actions throughout the manual where
relevant.
The following regulations must be strictly observed:
• The technical specifications and the typical application of the
excitation system (see Chapter 1 - Introduction, Field of Application)
must be strictly adhered to.
• Training of personnel: only trained personnel are allowed to install,
operate, maintain or service the excitation system.
• Modifications without authorization: modifications and constructional
changes of the equipment are not allowed.
• Duty of maintenance: the owner must ensure that the excitation
system is used only under proper conditions and in a fully serviceable
state.
2.4.2 Safety Rules
The following safety procedures according to EN 50110-1 must absolutely

be followed if any (maintenance) work is carried out on the excitation
system:
1 Disconnect completely.
2 Secure against re-connection.
3 Verify that the installation is dead.
4 Carry out grounding and short-circuiting.
5 Provide protection against adjacent live parts.

ABB Chapter 2 - Safety Instructions
2.5 Safety Regulations
2.5.1 Structure of Safety Instructions
Signal Word!
Symbol Situation – Type of Hazard Statement
Possible consequence – Consequence Statement
Essential safety measure – Avoidance Statement
The safety instructions always appear at the beginning of each chapter

and/or precede any instruction in the context where a potentially
dangerous situation may appear. The safety instructions are divided into
five categories and emphasized by the use of the following layout and
safety signs:
DANGER!
This symbol indicates an imminent danger resulting from mechanical
forces or high voltage. Non-observance leads to life-threatening physical
injury or death.
WARNING!
! This symbol indicates a dangerous situation. Non-observance can result

in bad or life-threatening physical injury or death.
CAUTION!
This symbol indicates a dangerous situation. Non-observance can lead
to physical injury or cause damage to the installation.
NOTICE!
This symbol emphasizes important information. Non-observance can
cause damage to the installation or to objects close to it.
IMPORTANT!
This symbol indicates useful information. Not to be used to indicate
dangerous situations.

Chapter 2 - Safety Instructions ABB
2.5.2 Pacemaker
DANGER!
Electrical and magnetic fields.
The system can cause malfunction of pacemakers.
Avoid being close to the excitation system.
Electrical and magnetic fields can influence pacemakers. It is difficult to

predict the general sensitivity of pacemakers.
2.6 Danger signs
Danger signs are attached to any equipment/location with a potential

danger.
The degree and likelihood of such dangers are described by the signal
words DANGER, WARNING and CAUTION. The content of the warning
sign contains information about the respective situation and the
preventive safety measures that must be taken.
Structure of danger signs:
Sign Description
Signal word
DANGER
Situation
Hazardous voltage inside.
Essential safety measures
Disconnect power and
ground equipment before
maintenance work.
Meaning of signal words and consequence statement:
Sign Description of the signal word

DANGER, electrical
DANGER
This symbol indicates imminent danger that will result
in life-threatening physical injury or death.
WARNING, electrical
WARNING This symbol indicates a possible dangerous situation
that could result in serious physical injury or death.

ABB Chapter 2 - Safety Instructions
CAUTION, electrical
CAUTION This symbol indicates a possible dangerous situation
that could result in moderate physical injury. This signal
word can also be used for warnings related to
equipment damage.

ABB
Chapter 3 - Device Overview
3.1 General
Chapter 3 - Device Overview provides the technical data of the device.

This chapter contains:
• Hardware description
• Operation modes and software features
• Parameter description
3.2 Description of the Excitation System
3.2.1 Introduction
UNITROL 1000 is an automatic voltage regulator of the latest design for

synchronous generators and synchronous motors. The unit contains the
most advanced microprocessor technology together with IGBT
semiconductor technology (Insulated Gate Bipolar Transistor).
All operations are effected through a practical and simple-to-operate
panel on the unit. In addition, user-friendly software facilitates
commissioning and allows optimization of operation.
The mechanical construction is extremely compact and robust.
The UNITROL 1000 unit can be connected to a 40 A Power Module
called UNITROL 1000-PM40. For further information please refer to the
separate User Manual.

Chapter 3 - Device Overview ABB
3.3 Hardware
Casing
The device is built into an aluminum casing with
cooling flanges. The connection terminals are
integrated into the front of the circuit boards,
which are arranged on top of one another.
Power electronics
The power part is fitted with an IGBT semi-
conductor. The average value of the output
voltage is always positive. The output is current-
limited and thus short-circuit-proof.
Control elements
The operating keys, the display and the sub-D
connector for the RS-232 interface are located
on the unit cover.
Installation
The site of installation must be dry and free of
Dimensions in mm dust.
3.3.1 Connection diagram
Auxiliary supply UAUX for control electronics

Digital in- and outputs L1 L2 L3
(+) (-)
Analog in- and outputs
UN1000-15
~/=
Measurement
UNET
and control
=
inputs
UM
RS-232
AVR
IM2 RS-485
CAN Bus
PWM
Supply power
electronics UPWR
Ie - (+) L1
SM E
E (-) L2
L3
+

ABB Chapter 3 - Device Overview
3.3.2 Control Interfaces
The UN1000 device can be operated in different ways and from remote locations as
described in the rest of this section.
3.3.2.1 Keyboard and Panel display
MAIN
The four-line display and the four keys are
Monitor sufficient to allow a complete operation.
Mode = Auto
Connected: 1
All settings can be carried out directly on the unit
without additional equipment:
• Configuration of inputs and outputs
OK • Parameter setting
• Display of important measuring values.
ESC The operation of the Panel is described in detail

in the section 6.3 Panel Operation.
3.3.2.2 PC software tool
Parameter configuration and optimization can be done with the user-friendly software
CMT1000 for Microsoft Windows. The CMT1000 can be used to access the UN1000-15
by using a serial connection point-to-point via the RS-232 port or by using an additional
TCP/IP converter gateway, which allows access from remote locations. The connection
options to use CMT1000 are described in Chapter 3.3.9 - Communication ports.
Basic features of the CMT1000

• Configuration of parameters
and I/O signals.
• Measurement reading
• Trending function for controller
optimization (Oscilloscope,
Power chart).
• Parameter File upload or
download.
• PID tuning, Setpoint step and
other powerful commissioning
tools.
The CMT1000 software operation is described in Chapter 6.4 - PC Software tool.
3.3.2.3 Remote Access using MODBUS
The Remote Access feature allows device access and control from local or remote
locations by using MODBUS as application protocol. The communication can be
performed either via RS485 or TCP/IP using an external gateway over the RS-232 device
interface. More information about the connection possibilities can be found in Chapter
3.3.9 - Communication ports.

Basic features and advantage of Remote Access
• Configuration of parameters and I/O signals.
• Measurement reading.
• Setpoint adjustment and PID tuning.
• Possibility to create a custom application that uses Remote Access to fully control the
device.
• Monitor only and full control possible.
The Remote Access is fully interoperable with the CMT1000 software; both interfaces can
access and read from the device at the same moment and control permission (write
parameters) is handled automatically by the AVR microcontroller. The Remote Access
feature is described in detail in Chapter 3.4.9 - Remote Access.
3.3.2.4 Terminal block
The UN1000 can be controlled by means of digital and analog inputs and can therefore
set up several configurations to fulfill most target applications. All devices' terminals are
located in the Terminal Block of the UN1000-15 which is shown in Figure 3-1.
serial port
DGND
DGND
+Vdig
+Vdig
+Vref
+AI 1
+AI 2
-Vref
-AI 1
-AI 2
DI 5
DI 6
DI 7
DI 8
32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
I M2 485 CAN
AGND
DIO 1
DIO 2
DIO 3
DIO 4
+Vdig
+Vdig
AO 2
+Vref
+AI 3
AO 1
-Vref
-AI 3
gnd
S1 S2 + - -
+
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 50 51 52 53 54 55
L1
UML2 L3 L1
U NET L3 NC +
Ie -
U PWR
L1(+) L2(-) L3 L1(+)
U AUX
L2(-) L3
1 2 3 4 5 46 7 8 49 10 11 12
4 13 14 15
4
J2 J4
RS-485 CAN
Figure 3-1Terminal block of UN1000-15

3.3.3 Overview of the Device Connections
UN1000-15
(+10 V) +Vref L1(+) 13
(-10 V) -Vref 14
(+24 V) +Vdig L2(-) UAUX
L3 15
7 AGND
DGND
10 L1(+) + 8
11 L2 (-)
UPWR Ie
12 L3 - 9
+ 50
J2 485
1 L1 120R or
PID RS-485
2 L2 - 51 MODBUS
UM
3 52
L3
16 gnd 53
S1
CAN
IM2 17 S2 + 54 CAN
Bus
DSP J4
120R
4 L1 - 55
UNET
5 L3
6 (NC)
RS-232 9 pol
serial port
32
33 +AI1 23
34 -AI1 ~ # AO1
AO2 24
35 +Vref AOUT
AGND 25
AIN 36 +AI2 ~
37 -AI2
38 -Vref # in, norm.
39 +Vdig 26
DIO1 27
18 +Vref DIO2 28 DIN,
19 +AI3 ~ in, inv. +Vdig 29 DOUT
20 -AI3 out, inv. DIO3 30
AIN
21 -Vref # DIO4 31
22
out, norm.
40 DGND
41 +Vdig
42 DI5 norm.
43 DI6
DIN
44 +Vdig
45 DI7
46 DI8 inv.
47 DGND

3.3.4 Device connections
Terminal Signal Circuit

designation
L1(+) = 13 Auxiliary supply UAUX UN1000-15
L2(-) = 14 - AC input voltage three-phase External 3~
9 to 250 V~ L1,L2,L3
L3 = 15 (250 V / 140 V) or
UN1000-15
- AC input voltage single-phase 1~
(250 V) or 50 to 250 V~ L1,L2
- DC input voltage UN1000-15
2=
18 to 300 V= L1(+),L2(-)
L1(+) = 10 Power electronics supply UPWR UN1000-15
L2(-) = 11 - AC input voltage three-phase, External 3~
0 to 250 V~ L1,L2,L3
L3 = 12 AC input voltage single-phase
UN1000-15
and excitation current < 10 A 1~
or 0 to 250 V~ L1,L2
- DC input voltage UN1000-15
2=
0 to 300 V= L1(+),L2(-)
- AC input voltage single-phase External UN1000-15
and excitation current >10 A
Rectifier: 35 A, 1200 V L1
0 to 250 V~
Capacitor: 1000 µF, 600 V L2
Three-phase: Measurement inputs External
L1=1, L2=2, L3=3 Three-phase: UN1000-15
L1
S1=16, S2=17 - Machine voltage UM L2 UM
L3
* max. 250 V / 0.2 VA
SM
Single-phase: Single-phase:
L1 = 1, L3 = 3 - Machine current IM2 S1
IM2 1 A / 0.1 VA
S1 = 16, S2 = 17
S2
or
External
*
Single-phase: UN1000-15
- Machine voltage UM L1
L3 UM
or
* max. 150 V / 0.2 VA
External
Three-phase with ground UN1000-15
L1
(Three ph gnd) L2 UM
*PT & CTs must - Machine voltage UM
be grounded L3
L1 L2 L3 * max. 150 V / 0.2 VA
L1 = 4, L3 = 5 Single-phase: External
UN1000-15
Line voltage measurement UNET L1
L3 UNET
*PT & CTs must
be grounded * max. 150 V / 0.2 VA
(+) = 8 Excitation current output Ie UN 1000-15 External

(-) = 9 +
0 to 300 V=
15 A = E
-
Earth connection=7 Earth connection

Terminal Signal Circuit

designation
DIO1 = 27 Digital inputs
DIO2 = 28 DIO1 … DIO4 External 24 V DC UN1000-15
DIO3 = 30 +Vdig
DIO4 = 31 DIO1 … DIO4 can be
+Vdig = 26, 29 operated either as inputs or 24 mA
outputs. in
DIO
1k
out
Digital outputs
DIO1 … DIO4
UN1000-15 External
24 V DC
Caution: +Vdig
Configured as outputs, DIO1
… DIO4 must not be in
connected directly with +Vdig
(causes short circuit via DIO
internal transistor)
out
DI5 = 42 Digital inputs

DI6 = 43 DI5 … DI8 External 24 V DC UN1000-15
DI7 = 45
+Vdig
DI8 = 46 Controlled from potential-free
+Vdig = 41, 44 contacts 24 mA
DGND = 40, 47 DI
1k
Note: The internal 24 V supply can be loaded with a maximum of 300 mA by all used
digital inputs and outputs.

Terminal designation Signal Circuit
+AI1 = 33, -AI1 = 34 Analog inputs

+AI2 = 36, -AI2 = 37 AI1 … AI3 External 10 V DC UN1000-15
+AI3 = 19, -AI3 = 20 +Vref
4.7k
+Vref = 18, 35 R = 10 kΩ, 1 W +AI 100k
+
-Vref = 21, 38 R 47k
-AI
AGND= 25 -
100k
Earth = 22,32,39
AGND 47k
AGND
4.7k
-Vref
-10 V DC
External
UN1000-15
max. ±10 V
+AI + 100k
+
47k
-AI -
-
100k
47k
+AI1 = 33, -AI1 = 34 Analog inputs digitally

+AI2 = 36, -AI2 = 37 assigned UN1000-15
+AI3 = 19, -AI3 = 20 AI1 … AI3 10 V DC
+Vref
+Vref = 18, 35 (DI9 … DI14)
4.7k
-Vref = 21, 38 see Chapter 3.3.7 - +AI 100k
+Vdig = 26, 29, 41, 44 Analog Inputs + Ain
47k
AGND= 25 -AI
-
DGND= 40, 47 100k
Earth = 22,32,39 47k
AO1 = 23 Analog outputs

AO2 = 24 AO1 … AO2 UN1000-15 External
max. ±10 V
AGND= 25 max. ±20 mA
- ±12 V 100R
AO
+
AGND
Serial port: Serial interface RS-232 Standard cable

Sub-D, 9 pol, Male RX = 2 (terminals 2 and 3 crossed)
TX = 3 2 2
GND = 5 3 3
5 5
RS485: (+)=50, (-)=51 - Serial interface RS-485
CAN: (+) = 54, (-) = 55 CAN Bus for Power

gnd = 53 Module UNITROL 1000-15 Power Module
UNITROL 1000-PM40 X102
53 1
gnd CAN_GND
Shielded cable: - 55 2
CAN_L
2x 2x 0.34 mm2, 120R 52 3
Impedance 120 Ω, J4
CAN_SHIELD
+ 54 4
CAN_H
Length of cable < 30 m 5
CAN_POWER
Earth: = 52

3.3.5 Digital Inputs
Input function Description

None Input not assigned
Excitation ON active Excitation ON command active:
- Field flashing begins if Off Level > 0%
- Auto mode: Soft start begins after the Off Level has been reached,
and rises up to the Auto Initial Setpoint.
- Other modes: Initial Setpoint is used.
Excitation ON not active Excitation ON command not active: Mode Initial Setpoint
All setpoints are immediately set to Auto 100%
their initial values and remain fixed Manual 0%
there (see table on the right).
Open Loop 0%
Auto, Manual and Open loop Initial PF 1.0
setpoints can be changed. Var 0%
Gen CB Closed Status Circuit-breaker closed status active:
active - Activates current measurement
- This message triggers immediately the ramp of the Softstart as if
still the hold time.
Gen CB Closed Status no Circuit-breaker closed status Mode Final value
longer active changes from active to not active. Manual 90% Ie No Load
All setpoints are immediately set
Open Loop 90% 1/Kceil
to the following values:
Auto 100%
Parallel with Grid Status Parallel with grid status active:
- Together with Gen CB Closed, enables the possibility to change
over to PF and Var modes.
- Disables VDC mode.
Increase Increase setpoint of active regulator
Decrease Decrease setpoint of active regulator
Reset Setpoint Status reset setpoint is active: Mode Final value
The setpoint of the active Manual Ie No Load
regulator goes to the following Open Loop 100% 1/Kceil
value at ramp speed:
PF 1.0
Var 0%
Auto 100%
Remote SP Enable When active it enables the setpoint adjustment from an analog input
(remote setpoints should be configured in Analog Input section).
PF Enable 5 Activates Power factor regulation.
Var Enable 5 Activates Reactive power regulation.
Manual Enable Activates Manual operation mode (field current regulation).
Open Loop Enable Open loop, direct control of power transistor active
Synchronize 3 Activates Synchronization or Voltage Matching:
If Synchronization SW (optional) is not available in the device, the
input signal will activate Voltage Matching only.
VDC Enable 4 Activates the Voltage Droop Compensation (VDC) control mode.
Secondary Net 4 Selects the Secondary Net 2 for VDC operation.
3
Requires Synchronization SW.
4
Requires Voltage Droop Compensation (VDC) SW. 5 Requires the PF/VAR SW.

Reset Alarm Clear the following alarms:
- SW Alarm
- Supervision Alarm 1
- Supervision Trip 1
- Changeover 1
- System OK (reserved use)
Standby When the AVR is in Standby mode:
- The excitation output of the AVR is turned off
- Boost is disabled
- Field flashing is off
- Integrator is kept in 1/Kceiling
- All limits are disabled
- No VDC data is transmitted via the RS-485.
- The AVR displays Standby as Operation Mode.
- DCH Follow-up1 operates, only if DCH communication is active;
otherwise the Channel Follow-up operates instead. For more
information see Chapter 3.4.8.4 - DCH Follow-Up and 3.4.2 - Channel
Follow-up.
- Alarm and Trip statuses1 output their values via digital outputs only if
they are configured to behave like that. For more information see
Chapter 3.4.8.2 - DCH Supervision.
RC Fieldbus Block It disables the Fieldbus communication in local operation.
FCB closed Status Field circuit breaker closed status active.
External Alarm1 Input to use as External Alarm input1.
1
Requires Double Channel SW.
3.3.5.1 Polarity
Polarity can be configured for all digital input/output ports (DIO) 1 to 4 separately, and
each one has a separate polarity configuration when configured as input or output. Each
DIO port can be configured as only input or only output at the same time.
24 V DC 24 V DC
inverted
DIO1 to 4 DIO1 to 4
DI5 to 8 DI5 to 8
normal DI9 to 14 DI9 to 14
3.3.5.2 Forcing digital input signals
Each digital input signal can be set to a predefined value (i.e. active/not active) by means
of configuration, without the need to make connections at the device's terminals; this
process is also known as forcing.
Forcing a digital input terminal can be done by configuring the Polarity parameter of an
input to Normal or Inverted. When Polarity is set to Normal, the digital input is set to not
active, i.e. false or logical 0. When it is set to Inverted, the input is set to active, i.e. true
or logic al 1. It is a must that the intended digital input, which is being configured, shall
not have connections at its device terminals. For more information about configuration
see Chapter 6 - Operation.

3.3.6 Digital Outputs
Output function Description

None Output not assigned
Boost Status signal boost is active
Boost supports excitation in the event of line short circuit or heavy load.
The boost function is blocked during field flashing and Softstart.
Field Flashing Field flashing (voltage built up) active, if Excitation ON
See section 2.4.2 The next field flashing can only be started after Excitation ON or after the
power has been switched off.
During field flashing the output of the regulator is blocked in all operation
modes.
System OK Reserved signal.
Limit Active One of the limiters (V/Hz, Ie, PQ or UM) is active
or setpoint limit has been reached (min. or max. position)
V/Hz Limit Active V/Hz limiter active
SP Limit Reached Setpoint limit has been reached
SP Minimum Minimum setpoint has been reached
Reached
SP Maximum Maximum setpoint has been reached
Reached
Operational Limit Ie, PQ, UM limiter or Diode Alarm active
Active
Min Ie Active Ie minimum current limiter active
Max Ie Active Ie maximum current limiter active
Min PQ Active PQ limiter active
Min UM Active Limit value for minimum machine voltage is fallen below,
voltage limiter active
Max UM Active Limit value for maximum machine voltage is exceeded,
voltage limiter active
Voltage Relay Active = machine voltage below boost threshold
Inactive = boost threshold plus hysteresis exceeded
Not dependent on signal Excitation ON.
Close CB The command is released:
Command 3 - Angle is in a value where it would take the Total CB Closing Time for the
breaker to close at zero degrees with current speed and acceleration.
- Sync Check demand active
- The command is active as long as the command Sync Check is active
Sync Check 3 Sync Check demand to be active:
- Generator circuit breaker is open
- Machine voltage is higher than 50%
- Synchronization is possible (unit with Sync-Option)
- Synchronize is enabled
- Slip is between minimum slip and maximum slip
- Machine voltage is deviating from network voltage maximum Delta U
- Angle is between -maximum delta angle and +maximum delta angle
3
Requires Synchronization SW.

SW Alarm Software program process is out of order
Diode Alarm2 Event of open diode
Diode Trip2 Event of a shorted diode
SW Alarm or Diode Trip2 SW alarm and event of a shorted diode
MODBUS Com Alarm Loss of MODBUS command
Close FCB Command Command to close the field circuit breaker
Open FCB Command Command to open the field circuit breaker
Alarm signal that can be connected to several monitoring
Supervision Alarm1
functions1.
Trip signal that can be connected to several monitoring
Supervision Trip1
functions1.
Configurable signal output used for Change-Over in a Double
Switch Over1
Channel System1.
1
Requires Double Channel SW.
2
Requires Rotating Diode Monitoring SW.
3.3.7 Analog Inputs

None Input not assigned
Auto Remote Setpoint External setpoint input to Auto regulator
PF Remote Setpoint 5 External setpoint input to PF regulator
Var Remote Setpoint 5 External setpoint input to Var regulator
Manual Remote Setpoint External setpoint input to Manual regulator
Open Loop Remote SP External setpoint input to open loop
UM Aux 6 Auxiliary supply to the summing point of Auto regulator
Ie External Reserved.
Cooling Media Temperature Input temperature measurement for the temperature influence
limiter
Reserved 4 to 5 Reserved for future software expansions
Digital Input 9(+) & 10(-) Assign digital inputs
5
Requires PF/VAR SW.
6
Requires UM AUX SW.
Note: When configuring an external setpoint from the analog input list shown above, the
"Remote SP Enable" digital input should be also configured. For more information see
Chapter 3.3.5 - Digital Inputs.

3.3.7.1 Level of the analog inputs
Internal signal value [%]

External setpoint input
Setpoint max
Setpoint min
Ext. Setpoint Auto
-10 10 [V]
Uin0% Uin100%
UM Aux [%]
Input to the summing 10
point max
Uin0% Analog in
-10 10 [V]
min Uin100%
-10
• Input voltage of the cooling media temperature

Range: Uin0% = - 10.0 V refers to - 100 °C
Uin100% = +10.0 V refers to +100 °C
• Analog inputs digitally assigned

Two digital inputs can be generated from one analog input. See example below.
Voltage between the (+)AI1 – (-)AI1 <= -5 V (+)AI1 – (-)AI1 >= 5 V

input terminals
Uin Uin
0V +AI1 10V +AI1
Principle hardware Ain Ain
10V -AI1 0V -AI1
configuration
DI9 = 1
-5.0 -2.0 DI9 = 0

DI10 = 0 Uin
2.0 5.0 [V]
Condition of the
digital inputs
DI10 = 1
Status of the digital -> Din9(+) = 0 -> Din9(+) = 1

inputs -> Din10(-) = 1 -> Din10(-) = 0
Note: +AI and -AI must not be active simultaneously!

3.3.8 Analog Outputs
None Output not assigned

Excitation Current Excitation current
PWM Pulse width modulation, control value is limited to a minimum of 2%
Fbias Analog continuous signal presenting difference between UNET and UM
Fbias = fNET – fNOM – (SlipMAX – SlipMIN)/2
Output signal Fbias is forced to zero:
- Not in Sync mode
- Synchronization function not enabled (unit without Sync-Option)
- Network frequency is not between 45 … 66 Hz
Slip Slip between Network and Machine frequencies
Active Power Machine Active Power
Note: The assignment of the analog outputs to the 2 terminals AO1 and AO2 can be
selected freely.
3.3.8.1 Level of the analog outputs
Excitation Current Aout [V]

10
Caution: Uout 100%
Ie0% must be less than
Ie100% Uout 0%
Ie
400 [%]
-10
Ie 0% Ie100%
Aout [V]
10
Uout 100%
Fbias
Uout 0% Fbias
-10 10 [Hz]
Fbias0% Fbias 100%
-10
Aout [V]
10
Uout 100%
PWM Output
Uout 0% PWM
100 [%]
-10

Aout [V]
Slip
10
* The parameter "Slip0%" Uout 100%

cannot be set by the user. (max) Slip
This parameter is internally
set as the negative of "Slip -10 10 [Hz]
100%": Uout 0%
"Slip0%" = (-)"Slip100%" (min)
-10
Slip 0%* Slip 100%*
(min) (max)
Aout [V]
Active Power
10
Uout 100%
(max)
ActivePower
200 [%]
Uout 0%
(min)
-10
ActivePower 100%
(max)
Note: The full voltage range runs from –10 V to 10 V at a resolution of 10 bits.
3.3.9 Communication ports
The UN1000 has three main communication ports to share several features which can be
used in combination to cover the requirements of an application.
• RS-232 is a point-to-point interface that can be used to connect with a PC and is
used by the CMT1000 software to control the device. As an alternative, the
interface port can be connected via a TCP/IP gateway to create a multi-point
Ethernet network and allows the connection to both CMT1000 and Remote
Access.
• RS-485 is a multi-point interface that could be used for Remote Access or VDC;
only one feature can be used at the same time.
• CAN is a multi-point interface used to connect an UN1000-PM40 module and
uses the Double Channel feature; both cannot share the CAN bus and they are
only partially compatible to operate together in the same device.
This section describes the hardware and wiring requirements for the communication
interfaces. The software features that use these communication interfaces are explained
in Chapter 3.4 Software.
3.3.9.1 RS232 interface
The UN1000 integrates a RS232 serial port with MODBUS capability to communicate
with the CMT1000 software and a remote terminal using Remote Access.

The serial RS232 port of UN1000 can be used to connect a PC, which runs a CMT1000
software (see Figure 3-2). If the application requires a TCP/IP connection or access from
remote locations, a TCP/IP gateway can be used to create a multi-point network (Modbus
TCP) as shown in Figure 3-3. The use of a TCP/IP gateway on the RS-232 interface is
further referred to as RS232 TCP/IP connection.
Abb UNITROL 1000

R
Maximum cable lenght = 3 meters
Modbus RTU via RS232

(point – to – point)
CMT1000
Figure 3-2 RS232 connection to a PC (no TCP/IP interface)
Abb UNITROL 1000

R
TCP/IP Gateway
Modbus RTU via RS232 Modbus TCP over Ethernet

Network
(point – to – point) (multi – point)
Maximum lenght = 3 meters Remote

Terminal
CMT1000
Figure 3-3 RS232 TCP/IP connection
The RS232 TCP/IP connection allows the device to be monitored and controlled from a
remote location. It also offers the possibility to have max. one CMT1000 connection and
one Remote Control accessing the AVR at the same moment. This solution can be
suitable for applications that, for instance, require control or monitoring from remote
location, a custom control software, MODBUS TCP as communication interface or a
single CMT1000 software that accesses several AVRs. More information about these
software features and configuration can be found in Chapters 3.4.9 Remote Access and
6.4 PC Software tool.
RS232 connection requirements
The UN1000 serial cable provided by ABB (see Figure 3-4) should be connected in order
to use the CMT1000 software. The cable should be connected between the RS232 port
from the AVR and the serial port from the PC where the CMT1000 is installed (see Figure
3-2); USB to RS232 converters can be used on the PC side.
If the UN1000 serial cable provided from ABB is not available, a replacement cable can
be used as long as it fulfils the following requirements:

Cable and connector types

• Serial null modem RS232:
Terminals 2 and 3 must be crossed. Terminal 5 must be used (ground).
Terminals 1, 4, 6, 7, 8 and 9 must not be connected.
• DB9 female-to-female
• Length: 3 meters (maximum)
Internal crossing schema

2 2
3 3
5 5
Note: other terminals must not be
connected.
Figure 3-4 UN1000 Serial
RS232 TCP/IP connection requirements cable for RS232
The RS232 TCP/IP connection requires a
UN1000 serial cable provided by ABB (Figure 3-4) to be connected between the UN1000
and the TCP/IP gateway (Figure 3-3).
The TCP/IP gateway converts Modbus RTU to Modbus TCP data and vice versa. There
are several TCP/IP gateways available which can be used with UN1000. ABB have
tested the UN1000 operation with the NetBiter® Modbus RTU-TCP Gateway from
IntelliCom Innovation AB.
Configuration of NetBiter® Modbus RTU-TCP Gateway

Settings at RS-232 side:
• Baud rate: 57600 /sec
• Data bits: 8
• Stop bit: 1
• Parity: none
Settings at TCP/IP side:
• Port number: 502
• IP and mask addresses: according to network.
• Slave response time: 200 ms
• The remaining settings should be left as factory default of the gateway.
The NetBiter® TCP/IP Gateway product datasheet and user manual can be found at the
manufacturer Internet address: http://www.netbiter.com.
Other TCP/IP Gateways can be used whenever it fulfills the following requirements:
Minimum requirements for a TCP/IP Gateway

• Modbus RTU Master on the serial side.
• RS232 serial compatible, preferred with DB9 male connector on the serial side.
• Modbus TCP Slave on the Ethernet side.
• TCP/IP Ethernet port compatible, minimum speed 10 Mbit/sec.
• Configurable at 57.6 Kbit/s baud rate, 8 data bits, 1 stop bit, no parity.
• Port configuration to 502. Configurable IP address according to the application.
Firewall configuration for RS232 TCP/IP connection

In case of a firewall (software or hardware), port 502 and 1025 must be opened for
communication in both directions.
3.3.9.2 RS485 interface
The UN1000 provides a RS485 interface for both VDC and Remote Access; however
only one should be activated and both can not use the bus simultaneously. If both
features are required and must be activated, the solution is the usage of Remote Access
over Modbus TCP (using a TCP/IP gateway) and VDC over RS485 (Figure 3-5). More
information about hardware connections over RS232 can be found in Chapter 3.3.9.1
RS232 interface.
Remote
Terminal
Modbus TCP (Ethernet)
Abb UNITROL 1000

R
Abb UNITROL 1000

R
TCP/IP Gateway TCP/IP Gateway
VDC communication over RS485
SM1 SM2
Figure 3-5 ABB solution if both Remote Access and VDC features are
required.
The electrical connections of the RS485 bus should be performed according to EIA485
standard specification. The 120 ohm resistor normally used to terminate a RS485 bus is
already included in UN1000 and should be used by placing a jumper bridge over the J2
terminals. The J2 location is shown in Chapter 3.3.2.4 Terminal block.
Cable type requirements

• Cable cross-section: 2 x 0.75mm2
• Cable impedance: 100 to 120R
• Shielded twisted pair.
The cable shielding shall be grounded as closely as possible to the device's terminals as
shown in Figure 3-6.

485 CAN
gnd
- -
+
50 51 52 53 54 55
J2 J4
RS-485 CAN
Abb UNITROL 1000

R
Max.
30 mm
Shielding
should be
grounded.
Figure 3-6 Shielding and wiring recommendation when using the RS-
485 interface.
RS485 for Remote Access
When using Remote Access over the RS-485 bus, a jumper bridge over J2 terminals
should be placed whenever the AVR is located at the end of the bus. There should not be
any resistor placed externally, i.e. on the other terminals of the device, if a jumper bridge
over J2 is already being placed. The Remote Access software configuration is explained
in Chapter 3.4.9 Remote Access.
RS485 for VDC
When configuring the RS485 interface for VDC, a jumper bridge should be placed over
the J2 terminals of each AVR located at the end of the bus; and it should be removed
from those not located at the end (see Figure 3-7). No resistor should be placed
externally, i.e. on the device's terminals, when the jumper bridge of the UN1000 is
already being used.
J2 J2
J2 + AVR 1 AVR 2 AVR 3 AVR 4 J2
50 1 RS-485 1 50 1 RS-485 1 50 1 RS-485 1 50 +
120R - 51 2 2 51 2 2 51 2 2 51 - 120R
52 52 52 52
Figure 3-7 RS-485 wiring and jumper settings to use VDC on a set of four AVRs.
As shown in Figure 3-7 the topology of the bus should be as "one line" with two endings,
and not as a "star". The recommendations described in Chapter 3.3.9.2 RS485 interface
should be strictly followed. The total length of the cable from end-to-end should not
exceed 250 meters. The VDC feature operates only over RS485 and could not work
properly if there is any other device incompatibly connected to the same bus.
The VDC software should be configured in each device prior to use. The configuration is
described in Chapter 3.4.3 Voltage droop compensation (VDC).

3.3.9.3 CAN interface
A CAN interface is provided for both Double Channel (connection with a second channel)
and UN1000-PM; however both cannot use the bus simultaneously. As explained in
Chapter 3.4.8 - Double Channel (DCH), the DCH Supervision can be used together with
a UN1000-PM connected to the AVR since the CAN communication is not needed for the
operation of the monitoring functions. However, the remaining functions from Double
Channel are not compatible with the UN1000-PM. For more information see Chapter
3.4.8.5 - DCH communication: configuration and compatibility.
The electrical connections should be performed according to CAN standard guidelines. A

120 ohm resistor normally used to terminate the bus, is already included in the device
and can be used by placing a jumper bridge over the J4 terminals. The location of the J4
terminals can be identified by referring to Chapter 3.3.2.4 Terminal block.
CAN for UN1000-PM40
The CAN connections between UN1000-15 and UN1000-PM40 are indicated in Figure
3-8. For more information refer to the UN1000-PM40 User Manual.
CAN: CAN Bus for

(+) = 54 Power Module UNITROL 1000-15 Power Module
(-) = 55 UNITROL 1000-PM40 X102
53 1
Gnd = 53 gnd CAN_GND
Shielded cable: - 55 2
CAN_L
2x 2x 0.34 mm2, 120R 52 3
Impedance 120 Ω, J4
CAN_SHIELD
+ 54 4
CAN_H
Length of cable < 30 m 5
CAN_POWER
Figure 3-8 CAN connections to use an UN1000-PM40 with UN1000-15.
CAN for Double Channel
When using Double Channel, the CAN connections should be performed as shown in
(Figure 3-9). The cable used for the CAN communication shall be connected only
between the two channels, i.e. Main and Redundant, and not to any other device. To
properly terminate the bus, there should be one jumper bridge placed over the J4
terminals of each device.
Cable type requirements

2
• Cable cross-section: 2 x 2 x 0.34 mm
• Cable impedance: 120 Ω
• Maximum cable length: 30 meters.
• Shielded twisted pair. The shielding shall be grounded.
The Double Channel is an optional feature that should be previously available in the
device (by password or product rubric), configured and the communication activated. For
more information refer to Chapter 3.4.8- Double Channel (DCH).

485 CAN 485 CAN
gnd
gnd
- - - -
+
+
+
50 51 52 53 54 55 50 51 52 53 54 55
J2 J4 J2 J4
Channel 1 RS-485 CAN Channel 2 RS-485 CAN
A bb UNITROL 1000 Abb UNITROL 1000

R R
CAN_L CAN_L
CAN_H CAN_H
Shielding Shielding
Double Channel CAN Communication
Figure 3-9 CAN connection for Double Channel SW.
3.4 Software
The UN1000 device supports several operating modes and software

features, such as machine voltage regulator (Auto), field regulator
(Manual), measurements monitoring, change of parameters and others
which are described in detail in this section.
A set of basic software features is enabled by default in each UN1000-
15 product and is referred to as basic software package. There are
optional software features which extend the UN1000 capabilities and
which can be enabled by password.
No. Name in SW- Descriptions Refer to chapter

Options
(Figure 6-20)
1 PSS Power system stabilizer 3.4.7
2 Modbus Modbus 3.3.2.2, 3.4.9
3 RDM Rotating Diode Monitoring 3.4.6
4 External Ie Meas. Excitation Current or Ie External 3.3.7 or 3.3.9
5 Synchronization Synchronization 3.4.4
6 VDC Voltage droop compensation 3.4.3
7 PF/VAR PF / Var regulator 3.4.1.3
8 UMAUX Auxiliary supply to summing point 3.3.7
9 Double Channel Double Channel 3.4.8

Once a password code has been acquired from ABB, optional software
can be enabled using the CMT1000 software. A pre-configured device
with selected optional features can also be ordered by means of the
product rubric number, and in this case there is no need of software
activation by password. More information regarding the activation
procedure can be found in Chapter 6.4.4 Menu structure of CMT 1000.
The following sections explain the complete UN1000 software including
optional features. It is clearly mentioned at the beginning of the
description if a software feature is optional or not. The Panel and
CMT1000 software are explained in Chapter 6 - Operation.
After the configuration of the device, the parameters should be stored in
the non-volatile EEPROM memory; otherwise the changes are lost after
restarting the device. The command Save to the EEPROM is used to
store parameters in the non-volatile memory and is explained in Chapter
6 - Operation.

3.4.1 Operating modes
There is a bumpless changeover between all modes performed by the Channel Follow-up
function. For more information see Chapter 3.4.2 - Channel Follow-up. Tuning and other
parameters are described in Chapter 3.4.11 Description of parameters.
3.4.1.1 Automatic voltage regulation (Auto)
Regulates the terminal voltage of the UN 1000-15

synchronous machine. PID Regulator
Note:
Current measurement for compensation /
droop
SM E
3.4.1.2 Manual control
Regulates the field current of the UN 1000-15

excitation machine.
PI Regulator
Note:
No limiters are active as long as this
mode is active.
SM E
3.4.1.3 PF or Var regulation (Optional)
Regulates the power factor or reactive UN 1000-15

power of the synchronous machine. PID Regulator
PF
MVar
SM E
3.4.1.4 Open loop
Control with a fixed output signal. UN 1000-15
Note:
No limiters are active as long as this
mode is active.
SM E

3.4.2 Channel Follow-up
A bumpless operation when changing between operation modes is provided by UN1000.

While the UN1000 device is operating at one operation mode, the setpoint from the other
modes are following the actual one in order to provide a soft transition, with no bumps, on
the generator regulation when a mode change takes place (e.g. from Auto to Manual).
This feature is called Channel Follow-up and is different from the DCH Follow-up; the
former is active as long as the DCH software is not used and the latter when DCH is
used. For more information about Double Channel software see Chapter 3.4.8 - Double
Channel (DCH).
When UN1000 is running at a specific operation mode, the other modes are following the
actual one by calculating their setpoints with a certain delay from the actual
measurements; i.e. the other setpoints are delayed with respect to the actual generator's
operating point (setpoint and measurements). This delaying method minimizes the
influence of system failures on the setpoint calculation (e.g. wrong measurement due to
PT failures) and improves the bumpless characteristic at the moment of changeover.
Channel Follow-up is the same function included in software release 4.xxx and, as
before, it requires no configuration from the user. If DCH Software is not used, Channel
Follow-up is enabled after Excitation On; except during SoftStart. During SoftStart, the
Channel Follow-up function is disabled.
3.4.3 Voltage droop compensation (VDC)
(Optional) – For island operation only –
UNITROL 1000 offers a special feature called Voltage Droop Compensation or VDC. This
feature equally shares the amount of reactive power between generators connected in
parallel to the same bus (see Figure 3-10), by using the RS485 bus for communication
between AVRs. The wiring connections of the RS485 bus are explained in Chapter
3.3.9.2 RS485 interface.
During VDC mode all AVRs operate in Auto mode with a voltage droop control. Each
AVR has to be configured with a unique AVR-ID number which identifies itself among the
others on the bus. Each AVR sends the value of its own amount of reactive power over
the RS-485 bus, while the other AVRs take this information to calculate a common
average MVAR setpoint and compensate the effect of the voltage droop. The setpoints
are calculated to maintain the voltage level on the busbar at 100% (not adjustable).
Load A Load B
RS-485
AVR 1 AVR 2 SM AVR 3 SM AVR 4

SM SM
Primary Net = 1
Primary Net = 1
Secondary Net = 2
Figure 3-10 VDC application example of four machines and two nets.

The VDC software supports the network to be divided into smaller entities. Each AVR can
operate in one of two pre-determined island grids called Primary and Secondary Nets.
The Primary Net is selected by default if the Secondary is not configured.
When the Secondary Net is required, it should be configured using a digital input. This
input determines whether the AVR uses data for VDC calculation from the devices
configured in the Primary or Secondary Net. When the Secondary Net digital input is
active (logical high), the AVR is selected to operate in the Secondary Net and shares
reactive power between those from Secondary Net only; information from the Primary
Net's AVRs is ignored. On the other hand, if Secondary Net digital input is low or not
configured, the AVR operates in Primary Net and shares reactive power data only with
the others which operate in Primary Net as well.
Normally the digital input for Secondary Net is configured (appears in the DI port list) only
on the AVRs intended to operate in Primary and Secondary Net (see Figure 3-10). On
the other AVRs, the Secondary Net digital input is not normally configured in the DIO
section, which causes the parameter value to be internally assigned to logical zero;
therefore the device only operates in Primary Net.
3.4.3.1 Configuration
Primary Net ID: Primary Net ID Machine voltage

Secondary Net ID: Secondary Net ID
Ramp Time: Ramp Up Time [s]
100
Ramp time to get machine voltage to

100% and Var equal between machines Reactive current
after VDC is activated.
Var SPmax [%]
Var SPmin
Important:
The Compensation Droop Kq shall be set at -5% (negative value) if VDC mode is used.
The AVR-ID number is used to identify the generator among the others and it should be
configured before using VDC. The AVR-ID shall be set as a number between 1 and 31
and it shall be a different number for each machine. In dual channel system, both AVRs
from the same machine (i.e. Main and Redundant) shall be configured with the same
AVR-ID number.
The Primary and Secondary Net ID numbers should be different from each other and
unique for each island grid.
3.4.3.2 Communication
The VDC communication refers to the data transmitted over the RS485 bus whereas the
VDC operating mode refers to whether this data is used for compensation of the reactive
power or not. The AVR enables the VDC communication (i.e. transmit data over the bus)
as soon as the "Gen CB Closed status" input is active (logical one) and VDC software is
available in the device; except during Standby or when Remote Access via the RS485 is
active. As long as the AVR is in Standby or Remote Access via RS485 is active, the VDC
communication is disabled and will not be transmitted over the bus. Once the VDC
communication is enabled, the data available on the bus is taken and used for the

regulation only when the AVR is switched to VDC operating mode (i.e. by VDC Enable
digital input).
The availability of the VDC communication disregarding the operation mode (even during
Excitation Off), allows the cabling connections and communication quality to be easily
tested. The testing is performed by forcing the "Gen CB Closed status" input signal and
monitoring the status of the communication using the VDC Monitor tool included in the
CMT1000. The VDC Monitor allows checking whether the cabling connections are ok or
not, but it does not distinguish if the VDC operating mode is enabled in the device or not;
this can be checked by connecting the CMT1000 or by Remote Access to each AVR. For
more information about VDC Monitor refer to Chapter 6.4.4.5 Communication Menu.
3.4.3.3 Activation
The VDC operation mode can be activated via a digital input (i.e. VDC Enable signal) or
Remote Access. For more information refer to Chapter 3.3.5 Digital Inputs, 3.4.9 Remote
Access and 6.4.4 Menu structure of CMT 1000.
3.4.4 Synchronization (SYNC)
(Optional)
The automatic synchronization of a synchronous machine with the Line is achieved using
the optional integrated synchronizing function. By setting few simple parameters,
UNITROL 1000 supplies the corresponding control signals for the speed governor and
closes the circuit breaker.
Analog speed correction Fbias is given out from the UNITROL 1000-15 analog output to
the speed governor control summing point (not as pulse). This signal represents the
difference of network NOMINAL and network ACTUAL frequency. The reference
(setpoint) value for the speed governor must be nominal (50 or 60 Hz) and the Fbias
given by UNITROL 1000 will drive the speed close to actual network frequency.
Note that the speed control is not with INC/DEC pulses, and that it is not possible to
derive such pulses from the Fbias signal. Also, the configuration possibilities of PTs
(machine/net) are very limited. Other functions, like dead bus synchronizing, etc. are also
missing. The circuit breaker closing command type is traditional with no specialties (for
one breaker).
UNET UN 1000-15
Setpoint fSP = fNom Synchrocheck
Command
CB
Fbias Sync
Speed Controller
Setpoint
UM
Regulator
T SM E
Figure 3-11 Typical application for Synchronization.

CAUTION!
Synchronization should never be performed by calculation only. All
measurements shall be confirmed on site before synchronization takes
place.
Power circuit breaker (CB) must not be closed unless both voltages
are at least approximately synchronous (coincident).
Otherwise, this may result in faults in line operation, loading of the
synchronous machine and, in extreme cases, damage to the
synchronous machine.
A separate synchrocheck relay must be used to secure the right
operation. For further information please contact ABB.
Measuring and Matching
The values are obtained by the two measurement signals UNET and UM
• Voltage difference (amplitude)
• Slip (frequency difference)
• Phase-angle difference
The voltage matching function gives the adjusting value to the internal voltage regulator
and the frequency matching function sends the analog signal Fbias to the turbine
regulator.
Monitoring and command generation
The command to close the breaker (CB) is released if all conditions are fulfilled.
Min Slip [Hz] : Minimum Slip (Delta U) UM -UNET [%]

Max Slip [Hz] : Maximum Slip 10.0
MaxDeltaU [%] : Max. voltage difference
5.0
Slip
Note: fM > fNET
Slip always negative [Hz]
-5.0
-10.0
-1.00 -0.40 0
Maximum Minimum
Angle = 10 -10
0
20 -20
Max Delta Angle Max Delta Angle [deg] 40 -20 -40
[deg] 60 -60
80 80

Tot CB CloseTime Time between closing command and closed breaker (see data
[ms] sheet of the breaker).
Voltage Offset [%] Voltage correction factor between UM and UNET.

UNET USED = UMEASURED FROM NET + Voltage Offset
Angle Offset [deg] Phase correction factor between UM and UNET. Delta angle is
calculated as follows:
Delta Angle = PhaseNET – PhaseM + Angle Offset
Example
Situation: Due to a step-up transformer between machine and
grid, UNET is delayed 30º with respect to UM.
Correction needed: Angle Offset = + 30º (positive).
SYNC When set to False (default), this enables the monitoring of Gen
DisableCBCheck CB Closed Status input during Synchronization (only): if Gen CB
[True / False] Closed Status is active, Voltage Matching is not performed.
When set to True, this disables the monitoring of Gen CB Closed
Status during Synchronization (only): Voltage Matching is
performed disregarding the Gen CB Closed Status input (not
recommended in most applications).
Important: Leave this parameter in False for backwards
compatibility with releases 4.401 or earlier.
IMPORTANT!
After the power circuit breaker has been closed, the Synchronize
command must be deactivated.
The setpoint of the speed controller must have the nominal value of 50
resp. 60 Hz for the synchronization.

Examples
[%] Setpoint AUTO
Voltage matcher
110 Maximum
The machine voltage is raised to the level 103

UNET
of the line voltage. Ramp = constant
100
Ramp Rate has to be adjusted in the menu UM
Setpoint AUTO 98
90 Minimum
Frequency matcher [Hz] Fbias

3
fNOM = 50 Hz (45 Hz < fNET ≤ 54 Hz, 50 Hz) -0.8
(54 Hz < fNET < 66 Hz, 60 Hz) -3
fNET = 49 Hz
fM = 50 Hz [Hz]
fSP = 50 Hz (Setpoint speed governor) 50 fNOM
Slipmax = -0.4 Hz fSP + Fbias
fM 0.4
49.2 49 fNET
Slipmin = 0 Hz
Fbias = fNET -fNOM -(Slipmax-Slipmin)/2 = -0.8 Hz
fSP+Fbias = 49.2Hz
3.4.4.2 Activation
The Synchronization can be activated via digital input or Remote Access. For more
information refer to Chapter 3.3.5 Digital Inputs, Chapter 3.4.9 Remote Access and 6.4.4
Menu structure of CMT 1000.
The Synchronization and Voltage Matching are features that are activated using the
same activation signal, called Synchronize. When the Synchronization SW is not
available in the AVR (i.e. blocked), only Voltage Matching will be activated when
Synchronize digital input is set to high. On the other hand, when Synchronization SW is
available (i.e. unblocked in the SW Options section of the CMT1000), Synchronize input
will fully activate the Synchronization feature, which also includes the capability of voltage
matching and the Fbias output. For more information about Voltage Matching see
Chapter 3.4.5 Voltage matching (VM).
3.4.5 Voltage matching (VM)
Voltage Matching is a function from the Synchronization software (Chapter 3.4.4) but
included in the AVR basic software package. When Voltage Matching is activated, the
generator voltage setpoint is adjusted to match UGEN with UNET, also during
Synchronization; however there is no Fbias output. More information about Voltage
Matching can be found in Chapter 3.4.4 - Synchronization (SYNC).
3.4.5.1 Activation
The Synchronization and Voltage Matching are features that are activated using the
same activation signal, called Synchronize. When the Synchronization SW is not
available in the AVR (i.e. blocked), only Voltage Matching will be activated when
Synchronize digital input is set to high. On the other hand, when Synchronization SW is
available (i.e. unblocked in the SW Options section of the CMT1000), Synchronize input

will fully activate the Synchronization feature, which includes also the capability of voltage
matching and the Fbias output.
3.4.6 Rotating Diode Monitoring (RDM)
(Optional)
The aim of the Diode Monitoring is to detect the following failures:

• Break of a diode
• Short circuit of a diode
It is needed in brushless excitation systems and can only be done indirectly, because the
diodes are part of the rotor. See the principle circuit for the excitation in Figure 3-12.
Regulator
ie AC Exciter Synchronous Machine
Ie
Figure 3-12 Rotating Diode Monitoring application
RDM parameters
Nominal exciter frequency f Exc Nominal [Hz]

(Machine) : Tconst Exc [s]
Exciter time constant : Active = TRUE/FALSE
Diode monitoring active : Alarm Level [%]
Diode alarm level : Alarm Delay [s]
Diode alarm delay : Trip Level [%]
Diode trip level : Trip Delay [s]
Diode trip delay :
The device evaluates the alternating current induced in the field circuit of the exciter in
the event of a fault in the rotating rectifier.
The ALARM is triggered in the event of a broken branch in the rotating exciter.
The TRIP is triggered in the event of a branch short-circuit in the rotating exciter.

3.4.7 Power system stabilizer (PSS)
(Optional)
The PSS is used to improve the damping of possible oscillations in large transmission
networks by adding a signal to the voltage regulator of the existing excitation system.
It is also used to attenuate local rotor oscillations in synchronous generators through
additional influencing of the excitation. The main application is in excitation systems in
single or multi-machine power plants.
Electromechanical oscillations can be classified in four main categories:
• Local oscillations between a unit and the rest of the generating station and
between the latter and the rest of the power system. Their frequencies typically
range from 0.8 to 2.0 Hz.
• Inter-plant oscillations between two electrically close generation plants.
Frequencies may vary from 1 to 2 Hz.
• Inter-area oscillations between two major groups of generation plants.
Frequencies are in a typical range of 0.2 to 0.8 Hz.
• Global oscillation characterized by a common in-phase oscillation of all
generators as found on an isolated system. The frequency of such a global mode
is typically under 0.2 Hz.
The IEEE Std. 421.5-1995 PSS 2A/2B type model functionally represents the PSS. This
model is shown in Figure 3-13.
The object of power system stabilizing (PSS) equipment is to increase the generator
exciter‘s contribution to improving the stability to the highest possible operating range of
the generator. The PSS derives additional signals from the generator internal frequency,
which considerably improves the stability of the power transmission.
• Dual input (frequency, electrical power).
Figure 3-14 shows a simplified diagram of the PSS and related functions
ΔP RAMP-TRACKING LEAD-LAGS WITH OUTPUT

WASH-OUTS PSS-GAIN
INTEGRATOR FILTER ANTI WIND-UP LIMIT
PSS MAX
V1 s . TW1 s . TW2 + (1 + s ⋅ T8) N

+ 1+ s . T1 1+ s . T3 1+ s . T10 PSS
1+ s . TW1 1+ s . TW2
Σ (1 + s ⋅ T9) M
Σ KS1
1+ s . T2 1+ s . T4 1+ s . T11
(Δω) _
+
PSS MIN
KS3
V2 s . TW3 s . TW4 KS2 +ΔPe'

1+ s . TW3 1+ s . TW4 1+ s . T7
(Pe)
Figure 3-13 PSS model.

V1 PSS
Frequency
UM Calc
f
PSS
UM V2
Power
IM2 Calc
Pe
Figure 3-14. Simplified diagram of PSS.
Due to the PSS function implementation and structure of UNITROL 1000 AVR, there are
some points to be noticed when using this PSS. The following elements limit the
maximum performance of the PSS:
• Brushless excitation system,

• Single-phase machine current measurement (only) is available,
• Positive field voltage (only) can be supplied.
PSS Parameters
The PSS function can be activated by the PSS_SELECT configuration, if the PSS feature
is available.
The parameters are not explained here. They can be calculated by ABB Switzerland. For
further information please see the Functional Description of UNITROL 1000, Power
System Stabilizer, and document number 3BHS213239 E01.
The manufacturer information can be found in Chapter 1.4 Manufacturer’s Address.

3.4.8 Double Channel (DCH)
(Optional)
The Double Channel (DCH) is an optional feature which integrates supervision functions
and redundant channel support to build robust and flexible double channel systems.
3.4.8.1 Overview
The Double Channel feature has the following main components (Figure 3-15):
1. DCH Supervision
The Double Channel Supervision is a feature with 12 monitoring functions that
can be used to trigger an Alarm and/or a Trip outputs from the AVR. The
configuration is performed using a so called Configuration Matrix.
In addition to the configuration of the 12 monitoring functions defined within the
Double Channel SW scope, the Configuration Matrix allows Alarm and Trip to be
triggered from five other monitoring functions, e.g. Diode Monitoring. The flexibility
to combine multiple statuses in one or two signals like Alarm and Trip can be used
to save the number of digital outputs necessary to indicate a problem in the AVR.
2. Redundant Channel support

Channel changeover, DCH Follow-up and DCH communication
The Channel Changeover is a feature used to transfer the control to the other
channel; normally used when the active channel trips or under special
circumstances (i.e. monitoring alarms) which can be configured in the AVR.
The DCH Follow-Up is a function which is active as long the AVR is in Standby
mode (i.e. not active), monitoring the setpoint used on the other channel in order
to be ready to takeover in case of changeover. The DCH Follow-up is different
from the Follow-up used to change between operation modes within the same
AVR. For more information see Chapter 3.4.8.4 - DCH Follow-Up.
The communication with the second channel is made using the CAN interface and
called DCH Communication. Throughout the CAN bus, measurements, statuses
and setpoints are transmitted and received from both channels. The data
information can be read from Panel, CMT1000, using Remote Access and is used
for the channel changeover functionality.
The features included in the Redundant Channel support (channel changeover, follow-up
and communication) are in operation and active as long the DCH CAN communication is
enabled and error-free. However, DCH Supervision can be used disregarding of the
existence of a second channel, and therefore, suitable also for single channel
applications. DCH Supervision does not depend of the DCH CAN communication.
The Double Channel software must be available in the AVR (i.e. unblocked) before the
use of DCH Supervision and/or functions from Redundant Channel support. Otherwise
the configuration is not possible and Alarm, Trip and Changeover digital output are
unconditionally set to logical zero (i.e. not active). The schema in Figure 3-15 shows the
relationship between the main functions described.

DCH Supervision
Configuration Matrix
Status
(Latch)
1
DCH
Monitoring 2
Functions 3
(12)
. .
Alarm assignation
Trip assignation
. .
. .
Other UN1000
Functions
(5) 16
17
Standby
Trip status config
to DO
Standby port
Alarm status config
Redundant Channel support

Channel Changeover
DCH Follow-up (block not shown)
DCH Communication
2nd. Channel Alarm
2nd. Channel Trip Channel

to DO
Change-over Switchover status
port
Comm. Status Logic
DCH CAN communication data flow

to second
Measurements, setpoint and
Measurement &
channel
other data used by DCH Communication
Follow-Up and user interfaces
Figure 3-15 Schema of main Double Channel functions.
3.4.8.2 DCH Supervision
The DCH Supervision has a total of 17 status signals from different monitoring functions
which can be configured to generate a (global) Alarm and/or a (global) Trip. As shown in
Figure 3-16, Alarm and Trip status signals are configured by a so called Configuration
Matrix. Alarm and Trip are independent from each other and they can be configured
different.
The Configuration Matrix allows the user to select which monitoring function will produce
an Alarm and/or a Trip at the output of the Supervision function. For instance, as soon a
monitoring function, which is configured to produce an Alarm, report a failure, the Alarm
status at the output of the Configuration Matrix will be set to active (logical true). The
same could happen to the Trip status if the monitoring function is configured to produce a
Trip. The configuration of Alarm and Trip are handled independent from each other and
therefore it provides great flexibility when engineering a project specific system.

Each monitoring function that can be configured in the Configuration Matrix, has a status
which is used to detect the failure and then, to trigger Alarm and/or Trip according to the
configuration. The status from each monitoring function is implemented with a latch
memory, which makes the value remaining as active (logical true) even after the failure
have been diminished and the monitoring function reports no failure anymore. Therefore,
it is possible to determine which monitoring function cause an Alarm or Trip even after
de-excite the machine. The latch memory of all monitoring function statuses can be
cleared by the digital input "Reset Alarm" (only if the failure has been already diminished)
or by powering off the device (Figure 3-16).
DCH Supervision
Configuration Matrix
Status
(Latch)
1
DCH
Monitoring 2
Functions
(12) 3
. .
Alarm assignation
Trip assignation
Other UN1000 . .
Functions
(5) . .
16 Trip and Alarm status Alarm and Trip may be

Reset may be monitored from configured to output or
Reset clears (to Logic 0) each 17 the user interfaces not its status during the
latched status only when the one Channel is in Standby
from the monitoring function is
already Off or Logic 0.
Standby
Trip status
Each status signal is latched config
to DO
when it goes to On or Logic 1 Standby port
( edge detection ) Alarm status config
Figure 3-16 Double Channel Supervision.
Both Alarm and Trip statuses are the outputs from the Configuration Matrix and they can
be monitored using the CMT1000 and Remote Access. Alarm and Trip Status can be
configured as digital outputs (DO), however as shown in Figure 3-16 they are not directly
connected to the output but to the Standby Configuration boxes. The Standby
Configuration boxes, shown in Figure 3-16, prevent Alarm and Trip to output their status
values to the DO port during Standby mode; and this function can be used to prevent
undesired alarms as long as the Channel is in Standby. When the Standby Configuration
blocks the status of Alarm and/or Trip, the value transferred to the DO port is logical zero.
A list with all the DCH monitoring functions (12) is shown in Table 3-1. Following, Table
3-2 shows the 5 status signals from other UN1000 functions which can also be
configured with the Configuration Matrix.

Monitoring Description Detection
Function time
1. Machine Voltage Machine PT monitoring function for 3-phases 30 msec.
One or Two phases system only.
lost Failure condition: The vectorial sum of 3
On CMT1000: phases is different to zero and it is within the
"Partial Loss of UM" range of failure.
2. Machine Voltage Machine PT monitoring function for 3-phases 60 msec.
system only. The function is activated only after
Loss of all phases the Softstart is finished.
Failure condition: Excitation current is higher
On CMT1000: than No-Load and Machine Voltage is below
"Loss of UM" 2%.
Machine Voltage Monitoring of the electronics for the Machine 60 msec.
Freeze monitoring voltage measurement components on the PCB
3. Phase L1 (this is not a PT monitoring function).
4. Phase L2 Failure condition: The voltage measurement is
Phase L3 more than 10%, constant and not alternating.
5.
6. Network Freeze Monitoring of the electronics for the Network 60 msec.
monitoring voltage measurement components on the PCB
(this is not a PT monitoring function).
Failure condition: The voltage measurement is
more than 10%, constant and not alternating.
7. Machine Current Monitoring of the electronics for the Machine 60 msec.
Freeze monitoring current measurement components on the PCB
(this is not a CT monitoring function).
On CMT1000: Failure condition: The current measurement is
"IM2 Freeze" more than 10%, constant and not alternating.
8. Loss of control Supervision of PWM control 500 msec.
Failure condition: Excitation is On, PWM stays
below 12.5% of 1/Kceiling and excitation current
is above 250% compared to No Load condition.
9. Loss of Excitation Supervision of Excitation current 500 msec.
Failure condition: Excitation current is less
than specified value of No-Load condition and
PWM is above 1/Kceiling.
10. Heat sink Supervision of Heat sink temperature 2 sec.
temperature Failure condition: Temperature is equal or
Level 1* above 80 ºC.
11. Heat sink Supervision of Heat sink temperature 2 sec.
temperature Failure condition: Temperature is equal or
Level 2* above 100 ºC.
12. External Alarm Supervision of external digital input signal (must 100 msec.
be assigned in the digital input section).
Failure condition: The digital input value is
copied to the status of this function.
Table 3-1 Double Channel Monitoring functions.

* Available in UN1000-7 only

Detection
Status signal Description
time
1. SW-Alarm DSP Watchdog failure. -
MODBUS Comm. Alarm
Supervision of MODBUS keep alive Remote
2. On CMT1000: "Loss of 1 sec.
Access feature.
Remote Control".
3. FCB Alarm Supervision of field current breaker. 1 sec.
Rotating diode monitoring alarm.
4. Diode Alarm 1 sec.
Requires RDM software (optional).
Supervision of diode monitoring trip status.
5. Diode Trip 1 sec.
Requires RDM software (optional).
Table 3-2 Other function statuses that can be configured with the
Configuration Matrix.
3.4.8.3 Channel Changeover
As shown in Figure 3-17, the Changeover status is the output of the AND-gate which
depends on the Alarm and Trip Status from the current channel, Alarm and Trip Status
from the Second Channel and the DCH Communication Status which is an indication of
the communication quality between both channels.
The DCH Communication refers to the data transmitted over CAN between the two
channels, and it contains setpoint information, measurements, status signals (including
Alarm and Trip) and others. The status of this communication is logical one (good) when
data coming from Double Channel feature is received well and free of errors (CRC
check). On the other hand, the Communication Status is logical zero (bad) when the data
received had errors, the communication is not enabled (no data received) and/or the
configuration is not set properly. Alarm and Trip from the Second Channel should be
configured using the DCH Supervision in the other channel.
To increase the flexibility, the Changeover dependency on Alarm and Trip status is
configurable; i.e. checkboxes allowing to configure whether these signals are part of the
AND and OR gate inputs of the logic decision (Figure 3-17). Each checkbox output is
determined according to the rules shown in Figure 3-18. An important setting is the
checkbox connected to the DCH Communication Status, which additionally lets the signal
pass through until the input of the AND gate. It also enables the DCH Communication
over CAN. The DCH Communication should be enabled to use the Changeover
functionality; otherwise the Changeover Status will be zero all the time (see Figure 3-17
and Figure 3-18).
The decision logic from Figure 3-17 shows that once the DCH Communication is
enabled, the dependency of Changeover Status is defined according to the checkbox
configuration and the Alarm and Trip status from both channels. When, for instance, the
checkboxes are configured according to Figure 3-17, the Changeover Status will be
logical one when: the Trip Status from the current channel is equal to one, the Trip Status
from the Second Channel is equal to zero (i.e. no trip in the Second Channel and it is
ready to takeover) and the Communication Status is equal to one (data from the Second
Channel is being received correctly).
The Changeover status value is latched (retains the value) when the AND gate output
changes from zero-to-one. The latched value may be cleared (to zero) using the Reset
command only if the output of the AND gate is already zero as well.
The Changeover status can be assigned to a digital output signal from the AVR. When

compared with Alarm and Trip DO signals, the DO assigned for Changeover always
outputs the Changeover Status disregarding whether the channel is Standby or Active;
for Changeover DO, this cannot be configured as it is for Alarm and Trip.
Changeover Logic
Alarm status
OR
Trip status
2nd. Channel Alarm to DO

AND Switchover status
port
OR
2nd. Channel Trip
Switchover status is latched

DCH Comm. Status when it goes from zero-to-one
(edge detection)
Reset
Enable DCH Communication
Clears (to zero) the latched
when
Switchover status only if the
AND output is also zero.
DCH CAN communication data flow

to second
Measurement &
channel
Communication
2nd. Channel measurements & Status

Measurements & Status and will be not available if DCH Comm. is
Setpoints for DCH Follow-Up not enable or if DCH Comm. Status
and user interfaces Ok is equal to zero (i.e. bad quality).
Figure 3-17 Channel Changeover logic and configuration.
Check box for Alarm & Trip (also 2nd. Channel)

A A
A 0 (logic)
Check box for DCH communication
AND AND
A A A 0
1 (enable) 0 (disable)
DCH DCH
Measurement & Measurement &
Communication Communication
Figure 3-18 Configuration check boxes rules.

The Changeover output is intended to be used together with the Standby input, in order
to activate the Redundant channel and deactivate the Main one. The Standby status can
be set via Remote Access or via a digital input (common case). Figure 3-19 shows a
typical example for the use of Changeover output to set the Redundant Channel to
Standby or Active mode. As also shown in Figure 3-19, the ResetAlarm input is normally
used to clear the latch memory of Changeover output and bring the Main Channel back
to Active (and the Redundant back to Standby) once the failure has been diminished or
fixed.
Main Channel Redundant Channel
DO - Switchover DI - Standby
DI - Standby
DI - ResetAlarm DI - ResetAlarm
CAN interface
Figure 3-19 Typical configuration of Changeover output
3.4.8.4 DCH Follow-Up
The DCH Follow-up is an automatic function that runs in the Standby channel, following
the actual setpoint used by the Active channel, in order to perform a bumpless transfer
during changeover. The DCH Follow-up is different from Channel Follow-up, which is
used to have bumpless between operating modes within the same Channel and could be
also used on systems without Double Channel software support. For more information
about Channel Follow-up see Chapter 3.4.2 - Channel Follow-up.
The DCH Follow-up uses the setpoint information from the Active channel over the CAN
interface. During DCH software operation, the Active channel sends the setpoints of the
current operation mode and the one for Manual mode through the CAN interface. These
two values are setpoints delayed and calculated out from the measurements of the Active
channel; the delaying method minimizes the influence of failures on the setpoint
calculation (e.g. wrong measurement due to PT failure) and improves the bumpless
characteristic at the moment of changeover.
At the moment of changeover, the Standby channel decides whether to take the setpoint
from the Active channel (over the CAN interface) or from its current measurements,
before goes to Active. The decision depends on the operation mode of both channels
according to the following:
• If operation modes on both channels are the same (except OpenLoop), the
setpoint is taken from the Active channel, i.e. delayed setpoint over CAN.
• If Standby channel has Manual mode enabled, the setpoint is taken from the
Active channel, i.e. delayed setpoint over CAN.
• If Standby channel has Open Loop mode enabled, the setpoint after changeover
is set to zero.

• For all other possibilities not described above, the setpoint will be calculated from
the current measurements of the Standby channel; i.e. not from CAN. Under
these conditions, the setpoint is calculated based on delayed measurements from
the own channel; the delaying method minimize the influence of failures on the
setpoint calculation and improves the bumpless characteristic.
A summary of the cases described are shown in Table 3-3.
Mode Standby AVR

Auto Manual PF VAR Openloop
Sync
VDC
Mode Auto Calculated Calculated

Manual SP
Sync Auto SP of from from
of Active SP = 0%
VDC Active AVR Standby AVR Standby AVR
AVR
Measurements Measurements
Active Manual Calculated Calculated Calculated
Manual SP
from from from
of Active SP = 0%
Standby AVR Standby AVR Standby AVR
AVR
Measurements Measurements Measurements
AVR PF Calculated Calculated
Manual SP
from PF SP of from
of Active SP = 0%
Standby AVR Active AVR Standby AVR
AVR
VAR Calculated Calculated
Manual SP
from from VAR SP of
of Active SP = 0%
Standby AVR Standby AVR Active AVR
AVR
Openloop Calculated Calculated Calculated
Manual SP
from from from
of Active SP = 0%
Standby AVR Standby AVR Standby AVR
AVR
Measurements Measurements Measurements
Table 3-3 Setpoint follow-up logic Note: SP = Setpoint.
The grey boxes show the setpoint follow-up taken from the CAN Interface (more reliable)
Limitations
DCH Follow-up is not supported during synchronization. If a double channel system is
engineered, the option Synchronization should be available only from one channel.
Remote Setpoint via analog inputs should be avoided when using any feature from
Redundant Channel support since it influences on the DCH Follow-up functionality, and
as a result, the latter could not work properly.
Activation
DCH Follow-up is automatically activated as long the channel is in Standby mode, DCH
CAN communication is enabled and error-free and DCH software is available (un-
blocked). If those conditions are not fulfilled and the channel is set to Standby, the DCH
Follow-up will not be activated. Instead the Channel Follow-up will be activated. For
more information about Channel Follow-up refer to Chapter 3.4.2 - Channel Follow-up.

3.4.8.5 DCH communication: configuration and compatibility
As explained in Chapter 3.4.8.3 Channel Changeover, the DCH communication must be

enabled to use the Changeover feature. When the DCH communication is enabled,
measurement, setpoints and status indications from the Second Channel are read and
valid as long as the DCH Communication Status is logic one; i.e. correctly configured,
enabled and free of communication errors.
The Double Channel software is only partially compatible with the UN1000-PM40
module. The DCH Supervision can be used together with UN1000-PM40, because it
does not depend on the CAN communication status and activation. However, a PM40
module cannot be used in the same device, where Changeover and/or DCH Follow-up
features are also required. Even whenever DCH Communication can be enabled, the
operation of the UN1000-PM40 has a higher priority and the DCH data transmission will
be stopped as soon as the AVR detects an UN1000-PM40 on the CAN bus. This priority
order is fixed in the AVR and not configurable.
Even without functions from Redundant Channel support, a double channel system with
UN1000-PM40 can be built using analog and digital inputs and outputs as communication
interface between the AVRs. Furthermore, Alarm and Trip output signals from DCH
Supervision could be used to extend the functionality to some extent.
The AVR-ID should be configured with the same number in both channels. One channel
should be configured as Main and the other as Redundant. The channel identification can
be configured using the CMT1000 or Remote Access. Only one channel should be Active
while the other is Standby. The use of interlocked contacts (connected externally) is a
recommended practice to assure this situation. The Standby/Active status of both
channels can be monitored using the CMT1000. For more information refer to Chapter
6.4 PC Software tool.
3.4.8.6 Redundant system without Double Channel software
A redundant system with no Double Channel software can be built using analog and
digital inputs and outputs as communication interface between the AVRs. However, due
to the limited number of DO ports in each AVR, it could be possible that there are not
enough digital outputs to use all functions required by an application (e.g. diode
monitoring alarm, etc.).
In case of a failure in
channel 1, the back-up
channel is activated Back-up channel
and the defective UN 1000-15 / 1 UN 1000-15 / 2
channel goes off.
Changeover to Regulator Regulator

channel 1 can be
controlled by an alarm
SM E
signal or with an
SW-Alarm Standby
external control signal.
Figure 3-20 Basic redundant system without DCH software

3.4.9 Remote Access
Remote Access is a feature that allows monitoring and control of the AVR using the
MODBUS protocol. It can be suitable for applications where the control from remote
locations is preferred (i.e. offshore) and/or a custom user interface is required.
The following sections explain the Remote Access software and configuration. The
electrical connections are described in Chapter 3.3.9 Communication ports. It is
recommended to read Chapter 3.4.10 Access Levels prior to this section, in order to fully
understand the software capabilities.
3.4.9.1 Overview
A remote terminal configured as MODBUS master can access the device through RS485
or Ethernet TCP/IP (via RS232) using Remote Access. The communication choice is up
to the application requirements but since VDC needs a dedicated RS485 connection,
Ethernet TCP/IP is then the only choice when VDC is used. When VDC is not needed,
Remote Access can be performed using the RS485 interface. More information about
the communication interfaces can be found in 3.3.9 Communication ports.
The Remote Access allows the user to read and write registers (measurements, setpoint
and other information) from the AVR. The document that describes the MODBUS
Registers Table is normally inside the CD-ROM that comes with new devices. It can also
be ordered from ABB. The manufacturer details and contact information can be found in
Chapter 1.4 - Manufacturer’s Address.
The feature supports up to one MODBUS remote terminal and it must be assured that
requests are sent from only one remote terminal using the same communication interface
(RS485 or Ethernet TCP/IP). If more than one request comes from different interfaces,
they might be answered via the same interface from where they come. This method is
however not recommended and should not be used.
In order to communicate with the device, the remote terminal should gain a determined
access level in the AVR according to the operation desired: Monitor Access for reading
only and Control Access for reading and writing to registers. More information about
Access Levels can be found in Chapter 3.4.10 - Access Levels.
3.4.9.2 Compatibility
The Remote Access feature over RS485 cannot be used together with VDC. If both
Remote Access and VDC are required, Remote Access should be used via TCP/IP using
an external gateway. When VDC mode is not required, Remote Access can be used via
either RS485 or Ethernet. For more information see Chapter 3.3.9 - Communication
ports.
Remote Access over RS485 has a number of parameters that should be configured:
Protocol (Modbus RTU or TCP), Activation (of the feature over RS485), Baud Rate,
Answer delay and others shown in Chapter 6.4.4.5 Communication Menu.
When using Remote Access over Ethernet, the protocol used between the RS232 port
and the TCP/IP gateway is Modbus RTU; which is fixed and not configurable in the AVR.
Additionally, Remote Access through RS232 is always activated (i.e. there is no

activation parameter) and it uses the following communication settings, which are fixed
and not configurable in the AVR:
• Protocol: Modbus RTU
• Baud rate: 57600 bps
• Character format: No Parity
• Stop Bits: 1
The Modbus Slave ID value is used for both Remote Access over RS485 and RS232
(and TCP/IP); there is no differentiation of the physical interface. This number can be
configured between 1 and 247; the latter being the default value. A restriction applies
when the number is configured between 1 and 63 (except 32) and matches with the
Modbus Slave ID used for communication with the CMT1000; in these situations, the
AVR will change the Remote Access Slave ID to 247 upon restart. The Modbus Slave-ID
for Remote Access can be configured between 64 and 247 without restrictions; being the
range, the recommended for most applications.
The Modbus ID used for CMT1000 access is a number between 1 and 63, which
depends on the AVR-ID and the Channel Identification (Main or Redundant), even if
Double Channel feature is not being used. When the parameterization is done using the
CMT1000, the Modbus ID used for CMT1000 is shown in the MODBUS Supervision
window. This number should not be used as Modbus Slave ID for Remote Access. For
further information refer to Chapter 6.4.4.5 Communication Menu.
3.4.10 Access Levels
The UN1000 device can be accessed from three different operators: front Panel,
CMT1000 or Remote Access. While all operators can read data simultaneously, only one
of them can have control access and is allowed to write or change parameters in the
AVR. This concurrence is managed in the AVR main controller by assigning, to each
operator, a determined Access Level or privilege:
• Offline or disconnected (no access)
When the status of an operator is Offline, the AVR microcontroller considers the
operator as not connected to the UN1000 and, therefore, there is mainly no data
exchange with the AVR. Only when using the CMT1000 as operator and the
presence of a compatible AVR is detected, a small quantity of data is exchanged to
provide and display the AVR-ID information on the main window of the software.
• Monitor (read access)
When an operator has Monitor Access, it is only possible to read data from the
device (i.e. measurements, parameters, etc.); and data cannot be changed or
modified in the AVR during this access mode. All the operators, i.e. Panel,
CMT1000 and Remote Access, can have Monitor access to the AVR at the same
time; all of them can read simultaneously from the same AVR.
• Control (read and write, full access)
If an operator has Control Access, this means that it has full control of the device
(write and read data). All operators are able to request Control access, but the
access will be granted to only one at the same time, based on the operator's
priority. The operator's priority is explained later in this section.
The Access Level status of each operator is stored in the AVR main controller and used
to grant and deny access requests. An operator can request the change of its Access

level to the AVR main controller, i.e. from Monitor to Control. Access changes to Monitor
are normally granted without restrictions since all sources can read simultaneously from
the AVR. Access changes to Monitor and/or Control are granted based on the following
operators' priority:
• Panel / CMT1000 access (highest priority)
The Panel and CMT1000 priority access are not differentiated from each other
since only one of them can be physically connected to the same AVR at the same
time. Whenever the CMT1000 or the Panel requests an access change to Control,
the change is granted disregarding the status of other sources (i.e. Remote
Access). If the Access status of Remote Access is Control at the time of the
request, it will be immediately changed to Monitor after the user confirms the action
from the Panel keypad. Remote Access can detect the change by reading back its
access status from the AVR.
• Remote Access (lowest priority)
Remote Access has the lowest priority during Access Level changes; a change to
Control is only granted when neither the Panel nor the CMT1000 have Control
Access to the AVR controller.
An Access Level changing request can be denied when more than one CMT1000 and/or
more than one Remote Access are trying to establish a connection to the same AVR. The
UN1000 supports a simultaneous connection of one CMT1000 and one Remote Access
per device (maximum). When those limitations are surpassed, one or all operators
connected can lose their accesses and go Offline; this practice is not recommended by
ABB. The method to change Access Levels from Panel, CMT1000 and Remote Access
are explained in the following sections. For more details about UN1000 user interfaces
refer to Chapter 6 - Operation.
3.4.10.1 Panel
The Panel has Offline status as long as the communication with the main AVR is not
established or if another device is connected to the RS232 port (PC or a TCP/IP
Gateway). If there is no other device connected to the RS232 port and the
communication between Panel and the AVR main controller has just been established,
the Panel has Monitor Access and it remains in this access level as long as the user does
not modify any parameters using the keyboard. When a parameter is changed, the Panel
automatically requests Control Access, changes the parameter's value and then,
requests the change back to Monitor; the process may ask for a confirmation from the
user only if a remote terminal has Control Access to the AVR.
3.4.10.2 CMT1000
The CMT1000 manages the Access changing requests: Offline, Monitor and Control by
using a graphic slide-bar displayed in the software's main window. The slide-bar shows
the CMT1000 current access status from the AVR and allows the user to simply change it
by sliding up and down. For more information about the user interfaces see Chapter 6 -
Operation.
3.4.10.3 Remote Access

Changing of Access Levels from Remote Access is performed by requests via Modbus
protocol. For more information refer to the UN1000 Modbus Reference document.

3.4.11 Description of parameters
3.4.11.1 System Data
Nominal excitation current: Ie Nominal [A]

Measuring voltage three- or single- PT [Single_Phase] PTNET
UNET
phase: [Three_Phase]
[Three_ph_gnd] f Nominal PTM
UM Primary UM Secondary Regulator
Nominal voltage of the Machine: UM Nominal [kV]

IM2 Primary
Potent. transformer, prim. voltage: UM Primary [kV]
IM2 Secondary
Potent. transformer, sec. voltage: UM Secondary [V]
IM2 Nominal
Nominal voltage of the Network: UNET Nominal [kV] UM Nominal Ie Nominal
Potent. transformer, prim. voltage: UNET Primary [kV] Ie No Load
Potent. transformer, sec. voltage: UNET Secondary[V] SM E
Xq
Nominal machine current IM2 Nominal [A]
Current transformer primary: IM2 Primary [A]
Current transformer secondary: IM2 Secondary [A]
No load excitation current: Ie No Load [%]
Ceiling factor: Kceil [V/V]
Machine reactance: Xq [p.u.]
Frequency nominal: f Nominal [Hz]
IMPORTANT!
If there is a block transformer with any circuit configuration between
PTGEN and PTNET, the phase shift must be compensated. The phase can
be compensated as described in Chapter 3.4.4 Synchronization (SYNC).
3.4.11.2 FCB Control
Field circuit breaker control

FCB Control is an alternative to control the field circuit breaker. The control is active,
when the FCB command signals are configured.
Excitation ON Input
1s
Close FCB Command Output
1s
Open FCB Command Output
FCB closed Status Input
PWM-Control
FCB closed Status FALSE Input

1s 1s
Alarm (MODBUS) Output

3.4.11.3 Field Flashing
Machine voltage
- Off Level Off Level [%] [%]
Signal field flashing
Setting the Off Level to 0% disables field Field flashing off level
flashing. Soft start level
[s]
Excitation ON
3.4.11.4 Soft Start
- Starting voltage : Start Level Machine voltage Initial Setpoint

[%] from Initial Setpoint [%] (Auto mode)
- Delay until ramp : Hold Time [s]
- Ramp time : Ramp Time [s]
Start level
The final value of Soft Start ramp is the Initial
Setpoint for Auto mode. For more information [s]
consult Chapter 3.4.11.7 Setpoint setting for
the regulator. Hold time Ramp
Gen CB Closed Status = active

Trigger immediately the soft start
Note: Soft Start is available only in Auto mode.
3.4.11.5 Limiters
V/Hz Limiter Machine voltage

[%]
- V/Hz knee point fknee [Hz] 100
frequency
- Slope Slope [%]
[Hz]
fknee
Ie Minimum current limiter P [W] Active power

underexcited overexcited
- Minimum limit Minimum [%] Limiter-
characteristics GENERATOR
- Limiter active Active = True/False
Iemin Reactive power
Q- Q+ [var]
UM2
MOTOR
Xq

IeMaximum current limiter Excitation current

- 1st limit Maximum [%] [%]
1st limit
- Hold time Maximum HoldTime [s]
2nd limit
- 2nd limit delay Delayed [%] Contin. current
- Hold time Delayed Hold Time [s]
- Continuous Hold time Hold time
[s]
current Limiter Continuous [%]
active Active = True/False
PQ Limiter P [W] Active power

The characteristic is determined by 5 points
P=100%
P=75%
- Q limit at P = 0% Minimum Q(P @ 0%) [%] Generator

P=50%
- Q limit at P = 25% Minimum Q(P @ 25%) [%] P=25%

Reactive power
- Q limit at P = 50% Minimum Q(P @ 50%) [%] Q- P=0% Q+ [var]

Motor
- Voltage P=75%
dependency active Volt.Dependency:True/False P=100%
- Limiter active Active = True/False
UM Limiter (only in PF / Var mode)

- Limiting value of the minimum machine voltage Minimum [%]
- Limiting value of the maximum machine voltage Maximum [%]
- Limiter active Minimum Active = True/False
- Limiter active Maximum Active = True/False
IM Limiter
- Limiting value of the maximum machine current Maximum [%]
- Time Multiplier according to IEC 60255-3, Table 1,
Col. B, very inversed characteristic Time Multiplier K
- Limiter active Maximum Active = True/False
Boost-Output Machine voltage

Excitation ON
- Pick-up volt. to Threshold [%] Soft start
not active
generate boost Excitation ON Voltage drop
100%
command
- Time boost Hold Time [s] Hysteresis

output is active Threshold
- Hysteresis for Hysteresis [%] t

the reset of
[s]
boost output Hold time
Boost = 0 1 0
Voltage Relay= 1 0 1 0 1

3.4.11.6 Limiters Temperature Influence
IM Limiter
Machine current IM
[%]
T1 at Max IM T1 [°]
Max IM P1
T2 at IM th2 T2 [°]
T3 at IM th3 T3 [°] Im_th2 P2
T4 at IM = 0 A T4 [°] Im_th3 P3
Machine current level IM th2[%] 25
Machine current level IM th3[%] P4 Cooling temp.
20 40 T1 T2 T3 T4 100 [°]
Ie Limiter Excitation current Ie [%]
T1 at Max continuous Ie T1 [°] Max.

Continuous Ie P1
T2 at Ie th2 T2 [°]
T3 at Ie th3 T3 [°] Ie_th2 P2
T4 at Ie = 0 A T4 [°] Ie_th3 P3
25
P4 Cooling temp.
Excitation current level Ie th2 [%]
20 40 T1 T2 T3 T4 100 [°]
Excitation current level Ie th3 [%]
3.4.11.7 Setpoint setting for the regulator
- Auto to voltage regulator

- PF, Var to power factor, reactive power regulator
- Manual to manual regulator
- Open Loop to open loop regulation circuit
All setpoints have the following parameters

- Minimum
- Maximum
- Ramp Rate
Auto, Manual and Open Loop also have the following parameters
- Initial Setpoint
Default Level of the setpoint if the digital input

Mode Initial Setpoints
Excitation ON is not active.
Auto 100% (configurable)
Auto, Manual and Open Loop initial setpoints Manual 0% (configurable)
can be configured. Open Loop 0% (configurable)
PF 1.0
Var 0%
The limits and ramp rate can be set separately for each operating mode.
The setpoints of the non-active regulators follow the relevant operating point. For
example, for reactive power regulation (Var) the setpoint of the auto-regulator follows the
current machine voltage. This allows surge-free switching between operating modes if the
new setpoint is within the setpoint limit.

Particulars to the setpoint in Sync mode

No Load: Regulator works in AUTO mode. The setpoint follows the line voltage and the
ramp rate corresponds with the increase respective decrease command.
3.4.11.8 Regulator tuning
Auto (voltage control) Gain

[p.u.]
- Proportional gain Proportional Gain
Vp
2 Vp
- Derivative time Derivation Time Tb
constant [s] Vp
Integration Time Ta
- Integral time [s]
constant 1/Ta 1/Tb 1257 ?[rad/s]
Compensation or Droop Kq [%] Machine voltage

droop [%] sation Kq= 20% (max. compensation)
Compen
Kq= 0.00 (no effect)
Droop Kq= -20% (max. droop)
Reactive current
[%]
PF or Var Control Proportional Gain Vp P [W] Active power

and PQ Limiter Derivation Time Tb [s]*) Var
Integration Time Ta [s] PF Generator PF
*) Only one parameter,

Reactive power
see voltage control Q- Q+ [var]
Motor
Manual Proportional Gain Vp

Gain
Field current control and Integration Time Ta [s] [p.u.]
Ie Limiter
Vp
1/Ta 1257 ω [rad/s]
All parameters should be stored in the EEPROM non-volatile memory after they are
configured. Store to EEPROM can be done via CMT1000, Panel or Remote Access. For
more information refer to the appropriate sections.

ABB
Chapter 4 - Installation and Storage
4.1 General
Chapter 4 – Installation and Storage provides all instructions for

installation and storage of the excitation system. It also contains
information on how to dispose of and recycle materials.
NOTICE!
First read and understand the general safety instructions in Chapter
2 - Safety Instructions before starting to work with the excitation
system.
NOTICE!
Converter components can be damaged while transporting the
excitation system.
4.3 Unpacking
The unit should be unpacked with the maximum degree of care, without
the use of force and using suitable tools.
The unit should be inspected visually to check for any damage caused
during transport. Complaints regarding defects resulting from
inappropriate transport are to be addressed immediately to the receiving
station or the last carrier.
NOTICE!
The unit is visibly damaged:
• Safe operation is not possible.
• The unit must not be installed and taken into operation.

Chapter 4 - Installation and Storage ABB
4.4 Mechanical Installation
O 7 mm 170 mm
The unit is mounted by means of four screws.
Abb UNITROLR 1000
See dimensional diagram for fixing holes and spacing.

Mounting instructions see Chapter 3.3 - Hardware
200 mm
The unit should only be installed in indoor areas which
are dry and dust-free and which do not contain any
gases, acid fumes or similar.
Mounting
Rack mounting Wall mounting

The UNITROL 1000 is designed for
rack or wall mounting in upright
100 mm
position.
A distance of approx. 100 mm around Abb UNITROL 1000
R
the unit shall be kept free for optimal

cooling. 100 mm
142 mm
NOTICE!
Electrostatic discharge (ESD) can damage electronic boards and
components!
• Do not touch printed circuit boards or other sensitive
components without taking static-sensitive handling
precautions.
• Do not touch the components without wearing a wrist
grounding strap.
• Put the board or component on a grounded working surface
which is protected against electrostatic discharges.
• Hold a board only at the edge.
• Handle a faulty board with care.

ABB Chapter 4 - Installation and Storage
4.5 Electrical Installation
The emission limits in accordance with standard EN 61000-6-4 will only

be complied with if the connections for the power electronics supply and
the field output are made using shielded cables earthed at each end. We
also recommend that shielded cables be used for the analog and digital
connections.
The connection terminals are fitted on the front side of the unit, on three
levels:
Cross sections - Power electronics, terminal numbers 1 to 15 0.2 to 4 mm2 (AWG 10 to 30)
- Electronic sections, terminal numbers 16 to 55 0.2 to 2.5 mm2 (AWG 12 to 30)
The casing must be earthed at terminal 7 with 4 mm2. Additional earth

terminals are provided for the shielded cables. The earth connection
should be kept as short as possible.
The tightening torque for all terminals is: 0.6 Nm (5 - 7 lbf. in.).
4.6 Storage
The storage procedures described below must be followed in order to

avoid damage or a degradation of quality due to corrosion, dirt or
mechanical damage. The corresponding precautions must be observed
from the time the equipment is put into storage until the time it is taken
out of storage and installed.
4.6.1 Storage Conditions
The equipment must be stored in the original packing.

Temperature for operation: 0 to 60 °C.
Make sure that the following environmental conditions are fulfilled during
the entire period of storage. ABB recommends keeping the air
temperature and the relative air humidity constant:
Air temperature : -20 °C to +75 °C
4.6.2 Disposal
Used materials can serve as raw materials for recycling or other

purposes. For an ecological separation of materials and waste handling
please contact your community or the local waste disposal company.

Chapter 4 - Installation and Storage ABB
Improper disposal of electrical devices can lead to environmental
damage. It is therefore important that qualified personnel carry out the
disposal of electronic equipment.
The metallic casing does not present any risk to the environment and can
be recycled.
The printed circuit boards are simple to remove. The boards must be
removed and should be disposed of by a licensed disposal company.
Environmentally hazardous elements such as capacitors must be
separated from the boards.
Dispose of the following components according to local regulations:
• Capacitors.
• Printed circuit boards.
• Electronic components.
• Batteries.

ABB
Chapter 5 - Commissioning
5.1 General
The Commissioning should be carried out by certified commissioning

personnel.
The Safety regulations according to Chapter 2 - Safety Instructions must

be followed.
WARNING!
! UNITROL 1000-15 units operate with dangerous voltages of up to

250 VAC or 300 VDC.
Manipulation of live parts can lead to death or injury to the persons
involved or damage to the surroundings.
Possible risks are largely excluded if the unit is handled properly in
accordance with these instructions.
WARNING!
! The secondary voltage of the excitation transformer and the voltage of

the excitation field are fed into the excitation cabinet.
These components present a great danger of electric shocks.
The control elements and the PC interface on the front plate of the
UNITROL 1000-15 unit are to be touched and/or attached only with
caution.
After the unit has been switched off, it must be ensured by measurement
that no measuring voltages or control voltages >50 V are present at the
terminals. At an interrupted field circuit the input capacitor is slowly
discharged through internal circuits.
In order to prevent unintentional closing of open voltage circuits by third
parties, the circuits in question should be identified at the point of
interruption (e.g. by means of a warning sign).
Before switching on, check whether the connection terminals are wired up
according to the plant schematic.

Chapter 5 - Commissioning ABB
5.3 Setting Aids
All parameters have to be controlled at the first commissioning.

See the description of the parameters in Chapter 3.4.11 - Description of
parameters and settings recorded in Chapter 7.3 - Standard Procedures
for Maintenance and in Chapter 9.3 Parameter Settings, default values
Overview of parameter blocks

Setup: System Data
Soft Start
Field Flashing
Limiters
Setpoints
Voltage Droop Compensation Control
Digital I/Os
Analog I/Os
Synchronization
Diode Monitoring
Power System Stabilizer (PSS)
Double Channel
Tune: Controller
Communication: AVR-ID / CMT1000 Port / MODBUS
5.3.1 Setting aids
5.3.1.1 Setup \ System Data, Ceiling Factor Kceil
The following section describes how to determine the Ceiling Factor in two different ways.
We recommend the measuring method.
Measuring method
Ue max 100 U PWR

K ceil =
Ueo = PWMnoload
Uemax: Maximum output voltage UM Nominal

Regulator
Ueo: Output voltage at nominal
voltage of the machine
(machine in no-load U emax
operation)
SM E U eo
PWM no load: Regulator output at no

load (PWM).
Definition: The ceiling factor Kceil determines the relationship between the maximum
output voltage of the regulator and the exciter voltage, which is required for no-load
excitation and is thus a measure for the possible overexcitation of the machine.

ABB Chapter 5 - Commissioning
Example: Regulator output signal (PWM) at no load shows 20% at nominal voltage
100
K ceil = =5
20
Calculating method
Power electronics supply: Three-phase: Uemax = 1.40 * UPWR – 8 V
Single-phase: Uemax = 1.25 * UPWR – 8 V
DC: Uemax = 0.98 * UPWR – 8 V
Example
Specifications: Power electronics supply UPWR = 240 V, single-phase
No-load exciter voltage Ueo = 50V
Calculation: Uemax = 1.25 * 240 V – 8 V = 292 V

Kceil = 292 V/50V = 5.8 p.u.
Remark: Kceiling must be in the range of 5-12. If not, please check the input voltage.
5.3.1.2 Setup \ System Data, Machine Reactance Xq (non-saturated)
- Salient pole machine: Xq ≈ 0.7 to 0.5 Xd

- Cylindrical-rotor machine (Turbo): Xq ≈ Xd
5.3.1.3 Setup \ Limiter, Manual and Open Loop
There are no limiters active in the mode Manual and Open loop.
5.3.1.4 Setup \ Limiter, UM Limiter
The limiting values of the UM limiter are, as a rule, set equally, like the setpoint range of
the voltage regulator (Auto mode).
Setpoint Auto UM Limiter Example

Minimum = Minimum 90%
Maximum = Maximum 110%
5.3.1.5 Setup \ Digital I/Os, configuration
Software configuration of the digital I/Os

• Define terminal as input or output
• Assign terminal to desired signal
• Select polarity

5.3.1.6 Setup \ Analog inputs / outputs, configuration
Software configuration of the analog inputs

• Assign terminal to desired signal.
• Define signal level of the input signal [Uin 0% to Uin 100%].
• If the input is used as a digital input, the desired signal name is to be assigned in the
menu.
Software configuration of the analog outputs

• Assign terminal to desired signal.
• Define signal level of the output signal [Uout 0% to Uout 100%].
• Define signal level of the field current [Ie 0% to Ie 100%].
5.3.1.7 Setup \ Digital I/Os, selection of operating mode
The operating mode is selected via the digital inputs. For this purpose, a maximum of
10 inputs have to be occupied by the following signals:
Mode Digital inputs to be assigned
Stand SYN Gen CB Parallel Manual Open Loop VDC PF Var

by Closed with Grid Enable Enable Enable Enable Enable
Status Status
Standby 1 X X X X X X X X
Sync 0 1 X X X X X X X
Manual 0 0 X X 1 X X X X
Open Loop 0 0 X X 0 1 X X X
VDC 0 0 1 0 0 0 1 X X
PF 0 0 1 1 0 0 0 1 X
Var 0 0 1 1 0 0 0 0 1
Auto 0 0 0 X 0 0 X X X
with *) 0 0 1 X 0 0 0 0 0
*) with droop or compensation

0 = logical 0 or open 1 = logical 1, X = not relevant
Note: If an input is to be continuously logical 1, then it can also be inverted by software

means. The input then naturally counts as being occupied.
The inputs DI9 to DI14 can be used as virtual digital inputs even if they are not defined in
Analog Inputs as Digital Inputs.
5.3.1.8 Setup \ Synchronization
The machine frequency must always be higher than the network frequency and cannot be
synchronized by a positive slip.

5.3.1.9 Setup \ Diode Monitoring
The Nominal Exciter Frequency has to be adjusted; for the others, the default value has to
be kept.
Nominal Exciter Frequency = p x n/60
p = Number of pole pairs [.]
n = Revolutions per minute [U/min].
5.3.1.10 Setup \ PSS
The parameters can be calculated by ABB Switzerland. For further information please see
the Functional Description of UNITROL 1000, Power System Stabilizer, and document
number 3BHS213239 E01.
See manufacturer’s details, Chapter 1.4 - Manufacturer’s Address.
5.3.1.11 Setup \ Double Channel
The configuration of Double Channel depends on the application and connections. For
detailed information about configuration, refer to 3.4.8 Double Channel (DCH).
5.3.1.12 Tune \ Setpoint Adjust, Step
Mode Maximum adjustable setpoint jump during 10 s

Manual ±50%
Open Loop ±20%
PF ±0.2
Var ±50%
Auto ±20%
5.3.1.13 Tune, Order of priorities
If several operating modes are selected simultaneously by the digital inputs, then the
following order of priority applies:
Priority Mode Remark

1. resp. top Standby
2. Sync
3. Manual
4. Open Loop
Only active, if Gen CB Closed status is active and
5. VDC
Parallel with Grid status is not active
6. PF Only active, if Parallel with Grid status is active
7. Var Only active, if Parallel with Grid status is active

8. resp.
Auto Active, if no other operation mode is active
lowest

5.3.1.14 Tune, Auto
The following settings can be pre-set on the basis of the machine data.
Integral time constant Ta

This lies within the range of Td‘ of the main machine.
Setting: Ta = Td‘ (Typically value 2 to 5 s).
Derivative time constant Tb

This approximately compensates the load time constant TE of the exciter machine.
Setting: Tb = 0.7 to 1.0 * TE (Typically value 0.1 to 0.3 s).
Proportional gain Vp
This most important setting value depends primarily on the controlled system.
If the ceiling factor Kceil has been set correctly, values between 10 and 40 should result in
stable regulation of the machine.
A default value of 20 is set for the first excitation.
Reactive power influence Kq

In the case of machines which, without step-up transformers, are connected to the fixed
grid or, via a busbar, to other synchronous machines, it is essential that the droop Kq is set
to a negative value of -5 to -20%. A higher negative value makes the machine more
independent of voltage fluctuations in the grid. This stabilizes the reactive power output or
consumption in those configurations. At low negative values, the machine will support the
grid or busbar voltage.
In the case of machines with step-up transformers, the voltage drop of the transformer can
be partly compensated with positive values of Kq.
Example
Step-up transformer Reactance = 12%
Compensation Kq = +6%
5.3.1.15 Communication \ MODBUS (Remote Access)
The RS485 port is shared between VDC mode and MODBUS. With factory settings,
MODBUS is disabled.
To use MODBUS, the parameter MB_Enable must be set to true, then the parameters
have to be written to the EEPROM. Afterwards, the UNITROL 1000 must be restarted.
This procedure has to be followed for any change to MODBUS related parameters to take
effect. It serves as a protection against inadvertently overwriting the setup by MODBUS
itself and therefore losing connection to the UNITROL 1000.
Standard Configuration Answer Delay: 10ms

Bit Rate = 19200
Character Framing = even
RTU: Protocol of the RS485

Slave ID
Zero and values higher than 247 are reserved, so the valid range for the slave ID is 1 to
247; 247 is the default. Recommended range is 64 to 247 due to the possible influence
with the Modbus ID used for CMT1000 access. For more information consult Chapter
3.4.9 - Remote Access.
Keep-alive time
The parameter “MB_KeepAliveTime” defines, in which time-period the “Keep Alive Bit” in
control word 1 must be changed. Valid settings are 1 to 120 seconds and 0 to disable the
connection monitoring.
Keep-alive action
If the timer reaches the supervision time, a “Modbus Communication Alarm” will appear
and one of the events can be selected with the “MB_KeepAliveAction”.
For more information, please refer to the UN1000 Modbus Reference document.
5.4 Work carried out while Machine is at Standstill
Preliminary Checks
• Wiring check, compare connections with schematics.
CAUTION!
Check the insulation strength of the plant with the insulation tester
During the test, the equipment could be damaged by the testing voltage.
Disconnect cables to the UNITROL 1000
• Switch on auxiliary voltage UAUX

• Adjust parameters
• Check measuring voltage and current transformer circuits
• Measure field resistance
• Low-load test: External power electronics supply (3x <250 V AC)
- Open loop mode
- Optimize regulator Ie
• Adjust limiter settings based on the customer’s power chart

5.5 Work carried out while Machine is Running
5.5.1 No-load tests (nominal speed, not synchronized)
• Field flashing and discharge in Auto and Manual mode

• Soft start in Auto mode
• Adapt setpoint range, optimize voltage regulator
• V/Hz limiter: The actuation point fknee is set to 48 Hz by default
For 60 Hz machines the fknee should be set at approximately 58 Hz.
5.5.2 Tests under load
• Stator current measurement, internal P- and Q-measurement, droop/compensation.

The droop/compensation is set to 0% by default. If the machine is paralleled directly
with the rigid grid or, via a busbar, with other synchronous machines, it is essential that
the droop Kq is set to a value of approx. –10% before the first synchronization. The
reactive current must be monitored carefully during the first paralleling. If it increases
uncontrollably following the first synchronization, then the current polarity of the IM2
measurement is incorrect or the CT phase position is wrong.
• Load rejection overexcited and underexcited
• Optimize Iemin / Iemax Limiter
• Optimize PQ Limiter
The setting of the PQ limiter must be coordinated with the settings of the generator
protection. As a rule, the limiter should be set at least 5% lower.
• PF and Var regulator, stability, setpoint range.

To enable correct operation of PQ Limiter, the PF / Var regulator must be tuned, even if
these modes are not used.
5.5.3 Synchronization
It is a prerequisite for the correct functioning of UN 1000-15

the synchronization that there is no error in UNET
phase or magnitude between UNET and UM,
caused by wrong connection or ratio of PTs on CB AVR
the grid side and generator side. UM
Isolator
SM

• Measurement of the phase angle of the voltages UNET and UM

Open the isolator, close the circuit breaker (CB). Due to safety reasons the
measurements have to be obtained not only from the Monitor\Oscilloscope or
Monitor\Sync Diagram but also from an oscilloscope.
• „Blind“ synchronization
Monitor the Synchronoscope (Monitor\Sync Diagram) by disconnecting the trigger of
the circuit breaker.
• „Live“ synchronization
Record the event with a Synchronoscope.
CAUTION!
The synchronoscope must stand at “twelve o’clock “. If the
synchronoscope stands at “six o’clock“, one voltage is incorrectly
connected. In other positions, either measuring is being carried out on
incorrect phases or a phase shift caused by the connection group of a
step-up transformer has not been compensated.
CAUTION!
In this status, the phase-angle difference must be 0 deg. Otherwise the
measuring cable is incorrectly connected. Incorrect polarity cannot be
detected by the UNITROL 1000. Paralleling with incorrect polarity can
lead to serious damage.
A phase shift caused by one of both measuring transformers or by the
connection group of a step-up transformer must never take place.
5.6 Concluding Work after Commissioning
Write the currently adjusted parameters to EEPROM so that they are

saved in the device. Save the corresponding settings into an INI file or
print out the INI file (see Chapter 9.3 - Parameter Settings, default
values).
The INI file can be opened using an editor (Word, Note- or WordPad) and
printed out.

ABB
Chapter 6 - Operation
6.1 General
NOTICE!
ABB recommends periodical training for operating personnel
DANGER!
Dangerous voltage.
There is a danger of electric shock.
NOTICE!
Before operating the excitation system the general safety instructions in
Chapter 2 - Safety Instructions must be read and understood.
CAUTION!
Parameters are set during commissioning of the device and must not be
changed afterwards without taking into consideration the consequences
they can produce.
Running the excitation system with incorrect data can result in improper
operation, reduction in control accuracy and damage to the equipment.
Only qualified and certified personnel are allowed to operate the device,
i.e. personnel who are familiar with the excitation system and the
hazards involved.

Chapter 6 - Operation ABB
6.3 Panel Operation
The Panel of the UN1000-15 allows the configuration of most of the parameters, with the
exception of Double Channel parameter and others, which can be configured using
Remote Access or the CMT1000. The parameters that can be configured with the Panel
are shown in Chapter 6.3.4 Menu structure.
The Panel is operated using the buttons from the keypad installed in the front. The Panel
can even be used to read measurements and/or change parameters when there is a
Remote Access connection over RS485. In this case, the functionality explained in
Chapter 3.4.10 Access Levels comes into operation, in order to establish rights to change
parameter values in both Panel and Remote Terminal.
6.3.1 Panel start-up
After powering up the device (UAUX power) the Panel performs an initialization stage to
establish the communication with the AVR main controller. The serial cable should be
disconnected from the RS232 serial port in order to operate the Panel and Keypad.
1. During power up the Panel tries to

establish communication with the AVR
main controller. During this process the
Panel displays the information shown in
Figure 6-1
Figure 6-1 Panel screen just after

connecting Uaux power.
2. Just after the communication has been

established with the main controller, the
Panel displays the main controller and
its own software revisions on the
screen (Figure 6-2).
Figure 6-2. The SW revisions are

shown after the connection with the
AVR main controller is established.
3. Few seconds after the SW revisions

have been shown, the Panel shows the
main menu as in Figure 6-3. The Panel
can now be operated using the Keypad.
Figure 6-3 Main menu. The Panel

can now be operated.

ABB Chapter 6 - Operation
6.3.1.1 CMT1000 or Remote Access connection over RS232
The Panel uses the same RS232 interface

that might be used for CMT1000 or Remote
Access to establish connection with the
AVR main controller. When the hardware
detects that the RS232 port is being used
by another device, the Panel stops its
communication with the main controller and Figure 6-4 Panel message when the
displays "REMOTE CONTROL" until the RS232 port from the UN1000 is
port is free and available again. being used by another device.
6.3.1.2 Panel and Remote Access over RS485
The presence of a remote terminal can be

monitored using the Panel of the AVR. An
"R" is shown on the upper right corner of the
screen during the time a remote terminal is
connected with the main controller using
Remote Access over RS485.
For more information about Remote Access Figure 6-5 An "R" is shown on the
refer to Chapter 3.4.9 Remote Access. upper right corner of the screen when
Remote Access over RS485 is used.
6.3.1.3 Connection problems
When the Panel is unable to communicate

with the AVR main controller due to
hardware problems, the screen might show
the message displayed in Figure 6-6. This
message can also appear when the Panel
and AVR main controller (DSP) firmware
are incompatible each other; which might Figure 6-6 Message shown when
occur after a firmware upgrade. communication problems occur
However, regulation and protection between Panel and AVR controller.
functions are normally still in operation,
without being influenced by communication
problems with the Panel.

6.3.2 Keypad operation
The keypad consists of four keys with the following functions:

Keys Commands
▲, ▼ Select mode: Moves the cursor up or down
Horizontal arrow cursor marks the active line
Parameter setting: Increases or reduces value
OK Select mode: Selects sub-menu in the line marked with the cursor
On parameter level, the cursor disappears and the following text is
displayed:
OK to write value => Accept new value, not yet saved in EEPROM
ESC to cancel => Retain old value
Parameter setting: Accept new value
ESC Select mode: Back to next-higher menu
Parameter setting: Retain saved value
ESC + ▼ Keys are locked if both are pressed during 2 seconds.
ESC + ▲ Keys are unlocked if both are pressed during 2 seconds.
All sub-menus are called up from the “MAIN” start menu

The vertical arrow (↓ ↑ ↕) indicates whether other lines are ↓∗∗∗
available
using the up (▲) or down (▼) keys. →
The horizontal arrow cursor (→) marks the active line.
"MAIN" start menu

The title and three lines are displayed ↓∗∗∗ MAIN ∗∗∗
- Online measurement of machine and field values → Monitor
- Current operating mode, serves only for information Mode = Auto
- Set ID number of the unit, serves only for information Connected: 1 MAIN
- Set parameters ▼ key Setup
- Set regulator parameters ▼ key Tune
- Set ID number ▼ key Communication
- Save parameters in UNITROL 1000 ▼ key Write EEPROM
6.3.3 Example of parameter setting
Example: Assigning Parallel wGrid to input DI6
Operating Key Resulting display

1. Display after auxiliary voltage is ↓∗∗∗ MAIN ∗∗∗
applied → Monitor
Mode = Auto
Connected: 1 MAIN
2. In the start menu, use ▼ key to MAIN ∗∗∗
move down to setup
3x ▼ ↕∗∗∗
Mode = Auto
Connected: 1 MAIN
→ Setup

Operating Key Resulting display

3. Select sub-menu 1, setup, and use SETUP ∗∗∗
▼ key to move down to digital I/Os OK, ↕∗∗∗
Setpoints
7x ▼ Volt. Droop Comp.
→ Digital I/Os
4. Select sub-menu 2, digital I/Os, and use DIGITAL I/Os
▼ key to move down to I/Os
OK,
→ I/Os
1x ▼ Din from Ain
5. Select sub-menu 3, digital I/Os, and use ↕ DIGITAL I/Os

▼ key to move down to DI6
OK, DIO4
5x ▼ DI5
→ DI6
6. Select sub-menu 4, DI6 ∗∗∗ DI6 ∗∗∗
OK
→ Din = None
Polarity = Normal
7. Select parameter DI Cursor disappears, ∗∗∗ DI6 ∗∗∗

text OK/ESC appears instead
OK
Din = None
- OK to write value
- ESC to cancel
8. Use ▲ key to select assignment ∗∗∗ DI6 ∗∗∗
3x ▲ Din = Parallel wGrid
- OK to write value
- ESC to cancel
9. Press OK key to save ∗∗∗ DI6 ∗∗∗
OK
→ Din = Parallel wGrid
Polarity = Normal
10. Press ESC key to return to start menu MAIN ∗∗∗

4x ESC ↕∗∗∗
Mode = Auto
Connected: 1 MAIN
→ Setup
• The above procedure only changes the parameters in the volatile memory. To make
the modification permanent, you have to save the entire parameter set.
• Save parameters: Start menu MAIN, Write EEPROM, OK, OK.

6.3.4 Menu structure
Main screenshots Menu items
∗∗∗ MAIN ∗∗∗

Monitor
Mode = Auto
AVR-ID: 1 MAIN
Setup
Tune
Communication
Write EEPROM
∗∗∗ MONITOR ∗∗∗

UM = kV
UM rel = %
IM2 = A
IM2rel = %
Q = kVar
Q rel = %
P = kW
P rel = %
Ie = A
Ie rel = %
freq = Hz
Un rel = %
∗∗∗ SETUP ∗∗∗

System Data
Field Flashing
Soft Start
Limiters
Synchronization
Setpoints
Volt. Droop Comp.
Digital I/Os
Analog Inputs
Analog Outputs
Diode Monitoring
PSS

∗∗∗ LIMITERS ∗∗∗

V/Hz Limiter
IeMin Limiter
IeMax Limiter
PQ Limiter
UM Limiter
IM Limiter
Boost
Temp Influence


Din: {input signal}

None,
Excitation ON,
Gen CB cl. st.,
Parallel wGrid,
Increase,
Decrease,
Reset Setpoint,
Remote SP Ena.,
PF Enable,
Var Enable,
Manual Enable,
Open Loop Ena.,
Sync,
VDC Enable,
Secondary Net,
Reset Alarm,
Standby,
Fieldbus Block,
FCB Closed st.
External Alarm
Dout: {output signal}

None,
Boost,
Field Flashing,
System OK,
Limit Active,
V/Hz Lim. Act.,
SP Lim. Reach.,
SP Min. Reach.,
SP Max. Reach.,
Oper.Lim.Act.,
Min Ie Act.,
Max Ie Act.,
Min PQ Act.,
Min UM Act.,
Max UM Act.,
Voltage Relay,
Close CB Comd,
Sync Check,
SW Alarm,
Diode Alarm,
Diode Trip,
SW or Di Trip,
Fieldbus Alarm,
FCB Close CMD,
FCB Open CMD
Sprv Alarm
Sprv Trip
Switch Over

∗∗ DIN from AIN ∗

DI9 from +AI
DI10 from –AI
DI11 from +AI
DI12 from –AI
DI13 from +AI
DI14 from –AI
Ain {input signal}

None,
Auto Remote SP,
PF Remote SP,
Var Remote SP,
Manual Rem SP,
OpenLoop R SP,
UM Aux,
Ie Ext,
Cool Med Temp,
Reserved4,
Reserved5,
DI9(+)&10(-),
DI11(+)&12(-),
DI13(+)&14(-)
∗ANALOG INPUTS
AI1
AI2
AI3
UM Aux
Ie Ext

ANALOG OUTPUTS
AO1
AO2
Ie Range
Fbias Range
Aout {output signals}

None,
Exc. Current,
PWM,
Fbias
Slip
Active PWR
PSS
Active =FALSE
PSS Settings
PSS Time Consts

∗∗∗ TUNE ∗∗∗

Auto
PF/Var/PQ Limiter
Manual/Ie Limiter
Open Loop
∗COMMUNICATION
AVR ID = 1 MAIN
Modbus Setup

∗∗∗ MAIN ∗∗∗

Write EEPROM
-OK to write value
-ESC to cancel
6.3.5 Limiters and Alarms
A number of limiter and alarm indications can be monitored from the Panel screen. The
message indications are shown in the first line of the screen, by toggling between the title
of the Panel menu and the message indication each for one second.
Example: Ie Max limiter is active
1. Initial screen:
* * * M A I N * * * *
M o n i t o r
M o d e = A u t o
C o n n e c t e d : 1 M A I N
2. One second later:

* * * I e H i g h A c t i v e * *
M o n i t o r
M o d e = A u t o
3. Another second later:

* * * M A I N * * * *
M o n i t o r
M o d e = A u t o

4. Another second later:
* * * I e H i g h A c t i v e * *
M o n i t o r
M o d e = A u t o
If more than one alarm or limiter is active at the same time, they are displayed one by one
after one second each.
The following alarms and limiters can be monitored from the Panel:
* I e
H i g h A c t i v e *
* U M
H i g h A c t i v e *
* * V / H z A c t i v e * *
* I M H i g h A c t i v e *
* * F C B A l a r m * *
* * I e L o w A c t i v e * *
* * U M L o w A c t i v e * *
* * I q L o w A c t i v e * *
* * I q M a x A c t i v e * *
* E x t e r n a l A l a r m *
* * M B C o m A l a r m * *
* * D i o d e A l a r m * *
* * D i o d e T r i p * *
* * S W A l a r m * *
M i n I M a x S P R e a c h e d
* * C o m m E r r o r * *
* * S p r v A l a r m * *
* * S p r v T r i p * *
* * S w i t c h O v e r * *
6.3.6 Fault messages
In certain circumstances the following fault messages could appear on the display:
XIRQ, SI, SYSTEM HALTED or COMM ERROR
The regulator could continue to work faultlessly and needs not be taken out of service.
However, no parameters can be entered or changed. The display is reset when the unit is
taken out of service and the auxiliary power is disconnected for a short time.
A defective unit should be sent for repair with a failure report attached to it. For contact
information, please refer to Chapter 1.4 Manufacturer’s Address.

6.4 PC Software tool
The PC software tool used with UNITROL 1000 is called CMT1000. The CMT1000 release
5 is not compatible with earlier releases of the product, release 4 and below.
6.4.1 System requirements for CMT1000 release 5
• Minimum Pentium 200MHz or equivalent processor. Recommended: Pentium III or

Celeron 600 MHz or equivalent processor or higher.
• Minimum of 64 MB of RAM. Recommended: 256 MB or higher.
• Minimum screen resolution of 800x600 pixels. Recommended: 1024 x 768 pixels or
higher.
• CD-ROM drive.
• Microsoft® Windows TM 2000 (Service Pack 3 or later), XP or Vista.
• Minimum of 250 MB of free hard disk space.
6.4.2 Installing CMT1000 software
To install the CMT 1000 software, please carry out the following steps:
1. Place the CMT 1000 CD in your CD-ROM drive.

2. Open “My Computer” using Windows Explorer or Start Menu.
3. Open the CD root directory .
4. Double-click Setup.exe from the directory CMT 1000 \ Installer setup.exe
5. Follow the instructions that appear on the screen. The Setup
loads the CMT 1000 program to your hard disk.
The application program is now installed and ready to use.
To start the program:

Open the user interface via Start menu, then Programs, then CMT1000
V5.000
CMT1000 and then Click on the Shortcut icon: CMT1000
V5.010.
Distribution rights:
CMT 1000 was developed with the Lab VIEW software and is distributed free of license
charges and costs. The copyright to Lab VIEW is owned by the company National
Instruments International Distribution (NIID).
“Copyright © [02-03-20] National Instruments Corporation.“
6.4.3 Starting with CMT1000
The CMT1000 communicates with the AVR via the RS232 port. The UN1000 serial cable
provided by ABB should be used to connect the RS232 port from the AVR to the PC (using
an USB adaptor if necessary) or to a TCP/IP gateway. For more information about the
hardware connections refer to chapter 3.3.9 Communication ports.

6.4.3.1 Configuring the port interface
Before the communication can

be established with the AVR, the
connection type should be
specified in the CMT1000. The
connection type is specified
using the Port Configuration
window, which can be accessed
from the main window of the
CMT1000 (Figure 6-7).
Figure 6-7 Port configuration.
Connection over a RS232 port from the PC (no Ethernet)
1. Connect via the RS232 port from the

PC (or by using a USB to RS232
adaptor), select the "Serial" tab (1) first.
See Figure 6-8
2. Click on the arrow (2) to display the
available COM ports and select the
one that is connected to the UN1000.
3. Press the Ok button (3) to save the
changes, or Cancel to abort the
configuration. Figure 6-8 RS232 COM port configuration.
In case the appropriated COM port is not found, check whether the required COMx is
correctly configured in the operating system or being used by another application.
Port settings normally used for COM:
Base I/O Port address: 3f8
Interrupt Request Line (IRQ): 4
Connection over an Ethernet port from the PC (TCP / IP)
1. To connect to the AVR using a

TCP/IP connection, select the
"TCP/IP" tab first. See Figure 6-9.
2. Fill out the IP Address of the remote
terminal in the Remote IP Address
field and press Enter on the
keyboard. A pinging process should
be automatically started to check
whether the remote terminal can be
reached using MODBUS TCP. Figure 6-9 Remote IP address configuration.

3. After some seconds the pinging

process should be finished and a
message is displayed whether the
remote terminal could be reached or
not.
The message "Connection Ok"
indicates that the remote terminal could
be reached and that the connection is
Ok. In case the message "Not
accessible" shows up, check whether
the Ethernet, gateway, firewall and/or
cabling are correctly configured and
installed. For configuration refer to
Chapter 3.3.9 Communication ports.
The pinging process is repeated
periodically and it should start a couple
of seconds after displaying the last
message.
4. Press the Ok button to save the
configuration or Cancel to abort the
changes.
Note: The message "In use" may
appear when the IP address is already
being used by CMT1000.
6.4.3.2 Communicating with the AVR
Once the port connection is

configured, the CMT1000 performs
a scanning process to detect the
AVR over the interface selected
(RS232 or Ethernet). During the
time the scanning process is
performed), CMT1000 is
disconnected from the AVR and
cannot be changed to any other
Access level, such as Monitor or
Control. Figure 6-10 CMT1000 during AVR scanning process.
As soon as an AVR is detected, the
CMT1000 reads the AVR-ID,
channel identification and its Access
status from the AVR controller
(Figure 6-11). The slide bar can now
be used to change to Monitor or
Control Access. As long as the
CMT1000 is Offline, only the
information shown in the main
window is read from the device.
Figure 6-11 CMT1000 during Offline.

As long as the CMT1000 has
Monitor or Control Access to the
AVR main controller, the main
window looks as in Figure 6-12 and
Figure 6-13.
As soon as the CMT1000 has
Monitor or Control Access, the
EEPROM LED (green light)
indicates whether the parameters in
the RAM are stored in the non- Figure 6-12 CMT1000 during Monitor Access.
volatile memory. The LED shines
(light green) when all current
parameter values match the ones
stored in the EEPROM memory.
Otherwise, the LED is dark,
indicating that at least one
parameter had been modified and
still not been stored in the non-
volatile memory.
To store all parameters in the
EEPROM using the CMT1000, click
on "Write parameters to EEPROM"
from the File menu. Figure 6-13 CMT1000 during Control Access.
AVR scanning process failure: "Link Not Found"
The CMT1000 scanning process

can last up to one minute before
the AVR is detected; especially if
connection type is Ethernet. If the
AVR is not possible to be detected
by that time, the message "Link
Not Found" might be shown in
main window of the CMT1000
(Figure 6-14). The configuration
and hardware should be checked
Figure 6-14 LinkNotFound message when the AVR can
to correct the problem. not be found or the communication port can not be
Even after the message "Link Not accessed by the CMT1000.
Found" has been displayed, the
CMT1000 continues the scanning
process in the background until
the AVR is found.
For details about the configuration
refer to 3.3.9.1 RS232 interface.

6.4.4 Menu structure of CMT 1000
The main window of the CMT1000 is shown in Figure 6-15 and is the starting point to access
all software features. The software features are accessed from the menu and each menu
item is grouped according to functionality.
• File: Load/save parameters

and enable optional SW.
• Monitor: Online measuring
• Setup: Set parameters
• Communication:
Set IDs / Ports / MODBUS
• Tune: Tune regulator
• Help: Software information
Figure 6-15 Main window of CMT1000.
The following sections describe the CMT1000 menu organization and window contents.
IMPORTANT!
All software windows shown in this User Manual were taken with
standard style of Microsoft Windows (R) XP and most of them can be
closed by using the mouse and clicking on the cross in the upper right
corner. If the cross button is not available, the information in the window
explains how to close it.
6.4.4.1 Help Menu
Software and AVR information
About CMT1000
AVR S/N: Unit’s serial number
Control: DSP software version
Panel: Panel software version
Revision: CMT1000 version
Configuration: ABB or Custom
Click on the window to close it.
Note: the serial number of the AVR is
shown in the window of Figure 6-16 and
it should be provided when an optional
software is requested from ABB.
Figure 6-16 About CMT1000 Window

6.4.4.2 File Menu
*. ini (see warning message below)

saves the parameters to the PC hard disk
saves the parameters to the device’s EEPROM
user defined application

enables SW optional features (password required)
closes the application
Open Parameter File

A set of parameters values, previously stored in a so-called Configuration INI file, can be
downloaded to the AVR by using the option Open Parameter File from the CMT1000
menu. In order to download parameters to the AVR, make sure that the CMT1000 has
Control Access before trying to use the Open Parameter File option. The Configuration INI
file can also be opened during OFFLINE, in order to verify the values of the parameters,
prior to downloading them to the AVR.
The Configuration INI file should be compatible

and previously created with CMT1000 release
5.xxx, otherwise a warning message may show
up (Figure 6-17). Additionally, a message
indicating writing failure can appear after
continuing the download of the incompatible
configuration INI file, when it contains at least one
parameter value out of the permitted range of
selection.
Figure 6-17 A warning
The download of an incompatible configuration INI
window is shown in case
file is not recommended and it is up to the user to the INI file is incompatible
verify if all parameters are set correctly before with the AVR software
going into Operation with the AVR. release.
While the parameters are downloading, a warning

message may appear if at least one optional SW
is marked as activated in the INI file but is not
available in the AVR (Figure 6-18).
The warning window (Figure 6-18) also shows a
list of all optional SW which is activated according
to the INI file but which is not available in the
AVR. These will only be activated in the AVR,
when they have been enabled (available) using
SW Options tool from the CMT1000. Figure 6-18 A warning message is
shown when one or more optional
SW is set as active in the INI file but
not available in the AVR.

Save Parameter File

The parameter values can be stored in a configuration INI file to the PC hard disk, for
further download to one or more AVRs (i.e. during commissioning) or for use as a
reference parameter file. A configuration INI file can be downloaded to an UN1000 AVR by
using the command "Open Parameter File".
When "Save Parameter File" is executed during Offline, it allows the user to create a
preconfigured file for further download to one or more AVRs. Once the CMT1000 is
started, all parameters are normally set to default values and they can be modified during
Offline Access. After they have been modified and the command "Save Parameter File" is
selected, all parameter values are stored in an INI file whose name is specified by the user
during the file creation process. The resulting INI file can be downloaded to an AVR by
using the command "Open Parameter File".
When "Save Parameter File" is executed during Monitor or Control mode, all parameter
values written in the configuration INI file are read directly from the connected AVR; i.e. the
created INI file reflects the actual configuration of the AVR. During Monitor or Control
mode, this command can be used when a device must be replaced by a spare unit.
Customer setup
Option for user defined application
only (password protected).
SW-Options
It allows the user to enable (un-block) optional software in the AVR. A password code is
required and should be provided by ABB.
The following steps should be

performed to enable an optional
software in the UN1000:
1. Make sure the CMT1000 has

Control Access with the AVR
(Figure 6-19).
2. Type the password (case sensitive)

in the white box located beside the
optional SW (Figure 6-20). Press .
the Enter key on the keyboard in Figure 6-19 CMT1000 must have Control Access before
order to validate the password. enabling an optional SW.

A couple of seconds after clicking
Enter, the SW activation button
(located on the right of the white
box) is not shaded anymore (i.e.
not grayed out) if the password is
correct. Please verify the password
code if this is not the case.
The behavior rules for the SW
activation buttons are shown in
Figure 6-21
3. The optional SW is enabled by

clicking once on the activation
button.
After a few seconds the LED on the
button should be bright, indicating
the optional SW is now enabled.
4. Once the button is On, press the

button “Save to EEPROM“ to save
the changes to the EEPROM
memory and close the window Figure 6-20.The SW Options window allows
afterwards. the user to enable optional software in the
AVR.
Do not close the window without

saving to EEPROM first.
5. From the menu in the CMT1000

main window, click File and then
"Write Parameters to EEPROM".
6. Restart the device. Once restarted,

check whether the optional SW was
enabled correctly, using the SW
Options option in the menu. Figure 6-21 Upper: LED is bright when the
optional SW is enabled in the AVR. Lower: A
wrong password does not allow to press the
button to enable the SW.
Close
Exit the CMT1000 software.

6.4.4.3 Monitor Menu
Online measurements (current Channel)

Online measurements
Online measurements
Online measurements for Synchronization
Temperature influence visualization
Online measurements read from the Second Channel
Temp. influence for Machine current

Temp. influence for Excitation current
Measurements
Monitor \ Measurements
• Network Voltage (UNet) [% and kV]
• Machine Voltage (UM) [% and kV]
• Machine Real Power (P) [% and kW]
• Excitation Current (Ie) [A]
• Machine Current (IM2) [% and A]
• Machine Reactive Power (Q) [% and kVar]
• Network Frequency (fNet) [Hz]
• Machine Frequency (fM) [Hz]
• Power Factor (PF) --
Figure 6-22 Measurements window.

Oscilloscope
Monitor \ Oscilloscope
Measurements and transients can be visualized, analyzed and stored to the hard disk
using the Oscilloscope tool of CMT1000. Up to 4 different measurements channels are
possible to be visualized simultaneously on the black box of the Oscilloscope window (see
Figure 6-23). The signal or measurement to be displayed is configured on the right end
side of the Oscilloscope window with the options shown in Figure 6-23.
The Buffer Length defines the length of the buffer size used to record the transient data
and display them on the display, i.e. the size of the black box of the Oscilloscope. The
selection can be performed at predefined values: 1, 2, 5, 10, 20, 50, 100 and higher up to
500 seconds. Each time the Buffer Length value is changed by the user, the black box is
resized in order to match with the new value selected. The transient shown on the black
box is possible to store to the hard disk afterwards; the transient data that could already
pass-through the black box and not shown anymore are lost (there is no additional
memory or buffer).
When a set of consecutives data measurements are received with errors (i.e. due to
cabling or communication problems) the Out of Frame LED indication should light-up.
Under these circumstances it is recommended to check the cabling and configuration
between CMT1000 and UN1000, in order to solve the problem. During the Out of Frame
indication, the Oscilloscope freezes and displays the last correct (error free) measurement
for each channel, until the failure is solved and the indication LED goes off (see Figure
6-23).
Figure 6-23 Oscilloscope window.

The Oscilloscope window menu and the function description of each item are explained in
Figure 6-24. The Oscilloscope can be started and stopped as explained in Figure 6-25.
Open a previously stored waveform (ASCII table or *.xls)

Open a custom settings file for the Oscilloscope (*.cfg)
Save the current waveform to an ASCII file

Save the current Oscilloscope settings to a file (*.cfg)
Save the current waveform to a BMP format file
Close the Oscilloscope window
Shows / hides cursors (shown on the left side of the screen).

Plays the stored recording using the cursor A.
Figure 6-24 Menu structure of the Oscilloscope tool window and function
of each item.
Start: Starts the Oscilloscope: reading and displaying the measurements on screen.
The menu item changes its name after click on it.
Freeze Waveform: Stops the Oscilloscope: stops data reading and freeze transients.
The menu item change its name after click on it.
Figure 6-25 The Oscilloscope is started and stopped using the "Start" /
"Freeze Waveform" button located in the menu of the window.
IMPORTANT!
Previous waveform files saved with CMT1000 releases 4.xxx or 3.xxx
are not compatible with CMT1000 release 5.
The user is kindly asked to use the appropriate version of CMT1000 to
open older waveform files than release 5.
Evaluation of the waveform

Instantaneous values from transients can be observed using the cursors feature of the
Oscilloscope (menu Edit > Cursors).
As long as the cursors are enabled (Edit > Cursors), the two pointers or cursors A and B
are shown in the black box of the Oscilloscope with their standard configuration options, as
shown in the Figure 6-26. The cursors can be moved with the mouse (click + hold + drag)
along the curve of the transient from the Channel they are configured. When the cursors
are moved, the user can see the instantaneous value of the curve at the time (dt) where

they are placed (Figure 6-26). If the instantaneous value from another Channel is object of
interest, the channel selection for the cursors A and/or B can be changed on the
Oscilloscope window itself (see Figure 6-26).
The temporal buffer of the UN1000 can be used for troubleshooting by allowing retrieval of
data history recorded during the AVR operation time. As long as the CMT1000 is Offline,
the cursor A can be used to observe measurements and data stored on the temporal
buffer but on the Instrument windows. When instruments such as Measurements, Setpoint
Adjust, PQ Monitor and/or others are open when the cursor A is displaced along a curve in
the Oscilloscope window, the Instruments will show measurements reading from the AVR
at the time the temporal buffer was recorded (Figure 6-26). This additional information is
also stored in the temporal buffer but (some of them) are not shown in the Oscilloscope
window.
Notice that the cursors moved along the temporal buffer will show historical data on the
Instrument only if the CMT1000 is Offline; otherwise the Instruments show actual
measurements and reading from the AVR (and the system).
Close
Measurements
Close
125 Voltage [UM]

Machine
100 Limiter characteristics
100
50 75
x
100
25 125 75
75 x
0 150
50 PQ Limiter is active
50 x
25
25 1.067 [kV] x
0
106.7 [%]
0 x
Zoom -300 -275 -250 -225 -200 -175 -150 -125 -100 -75 -50 -25 0 25 50 75 100
File Edit Start
Freeze Waveform
Channel 1
UM Relative
1 100.0 %/div
0.0 %
Channel 2
1 Iq Relative
100.0 %/div
2 2
0.0 Hz
B Channel 3
4 Combined Limit
1.0 /div
0.0
Channel 4
A 3 3 Gen. State
2.0 /div
4
0.0
Cursors A, B
A B
Channel 3 Channel 3
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0 50.0 0 3
20.0 s 30.0 s
time / s Sweep Buffer
Buffer Length 50.0 s dt = 10.0 s
1/dt = 0.010Hz
Figure 6-26 Evaluation of a waveform

A feature called Sweep Buffer can be used to displace the cursor A along the transient
curve at real time speed, and so, to observe the variations of measurements and data as
they might have been gathered during operation of the AVR.
When Sweep Buffer is enabled from the menu, a vertical line replaces the pointer A and
runs along the transient curve starting from the cursor A until the end of the transient at
real time speed (i.e. one second of cursor movement is equal to one second of operation
with the AVR). During the time the vertical line runs, the instantaneous value of the curve
is displayed on the Oscilloscope window, under the cursor A information. If an Instrument
window is opened during this process, the instantaneous data is also updated and shown
in the window. The Sweep Buffer is intended to be used together with Instruments
windows, and therefore, it is only available when the CMT1000 is Offline. It can only be
activated from the menu when the cursors were already enabled as well.
Examples
a) During OFF LINE: previously stored waveform files

File \ Open Waveform: Open stored waveform file.
Adjust the Buffer Length when necessary to see the full
transient on the Oscilloscope.
Edit \ Cursors: Assign channel with buttons A and B, use left mouse
button to drag cursor A to the desired point on the signal
curve. The measured values can be measured on the
oscilloscope, instruments or PQ diagram.
Edit \ Sweep Buffer: The curves are run through from cursor point A using the
scanning bar.
b) During MONITOR or CONTROL: Real time data

Start: The recording of the waveform is started.
Freeze Waveform: The recording is stopped.
File \ Save Waveform: Save waveform.
File \ Save Setup: Save oscilloscope settings.
Notes
• The window in "Tune" can also be opened to set the regulators.
• The setpoint step is simulated in “Tune Setpoint Adjust“.
• The buffer length can be adjusted from 1, 2, 5, 10, 20, 50, 100 and higher values
up to 500 seconds.
• The time scale can be adjusted in the bar above the waveform (Zoom).
Monitor \ oscilloscope, status display
There are 4 quasi analog signals which can be used to represent status changes on the
oscilloscope. The decoding of those signals is explained as follows:

Generator Control Mode :
0 = Auto
1 = Var
2 = PF
3 = Manual
4 = Open Loop
5 = VDC
6 = Sync
7 = Standby
Combined Limit :
0 = None
1 = Minimum Excitation Current Limiter active
2 = Minimum Machine Voltage Limiter active
3 = Minimum Iq Limiter active
4 = Maximum Excitation Current Limiter active
5 = Maximum Machine Voltage Limiter active
6 = Maximum Iq Limiter active
7 = Maximum Machine Current Limiter active
+8 = V/Hz Limiter active
+16 = Minimum Setpoint reached
+32 = Maximum Setpoint reached
Excitation ON active: Combined Limit = See values above
Excitation ON not active: Combined Limit = -1.0
GenState (Generator State) :
0 = Idle (NoLoad)
1 = Change NoLoad -> Primary Net
2 = Primary Net
3 = Change Primary Net <-> Secondary Net
4 = Secondary Net
5 = Change Secondary Net -> NoLoad
6 = Primary Net or Secondary Net -> Grid ON
7 = Grid ON
8 = Grid ON -> Primary Net or Secondary Net
AlarmTripStatus :
0 = None
+ 1 = SW Alarm active
+ 2 = FCB Alarm active
+ 4 = External Alarm active
+ 8 = Modbus Communication Alarm active
+ 16 = Diode Alarm active (requires RDM SW)
+ 32 = Diode Trip active (requires RDM SW)
+ 64 = Supervision Alarm active (requires Double Channel SW)
+128 = Supervision Trip active (requires Double Channel SW)
+256 = DCH SwitchOver active (requires Double Channel SW)
Figure 6-27 Example of Combined Limit status

Combined Limit
Max UM Active + V/Hz 13.0
Max Ie Active + V/Hz 12.0
Min Iq Active + V/Hz 11.0
Min UM Active + V/Hz 10.0
Min Ie Active + V/Hz 9.0
V/Hz Limit Active 8.0
+8
Max UM Active 5.0

+8
Max Ie Active 4.0
Min Iq Active 3.0
Min UM Active 2.0
Min Ie Active 1.0 s
None
Window PQ Diagram
Monitor \ PQ Diagram (Power chart)
Note: The Limiter points can be moved with the cursor.
Synchronization Diagram. Synchroscope.

Monitor \ Sync Diagram

IM or Ie Temperature Monitor
Monitor \ Temp Influence
IM Temperature
Monitor
Ie Temperature
Monitor

Second Channel Measurements

Displays status and measurements from the Second Channel. Double Channel SW is
required to show this window; otherwise it is not accessible from the CMT1000 menu.
1. Displays the current

measurements of UNET, UM,
Excitation Current and
Machine Current from the
second channel read from
the CAN interface.
2. Displays the current status

(Active or Standby) and
operating mode (Auto,
Manual, Standby, etc.) of
the second channel.
Example
3. Displays Alarm and Trip

status signals from the
second channel. A LED is
bright when the signal is
logical 1 in the second Figure 6-28 Second Channel Measurements window, when
channel. Double Channel communication over CAN is Ok (data is being
received correctly)
4. Displays the current status
from the Double Channel
communication. The LED is
bright when the double
channel communication is
configured and enabled in
both channels, and the
DCH data is being received
correctly (no CRC errors).
The Second Channel

Measurements window is
shaded when the Double
Channel Communication
Ok LED is dark, as shown
in Figure 6-29. There is no
valid data from the Second
Channel when this is the
case.
Figure 6-29 Second Channel Measurements, when Double

Channel communication failed or it is disabled.

6.4.4.4 Setup Menu
Configuration of system data parameters

Soft start ramp parameters
Field flashing configuration
Limiters configuration
Setpoint configuration
VDC software configuration
Digital Input / Output configuration
Analog inputs configuration
Analog outputs configuration
Synchronization parameters
Rotating Diode Monitoring settings
Power System Stabilizer parameters
Double Channel and Supervision
V / Hz limiter configuration
PQ, UM, IM and Ie limiter configuration
Line short circuit support
IM and Ie temperature monitor
Auto mode setpoint configuration

PF mode setpoint configuration
VAR mode setpoint configuration
Manual mode setpoint configuration
Open Loop mode setpoint configuration
Note: Some menu items may be shaded and are not accessible when the CMT1000 has
Monitor or Control Access and/or the AVR has optional software which is not available. All
menu items are accessible when the CMT is Offline.
Adjust System Data

Setup \ System Data

Configure Soft Start

Setup \ Soft Start
Adjust Field Flashing

Setup \ Field Flashing
Adjust V/Hz Limiter

Setup \ Limiters \ V/Hz
Limiter
Operational Limits. Adjust Ie, UM, PQ and IM Limiter

Setup \ Limiters \ Operational Limits
Excitation current (Ie) limiter

Machine voltage (UM) limiter
PQ limiter and machine current (IM) limiters
Adjust Short Circuit Support

Setup \ Limiters \ Boost
Adjust Limiters Temperature

Influence
Setup \ Limiters \ Temp
Influence
IM and Ie nominal values can

be changed in System Data
window.

Adjust Setpoint Range

Initial SP refers to the Initial setpoint of the operation mode.
Setup \ Setpoints \ Auto

The Initial Setpoint (SP) of Auto
mode is the final value of the Soft
Start ramp. For more information
consult 3.4.11.4 Soft Start.
1. Parameter configuration: "SYNC
DisableCBCheck".
For more information see Chapter
3.4.4 Synchronization (SYNC)
Setup \ Setpoints \ PF
Setup \ Setpoints \ Var
Setup \ Setpoints \ Manual
Setup \ Setpoints \ Open Loop
Adjust Voltage Droop Compensation

Control Range
Setup \ Voltage Droop Compensation
For configuration consult 3.4.3 Voltage

droop compensation (VDC).

Configure Digital I/O
Setup \ Digital I/Os

Example of configuration of the input signals with the CMT1000 software tool
1. Select the analog input AI1 2. Select one or two digital signals
(or AI2 or AI3) and adjust the DI9 from +AI
input range [Setup \ Analog DI10 from –AI
Inputs] [Setup \ Digital I/Os]
Range : Uin0% = 2.0 V

Uin100% = 5.0 V
When using AI pins for DI signals, both inputs should not be active at the same time.
Example of parameter setting using CMT 1000

Example: Assigning Parallel with Grid Status to input DI6
Make Control-connection to the unit
Menu bar CMT 1000, start

menu
1. Select setup and then

Digital I/Os

2. Open input DI6 by

clicking on the white
box.
3. Select input: "Parallel

with Grid Status"
4. Result: DI6 configured
The above procedure only changes the parameters in the volatile memory.
To make the modification permanent (even after restarting the AVR), all the parameters
have to be stored in the non-volatile EEPROM.
Save parameters during CONTROL Access:

- Unit: Menu bar CMT 1000 \ File \ Write Parameters to EEPROM
- Hard disk: Menu bar CMT 1000 \ File \ Save Parameter File

Configure Analog Inputs

Setup \ Analog Inputs
Configure Analog Outputs

Setup \ Analog Outputs

Adjust Synchronization
Setup \ Synchronization
The window is only shown if CMT1000 is

OFFLINE and/or Synchronization SW
(optional) is available in the device.
Adjust Diode Monitoring

Setup \ Diode Monitoring
The window is only shown when the

CMT1000 is OFFLINE and/or the
Rotating Diode Monitor SW (optional) is
available in the device.
Adjust PSS
Setup \ PSS
The window is only
shown when the
CMT1000 is
OFFLINE and/or the
Power System
Stabilizer SW
(optional) is available
in the device.

Double Channel configuration

Setup \ Double Channel
The window can only be accessed when Offline or when Double Channel (optional)
software is available in the AVR. For more information about the configuration refer to
3.4.8 Double Channel (DCH).

6.4.4.5 Communication Menu
Set AVR-ID (VDC) and the Channel Identification (DCH)

Configuration of serial COM port and IP address
Set MODBUS configuration for Remote Access
Monitoring tool for VDC
ID Definition (AVR-ID & DCH)

Communication \ ID Definition
Configuration window for AVR-ID (VDC) and

Channel Identification (Double Channel).
1. AVR-ID should be configured before the

use of VDC. For more information refer to
Chapter 3.4.3 Voltage droop
compensation (VDC).
2. Channel Identification should be

configured before using Changeover and
Follow-up from the Double Channel
feature. The chosen selection, Main or
Redundant, is displayed in the main
window of the CMT1000 (and Panel)
even if the Double Channel feature is not
available in the AVR.
If the Double Channel feature is not used,

the channel identification can be changed
without affecting other UN1000 functions
with exception of the Modbus ID, which is
used for CMT1000 access. That allows
changing the name displayed in the
CMT1000 and Panel. For more
information refer to Chapter 3.4.9 Remote
Access.
Port configuration
Communication \ Port configuration
Configures the connection interface with the

AVR. For more information consult Chapter
6.4.3.1 Configuring the port interface.

MODBUS configuration (RS485 and RS232)

Communication \ MODBUS
The MODBUS Slave-ID is the same used for MODBUS over RS232 and RS485. For
configuration consult Chapter 3.4.9 Remote Access.

VDC Monitor
Communication \ VDC Monitor
VDC Monitor is a tool to analyze the VDC communication between the AVRs connected to
the same RS485 bus.
1. Shows the AVR-ID number

and the actual compensation
used for regulation. The
compensation is only used if
the AVR is operating in VDC
mode.
2. Each LED indicates VDC
activity on the RS485 bus and
can be used to detect cabling
and configuration problems.
Each LED is numbered from
1 to 31 and corresponds to
the data quality status from
each of 31 possible AVR-IDs
supported within VCD feature.
A LED number "x" is bright
when communication with the
AVR, configured with AVR-ID
= "x", is established correctly
and there are no errors in the
data reception (no CRC
errors).
A LED number "x" is dark as
long as there is no
communication established
with any AVR, configured with Figure 6-30 VDC Monitor window
AVR-ID = "x", or data
reception with that AVR
contains errors (CRC errors).
The VDC communication should be enabled before using this tool. For more
information refer to 3.4.3.2 Communication.
3. The VDC data received from a specific AVR can be retrieved by specifying the AVR-
ID = "y" of the device.
4. The VDC data that is read from the bus and coming from the AVR whose AVR-ID =
"y" (from item 3) can be observed in Figure 6-30.
Net ID shows the Primary or Secondary Net number depending on the Net the AVR-
ID "y" is currently in operation. A special case may occur when Net ID is equal to
zero, which means the VDC data for the AVR-ID "y" had CRC errors or the
communication is not established; under these circumstances the LED "y" is dark.
IM Nominal refers to the Nominal Machine Current and Iq Rel to the Reactive
Current in p.u. units (both read from the RS485 bus).

6.4.5 Tune Menu
Setpoint adjust, operation modes and limiters status

Parameters for AUTO (PID) and Kq Droop
Parameters for PF, VAR and PQ Limiter (PI)
Parameters for Manual and Ie Limiter (PI)
Adjust Setpoint, Trigger Setpoint, Status Displays

Tune \ Setpoint Adjust
It allows setpoint adjustment, step response tests and visualization of operating
modes, generator states, limiters and alarms status.
1. Displays the generator state condition, according to the Gen CB Closed and
Parallel with Grid status signals. Prim. Net and Sec. Net are used during VDC
operation mode.
2. Displays the actual operating mode of the AVR. Some modes may be shaded
(disabled) if an optional feature is not available or due to system conditions or
configuration. For more information about the software feature and operation
modes consult Chapter 3.4 Software.
3. Displays Limiters status.
4. Displays AVR Alarms status. Not all alarms statuses are shown when an
optional feature is not available in the AVR.
5. The actual setpoint can be adjusted with the upper Up and Down buttons (if
the adjustment is not performed via analog or digital inputs). A step response
can be performed by specifying the Step value and then pressing the lower
Up (actual setpoint + Step) and Down (actual setpoint – Step) buttons.

Regulator parameters AUTO
Tune \ Auto
Allows the configuration of parameters of

the PID regulator used during AUTO
mode and the Kq Droop. For more
information refer to Chapter 3.4.11
Description of parameters.
Regulator parameters PF/VAR/PQ

Limiter
Tune \ [ PF/VAR/PQ Limiter ]

the PI regulator used during PF/VAR
modes and PQ Limiter. For more
information refer to Chapter 3.4.11
Description of parameters.
Regulator parameters Manual / Ie

Limiter
Tune \ [ Manual/Ie Limiter ]

the PI regulator used during Manual mode
and Ie Limiter. For more information refer
to Chapter 3.4.11 Description of
parameters.

6.4.6 Save parameter file
PC UNITROL 1000-15
CMT 1000
RAM EEPROM
Parameters Parameters
Write Parameters
Harddisk Open Parameter File OFF LINE to EEPROM
Save Parameter File
MONITOR/
CONTROL
EEPROM LED lights up, if data RAM = EEPROM (MONITOR or

CONTROL only)
6.4.6.1 Status during MONITOR or CONTROL
After switching from OFF LINE to MONITOR/CONTROL, CMT 1000 reads the parameters
from the device‘s RAM. Now, all parameter changes carried out using CMT 1000 are
written directly into the device‘s RAM.
- Write Parameters to EEPROM: The parameters in the RAM are stored in the device (only
possible during CONTROL Access).
- Save Parameter File: The parameters are saved on the hard disk as an INI file.
- Open Parameter File: The INI file is loaded into CMT 1000 and the RAM is
overwritten again (only possible during CONTROL
Access).
When opening a parameter file from disk, the old parameter file is immediately overwritten in the
RAM (only possible during CONTROL Access).
6.4.6.2 Status during OFF-LINE
Any parameter changes carried out in CMT 1000 are not transferred into the device.
- Write Parameters to EEPROM: No effect, since there is no communication between CMT

1000 and the device.
- Save Parameter File: The parameters are saved to the hard disk as an INI file.
- Open Parameter File: The INI file is only loaded into CMT 1000.
If you now switch to MONITOR or CONTROL the CMT 1000 reads data from the RAM again.

ABB
Chapter 7 - Preventive Maintenance
7.1 General
NOTICE!
ABB recommends periodical training for the maintenance personnel.
WARNING!
The secondary voltage of the excitation transformer and the voltage of
! the excitation field are fed into the excitation cabinet.
These components present a great danger of electric shocks.
The control elements and the PC interface on the front plate of the
UNITROL 1000 unit are to be touched and/or attached only with
caution.
7.3 Standard Procedures for Maintenance
When the system is at a standstill, the screwed terminals, which can get
loose due to vibrations, should be checked for tightness. Dusty cooling
flanges should also be cleaned.

ABB
Chapter 8 - Troubleshooting
8.1 General
Chapter 8 - Troubleshooting provides instructions to assist in localizing a

fault within the excitation system as a whole. However, it is not possible to
deal with all eventualities in full.
Before starting to work on the excitation system the general safety

instructions in Chapter 2 - Safety Instructions must be read and
understood.
8.3 List of Possible Faults
Possible causes Checks, action

Machine is not excited
Field circuit interrupted Check wiring for break
Field circuit-breaker does not close Check field circuit-breaker
Shunt supply:
Field flashing does not work Check field flashing circuit
No electronic supply UAUX Measure auxiliary supply UAUX
Check for tripped protective circuit-breaker
No control element supply UPWR Measure power electronics supply UPWR
Shunt supply:
Machine is only excited to the value supplied by the Measure auxiliary supply UAUX,
field flashing Measure power electronics supply UPWR
Check field flashing Off level
Machine is first excited then discharges again Check operating mode. For field flashing Auto is
normally used
Check field flashing Off level
Check setpoint
Measure power electronics supply UPWR
If all supplies and setpoints are correct, then
change the unit
Setpoint error Check operating mode. For field flashing normally
Auto is used
Check setpoint
Regulator error Measure output voltage at terminals 8, 9 (Osc.) ->
positive
Measure voltage UPWM (CMT 1000, Monitor)
-> positive rising

Chapter 8 - Troubleshooting ABB
Overvoltage during build-up
Overvoltage caused by voltage regulator Machine voltage UM present

Check system data
Check operating mode. For field flashing normally
Auto is used
Check setpoint
Check thresholds of UM Limiter
Check regulator settings
Field flashing current too high Check design of the field flashing circuit.
Field flashing should deliver 10 to 15% of the no
load excitation current
Machine voltage not stable in no-load operation
Regulator error Check operating mode. For field flashing Auto is

normally used
Check setpoints
Check parameters of Auto regulator
Setpoint error Higher, lower inputs unstable

Externally input setpoint unstable
Control element fault Check wiring, loose contact UM, Ie
Parallel operation with grid unstable.

Periodic oscillation of reactive and possibly active power
Regulator settings incorrect Were changes made to the grid configuration?

Additional outputs, loads etc. installed?
Yes: reset regulator

No: check parameters of Auto and PF, Var
regulator

ABB Chapter 8 - Troubleshooting

Irregular instability, i.e. sporadic over- or underexcitation which is not caused by grid
Droop influence of the voltage regulator ineffective or Check droop/compensation setting

IM2 measurement defective Check external current transformer circuit
Gen CB Closed Status not active
Machine within inadmissible operating range Bring machine into normal operating range by
(normally protected by limiters) adjusting the setpoint.
Check setting of limiters
Regulator fault Measure output voltage at terminals 8, 9 (oscillos-

cope)
Measure voltage UPWM (CMT 1000, Monitor)
Signals in phase opposition: unit defective

Signals in phase: disturbance possibly caused by
the driving side of the machine or by disturbances
from the grid
Operating point cannot be adjusted
Setpoint error Check operating mode. For field flashing normally

Auto is used
Check setpoint
Limiter active Bring machine into normal operating range by

adjusting the setpoint.
Check setting of limiters
Excitation with compounding and boost circuit:

Excitation is only supplied by the series compounding
No control element voltage

Measure power electronics supply UPWR
Regulator fault
Check operating mode. For field flashing normally
Auto is used
Check setpoint
Check parameters of Auto regulator

Chapter 8 - Troubleshooting ABB
External controls faulty
No external control voltage Measure control voltage

Check wiring
No internal control voltages Vdig, Vref Measure internal control voltages
Configuration of the digital or analog inputs or outputs Check configuration

is not correct
8.4 Repair
The unit must not be opened. A defective unit should be sent in for repair with failure
description and, if possible, trending of failure.
See manufacturer’s details on Chapter 1.4 Manufacturer’s Address.
8.5 Compatibility
Target Release PC Tools / CMT1000 Panel Release VDC

3.xxx PC Tools 3.xxx x
4.xxx CMT 1000 Release 4.xxx 4.xxx Fully backward
compatible
5.xxx CMT 1000 Release 5.xxx 5.xxx Fully backward
compatible

ABB
Chapter 9 - Technical data
9.1 General
9.1.1 Ordering information

Device designation UNITROL 1000-15, V5
Order number BASIC 3BHE014557 R0003

• PF / VAR regulation
• MODBUS (Remote Access)
• Voltage Droop Compensation (VDC)
FULL 3BHE014557 R0006

• BASIC options
• Synchronization (SYNC)
• Rotating Diode Monitoring (RDM)
• Double Channel Software (DCH)
9.1.2 Mechanical data

Weight 5 kg
Protection class IP20
Dimensions (HxWxD) 245x190x142 mm
9.1.3 Climatic stability

Temperature range for operation 0 to 60 °C
Temperature range for storage -20 to +75 °C
Vibration 2 mm f<15 Hz, 0.7 g f>15 Hz
Shock 5 g, 11 ms pulse
9.1.4 Electrical data

Auxiliary supply UAUX: Maximum power consumption 25 W
AC Input voltage, 3-ph min/max 9 to 250 VAC
DC Input voltage min/max 18 to 300 VDC
Test voltage 2 kV
Power electronics supply UPWR: Frequency range DC, 40 to 600
Test voltage 2 kV
Excitation output Ie: Continuous current at 50 °C 15 A
Continuous current at 55 °C 10 A

Chapter 9 - Technical data ABB
Continuous current at 60 °C 5A
Overload (maximum 10 s) 30 A DC
Overload (maximum 4 min) 20 A DC
10 to 100 Hz
Frequency range of measuring values UM and Maximum overcurrent 3A
Machine current IM2: Voltage regulation <0.1%
Accuracy:
Test voltage:
Power electronics supply UPWR against case and auxiliary supply UAUX 2830 V DC, 2 s
Auxiliary supply UAUX against case and power electronics supply UPWR 2830 V DC, 2 s
Voltage measurement inputs UM, UNET: High impedance voltage input without galvanic separation
According to (USA, Canada) UL specification:
The screw-type terminals for inputs and outputs are approved for maximum voltage 150 V
9.1.5 Relevant standards, CE conformity

EMC directive: 89/336/EEC
Generic emission standard IEC/EN 61000-6-4
Generic immunity standard IEC/EN-61000-6-2
9.1.6 Ordering information connection cable

Connection Cable PC to UNITROL 1000:
Serial RS232 cable (terminals 2 and 3 crossed) DB9 f/f/ 3 m
9.1.7 Reliability
MTBF (MIL-HDBK-217F) GB(40°C) 4100 FIT / 27.6 years
9.2 Settings record for UNITROL 1000
Name and Address of Customer:
Plant:
Order No.:
Plant Schematic No.:
Device Identification:
Type Plate:
Delivery Date:
Software Revision: Control:
Panel:
CMT 1000:
Remarks:

ABB Chapter 9 - Technical data
Place and Date of Commissioning:
Name: Company:
9.3 Parameter Settings, default values
Parameter Parameter INI-File Standard Setting range Set Unit

value
System Data [SYSTEM DATA]
- Nominal excitation current Ie Nominal 5.0 0.1 to 1000.0 A
- Measuring volt., three- or single-phase Potential Transformer Three_ Three_Phase /
Phase Single_Phase /
Three_ph_gnd
- Nominal voltage of the machine UM Nominal 1.000 0.010 to 32.000 kV
- Potential transformer, primary voltage UM Primary 1.000 0.010 to 32.000 kV
- Pot. transformer, secondary volt. 3-Ph UM Secondary 110.0 60.0 to 250.0 V
1-Ph 60.0 to 150.0 V
3-Ph gnd 60.0 to 150.0 V
- Nominal Voltage of the network Unet Nominal 10.000 0.10 to 320.00 kV

- Potential transformer, primary voltage (Net) Unet Primary 10.000 0.10 to 320.00 kV
- Pot. transformer, secondary voltage (Net) Unet Secondary 110.0 60.0 to 500.0 V
- Nominal machine current IM2 Nominal 500 1 to 32000 A

- Current transformer primary current IM2 Primary 500 1 to 32000 A
- Current transformer secondary current IM2 Secondary 1.000 0.500 to 1.500 A
- No-load current Ie No Load 30.0 0.1 to 100.0 %

- Ceiling factor Kceiling 3.00 1.00 to 100.00 V/V
- Machine reactance Xq 0.80 0.20 to 4.00
- Frequency nominal f Nominal 50.00 10.00 to 200.00 Hz
Field Flashing [FIELD FLASHING]
- Reached voltage off level Off Level 0.0 0 to 95.5 %
Soft Start [SOFT START]
- Starting voltage Starting Level 0.0 0 to 100.0 %
- Delay until ramp Hold Time 0.0 0 to 327.0 s
- Ramp time Ramp Time 10.0 0 to 327.0 s
Limiter
V/Hz Limiter: [V/Hz LIMITER]
- Cut-off frequency fKnee 48.0 10.0 to 200.0 Hz
- Slope Slope 100.0 0 to 327.0 %
IeMin Limiter: [IeMin LIMITER]
- Minimum limit Minimum 0.0 0 to 150.0 %

- Limiter active Active FALSE TRUE / FALSE
IeMax Limiter: [IeMax LIMITER]
- 1st limit Maximum 160.0 0 to 400.0 %
- Delay time Maximum Hold Time 10.0 0 to 327.0 s
- 2nd limit Delayed 120.0 0 to 300.0 %
- Delay time Delayed Hold Time 60.0 0 to 327.0 s
- Continuous current Continuous 105.0 0 to 150.0 %
- Limiter active Active TRUE TRUE / FALSE

value
PQ Limiter (Min Q): [PQ LIMITER]
- Q Limiter at P = 0% Minimum Q (P @ 0%) -40.0 -400.0 to -0.5 %
- Q Limiter at P = 25% Minimum Q (P @ 25%) -35.0 -400.0 to 0 %
- Voltage dependency active Voltage Dependency TRUE TRUE / FALSE
- Limiter active Active TRUE TRUE / FALSE
UM Limiter: [UM LIMITER]
- Limiting value mini. machine voltage Minimum 90.0 0 to 150.0 %
- Limiting value maxi. machine voltage Maximum 110.0 0 to 150.0 %
- Limiter low level Minimum Active TRUE TRUE / FALSE
- Limiter high level Maximum Active TRUE TRUE / FALSE
Boost: [BOOST]
- Minimum machine voltage Threshold 40.0 0 to 100.0 %
- Time boost output is active Hold Time 3.0 0 to 32.0 s
- Hysteresis Hysteresis 15.0 0 to 100.0 %
Range of Setpoints
Auto: [AUTO SETPOINT]
- Initial SP Initial 100.0 0 to 150.0 %
- Minimum value Minimum 90.0 0 to 150.0 %
- Maximum value Maximum 110.0 0 to 150.0 %
- Ramp rate Ramp Rate 0.30 0.01 to 100.00 %/s
PF: [PF SETPOINT]
- Minimum value Minimum -0.8500 -0.2500 to +0.2500
- Maximum value Maximum 0.8500 -0.2500 to +0.2500
- Ramp rate Ramp Rate 0.0050 0.0001 to 0.1000 /s
Var: [Var SETPOINT]
- Minimum value Minimum 0,0 -200.0 to +200.0 %
- Maximum value Maximum 100.0 -200.0 to +200.0 %
Manual: [MANUAL SETPOINT]
- Initial SP Initial 0.0 0 to 300.0 %
- Minimum value Minimum 0.0 0 to 50.0 %
- Maximum value Maximum 150.0 10.0 to 300.0 %
Open Loop: [OPEN LOOP SETPOINT]

- Initial SP Initial 0.0 0 to 100.0 -- %

- Minimum value Minimum 0.0 0 to 100.0 -- %
- Maximum value Maximum 100.0 10.0 to 100.0 -- %
- Ramp rate Ramp Rate 1.00 0.01 to 80.0 -- %/s
Voltage Droop Compensation Control [VDC]
- ID-Nr. Primary net Primary Net ID 1 1 to 31
- ID-Nr. Secondary net Secondary Net ID 2 1 to 31
- Ramp time Ramp Up Time 10.0 0.1 to 60.0 s

value
Digital I/Os
DIO1: [DIGITAL I/O 1]
- Input Input None DI / DO signal name
- Polarity Polarity_IN (for Input) Normal Normal / Inverted
Polarity_OUT (for Output)
- Output Output None Signal name
- Direction Direction In In / Out
Polarity_IN (for Input)
- Polarity Normal Normal / Inverted
DI5: [DIGITAL INPUT 5]
- Input Input None DI signal name
- Polarity Polarity_IN Normal Normal / Inverted

value
Assign analog input to digital signal
DI9 from +AI: [DIGITAL INPUT 9 from +AI]
DI10 from -AI: [DIGITAL INPUT 10 from -AI]
Signal name:
Digital inputs Direction = In Direction = Out Digital outputs
DIO1 to 4 DIO1 to 4
DI5 to 8
(DI9 to14)


value
Analog Inputs [ANALOG INPUT]
UM Aux:
- Minimum value UM Aux Minimum -10.0 -100.0 to +100.0 %
- Maximum value UM Aux Maximum 10.0 -100.0 to +100.0 %
Ie Ext Range:
- Minimum value Ie Ext Minimum 0.0 0 to 1000.0 A
- Maximum value Ie Ext Maximum 30.0 0 to 1000.0 A
AI1: [ANALOG INPUT 1]
- Input Input None AI signal name
- Low level Uin 0% 0.0 -10.0 to +10.0 V
- High level Uin 100% 10.0 -10.0 to +10.0 V
- Low level Uin 0% 0.0 -10.0 to +10.0 V
- Low level Uin 0% 0.0 -10.0 to +10.0 V
Analog Outputs [ANALOG OUTPUT]
AO1: - Output Output1 None AO signal name
AO2: - Output Output2 None AO signal name
- Low level Uout1 0% 0.0 -10.0 to +10.0 V
- High level Uout1 100% 10.0 -10.0 to +10.0 V
- Low level Uout2 0% 0.0 -10.0 to +10.0 V
- High level Uout2 100% 10.0 -10.0 to +10.0 V
Ie Range: Output voltage range
- Low level Ie 0% 0.0 0 to 400.0 %
- High level Ie 100% 300.0 0 to 400.0 %
Fbias Range: Offset signal
- Low level Fbias 0% -3.0 -10.0 to +10.0 Hz
- High level Fbias 100% 3.0 -10.0 to +10.0 Hz
Slip (range):
- Low level - -10.0 Fixed = (-1)*Slip 100% Hz
- High level Slip 100% 10.0 0.0 to +10.0 Hz
Active Power (range):
- Low level - 0.0 Fixed = 0 %
- High level Active Power 100% 200.0 0.0 to 200.0 %
Signal name:
Analog inputs Direction = In Direction = Out Analog outputs
AI1 to 3 AO1 to 2

value
Controller
Auto: [TUNE AUTO]
- Proportional gain Vp Proportional Gain (Vp) 20.0 1.0 to 200.0
- Derivative time constant Tb Derivation Time (Tb) 0.20 0.01 to 5.00 s
- Integral time constant Ta Integration Time (Ta) 4.00 0.01 to 20.00 s
- Reactive current influence Kq Droop (Kq) 0.0 -20.0 to +20.0 %
PF /Var /PQ Limiter: [TUNE PF/Var/PQ LIMITER]
Manual/Ie Limiter: [TUNE MANUAL/Ie LIMITER]
Communication [COMMUNICATION]
AVR-ID AVR ID 1 1 to 31
Channel Identification Channel Identification Main Main / Redundant
Synchronization [SYNCHRONIZATION]
- Voltage offset UNetoffset 0.0 -30.0 to 30.0 %
- Angle offset Angleoffset 0.0 -120.0 to 120.0 deg
- Minimum slip Min Slip 0.00 -1.00 to 0.00 Hz
- Maximum slip Max Slip -0.40 -1.00 to 0.00 Hz
- Maximum voltage difference MaxDeltaU 5.00 0 to 10.00 %
- Maximum delta angle Max Delta Angle 10 0 to 72 deg
- Total CB closing time Tot CB Close Time 90 0 to 630 ms
- SYNC DisableCBCheck SYNC_DisableCBCheck FALSE TRUE / FALSE
Diode Monitoring [DIODE MONITORING]
- Nominal exciter frequency f Exc Nominal 50 10 to 400 Hz
- Exciter time constant Tconst Exc 350 1 to 2000 ms
- Diode monitoring active Active FALSE TRUE / FALSE
- Alarm level Alarm Level 5.0 2.0 to 100.0 %
- Alarm delay Alarm Delay 10.0 2.0 to 50.0 s
- Trip level Trip Level 20.0 10.0 to 200.0 %
- Trip delay Trip Delay 0.3 0 to 50.0 s

Parameter Parameter INI-File Standar Setting range Set Unit

d value
PSS [PSS]
Active, General activation PSS_SELECT FALSE TRUE / FALSE
Wash out time constants TW1 5.0 0.0 to 30.0 s
PSS gain factor KS1 15.0 0.1 to 50.0 p.u.
Compensation factor for calculation of integral KS2 0.60 0.05 to 5.00 p.u.
of electric power
Signal matching factor KS3 1.00 0.05 to 5.00 p.u.
Lead time constants of conditioning network T1 0.10 0.02 to 6.00 s
Lag time constants of conditioning network T2 0.02 0.02 to 6.00 s
Time constant for integral of electrical power T7 5.00 0.00 to 30.00 s
Ramp tracking filter time constant T8 0.00 0.00 to 2.50 s
Ramp tracking filter time constant T9 0.10 0.00 to 2.50 s
Ramp tracking filter degree M 5 2 to 5
Ramp tracking filter degree N 1 0 to 4
Upper limit of stabilizing signal PSS max 10.0 0.0 to 25.0 %
Lower limit of stabilizing signal PSS min -10.0 0.0 to -25.0 %
Activation level for PSS functionality P min 5.0 0.0 to 50.0 %
IM Limiter [IM Limiter]
- Limiter high level IMlim_Active FALSE TRUE / FALSE
- Time Multiplier K IMlim_K 1.00 0.01 to 100.00
- Maximum IMlim_Im_th 100.0 0.0 to 150.0 %
TEMP INFLUENCE [TEMP INFLUENCE]
- T1 at Max IM IMlim_T1 50.0 -100.0 to 100.0 °
- Machine current level IMlim_Im_th2 75.0 0.0 to 150.0 %
- T2 at IM th2 IMlim_T2 60.0 -100.0 to 100.0 °
- Machine current level IMlim_Im_th3 50.0 0.0 to 150.0 %
- T3 at IM th3 IMlim_T3 70.0 -100.0 to 100.0 °
- T4 at IM = 0 A IMlim_T4 80.0 -100.0 to 100.0 °
- T1 at Max Continuous Ie IElim_T1 50.0 -100.0 to 100.0 °
- Excitation current level IElim_Ie_th2 75.0 0.0 to 150.0 %
- T2 at Ie th2 IElim_T2 60.0 -100.0 to 100.0 °
- Excitation current level IElim_Ie_th3 50.0 0.0 to 150.0 %
- T3 at Ie th3 IElim_T3 70.0 -100.0 to 100.0 °
- T4 at Ie = 0 A IElim_T4 80.0 -100.0 to 100.0 °

value
MODBUS [MODBUS]
Slave ID MB Slave 247 1 to 247
Protocol MB_Protocol 0 0 to 1
Bit rate MB_Bitrate 7 3 to 7 and 10 to 12
Character framing MB_ChrFrame 0 0 to 3
Keep-alive time MB_KeepAliveTime 0 0 to 120 s
Keep-alive actions MB_KeepAliveAction 0 0 to 3
MODBUS active MB_Enable FALSE TRUE / FALSE
Answer delay MB_Delay 10 10 to 500 (step of 10) ms


value
Double Channel [DOUBLE CHANNEL]
Redundant Channel support
- Enable DCH CAN communication CAN Enable TRUE TRUE / FALSE
- Changeover on Alarm Alarm Enable FALSE TRUE / FALSE
- Changeover on Trip Trip Enable TRUE TRUE / FALSE
- Block changeover on 2nd Ch. Alarm Changeover block at B. Alarm FALSE TRUE / FALSE
- Block changeover on 2nd Ch. Trip Changeover block at B. Trip TRUE TRUE / FALSE
Double Channel Supervision
- Enable Alarm DO during Standby Alarm(DO) at Standby TRUE TRUE / FALSE
- Enable Trip DO during Standby Trip(DO) at Standby FALSE TRUE / FALSE
Configuration Matrix for Alarm:

- UM One or two phases lost Alarm at Partial loss of UM TRUE TRUE / FALSE
- UM Loss of all phases Alarm at loss of UM TRUE TRUE / FALSE
- UM Freeze phase L1 Alarm at loss of UM phase 1 TRUE TRUE / FALSE
- Unet Freeze Alarm at loss of Unet TRUE TRUE / FALSE
- Machine current Freeze Alarm at loss of IM TRUE TRUE / FALSE
- Loss of control Alarm at loss of control TRUE TRUE / FALSE
- Loss of Excitation Alarm at loss of excitation TRUE TRUE / FALSE
- Heat sink temp. Level 1 Alarm at Temperature 1 TRUE TRUE / FALSE
- Heat sink temp. Level 2 Alarm at Temperature 2 TRUE TRUE / FALSE
- External Alarm Alarm at External Alarm TRUE TRUE / FALSE
- MODBUS Comm. Alarm Alarm at loss of Rem.Control TRUE TRUE / FALSE
- FCB Alarm Alarm at FCB TRUE TRUE / FALSE
- Diode alarm Alarm at Diode Alarm TRUE TRUE / FALSE
- Diode Trip Alarm at Diode Trip TRUE TRUE / FALSE
Configuration Matrix for Trip:

- UM One or two phases lost Trip at Partial loss of UM TRUE TRUE / FALSE
- UM Loss of all phases Trip at loss of UM TRUE TRUE / FALSE
- UM Freeze phase L1 Trip at loss of UM phase 1 TRUE TRUE / FALSE
- Unet Freeze Trip at loss of Unet TRUE TRUE / FALSE
- Machine current Freeze Trip at loss of IM TRUE TRUE / FALSE
- Loss of control Trip at loss of control TRUE TRUE / FALSE
- Loss of Excitation Trip at loss of excitation TRUE TRUE / FALSE
- Heat sink temp. Level 1 Trip at Temperature 1 FALSE TRUE / FALSE
- Heat sink temp. Level 2 Trip at Temperature 2 FALSE TRUE / FALSE
- External Alarm Trip at External Alarm FALSE TRUE / FALSE
- MODBUS Comm. Alarm Trip at loss of Rem.Control TRUE TRUE / FALSE
- FCB Alarm Trip at FCB FALSE TRUE / FALSE
- Diode alarm Trip at Diode Alarm FALSE TRUE / FALSE
- Diode Trip Trip at Diode Trip FALSE TRUE / FALSE
IMPORTANT!
Parameter values should be stored in the device's EEPROM after
configuration.
Panel: Start menu MAIN => Write EEPROM => OK => OK
CMT1000: Main Menu => File => Write Parameters to EEPROM
CMT1000 must be in Control mode.
For additional information refer to Chapter 6 - Operation.

16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.25 GE489 Generator Management Relay
Digital Energy
Multilin
489 Generator Management

Relay
Instruction Manual
Firmware Revision: 4.0X
Manual Part Number: 1601-0150-AD
Manual Order Code: GEK-106494M
Copyright © 2009 GE Multilin
GE Multilin T
GIS ERE
RE
215 Anderson Avenue, Markham, Ontario

D
ISO9001:2000
Canada L6E 1B3 EM I
G
U LT I L
Tel: (905) 294-6222 Fax: (905) 201-2098
Internet: http://www.GEindustrial.com/multilin GE Multilin's Quality Management
System is registered to
ISO9001:2000
*1601-0150-AD* QMI # 005094

UL # A3775
© 2009 GE Multilin Incorporated. All rights reserved.
GE Multilin 489 Generator Management Relay instruction manual for revision 4.0x.
489 Generator Management Relay, is a registered trademark of GE Multilin Inc.
The contents of this manual are the property of GE Multilin Inc. This documentation is
furnished on license and may not be reproduced in whole or in part without the permission
of GE Multilin. The content of this manual is for informational use only and is subject to
change without notice.
Part numbers contained in this manual are subject to change without notice, and should
therefore be verified by GE Multilin before ordering.
Part number: 1601-0150-AD (September 2009)

TOC TABLE OF CONTENTS
Table of Contents
1: GETTING STARTED IMPORTANT PROCEDURES .......................................................................................................... 1-1
CAUTIONS AND WARNINGS ............................................................................................... 1-1
INSPECTION CHECKLIST ...................................................................................................... 1-1
MANUAL ORGANIZATION ................................................................................................... 1-2
USING THE RELAY ............................................................................................................................ 1-3
MENU NAVIGATION ............................................................................................................. 1-3
PANEL KEYING EXAMPLE .................................................................................................... 1-7
CHANGING SETPOINTS ................................................................................................................. 1-9
INTRODUCTION ..................................................................................................................... 1-9
THE HELP KEY .................................................................................................................... 1-10
NUMERICAL SETPOINTS ...................................................................................................... 1-10
ENUMERATION SETPOINTS ................................................................................................. 1-11
OUTPUT RELAY SETPOINTS ................................................................................................ 1-14
TEXT SETPOINTS .................................................................................................................. 1-15
INSTALLATION ................................................................................................................................... 1-16
PLACING THE RELAY IN SERVICE ....................................................................................... 1-16
TESTING ................................................................................................................................ 1-16
2: INTRODUCTION OVERVIEW ........................................................................................................................................... 2-1

DESCRIPTION ........................................................................................................................ 2-1
ORDERING ............................................................................................................................ 2-4
OTHER ACCESSORIES .......................................................................................................... 2-5
SPECIFICATIONS ............................................................................................................................... 2-6
INPUTS .................................................................................................................................. 2-6
OUTPUTS ............................................................................................................................... 2-7
PROTECTION ......................................................................................................................... 2-8
DIGITAL INPUTS ................................................................................................................... 2-11
MONITORING ........................................................................................................................ 2-12
POWER SUPPLY ................................................................................................................... 2-13
COMMUNICATIONS .............................................................................................................. 2-14
TESTING ................................................................................................................................ 2-14
CERTIFICATION ..................................................................................................................... 2-15
PHYSICAL .............................................................................................................................. 2-15
ENVIRONMENTAL ................................................................................................................. 2-15
LONG-TERM STORAGE ........................................................................................................ 2-16
3: INSTALLATION MECHANICAL INSTALLATION ..................................................................................................... 3-1

DESCRIPTION ........................................................................................................................ 3-1
PRODUCT IDENTIFICATION .................................................................................................. 3-2
INSTALLATION ....................................................................................................................... 3-3
UNIT WITHDRAWAL AND INSERTION ................................................................................ 3-4
ETHERNET CONNECTION .................................................................................................... 3-6
TERMINAL LOCATIONS ........................................................................................................ 3-7
ELECTRICAL INSTALLATION ......................................................................................................... 3-9
TYPICAL WIRING .................................................................................................................. 3-9
GENERAL WIRING CONSIDERATIONS ................................................................................ 3-10
CONTROL POWER ................................................................................................................ 3-10
CURRENT INPUTS ................................................................................................................. 3-11
489 GENERATOR MANAGEMENT RELAY – INSTRUCTION MANUAL TOC–I

TABLE OF CONTENTS
VOLTAGE INPUTS ................................................................................................................. 3-14

DIGITAL INPUTS ................................................................................................................... 3-14
ANALOG INPUTS .................................................................................................................. 3-14
ANALOG OUTPUTS .............................................................................................................. 3-15
RTD SENSOR CONNECTIONS ............................................................................................ 3-15
OUTPUT RELAYS .................................................................................................................. 3-16
IRIG-B .................................................................................................................................. 3-17
RS485 PORTS ..................................................................................................................... 3-17
DIELECTRIC STRENGTH ....................................................................................................... 3-18
4: INTERFACES FACEPLATE INTERFACE ................................................................................................................. 4-1

DISPLAY ................................................................................................................................. 4-1
LED INDICATORS ................................................................................................................. 4-1
RS232 PROGRAM PORT .................................................................................................... 4-3
KEYPAD ................................................................................................................................. 4-3
SETPOINT ENTRY .................................................................................................................. 4-6
DIAGNOSTIC MESSAGES ..................................................................................................... 4-8
SELF-TEST WARNINGS ....................................................................................................... 4-8
FLASH MESSAGES ................................................................................................................ 4-9
ENERVISTA SOFTWARE INTERFACE ......................................................................................... 4-10
OVERVIEW ............................................................................................................................ 4-10
HARDWARE ........................................................................................................................... 4-10
INSTALLING THE ENERVISTA 489 SETUP SOFTWARE .................................................... 4-12
CONNECTING ENERVISTA 489 SETUP TO THE RELAY ...................................................... 4-15
CONFIGURING SERIAL COMMUNICATIONS ....................................................................... 4-15
USING THE QUICK CONNECT FEATURE ............................................................................ 4-16
CONFIGURING ETHERNET COMMUNICATIONS ................................................................. 4-17
CONNECTING TO THE RELAY .............................................................................................. 4-19
WORKING WITH SETPOINTS AND SETPOINT FILES ........................................................... 4-21
ENGAGING A DEVICE ........................................................................................................... 4-21
ENTERING SETPOINTS ......................................................................................................... 4-21
USING SETPOINT FILES ....................................................................................................... 4-23
UPGRADING RELAY FIRMWARE ................................................................................................. 4-30
DESCRIPTION ........................................................................................................................ 4-30
SAVING SETPOINTS TO A FILE ............................................................................................ 4-30
LOADING NEW FIRMWARE ................................................................................................. 4-30
ADVANCED ENERVISTA 489 SETUP FEATURES ................................................................... 4-33
TRIGGERED EVENTS ............................................................................................................. 4-33
WAVEFORM CAPTURE (TRACE MEMORY) ......................................................................... 4-33
PHASORS .............................................................................................................................. 4-35
TRENDING (DATA LOGGER) ................................................................................................ 4-37
EVENT RECORDER ................................................................................................................ 4-40
MODBUS USER MAP ........................................................................................................... 4-41
VIEWING ACTUAL VALUES .................................................................................................. 4-41
USING ENERVISTA VIEWPOINT WITH THE 489 ................................................................... 4-44
PLUG AND PLAY EXAMPLE ................................................................................................. 4-44
5: SETPOINTS OVERVIEW ........................................................................................................................................... 5-1

SETPOINT MESSAGE MAP ................................................................................................... 5-1
TRIPS / ALARMS/ CONTROL FEATURES ............................................................................ 5-6
RELAY ASSIGNMENT PRACTICES ........................................................................................ 5-7
DUAL SETPOINTS ................................................................................................................. 5-8
TOC–II 489 GENERATOR MANAGEMENT RELAY – INSTRUCTION MANUAL

COMMISSIONING .................................................................................................................. 5-8

S1 489 SETUP .................................................................................................................................... 5-9
PASSCODE ............................................................................................................................ 5-9
PREFERENCES ....................................................................................................................... 5-10
COMMUNICATIONS .............................................................................................................. 5-12
REAL TIME CLOCK ............................................................................................................... 5-13
DEFAULT MESSAGES ........................................................................................................... 5-14
MESSAGE SCRATCHPAD ...................................................................................................... 5-15
CLEAR DATA ......................................................................................................................... 5-16
S2 SYSTEM SETUP ............................................................................................................................ 5-18
CURRENT SENSING .............................................................................................................. 5-18
VOLTAGE SENSING .............................................................................................................. 5-18
GENERATOR PARAMETERS .................................................................................................. 5-19
SERIAL START/STOP INITIATION ........................................................................................ 5-20
S3 DIGITAL INPUTS .......................................................................................................................... 5-21
DESCRIPTION ........................................................................................................................ 5-21
BREAKER STATUS ................................................................................................................ 5-21
GENERAL INPUT A TO G ..................................................................................................... 5-22
REMOTE RESET .................................................................................................................... 5-23
TEST INPUT ........................................................................................................................... 5-23
THERMAL RESET .................................................................................................................. 5-23
DUAL SETPOINTS ................................................................................................................. 5-24
SEQUENTIAL TRIP ................................................................................................................ 5-25
FIELD-BREAKER ................................................................................................................... 5-26
TACHOMETER ....................................................................................................................... 5-26
WAVEFORM CAPTURE ......................................................................................................... 5-27
GROUND SWITCH STATUS ................................................................................................. 5-27
S4 OUTPUT RELAYS ......................................................................................................................... 5-28
DESCRIPTION ........................................................................................................................ 5-28
RELAY RESET MODE ............................................................................................................ 5-28
S5 CURRENT ELEMENTS ............................................................................................................... 5-29
INVERSE TIME OVERCURRENT CURVE CHARACTERISTICS .............................................. 5-29
OVERCURRENT ALARM ........................................................................................................ 5-33
OFFLINE OVERCURRENT ..................................................................................................... 5-33
INADVERTENT ENERGIZATION ............................................................................................ 5-34
PHASE OVERCURRENT ........................................................................................................ 5-35
NEGATIVE SEQUENCE ......................................................................................................... 5-36
GROUND OVERCURRENT .................................................................................................... 5-38
PHASE DIFFERENTIAL .......................................................................................................... 5-39
GROUND DIRECTIONAL ....................................................................................................... 5-40
HIGH-SET PHASE OC ......................................................................................................... 5-42
S6 VOLTAGE ELEMENTS ................................................................................................................ 5-43
UNDERVOLTAGE ................................................................................................................... 5-43
OVERVOLTAGE ...................................................................................................................... 5-44
VOLTS/HERTZ ...................................................................................................................... 5-45
PHASE REVERSAL ................................................................................................................. 5-48
UNDERFREQUENCY .............................................................................................................. 5-49
OVERFREQUENCY ................................................................................................................. 5-50
NEUTRAL OVERVOLTAGE .................................................................................................... 5-51
NEUTRAL UNDERVOLTAGE ................................................................................................. 5-53
LOSS OF EXCITATION .......................................................................................................... 5-55
DISTANCE ELEMENT ............................................................................................................ 5-56
S7 POWER ELEMENTS .................................................................................................................... 5-60
POWER MEASUREMENT CONVENTIONS ........................................................................... 5-60
489 GENERATOR MANAGEMENT RELAY – INSTRUCTION MANUAL TOC–III

TABLE OF CONTENTS
REACTIVE POWER ................................................................................................................ 5-61

REVERSE POWER ................................................................................................................. 5-62
LOW FORWARD POWER ..................................................................................................... 5-63
S8 RTD TEMPERATURE ................................................................................................................... 5-64
RTD TYPES ........................................................................................................................... 5-64
RTDS 1 TO 6 ....................................................................................................................... 5-65
RTDS 7 TO 10 ..................................................................................................................... 5-66
RTD 11 ................................................................................................................................ 5-67
RTD 12 ................................................................................................................................ 5-67
OPEN RTD SENSOR ............................................................................................................ 5-68
RTD SHORT/LOW TEMP .................................................................................................... 5-69
S9 THERMAL MODEL ...................................................................................................................... 5-70
489 THERMAL MODEL ....................................................................................................... 5-70
MODEL SETUP ...................................................................................................................... 5-71
THERMAL ELEMENTS ........................................................................................................... 5-89
S10 MONITORING ............................................................................................................................ 5-90
TRIP COUNTER ..................................................................................................................... 5-90
BREAKER FAILURE ............................................................................................................... 5-90
TRIP COIL MONITOR ............................................................................................................ 5-91
VT FUSE FAILURE ................................................................................................................ 5-92
DEMAND ............................................................................................................................... 5-93
PULSE OUTPUT .................................................................................................................... 5-94
RUNNING HOUR SETUP ...................................................................................................... 5-95
S11 ANALOG INPUTS/OUTPUTS ................................................................................................ 5-96
ANALOG OUTPUTS 1 TO 4 ................................................................................................. 5-96
ANALOG INPUTS 1 TO 4 ..................................................................................................... 5-98
S12 TESTING ....................................................................................................................................... 5-100
SIMULATION MODE ............................................................................................................. 5-100
PRE-FAULT SETUP ............................................................................................................... 5-101
FAULT SETUP ........................................................................................................................ 5-102
TEST OUTPUT RELAYS ......................................................................................................... 5-102
TEST ANALOG OUTPUT ....................................................................................................... 5-103
COMM PORT MONITOR ....................................................................................................... 5-104
FACTORY SERVICE ................................................................................................................ 5-104
6: ACTUAL VALUES OVERVIEW ........................................................................................................................................... 6-1

ACTUAL VALUES MAIN MENU ........................................................................................... 6-1
DESCRIPTION ........................................................................................................................ 6-3
A1 STATUS ........................................................................................................................................... 6-4
NETWORK STATUS ............................................................................................................... 6-4
GENERATOR STATUS ........................................................................................................... 6-4
LAST TRIP DATA ................................................................................................................... 6-5
ALARM STATUS .................................................................................................................... 6-6
TRIP PICKUPS ....................................................................................................................... 6-9
ALARM PICKUPS ................................................................................................................... 6-12
DIGITAL INPUTS ................................................................................................................... 6-15
REAL TIME CLOCK ............................................................................................................... 6-15
A2 METERING DATA ........................................................................................................................ 6-16
CURRENT METERING ........................................................................................................... 6-16
VOLTAGE METERING ........................................................................................................... 6-17
POWER METERING .............................................................................................................. 6-18
TEMPERATURE ...................................................................................................................... 6-19
DEMAND METERING ............................................................................................................ 6-20
TOC–IV 489 GENERATOR MANAGEMENT RELAY – INSTRUCTION MANUAL

ANALOG INPUTS .................................................................................................................. 6-20

SPEED .................................................................................................................................... 6-21
A3 LEARNED DATA .......................................................................................................................... 6-22
PARAMETER AVERAGES ....................................................................................................... 6-22
RTD MAXIMUMS ................................................................................................................. 6-22
ANALOG INPUT MIN/MAX ................................................................................................. 6-23
A4 MAINTENANCE ........................................................................................................................... 6-25
TRIP COUNTERS ................................................................................................................... 6-25
GENERAL COUNTERS .......................................................................................................... 6-27
TIMERS .................................................................................................................................. 6-27
A5 EVENT RECORDER ..................................................................................................................... 6-28
EVENT RECORDER ............................................................................................................... 6-28
A6 PRODUCT INFORMATION ...................................................................................................... 6-31
489 MODEL INFO ............................................................................................................... 6-31
CALIBRATION INFO .............................................................................................................. 6-31
DIAGNOSTICS .................................................................................................................................... 6-32
DIAGNOSTIC MESSAGES ..................................................................................................... 6-32
FLASH MESSAGES ................................................................................................................ 6-33
7: TESTING TEST SETUP ......................................................................................................................................... 7-1

DESCRIPTION ........................................................................................................................ 7-1
HARDWARE FUNCTIONAL TESTS .............................................................................................. 7-4
OUTPUT CURRENT ACCURACY .......................................................................................... 7-4
PHASE VOLTAGE INPUT ACCURACY .................................................................................. 7-4
GROUND (1 A), NEUTRAL, AND DIFFERENTIAL CURRENT ACCURACY ......................... 7-5
NEUTRAL VOLTAGE (FUNDAMENTAL) ACCURACY ........................................................... 7-6
NEGATIVE SEQUENCE CURRENT ACCURACY ................................................................... 7-6
RTD ACCURACY .................................................................................................................. 7-7
DIGITAL INPUTS AND TRIP COIL SUPERVISION ................................................................ 7-9
ANALOG INPUTS AND OUTPUTS ........................................................................................ 7-9
OUTPUT RELAYS .................................................................................................................. 7-11
ADDITIONAL FUNCTIONAL TESTS ............................................................................................. 7-12
OVERLOAD CURVE ACCURACY .......................................................................................... 7-12
POWER MEASUREMENT TEST ............................................................................................ 7-13
REACTIVE POWER ACCURACY ............................................................................................ 7-13
VOLTAGE PHASE REVERSAL ACCURACY ........................................................................... 7-14
INJECTION TEST SETUP #2 ................................................................................................ 7-15
GE MULTILIN 50:0.025 GROUND ACCURACY ............................................................... 7-15
NEUTRAL VOLTAGE (3RD HARMONIC) ACCURACY ......................................................... 7-16
PHASE DIFFERENTIAL TRIP ACCURACY ............................................................................. 7-16
INJECTION TEST SETUP #3 ................................................................................................ 7-19
VOLTAGE RESTRAINED OVERCURRENT ACCURACY ......................................................... 7-20
DISTANCE ELEMENT ACCURACY ........................................................................................ 7-21
APPENDIX STATOR GROUND FAULT .............................................................................................................. A-1

DESCRIPTION ........................................................................................................................ A-1
NEUTRAL OVERVOLTAGE ELEMENT ................................................................................... A-2
GROUND OVERCURRENT ELEMENT ................................................................................... A-3
GROUND DIRECTIONAL ELEMENT ..................................................................................... A-4
THIRD HARMONIC VOLTAGE ELEMENT ............................................................................. A-6
REFERENCES ......................................................................................................................... A-7
STATOR DIFFERENTIAL PROTECTION SPECIAL APPLICATION ...................................... A-8
489 GENERATOR MANAGEMENT RELAY – INSTRUCTION MANUAL TOC–V

TABLE OF CONTENTS
BACKGROUND ...................................................................................................................... A-8

STATOR DIFFERENTIAL LOGIC ............................................................................................ A-9
CURRENT TRANSFORMERS .......................................................................................................... A-11
GROUND FAULT CTS FOR 50:0.025 A CT .................................................................... A-11
GROUND FAULT CTS FOR 5 A SECONDARY CT ............................................................. A-13
PHASE CTS ........................................................................................................................... A-13
TIME OVERCURRENT CURVES .................................................................................................... A-15
ANSI CURVES ...................................................................................................................... A-15
DEFINITE TIME CURVES ...................................................................................................... A-19
IAC CURVES ......................................................................................................................... A-20
IEC CURVES ......................................................................................................................... A-24
REVISION HISTORY .......................................................................................................................... A-27
CHANGE NOTES ................................................................................................................... A-27
CHANGES TO THE 489 MANUAL ...................................................................................... A-27
EU DECLARATION OF CONFORMITY ........................................................................................ A-30
EU DECLARATION OF CONFORMITY ................................................................................ A-30
WARRANTY ......................................................................................................................................... A-31
GE MULTILIN WARRANTY .................................................................................................. A-31
TOC–VI 489 GENERATOR MANAGEMENT RELAY – INSTRUCTION MANUAL

Digital Energy
Multilin
489 Generator Management Relay
Chapter 1: Getting Started
Getting Started
1.1 Important Procedures
1.1.1 Cautions and Warnings

Please read this chapter to guide you through the initial setup of your new relay.
Before attempting to install or use the relay, it is imperative that all
WARNINGS and CAUTIONS in this manual are reviewed to help
WARNING prevent personal injury, equipment damage, and/or downtime.
1.1.2 Inspection Checklist

• Open the relay packaging and inspect the unit for physical damage.
• View the rear nameplate and verify that the correct model has been ordered.
• Ensure that the following items are included:
• Instruction Manual
• GE EnerVista CD (includes software and relay documentation)
• mounting screws
• For product information, instruction manual updates, and the latest software updates,
please visit the GE Multilin website at http://www.GEmultilin.com.
If there is any noticeable physical damage, or any of the contents listed are missing,
Note
please contact GE Multilin immediately.
489 GENERATOR MANAGEMENT RELAY – INSTRUCTION MANUAL 1–1

CHAPTER 1: GETTING STARTED
1.1.3 Manual Organization

Reading a lengthy instruction manual on a new product is not a task most people enjoy. To
speed things up, this introductory chapter provides guidelines for basic relay usability.
Important wiring considerations and precautions discussed in Electrical Installation on
page 3–9 should be observed for reliable operation. Detailed information regarding
accuracy, output relay contact ratings, and so forth are detailed in Specifications on page
2–6. The remainder of this manual should be read and kept for reference to ensure
maximum benefit from the 489 Generator Management Relay. For further information,
please consult your local sales representative or the factory. Comments about new
features or modifications for your specific requirements are welcome and encouraged.
Setpoints and actual values are indicated as follows in the manual:
A4 MAINTENANCE ZV TRIP COUNTERS Z TOTAL NUMBER OF TRIPS
This ‘path representation’ illustrates the location of an specific actual value or setpoint with
regards to its previous menus and sub-menus. In the example above, the TOTAL NUMBER
OF TRIPS actual value is shown to be an item in the TRIP COUNTERS sub-menu, which itself
is an item in the A4 MAINTENANCE menu, which is an item of ACTUAL VALUES.
Sub-menu levels are entered by pressing the MESSAGE X or ENTER key. When inside a
submenu, the W MESSAGE or ESCAPE key returns to the previous sub-menu. The
MESSAGE T and MESSAGE S keys are used to scroll through the settings in a sub-menu.
The display indicates which keys can be used at any given point.
1–2 489 GENERATOR MANAGEMENT RELAY – INSTRUCTION MANUAL

1.2 Using the Relay
1.2.1 Menu Navigation

The relay has three types of display messages: actual value, setpoint, and target
messages. A summary of the menu structure for setpoints and actual values can be found
at the beginning of chapters 5 and 6, respectively.
Setpoints are programmable settings entered by the user. These types of messages are
located within a menu structure that groups the information into categories. Navigating
the menu structure is described below.
Actual values include the following information:
1. Generator and System Status:
a. Generator status either online, offline, or tripped.
b. The status of digital inputs.

c. Last trip information, including values such as cause of last trip, time and date of
trip, pre-trip temperature measurements, pre-trip analog inputs values, and pre-
trip instantaneous values of power system quantities.
d. Active alarms.
e. Relay date and time.
2. Metering Data:
a. Instantaneous current measurements including phase, neutral, and ground cur-
rents.
b. Instantaneous phase to phase and phase to ground voltages (depending on the

VT connections), average voltage, and system frequency.
c. Power quantities including apparent, real and reactive power.
d. Current and power demand including peak values.
e. Analog inputs.
f. Generator speed.
g. System phasors.
h. RTD temperatures.
3. Learned Data:
a. Average magnitudes of generator load, negative-sequence current, and phase-
phase voltage.
b. RTD learned data, which includes the maximum temperature measured by each
of the twelve (12) RTDs.
c. Minimum and maximum values of analog inputs.
4. Maintenance data. This is useful statistical information that may be used for
preventive maintenance. It includes:
a. Trip counters

b. General counters such as number of breaker operations and number of thermal

resets.
c. Generator hours online timer.
5. Event recorder downloading tool.
6. Product information including model number, firmware version, additional product
information, and calibration dates.
7. Oscillography and data logger downloading tool.
Alarm, trip conditions, diagnostics, and system flash messages are grouped under Target
Messages.
Z Press the MENU key to access the header of each menu, which will
be displayed in the following sequence:
SETPOINTS [Z]
ACTUAL VALUES [Z]
TARGET MESSAGES [Z]
To access setpoints,
Z press the MENU key until the display shows the header of the
setpoints menu.
Z Press the MESSAGE X or ENTER key to display the header for the
first setpoints page.
The setpoint pages are numbered, have an ‘S’ prefix for easy
identification and have a name which provides a general idea of the
settings available in that page.
Z Press the MESSAGE T and MESSAGE S keys to scroll through all the
available setpoint page headers.
Setpoint page headers look as follows:
SETPOINTS [Z]
S1 489 SETUP
To enter a given setpoints page,

Z Press the MESSAGE X or ENTER key.
Z Press the MESSAGE T or MESSAGE S keys to scroll through sub-
page headers until the required message is reached.
The end of a page is indicated by the message END OF PAGE. The
beginning of a page is indicated by the message TOP OF PAGE.
To access actual values,

Z Press the MENU key until the display shows the header of the actual
values menu.
first actual values page.
The actual values pages are numbered, have an ‘A’ prefix for easy
identification and have a name, which gives a general idea of the
information available in that page.
Z Press the MESSAGE T or MESSAGE S keys to scroll through all the
available actual values page headers.
Actual values page headers look as follows:
ACTUAL VALUES [Z]
A1 STATUS
To enter a given actual values page,

Similarly, to access additional sub-pages,
Z Press the MESSAGE X or ENTER key to enter the first sub-page,
Z Press the MESSAGE T or MESSAGE S keys to scroll through the
available sub-pages, until the desired message is reached.
The process is identical for both setpoints and actual values.
The following procedure illustrates the key sequence to access the Current Demand actual
values.
Z Press the MENU key until you reach the actual values main menu.
ACTUAL VALUES [Z]
Z Press MESSAGE X or ENTER key to enter the first actual values

page.
Z Press the MESSAGE T or MESSAGE S key to scroll through pages,
until the A2 METERING DATA page appears.
ACTUAL VALUES [Z]
A2 METERING DATA
Z Press the MESSAGE X or ENTER key to display the first sub-page

heading for the Metering Data actual values page:
CURRENT [Z]
METERING

Pressing the MESSAGE T or MESSAGE S keys will scroll the display up and down
through the sub-page headers. Pressing the W MESSAGE or ESCAPE key at any sub-
page heading will return the display to the heading of the corresponding setpoint or
actual value page, and pressing it again, will return the display to the main menu
header.
Z Press the MESSAGE T key until the DEMAND METERING sub-page
heading appears.
DEMAND [Z]
METERING
At this point, pressing MESSAGE X or ENTER key will display the messages under this
sub-page. If instead you press the MESSAGE S key, it will return to the previous sub-
page heading. In this case,
TEMPERATURE [Z]
When the symbols and [Z] appear on the top line, it indicates that additional sub-
pages are available and can be accessed by pressing the MESSAGE X or ENTER key.
Z Press the MESSAGE X or ENTER while at the Demand Metering sub-
page heading to display the following:
CURRENT
DEMAND: 0 Amps
Z Press W MESSAGE key to return to the Demand Metering sub-page

heading.
Z Press the MESSAGE T key to display the next actual value of this
sub-page.
Actual values and setpoints messages always have a colon
separating the name of the value and the actual value or setpoint.
This particular message displays the current demand as measured
by the relay.
The menu path to the value shown above is indicated as A2 METERING DATA ZV DEMAND
METERING Z CURRENT DEMAND. Setpoints and actual values messages are referred to in
this manner throughout the manual.
For example, the A4 MAINTENANCE Z TRIP COUNTERS Z TOTAL NUMBER OF TRIPS path
representation describes the following key-press sequence:
Z Press the MENU key until the actual value header appears on the
display.
ACTUAL VALUES [Z]
Z Press MESSAGE X or the ENTER key, and then MESSAGE T key until
the A4 MAINTENANCE message is displayed.
ACTUAL VALUES [Z]
A4 MAINTENANCE

Z Press the MESSAGE X or ENTER key to display TRIP COUNTERS

message.
TRIP [Z]
COUNTERS
Z Press the MESSAGE X or ENTER key to reach the TOTAL NUMBER OF

TRIPS message and the corresponding actual value.
TOTAL NUMBER OF
TRIPS: 0
Z Press the MESSAGE T key to display the next actual value message
as shown below:
DIGITAL INPUT
TRIPS: 0
Z Press the MESSAGE T or MESSAGE S keys to scroll the display up

and down through all the actual value displays in this corresponding
sub-page.
Z Press the W MESSAGE key to reverse the process described above
and return the display to the previous level.
TRIP [Z]
COUNTERS
Z Press the W MESSAGE key twice to return to the A4 MAINTENANCE

page header.
ACTUAL VALUES [Z]
A4 MAINTENANCE
1.2.2 Panel Keying Example

The following figure provides a graphical example of how the keypad is used to navigate
through the menu structure. Specific locations are referred to throughout this manual by
using a ‘path representation’. The example shown in the figure gives the key presses
required to read the average negative-sequence current denoted by the path A3 LEARNED
DATA Z PARAMETER AVERAGES ZV AVERAGE NEG. SEQ. CURRENT.
Z Press the menu key until the relay displays the actual values page.

ACTUAL VALUES [Z]
Press the MESSAGE or ENTER key
ACTUAL VALUES [Z]

A1 STATUS
Press the MESSAGE key
ACTUAL VALUES [Z]

A2 METERING DATA
Press the MESSAGE key
ACTUAL VALUES [Z] PARAMETER [Z] AVERAGE GENERATOR

MESSAGE MESSAGE
A3 LEARNED DATA AVERAGES LOAD: 100% FLA
AVERAGE NEG. SEQ.
MESSAGE
CURRENT: 0% FLA

1.3 Changing Setpoints
1.3.1 Introduction
There are several classes of setpoints, each distinguished by the way their values are
displayed and edited.
The relay's menu is arranged in a tree structure. Each setting in the menu is referred to as a
setpoint, and each setpoint in the menu may be accessed as described in the previous
section.
The settings are arranged in pages with each page containing related settings; for
example, all the Phase Overcurrent settings are contained within the same page. As
previously explained, the top menu page of each setting group describes the settings
contained within that page. Pressing the MESSAGE keys allows the user to move between
these top menus.
All of the 489 settings fall into one of following categories: device settings, system settings,
digital input settings, output relay settings, current element settings, voltage element
settings, power element settings, RTD temperature settings, thermal model settings,
monitoring settings, analog input/output settings, and testing settings.
IMPORTANT NOTE: Settings are stored and used by the relay immediately after they are
Note
entered. As such, caution must be exercised when entering settings while the relay is in
service. Modifying or storing protection settings is not recommended when the relay is
in service since any incompatibility or lack of coordination with other previously saved
settings may cause unwanted operations.
Now that we have become more familiar with maneuvering through messages, we can
learn how to edit the values used by all setpoint classes.
Hardware and passcode security features are designed to provide protection against
unauthorized setpoint changes. Since we will be programming new setpoints using the
front panel keys, a hardware jumper must be installed across the setpoint access terminals
(C1 and C2) on the back of the relay case. Attempts to enter a new setpoint without this
electrical connection will result in an error message.
The jumper does not restrict setpoint access via serial communications. The relay has a
programmable passcode setpoint, which may be used to disallow setpoint changes from
both the front panel and the serial communications ports. This passcode consists of up to
eight (8) alphanumeric characters.
The factory default passcode is “0”. When this specific value is programmed into the relay it
has the effect of removing all setpoint modification restrictions. Therefore, only the
setpoint access jumper can be used to restrict setpoint access via the front panel and
there are no restrictions via the communications ports.
When the passcode is programmed to any other value, setpoint access is restricted for the
front panel and all communications ports. Access is not permitted until the passcode is
entered via the keypad or is programmed into a specific register (via communications).
Note that enabling setpoint access on one interface does not automatically enable access
for any of the other interfaces (i.e., the passcode must be explicitly set in the relay via the
interface from which access is desired).

A front panel command can disable setpoint access once all modifications are complete.
For the communications ports, writing an invalid passcode into the register previously
used to enable setpoint access disables access. In addition, setpoint access is
automatically disabled on an interface if no activity is detected for thirty minutes.
The EnerVista 489 Setup software incorporates a facility for programming the relay
passcode as well as enabling and disabling setpoint access. For example, when an
attempt is made to modify a setpoint but access is restricted, the software will prompt the
user to enter the passcode and send it to the relay before the setpoint is actually written to
the relay. If a SCADA system is used for relay programming, it is the programmer's
responsibility to incorporate appropriate security for the application.
1.3.2 The HELP Key

Pressing the HELP key displays context-sensitive information about setpoints such as the
range of values and the method of changing the setpoint. Help messages will
automatically scroll through all messages currently appropriate.
1.3.3 Numerical Setpoints

Each numerical setpoint has its own minimum, maximum, and step value. These
parameters define the acceptable setpoint value range. Two methods of editing and
storing a numerical setpoint value are available.
The first method uses the 489 numeric keypad in the same way as any electronic
calculator. A number is entered one digit at a time with the 0 to 9 and decimal keys. The
left-most digit is entered first and the right-most digit is entered last. Pressing ESCAPE
before the ENTER key returns the original value to the display.
The second method uses the VALUE S key to increment the displayed value by the step
value, up to a maximum allowed value. Likewise, the VALUE T key decrements the
displayed value by the step value, down to a minimum value. For example:
Z Select the S1 489 SETUP ZV PREFERENCES ZV DEFAULT MESSAGE
TIMEOUT setpoint message.
DEFAULT MESSAGE
TIMEOUT: 300 s
Z Press the 1, 2, and 0 keys. The display message will change as

shown.
DEFAULT MESSAGE
TIMEOUT: 120 s
Until the ENTER key is pressed, editing changes are not registered by the relay.
Therefore,

Z Press the ENTER key to store the new value in memory.

The following message will momentarily appear as confirmation of
the storing process.
NEW SETPOINT HAS
BEEN STORED
1.3.4 Enumeration Setpoints

The example shown in the following figures illustrates the keypress sequences required to
enter system parameters such as the phase CT primary rating, ground CT primary rating,
bus VT connection type, secondary voltage, and VT ratio.
The following values will be entered:
Phase CT primary rating: 600 A
Ground CT type: 1 A secondary
Ground CT ratio: 200:1
Neutral Voltage Transformer: None
Voltage Transformer Connection Type: Open Delta
VT Ratio: 115:1
To set the phase CT primary rating, modify the S2 SYSTEM SETUP Z CURRENT SENSING Z
PHASE CT PRIMARY setpoint as shown below.
Z Press the MENU key until the relay displays the setpoints menu
header.
SETPOINTS [Z]
Press MESSAGE X or ENTER

SETPOINTS [Z]
S1 489 SETUP
Press MESSAGE T
SETPOINTS [Z] Press CURRENT [Z] Press PHASE CT PRIMARY:
S2 SYSTEM SETUP MESSAGE X SENSING MESSAGE X -------------
or ENTER or ENTER
Press the VALUE keys until 600 A is displayed, PHASE CT PRIMARY:
or enter the value directly via the numeric 600 A
keypad.
NEW SETPOINT HAS
Press the ENTER key to store the setpoint.
BEEN STORED
To select the Ground CT type, modify the S2 SYSTEM SETUP Z CURRENT SENSING ZV GROUND
CT setpoint as shown below.
header.

SETPOINTS [Z]

SETPOINTS [Z]
S1 489 SETUP
Press MESSAGE T
S2 SYSTEM SETUP MESSAGE X SENSING MESSAGE X 600 A
or ENTER or ENTER
Press GROUND CT:
MESSAGE T 50:0.025
Press the VALUE keys until GROUND CT:

“1 A Secondary” is displayed. 1 A Secondary
NEW SETPOINT HAS

BEEN STORED

To set the ground CT ratio, modify the S2 SYSTEM SETUP Z CURRENT SENSING ZV GROUND
CT RATIO setpoint as shown below.
header.
SETPOINTS [Z]

SETPOINTS [Z]
S1 489 SETUP
Press MESSAGE T
S2 SYSTEM SETUP MESSAGE X SENSING MESSAGE X 600 A
or ENTER or ENTER
Press GROUND CT:
MESSAGE T 1 A Secondary
Press GROUND CT RATIO:

MESSAGE T 100: 1
Press the VALUE keys until 200: 1 is displayed, GROUND CT RATIO:

or enter the value directly via the numeric 200: 1
keypad.
NEW SETPOINT HAS
BEEN STORED
To set the VT connection type and ratings, modify the S2 SYSTEM SETUP ZV VOLTAGE
SENSING ZV VT CONNECTION TYPE and the S2 SYSTEM SETUP ZV VOLTAGE SENSING ZV
VOLTAGE TRANSFORMER RATIO setpoints as shown below.
header.
SETPOINTS [Z]

SETPOINTS [Z]
S1 489 SETUP
Press MESSAGE T
SETPOINTS [Z] Press CURRENT [Z]
S2 SYSTEM SETUP MESSAGE X SENSING
or ENTER
Press VOLTAGE [Z] Press VT CONNECTION TYPE:
MESSAGE T SENSING MESSAGE X None
or ENTER
Press the VALUE keys until VT CONNECTION TYPE:
“Open Delta” is displayed. Open Delta
NEW SETPOINT HAS

BEEN STORED

Press VOLTAGE TRANSFORMER

MESSAGE T RATIO: 5.00: 1
Press the VALUE keys until 115.00 : 1 is VOLTAGE TRANSFORMER

displayed, or enter the value directly via the RATIO: 115.0: 1
numeric keypad.
NEW SETPOINT HAS
BEEN STORED
If an entered setpoint value is out of range, the relay displays a message with the following
format:
OUT-OF-RANGE! ENTER: “1-300:1” indicates the range and “0.01:1” indicates the
1-300:1 by 0.01:1 step value
In this case, 1 is the minimum setpoint value, 300 is the maximum, and 0.01 is the step
value. To have access to information on maximum, minimum, and step value, press the
HELP key.
1.3.5 Output Relay Setpoints

The output relays 1 Trip and 5 Alarm can be associated to auxiliary relays 2 to 4. Each can
be selected individually, or in combination, in response to customer specific requirements.
These relays are initiated through the ASSIGN ALARM RELAYS or ASSIGN TRIP RELAYS
setpoints specific to a protection element or function.
Z Select the S6 VOLTAGE ELEMENTS Z UNDERVOLTAGE ZV ASSIGN TRIP
RELAYS (1-4) setpoint message.
ASSIGN TRIP
RELAYS (1-4): 1---
If an application requires the undervoltage protection element to trip the 3 Auxiliary

relay,
Z Select this output relay by pressing the “3” key; pressing the “3” key
again disables the 3 Auxiliary relay.
Enable/disable relays 1, 3, and 4 in the same manner until the
desired combination appear in the display.
ASSIGN TRIP
RELAYS (1-4): --3-
Z Press the ENTER key to store this change into memory.

As before, confirmation of this action will momentarily flash on the
display.
NEW SETPOINT HAS
BEEN STORED

1.3.6 Text Setpoints

Text setpoints have data values, which are fixed in length, but user defined in character.
They may be comprised of uppercase letters, lowercase letters, numerals, and a selection
of special characters. The editing and storing of a text value is accomplished with the use
of the decimal [.], VALUE, and ENTER keys.
For example:
Z Move to the S3 DIGITAL INPUTS Z GENERAL INPUT A ZV INPUT NAME
message:
INPUT NAME:
Input A
The name of this user-defined input will be changed in this example from the generic
“Input A” to something more descriptive.
If an application is to be using the relay as a station monitor, it is more informative to
rename this input “Stn. Monitor”.
Z Press the decimal [.] key to enter the text editing mode. The first
character will appear underlined as follows:
INPUT NAME:
Input A
Z Press the VALUE keys until the character “S” is displayed in the first
position.
Z Press the decimal [.] key to store the character and advance the
cursor to the next position.
Z Change the second character to a “t” in the same manner.
Z Continue entering characters in this way until all characters of the
text “Stn. Monitor” are entered.
Note that a space is selected like a character. If a character is
entered incorrectly, press the decimal [.] key repeatedly until the
cursor returns to the position of the error. Re-enter the character as
required.
Z Once complete, press the ENTER key to remove the solid cursor and
view the result.
Once a character is entered, by pressing the ENTER key, it is
automatically saved in flash memory, as a new setpoint.
INPUT NAME:
Stn. Monitor

1.4 Installation
1.4.1 Placing the Relay in Service

The relay is defaulted to the Not Ready state when it leaves the factory. A minor self-test
warning message informs the user that the 489 Generator Management Relay has not yet
been programmed. If this warning is ignored, protection will be active using factory default
setpoints and the Relay In Service LED Indicator will be on.
1.4.2 Testing
Extensive commissioning tests are available in Chapter 7. Tables for recording required
settings are available in Microsoft Excel format from the GE Multilin website at http://
www.GEmultilin.com. The website also contains additional technical papers and FAQs
relevant to the 489 Generator Management Relay.

Digital Energy
Multilin
Chapter 2: Introduction
Introduction
2.1 Overview
2.1.1 Description
The 489 Generator Management Relay is a microprocessor-based relay designed for the
protection and management of synchronous and induction generators. The 489 is
equipped with 6 output relays for trips and alarms. Generator protection, fault diagnostics,
power metering, and RTU functions are integrated into one economical drawout package.
The single line diagram illustrates the 489 functionality using ANSI (American National
Standards Institute) device numbers.

CHAPTER 2: INTRODUCTION
489
s
ronou
52 Trip Coil
tion
Supervision
Synch
Induc
27
12 overspeed 47
21 distance
59
24 volts/hertz
27 undervoltage 810
50/27 inadvertent generator energization
81U
32 reverse power/low forward power 40
38 bearing overtemperature (RTD) 24
39 bearing vibration (analog inputs) 21
40 loss of excitation (impedance) 32
loss of field (reactive power) 38
40Q 41
2
negative sequence overcurrent (I 2 t)
40Q
46 GENERATOR 12
47 voltage phase reversal 50/27
49 stator thermal (RTD/thermal model) 49
51V
50 high-set phase overcurrent 39
50BF breaker failure detection 60FL
50 offline overcurrent 76 Output
46 relays
50/51GN ground overcurrent
51V voltage restrained phase overcurrent 49 6 Output
86 relays
59 overvoltage
50BF
59GN/27TN 100% stator ground
60FL VT fuse failure 50 87G
67 ground directional RS232
76 overexcitation (analog input) RS485
81 overfrequency/underfrequency 67 50/51GN RS485
86 electrical lockout Analog
+ 4
87G percentage differential
59GN 27TN
- outputs
sequential tripping logic +
-
4 Analog
inputs
trip coil supervision
generator running hours alarm
808783E8.CDR
FIGURE 2–1: Single Line Diagram
Fault diagnostics are provided through pretrip data, event record, waveform capture, and
statistics. Prior to issuing a trip, the 489 takes a snapshot of the measured parameters and
stores them in a record with the cause of the trip. This pre-trip data may be viewed using
the NEXT key before the trip is reset, or by accessing the last trip data in actual values
page 1. The event recorder stores a maximum of 256 time and date stamped events
including the pre-trip data. Every time a trip occurs, the 489 stores a 16 cycle trace for all
measured AC quantities. Trip counters record the number of occurrences of each type of
trip. Minimum and maximum values for RTDs and analog inputs are also recorded. These
features allow the operator to pinpoint a problem quickly and with certainty.
A complete list protection features is shown below:

Table 2–1: Trip and Alarm Protection Features
Trip Protection Alarm Protection

7 assignable digital inputs: general input
Seven (7) Assignable Digital Inputs: and tachometer
General Input, Sequential Trip (low
forward power or reverse power), Field- Overload
Breaker discrepancy, and Tachometer
Negative Sequence
Offline Overcurrent (protection during
Ground Overcurrent
startup)
Inadvertent Energization Ground Directional
Phase Overcurrent with Voltage Restraint Undervoltage
Negative-Sequence Overcurrent Overvoltage
Ground Overcurrent Volts Per Hertz
Percentage Phase Differential Underfrequency
Ground Directional Overfrequency
High-Set Phase Overcurrent Neutral Overvoltage (Fundamental)
Undervoltage Neutral Undervoltage (3rd Harmonic)
Overvoltage Reactive Power (kvar)
Volts Per Hertz Reverse Power
Voltage Phase Reversal Low Forward Power
Underfrequency (two step) RTD: Stator, Bearing, Ambient, Other
Overfrequency (two step) Short/Low RTD
Neutral Overvoltage (Fundamental) Open RTD
Neutral Undervoltage (3rd Harmonic) Thermal Overload
Loss of Excitation (2 impedance circles) Trip Counter
Distance Element (2 zones of protection) Breaker Failure
Reactive Power (kvar) for loss of field Trip Coil Monitor
Reverse Power for anti-motoring VT Fuse Failure
Low Forward Power Demand: Current, MW, Mvar, MVA
RTDs: Stator, Bearing, Ambient, Other Generator Running Hours
Thermal Overload Analog Inputs 1 to 4
Analog Inputs 1 to 4 Service (Self-Test Failure)
Electrical Lockout IRIG-B Failure
The following protection elements require neutral-end current inputs.

Note
• Distance Element
• Offline Overcurrent
• Phase Differential

Power metering is a standard feature in the 489. The table below outlines the metered
parameters available to the operator through the front panel and communications ports.
The 489 is equipped with three independent communications ports. The front panel RS232
port may be used for setpoint programming, local interrogation or control, and firmware
upgrades. The computer RS485 port may be connected to a PLC, DCS, or PC based
interface software. The auxiliary RS485 port may be used for redundancy or simultaneous
interrogation and/or control from a second PLC, DCS, or PC program. There are also four
4 to 20 mA transducer outputs that may be assigned to any measured parameter. The
range of these outputs is scalable. Additional features are outlined below.
Table 2–2: Metering and Additional Features
Metering Additional Features
Voltage (phasors) Drawout Case (maintenance and testing)
Current (phasors) and Amps Demand Breaker Failure
Real Power, MW Demand, MWh Trip Coil Supervision
Apparent Power and MVA demand VT Fuse Failure
MW, Mvar, and ±MVarh demand Simulation
Flash Memory for easy firmware

Frequency
upgrades
Power Factor
RTD
Speed in RPM with a Key Phasor Input
User-Programmable Analog Inputs
2.1.2 Ordering
All features of the 489 are standard, there are no options. The phase CT secondaries,
control power, and analog output range must be specified at the time of order. There are
two ground CT inputs: one for a 50:0.025 CT and one for a ground CT with a 1 A secondary
(may also accommodate a 5 A secondary). The VT inputs accommodate VTs in either a
delta or wye configuration. The output relays are always non-failsafe with the exception of
the service relay. The EnerVista 489 Setup software is provided with each unit. A metal
demo case may be ordered for demonstration or testing purposes.

Table 2–3: 489 Order Codes

489 – * – * – * – * – *
Base unit 489 | | | | | 489 Generator Management Relay
P1 | | | | 1 A phase CT secondaries
Phase current inputs
P5 | | | | 5 A phase CT secondaries
| | | 20 to 60 V DC;
LO
| | | 20 to 48 V AC at 48 to 62 Hz
Control power
| | | 90 to 300 V DC;
HI
| | | 70 to 265 V AC at 48 to 62 Hz
A1 | | 0 to 1 mA analog outputs
Analog outputs
A20 | | 4 to 20 mA analog outputs
| | Basic display
Display E | Enhanced display, larger LCD
T | Enhanced with Ethernet (10Base-T)
Harsh (chemical) environment conformal
Harsh environment H
coating
For example, the 489-P1-LO-A20-E code specifies a 489 Generator Management Relay
with 1 A CT inputs, 20 to 60 V DC or 20 to 48 V AC control voltage, 4 to 20 mA analog
outputs, and an enhanced display.
2.1.3 Other Accessories

Additional 489 accessories are listed below.
• EnerVista 489 Setup software: no-charge software provided with the 489
• SR 19-1 PANEL: single cutout for 19” panel
• SR 19-2 PANEL: double cutout for 19” panel
• SCI MODULE: RS232 to RS485 converter box, designed for harsh industrial
environments
• Phase CT: 50, 75, 100, 150, 200, 250, 300, 350, 400, 500, 600, 750, 1000 phase CT
primaries
• HGF3, HGF5, HGF8: For sensitive ground detection on high resistance grounded
systems
• 489 1 3/8-inch Collar: For shallow switchgear, reduces the depth of the relay by 1
3/8 inches
• 489 3-inch Collar: For shallow switchgear, reduces the depth of the relay by 3
inches

2.2 Specifications
2.2.1 Inputs
ANALOG CURRENT INPUTS

Inputs: ..................................................................0 to 1 mA, 0 to 20 mA, 4 to 20mA (setpoint)
Input impedance: ..........................................226 Ω ±10%
Conversion range: .........................................0 to 20 mA
Accuracy:............................................................±1% of full scale
Type: .....................................................................Passive
Analog input supply: ....................................+24 V DC at 100 mA max.
Sampling Interval: .........................................50 ms
ANALOG INPUTS FREQUENCY TRACKING
Frequency tracking: Va for wye, Vab for open delta; 6 V minimum, 10 Hz/s
DIGITAL INPUTS
Inputs: 9 opto-isolated inputs
External switch: dry contact < 400 Ω, or open collector NPN transistor from
sensor. 6 mA sinking from internal 4K pull-up at 24 V DC with Vce < 4 V DC
489 sensor supply: 24 V DC at 20 mA max.
GROUND CURRENT INPUT
CT primary: 10 to 10000 A (1 A / 5 A CTs)
CT secondary: .................................................1 A / 5 A or 50:0.025 (HGF CTs)
Conversion range: 0.02 to 20 × CT for 1A/5A CTs
0.0 to 100 A primary for 50:0.025 CTs (HGF)
50:0.025 CT accuracy: ±0.1 A at < 10 A
±1.0 A at ≥ 10 to 100 A
1 A / 5 A CT accuracy: at < 2 × CT: ±0.5% of 2 × CT
at ≥ 2 × CT: ±1% of 20 × CT
GROUND CT BURDEN
Ground CT Input Burden
VA Ω
1A 0.024 0.024
1A/5A 5A 0.605 0.024
20 A 9.809 0.024
0.025 A 0.057 90.7
50:0.025 HGF 0.1 A 0.634 90.7
0.5 A 18.9 75.6
GROUND CT CURRENT WITHSTAND (SECONDARY)

Ground CT Withstand Time
1 sec. 2 sec. continuo
us
1A/5A 80 × CT 40 × CT 3 × CT
50:0.025 HGF N/A N/A 150 mA
NEUTRAL VOLTAGE INPUT

VT ratio: 1.00 to 240.00:1 in steps of 0.01
VT secondary: 100 V AC (full-scale)
Conversion range: 0.005 to 1.00 × Full Scale
Accuracy:............................................................Fundamental:+/-0.5% of Full Scale
3rd Harmonic at >3V secondary: +/-5% of reading
3rd Harmonic at < 3V secondary: +/- 0.15% of full scale

Max. continuous: 280 V AC

OUTPUT AND NEUTRAL END CURRENT INPUTS
CT primary: 10 to 50000 A
CT secondary: 1 A or 5 A (specify with order)
Conversion range: 0.02 to 20 × CT
Accuracy: at < 2 × CT: ±0.5% of 2 × CT
at ≥ 2 × CT: ±1% of 20 × CT
Burden: Less than 0.2 VA at rated load
CT withstand: 1 s at 80 × rated current
2 s at 40 × rated current
continuous at 3 × rated current
PHASE VOLTAGE INPUTS
VT ratio: 1.00 to 300.00:1 in steps of 0.01
VT secondary: 200 V AC (full-scale)
Conversion range: 0.02 to 1.00 × full-scale
Accuracy: ±0.5% of full-scale
Max. continuous: 280 V AC
Burden: > 500 KΩ
RTD INPUTS
RTDs (3-wire type): 100 Ω Platinum (DIN.43760)
100 Ω Nickel, 120 Ω Nickel,
10 Ω Copper
RTD sensing current: 5 mA
Isolation: 36 Vpk (isolated with analog inputs and outputs)
Range: –50 to +250°C
Accuracy: ±2°C/±4°F for Pt and Ni
±5°C/±9°F for Cu
Lead resistance: 25 Ω max. per lead (Pt and Ni types); 3 Ω max. per lead (Cu type)
NO sensor: >1 kΩ
Short/low alarm: <–50°C
2.2.2 Outputs
ANALOG CURRENT OUTPUT
Type: Active
Range: 4 to 20mA, 0 to 1 mA
(must be specified with order)
Accuracy: ±1% of full scale
4 to 20 mA max. load: 1.2 kΩ
0 to 1 mA max. load: 10 kΩ
Isolation: 36 Vpk (isolated with RTDs and analog inputs)
4 assignable outputs: phase A, B, C output current, three-phase average current,
negative sequence current, generator load, hottest stator RTD, hottest
bearing RTD, RTDs 1 to 12, voltage (AB, BC, and CA), average phase-phase
voltage, volts/hertz, frequency, third harmonic neutral voltage, power (3-
phase Mvar, MW, and MVA), power factor, analog inputs 1 to 4, tachometer,
thermal capacity used, demand (I, Mvar, MW, and MVA), torque
PULSE OUTPUT
Parameters: + kwh, +kvarh, –kvarh
Interval: 1 to 50000 in steps of 1
Pulse width: 200 to 1000 ms in steps of 1

RELAYS
Relay contacts must be considered unsafe to touch when the relay is energized! If the
output relay contacts are required for low voltage accessible applications, it is the
customer's responsibility to ensure proper insulation levels.
Configuration: 6 electromechanical Form-C relays

Contact material: silver alloy
Operate time: 10 ms
Make/carry: 30 A for 0.2 s,
10 A continuous (for 100000 operations)
Maximum ratings for 100000 operations:
Voltage Break Max. Load
30 V 10 A 300 W
DC Resistive 125 V 0.5 A 62.5 W
250 V 0.3 A 75 W
30 V 5A 150 W
DC inductive
125 V 0.25 A 31.3 W
L/R = 40 ms
250 V 0.15 A 37.5 W
120 V 10 A 2770 VA
AC Resistive
250 V 10 A 2770 VA
AC Inductive PF 120 V 4A 480 VA

= 0.4 250 V 3A 750 VA
2.2.3 Protection
PHASE DISTANCE (IMPEDANCE)
Characteristics: offset mho
Reach (secondary Ω): 0.1 to 500.0 Ω in steps of 0.1
Reach accuracy: ±5%
Characteristic angle: 50 to 85° in steps of 1
Time delay: 0.15 to 150.0 s in steps of 0.1
Timing accuracy: ±50 ms or ±0.5% of total time
Number of zones: 2
GROUND DIRECTIONAL
Pickup level: 0.05 to 20.00 × CT in steps of 0.01
Pickup accuracy: as per phase current inputs
Elements: Trip and Alarm
GROUND OVERCURRENT
Curve shapes: ANSI, IEC, IAC, Flexcurve, Definite Time
Pickup accuracy: as per ground current input
Timing accuracy: +50 ms at 50/60 Hz or ±0.5% total time
Elements: Trip
HIGH-SET PHASE OVERCURRENT

Timing accuracy: ±50 ms at 50/60 Hz or ±0.5% total time

Elements: Trip
INADVERTENT ENERGIZATION
Arming signal: undervoltage and/or offline from breaker status
Pickup level: 0.05 to 3.00 × CT in steps of 0.01 of any one phase
Time delay: no intentional delay
Timing accuracy: +50 ms at 50/60 Hz
Elements: Trip
LOSS OF EXCITATION (IMPEDANCE)
Pickup level: 2.5 to 300.0 Ω secondary in steps of 0.1 with adjustable
impedance offset 1.0 to 300.0 Ω secondary in steps of 0.1
Pickup accuracy: as per voltage and phase current inputs
Elements: Trip (2 zones using impedance circles)
NEGATIVE SEQUENCE OVERCURRENT
Pickup level: 3 to 100% FLA in steps of 1
Curve shapes: I22t trip defined by k, definite time alarm
Timing accuracy: ±100ms or ± 0.5% of total time
NEUTRAL OVERVOLTAGE (FUNDAMENTAL)
Pickup level: 2.0 to 100.0 V secondary in steps of 0.01
Pickup accuracy: as per neutral voltage input
NEUTRAL UNDERVOLTAGE
(3RD HARMONIC)
Blocking signals: low power and low voltage if open delta
Pickup level: 0.5 to 20.0 V secondary in steps of 0.01 if open delta VT;
adaptive if wye VT
Time delay: 5 to 120 s in steps of 1
Pickup accuracy: as per Neutral Voltage Input
Timing accuracy: ±3.0 s
OFFLINE OVERCURRENT
Time delay: 3 to 99 cycles in steps of 1
Timing accuracy: +50ms at 50/60 Hz
Elements: Trip
OTHER FEATURES
Serial Start/Stop Initiation, Remote Reset (configurable digital input), Test Input
(configurable digital input), Thermal Reset (configurable digital input), Dual
Setpoints, Pre-Trip Data, Event Recorder, Waveform Memory, Fault
Simulation, VT Failure, Trip Counter, Breaker Failure, Trip Coil Monitor,
Generator Running Hours Alarm, IRIG-B Failure Alarm
OVERCURRENT ALARM
Pickup level: 0.10 to 1.50 × FLA in steps of 0.01 (average phase current)


Elements: Alarm
OVERFREQUENCY
Required voltage: 0.50 to 0.99 × rated voltage in Phase A
Block from online: 0 to 5 sec. in steps of 1
Pickup level: 25.01 to 70.00 in steps of 0.01
Curve shapes: 1 level alarm, 2 level trip definite time
Pickup accuracy: ±0.02 Hz
Timing accuracy: ±150 ms or ±1% of total time at 50Hz and 60Hz; ±300 ms or 2%
of total time at 25Hz
OVERLOAD / STALL PROTECTION / THERMAL MODEL
Overload curves:
15 Standard Overload Curves, Custom Curve, and Voltage Dependent
Custom Curve (all curves time out against average phase current)
Curve biasing: Phase Unbalance, Hot/Cold Curve Ratio, Stator RTD, Online
Cooling Rate, Offline Cooling Rate, Line Voltage
Overload pickup: 1.01 to 1.25
Timing accuracy: ±100 ms or ±2% of total time
OVERVOLTAGE
Pickup level: 1.01 to 1.50 × rated V in steps of 0.01
Curve shapes: Inverse Time, definite time alarm
Time Delay: 0.2 to 120.0 s in steps of 0.1
Pickup accuracy: as per Voltage Inputs
PHASE DIFFERENTIAL
Curve shape: Dual Slope
Time delay: 0 to 100 cycles in steps of 1
Elements: Trip
PHASE OVERCURRENT
Voltage restraint: programmable fixed characteristic
Curve shapes: ANSI, IEC, IAC, FlexCurve, Definite Time
Elements: Trip
RTDS 1 TO 12
Pickup: 1 to 250°C in steps of 1
Pickup hysteresis: 2°C
Time delay: 3 sec.

UNDERFREQUENCY
Required voltage: 0.50 to 0.99 × rated voltage in Phase A
Block from online: 0 to 5 sec. in steps of 1
Pickup level: 20.00 to 60.00 in steps of 0.01
Curve shapes: 1 level alarm, two level trip definite time
Time delay: 0.1 to 5000.0 sec. in steps of 0.1
Pickup accuracy: ±0.02 Hz
Timing accuracy: ±150 ms or ±1% of total time at 50Hz and 60Hz; ±300 ms or 2%
of total time at 25Hz
UNDERVOLTAGE
Pickup level: 0.50 to 0.99 × rated V in steps of 0.01
Time Delay: 0.2 to 120.0 s in steps of 0.1
Pickup accuracy: as per voltage inputs
VOLTAGE PHASE REVERSAL
Configuration: ABC or ACB phase rotation
Timing accuracy: 200 to 400 ms
Elements: Trip
VOLTS PER HERTZ
Pickup level: 1.00 to 1.99 × nominal in steps of 0.01
Pickup accuracy: as per voltage inputs
Timing accuracy: ±100 ms at ≥ 1.2 × Pickup
±300 ms at < 1.2 × Pickup

FIELD BREAKER DISCREPANCY
Configurable: assignable to Digital Inputs 1 to 7
Elements: Trip

GENERAL INPUT A TO G
Configurable: ssignable Digital Inputs 1 to 7
Block from online: 0 to 5000 s in steps of 1
Elements: Trip, Alarm, and Control
SEQUENTIAL TRIP
Pickup level: 0.02 to 0.99 × rated MW in steps of 0.01, Low Forward Power /
Reverse Power
Pickup accuracy: see power metering
Elements: Trip
TACHOMETER
RPM measurement: 0 to 7200 RPM
Duty cycle of pulse: >10%
Pickup level: 101 to 175 × rated speed in steps of 1
Time delay: 1 to 250 s in steps of 1
Timing accuracy: ±0.5 s or ±0.5% of total time
2.2.5 Monitoring
DEMAND METERING
Metered values: maximum phase current,
3 phase real power,
3 phase apparent power,
3 phase reactive power
Measurement type: rolling demand
Demand interval: 5 to 90 min. in steps of 1
Update rate: 1 minute
Elements: Alarm
ENERGY METERING
Description: continuous total of +watthours and ±varhours
Range: 0.000 to 4000000.000 Mvarh
Timing accuracy: ±0.5%
Update Rate: 50 ms
LOW FORWARD POWER
Pickup level: 0.02 to 0.99 × rated MW

POWER METERING
Range: -2000.000 to 2000.000 MW,
–2000.000 to 2000.000 Mvar,
0 to 2000.000 MVA
Accuracy at Iavg < 2 × CT: ±1% of 3 × 2 × CT × VTratio × VTfull-scale
Accuracy at Iavg > 2 × CT: ±1.5% of 3 × 20 × CT × VTratio × VTfull-scale
REACTIVE POWER
Pickup level: 0.02 to 1.50 × rated Mvar
(positive and negative)
Timing accuracy: ±100ms or ±0.5% of total time
REVERSE POWER
Pickup level: 0.02 to 0.99 × rated MW
TRIP COIL SUPERVISION
Applicable voltage: 20 to 300 V DC/AC
Trickle current: 2 to 5 mA
2.2.6 Power Supply

CONTROL POWER
Options: LO / HI (specify with order)
LO range: 20 to 60 V DC
20 to 48 V AC at 48 to 62 Hz
HI range: 90 to 300 V DC
70 to 265 V AC at 48 to 62 Hz
Power: 45 VA (max.), 25 VA typical
Total loss of voltage ride through time (0% control power): 16.7 ms
It is recommended that the 489 be powered up at least once per year to prevent
deterioration of electrolytic capacitors in the power supply.
FUSE
Current rating: 2.5 A
Type: 5x20mm HRC SLO-BLO Littelfuse
Model: 215-02.5
An external fuse must be used if the supply voltage exceeds 250 V

2.2.7 Communications
COMMUNICATIONS PORTS
RS232 port: 1, front panel, non-isolated
RS485 ports: 2, isolated together at 36 Vpk
RS485 baud rates: 300, 1200, 2400, 4800, 9600, 19200
RS232 baud rate: 9600
Parity: None, Odd, Even
Protocol: Modbus® RTU / half duplex, DNP 3.0
2.2.8 Testing
PRODUCTION TESTS
Thermal cycling: Operational test at ambient, reducing to –40°C and then
increasing to 60°C
Dielectric strength: 1.9 kV AC for 1 second or 1.6 kV AC for one minute, per UL 508.
DO NOT CONNECT FILTER GROUND TO SAFETY GROUND DURING ANY PRODUCTION TESTS!
TYPE TESTING
The table below lists the 489 type tests:
Standard Test Name Level
EIA 485 RS485 Communications Test 32 units at 4000 ft.
GE Multilin Temperature Cycling –50°C / +80°C
IEC 60068-2-38 Composite Temperature/Humidity 65/–10°C at 93% RH
IEC 60255-5 Dielectric Strength 2300 V AC
IEC 60255-5 Impulse Voltage 5 kV
IEC 60255-5 Insulation Resistance >100 MΩ / 500 V AC / 10 s
IEC 60255-21-1 Sinusoidal Vibration 2g
IEC 60255-22-2 Electrostatic Discharge: Direct 8 kV
IEC 60255-22-3 Radiated RF Immunity 10 V/m
IEC 60255-22-4 Electrical Fast Transient / Burst Immunity 4 kV
IEC 60255-22-5 Surge Immunity 4 kV / 2 kV
IEC 60255-22-6 Conducted RF Immunity, 150 kHz to 80 MHz 10 V/m
IEC 60255-25 Radiated RF Emission Group 1 Class A
IEC 60255-25 Conducted RF Emission Group 1 Class A
IEC 60529 Ingress of Solid Objects and Water (IP) IP40 (front), IP20 (back)
IEC 61000-4-8 Power frequency magnetic field immunity 30 A/m
IEC 61000-4-11 Voltage Dip; Voltage Interruption 0%, 40%, 100%
IEEE C37.90 Make and carry 30 A DC
IEEE C37.90.1 Fast Transient SWC ±4 kV
IEEE C37.90.1 Oscillatory Transient SWC ±2.5 kV

2.2.9 Certification
CERTIFICATION
IEC 1010-1: LVD - CE for Europe
EN 50263: EMC - CE for Europe
ACA Tick Mark: RF emissions for Australia
FCC part 15: RF emissions for North America
UL: listed E83849
ISO 9001: registered
2.2.10 Physical
CASE
Drawout: Fully drawout (automatic CT shorts)
Seal: Seal provision
Door: Dust tight door
Mounting: Panel or 19" rack mount
IP Class: IP20-X
PACKAGING
Shipping box: 12” × 11” × 10” (W × H × D)
30.5cm × 27.9cm × 25.4cm
Shipping weight: 17 lbs / 7.7 kg max.
TERMINALS
Low voltage (A, B, C, D terminals): 12 AWG max
High voltage (E, F, G, H terminals): #8 ring lug, 10 AWG wire standard
2.2.11 Environmental
ENVIRONMENTAL
Ambient operating temperature:–40°C to +60°C
Ambient storage temperature:40°C to +80°C
Humidity: up to 90%, non-condensing
Altitude: up to 2000 m
Pollution degree: 2
At temperatures less than –20°C, the LCD contrast may be impaired.

Note

2.2.12 Long-term Storage

LONG-TERM STORAGE
Environment: In addition to the above environmental considerations, the
relay should be stored in an environment that is dry, corrosive-free, and not
in direct sunlight.
Correct storage: Prevents premature component failures caused by
environmental factors such as moisture or corrosive gases. Exposure to high
humidity or corrosive environments will prematurely degrade the electronic
components in any electronic device regardless of its use or manufacturer,
unless specific precautions, such as those mentioned in the Environmental
section above, are taken.
It is recommended that all relays be powered up once per year, for one hour continuously,
Note
to avoid deterioration of electrolytic capacitors and subsequent relay failure.

Digital Energy
Multilin
Chapter 3: Installation
Installation
3.1 Mechanical Installation
3.1.1 Description
The 489 is packaged in the standard GE Multilin SR-series arrangement, which consists of
a drawout unit and a companion fixed case. The case provides mechanical protection to
the unit, and is used to make permanent connections to all external equipment. The only
electrical components mounted in the case are those required to connect the unit to the
external wiring. Connections in the case are fitted with mechanisms required to allow the
safe removal of the relay unit from an energized panel, such as automatic CT shorting. The
unit is mechanically held in the case by pins on the locking handle, which cannot be fully
lowered to the locked position until the electrical connections are completely mated. Any
489 can be installed in any 489 case, except for custom manufactured units that are
clearly identified as such on both case and unit, and are equipped with an index pin keying
mechanism to prevent incorrect pairings.
No special ventilation requirements need to be observed during the installation of the unit,
but the unit should be wiped clean with a damp cloth.

CHAPTER 3: INSTALLATION
FIGURE 3–1: 489 Dimensions
To prevent unauthorized removal of the drawout unit, a wire lead seal can be installed in
the slot provided on the handle as shown below. With this seal in place, the drawout unit
cannot be removed. A passcode or setpoint access jumper can be used to prevent entry of
setpoints but still allow monitoring of actual values. If access to the front panel controls
must be restricted, a separate seal can be installed on the outside of the cover to prevent it
from being opened.
Seal location
FIGURE 3–2: Drawout Unit Seal
Hazard may result if the product is not used for its intended purpose.
3.1.2 Product Identification

Each 489 unit and case are equipped with a permanent label. This label is installed on the
left side (when facing the front of the relay) of both unit and case. The case label details
which units can be installed.
The case label details the model number, manufacture date, and special notes.
The unit label details the model number, type, serial number, file number, manufacture
date, phase current inputs, special notes, overvoltage category, insulation voltage,
pollution degree, control power, and output contact rating.

FIGURE 3–3: Product Case and Unit Labels
3.1.3 Installation
The 489 case, alone or adjacent to another SR-series unit, can be installed in a standard
19-inch rack panel (see 489 Dimensions on page 3–2). Provision must be made for the front
door to swing open without interference to, or from, adjacent equipment. The 489 unit is
normally mounted in its case when shipped from the factory and should be removed
before mounting the case in the supporting panel. Unit withdrawal is described in the next
section.
After the mounting hole in the panel has been prepared, slide the 489 case into the panel
from the front. Applying firm pressure on the front to ensure the front bezel fits snugly
against the front of the panel, bend out the pair of retaining tabs (to a horizontal position)
from each side of the case, as shown below. The case is now securely mounted, ready for
panel wiring.

808704A1.CDR
FIGURE 3–4: Bend Up Mounting Tabs
3.1.4 Unit Withdrawal and Insertion
TURN OFF CONTROL POWER BEFORE DRAWING OUT OR RE-INSERTING THE RELAY TO
PREVENT MALOPERATION!
If an attempt is made to install a unit into a non-matching case, the mechanical key
will prevent full insertion of the unit. Do not apply strong force in the following step or
damage may result.
To remove the unit from the case:
Z Open the cover by pulling the upper or lower corner of the right side,
which will rotate about the hinges on the left.
Z Release the locking latch, located below the locking handle, by
pressing upward on the latch with the tip of a screwdriver.
FIGURE 3–5: Press Latch to Disengage Handle

Z Grasp the locking handle in the center and pull firmly, rotating the
handle up from the bottom of the unit until movement ceases.
FIGURE 3–6: Rotate Handle to Stop Position
Once the handle is released from the locking mechanism, the unit can freely slide
out of the case when pulled by the handle. It may sometimes be necessary to
adjust the handle position slightly to free the unit.
FIGURE 3–7: Slide Unit out of Case
To insert the unit into the case:

Z Raise the locking handle to the highest position.
Z Hold the unit immediately in front of the case and align the rolling
guide pins (near the hinges of the locking handle) to the guide slots
on either side of the case.
Z Slide the unit into the case until the guide pins on the unit have
engaged the guide slots on either side of the case.
Z Grasp the locking handle from the center and press down firmly,
rotating the handle from the raised position toward the bottom of
the unit.
When the unit is fully inserted, the latch will be heard to click, locking the handle in
the final position.

3.1.5 Ethernet Connection

If using the 489 with the Ethernet 10Base-T option, ensure that the network cable is
disconnected from the rear RJ45 connector before removing the unit from the case. This
prevents any damage to the connector.
The unit may also be removed from the case with the network cable connector still
attached to the rear RJ45 connector, provided that there is at least 16 inches of network
cable available when removing the unit from the case. This extra length allows the network
cable to be disconnected from the RJ45 connector from the front of the switchgear panel.
Once disconnected, the cable can be left hanging safely outside the case for re-inserting
the unit back into the case.
The unit may be re-inserted by first connecting the network cable to the rear RJ45
connector of the 489 (see step 3 of Unit Withdrawal and Insertion on page 3–4).
Ensure that the network cable does not get caught inside the case while sliding in the
unit. This may interfere with proper insertion to the case terminal blocks and damage
the cable.
FIGURE 3–8: Ethernet Cable Connection
To ensure optimal response from the relay, the typical connection timeout should be set as
indicated in the following table:
TCP/IP sessions Timeout setting
up to 2 2 seconds
up to 4 3 seconds
The RS485 COM2 port is disabled if the Ethernet option is ordered.

3.1.6 Terminal Locations
FIGURE 3–9: Terminal Layout

Table 3–1: 489 Terminal List

Terminal Description Terminal Description
A01 RTD #1 Hot D21 Assignable Switch 6
A02 RTD #1 Compensation D22 Assignable Switch 7
A03 RTD Return D23 Switch Common
A04 RTD #2 Compensation D24 Switch +24 V DC
A05 RTD #2 Hot D25 Computer RS485 +
A06 RTD #3 Hot D26 Computer RS485 –
A07 RTD #3 Compensation D27 Computer RS485 Common
A08 RTD Return E01 1 Trip NC
A09 RTD #4 Compensation E02 1 Trip NO
A10 RTD #4 Hot E03 2 Auxiliary Common
A11 RTD #5 Hot E04 3 Auxiliary NC
A12 RTD #5 Compensation E05 3 Auxiliary NO
A13 RTD Return E06 4 Auxiliary Common
A14 RTD #6 Compensation E07 5 Alarm NC
A15 RTD #6 Hot E08 5 Alarm NO
A16 Analog Output Common – E09 6 Service Common
A17 Analog Output 1 + E10 Neutral VT Common
A18 Analog Output 2 + E11 Coil Supervision +
A19 Analog Output 3 + E12 IRIG-B +
A20 Analog Output 4 + F01 1 Trip Common
A21 Analog Shield F02 2 Auxiliary NO
A22 Analog Input 24 V DC Supply + F03 2 Auxiliary NC
A23 Analog Input 1 + F04 3 Auxiliary Common
A24 Analog Input 2 + F05 4 Auxiliary NO
A25 Analog Input 3 + F06 4 Auxiliary NC
A26 Analog Input 4 + F07 5 Alarm Common
A27 Analog Input Common – F08 6 Service NO
B01 RTD Shield F09 6 Service NC
B02 Auxiliary RS485 + F10 Neutral VT +
B03 Auxiliary RS485 – F11 Coil Supervision –
B04 Auxiliary RS485 Common F12 IRIG-B –
C01 Access + G01 Phase VT Common
C02 Access – G02 Phase A VT •
C03 Breaker Status + G03 Neutral Phase A CT •
C04 Breaker Status – G04 Neutral Phase B CT •
D01 RTD #7 Hot G05 Neutral Phase C CT •
D02 RTD #7 Compensation G06 Output Phase A CT •
D03 RTD Return G07 Output Phase B CT •
D04 RTD #8 Compensation G08 Output Phase C CT •
D05 RTD #8 Hot G09 1A Ground CT •
D06 RTD #9 Hot G10 HGF Ground CT •
D07 RTD #9 Compensation G11 Filter Ground
D08 RTD Return G12 Safety Ground
D09 RTD #10 Compensation H01 Phase B VT •
D10 RTD #10 Hot H02 Phase C VT •
D11 RTD #11 Hot H03 Neutral Phase A CT
D12 RTD #11 Compensation H04 Neutral Phase B CT
D13 RTD Return H05 Neutral Phase C CT
D14 RTD #12 Compensation H06 Output Phase A CT
D15 RTD #12 Hot H07 Output Phase B CT
D16 Assignable Switch 1 H08 Output Phase C CT
D17 Assignable Switch 2 H09 1A Ground CT
D18 Assignable Switch 3 H10 HGF Ground CT
D19 Assignable Switch 4 H11 Control Power –
D20 Assignable Switch 5 H12 Control Power +

3.2 Electrical Installation
3.2.1 Typical Wiring
FIGURE 3–10: Typical Wiring Diagram

3.2.2 General Wiring Considerations

A broad range of applications are available to the user and it is not possible to present
typical connections for all possible schemes. The information in this section will cover the
important aspects of interconnections, in the general areas of instrument transformer
inputs, other inputs, outputs, communications and grounding. See Terminal Layout on
page 3–7 and 489 Terminal List on page 3–8 for terminal arrangement, and Typical Wiring
Diagram on page 3–10 for typical connections.
FIGURE 3–11: Typical Wiring (Detail)
3.2.3 Control Power
Control power supplied to the relay must match the installed power supply range. If the
applied voltage does not match, damage to the unit may occur. All grounds MUST be
connected for normal operation regardless of control power supply type.
The label found on the left side of the relay specifies its order code or model number. The
installed power supply’s operating range will be one of the following.
LO: 20 to 60 V DC or 20 to 48 V AC
HI: 88 to 300 V DC or 70 to 265 V AC
The relay should be connected directly to the ground bus, using the shortest practical
path. A tinned copper, braided, shielding and bonding cable should be used. As a
minimum, 96 strands of number 34 AWG should be used. Belden catalog number 8660
is suitable.

Ensure applied control voltage and rated voltage on drawout case terminal label match.
For example, the HI power supply will work with any DC voltage from 90 to 300 V, or AC
voltage from 70 to 265 V. The internal fuse may blow if the applied voltage exceeds this
range.
Extensive filtering and transient protection are built into the 489 to ensure proper
operation in harsh industrial environments. Transient energy must be conducted back to
the source through the filter ground terminal. A separate safety ground terminal is
provided for hi-pot testing.
FIGURE 3–12: Control Power Connection
3.2.4 Current Inputs
Phase Current
The 489 has six phase current transformer inputs (three output side and three neutral end),
each with an isolating transformer. There are no internal ground connections on the CT
inputs. Each phase CT circuit is shorted by automatic mechanisms on the 489 case if the
unit is withdrawn. The phase CTs should be chosen such that the FLA is no less than 50% of
the rated phase CT primary. Ideally, the phase CT primary should be chosen such that the
FLA is 100% of the phase CT primary or slightly less. This will ensure maximum accuracy
for the current measurements. The maximum phase CT primary current is 50000 A.
The 489 will measure correctly up to 20 times the phase current nominal rating. Since the
conversion range is large, 1 A or 5 A CT secondaries must be specified at the time of order
such that the appropriate interposing CT may be installed in the unit. CTs chosen must be
capable of driving the 489 phase CT burden (see SPECIFICATIONS for ratings).
Verify that the 489 nominal phase current of 1 A or 5 A matches the secondary rating
and connections of the connected CTs. Unmatched CTs may result in equipment
damage or inadequate protection. Polarity of the phase CTs is critical for phase
differential, negative sequence, power measurement, and residual ground current
detection (if used).

Ground Current
The 489 has a dual primary isolating transformer for ground CT connections. There are no
internal ground connections on the ground current inputs. The ground CT circuits are
shorted by automatic mechanisms on the case if the unit is withdrawn. The 1 A tap is used
for 1 A or 5 A secondary CTs in either core balance or residual ground configurations. If the
1 A tap is used, the 489 measures up to 20 A secondary with a maximum ground CT ratio
of 10000:1. The ground CT must be capable of driving the ground CT burden.
The HGF ground CT input is designed for sensitive ground current detection on high
resistance grounded systems where the GE Multilin HGF core balance CT (50:0.025) is used.
In applications such as mines, where earth leakage current must be measured for
personnel safety, primary ground current as low as 0.25 A may be detected with the GE
Multilin HGF CT. Only one ground CT input tap should be used on a given unit.
The HGF CT has a rating of 50:0.025. However if the HGF CT is used in conjunction with the
489, the relay assumes a fixed ratio of 5:0.0025. Therefore, the pickup level in primary
amps will be Pickup × CT, where CT is equal to 5.
Only one ground input should be wired. The other input should be unconnected.
Note
FIGURE 3–13: Residual Ground CT Connection
DO NOT INJECT OVER THE RATED CURRENT TO HGF TERMINAL (0.25 to 25 A PRIMARY).
The exact placement of a zero sequence CT to detect ground fault current is shown below.
If the core balance CT is placed over shielded cable, capacitive coupling of phase current
into the cable shield may be detected as ground current unless the shield wire is also
passed through the CT window. Twisted pair cabling on the zero sequence CT is
recommended.

FIGURE 3–14: Core Balance Ground CT Installation – Unshielded Cable
FIGURE 3–15: Core Balance Ground CT Installation – Shielded Cable

3.2.5 Voltage Inputs

The 489 has four voltage transformer inputs, three for generator terminal voltage and one
for neutral voltage. There are no internal fuses or ground connections on the voltage
inputs. The maximum phase VT ratio is 300.00:1 and the maximum neutral VT ratio is
240.00:1. The two possible VT connections for generator terminal voltage measurement
are open delta or wye (see Typical Wiring Diagram on page 3–10). The voltage channels are
connected in wye internally, which means that the jumper shown on the delta-source
connection of the Typical Wiring Diagram, between the phase B input and the 489 neutral
terminal, must be installed for open delta VTs.
Polarity of the generator terminal VTs is critical for correct power measurement and
voltage phase reversal operation.
There are 9 digital inputs that are designed for dry contact connections only. Two of the
digital inputs, Access and Breaker Status have their own common terminal, the balance of
the digital inputs share one common terminal (see Typical Wiring Diagram on page 3–10).
In addition, the +24 V DC switch supply is brought out for control power of an inductive or
capacitive proximity probe. The NPN transistor output could be taken to one of the
assignable digital inputs configured as a counter or tachometer. Refer to the Specifications
section of this manual for maximum current draw from the +24 V DC switch supply.
DO NOT INJECT VOLTAGES TO DIGITAL INPUTS. DRY CONTACT CONNECTIONS ONLY.
3.2.7 Analog Inputs

Terminals are provided on the 489 for the input of four 0 to 1 mA, 0 to 20 mA, or 4 to 20 mA
current signals (field programmable). This current signal can be used to monitor any
external quantity such as: vibration, pressure, field current, etc. The four inputs share one
common return. Polarity of these inputs must be observed for proper operation The analog
input circuitry is isolated as a group with the Analog Output circuitry and the RTD circuitry.
Only one ground reference should be used for the three circuits. Transorbs limit this
isolation to ±36 V with respect to the 489 safety ground.
In addition, the +24 V DC analog input supply is brought out for control power of loop
powered transducers. Refer to the Specifications section of this manual for maximum
current draw from this supply.

FIGURE 3–16: Loop Powered Transducer Connection

The 489 provides four analog output channels, which when ordered, provide a full-scale
range of either 0 to 1 mA (into a maximum 10 kΩ impedance), or 4 to 20 mA (into a
maximum 1.2K Ω impedance). Each channel can be configured to provide full-scale output
sensitivity for any range of any measured parameter.
As shown in the Typical Wiring Diagram on page 3–10, these outputs share one common
return. The polarity of these outputs must be observed for proper operation. Shielded cable
should be used, with only one end of the shield grounded, to minimize noise effects.
The analog output circuitry is isolated as a group with the Analog Input circuitry and the
RTD circuitry. Only one ground reference should be used for the three circuits. Transorbs
limit this isolation to ±36 V with respect to the 489 safety ground.
If a voltage output is required, a burden resistor must be connected at the input of the
SCADA measuring device. Ignoring the input impedance of the input:
V FULL-SCALE
R LOAD = -----------------------------
- (EQ 3.1)
I MAX
For example, for a 0 to 1 mA input, if 5 V full scale corresponds to 1 mA, then RLOAD = 5 V /
0.001 A = 5000 Ω. For a 4 to 20 mA input, this resistor would be RLOAD = 5 V / 0.020
A = 250 Ω.
3.2.9 RTD Sensor Connections

The 489 can monitor up to 12 RTD inputs for Stator, Bearing, Ambient, or Other
temperature monitoring. The type of each RTD is field programmable as: 100 Ω Platinum
(DIN 43760), 100 Ω Nickel, 120 Ω Nickel, or 10 Ω Copper. RTDs must be three wire type.
Every two RTDs shares a common return.

The 489 RTD circuitry compensates for lead resistance, provided that each of the three
leads is the same length. Lead resistance should not exceed 25 Ω per lead for platinum
and nickel RTDs and 3 Ω per lead for copper RTDs. Shielded cable should be used to
prevent noise pickup in the industrial environment. RTD cables should be kept close to
grounded metal casings and avoid areas of high electromagnetic or radio interference.
RTD leads should not be run adjacent to or in the same conduit as high current carrying
wires.
489 3 WIRE SHIELDED CABLE

RELAY Route cable in separate conduit from
current carrying conductors
CHASSIS RTD TERMINALS
GROUND
AT GENERATOR
SHIELD B1
RTD SENSING
HOT A1 RTD IN
RTD #1
GENERATOR
COMPENSATION A2 STATOR
OR
BEARING
RETURN A3
OPTIONAL GROUND RTD

Shield is internally TERMINALS Maximum total lead resistance
connected to safety 25 ohms (Platinum & Nickel RTDs)
ground terminal G12 3 ohms (Copper RTDs) 808761E4.CDR
FIGURE 3–17: RTD Wiring
IMPORTANT NOTE: The RTD circuitry is isolated as a group with the Analog Input circuitry
Note
and the Analog Output circuitry. Only one ground reference should be used for the three
circuits. Transorbs limit this isolation to ±36 V with respect to the 489 safety ground. If code
requires that the RTDs be grounded locally at the generator terminal box, that will also be
the ground reference for the analog inputs and outputs.
3.2.10 Output Relays

There are six Form-C output relays (see Outputs on page 2–7). Five of the six relays are
always non-failsafe, the 6 Service relay is always failsafe. As a failsafe, the 6 Service relay
will be energized normally and de-energize when called upon to operate. It will also de-
energize when control power to the 489 is lost and therefore, be in its operated state. All
other relays, being non-failsafe, will be de-energized normally and energize when called
upon to operate. Obviously, when control power is lost to the 489, these relays must be de-
energized and therefore, they will be in their non-operated state. Shorting bars in the
drawout case ensure that when the 489 is drawn out, no trip or alarm occurs. The
6 Service output will however indicate that the 489 has been drawn out. Each output relay
has an LED indicator on the 489 front panel that comes on while the associated relay is in
the operated state.
• 1 TRIP: The trip relay should be wired such that the generator is taken offline when
conditions warrant. For a breaker application, the NO 1 Trip contact should be wired in
series with the Breaker trip coil.
Supervision of a breaker trip coil requires that the supervision circuit be paralleled with
the 1 Trip relay output contacts, as shown in the Typical Wiring Diagram on page 3–10.
With this connection made, the supervision input circuits will place an impedance
across the contacts that will draw a current of 2 to 5 mA (for an external supply

voltage from 30 to 250 V DC) through the breaker trip coil. The supervision circuits
respond to a loss of this trickle current as a failure condition. Circuit breakers equipped
with standard control circuits have a breaker auxiliary contact permitting the trip coil
to be energized only when the breaker is closed. When these contacts are open, as
detected by the Breaker Status digital input, trip coil supervision circuit is
automatically disabled. This logic provides that the trip circuit is monitored only when
the breaker is closed.
• 2 AUXILIARY, 3 AUXILIARY, 4 AUXILIARY: The auxiliary relays may be programmed for
numerous functions such as, trip echo, alarm echo, trip backup, alarm or trip
differentiation, control circuitry, etc. They should be wired as configuration warrants.
• 5 ALARM: The alarm relay should connect to the appropriate annunciator or
monitoring device.
• 6 SERVICE: The service relay will operate if any of the 489 diagnostics detect an
internal failure or on loss of control power. This output may be monitored with an
annunciator, PLC or DCS.
The service relay NC contact may also be wired in parallel with the trip relay on a
breaker application. This will provide failsafe operation of the generator; that is, the
generator will be tripped offline in the event that the 489 is not protecting it. Simple
annunciation of such a failure will allow the operator or the operation computer to
either continue, or do a sequenced shutdown.
Relay contacts must be considered unsafe to touch when the system is energized! If
the customer requires the relay contacts for low voltage accessible applications, it is
their responsibility to ensure proper insulation levels.
3.2.11 IRIG-B
IRIG-B is a standard time-code format that allows stamping of events to be synchronized
among connected devices within 1 millisecond. The IRIG-B time codes are serial, width-
modulated formats which are either DC level shifted or amplitude modulated (AM). Third
party equipment is available for generating the IRIG-B signal. This equipment may use a
GPS satellite system to obtain the time reference enabling devices at different geographic
locations to be synchronized.
Terminals E12 and F12 on the 489 unit are provided for the connection of an IRIG-B signal.
3.2.12 RS485 Ports

Two independent two-wire RS485 ports are provided. Up to 32 489 relays can be daisy-
chained together on a communication channel without exceeding the driver capability. For
larger systems, additional serial channels must be added. It is also possible to use
commercially available repeaters to increase the number of relays on a single channel to
more than 32. A suitable cable should have a characteristic impedance of 120 Ω (e.g.
Belden #9841) and total wire length should not exceed 4000 feet (approximately 1200
metres). Commercially available repeaters will allow for transmission distances greater
than 4000 ft.

Voltage differences between remote ends of the communication link are not uncommon.
For this reason, surge protection devices are internally installed across all RS485 terminals.
Internally, an isolated power supply with an optocoupled data interface is used to prevent
noise coupling.
To ensure that all devices in a daisy-chain are at the same potential, it is imperative that
Note
the common terminals of each RS485 port are tied together and grounded only once, at
the master. Failure to do so may result in intermittent or failed communications.
The source computer/PLC/SCADA system should have similar transient protection devices
installed, either internally or externally, to ensure maximum reliability. Ground the shield at
one point only, as shown below, to avoid ground loops.
Correct polarity is also essential. All 489s must be wired with all ‘+’ terminals connected
together, and all ‘–’ terminals connected together. Each relay must be daisy-chained to the
next one. Avoid star or stub connected configurations. The last device at each end of the
daisy chain should be terminated with a 120 Ω ¼ W resistor in series with a 1 nF capacitor
across the ‘+’ and ‘–’ terminals. Observing these guidelines will result in a reliable
communication system that is immune to system transients.
FIGURE 3–18: RS485 Communications Wiring
3.2.13 Dielectric Strength

It may be required to test a complete motor starter for dielectric strength (“flash” or hi-pot”)
with the 489 installed. The 489 is rated for 1.9 kV AC for 1 second, or 1.6 kV AC for 1 minute
(per UL 508) isolation between relay contacts, CT inputs, VT inputs, trip coil supervision,
and the safety ground terminal G12. Some precautions are required to prevent damage to
the 489 during these tests.
Filter networks and transient protection clamps are used between control power, trip coil
supervision, and the filter ground terminal G11. This filtering is intended to filter out high
voltage transients, radio frequency interference (RFI), and electromagnetic interference
(EMI). The filter capacitors and transient suppressors could be damaged by application
continuous high voltage. Disconnect filter ground terminal G11 during testing of control

power and trip coil supervision. CT inputs, VT inputs, and output relays do not require any
special precautions. Low voltage inputs (<30 V), RTDs, analog inputs, analog outputs, digital
inputs, and RS485 communication ports are not to be tested for dielectric strength under
any circumstance (see below).
g GE Multilin
FIGURE 3–19: Testing the 489 for Dielectric Strength


Digital Energy
Multilin
Chapter 4: Interfaces
Interfaces
4.1 Faceplate Interface
4.1.1 Display
All messages appear on a 40-character liquid crystal display. Messages are in plain English
and do not require the aid of an instruction manual for deciphering. When the user
interface is not being used, the display defaults to the user-defined status messages. Any
trip or alarm automatically overrides the default messages and is immediately displayed.
4.1.2 LED Indicators

There are three groups of LED indicators. They are 489 Status, Generator Status, and
Output Status.
808732A3.CDR
FIGURE 4–1: 489 LED Indicators

CHAPTER 4: INTERFACES
489 Status LED Indicators

• 489 IN SERVICE: Indicates that control power is applied, all monitored input/output
and internal systems are OK, the 489 has been programmed, and is in protection
mode, not simulation mode. When in simulation or testing mode, the LED indicator will
flash.
• SETPOINT ACCESS: Indicates that the access jumper is installed and passcode
protection has been satisfied. Setpoints may be altered and stored.
• COMPUTER RS232: Flashes when there is any activity on the RS232 communications
port. Remains on continuously if incoming data is valid.
• COMPUTER RS485 / AUXILIARY RS485: Flashes when there is any activity on the
computer/auxiliary RS485 communications port. These LEDs remain on continuously
if incoming data is valid and intended for the slave address programmed in the relay.
• ALT. SETPOINTS: Flashes when the alternate setpoint group is being edited and the
primary setpoint group is active. Remains on continuously if the alternate setpoint
group is active. The alternate setpoint group feature is enabled as one of the
assignable digital inputs. The alternate setpoints group can be selected by setting the
S3 DIGITAL INPUTS ZV DUAL SETPOINTS ZV ACTIVATE SETPOINT GROUP setpoint to
“Group 2”.
• RESET POSSIBLE: A trip or latched alarm may be reset. Pressing the RESET key clears
the trip/alarm.
• MESSAGE: Under normal conditions, the default messages selected during setpoint
programming are displayed. If any alarm or trip condition is generated, a diagnostic
message overrides the displayed message and this indicator flashes. If there is more
than one condition present, MESSAGE T can be used to scroll through the messages.
Pressing any other key return to the normally displayed messages. While viewing
normally displayed messages, the Message LED continues to flash if any diagnostic
message is active.
Z To return to the diagnostic messages from the normally displayed
messages, press the MENU key until the following message is
displayed:
TARGET MESSAGES [w]
Z Now, press the MESSAGE X key followed by the message T key to

scroll through the messages.
Note that diagnostic messages for alarms disappear with the
condition while diagnostic messages for trips remain until cleared by
a reset.
Generator Status LED Indicators

• BREAKER OPEN: Uses the breaker status input signal to indicate that the breaker is
open and the generator is offline.
• BREAKER CLOSED: Uses the breaker status input signal to indicate that the breaker is
closed and the generator is online.

• HOT STATOR: Indicates that the generator stator is above normal temperature when
one of the stator RTD alarm or trip elements is picked up or the thermal model trip
element is picked up.
• NEG. SEQUENCE: Indicates that the negative sequence current alarm or trip element
is picked up.
• GROUND: Indicates that at least one of the ground overcurrent, neutral overvoltage
(fundamental), or neutral undervoltage (3rd harmonic) alarm/trip elements is picked
up.
• LOSS OF FIELD: Indicates that at least one of the reactive power (kvar) or field-breaker
discrepancy alarm/trip elements is picked up.
• VT FAILURE: Indicates that the VT fuse failure alarm is picked up.
• BREAKER FAILURE: Indicates that the breaker failure or trip coil monitor alarm is
picked up.
Output Status LED Indicators

• 1 TRIP: The 1 Trip relay has operated (energized).
• 2 AUXILIARY: The 2 Auxiliary relay has operated (energized).
• 5 ALARM: The 5 Alarm relay has operated (energized).
• 6 SERVICE: The 6 Service relay has operated (de-energized, 6 Service is fail-safe,
normally energized).
4.1.3 RS232 Program Port

This port is intended for connection to a portable PC. Setpoint files may be created at any
location and downloaded through this port with the EnerVista 489 Setup software. Local
interrogation of setpoint and actual values is also possible. New firmware may be
downloaded to the 489 flash memory through this port. Upgrading the relay firmware
does not require a hardware EEPROM change.
4.1.4 Keypad
Description
The 489 display messages are organized into main menus, pages, and sub-pages. There
are three main menus labeled Setpoints, Actual Values, and Target Messages.
Z Press the MENU key followed by the MESSAGE T key to scroll
through the three main menu headers, which appear in sequence as
follows:
SETPOINTS [w ]

ACTUAL VALUES [w ]
TARGET MESSAGES [w ]
Z Press the MESSAGE X key or the ENTER key from these main menu
pages to display the corresponding menu page.
Use the MESSAGE T and MESSAGE S keys to scroll through the
page headers.
When the display shows SETPOINTS,
Z Press the MESSAGE X key or the ENTER key to display the page
headers of programmable parameters (referred to as setpoints in the
manual).
When the display shows ACTUAL VALUES,
headers of measured parameters (referred to as actual values in the
manual).
When the display shows TARGET MESSAGES,
headers of event messages or alarm conditions.
Each page is broken down further into logical sub-pages. The MESSAGE T and
MESSAGE S keys are used to navigate through the sub-pages. A summary of the setpoints
and actual values can be found in the chapters 5 and 6, respectively.
The ENTER key is dual-purpose. It is used to enter the sub-pages and to store altered
setpoint values into memory to complete the change. The MESSAGE X key can also be
used to enter sub-pages but not to store altered setpoints.
The ESCAPE key is also dual-purpose. It is used to exit the sub-pages and to cancel a
setpoint change. The MESSAGE W key can also be used to exit sub-pages and to cancel
setpoint changes.
The VALUE keys are used to scroll through the possible choices of an enumerated setpoint.
They also decrement and increment numerical setpoints. Numerical setpoints may also be
entered through the numeric keypad.
Z Press the HELP key to display context-sensitive information about
setpoints such as the range of values and the method of changing
the setpoint.
Help messages will automatically scroll through all messages
currently appropriate.
The RESET key resets any latched conditions that are not presently active. This includes
resetting latched output relays, latched Trip LEDs, breaker operation failure, and trip coil
failure.

The MESSAGE T and MESSAGE S keys scroll through any active conditions in the relay.
Diagnostic messages are displayed indicating the state of protection and monitoring
elements that are picked up, operating, or latched. When the Message LED is on, there are
messages to be viewed with the MENU key by selecting target messages as described
earlier.
Entering Alphanumeric Text

Text setpoints have data values that are fixed in length but user-defined in character. They
may be comprised of upper case letters, lower case letters, numerals, and a selection of
special characters. The editing and storing of a text value is accomplished with the use of
the decimal [.], VALUE, and ENTER keys.
Z Move to message S3 DIGITAL INPUTS ZV GENERAL INPUT A Z ASSIGN
DIGITAL INPUT, and scrolling with the VALUE keys, select “Input 1”.
The relay will display the following message:
ASSIGN DIGITAL
INPUT: Input 1
Z Press the MESSAGE T key to view the INPUT NAME setpoint.

The name of this user-defined input will be changed in this example
from the generic “Input A” to something more descriptive.
If an application is to be using the relay as a station monitor, it is more informative to
rename this input “Stn. Monitor”.
Z Press the decimal [.] to enter the text editing mode.
The first character will appear underlined as follows:
INPUT NAME:
Input A
Z Press the VALUE keys until the character “S” is displayed in the first
position.
Z Press the decimal [.] key to store the character and advance the
cursor to the next position.
Z Change the second character to a “t” in the same manner.
Z Continue entering characters in this way until all characters of the
text “Stn. Monitor” are entered.
Note that a space is selected like a character.
If a character is entered incorrectly, press the decimal [.] key
repeatedly until the cursor returns to the position of the error. Re-
enter the character as required.
Z Once complete, press the ENTER key to remove the solid cursor and
view the result.
Once a character is entered, by pressing the ENTER key, it is
automatically saved in Flash Memory, as a new setpoint.
INPUT NAME:
Stn. Monitor

The 489 does not have '+' or '–' keys. Negative numbers may be entered in one of two
manners.
• Immediately pressing one of the VALUE keys causes the setpoint to
scroll through its range including any negative numbers.
• After entering at least one digit of a numeric setpoint value, pressing the
VALUE keys changes the sign of the value where applicable.
4.1.5 Setpoint Entry

To store any setpoints, terminals C1 and C2 (access terminals) must be shorted (a
keyswitch may be used for security). There is also a setpoint passcode feature that restricts
access to setpoints. The passcode must be entered to allow the changing of setpoint
values. A passcode of “0” effectively turns off the passcode feature - in this case only the
access jumper is required for changing setpoints. If no key is pressed for 5 minutes, access
to setpoint values will be restricted until the passcode is entered again. To prevent setpoint
access before the 5 minutes expires, the unit may be turned off and back on, the access
jumper may be removed, or the SETPOINT ACCESS setpoint may be changed to “Restricted”.
The passcode cannot be entered until terminals C1 and C2 (access terminals) are shorted.
When setpoint access is allowed, the Setpoint Access LED indicator on the front of the 489
will be lit.
Setpoint changes take effect immediately, even when generator is running. However,
changing setpoints while the generator is running is not recommended as any mistake
may cause a nuisance trip.
The following procedure may be used to access and alter setpoints. This specific example
refers to entering a valid passcode to allow access to setpoints if the passcode was “489”.
Z Press the MENU key to access the header of each menu, which will
be displayed in the following sequence:
SETPOINTS [w ]
ACTUAL VALUES [w ]
TARGET MESSAGES [w ]
Z Press the MENU key until the display shows the header of the
setpoints menu.
first setpoints page.
The set point pages are numbered, have an 'S' prefix for easy
identification and have a name which gives a general idea of the
setpoints available in that page.

Z Press the MESSAGE T or MESSAGE S keys to scroll through all the

available setpoint page headers.
Setpoint page headers look as follows:
SETPOINTS [w]
S1 489 SETUP
To enter a given setpoints page,

Each page is broken further into subgroups.
Z Press MESSAGE T or MESSAGE S to cycle through subgroups until
the desired subgroup appears on the screen.
Z Press the MESSAGE X or ENTER key to enter a subgroup.
PASSCODE [w]
Each sub-group has one or more associated setpoint messages.

Z Press the MESSAGE T or MESSAGE S keys to scroll through setpoint
messages until the desired message appears.
ENTER PASSCODE
FOR ACCESS:
The majority of setpoints are changed by pressing the VALUE keys until the desired value
appears, and then pressing ENTER . Numeric setpoints may also be entered through the
numeric keys (including decimals). If the entered setpoint is out of range, the original
setpoint value reappears. If the entered setpoint is out of step, an adjusted value will be
stored (e.g. 101 for a setpoint that steps 95, 100, 105 is stored as 100). If a mistake is made
entering the new value, pressing ESCAPE returns the setpoint to its original value. Text
editing is a special case described in detail in Entering Alphanumeric Text on page 4–5.
Each time a new setpoint is successfully stored, a message will flash on the display stating
NEW SETPOINT HAS BEEN STORED.
Z Press the 4, 8, 9 keys, then press ENTER .

The following flash message is displayed:
NEW SETPOINT
HAS BEEN STORED
and the display returns to:

SETPOINT ACCESS:
PERMITTED
Z Press ESCAPE or MESSAGE W to exit the subgroup.

Pressing ESCAPE or MESSAGE W numerous times will always return
the cursor to the top of the page.

4.1.6 Diagnostic Messages

Diagnostic messages are automatically displayed for any active conditions in the relay
such as trips, alarms, or asserted logic inputs. These messages provide a summary of the
present state of the relay. The Message LED flashes when there are diagnostic messages
available; press the MENU key until the relay displays TARGET MESSAGES, then press the
MESSAGE X key, followed by the MESSAGE T key, to scroll through the messages. For
additional information and a complete list of diagnostic messages, refer to Diagnostic
Messages on page 6–32.
4.1.7 Self-Test Warnings

The 489 relay performs self test diagnostics at initialization (after power up), and
continuously as a background task to ensure every testable unit of the hardware and
software is functioning correctly. There are two types of self-test warnings indicating either
a minor or major problem. Minor problems indicate a problem with the relay that does not
compromise protection. Major problems indicate a very serious relay problem which
comprises all aspects of relay operation.
Upon detection of either a minor or a major problem the relay will:
• De-energize the self-test warning relay
• Light the self-test warning LED
• Flash a diagnostic message periodically on the display screen
The 489 self-test warnings are shown below.
Table 4–1: Self-Test Warnings
Message Severity Description
Self-Test Warning 1 This warning is caused by detection of a

Replace Immediately corrupted location in the program memory as
Major determined by a CRC error checking code. Any
function of the relay is susceptible to
malfunction from this failure.
Self-Test Warning 2 This warning is caused by a failure of the
Replace Immediately analog to digital converter. The integrity of
Major
system input measurements is affected by this
failure.
Self-Test Warning 3 This warning is caused by a failure of the
Replace Immediately analog to digital converter. The integrity of
Major
system input measurements is affected by this
failure.
Self-Test Warning 5 This warning is caused by out of range reading
Replace Immediately Major of self test RTD 13. The integrity of system
input measurements is affected by this failure.
Replace Immediately Major of self test RTD 14. The integrity of system
input measurements is affected by this failure.
Replace Immediately Major of self test RTD15. The integrity of system input
measurements is affected by this failure.

Table 4–1: Self-Test Warnings
Message Severity Description

Replace Immediately Major of self test RTD16. The integrity of system input
measurements is affected by this failure.
Clock Not Set
Minor Occurs if the clock has not been set.
Program Date/Time
Unit Temp. Exceeded Caused by the detection of unacceptably low

Service/CheckAmbient Minor (less than –40°C) or high (greater than 85°C)
temperatures detected inside the unit.
Unit Not Calibrated This warning occurs when the relay has not
Minor
Replace Immediately been factory calibrated.
Relay Not Configured This warning occurs when the 489 CT Primary
Minor
Consult User Manual or Generator parameters are not set.
Service Required This warning is caused by a failure of the Real
Schedule Maintenance Minor Time Clock circuit. The ability of the relay to
maintain the current date and time is lost.
4.1.8 Flash Messages

Flash messages are warning, error, or general information messages displayed in response
to certain key presses. The length of time these messages remain displayed can be
programmed in S1 RELAY SETUP ZV PREFERENCES ZV DEFAULT MESSAGE CYCLE TIME. The
factory default flash message time is 4 seconds. For additional information and a complete
list of flash messages, refer to Flash Messages on page 6–33.

4.2 EnerVista Software Interface
4.2.1 Overview
The front panel provides local operator interface with a liquid crystal display. The EnerVista
489 Setup software provides a graphical user interface (GUI) as one of two human
interfaces to a 489 device. The alternate human interface is implemented via the device's
faceplate keypad and display (see the first section in this chapter).
The EnerVista 489 Setup software provides a single facility to configure, monitor, maintain,
and trouble-shoot the operation of relay functions, connected over serial communication
networks. It can be used while disconnected (i.e. off-line) or connected (i.e. on-line) to a 489
device. In off-line mode, setpoint files can be created for eventual downloading to the
device. In on-line mode, you can communicate with the device in real-time.
This no-charge software, provided with every 489 relay, can be run from any computer
supporting Microsoft Windows® 95 or higher. This chapter provides a summary of the
basic EnerVista 489 Setup software interface features. The EnerVista 489 Setup help file
provides details for getting started and using the software interface.
With the EnerVista 489 Setup running on your PC, it is possible to
• Program and modify setpoints
• Load/save setpoint files from/to disk
• Read actual values and monitor status
• Perform waveform capture and log data
• Plot, print, and view trending graphs of selected actual values
• Download and playback waveforms
• Get help on any topic
4.2.2 Hardware
Communications from the EnerVista 489 Setup to the 489 can be accomplished three
ways: RS232, RS485, and Ethernet (requires the MultiNet adapter) communications. The
following figures below illustrate typical connections for RS232 and RS485
communications. For additional details on Ethernet communications, please see the
MultiNet manual (GE Publication number GEK-106498).

FIGURE 4–2: Communications using The Front RS232 Port

FIGURE 4–3: Communications using Rear RS485 Port
4.2.3 Installing the EnerVista 489 Setup Software

The following minimum requirements must be met for the EnerVista 489 Setup software to
operate on your computer.
• Pentium class or higher processor (Pentium II 400 MHz or better recommended)
• Microsoft Windows 95, 98, 98SE, ME, NT 4.0 (SP4 or higher), 2000, XP
• Internet Explorer version 4.0 or higher (required libraries)
• 128 MB of RAM (256 MB recommended)
• Minimum of 200 MB hard disk space
A list of qualified modems for serial communications is shown below:
• US Robotics external 56K Faxmodem 5686
• US Robotics external Sportster 56K X2
• PCTEL 2304WT V.92 MDC internal modem
After ensuring these minimum requirements, use the following procedure to install the
EnerVista 489 Setup software from the enclosed GE EnerVista CD.

Z Insert the GE EnerVista CD into your CD-ROM drive.

Z Click the Install Now button and follow the installation instructions
to install the no-charge EnerVista software on the local PC.
Z When installation is complete, start the EnerVista Launchpad
application.
Z Click the IED Setup section of the Launch Pad window.
Z In the EnerVista Launch Pad window, click the Add Product button
and select the “489 Generator Management Relay” from the Install
Software window as shown below.
Z Select the “Web” option to ensure the most recent software release,
or select “CD” if you do not have a web connection.
Z Click the Add Now button to list software items for the 489.

EnerVista Launchpad will obtain the latest installation software from the Web or CD and
automatically start the installation process. A status window with a progress bar will be
shown during the downloading process.
Z Select the complete path, including the new directory name, where
the EnerVista 489 Setup software will be installed.
Z Click on Next to begin the installation.
The files will be installed in the directory indicated and the
installation program will automatically create icons and add
EnerVista 489 Setup software to the Windows start menu.
Z Click Finish to end the installation.
The 489 device will be added to the list of installed IEDs in the
EnerVista Launchpad window, as shown below.

4.3 Connecting EnerVista 489 Setup to the Relay
4.3.1 Configuring Serial Communications

Before starting, verify that the serial cable is properly connected to either the RS232 port
on the front panel of the device (for RS232 communications) or to the RS485 terminals on
the back of the device (for RS485 communications). See Hardware on page 4–10 for
connection details.
This example demonstrates an RS232 connection. For RS485 communications, the GE
Multilin F485 converter will be required. Refer to the F485 manual for additional details. To
configure the relay for Ethernet communications, see Configuring Ethernet
Communications on page 4–17.
Z Install and start the latest version of the EnerVista 489 Setup
software (available from the GE EnerVista CD).
See the previous section for the installation procedure.
Z Click on the Device Setup button to open the Device Setup window.
Z Click the Add Site button to define a new site.
Z Enter the desired site name in the Site Name field.
If desired, a short description of site can also be entered along with
the display order of devices defined for the site.
In this example, we will use “Pumping Station 1” as the site name.
Z Click the OK button when complete.
The new site will appear in the upper-left list in the EnerVista 489 Setup window.
Z Click the Add Device button to define the new device.
Z Enter the desired name in the Device Name field and a description
(optional) of the site.

Z Select “Serial” from the Interface drop-down list.

This will display a number of interface parameters that must be
entered for proper RS232 functionality.
Z Enter the slave address and COM port values (from the S1 489 SETUP
ZV COMMUNICATIONS menu) in the Slave Address and COM Port
fields.
Z Enter the physical communications parameters (baud rate and
parity setpoints) in their respective fields.
Note that when communicating to the relay from the front port, the
default communications setpoints are a baud rate of 9600, with
slave address of 1, no parity, 8 bits, and 1 stop bit. These values
cannot be changed.
Z Click the Read Order Code button to connect to the 489 device and
upload the order code.
If a communications error occurs, ensure that the 489 serial
communications values entered in the previous step correspond to
the relay setting values.
Z Click OK when the relay order code has been received.
The new device will be added to the Site List window (or Online
window) located in the top left corner of the main EnerVista 489
Setup window.
The 489 Site Device has now been configured for serial communications. Proceed to
Connecting to the Relay on page 4–19 to begin communications.
4.3.2 Using the Quick Connect Feature

The Quick Connect button can be used to establish a fast connection through the front
panel RS232 port of a 489 relay.

Z Press the Quick Connect button.

The following window will appear:
As indicated by the window, the Quick Connect feature quickly connects the EnerVista 489
Setup software to a 489 front port with the following setpoints: 9600 baud, no parity, 8 bits,
1 stop bit.
Z Select the PC communications port connected to the relay.
Z Press the Connect button.
The EnerVista 489 Setup software will display a window indicating the status of
communications with the relay. When connected, a new Site called “Quick Connect” will
appear in the Site List window. The properties of this new site cannot be changed.
The 489 Site Device has now been configured via the Quick Connect feature for serial
communications. Proceed to Connecting to the Relay on page 4–19 to begin
communications.
4.3.3 Configuring Ethernet Communications

Z Before starting, verify that the Ethernet cable is properly connected
to the RJ-45 Ethernet port.

Z Install and start the latest version of the EnerVista 489 Setup
software (available from the GE EnerVista CD).
See the previous section for the installation procedure.
the display order of devices defined for the site. In this example, we
will use “Pumping Station 2” as the site name.
The new site will appear in the upper-left list.
(optional).
Z Select “Ethernet” from the Interface drop-down list.
This will display a number of interface parameters that must be
entered for proper Ethernet functionality.
Z Enter the IP address assigned to the relay.

Z Enter the slave address and Modbus port values (from the S1 489
SETUP ZV COMMUNICATIONS menu) in the Slave Address and
Modbus Port fields.
If a communications error occurs, ensure that the 489 Ethernet
communications values entered in the previous step correspond to
the relay setting values.


window) located in the top left corner of the main EnerVista 489
Setup window.
The 489 Site Device has now been configured for Ethernet communications. Proceed to
the following section to begin communications.
4.3.4 Connecting to the Relay

Now that the communications parameters have been properly configured, the user can
easily connect to the relay.
Z Expand the Site list by double clicking on the site name or clicking on
the «+» box to list the available devices for the given site (for
example, in the “Pumping Station 1” site shown below).
Z Expand the desired device trees by clicking the «+» box.
The following list of headers is shown for each device:
• Device Definitions
• Setpoints
• Actual Values
• Commands
• Communications
Z Expand the Setpoints > Protection > Current Elements list item and
select the Phase Overcurrent tab to open the Phase Overrcurrent
setpoint window as shown below:
Expand the Site List by double-

clicking or by selecting the [+] box
Communications Status Indicator

Green = OK, Red = No Comms
FIGURE 4–4: Main Window after Connection

The Phase Overcurrent setpoint window will open with a corresponding status indicator on
the lower left of the EnerVista 489 Setup window.
Z If the status indicator is red, verify that the serial cable is properly
connected to the relay, and that the relay has been properly
configured for communications (steps described earlier).
Setpoints can now be edited, printed, or changed according to user specifications. Other
setpoint and commands windows can be displayed and edited in a similar manner. Actual
values windows are also available for display. These windows can be locked, arranged,
and resized at will.
Note Refer to the EnerVista 489 Setup help file for additional information about using the
software.

4.4 Working with Setpoints and Setpoint Files
4.4.1 Engaging a Device

The EnerVista 489 Setup software may be used in on-line mode (relay connected) to
directly communicate with a 489 relay. Communicating relays are organized and grouped
by communication interfaces and into sites. Sites may contain any number of relays
selected from the SR or UR product series.
4.4.2 Entering Setpoints

The System Setup page will be used as an example to illustrate the entering of setpoints. In
this example, we will be changing the current sensing setpoints.
Z Establish communications with the relay.
Z Select the Setpoint > System Setup menu item.
This can be selected from the device setpoint tree or the main
window menu bar.
Z Select the Current Sensing menu item.
Z Select the PHASE CT PRIMARY setpoint by clicking anywhere in the
parameter box.
This will display three arrows: two to increment/decrement the value
and another to launch the numerical calculator.

Z Click the arrow at the end of the box to display a numerical keypad
interface that allows the user to enter a value within the setpoint
range displayed near the top of the keypad:
Z Click Accept to exit from the keypad and keep the new value.
Z Click on Cancel to exit from the keypad and retain the old value.
For setpoints requiring non-numerical pre-set values (e.g. VT CONNECTION TYPE below, in
the Voltage Sensing window),
Z Click anywhere within the setpoint value box to display a drop-down
selection menu arrow.
Z Click on the arrow to select the desired setpoint.
For setpoints requiring an alphanumeric text string (e.g. message scratchpad messages),
the value may be entered directly within the setpoint value box.
Z In the Setpoint / System Setup dialog box, click on Save to save the
values into the 489.
Z Click Yes to accept any changes.
Z Click No, and then Restore to retain previous values and exit.

4.4.3 Using Setpoint Files
Overview
The EnerVista 489 Setup software interface supports three ways of handling changes to
relay setpoints:
• In off-line mode (relay disconnected) to create or edit relay setpoint files for later
download to communicating relays.
• Directly modifying relay setpoints while connected to a communicating relay, then
saving the setpoints when complete.
• Creating/editing setpoint files while connected to a communicating relay, then
saving them to the relay when complete.
Settings files are organized on the basis of file names assigned by the user. A settings file
contains data pertaining to the following types of relay settings:
• Device Definition
• Product Setup
• System Setup
• Digital Inputs
• Output Relays
• Voltage Elements
• Power Elements
• RTD Temperature
• Thermal Model
• Monitoring Functions
• Analog Inputs and Outputs
• Relay Testing
• User Memory Map Setting Tool
Factory default values are supplied and can be restored after any changes.
The EnerVista 489 Setup display relay setpoints with the same hierarchy as the front panel
display. For specific details on setpoints, refer to Chapter 5.
Downloading and Saving Setpoints Files

Setpoints must be saved to a file on the local PC before performing any firmware
upgrades. Saving setpoints is also highly recommended before making any setpoint
changes or creating new setpoint files.
The EnerVista 489 Setup window, setpoint files are accessed in the Setpoints List control
bar window or the Files window. Use the following procedure to download and save
setpoint files to a local PC.
Z Ensure that the site and corresponding device(s) have been properly
defined and configured as shown in Connecting EnerVista 489 Setup
to the Relay on page 4–15.
Z Select the desired device from the site list.

Z Select the File > Read Settings from Device menu item to obtain
settings information from the device.
After a few seconds of data retrieval, the software will request the name and destination
path of the setpoint file. The corresponding file extension will be automatically assigned.
Z Press Save to complete the process.
A new entry will be added to the tree, in the File pane, showing path
and file name for the setpoint file.
Adding Setpoints Files to the Environment

The EnerVista 489 Setup software provides the capability to review and manage a large
group of setpoint files. Use the following procedure to add a new or existing file to the list.
Z In the files pane, right-click on ‘Files’
Z Select the Add Existing Setting File item as shown:
The Open dialog box will appear, prompting for a previously saved setting file. As for any
other Windows® application,
Z Browse for the file to add.
Z Click Open.
The new file and complete path will be added to the file list.
Creating a New Setpoint File

The EnerVista 489 Setup software allows the user to create new setpoint files independent
of a connected device. These can be uploaded to a relay at a later date. The following
procedure illustrates how to create new setpoint files.
Z In the File pane, right click on ‘File’.

Z Select the New Settings File item. The EnerVista 489 Setup software
displays the following box, allowing for the configuration of the
setpoint file for the correct firmware version. It is important to define
the correct firmware version to ensure that setpoints not available in
a particular version are not downloaded into the relay.
Z Select the Firmware Version for the new setpoint file.

Z For future reference, enter some useful information in the
Description box to facilitate the identification of the device and the
purpose of the file.
Z To select a file name and path for the new file, click the button
beside the Enter File Name box.
Z Select the file name and path to store the file, or select any displayed
file name to update an existing file.
All 489 setpoint files should have the extension ‘489’ (for example,
‘motor1.489’).
Z Click Save and OK to complete the process.
Once this step is completed, the new file, with a complete path, will
be added to the EnerVista 489 Setup software environment.
Upgrading Setpoint Files to a New Revision

It is often necessary to upgrade the revision code for a previously saved setpoint file after
the 489 firmware has been upgraded (for example, this is required for firmware upgrades).
This is illustrated in the following procedure.
Z Establish communications with the 489 relay.
Z Select the Actual > Product Information menu item and record the
Software Revision identifier of the relay firmware as shown below.

Z Load the setpoint file to be upgraded into the EnerVista 489 Setup
environment as described in Adding Setpoints Files to the
Environment on page 4–24.
Z In the File pane, select the saved setpoint file.
Z From the main window menu bar, select the File > Properties menu
item and note the version code of the setpoint file.
If this version (e.g. 4.0X shown below) is different than the Software
Revision code noted in step 2, select a New File Version that
matches the Software Revision code from the pull-down menu.
For example, if the software revision is 3.00 and the current setpoint file revision is
1.50, change the setpoint file revision to “3.0X”, as shown below.
Enter any special comments Select the desired setpoint version

about the setpoint file here. from this menu. The 3.0x indicates
versions 3.00, 3.01, 3.02, etc.
Z When complete, click Convert to convert the setpoint file to the

desired revision.
A dialog box will request confirmation. See Loading Setpoints from a
File on page 4–28 for instructions on loading this setpoint file into the
489.

Printing Setpoints and Actual Values

The EnerVista 489 Setup software allows the user to print partial or complete lists of
setpoints and actual values. Use the following procedure to print a list of setpoints:
Z Select a previously saved setpoints file in the File pane or establish
communications with a 489 device.
Z From the main window, select the File > Print Settings menu item.
The Print/Export Options dialog box will appear.
Z Select Settings in the upper section.
Z Select either Include All Features (for a complete list) or Include Only
Enabled Features (for a list of only those features which are
currently used) in the filtering section.
Z Click OK.
The process for File > Print Preview Settings is identical to the steps above.
Setpoints lists can be printed in the same manner by right clicking on the desired file (in the
file list) or device (in the device list) and selecting the Print Device Information or Print
Settings File options.
A complete list of actual values can also be printed from a connected device with the
following procedure:
Z Establish communications with the desired 489 device.
Z From the main window, select the File > Print Settings menu item.
The Print/Export Options dialog box will appear.
Z Select Actual Values in the upper section.
Z Select either Include All Features (for a complete list) or Include Only
Enabled Features (for a list of only those features which are
currently used) in the filtering section.
Z Click OK.
Actual values can be printed in the same manner by right clicking on the desired device (in
the device list) and selecting the Print Device Information option.

Loading Setpoints from a File
An error message will occur when attempting to download a setpoint file with a revision
number that does not match the relay firmware. If the firmware has been upgraded since
saving the setpoint file, see Upgrading Setpoint Files to a New Revision on page 4–25 for
instructions on changing the revision number of a setpoint file.
The following procedure illustrates how to load setpoints from a file. Before loading a
setpoint file, it must first be added to the EnerVista 489 Setup environment as described in
Adding Setpoints Files to the Environment on page 4–24.
Z Select the previously saved setpoint file from the File pane of the
EnerVista 489 Setup software main window.
Z Select the File > Properties menu item and verify that the
corresponding file is fully compatible with the hardware and
firmware version of the target relay.
If the versions are not identical, see Upgrading Setpoint Files to a
New Revision on page 4–25 for details on changing the setpoints file
version.
Z Right-click on the selected file.
Z Select the Write Settings to Device item.
The software will prompt for a target device.
Z Select the desired device.
Z Click Send.

If there is an incompatibility, an error of the following type will occur.
If there are no incompatibilities between the target device and the Setpoints file, the data
will be transferred to the relay. An indication of the percentage completed will be shown in
the bottom of the main menu.

4.5 Upgrading Relay Firmware
4.5.1 Description
To upgrade the 489 firmware, follow the procedures listed in this section. Upon successful
completion of this procedure, the 489 will have new firmware installed with the original
setpoints.
The latest firmware files are available from the GE Multilin website at
http://www.GEmultilin.com.
4.5.2 Saving Setpoints to a File

Before upgrading firmware, it is very important to save the current 489 settings to a file on
your PC. After the firmware has been upgraded, it will be necessary to load this file back
into the 489.
Refer to Downloading and Saving Setpoints Files on page 4–23 for details on saving relay
setpoints to a file.
4.5.3 Loading New Firmware

Loading new firmware into the 489 flash memory is accomplished as follows:
Z Connect the relay to the local PC and save the setpoints to a file as
shown in Downloading and Saving Setpoints Files on page 4–23.
Z Select the Communications > Update Firmware menu item.
The following warning message will appear.
Z Select Yes to proceed or No to cancel the process.

Do not proceed unless you have saved the current setpoints
An additional message will be displayed to ensure the PC is connected to the relay front
port, as the 489 cannot be upgraded via the rear RS485 ports.

The EnerVista 489 Setup software will request the new firmware file. Locate the file to load
into the 489. The firmware filename has the following format:
32 J 300 A8 . 000
Modification Number (000 = none)
GE Multilin use only
Firmware version
Required 489 hardware revision
Product code (32 = 489)
FIGURE 4–5: Firmware File Format
The EnerVista 489 Setup software automatically lists all filenames beginning with ‘32’.
Z Select the appropriate file.
Z Click OK to continue.
The software will prompt with another Upload Firmware Warning window. This will be the
final chance to cancel the firmware upgrade before the flash memory is erased.
Z Click Yes to continue or No to cancel the upgrade.
The EnerVista 489 Setup software now prepares the 489 to receive the new firmware file.
The 489 will display a message indicating that it is in Upload Mode. While the file is being
loaded into the 489, a status box appears showing how much of the new firmware file has
been transferred and how much is remaining, as well as the upgrade status. The entire
transfer process takes approximately five minutes.
The EnerVista 489 Setup software will notify the user when the 489 has finished loading
the file.
Z Carefully read any displayed messages and click OK to return the
main screen.
Note Cycling power to the relay is recommended after a firmware upgrade.
After successfully updating the 489 firmware, the relay will not be in service and will
require setpoint programming. To communicate with the relay, the following settings will
have to be manually programmed.
MODBUS COMMUNICATION ADDRESS
BAUD RATE
PARITY (if applicable)

When communications is established, the saved setpoints must be reloaded back into the
relay. See Loading Setpoints from a File on page 4–28 for details.
Modbus addresses assigned to firmware modules, features, settings, and corresponding
data items (i.e. default values, min/max values, data type, and item size) may change
slightly from version to version of firmware.
The addresses are rearranged when new features are added or existing features are
enhanced or modified. The EEPROM DATA ERROR message displayed after upgrading/
downgrading the firmware is a resettable, self-test message intended to inform users that
the Modbus addresses have changed with the upgraded firmware. This message does not
signal any problems when appearing after firmware upgrades.

4.6 Advanced EnerVista 489 Setup Features
4.6.1 Triggered Events

While the interface is in either on-line or off-line mode, data generated by triggered
specified parameters can be viewed and analyzed via one of the following:
• Event Recorder: The event recorder captures contextual data associated with the
last 256 events, listed in chronological order from most recent to the oldest.
• Oscillography: The oscillography waveform traces provide a visual display of
power system and relay operation data captured during specific triggered events.
4.6.2 Waveform Capture (Trace Memory)

The EnerVista 489 Setup software can be used to capture waveforms (or view trace
memory) from the 489 relay at the instance of a trip. A maximum of 128 cycles can be
captured and the trigger point can be adjusted to anywhere within the set cycles. A
maximum of 16 waveforms can be buffered (stored) with the buffer/cycle trade-off.
The following waveforms can be captured:
• Phase A, B, and C currents (Ia, Ib, and Ic)
• Neutral end A, B, and C currents (Ineutral_a, Ineutral_b, and Ineutral_c)
• Ground currents (Ig)
• Phase A-N, B-N, and C-N voltages (Va, Vb, and Vc)
Z With EnerVista 489 Setup running and communications established,
select the Actual > Waveform Capture menu item to open the
waveform capture setup window:
Number of available files
Files to be saved or viewed Save waveform to a file
Z Click on Trigger Waveform to trigger a waveform capture.

The waveform file numbering starts with the number zero in the 489; therefore, the
maximum trigger number will always be one less then the total number triggers
available.

Z Click on the Save to File button to save the selected waveform to the
local PC.
A new window will appear requesting for file name and path.
The file is saved as a CSV (comma delimited values) file, which can be viewed and
manipulated with compatible third-party software.
To view a previously saved file,
Z Click the Open button and select the corresponding CSV file.
To view the captured waveforms,
Z Click the Launch Viewer button.
A detailed Waveform Capture window will appear as shown below:
TRIGGER TIME & DATE CURSOR LINE POSITION

Display the time & date of the VECTOR DISPLAY SELECT Indicate the cursor line position
Trigger Click here to open a new graph in time with respect to the
to display vectors trigger time DELTA
Indicates time difference
between the two cursor lines
Display graph values CURSOR

at the corresponding FILE NAME LINES TRIGGER LINE
cursor line. Cursor Indicates the To move lines locate the mouse pointer Indicates the
lines are identified by file name and over the cursor line then click and drag point in time for
their colors. complete path the cursor to the new location. the trigger
(if saved)
FIGURE 4–6: Waveform Capture Window Attributes
The red vertical line indicates the trigger point of the relay.
The date and time of the trigger is displayed at the top left corner of the window. To match
the captured waveform with the event that triggered it,
Z Make note of the time and date shown in the graph.
Z Find the event that matches the same time and date in the event
recorder.

The event record will provide additional information on the cause and the system
conditions at the time of the event.
Additional information on how to download and save events is shown in Event Recorder on
page 4–40.
Z From the window main menu bar, press the Preference button to
open the Setup page to change the graph attributes.
Preference button
The following window will appear:
Z Change the Color of each graph as desired, and select other options,
as required, by checking the appropriate boxes.
Z Click OK to store these graph attributes, and to close the window.
The Waveform Capture window will reappear with the selected graph attributes available
for use.
4.6.3 Phasors
The EnerVista 489 Setup software can be used to view the phasor diagram of three-phase
currents and voltages. The phasors are for: Phase Voltages Va, Vb, and Vc; Phase Currents
Ia, Ib, and Ic.

Z With the EnerVista 489 Setup software running and communications

established, open the Actual Values > Metering Data window.
Z Click on the Phasors tab.
The EnerVista 489 Setup software will display the following window:
Z Press the “View” button to display the following window:
VOLTAGE LEVEL CURRENT LEVEL

Displays the value Displays the value
and the angle of and angle of the
the voltage phasors current phasor
VOLTAGE VECTORS CURRENT VECTORS

Assigned to Phasor Assigned to Phasor
Set 1, Graph 1 Set 2, Graph 2
The 489 Generator Management Relay was designed to display lagging angles. Therefore,
if a system condition would cause the current to lead the voltage by 45°, the 489 relay will
display such angle as 315° Lag instead of 45° Lead.

When the currents and voltages measured by the relay are zero, the angles displayed by
the relay and those shown by the EnerVista 489 Setup software are not fixed values.
4.6.4 Trending (Data Logger)

The trending or data logger feature is used to sample and record up to eight actual values
at an interval defined by the user. Several parameters can be trended and graphed at
sampling periods ranging from 1 second up to 1 hour. The parameters which can be
trended by the EnerVista 489 Setup software are:
• Currents/Voltages:
Phase Currents A, B, and C
Generator Load
Negative-Sequence Current
Ground Current and Neutral Current
Differential Currents A, B, and C
System Frequency
Voltages Vab, Vbc, Vca Van, Vbn & Vcn
• Power:
Power Factor
Real (kW) Reactive (kvar), and Apparent (kVA) Power
Positive Watthours
Positive and Negative Varhours
• Temperature:
Hottest Stator RTD
Thermal Capacity Used
RTDs 1 through 12
• Demand:
Current
Peak Current
Reactive Power
Peak Reactive Power
Apparent Power
Peak Apparent Power
• Others:
Analog Inputs 1, 2, 3, and 4
Tachometer

With EnerVista 489 Setup running and communications established,

Z Select the Actual Values > Trending menu item to open the trending
window.
The following window will appear.
To prepare for new trending,

Z Select Stop to stop the data logger and Reset to clear the screen.
Z Select the graphs to be displayed through the pull-down menu
beside each channel description.
Z Select the Sample Rate through the pull-down menu.
If you want to save the information captured by trending,
Z Check the box besides Log Samples to File.
The following dialog box will appear requesting for file name and
path. The file is saved as 'csv' (comma delimited values) file, which
can be viewed and manipulated with compatible third-party
software.
Z Ensure that the sample rate is not less than 5 seconds, otherwise,
some data may not get written to the file.

To limit the size of the saved file,

Z Enter a number in the Limit File Capacity To box.
The minimum number of samples is 1000. At a sampling rate of 5
seconds (or 1 sample every 5 seconds), the file will contain data
collected during the past 5000 seconds. The EnerVista 489 Setup
software will automatically estimate the size of the trending file.
Z Press “Run” to start the data logger.
If the Log Samples to File item is selected, the EnerVista 489 Setup
software will begin collecting data at the selected sampling rate and
will display it on the screen. The data log will continue until the Stop
button is pressed or until the selected number of samples is reached,
whichever occurs first.
During the process of data logging, the trending screen appears as shown below.
SAVE DATA TO FILE MODE SELECT BUTTONS

Select to save the Select to view Cursor 1, Zoom In enlarges the graph
information to a CSV Cursor 2, or the Delta Zoom Out shrinks the graph
file on the PC (difference) values for Reset clears the screen
the graph Run/Stop starts and stops
the data logger
GRAPH CHANNEL LEVEL CURSOR LINES WAVEFORM

Select the desired Displays the value Click and drag the The trended data
channel to be captured at the active cursor lines with from the 469 relay
from the pull-down menu cursor line the left mouse
button
FIGURE 4–7: Trending Screen

4.6.5 Event Recorder

The 489 event recorder can be viewed through the EnerVista 489 Setup software. The
event recorder stores generator and system information each time an event occurs (e.g.
breaker failure). A maximum of 256 events can be stored. Each event is assigned an event
number, from E001 to E256. When the E256 is reached, E001 is assigned to the next event.
Refer to Event Recorder on page 6–28 for additional information on the event recorder.
Use the following procedure to view the event recorder with EnerVista 489 Setup:
With EnerVista 489 Setup running and communications established,
Z Select the Actual > A4 Event Recorder item from the main menu.
This displays the Event Recorder window indicating the list of
recorded events, with the most current event displayed first.
EVENT LISTING EVENT SELECTION EVENT NUMBER CLEAR EVENTS

Select an event row to view The event data Click the Clear
Lists the last 256
event data information, information is related Events button to
events with the most
which will be displayed in to the selected event, clear the event list
recent displayed at
the window to the right. as shown. from memory.
top of list.
DEVICE ID EVENT DATA SAVE EVENTS

The events shown System information as Click the Save Events
here correspond to measured by the relay at button to save the event
the device shown. the instant of the event record to the PC as a
occurrence. CSV file.
FIGURE 4–8: Event Recorder Window (shown unconnected)

To view detailed information for a given event and the system information at the moment
of the event occurrence,
Z Change the event number on the Select Event box.
4.6.6 Modbus User Map

The EnerVista 489 Setup software provides a means to program the 489 User Map
(Modbus addresses 0180h to 01F7h). Refer to GE Publication GEK-106491: 489
Communications Guide for additional information on the User Map.
Z Select a connected device in EnerVista 489 Setup.
Z Select the Setpoint > User Map menu item to open the following
window.
This window allows the desired addresses to be written to User Map locations. The
User Map values that correspond to these addresses are then displayed.
4.6.7 Viewing Actual Values

You can view real-time relay data such as input/output status and measured parameters.
From the main window menu bar, selecting Actual Values opens a window with tabs, each
tab containing data in accordance with the following list:
1. Generator and System Status:

• Generator status either stopped, starting, or running. It includes values such as

generator load, thermal capacity used, generator speed, and instantaneous values
of power system quantities.
• The status of digital inputs.
• Last trip information, including values such as cause of last trip, time and date of
trip, generator speed and load at the time of trip, pre-trip temperature
measurements, pre-trip analog inputs values, and pre-trip instantaneous values of
power system quantities.
• Active alarms.
• Relay date and time.
• Present blocking conditions.
• General system status indication including the status of output relays, active
pickup, alarm and trip conditions.
2. Metering Data:
• Instantaneous current measurements including phase, differential, unbalance,
ground, average, generator load, and differential currents.
• RTD Temperatures including hottest RTDs.
• Instantaneous phase to phase and phase to ground voltages (depending on the VT
connections), average voltage, and system frequency.
• Generator Speed
• Power Quantities including Apparent, Real and Reactive Power.
• Current and power demand including peak values.
• Analog inputs
• Vector information.
3. Generator Learned Data:
• Average Generator Load
• Average Negative-Sequence Current
• Phase-Phase Voltage
• RTD Maximum Values
4. Maintenance data.
This is useful statistical information that may be used for preventive maintenance. It
includes:
• Trip counters
• General counter such as Number of Breaker Operations.
• Timers such as Generator Running Hours.
5. RTD Learned Data - includes the maximum temperature measured by each of the 12
RTDs.
6. Event recorder downloading tool.
7. Product information including model number, firmware version, additional product
information, and calibration dates.
8. Oscillography and Data Logger downloading tool.

Selecting an actual values window also opens the actual values tree from the
corresponding device in the site list and highlights the current location in the hierarchy.
For complete details on actual values, refer to Chapter 6.
To view a separate window for each group of actual values, select the desired item from
the tree, and double click with the left mouse button. Each group will be opened on a
separate tab. The windows can be re-arranged to maximize data viewing as shown in the
following figure (showing actual current, voltage, and generator status values tiled in the
same window):
FIGURE 4–9: Actual Values Display (shown unconnected)

4.7 Using EnerVista Viewpoint with the 489
4.7.1 Plug and Play Example

EnerVista Viewpoint is an optional software package that puts critical 489 information on
any PC with plug-and-play simplicity. EnerVista Viewpoint connects instantly to the 489 via
serial, ethernet or modem and automatically generates detailed overview, metering,
power, demand, energy and analysis screens. Installing EnerVista Launchpad (see previous
section) allows the user to install a fifteen-day trial version of EnerVista Viewpoint. After
the fifteen day trial period you will need to purchase a license to continue using EnerVista
Viewpoint. Information on license pricing can be found at http://www.EnerVista.com.
Z Install the EnerVista Viewpoint software from the GE EnerVista CD.
Z Ensure that the 489 device has been properly configured for either
serial or Ethernet communications (see previous sections for details).
Z Click the Viewpoint window in EnerVista to log into EnerVista
Viewpoint.
At this point, you will be required to provide a login and password if
you have not already done so.
FIGURE 4–10: EnerVista Viewpoint Main Window
Z Click the Device Setup button to open the Device Setup window.
the display order of devices defined for the site.
The new site will appear in the upper-left list in the EnerVista 489
Setup window.

Z Select the appropriate communications interface (Ethernet or Serial)
and fill in the required information for the 489. See Connecting
EnerVista 489 Setup to the Relay on page 4–15 for details.
FIGURE 4–11: Device Setup Screen (Example)
upload the order code. If an communications error occurs, ensure
that communications values entered in the previous step correspond
to the relay setting values.
Z Click OK when complete.
Z From the EnerVista main window, select the IED Dashboard item to
open the Plug and Play IED dashboard.
An icon for the 489 will be displayed.

FIGURE 4–12: ‘Plug and Play’ Dashboard
Z Click the Dashboard button below the 489 icon to view the device
information.
We have now successfully accessed our 489 through EnerVista Viewpoint.

FIGURE 4–13: EnerVista Plug and Play Screens
For additional information on EnerVista viewpoint, please visit the EnerVista website at
http://www.EnerVista.com.


Digital Energy
Multilin
Chapter 5: Setpoints
Setpoints
5.1 Overview
5.1.1 Setpoint Message Map

The 489 has a considerable number of programmable setpoints which makes it extremely
flexible. The setpoints have been grouped into a number of pages and sub-pages as
shown below. Each page of setpoints (e.g. S2 SYSTEM SETUP) has a section which describes
in detail all the setpoints found on that page.
PASSCODE [Z]
See page 5–9.
SETPOINTS [Z]

MESSAGE See page 5–10.
PREFERENCES [Z]

COMMUNICATIONS [Z]
REAL TIME [Z]
CLOCK

DEFAULT [Z]

MESSAGE [Z]
CLEAR DATA [Z]
END OF PAGE
MESSAGE

CHAPTER 5: SETPOINTS

See page 5–18.
SETPOINTS [Z] CURRENT [Z]

VOLTAGE [Z]

GENERATOR [Z]

SERIAL [Z]
END OF PAGE
MESSAGE

See page 5–21.
SETPOINTS [Z] BREAKER [Z]

GENERAL [Z]

GENERAL [Z]
↓

GENERAL [Z]
REMOTE RESET [Z]
TEST INPUT [Z]

THERMAL RESET [Z]


DUAL [Z]

SEQUENTIAL [Z]
FIELD-
BREAKER [Z]

TACHOMETER [Z]

WAVEFORM [Z]

GROUND [Z]
END OF PAGE
MESSAGE


See page 5–28.
SETPOINTS [Z] RELAY [Z]
END OF PAGE
MESSAGE
1 SETPOINTS [Z] 1 OVERCURRENT [Z]

See page 5–33.
S5 CURRENT ELEM. ALARM
1 OFFLINE [Z]
OVERCURRENT
1 INADVERTENT [Z]
ENERGIZATION
1 PHASE [Z]
OVERCURRENT
1 NEGATIVE [Z]
SEQUENCE
1 GROUND [Z]
OVERCURRENT
1 PHASE [Z]
DIFFERENTIAL
1 GROUND [Z]
DIRECTIONAL
1 HIGH-SET [Z]
PHASE OVERCURRENT
END OF PAGE
MESSAGE
1 SETPOINTS [Z] 1 UNDERVOLTAGE [Z]

See page 5–43.
S6 VOLTAGE ELEM.
1 OVERVOLTAGE [Z]
1 VOLTS/HERTZ [Z]
1 PHASE [Z]
REVERSAL
1 UNDERFREQUENCY [Z]
1 OVERFREQUENCY [Z]
1 NEUTRAL O/V [Z]

(FUNDAMENTAL)

1 NEUTRAL U/V [Z]

(3rd HARMONIC)
1 LOSS OF [Z]
EXCITATION
1 DISTANCE [Z]
ELEMENT
END OF PAGE
MESSAGE
1 SETPOINTS [Z] 1 REACTIVE [Z]

See page 5–61.
S7 POWER ELEMENTS POWER
1 REVERSE [Z]
POWER
1 LOW FORWARD [Z]
POWER
END OF PAGE
MESSAGE
1 SETPOINTS [Z] 1 RTD TYPES [Z]

See page 5–64.
S8 RTD TEMPERATURE
1 RTD #1 [Z]
1 RTD #2 [Z]
1 RTD #3 [Z]
↓
1 RTD #12 [Z]
1 OPEN RTD [Z]

SENSOR
1 RTD [Z]
SHORT/LOW TEMP
END OF PAGE
MESSAGE
1 SETPOINTS [Z] 1 MODEL SETUP [Z]

See page 5–71.
S9 THERMAL MODEL
1 THERMAL [Z]
ELEMENTS

END OF PAGE
MESSAGE

See page 5–90.
SETPOINTS [Z] TRIP [Z]

BREAKER [Z]
TRIP COIL [Z]
MONITOR
VT FUSE [Z]
FAILURE

CURRENT [Z]
MW DEMAND [Z]
Mvar DEMAND [Z]

MVA DEMAND [Z]


PULSE [Z]

RUNNING [Z]
END OF PAGE
MESSAGE

See page 5–96.
SETPOINTS [Z] ANALOG [Z]

ANALOG [Z]

ANALOG [Z]

ANALOG [Z]

ANALOG [Z]

ANALOG [Z]

ANALOG [Z]


ANALOG [Z]
END OF PAGE
MESSAGE

See page 5–100.
SETPOINTS [Z] SIMULATION [Z]
PRE-
FAULT [Z]

FAULT [Z]

TEST [Z]

TEST [Z]

COMMUNICATION [Z]

FACTORY [Z]
END OF PAGE
MESSAGE
5.1.2 Trips / Alarms/ Control Features

The 489 Generator Management Relay has three basic function categories: TRIPS, ALARMS,
and CONTROL.
Trips
A 489 trip feature may be assigned to any combination of the four output relays: 1 Trip,
2 Auxiliary, 3 Auxiliary, and 4 Auxiliary. If a Trip becomes active, the appropriate LED
(indicator) on the 489 faceplate illuminates to indicate which output relay has operated.
Each trip feature may be programmed as latched or unlatched. Once a latched trip feature
becomes active, the RESET key must be pressed to reset that trip. If the condition that
caused the trip is still present (for example, hot RTD) the trip relay(s) will not reset until the
condition disappears. On the other hand, if an unlatched trip feature becomes active, that
trip resets itself (and associated output relay(s)) after the condition that caused the trip
ceases and the Breaker Status input indicates that the breaker is open. If there is a lockout
time, the trip relay(s) will not reset until the lockout time has expired. Immediately prior to
issuing a trip, the 489 takes a snapshot of generator parameters and stores them as pre-
trip values, allowing for troubleshooting after the trip. The cause of last trip message is
updated with the current trip and the 489 display defaults to that message. All trip features
are automatically logged and date and time stamped as they occur. In addition, all trips
are counted and logged as statistics such that any long term trends may be identified.

Note that a lockout time will occur due to overload trip (see Model Setup on page 5–71 for
additional details).
Alarms
A 489 alarm feature may be assigned to operate any combination of four output relays:
2 Auxiliary, 3 Auxiliary, 4 Auxiliary, and 5 Alarm. When an alarm becomes active, the
appropriate LED (indicator) on the 489 faceplate will illuminate when an output relay(s) has
operated. Each alarm feature may be programmed as latched or unlatched. Once a
latched alarm feature becomes active, the reset key must be pressed to reset that alarm. If
the condition that has caused the alarm is still present (for example, hot RTD) the Alarm
relay(s) will not reset until the condition is no longer present. If on the other hand, an
unlatched alarm feature becomes active, that alarm will reset itself (and associated output
relay(s)) as soon as the condition that caused the alarm ceases. As soon as an alarm
occurs, the alarms messages are updated to reflect the alarm and the 489 display defaults
to that message. Since it may not be desirable to log all alarms as events, each alarm
feature may be programmed to log as an event or not. If an alarm is programmed to log as
an event, when it becomes active, it is automatically logged as a date and time stamped
event.
Control
A 489 control feature may be assigned to operate any combination of five output relays:
1 Trip, 2 Auxiliary, 3 Auxiliary, 4 Auxiliary, and 5 Alarm. The combination of relays available
for each function is determined by the suitability of each relay for that particular function.
The appropriate LED (indicator) on the 489 faceplate will illuminate when an output relay(s)
has been operated by a control function. Since it may not be desirable to log all control
function as events, each control feature may be programmed to log as an event or not. If a
control feature is programmed to log as an event, each control relay event is automatically
logged with a date and time stamp.
5.1.3 Relay Assignment Practices

There are six output relays. Five of the relays are always non-failsafe, the other (Service) is
failsafe and dedicated to annunciate internal 489 faults (these faults include setpoint
corruption, failed hardware components, loss of control power, etc.). The five remaining
relays may be programmed for different types of features depending on what is required.
One of the relays, 1 Trip, is intended to be used as a trip relay wired to the unit trip breaker.
Another relay, 5 Alarm, is intended to be used as the main alarm relay. The three remaining
relays, 2 Auxiliary, 3 Auxiliary, and 4 Auxiliary, are intended for special requirements.
When assigning features to relays 2, 3, and 4, it is a good idea to decide early on what is
required since features that may be assigned may conflict. For example, if relay 2 is to be
dedicated as a relay for sequential tripping, it cannot also be used to annunciate a specific
alarm condition.
In order to ensure that conflicts in relay assignments do not occur, several precautions
have been taken. All trips default to the 1 Trip output relay and all alarms default to the
5 Alarm relay. It is recommended that relay assignments be reviewed once all the setpoints
have been programmed.

5.1.4 Dual Setpoints

The 489 has dual settings for the current, voltage, power, RTD, and thermal model
protection elements (setpoints pages S5 to S9). These setpoints are organized in two
groups: the main group (Group 1) and the alternate group (Group 2). Only one group of
settings is active in the protection scheme at a time. The active group can be selected
using the ACTIVATE SETPOINT GROUP setpoint or an assigned digital input in the S3 Digital
Inputs setpoints page. The LED indicator on the faceplate of the 489 will indicate when the
alternate setpoints are active in the protection scheme. Independently, the setpoints in
either group can be viewed and/or edited using the EDIT SETPOINT GROUP setpoint.
Headers for each setpoint message subgroup that has dual settings will be denoted by a
superscript number indicating which setpoint group is being viewed or edited. Also, when a
setpoint that has dual settings is stored, the flash message that appears will indicate
which setpoint group setting has been changed.
If only one setting group is required, edit and activate only Group 1 (that is, do not assign a
digital input to Dual Setpoints, and do not alter the ACTIVATE SETPOINT GROUP setpoint or
EDIT SETPOINT GROUP setpoint in S3 DIGITAL INPUTS).
5.1.5 Commissioning
Tables for recording of 489 programmed setpoints are available as a Microsoft Word
document from the GE Multilin website at http://www.GEmultilin.com. See the Support
Documents section of the 489 Generator Management Relay page for the latest version.
This document is also available in print from the GE Multilin literature department (request
publication number GET-8445).

5.2 S1 489 Setup
5.2.1 Passcode
PATH: SETPOINTS Z S1 489 SETUP Z PASSCODE
PASSCODE [Z] ENTER PASSCODE FOR Range: 1 to 8 numeric digits

ACCESS:
SETPOINT ACCESS: Range: Permitted, Restricted
MESSAGE
Permitted
CHANGE PASSCODE: Range: No, Yes
MESSAGE
No
A passcode access security feature is provided with the 489. The passcode is defaulted to
“0” (without the quotes) at the time of shipping. Passcode protection is ignored when the
passcode is “0”. In this case, the setpoint access jumper is the only protection when
programming setpoints from the front panel keypad and setpoints may be altered using
the RS232 and RS485 serial ports without access protection. If however, the passcode is
changed to a non-zero value, passcode protection is enabled. The access jumper must be
installed and the passcode must be entered, to program setpoints from the front panel
keypad. The passcode must also be entered individually from each serial communications
port to gain setpoint programming access from that port.
The ENTER PASSCODE FOR ACCESS setpoint is seen only if the passcode is not 0 and
SETPOINT ACCESS is “Restricted”. The SETPOINT ACCESS and CHANGE PASSWORD setpoints
are seen only if the passcode is 0 and the SETPOINT ACCESS is “Permitted”.
To enable passcode protection on a new relay, follow the procedure below:
Z Press ENTER then MESSAGE DOWN until CHANGE PASSCODE
message is displayed.
Z Select Yes and follow directions to enter a new passcode 1 to 8 digits
in length.
Once a new passcode (other than “0”) is programmed, it must be entered to gain setpoint
access whenever setpoint access is restricted. Assuming that a non-zero passcode has
been programmed and setpoint access is restricted, then selecting the passcode subgroup
causes the ENTER PASSCODE AGAIN message to appear.
Z Enter the correct passcode. A flash message will advise if the code is
incorrect and allow a retry. If it is correct and the setpoint access
jumper is installed, the SETPOINT ACCESS: Permitted message
appears.
Setpoints can now be entered.
Z Exit the passcode message with the ESCAPE key and program the
appropriate setpoints.
If no keypress occurs for 30 minutes, access will be disabled and the
passcode must be re-entered. Removing the setpoint access jumper
or setting SETPOINT ACCESS to Restricted also disables setpoint
access immediately.

If a new passcode is required, gain setpoint access as follows:

Z Enter the current valid passcode.
Z Press MESSAGE DOWN to display the CHANGE PASSCODE
message and follow the directions.
If an invalid passcode is entered, the encrypted passcode is viewable
by pressing HELP.
Z Consult GE Multilin with this number if the currently programmed
passcode is unknown. The passcode can be determined with
deciphering software.
5.2.2 Preferences
PATH: SETPOINTS Z S1 489 SETUP ZV PREFERENCES
DEFAULT MESSAGE Range: 0.5 to 10.0 s in steps of 1

PREFERENCES [Z] CYCLE TIME: 2.0 s
DEFAULT MESSAGE Range: 10 to 900 s in steps of 1
MESSAGE
TIMEOUT: 300 s
PARAMETER AVERAGES Range: 1 to 90 min. in steps of 1
MESSAGE
CALC. PERIOD: 15 min
TEMPERATURE DISPLAY: Range: Celsius, Fahrenheit
MESSAGE
Celsius
WAVEFORM TRIGGER Range: 1 to 100% in steps of 1
MESSAGE
POSITION: 25%
WAVEFORM MEM BUFFER Range: 1x64, 2x42, 3x32, 4x35, 5x21,
MESSAGE 6x18, 7x16, 8x14, 9x12, 10x11,
8x14 cycles
11x10, 12x9, 13x9, 14x8, 15x8,
16x7 cycles
Some of the 489 characteristics can be modified to suit different situations. Normally the
S1 489 SETUP ZV PREFERENCES setpoints group will not require any changes.
• DEFAULT MESSAGE CYCLE TIME: If multiple default messages are chosen, the display
automatically cycles through these messages. The messages display time can be
changed to accommodate different reading rates.
• DEFAULT MESSAGE TIMEOUT: If no keys are pressed for a period of time then the relay
automatically scans through a programmed set of default messages. This time can be
modified to ensure messages remain on the screen long enough during programming
or reading of actual values.
• PARAMETER AVERAGES CALCULATION PERIOD: The period of time over which the
parameter averages are calculated may be adjusted with this setpoint. The
calculation is a sliding window.
• TEMPERATURE DISPLAY: Measurements of temperature may be displayed in either
Celsius or Fahrenheit. Each actual value temperature message will be denoted by
either °C for Celsius or °F for Fahrenheit. RTD setpoints are always displayed in Celsius.
• WAVEFORM TRIGGER: The trigger setpoint allows the user to adjust how many pre-
trip and post-trip cycles are stored in the waveform memory when a trip occurs. A

value of 25%, for example, when the WAVEFORM MEMORY BUFFER is “7 x 16" cycles,
would produce a waveform of 4 pre-trip cycles and 12 post-trip cycles.
• WAVEFORM MEMORY BUFFER: Selects the partitioning of the waveform memory. The
first number indicates the number of events and the second number, the number of
cycles. The relay captures 12 samples per cycle. When more waveform captures occur
than the available storage, the oldest data will be discarded.

Serial Communications
The following setpoints appear when the relay is ordered with the regular enhanced (E)
option.
PATH: SETPOINTS Z S1 489 SETUP ZV COMMUNICATIONS
SERIAL PORTS [Z] SLAVE ADDRESS: Range: 1 to 254 in steps of 1

254
COMPUTER RS485 Range: 300, 1200, 2400, 4800, 9600,
MESSAGE 19200
BAUD RATE: 9600
COMPUTER RS485 Range: None, Odd, Even
MESSAGE
PARITY: None
AUXILIARY RS485 Range: 300, 1200, 2400, 4800, 9600,
MESSAGE 19200
BAUD RATE: 9600
AUXILIARY RS485 Range: None, Odd, Even
MESSAGE
PARITY: None
The 489 is equipped with 3 independent serial communications ports supporting a subset
of Modbus RTU protocol. The front panel RS232 has a fixed baud rate of 9600 and a fixed
data frame of 1 start/8 data/1stop/no parity. The front port is intended for local use only
and will respond regardless of the slave address programmed. The front panel RS232
program port may be connected to a personal computer running the EnerVista 489 Setup
software. This program may be used for downloading and uploading setpoint files, viewing
measured parameters, and upgrading the 489 firmware to the latest revision.
For RS485 communications, each relay must have a unique address from 1 to 254. Address
0 is the broadcast address monitored by all relays. Addresses do not have to be sequential
but no two units can have the same address or errors will occur. Generally, each unit
added to the link will use the next higher address starting at 1. Baud rates can be selected
as 300, 1200, 2400, 4800, 9600, or 19200. The data frame is fixed at 1 start, 8 data, and 1
stop bits, while parity is optional. The computer RS485 port is a general purpose port for
connection to a DCS, PLC, or PC. The Auxiliary RS485 port may also be used as another
general purpose port or it may be used to talk to Auxiliary GE Multilin devices in the future.

Ethernet Communications
The following setpoints appear when the relay is ordered with the Ethernet (T) option.
PATH: SETPOINTS Z S1 489 SETUP ZV COMMUNICATIONS
SLAVE ADDRESS: Range: 1 to 254 in steps of 1

COMMUNICATIONS [Z] 254
COMPUTER RS485 Range: 300, 1200, 2400, 4800, 9600,
MESSAGE 19200
BAUD RATE: 9600
COMPUTER RS485 Range: None, Odd, Even
MESSAGE
PARITY: None
FRONT PORT RS232 Range: 300, 1200, 2400, 4800, 9600,
MESSAGE 19200
BAUD RATE: 19200
IP ADDRESS: Range: standard IP address format
MESSAGE
0.0.0.0
SUBNET IP MASK: Range: standard IP address format
MESSAGE
255.255.255.000
GATEWAY IP ADDRESS: Range: standard IP address format
MESSAGE
0.0.0.0
The IP addresses are used with the Modbus protocol. Enter the dedicated IP, subnet IP, and
gateway IP addresses provided by the network administrator.
To ensure optimal response from the relay, the typical connection timeout should be set as
indicated in the following table:
TCP/IP sessions Timeout setting
up to 2 2 seconds
up to 4 3 seconds
The RS485 COM2 port is disabled if the Ethernet option is ordered.

Note
5.2.4 Real Time Clock

PATH: SETPOINTS Z S1 489 SETUP ZV REAL TIME CLOCK
REAL TIME [Z] DATE (MM, DD, YYYY): Range: 01/01/1995 to 12/31/2094
CLOCK 01/01/1995
TIME (HH.MM.SS): Range: 00:00:00 to 23:59:59
MESSAGE
12:00:00
IRIG-B SIGNAL TYPE: Range: None, DC Shift, Amplitude
MESSAGE Modulated
NONE
For events that are recorded by the event recorder to be correctly time/date stamped, the
correct time and date must be entered. A battery backed internal clock runs continuously
even when power is off. It has the same accuracy as an electronic watch approximately ±1
minute per month. It must be periodically corrected either manually through the front

panel or via the clock update command over the RS485 serial link. If the approximate time
an event occurred without synchronization to other relays is sufficient, then entry of time/
date from the front panel keys is adequate.
If the RS485 serial communication link is used then all the relays can keep time in
synchronization with each other. A new clock time is pre-loaded into the memory map via
the RS485 communications port by a remote computer to each relay connected on the
communications channel. The computer broadcasts (address 0) a “set clock” command to
all relays. Then all relays in the system begin timing at the exact same instant. There can
be up to 100 ms of delay in receiving serial commands so the clock time in each relay is
±100 ms, ± the absolute clock accuracy in the PLC or PC. See the chapter on
Communications for information on programming the time preload and synchronizing
commands.
An IRIG-B signal receiver may be connected to 489 units with hardware revision G or
higher. The relay will continuously decode the time signal and set its internal time
correspondingly. The “signal type” setpoint must be set to match the signal provided by the
receiver.
5.2.5 Default Messages

PATH: SETPOINTS Z S1 489 SETUP ZV DEFAULT MESSAGES
GENERATOR STATUS: Range: N/A

DEFAULT [Z] Stopped
A: 0 B: 0 Range: N/A
MESSAGE
C: 0 Amps
Vab: 0 Vbc: 0 Range: N/A
MESSAGE
Vca: 0 Volts
FREQUENCY: Range: N/A
MESSAGE
0.00 Hz
POWER FACTOR: Range: N/A
MESSAGE
0.00
REAL POWER: Range: N/A
MESSAGE
0 MW
REACTIVE POWER Range: N/A
MESSAGE
0 Mvar
DATE: 01/01/1995 Range: N/A
MESSAGE
TIME: 12:00:00
GE MULTILIN Range: N/A
MESSAGE
489 GENERATOR RELAY
The 489 displays default messages after a period of keypad inactivity. Up to 20 default
messages can be selected for display. If more than one message is chosen, they will
automatically scroll at a rate determined by the S1 489 SETUP ZV PREFERENCES Z DEFAULT
MESSAGE CYCLE TIME setpoint. Any actual value can be selected for display. In addition, up
to 5 user-programmable messages can be created and displayed with the message

scratchpad. For example, the relay could be set to alternately scan a generator
identification message, the current in each phase, and the hottest stator RTD. Currently
selected default messages can be viewed in DEFAULT MESSAGES subgroup.
Default messages can be added to the end of the default message list, as follows:
Z Enter the correct passcode at S1 489 SETUP Z PASSCODE Z ENTER
PASSCODE FOR ACCESS to allow setpoint entry (unless it has already
been entered or is “0”, defeating the passcode security feature).
Z Select the message to be add to the default message list using the
MESSAGE keys.
The selected message can be any actual value or message
scratchpad message.
Z Press ENTER.
The PRESS [ENTER] TO ADD DEFAULT MESSAGES message will
be displayed for 5 seconds:
Z Press ENTER again while this message is displayed to add the
current message to the end of the default message list.
If the procedure was followed correctly, the DEFAULT MESSAGE HAS BEEN
ADDED flash message is displayed:
Z To verify that the message was added, view the last message under
the S1 489 SETUP ZV DEFAULT MESSAGES menu.
Default messages can be removed from the default message list, as follows:
Z Enter the correct passcode at S1 489 SETUP Z PASSCODE Z ENTER
PASSCODE FOR ACCESS to allow setpoint entry (unless the passcode
has already been entered or unless the passcode is “0” defeating the
passcode security feature).
Z Select the message to remove from the default message list under
the S1 489 SETUP ZV DEFAULT MESSAGES menu.
Z Select the default message to remove and press ENTER.
The relay will display PRESS [ENTER] TO REMOVE MESSAGE.
Z Press ENTER while this message is displayed to remove the current
message out of the default message list.
If the procedure was followed correctly, the DEFAULT MESSAGE HAS BEEN
REVOVED flash message is displayed.
5.2.6 Message Scratchpad

PATH: SETPOINTS Z S1 489 SETUP ZV MESSAGE SCRATCHPAD
TEXT 1 Range: 40 alphanumeric characters

MESSAGE [Z]
MESSAGE

MESSAGE


MESSAGE
GE MULTILIN Range: 40 alphanumeric characters

MESSAGE
489 GENERATOR RELAY
Up to 5 message screens can be programmed under the message scratchpad area. These
messages may be notes that pertain to the installation of the generator. In addition, these
notes may be selected for scanning during default message display. This might be useful
for reminding operators to perform certain tasks. The messages may be entered from the
communications ports or through the keypad. To enter a 40 character message:
Z Select the user message to be changed.
Z Press the decimal [.] key to enter text mode.
An underscore cursor will appear under the first character.
Z Use the VALUE keys to display the desired character.
A space is selected like a character.
Z Press the [.] key to advance to the next character.
To skip over a character press the [.] key.
If an incorrect character is accidentally stored, press the [.] key
enough times to scroll the cursor around to the character.
Z When the desired message is displayed press the ENTER key to
store or the ESCAPE key to abort.
The message is now permanently stored.
Z Press ESCAPE to cancel the altered message.
5.2.7 Clear Data

PATH: SETPOINTS Z S1 489 SETUP ZV CLEAR DATA
CLEAR DATA [Z] CLEAR LAST TRIP Range: No, Yes

DATA: No
RESET MWh and Mvarh Range: No, Yes
MESSAGE
METERS: No
CLEAR PEAK DEMAND Range: No, Yes
MESSAGE
DATA: No
CLEAR RTD Range: No, Yes
MESSAGE
MAXIMUMS: No
CLEAR ANALOG I/P Range: No, Yes
MESSAGE
MIN/MAX: No
CLEAR TRIP Range: No, Yes
MESSAGE
COUNTERS: No
CLEAR EVENT Range: No, Yes
MESSAGE
RECORD: No
CLEAR GENERATOR Range: No, Yes
MESSAGE
INFORMATION: No

CLEAR BREAKER Range: No, Yes

MESSAGE
INFORMATION: No
These commands may be used to clear various historical data.

• CLEAR LAST TRIP DATA: The Last Trip Data may be cleared by executing this
command.
• CLEAR MWh and Mvarh METERS: Executing this command will clear the MWh and
Mvarh metering to zero.
• CLEAR PEAK DEMAND DATA: Execute this command to clear peak demand values.
• CLEAR RTD MAXIMUMS: All maximum RTD temperature measurements are stored
and updated each time a new maximum temperature is established. Execute this
command to clear the maximum values.
• CLEAR ANALOG I/P MIN/MAX: The minimum and maximum analog input values are
stored for each Analog Input. Those minimum and maximum values may be cleared
at any time.
• CLEAR TRIP COUNTERS: There are counters for each possible type of trip. Those
counters may be cleared by executing this command.
• CLEAR EVENT RECORD: The event recorder saves the last 256 events, automatically
overwriting the oldest event. If desired, all events can be cleared using this command
to prevent confusion with old information.
• CLEAR GENERATOR INFORMATION: The number of thermal resets and the total
generator running hours can be viewed in actual values. On a new installation, or if
new equipment is installed, this information is cleared through this setpoint.
• CLEAR BREAKER INFORMATION: The total number of breaker operations can be
viewed in actual values. On a new installation or if maintenance work is done on the
breaker, this accumulator can be cleared with this setpoint.

5.3 S2 System Setup
5.3.1 Current Sensing

PATH: SETPOINTS ZV S2 SYSTEM SETUP Z CURRENT SENSING
PHASE CT PRIMARY: Range: 1 to 5000 in steps of 1, Not

CURRENT [Z] ------------- Programmed
GROUND CT: Range: None, 1A Secondary, 5A

MESSAGE Secondary, 50:0.025
50:0.025
GROUND CT RATIO: Range: 10 to 10000 in steps of 1. Seen
MESSAGE only if Ground CT Type is 1 A
100: 1
GROUND CT RATIO: Range: 10 to 10000 in steps of 1. Seen
MESSAGE only if Ground CT Type is 5 A
100: 5
As a safeguard, the PHASE CT PRIMARY and GENERATOR PARAMETERS setpoints are

defaulted to “--------” when shipped, indicating that the 489 was never programmed. Once
these values are entered, the 489 will be in service. Select the Phase CT so that the
maximum fault current does not exceed 20 times the primary rating. When relaying class
CTs are purchased, this precaution helps prevent CT saturation under fault conditions. The
secondary value of 1 or 5 A must be specified when ordering so the proper hardware will
be installed. The PHASE CT PRIMARY setpoint applies to both the neutral end CTs as well as
the output CTs.
For high resistance grounded systems, sensitive ground current detection is possible if the
50:0.025 Ground CT is used. To use the 50:0.025 CT input, set GROUND CT to “50:0.025”. No
additional ground CT messages will appear. On solid or low resistance grounded systems,
where fault currents may be quite large, the 489 1 A/5 A secondary Ground CT input should
be used. Select the Ground CT primary so that potential fault current does not exceed 20
times the primary rating. When relaying class CTs are purchased, this precaution will
ensure that the Ground CT does not saturate under fault conditions.
The 489 uses a nominal CT primary rating of 5 A for calculation of pickup levels.
5.3.2 Voltage Sensing

PATH: SETPOINTS Z S2 SYSTEM SETUP ZV VOLTAGE SENSING
VT CONNECTION TYPE: Range: Open Delta, Wye, None

VOLTAGE [Z] None
VOLTAGE TRANSFORMER Range: 1.00:1 to 300.00:1 in steps of
MESSAGE 0.01
RATIO: 5.00:1
NEUTRAL VOLTAGE Range: No, Yes
MESSAGE
TRANSFORMER: No
NEUTRAL VT Range: 1.00:1 to 240.00:1 in steps of
MESSAGE 0.01.
RATIO: 5.00:1

The NEUTRAL VT RATIO setpoint is seen only if NEUTRAL VOLTAGE TRANSFORMER setpoint is
Note
“Yes”.
The voltage transformer connections and turns ratio are entered here. The VT should be
selected such that the secondary phase-phase voltage of the VTs is between 70.0 and
135.0 V when the primary is at generator rated voltage.
The Neutral VT ratio must be entered here for voltage measurement across the neutral
grounding device. Note that the neutral VT input is not intended to be used at continuous
voltages greater than 240 V. If the voltage across the neutral input is less than 240 V during
fault conditions, an auxiliary voltage transformer is not required. If this is not the case, use
an auxiliary VT to drop the fault voltage below 240 V. The NEUTRAL VT RATIO entered must
be the total effective ratio of the grounding transformer and any auxiliary step up or step
down VT.
For example, if the distribution transformer ratio is 13200:480 and the auxiliary VT ratio is
600:120, the NEUTRAL VT RATIO setpoint is calculated as:
NEUTRAL VT RATIO = Distribution Transformer Ratio × Auxiliary VT Ratio : 1
13200 600 (EQ 0.1)
= --------------- × --------- : 1 = 137.50 : 1
480 120
Therefore, set NEUTRAL VT RATIO to 137.50:1
5.3.3 Generator Parameters

PATH: SETPOINTS ZV S2 SYSTEM SETUP ZV GENERATOR PARAMETERS
GENERATOR RATED Range: 0.050 to 2000.000 MVA or Not

GENERATOR [Z] MVA: ---------------- Programmed
GENERATOR RATED Range: 0.05 to 0.99 or Not

MESSAGE Programmed
POWER FACTOR: -------
GENERATOR VOLTAGE Range: 100 to 30000 V in steps of 1
MESSAGE or Not Programmed
PHASE-PHASE: --------
GENERATOR NOMINAL Range: 25 Hz, 50 Hz, 60 Hz, or
MESSAGE Not Programmed
FREQUENCY: ----------
GENERATOR PHASE Range: ABC, ACB, or Not Programmed
MESSAGE
SEQUENCE: -----------
As a safeguard, when a unit is received from the factory, the PHASE CT PRIMARY and
Generator Parameters setpoints will be defaulted to “--------”, indicating they are not
programmed. The 489 indicates that it was never programmed. Once these values are
entered, the 489 will be in service. All elements associated with power quantities are
programmed in per unit values calculated from the rated MVA and power factor. The
generator full load amps (FLA) is calculated as
Generator Rated MVA
Generator FLA = -------------------------------------------------------------------------------------------------------------
- (EQ 0.2)
3 × Generator Rated Phase-Phase Voltage
All voltage protection features that require a level setpoint are programmed in per unit of
the rated generator phase-phase voltage.The nominal system frequency must be entered
here. This setpoint allows the 489 to determine the internal sampling rate for maximum
accuracy. If the sequence of phase rotation for a given system is ACB rather than the

standard ABC, the system phase sequence setpoint may be used to accommodate this
rotation. This setpoint allows the 489 to properly calculate phase reversal and negative
sequence quantities.
5.3.4 Serial Start/Stop Initiation

PATH: SETPOINTS ZV S2 SYSTEM SETUP ZV SERIAL START/STOP
SERIAL START/STOP Range: On, Off

SERIAL [Z] INITIATION: Off
STARTUP INITIATION Range: Any Combination of Relays 2 to
MESSAGE 5
RELAYS (2-5): ----
SHUTDOWN INITIATION Range: Any Combination of Relays 1 to
MESSAGE 4
RELAYS (1-4): ----
SERIAL START/STOP Range: On, Off
MESSAGE
EVENTS: Off
If enabled, this feature will allow the user to initiate a generator startup or shutdown via
the RS232/RS485 communication ports. Refer to GE publication number GEK-106495: 489
Communications Guide for command formats. When a startup command is issued, the
auxiliary relay(s) assigned for starting control will be activated for 1 second to initiate
startup. When a stop command is issued, the assigned relay(s) will be activated for 1
second to initiate a shutdown.

5.4 S3 Digital Inputs
5.4.1 Description
The 489 has nine (9) digital inputs for use with external contacts. Two of the 489 digital
inputs have been pre-assigned as inputs having a specific function. The Access Switch
does not have any setpoint messages associated with it. The Breaker Status input, may be
configured for either an 'a' or 'b' auxiliary contact. The remaining seven digital inputs are
assignable; that is to say, each input may be assigned to any of a number of different
functions. Some of those functions are very specific, others may be programmed to adapt
to user requirements.
Terminals C1 and C2 must be shorted to allow changing of any setpoint values from the
front panel keypad. This safeguard is in addition to the setpoint passcode feature, which
functions independently (see the S1 489 SETUP Z PASSCODE menu). The access switch has no
effect on setpoint programming from the RS232 and RS485 serial communications ports.
5.4.2 Breaker Status

PATH: SETPOINTS ZV S3 DIGITAL INPUTS Z BREAKER STATUS
BREAKER STATUS: Range: Breaker Auxiliary a,

BREAKER [Z] Breaker Auxiliary b Breaker Auxiliary b
This input is necessary for all installations. The 489 determines when the generator is
online or offline based on the Breaker Status input. Once 'Breaker Auxiliary a' is chosen,
terminals C3 and C4 will be monitored to detect the state of the machine main breaker,
open signifying the breaker is open and shorted signifying the breaker is closed. Once
“Breaker Auxiliary b” is chosen, terminals C3 and C4 will be monitored to detect the state of
the breaker, shorted signifying the breaker is open and open signifying the breaker is
closed.

5.4.3 General Input A to G

PATH: SETPOINTS ZV S3 DIGITAL INPUTS ZV GENERAL INPUT A(G)
ASSIGN DIGITAL Range: None, Input 1 to Input 7. See

GENERAL [Z] INPUT: None note below.
ASSERTED DIGITAL Range: Closed, Open

MESSAGE
INPUT STATE: Closed
INPUT NAME: Range: 12 alphanumeric characters
MESSAGE
Input A
BLOCK INPUT Range: 0 to 5000 s in steps of 1.
MESSAGE
FROM ONLINE: 0 s
GENERAL INPUT A Range: Off, On
MESSAGE
CONTROL: Off
PULSED CONTROL RELAY Range: 0.0 to 25.0 s in steps of 0.1
MESSAGE
DWELL TIME: 0.0 s
ASSIGN CONTROL Range: Any combination of Relays 1 to
MESSAGE 5
RELAYS (1-5): -----
MESSAGE
CONTROL EVENTS: Off
GENERAL INPUT A Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
ASSIGN ALARM Range: Any combination of Relays 2 to
MESSAGE 5
RELAYS (2-5): ---5
GENERAL INPUT A Range: 0.1 to 5000.0 s in steps of 0.1
MESSAGE
ALARM DELAY: 0.5 s
MESSAGE
ALARM EVENTS: Off
GENERAL INPUT A Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
ASSIGN TRIP Range: Any combination of Relays 1 to
MESSAGE 4
RELAYS (1-4): 1---
GENERAL INPUT A Range: 0.1 to 5000.0 in steps of 0.1
MESSAGE
TRIP DELAY: 5.0 s
If an input is assigned to the Tachometer function, it may not be assigned via the ASSIGN
Note
DIGITAL INPUT setpoint.
The seven General Input functions are flexible enough to meet most of the desired digital
input requirements. The asserted state and the name of the digital inputs are
programmable. To disable the input functions when the generator is offline, until some
time after the generator is brought online, a block time should be set. The input functions
will be enabled once the block delay has expired. A value of “0 s” for the BLOCK INPUT FROM
ONLINE block time indicates that the input functions are always enabled while the
generator is offline as well as online.

Inputs may be configured for control, alarm, or trip. If the control feature is enabled, the
assigned output relay(s) operate when the input is asserted. If the PULSED CONTROL RELAY
DWELL TIME is set to “0”, the output relay(s) operate only while the input is asserted.
However, if a dwell time is assigned, the output relay(s) operate as soon as the input is
asserted for a period of time specified by the setpoint. If an alarm or trip is enabled and the
input is asserted, an alarm or trip will occur after the specified delay.
5.4.4 Remote Reset

PATH: SETPOINTS ZV S3 DIGITAL INPUTS ZV REMOTE RESET
REMOTE RESET [Z] ASSIGN DIGITAL Range: None, Input 1, Input 2, Input 3,
INPUT: None Input 4, Input 5, Input 6, Input 7
Once an input is assigned to the Remote Reset function, shorting that input will reset any
latched trips or alarms that may be active, provided that any thermal lockout time has
expired and the condition that caused the alarm or trip is no longer present.
If an input is assigned to the tachometer function, it may not be used here.
5.4.5 Test Input

PATH: SETPOINTS ZV S3 DIGITAL INPUTS ZV TEST INPUT
TEST INPUT [Z] ASSIGN DIGITAL Range: None, Input 1, Input 2, Input 3,
Once the 489 is in service, it may be tested from time to time as part of a regular
maintenance schedule. The unit will have accumulated statistical information relating
historically to generator and breaker operation. This information includes: last trip data,
peak demand data, MWh and Mvarh metering, parameter averages, RTD maximums,
analog input minimums and maximums, number of trips, number of trips by type, number
of breaker operations, the number of thermal resets, total generator running hours, and
the event record. When the unit is under test and one of the inputs is assigned to the Test
Input function, shorting that input will prevent all of this data from being corrupted or
updated.
5.4.6 Thermal Reset

PATH: SETPOINTS ZV S3 DIGITAL INPUTS ZV THERMAL RESET
THERMAL RESET [Z] ASSIGN DIGITAL Range: None, Input 1, Input 2, Input 3,
During testing or in an emergency, it may be desirable to reset the thermal memory used
to zero. If an input is assigned to the Thermal Reset function, shorting that input will reset
the thermal memory used to zero. All Thermal Resets will be recorded as events.

5.4.7 Dual Setpoints

PATH: SETPOINTS ZV S3 DIGITAL INPUTS ZV DUAL SETPOINTS
ASSIGN DIGITAL Range: None, Input 1, Input 2, Input 3,

DUAL [Z] INPUT: None Input 4, Input 5, Input 6, Input 7
ACTIVATE SETPOINT Range: Group 1, Group 2

MESSAGE
GROUP: Group 1
EDIT SETPOINT Range: Group 1, Group 2
MESSAGE
GROUP: Group 1

This feature allows for dual settings for the current, voltage, power, RTD, and thermal
model protection elements (setpoint pages S5 to S9). These settings are organized in two
setpoint groups: the main group (Group 1) and the alternate group (Group 2). Only one
group of settings are active in the protection scheme at a time.
When accessing the Group 2 setpoints, the block character () for the setpoints menu
header will be replaced by the number two (2) as indicated below.
The following chart illustrates the available Group 2 (alternate group) setpoints
2 SETPOINTS [Z]
2 SETPOINTS [Z] 2 SETPOINTS [Z] 2 SETPOINTS [Z] 2 SETPOINTS [Z]
S8 RTD TEMPERA-
S5 CURRENT ELEM. S6 VOLTAGE ELEM. S7 POWER ELEMENTS S9 THERMAL MODEL
TURE
2 OVERCURRENT [Z] 2 UNDERVOLTAGE [Z] 2 REACTIVE [Z] 2 RTD [Z] 2 MODEL [Z]
ALARM POWER TYPES SETUP
2 OFFLINE [Z] 2 OVERVOLTAGE [Z] 2 REVERSE [Z] 2 RTD #1 [Z] 2 THERMAL [Z]
OVERCURRENT POWER ELEMENTS
2 INADVERTENT [Z] 2 VOLTS/HERTZ [Z] 2 LOW [Z]

↓
ENERGIZATION FORWARD POWER
2 PHASE [Z] 2 PHASE [Z] 2 RTD #12 [Z]

OVERCURRENT REVERSAL
2 NEGATIVE [Z] 2 UNDERFREQUENCY[Z] 2 OPEN [Z]

SEQUENCE RTD SENSOR
2 GROUND [Z] 2 OVERFREQUENCY [Z] 2 RTD [Z]

OVERCURRENT SHORT/LOW TEMP
2 NEUTRAL [Z]
2 PHASE [Z]
OVERVOLTAGE
DIFFERENTIAL
(Fund)
2 NEUTRAL U/
2 GROUND [Z]
V [Z]
DIRECTIONAL
(3rd HARMONIC)
2 HIGH-SET [Z] 2 LOSS [Z]

PHASE OVERCURRENT OF EXCITATION
2 DISTANCE [Z]
ELEMENT

The active group can be selected using the ACTIVATE SETPOINT GROUP setpoint or the
assigned digital input (shorting that input will activate the alternate set of protection
setpoints, Group 2). In the event of a conflict between the ACTIVATE SETPOINT GROUP
setpoint or the assigned digital input, Group 2 will be activated. The LED indicator on the
faceplate of the 489 will indicate when the alternate setpoints are active in the protection
scheme. Changing the active setpoint group will be logged as an event. Independently, the
setpoints in either group can be viewed and/or edited using the EDIT SETPOINT GROUP
setpoint. Headers for each setpoint message subgroup that has dual settings will be
denoted by a superscript number indicating which setpoint group is being viewed or
edited. Also, when a setpoint that has dual settings is stored, the flash message that
appears will indicate which setpoint group setting has been changed.
5.4.8 Sequential Trip

PATH: SETPOINTS ZV S3 DIGITAL INPUTS ZV SEQUENTIAL TRIP
ASSIGN DIGITAL Range: None, Input 1 to Input 7.

SEQUENTIAL [Z] INPUT: None
SEQUENTIAL TRIP TYPE Range: Low Forward Power, Reverse
MESSAGE Power
Low Forward Power
MESSAGE 4
RELAYS (1-4): 1---
SEQUENTIAL TRIP Range: 0.02 to 0.99 × Rated MW in
MESSAGE steps of 0.01
LEVEL: 0.05 x Rated
SEQUENTIAL TRIP Range: 0.2 to 120.0 s in steps of 0.1
MESSAGE
DELAY: 1.0 s

During routine shutdown and for some less critical trips, it may be desirable to use the
sequential trip function to prevent overspeed. If an input is assigned to the sequential trip
function, shorting that input will enable either a low forward power or reverse power
function. Once the measured 3-phase total power falls below the low forward power level,
or exceeds the reverse power level for the period of time specified, a trip will occur. This
time delay will typically be shorter than that used for the standard reverse power or low
forward power elements. The level is programmed in per unit of generator rated MW
calculated from the rated MVA and rated power factor. If the VT type is selected as None,
the sequential trip element will operate as a simple timer. Once the input has been shorted
for the period of time specified by the delay, a trip will occur.
The minimum magnitude of power measurement is determined by the phase CT minimum

Note
of 2% rated CT primary. If the level for reverse power is set below that level, a trip will only
occur once the phase current exceeds the 2% cutoff.
Users are cautioned that a reverse power element may not provide reliable indication
when set to a very low setting, particularly under conditions of large reactive loading on
the generator. Under such conditions, low forward power is a more reliable element.

5.4.9 Field-Breaker
PATH: SETPOINTS ZV S3 DIGITAL INPUTS ZV FIELD-BREAKER DISCREPANCY
FIELD- ASSIGN DIGITAL Range: None, Input 1 to Input 7

BREAKER [Z] INPUT: None
FIELD STATUS Range: Auxiliary a, Auxiliary b
MESSAGE
CONTACT: Auxiliary a
MESSAGE 4
RELAYS (1-4): 1---
FIELD-BKR DISCREP. Range: 0.1 to 500.0 s in steps of 0.1
MESSAGE
TRIP DELAY: 1.0 s

The field-breaker discrepancy function is intended for use with synchronous generators. If
a digital input is assigned to this function, any time the field status contact indicates the
field is not applied and the breaker status input indicates that the generator is online, a trip
will occur once the time delay has expired. The time delay should be used to prevent
possible nuisance tripping during shutdown. The field status contact may be chosen as
“Auxiliary a”, open signifying the field breaker or contactor is open and shorted signifying
the field breaker or contactor is closed. Conversely, the field status contact may be chosen
as “Auxiliary b”, shorted signifying the field breaker or contactor is open and open
signifying it is closed.
5.4.10 Tachometer
PATH: SETPOINTS ZV S3 DIGITAL INPUTS ZV TACHOMETER
ASSIGN DIGITAL Range: None, Inputs 4 to 7.

TACHOMETER [Z] INPUT: None
RATED SPEED: Range: 100 to 3600 RPM in steps of 1
MESSAGE
3600 RPM
TACHOMETER Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
TACHOMETER ALARM Range: 101 to 175% in steps of 1
MESSAGE
SPEED: 110% Rated
TACHOMETER ALARM Range: 1 to 250 s in steps of 1
MESSAGE
DELAY: 1 s
TACHOMETER ALARM Range: On, Off
MESSAGE
EVENTS: Off
TACHOMETER Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---

TACHOMETER TRIP Range: 101 to 175% in steps of 1

MESSAGE
SPEED: 110% Rated
TACHOMETER TRIP Range: 1 to 250 s in steps of 1
MESSAGE
DELAY: 1 s
One of assignable digital inputs 4 to 7 may be assigned to the tachometer function to

measure mechanical speed. The time between each input closure is measured and
converted to an RPM value based on one closure per revolution. If an overspeed trip or
alarm is enabled, and the measured RPM exceeds the threshold setpoint for the time
specified by the delay, a trip or alarm will occur. The RPM value can be viewed with the A2
METERING DATA ZV SPEED ZV TACHOMETER actual value.
For example, an inductive proximity probe or hall effect gear tooth sensor may be used to
sense the key on the generator. The probe could be powered from the +24V from the digital
input power supply. The NPN transistor output could be taken to one of the assignable
digital inputs assigned to the tachometer function.
5.4.11 Waveform Capture

PATH: SETPOINTS ZV S3 DIGITAL INPUTS ZV WAVEFORM CAPTURE
ASSIGN DIGITAL Range: None, Input 1 to Input 7.

WAVEFORM [Z] INPUT: None

This feature may be used to trigger the waveform capture from an external contact. When
one of the inputs is assigned to the Waveform Capture function, shorting that input will
trigger the waveform.
5.4.12 Ground Switch Status

PATH: SETPOINTS ZV S3 DIGITAL INPUTS ZV GND SWITCH STATUS
ASSIGN DIGITAL Range: None, Input 1 to Input 7

GROUND [Z] INPUT: None
GROUND SWITCH Range: Auxiliary a, Auxiliary b
MESSAGE
CONTACT: Auxiliary a

This function is used to detect the status of a grounding switch for the generator for which
the relay is installed. Refer to Stator Ground Fault on page A–1 for additional details.

5.5 S4 Output Relays
5.5.1 Description
Five of the six output relays are always non-failsafe; the 6 Service relay is always failsafe.
As a failsafe, the 6 Service relay will be energized normally and de-energize when called
upon to operate. It will also de-energize when control power to the 489 is lost and
therefore, be in its operated state. All other relays, being non-failsafe, will be de-energized
normally and energize when called upon to operate. Obviously, when control power is lost
to the 489, the output relays must be de-energized and therefore, they will be in their non-
operated state. Shorting bars in the drawout case ensure that when the 489 is drawn out,
no trip or alarm occurs. The 6 Service output will however indicate that the 489 has been
drawn out.
5.5.2 Relay Reset Mode

PATH: SETPOINTS ZV S4 OUTPUT RELAYS Z RELAY RESET MODE
1 TRIP: Range: All Resets, Remote Reset Only

RELAY [Z] All Resets
2 AUXILIARY: Range: All Resets, Remote Reset Only
MESSAGE
All Resets
MESSAGE
All Resets
MESSAGE
All Resets
5 ALARM: Range: All Resets, Remote Reset Only
MESSAGE
All Resets
6 SERVICE: Range: All Resets, Remote Reset Only
MESSAGE
All Resets
Unlatched trips and alarms will reset automatically once the condition is no longer
present. Latched trip and alarm features may be reset at any time, providing that the
condition that caused the trip or alarm is no longer present and any lockout time has
expired. If any condition may be reset, the Reset Possible LED will be lit. The relays may be
programmed to All Resets which allows reset from the front keypad or the remote reset
digital input or the communications port. Optionally, they may be programmed to reset by
the Remote Reset Only (by the remote reset digital input or the communications port).
For example, selected trips such as Instantaneous Overcurrent and Ground Fault may be
assigned to output relay 2 so that they may only be reset via. the Remote Reset digital
input or the communication port. The Remote Reset terminals would be connected to a
keyswitch so that only authorized personnel could reset such a critical trip.
Z Assign only Short Circuit and Ground Fault to relay 2.
Z Program relay 2 to Remote Reset Only.

5.6 S5 Current Elements
5.6.1 Inverse Time Overcurrent Curve Characteristics
Description
The 489 inverse time overcurrent curves may be either ANSI, IEC, or GE Type IAC standard
curve shapes. This allows for simplified coordination with downstream devices. If however,
none of these curve shapes is adequate, the FlexCurve™ may be used to customize the
inverse time curve characteristics. Definite time is also an option that may be appropriate
if only simple protection is required.
Table 5–1: 489 Overcurrent Curve Types
ANSI IEC GE Type IAC Other
Extremely Inverse Curve A (BS142) Extremely Inverse FlexCurve™
Very Inverse Curve B (BS142) Very Inverse Definite Time
Normally Inverse Curve C (BS142) Inverse
Moderately Inverse Short Inverse Short Inverse
A multiplier setpoint allows selection of a multiple of the base curve shape that is selected
with the curve shape setpoint. Unlike the electromechanical time dial equivalent, trip times
are directly proportional to the time multiplier setting value. For example, all trip times for a
multiplier of 10 are 10 times the multiplier 1 or base curve values. Setting the multiplier to
zero results in an instantaneous response to all current levels above pickup.
Regardless of the trip time that results from the curve multiplier setpoint, the 489
Note
cannot trip any quicker than one to two cycles plus the operate time of the output
relay.
Time overcurrent tripping time calculations are made with an internal “energy capacity”
memory variable. When this variable indicates that the energy capacity has reached
100%, a time overcurrent trip is generated. If less than 100% is accumulated in this
variable and the current falls below the dropout threshold of 97 to 98% of the pickup value,
the variable must be reduced. Two methods of this resetting operation are available,
“Instantaneous” and “Linear”. The Instantaneous selection is intended for applications with
other relays, such as most static units, which set the energy capacity directly to zero when
the current falls below the reset threshold. The Linear selection can be used where the 489
must coordinate with electromechanical units. With this setting, the energy capacity
variable is decremented according to the following equation.
E×M×C
T RESET = -------------------------R- (EQ 0.3)
100
where: TRESET = reset time in seconds
E = energy capacity reached (in %)
M = curve multiplier
CR= characteristic constant (5 for ANSI, IAC, Definite Time and FlexCurves™, 8 for
IEC curves)

ANSI Curves
The ANSI time overcurrent curve shapes conform to industry standard curves and fit into
the ANSI C37.90 curve classifications for extremely, very, normally, and moderately
inverse. The 489 ANSI curves are derived from the formula:
⎛ B D E ⎞
T = M × ⎜ A + -----------------------------------
- + ------------------------------------------ -⎟
- + ------------------------------------------ (EQ 0.4)
⎝ ( I ⁄ I pickup ) – C ( ( I ⁄ I pickup ) – C ) 2 3
( ( I ⁄ I pickup ) – C ) ⎠
where: T = Trip Time in seconds

M = Multiplier setpoint
I = Input Current
Ipickup = Pickup Current setpoint
A, B, C, D, E = Constants
Table 5–2: ANSI Inverse Time Curve Constants
ANSI Curve Shape Constants
A B C D E
Extremely Inverse 0.0399 0.2294 0.5000 3.0094 0.7222
Very Inverse 0.0615 0.7989 0.3400 –0.2840 4.0505
Normally Inverse 0.0274 2.2614 0.3000 –4.1899 9.1272
Moderately Inverse 0.1735 0.6791 0.8000 –0.0800 0.1271
IEC Curves
For European applications, the relay offers the four standard curves defined in IEC 255-4
and British standard BS142. These are defined as IEC Curve A, IEC Curve B, IEC Curve C, and
Short Inverse. The formula for these curves is:
⎛ K ⎞
T = M × ⎜ -------------------------------------
-⎟ (EQ 0.5)
E
⎝ ( I ⁄ I pickup ) – 1⎠

I = Input Current
K, E = Constants
Table 5–3: IEC (BS) Inverse Time Curve Constants
IEC (BS) Curve Shape Constants
K E
IEC Curve A (BS142) 0.140 0.020
IEC Curve B (BS142) 13.500 1.000
IEC Curve C (BS142) 80.000 2.000
Short Inverse 0.050 0.040

IAC Curves
The curves for the General Electric type IAC relay family are derived from the formula:
⎛ B D E ⎞
T = M × ⎜ A + ------------------------------------ + ------------------------------------------- + -------------------------------------------⎟ (EQ 0.6)
⎝ ( I ⁄ I ) C 2 3
pickup – ( ( I ⁄ I pickup ) – C ) ( ( I ⁄ I pickup ) – C ) ⎠

I = Input Current
A, B, C, D, E = Constants
Table 5–4: IAC Inverse Time Curve Constants
IAC Curve Shape Constants
A B C D E
Extreme Inverse 0.0040 0.6379 0.6200 1.7872 0.2461
Very Inverse 0.0900 0.7955 0.1000 –1.2885 7.9586
Inverse 0.2078 0.8630 0.8000 –0.4180 0.1947
Short Inverse 0.0428 0.0609 0.6200 –0.0010 0.0221
FlexCurve™
The custom FlexCurve™ has setpoints for entering times to trip at the following current
levels: 1.03, 1.05, 1.1 to 6.0 in steps of 0.1 and 6.5 to 20.0 in steps of 0.5. The relay then
converts these points to a continuous curve by linear interpolation between data points. To
enter a custom FlexCurve™, read off each individual point from a time overcurrent
coordination drawing and enter it into a table as shown. Then transfer each individual
point to the 489 using either the EnerVista 489 Setup software or the front panel keys and
display.

Table 5–5: FlexCurve™ Trip Times
Pickup Trip Pickup Trip Pickup Trip Pickup Trip

I/Ipkp Time I/Ipkp Time I/Ipkp Time I/Ipkp Time
(ms) (ms) (ms) (ms)
1.03 2.9 4.9 10.5
1.05 3.0 5.0 11.0
1.1 3.1 5.1 11.5
1.2 3.2 5.2 12.0
1.3 3.3 5.3 12.5
1.4 3.4 5.4 13.0
1.5 3.5 5.5 13.5
1.6 3.6 5.6 14.0
1.7 3.7 5.7 14.5
1.8 3.8 5.8 15.0
1.9 3.9 5.9 15.5
2.0 4.0 6.0 16.0
2.1 4.1 6.5 16.5
2.2 4.2 7.0 17.0
2.3 4.3 7.5 17.5
2.4 4.4 8.0 18.0
2.5 4.5 8.5 18.5
2.6 4.6 9.0 19.0
2.7 4.7 9.5 19.5
2.8 4.8 10.0 20.0
Definite Time Curve

The definite time curve shape causes a trip as soon as the pickup level is exceeded for a
specified period of time. The base definite time curve delay is 100 ms. The curve multiplier
of 0.00 to 1000.00 makes this delay adjustable from instantaneous to 100.00 seconds in
steps of 1 ms.
T = M × 100 ms, when I > I pickup (EQ 0.7)

M = Multiplier Setpoint
I = Input Current
Ipickup = Pickup Current Setpoint

5.6.2 Overcurrent Alarm

PATH: SETPOINTS ZV S5 CURRENT ELEM. Z OVERCURRENT ALARM
1 OVERCURRENT [Z] OVERCURRENT Range: Off, Latched, Unlatched

ALARM ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
OVERCURRENT ALARM Range: 0.10 to 1.50 × FLA in steps of
MESSAGE 0.01
LEVEL: 1.01 x FLA
OVERCURRENT ALARM Range: 0.1 to 250.0 s in steps of 0.1
MESSAGE
DELAY: 0.1 s
OVERCURRENT ALARM Range: On, Off
MESSAGE
EVENTS: Off
If enabled as Latched or Unlatched, the Overcurrent Alarm will function as follows: If the
average generator current (RMS) measured at the output CTs exceeds the level
programmed for the period of time specified, an alarm will occur. If programmed as
unlatched, the alarm will reset itself when the overcurrent condition is no longer present. If
programmed as latched, once the overcurrent condition is gone, the reset key must be
pressed to reset the alarm. The generator FLA is calculated as:
Generator Rated MVA
Generator FLA = -------------------------------------------------------------------------------------------------------------
- (EQ 0.8)
5.6.3 Offline Overcurrent

PATH: SETPOINTS ZV S5 CURRENT ELEM. ZV OFFLINE OVERCURRENT
1 OFFLINE [Z] OFFLINE OVERCURRENT Range: Off, Latched, Unlatched

OVERCURRENT TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
OFFLINE OVERCURRENT Range: 0.05 to 1.00 × CT in steps of
MESSAGE 0.01
PICKUP: 0.05 x CT
OFFLINE OVERCURRENT Range: 3 to 99 cycles in steps of 1
MESSAGE
TRIP DELAY: 5 cycles
When a synchronous generator is offline, there should be no measurable current flow in

any of the three phases unless the unit is supplying its own station load. Also, since the
generator is not yet online, differentiation between system faults and machine faults is
easier. The offline overcurrent feature is active only when the generator is offline and uses
the neutral end CT measurements (Ia, Ib, Ic). It may be set much more sensitive than the
differential element to detect high impedance phase faults. Since the breaker auxiliary
contacts wired to the 489 Breaker Status input may not operate at exactly the same time
as the main breaker contacts, the time delay should be coordinated with the difference of
the operation times. In the event of a low impedance fault, the differential element will still
shutdown the generator quickly.

If the unit auxiliary transformer is on the generator side of the breaker, the pickup level
Note
must be set greater than the unit auxiliary load.
5.6.4 Inadvertent Energization

PATH: SETPOINTS ZV S5 CURRENT ELEM. ZV INADVERTENT ENERG.
1 INADVERTENT [Z] INADVERTENT ENERGIZE Range: Off, Latched, Unlatched

ENERGIZATION TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
ARMING SIGNAL: Range: U/V and Offline, U/V or Offline
MESSAGE
U/V and Offline
INADVERTENT ENERGIZE Range: 0.05 to 3.00 × CT in steps of
MESSAGE 0.01
O/C PICKUP: 0.05 x CT
INADVERTENT ENERGIZE Range: 0.50 to 0.99 × Rated Voltage in
PICKUP: 0.50 x Rated
The logic diagram for the inadvertent energization protection feature is shown below. The
feature may be armed when all of the phase voltages fall below the undervoltage pickup
level and the unit is offline. This would be the case when the VTs are on the generator side
of the disconnect device. If however, the VTs are on the power system side of the
disconnect device, the feature should be armed if all of the phase voltages fall below the
undervoltage pickup level or the unit is offline. When the feature is armed, if any one of the
phase currents measured at the output CTs exceeds the overcurrent level programmed, a
trip will occur.
This feature requires 5 seconds to arm, 250 ms to disarm.

Note
Protection can be provided for poor synchronization by using the “U/V or Offline” arming
signal. During normal synchronization, there should be relatively low current measured. If
however, synchronization is attempted when conditions are not appropriate, a large
current that is measured within 250 ms after the generator is placed online would result in
a trip.
Iphase > O/C Level Operate

AND
Vphase < U/V Level 5s

AND
Breaker Status = Offline OR
250 ms
OR
AND
Arming Signal = U/V or Offline
808731A1.CDR
FIGURE 5–1: Inadvertent Energization Logic

5.6.5 Phase Overcurrent

PATH: SETPOINTS ZV S5 CURRENT ELEM. ZV PHASE OVERCURRENT
1 PHASE [Z] PHASE OVERCURRENT Range: Off, Latched, Unlatched

OVERCURRENT TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
ENABLE VOLTAGE Range: No, Yes
MESSAGE
RESTRAINT: No
VOLTAGE LOWER Range: 10 to 60%. Seen only if ENABLE
MESSAGE VOLTAGE RESTRAINT is "Yes"
LIMIT: 10%
PHASE OVERCURRENT Range: 0.15 to 20.00 × CT in steps of
MESSAGE 0.01
PICKUP: 10.00 x CT
CURVE SHAPE: Range: See Table 5–1: 489 Overcurrent
MESSAGE Curve Types on page –29.
ANSI Extremely Inv.
FLEXCURVE TRIP TIME Range: 0 to 65535 ms Seen only if
MESSAGE CURVE SHAPE is “Flexcurve”
AT 1.03 x PU: 65535 ms
↓
FLEXCURVE TRIP TIME Range: 0 to 65535 ms. Seen only if
MESSAGE CURVE SHAPE is “Flexcurve”
AT 20.0 x PU: 65535 ms
OVERCURRENT CURVE Range: 0.00 to 1000.00 in steps of 0.01
MESSAGE
MULTIPLIER: 1.00
OVERCURRENT CURVE Range: Instantaneous, Linear
MESSAGE
RESET: Instantaneous
If the primary system protection fails to properly isolate phase faults, the voltage
restrained overcurrent acts as system backup protection. The magnitude of each phase
current measured at the output CTs is used to time out against an inverse time curve. The
489 inverse time curve for this element may be either ANSI, IEC, or GE Type IAC standard
curve shapes. This allows for simplified coordination with downstream devices. If these
curve shapes are not adequate, FlexCurves™ may be used to customize the inverse time
curve characteristics.
The voltage restraint feature lowers the pickup value of each phase time overcurrent
element in a fixed relationship (see figure below) with the corresponding input voltage to a
minimum pickup of 0.15 × CT. The VOLTAGE LOWER LIMIT setpoint prevents very rapid
tripping prior to primary protection clearing a fault when voltage restraint is enabled and
severe close-in fault has occurred. If voltage restraint is not required, select “No” for this
setpoint. If the VT type is selected as “None” or a VT fuse loss is detected, the voltage
restraint is ignored and the element operates as simple phase overcurrent.
A fuse failure is detected within 99 ms; therefore, any voltage restrained overcurrent trip
Note
should have a time delay of 100 ms or more or nuisance tripping on fuse loss could occur.
For example, to determine the voltage restrained phase overcurrent pickup level under the
following situation:
• PHASE OVERCURRENT PICKUP: “2.00 × CT”

• ENABLE VOLTAGE RESTRAINT: “Yes”

• VOLTAGE LOWER LIMIT: 10%
• Phase-Phase Voltage / Rated Phase-Phase Voltage = 0.4 p.u. V

The voltage restrained phase overcurrent pickup level is calculated as follows:
Pickup vrest = Phase OC Pickup × Voltage Rest. Pickup Multiplier × CT
(EQ 5.9)
= ( 2 × 0.4 ) × CT = 0.8 × CT
The 489 phase overcurrent restraint voltages and restraint characteristic are shown below.
Phase Overcurrent Restraint Voltages: 1
CURRENT VOLTAGE 0.9
IA Vab
Curve Pickup Multiplier

0.8
IB Vbc 0.7
IC Vca 0.6
0.5
0.4
0.3
0.2
0.1
808792A4.CDR 0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Phase-Phase Voltage / Rated Phase-Phase Voltage
FIGURE 5–2: Voltage Restraint Characteristic
5.6.6 Negative Sequence

PATH: SETPOINTS ZV S5 CURRENT ELEM. ZV NEGATIVE SEQUENCE
1 NEGATIVE [Z] NEGATIVE SEQUENCE Range: Off, Latched, Unlatched

SEQUENCE ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
NEG. SEQUENCE ALARM Range: 3 to 100% FLA in steps of 1
MESSAGE
PICKUP: 3% FLA
NEGATIVE SEQUENCE Range: 0.1 to 100.0 s in steps of 0.1
MESSAGE
ALARM DELAY: 0.5 s
NEGATIVE SEQUENCE Range: On, Off
MESSAGE
ALARM EVENTS: Off
NEGATIVE SEQUENCE Range: Off, Latched, Unlatched
MESSAGE
O/C TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
NEG. SEQUENCE O/C Range: 3 to 100% FLA in steps of 1
MESSAGE
TRIP PICKUP: 8% FLA
NEG. SEQUENCE O/C Range: 1 to 100 in steps of 1
MESSAGE
CONSTANT K: 1
NEG. SEQUENCE O/C Range: 10 to 1000 s in steps of 1
MESSAGE
MAX. TIME: 1000 s

NEG. SEQUENCE O/C Range: 0.0 to 999.9 s in steps of 0.01

MESSAGE
RESET RATE: 227.0 s
Rotor heating in generators due to negative sequence current is a well known

phenomenon. Generators have very specific capability limits where unbalanced current is
concerned (see ANSI C50.13). A generator should have a rating for both continuous and
also short time operation when negative sequence current components are present.
The short time negative-sequence capability of the generator is defined as follows:
2
K = I2 T (EQ 5.10)
where: K = constant from generator manufacturer depending on size and design;

I2 = negative sequence current as a percentage of generator rated FLA as
measured at the output CTs;
t = time in seconds when I2 > pickup (minimum 250 ms, maximum defined by
setpoint).
The 489 has a definite time alarm and inverse time overcurrent curve trip to protect the
generator rotor from overheating due to the presence of negative sequence currents.
Pickup values are negative sequence current as a percent of generator rated full load
current. The generator FLA is calculated as:
Generator Rated MVA
Generator FLA = -------------------------------------------------------------------------------------------------------------
- (EQ 5.11)
3 × Rated Generator Phase-Phase Voltage
Negative sequence overcurrent maximum time defines the maximum time that any value
of negative sequence current in excess of the pickup value will be allowed to persist before
a trip is issued. The reset rate provides a thermal memory of previous unbalance
conditions. It is the linear reset time from the threshold of trip.
Unusually high negative sequence current levels may be caused by incorrect phase CT
Note
wiring.
808791A2.CDR
FIGURE 5–3: Negative-Sequence Inverse Time Curves

5.6.7 Ground Overcurrent

PATH: SETPOINTS ZV S5 CURRENT ELEM. ZV GROUND OVERCURRENT
1 GROUND [Z] GROUND OVERCURRENT Range: Off, Latched, Unlatched

OVERCURRENT ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
GROUND O/C ALARM Range: 0.05 to 20.00 × CT in steps of
MESSAGE 0.01
PICKUP: 0.20 x CT
GROUND O/C ALARM Range: 0 to 100 cycles in steps of 1
MESSAGE
DELAY: 0 cycles
GROUND OVERCURRENT Range: On, Off
MESSAGE
ALARM EVENTS: Off
GROUND OVERCURRENT Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
GROUND O/C TRIP Range: 0.05 to 20.00 × CT in steps of
MESSAGE 0.01
PICKUP: 0.20 x CT
CURVE SHAPE: Range: see Table 5–1: 489 Overcurrent
MESSAGE Curve Types on page –29.
ANSI Extremely Inv.
MESSAGE CURVE SHAPE is Flexcurve
AT 1.03 x PU: 65535 ms
AT 1.05 x PU: 65535 ms
↓
AT 20.0 x PU: 65535 ms
OVERCURRENT CURVE Range: 0.00 to 1000.00 in steps of 0.01
MESSAGE
MULTIPLIER: 1.00
OVERCURRENT CURVE Range: Instantaneous, Linear
MESSAGE
RESET: Instantaneous
The 489 ground overcurrent feature consists of both an alarm and a trip element. The
magnitude of measured ground current is used to time out against the definite time alarm
or inverse time curve trip. The 489 inverse time curve for this element may be either ANSI,
IEC, or GE Type IAC standard curve shapes. This allows for simplified coordination with
downstream devices. If however, none of these curves shapes is adequate, the FlexCurve™
may be used to customize the inverse time curve characteristics. If the Ground CT is
selected as “None”, the ground overcurrent protection is disabled.
The pickup level for the ground current elements is programmable as a multiple of the
Note
CT. The 50:0.025 CT is intended for very sensitive detection of ground faults and its
nominal CT rating for the 489 is 50:0.025.

For example, if the ground CT is 50:0.025, a pickup of 0.20 would be 0.20 × 50 = 10 A

primary. If the ground CT is 50:0.025, a pickup of 0.05 would be 0.05 × 50 = 2.5 A primary.
5.6.8 Phase Differential

PATH: SETPOINTS ZV S5 CURRENT ELEM. ZV PHASE DIFFERENTIAL
1 PHASE [Z] PHASE DIFFERENTIAL Range: Off, Latched, Unlatched

DIFFERENTIAL TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
DIFFERENTIAL TRIP Range: 0.05 to 1.00 × CT in steps of
MESSAGE 0.01
MIN. PICKUP: 0.10 x
DIFFERENTIAL TRIP Range: 1 to 100% in steps of 1
MESSAGE
SLOPE 1: 10%
DIFFERENTIAL TRIP Range: 1 to 100% in steps of 1
MESSAGE
SLOPE 2: 20%
DIFFERENTIAL TRIP Range: 0 to 100 cycles in steps of 1
MESSAGE
DELAY: 0 cycles
The 489 differential element consists of the well known, dual slope, percent restraint
characteristic. A differential signal is derived from the phasor sum of the currents on either
side of the machine. A restraint signal is derived from the average of the magnitudes of
these two currents. An internal flag (DIFF) is asserted when the differential signal crosses
the operating characteristic as defined by the magnitude of the restraint signal. The DIFF
flag produces a relay operation.
External faults near generators typically result in very large time constants of dc
components in the fault currents. This creates a real danger of CT saturation.
The external fault currents will be large and the CTs will initially reproduce the fault current
without distortion. Consequently the relay will see a large restraint signal coupled with a
small differential signal. This condition is used as an indication of the possible onset of ac
saturation of the CTs.
Magnetizing Inrush current due to the energizing of a step-up transformer or a sudden
change of load, could cause a large dc offset on even very small currents that would
saturate poor quality or mismatched CTs within a few power system cycles.
In order to provide additional security against maloperations during these events, an
internal flag, SC, is set when either an ac or a dc saturation condition is indicated. Once the
SC flag has been set, a comparison of the phase angles of the currents on either side of the
generator is carried out. An external fault is inferred if the phase comparison indicates
both currents are flowing in the same direction. An internal fault is inferred if the phase
comparison indicates that the currents are flowing in opposite directions. In this case an
internal flag, DIR, is set.
If the SC flag is not set, then the relay will operate for a DIFF flag alone. If the SC flag is set
then the directional flag supervises the differential flag. The requirement for both the DIFF
flag and the DIR flag during the period where CT saturation is likely therefore enhances the
security of the scheme.

The differential element for phase A will operate when:

I operate > k × I restraint (EQ 5.12)
where the following hold:
I operate = I A + I a = operate current (EQ 5.13)
IA + Ia
I restraint = -------------------- = restraint current (EQ 5.14)
2
k = characteristic slope of the differential element in percent
k = Slope1 if I R < 2 × CT ; k = Slope2 if I R ≥ 2 × CT (EQ 5.15)
IA = phase current measured at the output CT (EQ 5.16)
Ia = phase current measured at the neutral end CT (EQ 5.17)
Differential elements for phase B and phase C operate in the same manner.
0.9
(multiples of CT)
0.8
0.7
OPERATE Slope 2 = 20%
0.6 REGION
0.5
0.4
OPERATE
0.3
0.2
Slope 1 = 10%
I
Minimum Pickup = 0.10 x CT

0.1
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
I RESTRAINT (multiples of CT) 808790A2.CDR
FIGURE 5–4: Differential Elements
5.6.9 Ground Directional

PATH: SETPOINTS ZV S5 CURRENT ELEM. ZV GROUND DIRECTIONAL
1 GROUND [Z] SUPERVISE WITH Range: Yes, No.

DIRECTIONAL DIGITAL INPUTS: Yes
GROUND DIRECTIONAL Range: 0°, 90°, 180°, 270°
MESSAGE MTA = Maximum Torque Angle
MTA: 0°
GROUND DIRECTIONAL Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
GROUND DIR. ALARM Range: 0.05 to 20.00 × CT in steps of
MESSAGE 0.01
PICKUP: 0.05 x CT

GROUND DIR. ALARM Range: 0.1 to 120.0 sec. in steps of 0.1

MESSAGE
DELAY: 3.0 sec.
GROUND DIR. ALARM Range: On, Off
MESSAGE
EVENTS: Off
GROUND DIRECTIONAL Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
GROUND DIR. TRIP Range: 0.05 to 20.00 × CT in steps of
MESSAGE 0.01
PICKUP: 0.05 x CT
GROUND DIR. TRIP Range: 0.1 to 120.0 sec. in steps of 0.1
MESSAGE
DELAY: 3.0 sec.
The SUPERVISE WITH DIGITAL INPUTS setpoint is seen only if a digital input assigned to
Note
Ground Switch Status.

The 489 detects ground directional by using two measurement quantities: V0 and I0. The
angle between these quantities determines if a ground fault is within the generator or not.
This function should be coordinated with the 59GN element (95% stator ground protection)
to ensure proper operation of the element. Particularly, this element should be faster. This
element must use a core balance CT to derive the I0 signal. Polarity is critical in this
element. The protection element is blocked for neutral voltages, V0, below 2.0 V secondary.
The pickup level for the ground current elements is programmed as a multiple of ground
Note
CT. The 50:0.025 CT is intended for measuring very small ground fault currents when
connected to a sensitive ground CT having the same ratio.
For example, a pickup to 0.2xCT translates into 0.2x0.0025A = 0.5mA secondary on the
terminals of the sensitive ground CT, with a relay measuring 0.2x5A = 1 A primary. A pickup
setting of 0.05xCT would lead to 0.05x0.0025A = 0.125mA secondary, or 0.05x5A =0. 25A
primary current.
It is strongly recommended not to exceed the CT continuous rating of 150mA for long
periods of time during tests.

AUXILIARY
CONTACT
GROUNDING SWITCH
C(B) C(B)
A A
59G
B(C) B(C)
I0
TO Vneutral OF EACH 489 TO 50:0.025
50:0.025 GROUND
INPUTS
808812A3.CDR
FIGURE 5–5: Ground Directional Detection
5.6.10 High-Set Phase OC

PATH: SETPOINTS ZV S5 CURRENT ELEM. ZV HIGH-SET PHASE OVERCURRENT
1 HIGH-SET [Z] HIGH-SET PHASE O/C Range: Off, Latched, Unlatched

PHASE OVERCURRENT TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
HIGH-SET PHASE O/C Range: 0.15 to 20.00 x CT in steps of
MESSAGE 0.01
PICKUP: 5.00 x CT
HIGH-SET PHASE O/C Range: 0.00 to 100.00 s in steps of 0.01
MESSAGE
DELAY: 1.00 s
If any individual phase current exceeds the pickup level for the specified trip time a trip will
occur if the feature is enabled. The element operates in both online and offline conditions.
This element can be used as a backup feature to other protection elements. In situations
where generators are connected in parallel this element would be set above the maximum
current contribution from the generator on which the protection is installed. With this
setting, the element would provide proper selective tripping. The basic operating time of
the element with no time delay is 50 ms at 50/60 Hz.

5.7 S6 Voltage Elements
5.7.1 Undervoltage
PATH: SETPOINTS ZV S6 VOLTAGE ELEM. Z UNDERVOLTAGE
1 UNDERVOLTAGE [Z] UNDERVOLTAGE Range: Off, Latched, Unlatched

ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
UNDERVOLTAGE ALARM Range: 0.50 to 0.99 × Rated in steps of
MESSAGE 0.01
UNDERVOLTAGE ALARM Range: 0.2 to 120.0 s in steps of 0.1
MESSAGE
DELAY: 3.0 s
UNDERVOLTAGE ALARM Range: On, Off
MESSAGE
EVENTS: Off
UNDERVOLTAGE Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
UNDERVOLTAGE TRIP Range: 0.50 to 0.99 × Rated in steps of
MESSAGE 0.01
UNDERVOLTAGE TRIP Range: 0.2 to 10.0 s in steps of 0.1
MESSAGE
DELAY: 1.0 s
UNDERVOLTAGE CURVE Range: 0.0 to 999.9 s in steps of 0.1
MESSAGE
RESET RATE: 1.4 s
UNDERVOLTAGE CURVE Range: Curve, Definite Time
MESSAGE
ELEMENT: Curve
The undervoltage elements may be used for protection of the generator and/or its
auxiliary equipment during prolonged undervoltage conditions. They are active only when
the generator is online. The alarm element is definite time and the trip element can be
definite time or a curve. When the magnitude of the average phase-phase voltage is less
than the pickup × the generator rated phase-phase voltage, the element will begin to time
out. If the time expires, a trip or alarm will occur.
The curve reset rate is a linear reset time from the threshold of trip. If the VT type is
selected as None, VT fuse loss is detected, or the magnitude of I1< 7.5% CT, the
undervoltage protection is disabled. The pickup levels are insensitive to frequency over the
range of 5 to 90 Hz.
The formula for the undervoltage curve is:
D - , when V < V pickup
T = --------------------------------- (EQ 5.18)
1 – V ⁄ V pickup

where: T = trip time in seconds

D = UNDERVOLTAGE TRIP DELAY setpoint
V = actual average phase-phase voltage
Vpickup= UNDERVOLTAGE TRIP PICKUP setpoint
1000 10
TIME DELAY SETTING

3
100 1
Time to Trip (seconds)

0.3
10
0.1
0 0.2 0.4 0.6 0.8 1
Multiples of Undervoltage Pickup

808742A1.CDR
FIGURE 5–6: Undervoltage Curves
5.7.2 Overvoltage
PATH: SETPOINTS ZV S6 VOLTAGE ELEM. ZV OVERVOLTAGE
1 OVERVOLTAGE [Z] OVERVOLTAGE Range: Off, Latched, Unlatched

ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
OVERVOLTAGE ALARM Range: 1.01 to 1.50 × Rated in steps of
MESSAGE 0.01
OVERVOLTAGE ALARM Range: 0.2 to 120.0 s in steps of 0.1
MESSAGE
DELAY: 3.0 s
OVERVOLTAGE ALARM Range: On, Off
MESSAGE
EVENTS: Off
OVERVOLTAGE Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
OVERVOLTAGE TRIP Range: 1.01 to 1.50 × Rated in steps of
MESSAGE 0.01
OVERVOLTAGE TRIP Range: 0.1 to 10.0 s in steps of 0.1
MESSAGE
DELAY: 1.0 s

OVERVOLTAGE CURVE Range: 0.0 to 999.9 s in steps of 0.1

MESSAGE
RESET RATE: 1.4 s
OVERVOLTAGE CURVE Range: Curve, Definite Time
MESSAGE
ELEMENT: Curve
The overvoltage elements may be used for protection of the generator and/or its auxiliary
equipment during prolonged overvoltage conditions. They are always active (when the
generator is offline or online). The alarm element is definite time and the trip element can
be either definite time or an inverse time curve. When the average of the measured phase-
phase voltages rises above the pickup level x the generator rated phase-phase voltage,
the element will begin to time out. If the time expires, a trip or alarm will occur. The reset
rate is a linear reset time from the threshold of trip. The pickup levels are insensitive to
frequency over the range of 5 to 90 Hz.
The formula for the curve is:
D - , when V > V pickup
T = -------------------------------------- (EQ 5.19)
( V ⁄ V pickup ) – 1

D = OVERVOLTAGE TRIP DELAY setpoint
V = actual average phase-phase voltage
Vpickup= OVERVOLTAGE TRIP PICKUP setpoint
1000
100
10 10
TIME DELAY SETTING

3
1 1
0.3
0.1 0.1
1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2
Multiples of Overvoltage Pickup
808741A1.CDR
FIGURE 5–7: Overvoltage Curves
5.7.3 Volts/Hertz
PATH: SETPOINTS ZV S6 VOLTAGE ELEM. ZV VOLTS/HERTZ
1 VOLTS/HERTZ [Z] VOLTS/HERTZ Range: Off, Latched, Unlatched

ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5

VOLTS/HERTZ ALARM Range: 0.50 to 1.99 ×Nominal in steps

MESSAGE of 0.01
PICKUP: 1.00 xNominal
VOLTS/HERTZ ALARM Range: 0.1 to 150.0 s in steps of 0.1
MESSAGE
DELAY: 3.0 s
VOLTS/HERTZ ALARM Range: On, Off
MESSAGE
EVENTS: Off
VOLTS/HERTZ Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
VOLTS/HERTZ TRIP Range: 0.50 to 1.99 ×Nominal in steps
MESSAGE of 0.01
PICKUP: 1.00 xNominal
VOLTS/HERTZ TRIP Range: 0.1 to 150.0 s in steps of 0.1
MESSAGE
DELAY: 1.0 s
VOLTS/HERTZ CURVE Range: 0.0 to 999.9 s in steps of 0.1
MESSAGE
RESET RATE: 1.4 s
VOLTS/HERTZ TRIP Range: Curve #1, Curve #2, Curve #3,
MESSAGE Definite Time
ELEMENT: Curve #1
The Volts Per Hertz elements may be used generator and unit transformer protection. They
are active as soon as the magnitude and frequency of Vab is measurable. The alarm
element is definite time; the trip element can be definite time or a curve. Once the V/Hz
measurement Vab exceeds the pickup level for the specified time, a trip or alarm will occur.
The reset rate is a linear reset time from the threshold of trip and should be set to match
cooling characteristics of the protected equipment. The measurement of V/Hz will be
accurate through a frequency range of 5 to 90 Hz. Settings less than 1.00 only apply for
special generators such as short circuit testing machines.
The formula for Volts/Hertz Curve 1 is:
D V
T = ------------------------------------------------------------------- , when --- > Pickup (EQ 5.20)
V ⁄ F 2
⎛ --------------------------------------------------⎞ – 1 F
⎝ ( V nom ⁄ F s ) × Pickup⎠

D = VOLTS/HERTZ TRIP DELAY setpoint
V = RMS measurement of Vab
F = frequency of Vab
VNOM = generator voltage setpoint
FS = generator frequency setpoint
Pickup = VOLTS/HERTZ TRIP PICKUP setpoint

The V/Hz Curve 1 trip curves are shown below for delay settings of 0.1, 0.3, 1, 3, and 10
seconds.
1000
100

10
10
TIME DELAY SETTING

1 3
0.1 0.3
0.1
0.01
1.00 1.20 1.40 1.60 1.80 2.00
Multiples of Volts/Hertz Pickup
808743A1-X1.CDR

D V
T = ----------------------------------------------------------- , when --- > Pickup (EQ 5.21)
V⁄F F
-–1
-------------------------------------------------
( V nom ⁄ F s ) × Pickup

seconds.
1000
100
10 10
TIME DELAY SETTING
1 1
0.3
0.1 0.1
1.00 1.20 1.40 1.60 1.80 2.00
Multiples of Volts/Hertz Pickup
808743A1-X2.CDR


D V
T = ----------------------------------------------------------------------- , when --- > Pickup (EQ 5.22)
V ⁄ F 0.5
⎛ --------------------------------------------------⎞ – 1 F
⎝ ( V nom ⁄ F s ) × Pickup⎠

seconds.
10000
1000
100
10
TIME DELAY SETTING

10
3
1
1
0.3
0.1
0.1
1.00 1.20 1.40 1.60 1.80 2.00
Multiples of Voltz/Hertz Pickup
808743A1-X3.CDR
Volts/Hertz is calculated per unit as follows:

Note
voltage ⁄ rated phase-phase voltage-

Volts/Hertz = phase-phase
----------------------------------------------------------------------------------------------------------------------------
frequency ⁄ rated frequency
5.7.4 Phase Reversal

PATH: SETPOINTS ZV S6 VOLTAGE ELEM. ZV PHASE REVERSAL
1 PHASE [Z] PHASE REVERSAL Range: Off, Latched, Unlatched

REVERSAL TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
The 489 can detect the phase rotation of the three phase voltages. A trip will occur within
200 ms if the Phase Reversal feature is turned on, the generator is offline, each of the
phase-phase voltages is greater than 50% of the generator rated phase-phase voltage

and the phase rotation is not the same as the setpoint. Loss of VT fuses cannot be
detected when the generator is offline and could lead to maloperation of this element. If
the VT type is selected as “None”, the phase reversal protection is disabled.
5.7.5 Underfrequency
PATH: SETPOINTS ZV S6 VOLTAGE ELEM. ZV UNDERFREQUENCY
1 UNDERFREQUENCY [Z] BLOCK UNDERFREQUENCY Range: 0 to 5 s in steps of 1

FROM ONLINE: 1 s
VOLTAGE LEVEL Range: 0.50 to 0.99 × Rated in steps of
MESSAGE 0.01
CUTOFF: 0.50 x Rated
UNDERFREQUENCY Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
UNDERFREQUENCY Range: 20.00 to 60.00 Hz in steps of
MESSAGE 0.01
ALARM LEVEL: 59.50 Hz
UNDERFREQUENCY Range: 0.1 to 5000.0 s in steps of 0.1
MESSAGE
ALARM DELAY: 5.0 s
UNDERFREQUENCY Range: On, Off
MESSAGE
ALARM EVENTS: Off
UNDERFREQUENCY Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
MESSAGE 0.01
TRIP LEVEL1: 59.50 Hz
MESSAGE
TRIP DELAY1: 60.0 s
MESSAGE 0.01
MESSAGE
TRIP DELAY2: 30.0 s
It may be undesirable to enable the underfrequency elements until the generator is online.
This feature can be blocked until the generator is online and the block time expires. From
that point forward, the underfrequency trip and alarm elements will be active. A value of
zero for the block time indicates that the underfrequency protection is active as soon as
voltage exceeds the cutoff level (programmed as a multiple of the generator rated phase-
phase voltage). Frequency is then measured. Once the frequency of Vab is less than the
underfrequency setpoints, for the period of time specified, a trip or alarm will occur. There
are dual level and time setpoints for the trip element.

5.7.6 Overfrequency
PATH: SETPOINTS ZV S6 VOLTAGE ELEM. ZV OVERFREQUENCY
1 OVERFREQUENCY [Z] BLOCK OVERFREQUENCY Range: 0 to 5 s in steps of 1

FROM ONLINE: 1 s
VOLTAGE LEVEL Range: 0.50 to 0.99 × Rated in steps of
MESSAGE 0.01
CUTOFF: 0.50 x Rated
OVERFREQUENCY Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
OVERFREQUENCY Range: 25.01 to 70.00 Hz in steps of
MESSAGE 0.01
ALARM LEVEL: 60.50 Hz
OVERFREQUENCY Range: 0.1 to 5000.0 s in steps of 0.1
MESSAGE
ALARM DELAY: 5.0 s
OVERFREQUENCY Range: On, Off
MESSAGE
ALARM EVENTS: Off
OVERFREQUENCY Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
MESSAGE 0.01
MESSAGE
TRIP DELAY1: 60.0 s
MESSAGE 0.01
MESSAGE
TRIP DELAY2: 30.0 s
It may be undesirable to enable the overfrequency elements until the generator is online.
This feature can be blocked until the generator is online and the block time expires. From
that point forward, the overfrequency trip and alarm elements will be active. A value of
zero for the block time indicates that the overfrequency protection is active as soon as
voltage exceeds the cutoff level (programmed as a multiple of the generator rated phase-
phase voltage). Frequency is then measured. Once the frequency of Vab exceeds the
overfrequency setpoints, for the period of time specified, a trip or alarm will occur. There
are dual level and time setpoints for the trip element.

5.7.7 Neutral Overvoltage

PATH: SETPOINTS ZV S6 VOLTAGE ELEM. ZV NEUTRAL O/V (FUNDAMENTAL)
1 NEUTRAL O/V [Z] SUPERVISE WITH Range: Yes, No

(FUNDAMENTAL) DIGITAL INPUT: No
NEUTRAL OVERVOLTAGE Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
NEUTRAL O/V ALARM Range: 2.0 to 100.0 Vsec in steps of 0.1
MESSAGE
LEVEL: 3.0 Vsec
NEUTRAL OVERVOLTAGE Range: 0.1 to 120.0 s in steps of 0.1
MESSAGE
ALARM DELAY: 1.0 s
NEUTRAL OVERVOLTAGE Range: On, Off
MESSAGE
ALARM EVENTS: Off
NEUTRAL OVERVOLTAGE Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
NEUTRAL O/V TRIP Range: 2.0 to 100.0 Vsec in steps of 0.1
MESSAGE
LEVEL: 5.0 Vsec
NEUTRAL OVERVOLTAGE Range: 0.1 to 120.0 s in steps of 0.1
MESSAGE
TRIP DELAY: 1.0 s
NEUTRAL O/V CURVE Range: 0.0 to 999.9 in steps of 0.1
MESSAGE
RESET RATE: 0.0
NEUTRAL O/V TRIP Range: Curve, Definite Time
MESSAGE
ELEM.: Time
The SUPERVISE WITH DIGITAL INPUT setpoint is seen only if a digital input assigned to
Note
Ground Switch Status.

The neutral overvoltage function responds to fundamental frequency voltage at the
generator neutral. It provides ground fault protection for approximately 95% of the stator
windings. 100% protection is provided when this element is used in conjunction with the
Neutral Undervoltage (3rd harmonic) function. The alarm element is definite time and the
trip element can be either definite time or an inverse time curve. When the neutral voltage
rises above the pickup level the element will begin to time out. If the time expires an alarm
or trip will occur. The reset rate is a linear reset time from the threshold of trip. The alarm
and trip levels are programmable in terms of Neutral VT secondary voltage.
The formula for the curve is:
D
T = --------------------------------------- when V > V pickup (EQ 5.23)
( V ⁄ V pickup ) – 1

where T = trip time in seconds

D = NEUTRAL OVERVOLTAGE TRIP DELAY setpoint
V = neutral voltage
Vpickup = NEUTRAL O/V TRIP LEVEL setpoint
The neutral overvoltage curves are shown below. Refer to Appendix B for Application
Notes.
1000
100
Time to Trip (seconds) 10 10
TIME DELAY SETTING

3
1 1
0.3
0.1 0.1
1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2
Multiples of Overvoltage Pickup
808741A1.CDR
FIGURE 5–8: Neutral Overvoltage Curves
AUXILIARY CONTACT
TO DIGITAL INPUT FOR
NEUTRAL O/V SUPERVISION
GROUNDING SWITCH
C(B) C(B)
A A
59G
B(C) B(C)
GENERATOR 1 GENERATOR 2
808816A3.CDR
TO Vneutral OF EACH 489
FIGURE 5–9: Neutral Overvoltage Detection
If the ground directional element is enabled, the Neutral Overvoltage element should be
Note
coordinated with it. In cases of paralleled generator grounds through the same point, with
individual ground switches, per sketch below, it is recommended to use a ground switch
status function to prevent maloperation of the element.

5.7.8 Neutral Undervoltage

PATH: SETPOINTS ZV S6 VOLTAGE ELEM. ZV NEUTRAL U/V (3RD HARMONIC)
1 NEUTRAL U/V [Z] LOW POWER BLOCKING Range: 0.02 to 0.99 × Rated MW in
(3rd HARMONIC) LEVEL: 0.05 x Rated steps of 0.01
LOW VOLTAGE BLOCKING Range: 0.50 to 1.00 × Rated in steps of

MESSAGE 0.01
LEVEL: 0.75 x Rated
NEUTRAL UNDERVOLTAGE Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
NEUTRAL U/V ALARM Range: 0.5 to 20.0 Vsec in steps of 0.1
MESSAGE
LEVEL: 0.5 Vsec
NEUTRAL UNDERVOLTAGE Range: 5 to 120 s in steps of 1
MESSAGE
ALARM DELAY: 30 s
NEUTRAL UNDERVOLTAGE Range: On, Off
MESSAGE
ALARM EVENTS: Off
NEUTRAL UNDERVOLTAGE Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
NEUTRAL U/V TRIP Range: 0.5 to 20.0 Vsec in steps of 0.1
MESSAGE
LEVEL: 1.0 Vsec
NEUTRAL UNDERVOLTAGE Range: 5 to 120 s in steps of 1
MESSAGE
TRIP DELAY: 30 s
The LOW POWER BLOCKING LEVEL , NEUTRAL U/V ALARM LEVEL , and NEUTRAL U/V TRIP
Note
LEVEL setpoints are seen only if the S2 SYSTEM SETUP ZV VOLTAGE ZV VT CONNECTION
setpoint is “Delta”
The neutral undervoltage function responds to 3rd harmonic voltage measured at the
generator neutral and output terminals. When used in conjunction with the Neutral
Overvoltage (fundamental frequency) function, it provides 100% ground fault protection of
the stator windings.
For Wye connected VTs:
Since the amount of third harmonic voltage that appears in the neutral is both load and
machine dependent, the protection method of choice is an adaptive method. If the phase
VT connection is wye, the following formula is used to create an adaptive neutral
undervoltage pickup level based on the amount of third harmonic that appears at the
generator terminals.
V N3
-----------------------------------
- ≤ 0.15 which simplifies to V P3 ≥ 17V N3 (EQ 5.24)
( V P3 ⁄ 3 ) + V N3
The 489 tests the following permissives prior to testing the basic operating equation to
ensure that VN3’ should be of a measurable magnitude for an unfaulted generator:

Neutral VT Ratio
V P3 ′ > 0.25 V and V P3 ′ ≥ Threshold × 17 × ---------------------------------------- (EQ 5.25)
Phase VT Ratio
where: VN3 = magnitude of the third harmonic voltage at generator neutral;
VP3 = magnitude of the third harmonic voltage at the generator terminals
VP3´ = VT secondary magnitude of the third harmonic voltage measured at the
generator terminals;
VN3´ = VT sec. magnitude of 3rd harmonic voltage at generator neutral;
Threshold = 0.15 V for the alarm element and 0.1875 V for the trip element
For Open Delta connected VTs:
If the phase VT connection is open delta, it is not possible to measure the third harmonic
voltages at the generator terminals and a simple third harmonic neutral undervoltage
element is used. The level is programmable in terms of Neutral VT secondary voltage. In
order to prevent nuisance tripping at low load or low generator voltages, two blocking
functions are provided. They apply to both the alarm and trip functions. When used as a
simple undervoltage element, settings should be based on measured 3rd harmonic
neutral voltage of the healthy machine.
This method of using 3rd harmonic voltages to detect stator ground faults near the
Note
generator neutral has proved feasible on generators with unit transformers. Its usefulness
in other generator applications is unknown.

5.7.9 Loss of Excitation

PATH: SETPOINTS ZV S6 VOLTAGE ELEM. ZV LOSS OF EXCITATION
1 LOSS OF [Z] ENABLE VOLTAGE Range: Yes, No

EXCITATION SUPERVISION: Yes
VOLTAGE Range: 0.70 to 1.00 × Rated in steps of
MESSAGE 0.01
LEVEL: 0.70 x Rated
CIRCLE 1 Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
ASSIGN CIRCLE 1 TRIP Range: Any combination of Relays 1 to
MESSAGE 4
RELAYS (1-4): 1---
CIRCLE 1 Range: 2.5 to 300.0 Ωsec in steps of 0.1
MESSAGE
DIAMETER: 25.0 Ωsec
MESSAGE
OFFSET: 2.5 Ωsec
CIRCLE 1 TRIP Range: 0.1 to 10.0 s in steps of 0.1
MESSAGE
DELAY: 5.0 s
CIRCLE 2 Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
ASSIGN CIRCLE 2 TRIP Range: Any combination of Relays 1 to
MESSAGE 4
RELAYS (1-4): 1---
MESSAGE
DIAMETER: 35.0 Ωsec
MESSAGE
OFFSET: 2.5 Ωsec
CIRCLE 2 TRIP Range: 0.1 to 10.0 s in steps of 0.1
MESSAGE
DELAY: 5.0 s
The VOLTAGE LEVEL setpoint is seen only if ENABLE VOLTAGE SUPERVISION is set to “Yes”.
Note
Loss of excitation is detected with an impedance element. When the impedance falls
within the impedance circle for the specified delay time, a trip will occur if it is enabled.
Circles 1 and/or 2 can be tuned to a particular system. The larger circle diameter should be
set to the synchronous reactance of the generator, xd, and the circle offset to the
generator transient reactance x’d / 2. Typically the smaller circle (if used) is set to minimum
time with a diameter set to 0.7xd and an offset of x’d / 2. This feature is blocked if voltage
supervision is enabled and the generator voltage is above the VOLTAGE LEVEL setpoint.
The trip feature is supervised by minimum current of 0.05 × CT. Note that the Loss of
Excitation element will be blocked if there is a VT fuse failure or if the generator is offline.
Also, it uses output CT inputs.
The secondary phase-phase loss of excitation impedance is defined as:
V AB
- = M loe ∠θ loe
Z loe = ------------- (EQ 5.26)
IA – IB
where: Zloe = secondary phase-to-phase loss of excitation impedance

Mloe∠θloe= Secondary impedance phasor (magnitude and angle)

All relay quantities are in terms of secondary impedances. The formula to convert primary
impedance quantities to secondary impedance quantities is provided below.
Z primary × CT Ratio
Z sec ondary = -----------------------------------------------
- (EQ 5.27)
VT Ratio
where: Zprimary= primary ohms impedance;
CT Ratio = programmed CT ratio,
if CT ratio is 1200:5 use a value of 1200 / 5 = 240;
VT Ratio = programmed VT ratio, if VT ratio is 100:1 use a value of 100
FIGURE 5–10: Loss of Excitation R-X Diagram
5.7.10 Distance Element

PATH: SETPOINTS ZV S6 VOLTAGE ELEM. ZV DISTANCE ELEMENT
1 DISTANCE [Z] STEP UP TRANSFORMER Range: None, Delta/Wye

ELEMENT SETUP: None
FUSE FAILURE Range: On, Off
MESSAGE
SUPERVISION: On
ZONE #1 Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
ASSIGN ZONE #1 TRIP Range: Any combination of Relays 1 to
MESSAGE 4
RELAYS (1-4): 1---
ZONE #1 Range: 0.1 to 500.0 Ωsec in steps of 0.1
MESSAGE
REACH: 10.0 Ωsec
ZONE #1 Range: 50 to 85° in steps of 1
MESSAGE
ANGLE: 75°
ZONE #1 TRIP Range: 0.0 to 150.0 s in steps of 0.1
MESSAGE
DELAY: 0.4 s
ZONE #2 Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
ASSIGN ZONE #2 TRIP Range: Any combination of Relays 1 to
MESSAGE 4
RELAYS (1-4): 1---

ZONE #2 Range: 0.1 to 500.0 Ωsec in steps of 0.1

MESSAGE
REACH: 15.0 Ωsec
ZONE #2 Range: 50 to 85° in steps of 1
MESSAGE
ANGLE: 75°
ZONE #2 TRIP Range: 0.0 to 150.0 s in steps of 0.1
MESSAGE
DELAY: 2.0 s
The distance protection function (ANSI device 21) implements two zones of mho phase-to-
phase distance protection (six elements total) using the conventional phase comparator
approach, with the polarizing voltage derived from the pre-fault positive sequence voltage
of the protected loop. This protection is intended as backup for the primary line protection.
The elements make use of the neutral-end current signals and the generator terminal
voltage signals (see figure below), thus providing some protection for internal and unit
transformer faults. In systems with a delta-wye transformer (DY330°), the appropriate
transformations of voltage and current signals are implemented internally to allow proper
detection of transformer high-side phase-to-phase faults. The reach setting is the positive
sequence impedance to be covered, per phase, expressed in secondary ohms. The same
transformation shown for the Loss of Excitation element can be used to calculate the
desired settings as functions of the primary-side impedances.
The elements have a basic operating time of 150 ms. A VT fuse failure could cause a
maloperation of a distance element unless the element is supervised by the VTFF element.
In order to prevent nuisance tripping the elements require a minimum phase current of
0.05 x CT.
Protection Zone 1
Protection Zone 2
Neutral End CT
52
Terminal VT
489
Relay
808740A1.CDR
FIGURE 5–11: Distance Element Setup
The 489 phase distance element is intended to provide backup protection for phase-to-
phase faults on the electric power system. This element uses the phase-to-phase voltage
measured at the generator terminals and phase currents measured at the neutral side of
the generator. As such this element will provide coverage for the generator step-up
transformer and will also provide a degree of protection for stator phase-to-phase faults.
The element has a offset mho characteristic as shown in FIGURE 5–12: Distance Element
Characteristics on page –59. Offset in the third quadrant is 1/8th of the forward reach to
provide better resistive fault coverage for close-in faults. The element provides a separate
measurement in three loops for AB, BC, and CA faults. There is a setting for specification of

the step-up transformer connection. If this setting is chosen as “None”, then it is assumed
that the transformer is Wye-Wye connected or that there is no step-up transformer. In this
case the element will use the following operating quantities.
Element Voltage Current

AB Va – Vb Ia – Ib
BC Vb – Vc Ib – Ic
CA Vc – Va Ic – Ia
If this setting is chosen as “Delta/Wye” then it is assumed that the transformer is Yd1 or
Yd11. In this case the following operating quantities are used.
Element Voltage Current

AB (Vab – Vca) / 3 3 × Ia
BC (Vbc – Vab) / 3 3 × Ib
CA (Vca – Vbc) / 3 3 × Ic
The first zone is typically used to provide a backup protection for a step-up transformer
and generator system bus protection (generator impedance should not be included into
reach setting). The reach is set to cover the step-up transformer impedance with some
margin, say 25%. The time delay should be coordinated with step up transformer and bus
backup protection.
The second zone reach is typically set to cover the longest transmission line or feeder
leaving the generating station. Care must be taken for possible under-reaching effects due
to the fault contribution from other lines or generators. The element is intended for backup
protection and therefore time delay should always be included. This element is typically set
to coordinate with the longest operating time of the system distance relays protecting
lines leaving station.
The measuring point of the element is defined by the location of the VT and CT as shown in
FIGURE 5–11: Distance Element Setup on page –57. Therefore, the impedance of the step-
up transformer should be included and the impedance of the generator should not be
included. Care should also be taken to ensure the apparent impedance seen by the
element when the machine is operating at worst-case load and power factor does not
encroach into the operating characteristic. The reach setting is in secondary ohms. The
minimum operating time of the element is 150 ms to coordinate with VTFF operating time
(99 ms).

etting
ZR
Reach s
Characteristic
angle
ZR*0.125
808838A2.CDR
FIGURE 5–12: Distance Element Characteristics

5.8 S7 Power Elements
5.8.1 Power Measurement Conventions

Generation of power will be displayed on the 489 as positive watts. By convention, an
induction generator normally requires reactive power from the system for excitation. This
is displayed on the 489 as negative vars. A synchronous generator on the other hand has
its own source of excitation and can be operated with either lagging or leading power
factor. This is displayed on the 489 as positive vars and negative vars, respectively. All
power quantities are measured from the phase-phase voltage and the currents measured
at the output CTs.
^
I 1
^
I 2
^
I 3
^
I 4
FIGURE 5–13: Power Measurement Conventions

5.8.2 Reactive Power

PATH: SETPOINTS ZV S7 POWER ELEMENTS Z REACTIVE POWER
1 REACTIVE [Z] BLOCK Mvar ELEMENT Range: 0 to 5000 s in steps of 1

POWER FROM ONLINE: 1 s
REACTIVE POWER Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
POSITIVE Mvar ALARM Range: 0.02 to 2.01 × Rated in steps of
MESSAGE 0.01
LEVEL: 0.85 x Rated
NEGATIVE Mvar ALARM Range: 0.02 to 2.01 × Rated in steps of
MESSAGE 0.01
LEVEL: 0.85 x Rated
POSITIVE Mvar ALARM Range: 0.2 to 120.0 s in steps of 0.1
MESSAGE (lagging vars, overexcited)
DELAY: 10.0 s
NEGATIVE Mvar ALARM Range: 0.2 to 120.0 s in steps of 0.1
MESSAGE (leading vars, underexcited)
DELAY: 1.0 s
REACTIVE POWER ALARM Range: On, Off
MESSAGE
EVENTS: Off
REACTIVE POWER Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
POSITIVE Mvar TRIP Range: 0.02 to 2.01 × Rated in steps of
MESSAGE 0.01
LEVEL: 0.80 x Rated
NEGATIVE Mvar TRIP Range: 0.02 to 2.01 × Rated in steps of
MESSAGE 0.01
LEVEL: 0.80 x Rated
POSITIVE Mvar TRIP Range: 0.2 to 120.0 s in steps of 0.1
MESSAGE (lagging vars, overexcited)
DELAY: 20.0 s
NEGATIVE Mvar TRIP Range: 0.2 to 120.0 s in steps of 0.1
MESSAGE (leading vars, underexcited)
DELAY: 20.0 s
In a motor/generator application, it may be desirable not to trip or alarm on reactive power

until the machine is online and the field has been applied. Therefore, this feature can be
blocked until the machine is online and adequate time has expired during which the field
had been applied. From that point forward, the reactive power trip and alarm elements will
be active. A value of zero for the block time indicates that the reactive power protection is
active as soon as both current and voltage are measured regardless of whether the
generator is online or offline. Once the 3-phase total reactive power exceeds the positive
or negative level, for the specified delay, a trip or alarm will occur indicating a positive or
negative Mvar condition. The level is programmed in per unit of generator rated Mvar
calculated from the rated MVA and rated power factor. The reactive power elements can
be used to detect loss of excitation. If the VT type is selected as “None” or VT fuse loss is
detected, the reactive power protection is disabled. Rated Mvars for the system can be
calculated as follows:

For example, given Rated MVA = 100 MVA and Rated Power Factor = 0.85, we have
–1
Rated Mvars = Rated MVA × sin ( cos ( Rated PF ) )
–1 (EQ 5.28)
= 100 × sin ( cos 0.85 )
= 52.67 Mvars
5.8.3 Reverse Power

PATH: SETPOINTS ZV S7 POWER ELEMENTS ZV REVERSE POWER
1 REVERSE [Z] BLOCK REVERSE POWER Range: 0 to 5000 s in steps of 1

REVERSE POWER Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
REVERSE POWER ALARM Range: 0.02 to 0.99 × Rated MW in
LEVEL: 0.05 x Rated
REVERSE POWER ALARM Range: 0.2 to 120.0 s in steps of 0.1
MESSAGE
DELAY: 10.0 s
REVERSE POWER ALARM Range: On, Off
MESSAGE
EVENTS: Off
REVERSE POWER Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
REVERSE POWER TRIP Range: 0.02 to 0.99 × Rated MW in
LEVEL: 0.05 x Rated
REVERSE POWER TRIP Range: 0.2 to 120.0 s in steps of 0.1
MESSAGE
DELAY: 20.0 s
If enabled, once the magnitude of 3-phase total power exceeds the Pickup Level in the
reverse direction (negative MW) for a period of time specified by the Delay, a trip or alarm
will occur. The level is programmed in per unit of generator rated MW calculated from the
rated MVA and rated power factor. If the generator is accelerated from the power system
rather than the prime mover, the reverse power element may be blocked from start for a
specified period of time. A value of zero for the block time indicates that the reverse power
protection is active as soon as both current and voltage are measured regardless of
whether the generator is online or offline. If the VT type is selected as “None” or VT fuse
loss is detected, the reverse power protection is disabled.
The minimum magnitude of power measurement is determined by the phase CT minimum

Note
of 2% rated CT primary. If the level for reverse power is set below that level, a trip or alarm
will only occur once the phase current exceeds the 2% cutoff.

Users are cautioned that a reverse power element may not provide reliable indication
when set to a very low setting, particularly under conditions of large reactive loading on
the generator. Under such conditions, low forward power is a more reliable element.
5.8.4 Low Forward Power

PATH: SETPOINTS ZV S7 POWER ELEMENTS ZV LOW FORWARD POWER
1 LOW FORWARD [Z] BLOCK LOW FWD POWER Range: 0 to 15000 s in steps of 1
LOW FORWARD POWER Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
LOW FWD POWER ALARM Range: 0.02 to 0.99 × Rated MW in
LEVEL: 0.05 x Rated
LOW FWD POWER ALARM Range: 0.2 to 120.0 s in steps of 0.1
MESSAGE
DELAY: 10.0 s
LOW FWD POWER ALARM Range: On, Off
MESSAGE
EVENTS: Off
LOW FORWARD POWER Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
LOW FWD POWER TRIP Range: 0.02 to 0.99 × Rated MW in
LEVEL: 0.05 x Rated
LOW FWD POWER TRIP Range: 0.2 to 120.0 s in steps of 0.1
MESSAGE
DELAY: 20.0 s
If enabled, once the magnitude of 3-phase total power in the forward direction (+MW) falls
below the Pickup Level for a period of time specified by the Delay, an alarm will occur. The
level is programmed in per unit of generator rated MW calculated from the rated MVA and
rated power factor. The low forward power element is active only when the generator is
online and will be blocked until the generator is brought online, for a period of time defined
by the setpoint Block Low Fwd Power From Online. The pickup level should be set lower
than expected generator loading during normal operations. If the VT type is selected as
“None” or VT fuse loss is detected, the low forward power protection is disabled.

5.9 S8 RTD Temperature
5.9.1 RTD Types

PATH: SETPOINTS ZV S8 RTD TEMPERATURE Z RTD TYPES
1 RTD TYPES [Z] STATOR RTD TYPE: Range: 100 Ohm Platinum, 120 Ohm
100 Ohm Platinum Nickel, 100 Ohm Nickel, 10 Ohm
Copper
BEARING RTD TYPE: Range: as above
MESSAGE
100 Ohm Platinum
AMBIENT RTD TYPE: Range: as above
MESSAGE
100 Ohm Platinum
OTHER RTD TYPE: Range: as above
MESSAGE
100 Ohm Platinum
Each of the twelve RTDs may be configured as None or any one of four application types,
Stator, Bearing, Ambient, or Other. Each of those types may in turn be any one of four
different RTD types: 100 ohm Platinum, 120 ohm Nickel, 100 ohm Nickel, 10 ohm Copper.
The table below lists RTD resistance vs. temperature.
Table 5–6: RTD Temperature vs. Resistance

Temperature 100 Ω Pt 120 Ω Ni 100 Ω Ni 10 Ω Cu
(DIN 43760)
°C °F
–50 –58 80.31 86.17 71.81 7.10
–40 –40 84.27 92.76 77.30 7.49
–30 –22 88.22 99.41 82.84 7.88
–20 –4 92.16 106.15 88.45 8.26
–10 14 96.09 113.00 94.17 8.65
0 32 100.00 120.00 100.00 9.04
10 50 103.90 127.17 105.97 9.42
20 68 107.79 134.52 112.10 9.81
30 86 111.67 142.06 118.38 10.19
40 104 115.54 149.79 124.82 10.58
50 122 119.39 157.74 131.45 10.97
60 140 123.24 165.90 138.25 11.35
70 158 127.07 174.25 145.20 11.74
80 176 130.89 182.84 152.37 12.12
90 194 134.70 191.64 159.70 12.51
100 212 138.50 200.64 167.20 12.90
110 230 142.29 209.85 174.87 13.28
120 248 146.06 219.29 182.75 13.67
130 266 149.82 228.96 190.80 14.06
140 284 153.58 238.85 199.04 14.44
150 302 157.32 248.95 207.45 14.83
160 320 161.04 259.30 216.08 15.22
170 338 164.76 269.91 224.92 15.61

Table 5–6: RTD Temperature vs. Resistance

Temperature 100 Ω Pt 120 Ω Ni 100 Ω Ni 10 Ω Cu
(DIN 43760)
°C °F
180 356 168.47 280.77 233.97 16.00
190 374 172.46 291.96 243.30 16.39
200 392 175.84 303.46 252.88 16.78
210 410 179.51 315.31 262.76 17.17
220 428 183.17 327.54 272.94 17.56
230 446 186.82 340.14 283.45 17.95
240 464 190.45 353.14 294.28 18.34
250 482 194.08 366.53 305.44 18.73
5.9.2 RTDs 1 to 6
PATH: SETPOINTS ZV S8 RTD TEMPERATURE ZV RTD #1(6)
1 RTD #1 [Z] RTD #1 APPLICATION: Range: Stator, Bearing, Ambient, Other,

Stator None
RTD #1 NAME: Range: 8 alphanumeric characters

MESSAGE
RTD #1 ALARM: Range: Off, Latched, Unlatched

MESSAGE
Off
MESSAGE 5.
RELAYS (2-5): ---5
RTD #1 ALARM Range: 1 to 250°C in steps of 1
MESSAGE
TEMPERATURE: 130°C
RTD #1 ALARM Range: On, Off
MESSAGE
EVENTS: Off
RTD #1 TRIP: Range: Off, Latched, Unlatched
MESSAGE
Off
RTD #1 TRIP VOTING: Range: RTD #1 to RTD #12
MESSAGE
RTD #1
MESSAGE 4
RELAYS (1-4): 1---
RTD #1 TRIP Range: 1 to 250°C in steps of 1
MESSAGE
TEMPERATURE: 155°C
RTDs 1 through 6 default to Stator RTD type. There are individual alarm and trip
configurations for each RTD. This allows one of the RTDs to be turned off if it malfunctions.
The alarm level is normally set slightly above the normal running temperature. The trip
level is normally set at the insulation rating. Trip voting has been added for extra reliability
in the event of RTD malfunction. If enabled, a second RTD must also exceed the trip
temperature of the RTD being checked before a trip will be issued. If the RTD is chosen to
vote with itself, the voting feature is disabled. Each RTD name may be changed if desired.

5.9.3 RTDs 7 to 10
PATH: SETPOINTS ZV S8 RTD TEMPERATURE ZV RTD #7(10)

Bearing None

MESSAGE

MESSAGE
Off
MESSAGE 5.
RELAYS (2-5): ---5
MESSAGE
TEMPERATURE: 80°C
MESSAGE
EVENTS: Off
MESSAGE
Off
MESSAGE
RTD #7
MESSAGE 4
RELAYS (1-4): 1---
MESSAGE
TEMPERATURE: 90°C
RTDs 7 through 10 default to Bearing RTD type. There are individual alarm and trip
configurations for each RTD. This allows one of the RTDs to be turned off if it malfunctions.
The alarm level and the trip level are normally set slightly above the normal running
temperature, but below the bearing temperature rating. Trip voting has been added for
extra reliability in the event of RTD malfunction. If enabled, a second RTD must also exceed
the trip temperature of the RTD being checked before a trip will be issued. If the RTD is
chosen to vote with itself, the voting feature is disabled. Each RTD name may be changed if
desired.

5.9.4 RTD 11
PATH: SETPOINTS ZV S8 RTD TEMPERATURE ZV RTD #11
Other None

MESSAGE

MESSAGE
Off
MESSAGE 5.
RELAYS (2-5): ---5
MESSAGE
TEMPERATURE: 80°C
MESSAGE
EVENTS: Off
MESSAGE
Off
MESSAGE
RTD #11
MESSAGE 4
RELAYS (1-4): 1---
MESSAGE
TEMPERATURE: 90°C
RTD 11 defaults to Other RTD type. The Other selection allows the RTD to be used to
monitor any temperature that might be required, either for a process or additional
bearings or other. There are individual alarm and trip configurations for this RTD. Trip
voting has been added for extra reliability in the event of RTD malfunction. If enabled, a
second RTD must also exceed the trip temperature of the RTD being checked before a trip
will be issued. If the RTD is chosen to vote with itself, the voting feature is disabled. The RTD
name may be changed if desired.
5.9.5 RTD 12
PATH: SETPOINTS ZV S8 RTD TEMPERATURE ZV RTD #12
Ambient None

MESSAGE

MESSAGE
Off
MESSAGE 5.
RELAYS (2-5): ---5


MESSAGE
TEMPERATURE: 60°C
MESSAGE
EVENTS: Off
MESSAGE
Off
MESSAGE
RTD #12
MESSAGE 4
RELAYS (1-4): 1---
MESSAGE
TEMPERATURE: 80°C
RTDs 12 defaults to Ambient RTD type. The Ambient selection allows the RTD to be used to
monitor ambient temperature. There are individual alarm and trip configurations for this
RTD. Trip voting has been added for extra reliability in the event of RTD malfunction. If
enabled, a second RTD must also exceed the trip temperature of the RTD being checked
before a trip will be issued. If the RTD is chosen to vote with itself, the voting feature is
disabled. The RTD name may be changed if desired.
5.9.6 Open RTD Sensor

SETPOINTS ZV S8 RTD TEMPERATURE ZV OPEN RTD SENSOR
1 OPEN RTD [Z] OPEN RTD SENSOR: Range: Off, Latched, Unlatched
SENSOR Off
MESSAGE 5
RELAYS (2-5): ---5
OPEN RTD SENSOR Range: On, Off
MESSAGE
ALARM EVENTS: Off
The 489 has an Open RTD Sensor Alarm. This alarm will look at all RTDs that have either an
alarm or trip programmed and determine if an RTD connection has been broken. Any RTDs
that do not have a trip or alarm associated with them will be ignored for this feature. When
a broken sensor is detected, the assigned output relay will operate and a message will
appear on the display identifying the RTD that is broken. It is recommended that if this
feature is used, the alarm be programmed as latched so that intermittent RTDs are
detected and corrective action may be taken.

5.9.7 RTD Short/Low Temp

PATH: SETPOINTS ZV S8 RTD TEMPERATURE ZV RTD SHORT/LOW TEMP
1 RTD [Z] RTD SHORT/LOW TEMP Range: Off, Latched, Unlatched

SHORT/LOW TEMP ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
RTD SHORT/LOW TEMP Range: On, Off
MESSAGE
ALARM EVENTS: Off
The 489 has an RTD Short/Low Temperature alarm. This alarm will look at all RTDs that
have either an alarm or trip programmed and determine if an RTD has either a short or a
very low temperature (less than –50°C). Any RTDs that do not have a trip or alarm
associated with them will be ignored for this feature. When a short/low temperature is
detected, the assigned output relay will operate and a message will appear on the display
identifying the RTD that caused the alarm. It is recommended that if this feature is used,
the alarm be programmed as latched so that intermittent RTDs are detected and
corrective action may be taken.

5.10 S9 Thermal Model
5.10.1 489 Thermal Model

The thermal model of the 489 is primarily intended for induction generators, especially
those that start on the system bus in the same manner as induction motors. However,
some of the thermal model features may be used to model the heating that occurs in
synchronous generators during overload conditions.
One of the principle enemies of generator life is heat. Generator thermal limits are dictated
by the design of both the stator and the rotor. Induction generators that start on the
system bus have three modes of operation: locked rotor or stall (when the rotor is not
turning), acceleration (when the rotor is coming up to speed), and generating (when the
rotor turns at super-synchronous speed). Heating occurs in the generator during each of
these conditions in very distinct ways. Typically, during the generator starting, locked rotor
and acceleration conditions, the generator will be rotor limited. That is to say that the rotor
will approach its thermal limit before the stator. Under locked rotor conditions, voltage is
induced in the rotor at line frequency, 50 or 60 Hz. This voltage causes a current to flow in
the rotor, also at line frequency, and the heat generated (I2R) is a function of the effective
rotor resistance. At 50 or 60 Hz, the reactance of the rotor cage causes the current to flow
at the outer edges of the rotor bars. The effective resistance of the rotor is therefore at a
maximum during a locked rotor condition as is rotor heating. When the generator is
running at above rated speed, the voltage induced in the rotor is at a low frequency
(approximately 1 Hz) and therefore, the effective resistance of the rotor is reduced quite
dramatically. During overloads, the generator thermal limit is typically dictated by stator
parameters. Some special generators might be all stator or all rotor limited. During
acceleration, the dynamic nature of the generator slip dictates that rotor impedance is
also dynamic, and a third thermal limit characteristic is necessary.
The figure below illustrates typical thermal limit curves for induction motors. The starting
characteristic is shown for a high inertia load at 80% voltage. If the machine started
quicker, the distinct characteristics of the thermal limit curves would not be required and
the running overload curve would be joined with locked rotor safe stall times to produce a
single overload curve.
The generator manufacturer should provide a safe stall time or thermal limit curves for any
generator that is started as an induction motor. These thermal limits are intended to be
used as guidelines and their definition is not always precise. When operation of the
generator exceeds the thermal limit, the generator insulation does not immediately melt,
rather, the rate of insulation degradation reaches a point where continued operation will
significantly reduce generator life.

400
HIGH
300
INERTIA
MOTOR RUNNING OVERLOAD
200
100 A,B,AND C ARE THE

80 ACCELERATION THERMAL LIMIT
60 CURVES AT 100%, 90%, AND
80%VOLTAGE, REPECTIVELY
40
TIME-SECONDS
C
B
20
A
G
10 F
8 E
6
4
E,F, AND G ARE THE
SAFE STALL THERMAL LIMIT
2 TIMES AT 100%, 90%, AND
80%VOLTAGE, REPECTIVELY
1
0 100 200 300 400 500 600 % CURRENT
806827A1.CDR
FIGURE 5–14: Typical Time-Current and Thermal Limit Curves

(ANSI/IEEE C37.96)
5.10.2 Model Setup
Setpoints
PATH: SETPOINTS ZV S9 THERMAL MODEL Z MODEL SETUP
1 MODEL SETUP [Z] ENABLE THERMAL Range: No, Yes

MODEL: No
OVERLOAD PICKUP Range: 1.01 to 1.25 × FLA in steps of
MESSAGE 0.01
LEVEL: 1.01 x FLA
UNBALANCE BIAS Range: 0 to 12 in steps of 1. A value of
MESSAGE “0” disables this feature
K FACTOR: 0
COOL TIME CONSTANT Range: 0 to 500 min. in steps of 1
MESSAGE
ONLINE: 15 min.
COOL TIME CONSTANT Range: 0 to 500 min. in steps of 1
MESSAGE
OFFLINE: 30 min.
HOT/COLD SAFE Range: 0.01 to 1.00 in steps of 0.01
MESSAGE
STALL RATIO: 1.00
ENABLE RTD Range: No, Yes
MESSAGE
BIASING: No
RTD BIAS Range: 0 to 250°C in steps of 1
MESSAGE
MINIMUM: 40°C

RTD BIAS CENTER Range: 0 to 250°C in steps of 1

MESSAGE
POINT: 130°C
RTD BIAS Range: 0 to 250°C in steps of 1
MESSAGE
MAXIMUM: 155°C
SELECT CURVE STYLE: Range: Standard, Custom, Voltage
MESSAGE Dependent
Standard
STANDARD OVERLOAD Range: 1 to 15 in steps of 1. See Note
MESSAGE below.
CURVE NUMBER: 4
TIME TO TRIP AT Range: 0.5 to 99999.9 in steps of 0.1.
MESSAGE See Notes below.
1.01 x FLA: 17414.5 s
↓
TIME TO TRIP AT Range: 0.5 to 99999.9 in steps of 0.1.
MESSAGE See Notes below.
20.0 x FLA: 5.6 s
MINIMUM ALLOWABLE Range: 70 to 95% in steps of 1. See
MESSAGE Notes below.
VOLTAGE: 80%
STALL CURRENT @ MIN Range: 2.00 to 15.00 × FLA in steps of
MESSAGE 0.01. See Notes below.
VOLTAGE: 4.80 x FLA
SAFE STALL TIME @ Range: 0.5 to 999.9 in steps of 0.1. See
MIN VOLTAGE: 20.0 s
ACCEL. INTERSECT @ Range: 2.00 to STALL CURRENT @ MIN
MESSAGE VOLTAGE in steps of 0.01. See
MIN VOLT: 3.80 x FLA
Notes below.
STALL CURRENT @ 100% Range: 2.00 to 15.00 × FLA in steps of
MESSAGE 0.01. See Note below.
VOLTAGE: 6.00 x FLA
SAFE STALL TIME @ Range: 0.5 to 999.9 in steps of 0.1. See
100% VOLTAGE: 10.0 s
ACCEL. INTERSECT @ Range: 2.00 to STALL CURRENT @ 100%
MESSAGE VOLTAGE in steps of 0.01. See
100% VOLT: 5.00 x FLA
Notes below.
The RTD BIAS MINIMUM, RTD BIAS CENTER , and RTD BIAS MAXIMUM setpoints is are seen
Note
only if ENABLE RTD BIASING is set to “Yes”.
The STANDARD OVERLOAD CURVE NUMBER is seen only if SELECT CURVE STYLE is set to
Note
“Standard”. If the SELECT CURVE STYLE is set to “Voltage Dependent”, all setpoints shown
after the STANDARD OVERLOAD CURVE NUMBER are displayed. If the SELECT CURVE STYLE is
set to “Custom”, the setpoints shown after TIME TO TRIP AT 20.0 X FLA are not displayed.
The current measured at the output CTs is used for the thermal model. The thermal model
consists of five key elements: the overload curve and overload pickup level, the unbalance
biasing of the generator current while the machine is running, the cooling time constants,
and the biasing of the thermal model based on hot/cold generator information and
measured stator temperature. Each of these elements are described in detail in the
sections that follow.

The generator FLA is calculated as:

Note
Generator Rated MVA

-------------------------------------------------------------------------------------------------------------- (EQ 5.29)
3 × Rated Generator Phase-Phase Voltage
The 489 integrates both stator and rotor heating into one model. Machine heating is
reflected in a register called Thermal Capacity Used. If the machine has been stopped for a
long period of time, it will be at ambient temperature and thermal capacity used should be
zero. If the machine is in overload, once the thermal capacity used reaches 100%, a trip will
occur.
The overload curve accounts for machine heating during stall, acceleration, and running in
both the stator and the rotor. The Overload Pickup setpoint defines where the running
overload curve begins as the generator enters an overload condition. This is useful to
accommodate a service factor. The curve is effectively cut off at current values below this
pickup.
Generator thermal limits consist of three distinct parts based on the three conditions of
operation, locked rotor or stall, acceleration, and running overload. Each of these curves
may be provided for both a hot and cold machine. A hot machine is defined as one that
has been running for a period of time at full load such that the stator and rotor
temperatures have settled at their rated temperature. A cold machine is defined as a
machine that has been stopped for a period of time such that the stator and rotor
temperatures have settled at ambient temperature. For most machines, the distinct
characteristics of the thermal limits are formed into one smooth homogeneous curve.
Sometimes only a safe stall time is provided. This is acceptable if the machine has been
designed conservatively and can easily perform its required duty without infringing on the
thermal limit. In this case, the protection can be conservative. If the machine has been
designed very close to its thermal limits when operated as required, then the distinct
characteristics of the thermal limits become important.
The 489 overload curve can take one of three formats, Standard, Custom Curve, or Voltage
Dependent. Regardless of which curve style is selected, the 489 will retain thermal memory
in the form of a register called Thermal Capacity Used. This register is updated every 50 ms
using the following equation:
50 ms
TC used t = TC used t – 50ms + --------------------------- × 100% (EQ 5.30)
time to trip
where time to trip = time taken from the overload curve at Ieq as a function of FLA.
The overload protection curve should always be set slightly lower than the thermal limits
provided by the manufacturer. This will ensure that the machine is tripped before the
thermal limit is reached. If the starting times are well within the safe stall times, it is
recommended that the 489 Standard Overload Curve be used. The standard overload
curves are a series of 15 curves with a common curve shape based on typical generator
thermal limit curves (see the following figure and table).
When the generator trips offline due to overload the generator will be locked out (the trip
relay will stay latched) until generator thermal capacity reaches 15%.

100000
10000
TIME IN SECONDS
1000
100
x15
10
x1
1.00
0.10 1.00 10 100 1000
MULTIPLE OF FULL LOAD AMPS

806804A5.CDR
FIGURE 5–15: 489 Standard Overload Curves
Above 8.0 × Pickup, the trip time for 8.0 is used. This prevents the overload curve from
Note
acting as an instantaneous element.
The standard overload curves equation is:

Curve Multiplier × 2.2116623
Time to Trip = ---------------------------------------------------------------------------------------------------------------------------------------------
- (EQ 5.31)
2
0.02530337 × ( Pickup – 1 ) + 0.05054758 × ( Pickup – 1 )

Table 5–7: 489 Standard Overload Curve Multipliers
PICKUP STANDARD CURVE MULTIPLIERS

(× FLA)
×1 ×2 ×3 ×4 ×5 ×6 ×7 ×8 ×9 × 10 × 11 × 12 × 13 × 14 × 15
1.0 435 870 130 174 217 261 304 348 391 435 478 522 565 609 653
1 3.6 7.2 61 14 68 22 75 29 83 36 90 43 97 51 04
1.0 853. 170 256 341 426 512 597 682 768 853 939 102 110 119 128
5 71 7.4 1.1 4.9 8.6 2.3 6.0 9.7 3.4 7.1 0.8 45 98 52 06
1.1 416. 833. 125 166 208 250 291 333 375 416 458 500 541 583 625
0 68 36 0.0 6.7 3.4 0.1 6.8 3.5 0.1 6.8 3.5 0.2 6.9 3.6 0.2
1.2 198. 397. 596. 795. 994. 119 139 159 178 198 218 238 258 278 298
0 86 72 58 44 30 3.2 2.0 0.9 9.7 8.6 7.5 6.3 5.2 4.1 2.9
1.3 126. 253. 380. 507. 634. 760. 887. 101 114 126 139 152 164 177 190
0 80 61 41 22 02 82 63 4.4 1.2 8.0 4.8 1.6 8.5 5.3 2.1
1.4 91.1 182. 273. 364. 455. 546. 637. 729. 820. 911. 100 109 118 127 136
0 4 27 41 55 68 82 96 09 23 37 2.5 3.6 4.8 5.9 7.0
1.5 69.9 139. 209. 279. 349. 419. 489. 559. 629. 699. 769. 839. 909. 979. 104
0 9 98 97 96 95 94 93 92 91 90 89 88 87 86 9.9
1.7 42.4 84.8 127. 169. 212. 254. 296. 339. 381. 424. 466. 508. 551. 593. 636.
5 1 3 24 66 07 49 90 32 73 15 56 98 39 81 22
2.0 29.1 58.3 87.4 116. 145. 174. 204. 233. 262. 291. 320. 349. 379. 408. 437.
0 6 2 7 63 79 95 11 26 42 58 74 90 05 21 37
2.2 21.5 43.0 64.5 86.1 107. 129. 150. 172. 193. 215. 236. 258. 279. 301. 322.
5 3 6 9 2 65 18 72 25 78 31 84 37 90 43 96
2.5 16.6 33.3 49.9 66.6 83.3 99.9 116. 133. 149. 166. 183. 199. 216. 233. 249.
0 6 2 8 4 0 6 62 28 94 60 26 92 58 24 90
2.7 13.3 26.6 39.9 53.3 66.6 79.9 93.2 106. 119. 133. 146. 159. 173. 186. 199.
5 3 5 8 1 4 6 9 62 95 27 60 93 25 58 91
3.0 10.9 21.8 32.8 43.7 54.6 65.5 76.5 87.4 98.3 109. 120. 131. 142. 153. 163.
0 3 6 0 3 6 9 2 6 9 32 25 19 12 05 98
3.2 9.15 18.2 27.4 36.5 45.7 54.8 64.0 73.1 82.3 91.4 100. 109. 118. 128. 137.
5 9 4 8 3 7 2 6 1 6 60 75 89 04 18
3.5 7.77 15.5 23.3 31.0 38.8 46.6 54.4 62.1 69.9 77.7 85.5 93.2 101. 108. 116.
0 5 2 9 7 4 1 9 6 3 1 8 05 83 60
3.7 6.69 13.3 20.0 26.7 33.4 40.1 46.8 53.5 60.2 66.9 73.6 80.3 87.0 93.7 100.
5 9 8 8 7 7 6 6 5 5 4 4 3 3 42
4.0 5.83 11.6 17.4 23.3 29.1 34.9 40.8 46.6 52.4 58.3 64.1 69.9 75.7 81.6 87.4
0 6 9 2 5 8 1 4 7 0 3 6 9 2 5
4.2 5.12 10.2 15.3 20.5 25.6 30.7 35.8 41.0 46.1 51.2 56.3 61.5 66.6 71.7 76.8
5 5 7 0 2 5 7 0 2 5 7 0 2 5 7
4.5 4.54 9.08 13.6 18.1 22.7 27.2 31.8 36.3 40.8 45.4 49.9 54.5 59.0 63.5 68.1
0 3 7 1 5 0 4 8 2 7 1 5 9 4
4.7 4.06 8.11 12.1 16.2 20.2 24.3 28.3 32.4 36.5 40.5 44.6 48.6 52.7 56.7 60.8
5 7 2 8 3 9 4 0 5 1 6 2 7 3
5.0 3.64 7.29 10.9 14.5 18.2 21.8 25.5 29.1 32.7 36.4 40.0 43.7 47.3 51.0 54.6
0 3 7 2 6 0 5 9 3 8 2 6 1 5
5.5 2.99 5.98 8.97 11.9 14.9 17.9 20.9 23.9 26.9 29.8 32.8 35.8 38.8 41.8 44.8
0 6 5 4 3 1 0 9 8 7 6 5 4

Table 5–7: 489 Standard Overload Curve Multipliers
PICKUP STANDARD CURVE MULTIPLIERS

(× FLA)
×1 ×2 ×3 ×4 ×5 ×6 ×7 ×8 ×9 × 10 × 11 × 12 × 13 × 14 × 15
6.0 2.50 5.00 7.49 9.99 12.4 14.9 17.4 19.9 22.4 24.9 27.4 29.9 32.4 34.9 37.4
0 9 9 9 9 8 8 8 8 8 7 7
6.5 2.12 4.24 6.36 8.48 10.6 12.7 14.8 16.9 19.0 21.2 23.3 25.4 27.5 29.6 31.7
0 0 2 4 6 8 0 2 4 5 7 9
7.0 1.82 3.64 5.46 7.29 9.11 10.9 12.7 14.5 16.3 18.2 20.0 21.8 23.6 25.5 27.3
0 3 5 7 9 1 4 6 8 0 2
7.5 1.58 3.16 4.75 6.33 7.91 9.49 11.0 12.6 14.2 15.8 17.4 18.9 20.5 22.1 23.7
0 8 6 4 2 1 9 7 5 4
8.0 1.39 2.78 4.16 5.55 6.94 8.33 9.71 11.1 12.4 13.8 15.2 16.6 18.0 19.4 20.8
0 0 9 8 7 5 4 3 2
10. 1.39 2.78 4.16 5.55 6.94 8.33 9.71 11.1 12.4 13.8 15.2 16.6 18.0 19.4 20.8
00 0 9 8 7 5 4 3 2
15. 1.39 2.78 4.16 5.55 6.94 8.33 9.71 11.1 12.4 13.8 15.2 16.6 18.0 19.4 20.8
00 0 9 8 7 5 4 3 2
20. 1.39 2.78 4.16 5.55 6.94 8.33 9.71 11.1 12.4 13.8 15.2 16.6 18.0 19.4 20.8
00 0 9 8 7 5 4 3 2
Custom Overload Curve

If the induction generator starting current begins to infringe on the thermal damage
curves, it may become necessary to use a custom curve to tailor generator protection so
successful starting may be possible without compromising protection. Furthermore, the
characteristics of the starting thermal (locked rotor and acceleration) and the running
thermal damage curves may not fit together very smoothly. In this instance, it may be
necessary to use a custom curve to tailor protection to the thermal limits to allow the
generator to be started successfully and utilized to its full potential without compromising
protection. The distinct parts of the thermal limit curves now become more critical. For
these conditions, it is recommended that the 489 custom curve thermal model be used.
The custom overload curve allows users to program their own curves by entering trip
times for 30 pre-determined current levels.
The curves below show that if the running overload thermal limit curve were smoothed
into one curve with the locked rotor thermal limit curve, the induction generator could not
be started at 80% voltage. A custom curve is required.

489
GE Multilin TYPICAL CUSTOM CURVE
10000
1 PROGRAMMED 469 CUSTOM CURVE
2 RUNNING SAFETIME (STATOR LIMIT)
3 ACCELERATION SAFETIME (ROTOR LIMIT)
4 MACHINE CURRENT @ 100% VOLTAGE

1000
5 MACHINE CURRENT @ 80% VOLTAGE
1
TIME TO TRIP IN SECONDS
2
100
3
10
5
1.0
0.1
1
1000
10
100
0.5
MULTIPLE OF FULL LOAD CURRENT SETPOINT

808825A3.CDR
FIGURE 5–16: Custom Curve Example
Voltage Dependent Overload Curve

It is possible and acceptable that the acceleration time exceeds the safe stall time (bearing
in mind that a locked rotor condition is quite different than an acceleration condition). In
this instance, each distinct portion of the thermal limit curve must be known and
protection coordinated against that curve. The protection relay must be able to distinguish
between a locked rotor condition, an accelerating condition, and a running condition. The
489 voltage dependent overload curve feature is tailored to protect these types of
machines. Voltage is monitored constantly during starting and the acceleration thermal

limit curve adjusted accordingly. If the VT Connection setpoint is set to none or if a VT fuse
failure is detected, the acceleration thermal limit curve for the minimum allowable voltage
will be used.
The voltage dependent overload curve is comprised of the three characteristic thermal
limit curve shapes determined by the stall or locked rotor condition, acceleration, and
running overload. The curve is constructed by entering a custom curve shape for the
running overload protection curve. Next, a point must be entered for the acceleration
protection curve at the point of intersection with the custom curve, based on the minimum
allowable starting voltage as defined by the minimum allowable voltage. Locked Rotor
Current and safe stall time must also be entered for that voltage. A second point of
intersection must be entered for 100% voltage. Once again, the locked rotor current and
the safe stall time must be entered, this time for 100% voltage. The protection curve that is
created from the safe stall time and intersection point will be dynamic based on the
measured voltage between the minimum allowable voltage and the 100% voltage. This
method of protection inherently accounts for the change in speed as an impedance relay
would. The change in impedance is reflected by machine terminal voltage and line current.
For any given speed at any given voltage, there is only one value of line current.

489
THERMAL LIMITS
GE Multilin FOR HIGH INERTIAL LOAD
1000
900
800
700
1- Running Overload Thermal Limit
600 1
2- Acceleration Thermal Limit @ 80%V
500 3- Acceleration Thermal Limit @ 100%V
4- Locked Rotor Thermal Limit
400 5- Machine Acceleration Curve @ 80% V
6- Machine Acceleration Curve @ 100%V
300
2
200
100
90
80
TIME TO TRIP (SECONDS)
70
60
50
40
30
20
10
9
8
7
4
6
5
4
5
3
6
2
1
1 2 3 4 5 6 7 8
MULTIPLES OF FULL LOAD AMPS 808826A3.CDR
FIGURE 5–17: Thermal Limits for High Inertial Load
To illustrate the Voltage Dependent Overload Curve feature, the thermal limits shown in
Thermal Limits for High Inertial Load on page 5–79 will be used.
Z Construct a custom curve for the running overload thermal limit.
If the curve does not extend to the acceleration thermal limits,
extend it such that the curve intersects the acceleration thermal limit
curves. (see the custom curve below).

489
VOLTAGE DEPENDENT OVERLOAD
GE Multilin (CUSTOM CURVE)
1000
900
800
700
600
500
400
300
Acceleration Intersect at 80%V
200

100
90
80
70
60
50
40
30
20
10
9
8
7
6
5
1
1 2 3 4 5 6 7 8
FIGURE 5–18: Voltage Dependent Overload Curve (Custom)
Z Enter the per unit current value for the acceleration overload curve
intersect with the custom curve for 80% voltage.
Z Enter the per unit current and safe stall protection time for 80%
voltage (see the acceleration curves below).
Z Enter the per unit current value for the acceleration overload curve
intersect with the custom curve for 100% voltage.
Z Enter the per unit current and safe stall protection time for 100%
voltage (see the acceleration curves below).

489
VOLTAGE DEPENDENT OVERLOAD
GE Multilin (ACCELERATION CURVES)
1000
900
800
700
600
500
489 Custom Curve
400
300
200
100
90
80
70
60
50
40
30
20
10
9
8
7
6
5
1
1 2 3 4 5 6 7 8
MULTIPLES OF FULL LOAD AMPS
808828A3.CDR
FIGURE 5–19: Voltage Dependent Overload Curve (Acceleration Curves)

The 489 takes the information provided and create protection curves for any voltage
between the minimum and 100%. For values above the voltage in question, the 489
extrapolates the safe stall protection curve to 110% voltage. This current level is calculated
by taking the locked rotor current at 100% voltage and multiplying by 1.10. For trip times
above the 110% voltage level, the trip time of 110% will be used (see the figure below).
489
VOLTAGE DEPENDENT
GE Multilin OVERLOAD PROTECTION CURVES
1000
900
800
700
600
Custom Curve
500
400
300
200

100
90
80
70
60
50
40
30
Safe Stall Time at 80%V,

20 80%V Stall Current
Safe Stall Time at 100%V,

10 100%V Stall Current
9
8
7
6
5
Safe Stall Points
4 Extrapolated to 110%V
1
1 2 3 4 5 6 7 8
FIGURE 5–20: Voltage Dependent Overload Protection Curves
The safe stall curve is in reality a series of safe stall points for different voltages. For a given
Note
voltage, there can be only one value of stall current, and therefore only one safe stall time.

The following curves illustrate the resultant overload protection for 80% and 100%
voltage, respectively. For voltages between these levels, the 489 shifts the acceleration
curve linearly and constantly based upon the measured voltage during generator start.
489
VOLTAGE DEPENDENT
GE Multilin OVERLOAD PROTECTION at 80% V
1000
900
800
700
600
500
400
300
200
100
90
80
70
60
50
40
30
20
10
9
8
7
6
5
1
1 2 3 4 5 6 7 8
FIGURE 5–21: Voltage Dependent Overload Protection at 80% Voltage

489
VOLTAGE DEPENDENT
GE Multilin OVERLOAD PROTECTION at 100% V
1000
900
800
700
600
500
400
300
200
100
90
80
70
60
50
40
30
20
10
9
8
7
6
5
1
1 2 3 4 5 6 7 8
FIGURE 5–22: Voltage Dependent Overload Protection at 100% Voltage
Unbalance Bias
Unbalanced phase currents will cause additional rotor heating that will not be accounted
for by electromechanical relays and may not be accounted for in some electronic
protective relays. When the generator is running, the rotor will rotate in the direction of the
positive sequence current at near synchronous speed. Negative sequence current, which
has a phase rotation that is opposite to the positive sequence current, and hence, opposite
to the rotor rotation, will generate a rotor voltage that will produce a substantial rotor
current. This induced current will have a frequency that is approximately twice the line
frequency, 100 Hz for a 50 Hz system or 120 Hz for a 60 Hz system. Skin effect in the rotor
bars at this frequency will cause a significant increase in rotor resistance and therefore, a

significant increase in rotor heating. This extra heating is not accounted for in the thermal
limit curves supplied by the generator manufacturer as these curves assume positive
sequence currents only that come from a perfectly balanced supply and generator design.
The 489 measures the ratio of negative to positive sequence current. The thermal model
may be biased to reflect the additional heating that is caused by negative sequence
current when the machine is running. This biasing is done by creating an equivalent
heating current rather than simply using average current (Iper_unit). This equivalent current
is calculated using the equation shown below.
2 2
I eq = I 1 + kI 2 (EQ 5.32)
where: Ieq = equivalent motor heating current in per unit (based on FLA)
I2= negative-sequence current in per unit (based on FLA)
I1= positive-sequence current in per unit (based on FLA)
k = constant relating negative-sequence rotor resistance to positive-sequence
rotor resistance, not to be confused with the k indicating generator negative-
sequence capability for an inverse time curve.
The figure below shows induction machine derating as a function of voltage unbalance as
recommended by NEMA (National Electrical Manufacturers Association). Assuming a
typical inrush of 6 × FLA and a negative sequence impedance of 0.167, voltage unbalances
of 1, 2, 3, 4, and 5% equal current unbalances of 6, 12, 18, 24, and 30%, respectively. Based
on this assumption, the GE curve illustrates the amount of machine derating for different
values of k entered for the UNBALANCE BIAS K FACTOR setpoint. Note that the curve
created when k = 8 is almost identical to the NEMA derating curve.
1.05 1.05
1.00 1.00
DERATING FACTOR
DERATING FACTOR
0.95 0.95
k=2
0.90 0.90
0.85 0.85 k=4
0.80 0.80 k=6
k=8
0.75 0.75
k=10
0.70 0.70
0 1 2 3 4 5 0 1 2 3 4 5
PERCENT VOLTAGE UNBALANCE PERCENT VOLTAGE UNBALANCE
NEMA GE MULTILIN
808728A1.CDR
If a k value of 0 is entered, the unbalance biasing is defeated and the overload curve will
time out against the measured per unit motor current. k may be calculated conservatively
as:
175 230
k = --------- (typical estimate); k = --------- (conservative estimate) (EQ 5.33)
2 2
I LR I LR
where ILR is the per-unit locked rotor current.
Machine Cooling
The 489 thermal capacity used value is reduced exponentially when the motor current is
below the OVERLOAD PICKUP setpoint. This reduction simulates machine cooling. The
cooling time constants should be entered for both stopped and running cases (the

generator is assumed to be running if current is measured or the generator is online). A

machine with a stopped rotor normally cools significantly slower than one with a turning
rotor. Machine cooling is calculated using the following formulae:
–t ⁄ τ
TC used = ( TC used_start – TC used_end ) ( e ) + TC used_end (EQ 5.34)
I eq hot
TC used_end = ⎛ -----------------------------------------⎞ ⎛ 1 – ----------⎞ × 100% (EQ 5.35)
⎝ overload_pickup⎠ ⎝ cold⎠
where: TCused = thermal capacity used

TCused_start = TCused value caused by overload condition
TCused_end = TCused value dictated by the hot/cold safe stall ratio when the
machine is running (= 0 when the machine is stopped)
t = time in minutes
τ = Cool Time Constant (running or stopped)
Ieq = equivalent heating current
overload_pickup = overload pickup setpoint as a multiple of FLA
hot / cold = hot/cold safe stall ratio
100 100
75 75

Cool Time Constant= 15 min Cool Time Constant= 15 min

TCused_start= 85% TCused_start= 85%
Hot/Cold Ratio= 80% Hot/Cold Ratio= 80%
50 Ieq/Overload Pickup= 80% 50 Ieq/Overload Pickup= 100%
25 25
0 0
0 30 60 90 120 150 180 0 30 60 90 120 150 180
Time in Minutes Time in Minutes
80% LOAD 100% LOAD
100 100
75 75
Cool Time Constant= 30 min Cool Time Constant= 30 min

TCused_start= 85% TCused_start= 100%
Hot/Cold Ratio= 80% Hot/Cold Ratio= 80%
Motor Stopped after running Rated Load Motor Overload
50 TCused_end= 0% 50 TCused_end= 0%
25 25
0 0
0 30 60 90 120 150 180 0 30 60 90 120 150 180
Time in Minutes Time in Minutes
MOTOR STOPPED MOTOR TRIPPED

808705A2.CDR
FIGURE 5–23: Thermal Model Cooling

Hot/Cold Safe Stall Ratio

When thermal limit information is available for both a hot and cold machine, the 489
thermal model will adapt for the conditions if the HOT/COLD SAFE STALL RATIO is
programmed. The value entered for this setpoint dictates the level of thermal capacity
used that the relay will settle at for levels of current that are below the OVERLOAD PICKUP
LEVEL. When the generator is running at a level below the OVERLOAD PICKUP LEVEL, the
thermal capacity used will rise or fall to a value based on the average phase current and
the entered HOT/COLD SAFE STALL RATIO. Thermal capacity used will either rise at a fixed
rate of 5% per minute or fall as dictated by the running cool time constant.
hot-⎞ × 100%
TC used_end = I eq × ⎛ 1 – --------- (EQ 5.36)
⎝ cold⎠
where: TCused_end = Thermal Capacity Used if Iper_unit remains steady state

Ieq = equivalent generator heating current
hot/cold = HOT/COLD SAFE STALL RATIO setpoint
The hot/cold safe stall ratio may be determined from the thermal limit curves, if provided,
or the hot and cold safe stall times. Simply divide the hot safe stall time by the cold safe
stall time. If hot and cold times are not provided, there can be no differentiation and the
HOT/COLD SAFE STALL RATIO should be entered as “1.00”.
RTD Bias
The thermal replica created by the features described in the sections above operates as a
complete and independent model. However, the thermal overload curves are based solely
on measured current, assuming a normal 40°C ambient and normal machine cooling. If
there is an unusually high ambient temperature, or if machine cooling is blocked,
generator temperature will increase. If the stator has embedded RTDs, the 489 RTD bias
feature should be used to correct the thermal model.
The RTD bias feature is a two part curve, constructed using 3 points. If the maximum stator
RTD temperature is below the RTD BIAS MINIMUM setpoint (typically 40°C), no biasing
occurs. If the maximum stator RTD temperature is above the RTD BIAS MAXIMUM setpoint
(typically at the stator insulation rating or slightly higher), then the thermal memory is fully
biased and thermal capacity is forced to 100% used. At values in between, the present
thermal capacity used created by the overload curve and other elements of the thermal
model, is compared to the RTD Bias thermal capacity used from the RTD Bias curve. If the
RTD Bias thermal capacity used value is higher, then that value is used from that point
onward. The RTD BIAS CENTER POINT should be set at the rated running temperature of the
machine. The 489 automatically determines the thermal capacity used value for the center
point using the HOT/COLD SAFE STALL RATIO setpoint.
hot-⎞ × 100%
TC used at RBC = ⎛ 1 – --------- (EQ 5.37)
⎝ cold⎠
At temperatures less that the RTD Bias Center temperature,

Temp actual – Temp min
RTD_Bias_TC used = ------------------------------------------------------ × TC used at RBC (EQ 5.38)
Temp center – Temp min
At temperatures greater than the RTD Bias Center temperature,

Temp actual – Temp center
RTD_Bias_TC used = ---------------------------------------------------------- × ( 100 – TC used at RBC ) + TC used at RBC (EQ 5.39)
Temp max – Temp center

where: RTD_Bias_TCused = TC used due to hottest stator RTD

Tempactual = current temperature of the hottest stator RTD
Tempmin = RTD Bias minimum setpoint
Tempcenter = RTD Bias center setpoint
Tempmax = RTD Bias maximum setpoint
TCused at RBC = TC used defined by the HOT/COLD SAFE STALL RATIO setpoint
In simple terms, the RTD bias feature is real feedback of measured stator temperature. This
feedback acts as correction of the thermal model for unforeseen situations. Since RTDs are
relatively slow to respond, RTD biasing is good for correction and slow generator heating.
The rest of the thermal model is required during high phase current conditions when
machine heating is relatively fast.
It should be noted that the RTD bias feature alone cannot create a trip. If the RTD bias
feature forces the thermal capacity used to 100%, the machine current must be above the
over-load pickup before an overload trip occurs. Presumably, the machine would trip on
stator RTD temperature at that time.
No biasing occurs if the hottest stator RTD is open or short.

Note
RTD Bias Maximum

100
Hot/Cold = 0.85
RTD Thermal Capacity Used
80 Rated Temperature=130°C
Insulation Rating=155°C
60
40
20
RTD Bias Center Point
RTD Bias Minimum
0
–50 0 50 100 150 200 250
Maximum Stator RTD Temperature
808721A1.CDR
FIGURE 5–24: RTD Bias Curve

5.10.3 Thermal Elements

SETPOINTS ZV S9 THERMAL MODEL ZV THERMAL ELEMENTS
1 THERMAL [Z] THERMAL MODEL Range: Off, Latched, Unlatched

ELEMENTS ALARM: Off
ASSIGN ALARM Range: Any combination of Relays
MESSAGE 2 to 5
RELAYS (2-5): ---5
THERMAL ALARM Range: 10 to 100% Used in steps of 1
MESSAGE
LEVEL: 75% Used
THERMAL MODEL Range: On, Off
MESSAGE
ALARM EVENTS: Off
THERMAL MODEL Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
ASSIGN TRIP Range: Any combination of Relays
MESSAGE 1 to 4
RELAYS (1-4): 1---
Once the thermal model is setup, an alarm and/or trip element can be enabled. If the
generator has been offline for a long period of time, it will be at ambient temperature and
thermal capacity used should be zero. If the generator is in overload, once the thermal
capacity used reaches 100%, a trip will occur. The thermal model trip will remain active
until a lockout time has expired. The lockout time will be based on the reduction of thermal
capacity from 100% used to 15% used. This reduction will occur at a rate defined by the
offline cooling time constant. The thermal capacity used alarm may be used as a warning
indication of an impending overload trip.

5.11 S10 Monitoring
5.11.1 Trip Counter

PATH: SETPOINTS ZV S10 MONITORING Z TRIP COUNTER
TRIP COUNTER Range: Off, Latched, Unlatched

TRIP [Z] ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
TRIP COUNTER ALARM Range: 1 to 50000 Trips in steps of 1
MESSAGE
LEVEL: 25 Trips
TRIP COUNTER ALARM Range: On, Off
MESSAGE
EVENTS: Off
When enabled, a trip counter alarm will occur when the TRIP COUNTER ALARM LEVEL is
reached. The trip counter must be cleared or the alarm level raised and the reset key must
be pressed (if the alarm was latched) to reset the alarm.
For example, it might be useful to set a Trip Counter alarm at 100 trips, prompting the
operator or supervisor to investigate the type of trips that have occurred. A breakdown of
trips by type may be found in the A4 MAINTENANCE ZV TRIP COUNTERS actual values page.
If a trend is detected, it would warrant further investigation.
5.11.2 Breaker Failure

PATH: SETPOINTS ZV S10 MONITORING ZV BREAKER FAILURE
BREAKER FAILURE Range: Off, Latched, Unlatched

BREAKER [Z] ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
BREAKER FAILURE Range: 0.05 to 20.00 × CT in steps of
MESSAGE 0.01
LEVEL: 1.00 x CT
BREAKER FAILURE Range: 10 to 1000 ms in steps of 10
MESSAGE
DELAY: 100 ms
BREAKER FAILURE Range: On, Off
MESSAGE
ALARM EVENTS: Off
If the breaker failure alarm feature may be enabled as latched or unlatched. If the 1 Trip
output relay is operated and the generator current measured at any of the three output
CTs is above the level programmed for the period of time specified by the delay, a breaker
failure alarm will occur. The time delay should be slightly longer than the breaker clearing
time.

5.11.3 Trip Coil Monitor

PATH: SETPOINTS ZV S10 MONITORING ZV TRIP COIL MONITOR
TRIP COIL [Z] TRIP COIL MONITOR Range: Off, Latched, Unlatched
MONITOR ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
SUPERVISION OF TRIP Range: 52 Closed, 52 Open/Closed
MESSAGE
COIL: 52 Closed
TRIP COIL MONITOR Range: On, Off
MESSAGE
ALARM EVENTS: Off
If the trip coil monitor alarm feature is enabled as latched or unlatched, the trip coil
supervision circuitry will monitor the trip coil circuit for continuity any time that the breaker
status input indicates that the breaker is closed. If that continuity is broken, a trip coil
monitor alarm will occur in approximately 300 ms.
If 52 Open/Closed is selected, the trip coil supervision circuitry monitors the trip coil circuit
for continuity at all times regardless of breaker state. This requires an alternate path
around the 52a contacts in series with the trip coil when the breaker is open. See the figure
below for modifications to the wiring and proper resistor selection. If that continuity is
broken, a Starter Failure alarm will indicate Trip Coil Supervision.
TRIP COIL E11 TRIP COIL E11 TRIP COIL E11

SUPERVISION F11 SUPERVISION F11 SUPERVISION F11
R1 TRIP E2 R1 TRIP E2 R1 TRIP E2

CONTACT F1 CONTACT F1 CONTACT F1
52a
TRIP COIL 52a 52a
OPEN/CLOSED
TRIP SUPERVISION
COIL "52 Open/Closed"
TRIP TRIP
COIL COIL
WITH MULTIPLE
BREAKER AUX
TRIP COIL CLOSED SUPERVISION CONTACTS
"52 Closed" 52a TRIP COIL OPEN/CLOSED SUPERVISION
"52 Open/Closed"
VALUE OF RESISTOR 'R'

SUPPLY OHMS WATTS
48 VDC 10 K 2
125 VDC 25 K 5
808727A1.CDR 250 VDC 50 K 5
FIGURE 5–25: Trip Coil Supervision

5.11.4 VT Fuse Failure

PATH: SETPOINTS ZV S10 MONITORING ZV VT FUSE FAILURE
VT FUSE [Z] VT FUSE FAILURE Range: Off, Latched, Unlatched

FAILURE ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
VT FUSE FAILURE Range: On, Off
MESSAGE
ALARM EVENTS: Off
A fuse failure is detected when there are significant levels of negative sequence voltage
without corresponding levels of negative sequence current measured at the output CTs.
Also, if the generator is online and there is not significant positive sequence voltage, it
could indicate that all VT fuses have been pulled or the VTs are racked out. If the alarm is
enabled and a VT fuse failure detected, elements that could nuisance operation are
blocked and an alarm occurs. These blocked elements include voltage restraint for the
phase overcurrent, undervoltage, phase reversal, and all power elements.
I2 / I1 < 20%
V2 / V1 > 25% 99ms
I1 > 0.075 x CT AND
0 Block
V1 > 0.05 x Full Scale Appropriate
Breaker Status = Online Elements
OR &
Operate
Alarm
99ms Relay
AND
V1 < 0.05 × Full Scale 0
FIGURE 5–26: VT Fuse Failure Logic

5.11.5 Demand
PATH: SETPOINTS ZV S10 MONITORING ZV CURRENT DEMAND...
CURRENT DEMAND Range: 5 to 90 min. in steps of 1

CURRENT [Z] PERIOD: 15 min.
CURRENT DEMAND Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
CURRENT DEMAND Range: 0.10 to 20.00 × FLA in steps of
MESSAGE 0.01
LIMIT: 1.25 x FLA
CURRENT DEMAND Range: On, Off
MESSAGE
ALARM EVENTS: Off
MW DEMAND [Z] MW DEMAND Range: 5 to 90 min. in steps of 1

PERIOD: 15 min.
MW DEMAND Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
MW DEMAND Range: 0.10 to 2.00 × Rated in steps of
MESSAGE 0.01
LIMIT: 1.25 x Rated
MW DEMAND Range: On, Off
MESSAGE
ALARM EVENTS: Off
Mvar DEMAND [Z] Mvar DEMAND Range: 5 to 90 min. in steps of 1

PERIOD: 15 min.
Mvar DEMAND Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
Mvar DEMAND Range: 0.10 to 2.00 × Rated in steps of
MESSAGE 0.01
LIMIT: 1.25 x Rated
Mvar DEMAND Range: On, Off
MESSAGE
ALARM EVENTS: Off
MVA DEMAND [Z] MVA DEMAND Range: 5 to 90 min. in steps of 1

PERIOD: 15 min.
MVA DEMAND Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
MVA DEMAND Range: 0.10 to 2.00 × Rated in steps of
MESSAGE 0.01
LIMIT: 1.25 x Rated

MVA DEMAND Range: On, Off

MESSAGE
ALARM EVENTS: Off
The 489 can measure the demand of the generator for several parameters (current, MW,
Mvar, MVA). The demand values of generators may be of interest for energy management
programs where processes may be altered or scheduled to reduce overall demand on a
feeder. The generator FLA is calculated as:
Generator Rated MVA
Generator FLA = -------------------------------------------------------------------------------------------------------------
- (EQ 5.40)
Power quantities are programmed as per unit calculated from the rated MVA and rated
power factor.
Demand is calculated in the following manner. Every minute, an average magnitude is
calculated for current, +MW, +Mvar, and MVA based on samples taken every 5 seconds.
These values are stored in a FIFO (First In, First Out buffer).The size of the buffer is dictated
by the period that is selected for the setpoint. The average value of the buffer contents is
calculated and stored as the new demand value every minute. Demand for real and
reactive power is only positive quantities (+MW and +Mvar).
N
1
Demand = ---
N ∑ Average N (EQ 5.41)
n=1
where: N = programmed Demand Period in minutes,

n = time in minutes
160
140
120
MAGNITUDE
100
80
60
40
20
0
t=0 t+10 t+20 t+30 t+40 t+50 t+60 t+70 t+80 t+90 t+100
TIME 808717A1.CDR
FIGURE 5–27: Rolling Demand (15 Minute Window)
5.11.6 Pulse Output

PATH: SETPOINTS ZV S10 MONITORING ZV PULSE OUTPUT
POS. kWh PULSE OUT Range: Any combination of Relays 2 to

PULSE [Z] RELAYS (2-5): ---- 5
POS. kWh PULSE OUT Range: 1 to 50000 kWh in steps of 1

MESSAGE
INTERVAL: 10 kWh
POS. kvarh PULSE OUT Range: Any combination of Relays 2 to
MESSAGE 5
RELAYS (2-5): ----

POS. kvarh PULSE OUT Range: 1 to 50000 kvarh in steps of 1

MESSAGE
INTERVAL: 10 kvarh
NEG. kvarh PULSE OUT Range: Any combination of Relays 2 to
MESSAGE 5
RELAYS (2-5): ----
NEG. kvarh PULSE OUT Range: 1 to 50000 kvarh in steps of 1
MESSAGE
INTERVAL: 10 kvarh
PULSE WIDTH: Range: 200 to 1000 ms in steps of 1
MESSAGE
200 ms
The 489 can perform pulsed output of positive kWh and both positive and negative kvarh.
Each output parameter can be assigned to any one of the alarm or auxiliary relays. Pulsed
output is disabled for a parameter if the relay setpoint is selected as OFF for that pulsed
output. The minimum time between pulses is fixed to 400 milliseconds.
This feature should be programmed so that no more than one pulse per 600 milliseconds is
Note
required or the pulsing will lag behind the interval activation. Do not assign pulsed outputs
to the same relays as alarms and trip functions.
status status status

↓ ↓ ↓
normally open (NO) contact → OPEN CLOSED OPEN
normally closed (NC) contact → CLOSED OPEN CLOSED
PULSE
WIDTH
808738A1.CDR
FIGURE 5–28: Pulse Output
5.11.7 Running Hour Setup

PATH: SETPOINTS ZV S10 MONITORING ZV RUNNING HOUR SETUP
INITIAL GEN. RUNNING Range: 0 to 999999 h in steps of 1

RUNNING [Z] HOURS: 0 h
GEN. RUNNING HOURS Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
GEN. RUNNING HOURS Range: 1 to 1000000 h in steps of 1
MESSAGE
LIMIT: 1000 h
The 489 can measure the generator running hours. This value may be of interest for
periodic maintenance of the generator. The initial generator running hour allows the user
to program existing accumulated running hours on a particular generator the relay is
protecting. This feature switching 489 relays without losing previous generator running
hour values.

5.12 S11 Analog Inputs/Outputs
5.12.1 Analog Outputs 1 to 4

PATH: SETPOINTS ZV S11 ANALOG I/O Z ANALOG OUTPUT 1(4)
ANALOG OUTPUT 1: Range: See Table 5–8: Analog Output

ANALOG [Z] Real Power (MW) Parameters on page –97.
REAL POWER (MW) Range: 0.00 to 2.00 × Rated in steps of

MESSAGE 0.01
MIN: 0.00 x Rated
REAL POWER (MW) Range: 0.00 to 2.00 × Rated in steps of
MESSAGE 0.01
MAX: 1.25 x Rated

ANALOG [Z] Apparent Power (MVA) Parameters on page –97.
APPARENT POWER (MVA) Range: 0.00 to 2.00 × Rated in steps of

MESSAGE 0.01
MIN: 0.00 x Rated
APPARENT POWER (MVA) Range: 0.00 to 2.00 × Rated in steps of
MESSAGE 0.01
MAX: 1.25 x Rated

ANALOG [Z] Avg. Output Current Parameters on page –97.
AVG. OUTPUT CURRENT Range: 0.00 to 20.00 × Rated in steps

MESSAGE of 0.01
MIN: 0.00 x FLA
AVG. OUTPUT CURRENT Range: 0.00 to 20.00 × Rated in steps
MESSAGE of 0.01
MAX: 1.25 x FLA

ANALOG [Z] Average Voltage Parameters on page –97.
AVERAGE VOLTAGE Range: 0.00 to 1.50 × Rated in steps of

MESSAGE 0.01
MIN: 0.00 x Rated
AVERAGE VOLTAGE Range: 0.00 to 1.50 × Rated in steps of
MESSAGE 0.01
MAX: 1.25 x Rated
The 489 has four analog output channels (4 to 20 mA or 0 to 1 mA as ordered). Each

channel may be individually configured to represent a number of different measured
parameters as shown in the table below. The minimum value programmed represents the
4 mA output. The maximum value programmed represents the 20 mA output. All four of
the outputs are updated once every 50 ms. Each parameter may only be used once.
The analog output parameter may be chosen as Real Power (MW) for a 4 to 20 mA output.
If rated power is 100 MW, the minimum is set for 0.00 × Rated, and the maximum is set for
1.00 × Rated, the analog output channel will output 4 mA when the real power

measurement is 0 MW. When the real power measurement is 50 MW, the analog output
channel will output 12 mA. When the real power measurement is 100 MW, the analog
output channel will output 20 mA.
Table 5–8: Analog Output Parameters
Parameter Name Range / Units Step Default
Min. Max
IA Output Current 0.00 to 20.00 × FLA 0.01 0.00 1.25
IB Output Current 0.00 to 20.00 × FLA 0.01 0.00 1.25
IC Output Current 0.00 to 20.00 × FLA 0.01 0.00 1.25
Avg. Output Current 0.00 to 20.00 × FLA 0.01 0.00 1.25
Neg. Seq. Current 0 to 2000% FLA 1 0 100
Averaged Gen. Load 0.00 to 20.00 × FLA 0.01 0.00 1.25
Hottest Stator RTD –50 to +250°C or –58 to +482°F 1 0 200
Hottest Bearing RTD –50 to +250°C or –58 to +482°F 1 0 200
Ambient RTD –50 to +250°C or –58 to +482°F 1 0 70
RTDs 1 to 12 –50 to +250°C or –58 to +482°F 1 0 200
AB Voltage 0.00 to 1.50 × Rated 0.01 0.00 1.25
BC Voltage 0.00 to 1.50 × Rated 0.01 0.00 1.25
CA Voltage 0.00 to 1.50 × Rated 0.01 0.00 1.25
Volts/Hertz 0.00 to 2.00 × Rated 0.01 0.00 1.50
Frequency 0.00 to 90.00 Hz 0.01 59.00 61.00
Neutral Volt. (3rd) 0 to 25000 V 0.1 0.0 45.0
Average Voltage 0.00 to 1.50 × Rated 0.01 0.00 1.25
Power Factor 0.01 to 1.00 lead/lag 0.01 0.8 lag 0.8 lead
Reactive Power (Mvar) –2.00 to 2.00 × Rated 0.01 0.00 1.25
Real Power –2.00 to 2.00 × Rated 0.01 0.00 1.25
Apparent Power 0.00 to 2.00 × Rated 0.01 0.00 1.25
Analog Inputs 1 to 4 –50000 to +50000 1 0 50000
Tachometer 0 to 7200 RPM 1 3500 3700
Thermal Capacity Used 0 to 100% 1 0 100
Current Demand 0.00 to 20.00 × FLA 0.01 0.00 1.25
Mvar Demand 0.00 to 2.00 × Rated 0.01 0.00 1.25
MW Demand 0.00 to 2.00 × Rated 0.01 0.00 1.25
MVA Demand 0.00 to 2.00 × Rated 0.01 0.00 1.25

5.12.2 Analog Inputs 1 to 4

PATH: SETPOINTS ZV S11 ANALOG I/O ZV ANALOG INPUT 1(4)
ANALOG INPUT1: Range: Disabled, 4-20 mA, 0-20 mA, 0-

ANALOG [Z] Disabled 1 mA
ANALOG INPUT1 NAME: Range: 12 alphanumeric characters

MESSAGE
Analog I/P 1
ANALOG INPUT1 UNITS: Range: 6 alphanumeric characters
MESSAGE
Units
ANALOG INPUT1 Range: –50000 to 50000 in steps of 1
MESSAGE
MINIMUM: 0
ANALOG INPUT1 Range: –50000 to 50000 in steps of 1
MESSAGE
MAXIMUM: 100
BLOCK ANALOG INPUT1 Range: 0 to 5000 sec. in steps of 1
MESSAGE
FROM ONLINE: 0 s
ANALOG INPUT1 Range: Off, Latched, Unlatched
MESSAGE
ALARM: Off
MESSAGE 5
RELAYS (2-5): ---5
ANALOG INPUT1 ALARM Range: –50000 to 50000 in steps of 1
MESSAGE Units reflect ANALOG INPUT 1
LEVEL: 10 Units
UNITS above
ANALOG INPUT1 ALARM Range: Over, Under

MESSAGE
PICKUP: Over
ANALOG INPUT1 ALARM Range: 0.1 to 300.0 s in steps of 0.1
MESSAGE
DELAY: 0.1 s
ANALOG INPUT1 ALARM Range: On, Off
MESSAGE
EVENTS: Off
ANALOG INPUT1 Range: Off, Latched, Unlatched
MESSAGE
TRIP: Off
MESSAGE 4
RELAYS (1-4): 1---
ANALOG INPUT1 TRIP Range: –50000 to 50000 in steps of 1
MESSAGE Units reflect ANALOG INPUT 1
LEVEL: 20 Units
UNITS above
ANALOG INPUT1 TRIP Range: Over, Under

MESSAGE
PICKUP: Over
ANALOG INPUT1 TRIP Range: 0.1 to 300.0 s in steps of 0.1
MESSAGE
DELAY: 0.1 s
There are 4 analog inputs (4 to 20 mA, 0 to 20 mA, or 0 to 1 mA) that may be used to
monitor transducers such as vibration monitors, tachometers, pressure transducers, etc.
These inputs may be used for alarm and/or tripping purposes. The inputs are sampled
every 50 ms. The level of the analog input is also available over the communications port.
With the EnerVista 489 Setup program, the level of the transducer may be trended and
graphed.

Before the input may be used, it must be configured. A name may be assigned for the
input, units may be assigned, and a minimum and maxi-mum value must be assigned.
Also, the trip and alarm features may be blocked until the generator is online for a
specified time delay. If the block time is 0 seconds, there is no block and the trip and alarm
features will be active when the generator is offline or online. If a time is programmed
other than 0 seconds, the feature will be disabled when the generator is offline and also
from the time the machine is placed online until the time entered expires. Once the input is
setup, both the trip and alarm features may be configured. In addition to programming a
level and time delay, the PICKUP setpoint may be used to dictate whether the feature picks
up when the measured value is over or under the level.
If a vibration transducer is to be used, program the name as “Vib Monitor”, the units as
“mm/s”, the minimum as “0”, the maximum as “25”, and the Block From Online as “0 s”. Set
the alarm for a reasonable level slightly higher than the normal vibration level. Program a
delay of “3 s” and the pickup as “Over”.

5.13 S12 Testing
5.13.1 Simulation Mode

PATH: SETPOINTS ZV S12 489 TESTING Z SIMULATION MODE
SIMULATION MODE: Range: Off, Simulate Pre-Fault,

SIMULATION [Z] Off Simulate Fault, Pre-Fault to
Fault
PRE-FAULT TO FAULT Range: 0 to 300 s in steps of 1
MESSAGE
TIME DELAY: 15 s
The 489 may be placed in several simulation modes. This simulation may be useful for
several purposes. First, it may be used to under-stand the operation of the 489 for learning
or training purposes. Second, simulation may be used during startup to verify that control
circuitry operates as it should in the event of a trip or alarm. In addition, simulation may be
used to verify that setpoints had been set properly in the event of fault conditions.
The SIMULATION MODE setpoint may be entered only if the generator is offline, no current
is measured, and there are no trips or alarms active. The values entered as Pre-Fault
Values will be substituted for the measured values in the 489 when the SIMULATION MODE
is “Simulate Pre-Fault”. The values entered as Fault Values will be substituted for the
measured values in the 489 when the SIMULATION MODE is “Simulate Fault”. If the
SIMULATION MODE is set to “Pre-Fault to Fault”, the Pre-Fault values will be substituted for
the period of time specified by the delay, followed by the Fault values. If a trip occurs, the
SIMULATION MODE reverts to “Off”. Selecting “Off” for the SIMULATION MODE places the 489
back in service. If the 489 measures current or control power is cycled, the SIMULATION
MODE automatically reverts to “Off”.
If the 489 is to be used for training, it might be desirable to allow all parameter averages,
statistical information, and event recording to update when operating in simulation mode.
If however, the 489 has been installed and will remain installed on a specific generator, it
might be desirable assign a digital input to Test Input and to short that input to prevent all
of this data from being corrupted or updated. In any event, when in simulation mode, the
489 In Service LED (indicator) will flash, indicating that the 489 is not in protection mode.

5.13.2 Pre-Fault Setup

PATH: SETPOINTS ZV S12 489 TESTING ZV PRE-FAULT SETUP
PRE- PRE-FAULT Iphase Range: 0.00 to 20.00 × CT in steps of

FAULT [Z] OUTPUT: 0.00 x CT 0.01
PRE-FAULT VOLTAGES Range: 0.00 to 1.50 × Rated in steps of

MESSAGE 0.01. Enter as a phase-to-
PHASE-N: 1.00 x Rated
neutral quantity.
PRE-FAULT CURRENT Range: 0 to 359° in steps of 1
MESSAGE
LAGS VOLTAGE: 0°
PRE-FAULT Iphase Range: 0.00 to 20.00 × CT in steps of
MESSAGE 0.01 180° phase shift with
NEUTRAL: 0.00 x CT
respect to Iphase OUTPUT
PRE-FAULT CURRENT Range: 0.00 to 20.00 × CT in steps of
MESSAGE 0.01. CT is either XXX:1 or
GROUND: 0.00 x CT
50:0.025
PRE-FAULT VOLTAGE Range 0.0 to 100.0 Vsec in steps of 0.1
MESSAGE Fundamental value only in
NEUTRAL: 0 Vsec
secondary units
PRE-FAULT STATOR Range: –50 to 250°C in steps of 1
MESSAGE
RTD TEMP: 40°C
PRE-FAULT BEARING Range: –50 to 250°C in steps of 1
MESSAGE
RTD TEMP: 40°C
PRE-FAULT OTHER Range: –50 to 250°C in steps of 1
MESSAGE
RTD TEMP: 40°C
PRE-FAULT AMBIENT Range: –50 to 250°C in steps of 1
MESSAGE
RTD TEMP: 40°C
PRE-FAULT SYSTEM Range: 5.0 to 90.0 Hz in steps of 0.1
MESSAGE
FREQUENCY: 60.0 Hz
PRE-FAULT ANALOG Range: 0 to 100% in steps of 1
MESSAGE
INPUT 1: 0%
MESSAGE
INPUT 2: 0%
MESSAGE
INPUT 3: 0%
MESSAGE
INPUT 4: 0%
The values entered under Pre-Fault Values will be substituted for the measured values in
the 489 when the SIMULATION MODE is “Simulate Pre-Fault”.

5.13.3 Fault Setup

PATH: SETPOINTS ZV S12 489 TESTING ZV FAULT SETUP
FAULT Iphase Range: 0.00 to 20.00 × CT in steps of

FAULT [Z] OUTPUT: 0.00 x CT 0.01
FAULT VOLTAGES Range: 0.00 to 1.50 × Rated in steps of

MESSAGE 0.01. Enter as a phase-to-
PHASE-N: 1.00 x Rated
neutral quantity.
FAULT CURRENT Range: 0 to 359° in steps of 1
MESSAGE
LAGS VOLTAGE: 0°
FAULT Iphase Range: 0.00 to 20.00 × CT in steps of
MESSAGE 0.01. (180° phase shift with
NEUTRAL: 0.00 x CT
respect to Iphase OUTPUT)
FAULT CURRENT Range: 0.00 to 20.00 × CT in steps of
MESSAGE 0.01. CT is either XXX:1 or
GROUND: 0.00 x CT
50:0.025
FAULT VOLTAGE Range: 0.0 to 100.0 Vsec in steps of 0.1
MESSAGE Fundamental value only in
NEUTRAL: 0 Vsec
secondary volts
FAULT STATOR Range: –50 to 250°C in steps of 1
MESSAGE
RTD TEMP: 40°C
FAULT BEARING Range: –50 to 250°C in steps of 1
MESSAGE
RTD TEMP: 40°C
FAULT OTHER Range: –50 to 250°C in steps of 1
MESSAGE
RTD TEMP: 40°C
FAULT AMBIENT Range: –50 to 250°C in steps of 1
MESSAGE
RTD TEMP: 40°C
FAULT SYSTEM Range: 5.0 to 90.0 Hz in steps of 0.1
MESSAGE
FREQUENCY: 60.0 Hz
FAULT ANALOG Range: 0 to 100% in steps of 1
MESSAGE
INPUT 1: 0%
MESSAGE
INPUT 2: 0%
MESSAGE
INPUT 3: 0%
MESSAGE
INPUT 4: 0%
The values entered here are substituted for the measured values in the 489 when the
SIMULATION MODE is “Simulate Fault”.
5.13.4 Test Output Relays

PATH: SETPOINTS ZV S12 489 TESTING ZV TEST OUTPUT RELAYS
FORCE OPERATION OF Range: Disabled, 1 Trip, 2 Auxiliary,

TEST [Z] RELAYS: Disabled 3 Auxiliary, 4 Auxiliary, 5 Alarm,
6 Service, All Relays, No Relays

The test output relays setpoint may be used during startup or testing to verify that the
output relays are functioning correctly. The output relays can be forced to operate only if
the generator is offline, no current is measured, and there are no trips or alarms active. If
any relay is forced to operate, the relay will toggle from its normal state. The appropriate
relay indicator will illuminate at that time. Selecting “Disabled” places the output relays
back in service. If the 489 measures current or control power is cycled, the force operation
of relays setpoint will automatically become disabled and the output relays will revert back
to their normal states.
If any relay is forced, the 489 In Service indicator will flash, indicating that the 489 is not in
protection mode.
5.13.5 Test Analog Output

PATH: SETPOINTS ZV S12 489 TESTING ZV TEST ANALOG OUTPUT
FORCE ANALOG OUTPUTS Range: Enabled, Disabled

TEST [Z] FUNCTION: Disabled
ANALOG OUTPUT 1 Range: 0 to 100% in steps of 1
MESSAGE
FORCED VALUE: 0%
MESSAGE
FORCED VALUE: 0%
MESSAGE
FORCED VALUE: 0%
MESSAGE
FORCED VALUE: 0%
These setpoints may be used during startup or testing to verify that the analog outputs are
functioning correctly. The analog outputs can be forced only if the generator is offline, no
current is measured, and there are no trips or alarms active. When the FORCE ANALOG
OUTPUTS FUNCTION is “Enabled”, the output reflects the forced value as a percentage of the
range 4 to 20 mA or 0 to 1 mA. Selecting “Disabled” places all four analog output channels
back in service, reflecting their programmed parameters. If the 489 measures current or
control power is cycled, the force analog output function is automatically disabled and all
analog outputs will revert back to their normal state.
Any time the analog outputs are forced, the In Service indicator will flash, indicating that
the 489 is not in protection mode.

5.13.6 Comm Port Monitor

PATH: SETPOINTS ZV S12 489 TESTING ZV COMMUNICATION PORT MONITOR
MONITOR COMM. PORT: Range: Computer RS485, Auxiliary

COMMUNICATION [Z] Computer RS485 RS485, Front Panel RS232
CLEAR COMM. Range: No, Yes

MESSAGE
BUFFERS: No
LAST Rx BUFFER: Range: Buffer Cleared, Received OK,
MESSAGE Wrong Slave Addr., Illegal
Received OK
Function, Illegal Count, Illegal
Reg. Addr., CRC Error, Illegal
Data
Rx1: 02,03,00,67,00, Range: received data in HEX
MESSAGE
03,B4,27
Rx2: Range: received data in HEX
MESSAGE
Tx1: 02,03,06,00,64, Range: transmit data in HEX

MESSAGE
00,0A,00,0F
Tx2: Range: transmit data in HEX
MESSAGE
During communications troubleshooting, it can be useful to see the data being transmitted
to the 489 from some master device, as well as the data transmitted back to that master
device. The messages shown here make it possible to view that data. Any of the three
communications ports may be monitored. After the communications buffers are cleared,
any data received from the monitored communications port is stored in Rx1 and Rx2. If the
489 transmits a message, it appears in the Tx1 and Tx2 buffers. In addition to these
buffers, there is a message indicating the status of the last received message.
5.13.7 Factory Service

PATH: SETPOINTS ZV S12 489 TESTING ZV FACTORY SERVICE
ENTER FACTORY Range: N/A

FACTORY [Z] PASSCODE: 0
This section is for use by GE Multilin personnel for testing and calibration purposes.

Digital Energy
Multilin
Chapter 6: Actual Values
Actual Values
6.1 Overview
6.1.1 Actual Values Main Menu

The actual values message map is shown below.
ACTUAL VALUES [Z]

See page 6–4.
A1 STATUS NETWORK STATUS [Z]

GENERATOR [Z]
LAST TRIP [Z]
DATA
ALARM STATUS [Z]
TRIP PICKUPS [Z]

ALARM PICKUPS [Z]


DIGITAL [Z]
REAL TIME [Z]
CLOCK
END OF PAGE
MESSAGE

CHAPTER 6: ACTUAL VALUES
ACTUAL VALUES [Z]

See page 6–16.
A2 METERING DATA CURRENT [Z]

VOLTAGE [Z]

POWER [Z]

TEMPERATURE [Z]

DEMAND [Z]

ANALOG [Z]

SPEED [Z]
END OF PAGE
MESSAGE
ACTUAL VALUES [Z]

See page 6–22.
A3 LEARNED DATA PARAMETER [Z]

RTD [Z]
ANALOG INPUT [Z]
MIN/MAX
END OF PAGE
MESSAGE
ACTUAL VALUES [Z]

See page 6–25.
A4 MAINTENANCE TRIP [Z]

GENERAL [Z]

TIMERS [Z]
END OF PAGE
MESSAGE
ACTUAL VALUES [Z]

See page 6–28.
A5 EVENT RECORD E255 [Z]

E254 [Z]
↓


E000 [Z]
END OF PAGE
MESSAGE
ACTUAL VALUES [Z] 489 MODEL [Z]

See page 6–31.
A6 PRODUCT INFO. INFORMATION

CALIBRATION [Z]
END OF PAGE
MESSAGE
6.1.2 Description
Measured values, maintenance and fault analysis information are accessed in the actual
values. Actual values may be accessed via one of the following methods:
1. Front panel, using the keys and display.
2. Front program port and a portable computer running the EnerVista 489 Setup
software supplied with the relay.
3. Rear terminal RS485 port and a PLC/SCADA system running user-written
software.
Any of these methods can be used to view the same information. However, a computer
makes viewing much more convenient since many variables may be viewed
simultaneously.
Actual value messages are organized into logical groups, or pages, for easy reference, as
shown below. All actual value messages are illustrated and described in blocks throughout
this chapter. All values shown in these message illustrations assume that no inputs
(besides control power) are connected to the 489.
In addition to the actual values, there are also diagnostic and flash messages that appear
only when certain conditions occur. They are described later in this chapter.

6.2 A1 Status
6.2.1 Network Status

PATH: ACTUAL VALUES Z A1 STATUS ZV NETWORK STATUS
NETWORK STATUS [Z] Ethernet Lnk Con Dia Range: see description below
Status [] [] [ ]
This actual value appears when the relay is ordered with the Ethernet (T) option.
The ETHERNET STATUS actual value message indicates the status of the Ethernet link,
connection, and diagnostic via three indicators. The [] symbol indicates on, and the [ ]
symbol indicates off. There is also a blinking indication.
The box under LNK column indicates the Ethernet link status. If it is on, the Ethernet port is
connected to the network; if it is off, the port is disconnected. This indicator is normally on.
The box under the CON column indicates the connection status. If on, the Ethernet port is
configured and ready to transmit and receive data. If blinking, the Ethernet port is either
active (transmitting or receiving data) or indicating an error if the diagnostic status is also
on or blinking.
The box under the DIA column indicates the diagnostic status. If it is on, then either a fatal
Ethernet port error has occurred or there is a duplicate IP address on the network. If
blinking, then there is a non-fatal network error. Off indicates no errors.
6.2.2 Generator Status

PATH: ACTUAL VALUES Z A1 STATUS Z GENERATOR STATUS
GENERATOR STATUS: Range: Online, Offline, Tripped

GENERATOR [Z] Offline
GENERATOR THERMAL Range: 0 to 100%. Seen only if the
MESSAGE Thermal Model is enabled
CAPACITY USED: 0%
ESTIMATED TRIP TIME Range: 0 to 10000 sec., Never. Seen
MESSAGE only if the Thermal Model is
ON OVERLOAD: Never
enabled
These messages describe the status of the generator at any given point in time. If the
generator has been tripped, is still offline, and the 489 has not yet been reset, the
GENERATOR STATUS will be “Tripped”. The GENERATOR THERMAL CAPACITY USED value
reflects an integrated value of both the stator and rotor thermal capacity used. The values
for ESTIMATED TRIP TIME ON OVERLOAD will appear whenever the 489 thermal model picks
up on the overload curve.

6.2.3 Last Trip Data

PATH: ACTUAL VALUES Z A1 STATUS ZV LAST TRIP DATA
LAST TRIP [Z] CAUSE OF LAST TRIP: Range: see Note below.
DATA No Trip to Date
TIME OF LAST TRIP: Range: hour:min:sec
MESSAGE
09:00:00.00
DATE OF LAST TRIP: Range: Month Day Year
MESSAGE
Jan 01 1995
TACHOMETER Range: 0 to 3600 RPM. Seen only if
MESSAGE Tachometer is assigned.
PRETRIP: 3600 RPM
A: 0 B: 0 Range: 0 to 999999 A. Represents
MESSAGE current measured from output
C: 0 A PreTrip
CTs. Seen only if a trip has
occurred.
a: 0 b: 0 Range: 0 to 999999 A. Represents
MESSAGE differential current. Seen only if
c: 0 A PreTrip
differential element is enabled.
NEG. SEQ. CURRENT Range: 0 to 2000% FLA. Seen only if
MESSAGE there has been a trip.
PRETRIP: 0% FLA
GROUND CURRENT Range: 0.00 to 200000.00 A. Not seen if
MESSAGE GROUND CT is “None”
PRETRIP: 0.00 A
GROUND CURRENT Range: 0.0 to 5000.0 A
MESSAGE
PRETRIP: 0.00 Amps
Vab: 0 Vbc: 0 Range: 0 to 50000 V. Not seen if VT
MESSAGE CONNECTION is “None”
Vca: 0 V PreTrip
FREQUENCY Range: 0.00 to 90.00 Hz. Not seen if VT
PRETRIP: 0.00 Hz
NEUTRAL VOLT (FUND) Range: 0.0 to 25000.0 V. Seen only if
MESSAGE there is a neutral VT.
PRETRIP: 0.0 V
NEUTRAL VOLT (3rd) Range: 0.0 to 25000.0 V. Seen only if
PRETRIP: 0.0 V
REAL POWER (MW) Range: 0.000 to ±2000.000 MW. Not
MESSAGE seen if VT CONNECTION is
PRETRIP: 0.000
“None”
REACTIVE POWER Mvar Range: 0.000 to ±2000.000 Mvar. Not
PRETRIP: 0.00 Hz
“None”
APPARENT POWER MVA Range: 0.000 to ±2000.000 MVA. Not
PRETRIP: 0.00 Hz
“None”
HOTTEST STATOR RTD Range: –50 to 250°C. Seen only if at
MESSAGE least one RTD is “Stator”
RTD #1: 0°C PreTrip
HOTTEST BEARING RTD Range: –50 to 250°C. Seen only if at
MESSAGE least one RTD is “Bearing”
HOTTEST OTHER RTD Range: –50 to 250°C. Seen only if at
MESSAGE least one RTD is “Other”

AMBIENT RTD Range: –50 to 250°C. Seen only if at

MESSAGE least one RTD is Ambient
RTD#12: 0°C PreTrip
ANALOG INPUT 1 Range: –50000 to 50000. Not seen if
MESSAGE ANALOG INPUT 1 is “Disabled”
PreTrip: 0 Units
PreTrip: 0 Units
PreTrip: 0 Units
PreTrip: 0 Units
Vab/Iab PreTrip: Range: 0 to 65535 Ωsec.; 0 to 359°.
MESSAGE Seen only if Loss of Excitation is
0.0 Ωsec. 0°
enabled
The range for the CAUSE OF LAST TRIP setpoint is: No Trip to Date, General Inputs A to G,
Sequential Trip, Field-Bkr Discrep., Tachometer, Thermal Model, Offline Overcurrent, Phase
NOTE
Overcurrent, Neg. Seq. Overcurrent, Ground Overcurrent, Phase Differential, RTDs 1 to 12,
Overvoltage, Undervoltage, Volts/Hertz, Phase Reversal, Underfrequency, Overfrequency,
Neutral O/V, Neutral U/V (3rd), Reactive Power, Reverse Power, Low Forward Power,
Inadvertent Energ., and Analog Inputs 1 to 4.
Immediately prior to issuing a trip, the 489 takes a snapshot of generator parameters and
stores them as pre-trip values; this allows for troubleshooting after the trip occurs. The
cause of last trip message is updated with the current trip and the screen defaults to that
message. All trip features are automatically logged as date and time stamped events as
they occur. This information can be cleared using the S1 489 SETUP ZV CLEAR DATA ZV
CLEAR LAST TRIP DATA setpoint. If the cause of last trip is “No Trip To Date”, the subsequent
pretrip messages will not appear. Last Trip Data will not update if a digital input
programmed as Test Input is shorted.
6.2.4 Alarm Status

PATH: ACTUAL VALUES Z A1 STATUS ZV ALARM STATUS
ALARM STATUS [Z] NO ALARMS Range: N/A. Message seen when no

alarms are active
Input A ALARM Range: Active, Latched. See Note

MESSAGE below.
STATUS: Active
Input B ALARM Range: Active, Latched. See Note
MESSAGE below.
STATUS: Active
Input C ALARM Range: Active, Latched. See Note
MESSAGE below.
STATUS: Active
Input D ALARM Range: Active, Latched. See Note
MESSAGE below.
STATUS: Active
Input E ALARM Range: Active, Latched. See Note
MESSAGE below.
STATUS: Active

Input F ALARM Range: Active, Latched. See Note

MESSAGE below.
STATUS: Active
Input G ALARM Range: Active, Latched. See Note
MESSAGE below.
STATUS: Active
TACHOMETER Range: 0 to 3600 RPM
MESSAGE
ALARM: 3000 RPM
OVERCURRENT Range: 0.00 to 20.00 × FLA
MESSAGE
ALARM: 10.00 x FLA
NEG. SEQ. CURRENT Range: 0 to 100% FLA
MESSAGE
ALARM: 15% FLA
GROUND OVERCURRENT Range: 0.00 to 200000.00 A. Seen only
MESSAGE if the GE 50:0.025 CT is used.
ALARM: 5.00 A
GROUND DIRECTIONAL Range: 0.00 to 200000.00 A
MESSAGE
ALARM: 5.00 A
UNDERVOLTAGE ALARM Range: 0 to 20000 V; 50 to 99% of
MESSAGE Rated
Vab= 3245 V 78%
OVERVOLTAGE ALARM Range: 0 to 20000 V; 101 to 150% of
MESSAGE Rated
Vab= 4992 V 120%
VOLTS/HERTZ ALARM Range: 0.00 to 2.00. Not seen if VT
MESSAGE CONNECTION is None.
PER UNIT V/Hz: 1.15
UNDERFREQUENCY Range: 0.00 to 90.00 Hz
MESSAGE
ALARM: 59.4 Hz
OVERFREQUENCY Range: 0.00 to 90.00 Hz
MESSAGE
ALARM: 60.6 Hz
NEUTRAL O/V (FUND) Range: 0.0 to 25000.0 V
MESSAGE
ALARM: 0.0 V
NEUTRAL U/V (3rd) Range: 0.0 to 25000.0 V
MESSAGE
ALARM: 0.0 V
REACTIVE POWER Mvar Range: –2000.000 to +2000.000 Mvar
MESSAGE
ALARM: +20.000
REVERSE POWER Range: –2000.000 to +2000.000 MW
MESSAGE
ALARM: –20.000 MW
LOW FORWARD POWER Range: –2000.000 to +2000.000 MW
MESSAGE
ALARM: –20.000 MW
RTD #1 Range: –50 to +250°C. Top line displays
MESSAGE the RTD name as programmed.
ALARM: 135°C
ALARM: 135°C
ALARM: 135°C
ALARM: 135°C


ALARM: 135°C
ALARM: 135°C
ALARM: 135°C
ALARM: 135°C
ALARM: 135°C
ALARM: 135°C
ALARM: 135°C
ALARM: 135°C
OPEN SENSOR ALARM: Range: RTDs 1 to 12
MESSAGE
RTD # 1 2 3 4 5 6 ...
SHORT/LOW TEMP ALARM Range: RTDs 1 to 12
MESSAGE
RTD # 7 8 9 10 11 ...
THERMAL MODEL Range: 1 to 100%
MESSAGE
ALARM: 100% TC USED
TRIP COUNTER Range: 1 to 10000
MESSAGE
ALARM: 25 Trips
BREAKER FAILURE Range: Active, Latched
MESSAGE
ALARM: Active
TRIP COIL MONITOR Range: Active, Latched
MESSAGE
ALARM: Active
VT FUSE FAILURE Range: Active, Latched
MESSAGE
ALARM: Active
CURRENT DEMAND Range: 1 to 999999 A
MESSAGE
ALARM: 1053 A
MW DEMAND Range: –2000.000 to +2000.000 MW
MESSAGE
ALARM: 50.500
Mvar DEMAND Range: –2000.000 to +2000.000 Mvar
MESSAGE
ALARM: –20.000
MVA DEMAND Range: 0 to 2000.000 MVA
MESSAGE
ALARM: 20.000
GEN. RUNNING HOURS Range: 0 to 1000000 hrs. Seen only if
MESSAGE Running Hr. Alarm is enabled.
ALARM: 1000 h
ANALOG I/P 1 Range: –50000 to +50000
MESSAGE
ALARM: 201 Units


MESSAGE
ALARM: 201 Units
MESSAGE
ALARM: 201 Units
MESSAGE
ALARM: 201 Units
ALARM, 489 NOT Range: N/A
MESSAGE
INSERTED PROPERLY
489 NOT IN SERVICE Range: Not Programmed, Simulation
MESSAGE Mode, Output Relays Forced,
Simulation Mode
Analog Output Forced, Test
Switch Shorted
IRIG-B FAILURE Range: Active. Seen only if IRIG-B is
MESSAGE enabled and the associated
ALARM: Active
signal input is lost.
Any active or latched alarms may be viewed here.

The various alarm and alarm status actual values reflect the Input Name as programmed
in the first line of the message. The status is “Active” if the condition that caused the alarm
is still present.
If the 489 chassis is only partially engaged with the case, the ALARM, 489 NOT INSERTED
PROPERLY service alarm appears after 1 sec. Secure the chassis handle to ensure that all
contacts mate properly.
6.2.5 Trip Pickups

PATH: ACTUAL VALUES Z A1 STATUS ZV TRIP PICKUPS
TRIP PICKUPS [Z] Input A Range: Not Enabled, Inactive, Timing

PICKUP: Not Enabled Out, Active Trip, Latched Trip
Input B Range: Not Enabled, Inactive, Timing

MESSAGE Out, Active Trip, Latched Trip
PICKUP: Not Enabled
Input C Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
Input D Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
Input E Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
Input F Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
Input G Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
SEQUENTIAL TRIP Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
FIELD-BKR DISCREP. Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled

TACHOMETER Range: Not Enabled, Inactive, Timing

PICKUP: Not Enabled
OFFLINE OVERCURRENT Range: Not Enabled, Inactive, Timing
MESSAGE Out, Active Trip, Latched Trip.
PICKUP: Not Enabled
INADVERTENT ENERG. Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
PHASE OVERCURRENT Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
NEG. SEQ. OVERCURRENT Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
GROUND OVERCURRENT Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
PHASE DIFFERENTIAL Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
GROUND DIRECTIONAL Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
HIGH-SET PHASE O/C Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
UNDERVOLTAGE Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
OVERVOLTAGE Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
VOLTS/HERTZ Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
PHASE REVERSAL Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
UNDERFREQUENCY Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
OVERFREQUENCY Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
NEUTRAL O/V (FUND) Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
NEUTRAL U/V (3rd) Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
LOSS OF EXCITATION 1 Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
LOSS OF EXCITATION 2 Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
DISTANCE ZONE 1 Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
DISTANCE ZONE 2 Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled

REACTIVE POWER Range: Not Enabled, Inactive, Timing

PICKUP: Not Enabled
REVERSE POWER Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
LOW FORWARD POWER Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
RTD #1 Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
THERMAL MODEL Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
ANALOG I/P 1 Range: Not Enabled, Inactive, Timing
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled

The various trip pickup actual values reflect the Input Name as programmed in the first line
Note
of the message. The various digital and analog input functions are shown only if the
function has been assigned as an input.
The trip pickup messages may be very useful during testing. They will indicate if a trip
feature has been enabled, if it is inactive (not picked up), timing out (picked up and timing),
active trip (still picked up, timed out, and causing a trip), or latched tip (no longer picked up,
but had timed out and caused a trip that is latched). These values may also be particularly
useful as data transmitted to a master device for monitoring.
6.2.6 Alarm Pickups

PATH: ACTUAL VALUES Z A1 STATUS ZV ALARM PICKUPS
ALARM PICKUPS [Z] Input A Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled Active Alarm, Latched Alarm.
Input B Range: Not Enabled, Inactive, Timing Out,

MESSAGE Active Alarm, Latched Alarm.
PICKUP: Not Enabled
Input C Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
Input D Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
Input E Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
Input F Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
Input G Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
TACHOMETER Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
OVERCURRENT Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
NEG. SEQ. OVERCURRENT Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
GROUND OVERCURRENT Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
GROUND DIRECTIONAL Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
UNDERVOLTAGE Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
OVERVOLTAGE Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
VOLTS/HERTZ Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled

UNDERFREQUENCY Range: Not Enabled, Inactive, Timing Out,

PICKUP: Not Enabled
OVERFREQUENCY Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
NEUTRAL O/V (FUND) Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
NEUTRAL U/V (3rd) Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
REACTIVE POWER Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
REVERSE POWER Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
LOW FORWARD POWER Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
RTD #1 Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
OPEN SENSOR Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
SHORT/LOW TEMP Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled

THERMAL MODEL Range: Not Enabled, Inactive, Timing Out,

PICKUP: Not Enabled
TRIP COUNTER Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
BREAKER FAILURE Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
TRIP COIL MONITOR Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
VT FUSE FAILURE Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
CURRENT DEMAND Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
MW DEMAND Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
Mvar DEMAND Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
MVA DEMAND Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
GEN. RUNNING HOURS Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
ANALOG I/P 1 Range: Not Enabled, Inactive, Timing Out,
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
PICKUP: Not Enabled
The various alarm pickup actual values reflect the Input Name as programmed in the first
Note
line of the message. The various digital and analog input functions are shown only if the
function has been assigned as an input.
The alarm pickup messages may be very useful during testing. They will indicate if a alarm
feature has been enabled, if it is inactive (not picked up), timing out (picked up and timing),
active alarm (still picked up, timed out, and causing an alarm), or latched alarm (no longer
picked up, but had timed out and caused a alarm that is latched). These values may also be
particularly useful as data transmitted to a master device for monitoring.


PATH: ACTUAL VALUES Z A1 STATUS ZV DIGITAL INPUTS
DIGITAL [Z] ACCESS Range: Open, Shorted

INPUTS SWITCH STATE: Open
BREAKER STATUS Range: Open, Shorted
MESSAGE
SWITCH STATE: Open
ASSIGNABLE DIGITAL Range: Open, Shorted
MESSAGE
INPUT1 STATE: Open
MESSAGE
INPUT2 STATE: Open
MESSAGE
INPUT3 STATE: Open
MESSAGE
INPUT4 STATE: Open
MESSAGE
INPUT5 STATE: Open
MESSAGE
INPUT6 STATE: Open
MESSAGE
INPUT7 STATE: Open
TRIP COIL Range: Open, Shorted
MESSAGE
SUPERVISION: No Coil
The messages shown here may be used to monitor digital input status. This may be useful
during relay testing or during installation.
6.2.8 Real Time Clock

PATH: ACTUAL VALUES Z A1 STATUS ZV REAL TIME CLOCK
REAL TIME [Z] DATE: 01/01/1995 Range: 01/01/1995 to 12/31/2094,

CLOCK TIME: 12:00:00 00:00:00 to 23:59:59
The time and date from the 489 real time clock may be viewed here.

6.3 A2 Metering Data
6.3.1 Current Metering

PATH: ACTUAL VALUES ZV A2 METERING DATA Z CURRENT METERING
A: 0 B: 0 Range: 0 to 999999 A
CURRENT [Z] C: 0 Amps
a: 0 b: 0 Range: 0 to 999999 A
MESSAGE
c: 0 Neut.Amps
a: 0 b: 0 Range: 0 to 999999 A
MESSAGE
c: 0 Diff.Amps
AVERAGE PHASE Range: 0 to 999999 A
MESSAGE
CURRENT: 0 Amps
GENERATOR LOAD: Range: 0 to 2000% FLA
MESSAGE
0% FLA
NEGATIVE SEQUENCE Range: 0 to 2000% FLA
MESSAGE
CURRENT: 0% FLA
PHASE A CURRENT: Range: 0 to 999999 A, 0 to 359°
MESSAGE
0 A 0° Lag
PHASE B CURRENT: Range: 0 to 999999 A, 0 to 359°
MESSAGE
0 A 0° Lag
PHASE C CURRENT: Range: 0 to 999999 A, 0 to 359°
MESSAGE
0 A 0° Lag
NEUT. END A CURRENT: Range: 0 to 999999 A, 0 to 359°
MESSAGE
0 A 0° Lag
NEUT. END B CURRENT: Range: 0 to 999999 A, 0 to 359°
MESSAGE
0 A 0° Lag
NEUT. END C CURRENT: Range: 0 to 999999 A, 0 to 359°
MESSAGE
0 A 0° Lag
DIFF. A CURRENT: Range: 0 to 999999 A, 0 to 359°
MESSAGE
0 A 0° Lag
DIFF. B CURRENT: Range: 0 to 999999 A, 0 to 359°
MESSAGE
0 A 0° Lag
DIFF. C CURRENT: Range: 0 to 999999 A, 0 to 359°
MESSAGE
0 A 0° Lag
GROUND CURRENT: Range: 0.0 to 200000.0 A, 0 to 359°.
MESSAGE Seen only if 1 A or 5 A Ground
0.0 A 0° Lag
CT is used
GROUND CURRENT: Range: 0.00 to 100.00 A, 0 to 359°.
MESSAGE Seen only if 50:0.025 CT is used
0.00 A 0° Lag

All measured current values are displayed here. A, B, C AMPS represent the output side CT
measurements: A, B, C NEUT. AMPS the neutral end CT measurements, and A, B, C DIFF. AMPS
the differential operating current calculated as the vector difference between the output
side and the neutral end CT measurements on a per phase basis. The 489 negative-
sequence current is defined as the ratio of negative-sequence current to generator rated
FLA, I2 / FLA × 100%. The generator full load amps is calculated as: generator rated MVA /
( 3 × generator phase-to-phase voltage). Polar coordinates for measured currents are
also shown using Va (wye connection) or Vab (open delta connection) as a zero angle
reference vector. In the absence of a voltage signal (Va or Vab), the IA output current is
used as the zero angle reference vector.
6.3.2 Voltage Metering

PATH: ACTUAL VALUES ZV A2 METERING DATA ZV VOLTAGE METERING

VOLTAGE [Z] Vca: 0 Volts CONNECTION is “None”.
AVERAGE LINE Range: 0 to 50000 V. Not seen if VT

MESSAGE CONNECTION is “None”.
VOLTAGE: 0 Volts
Van: 0 Vbn: 0 Range: 0 to 50000 V. Not seen if VT
MESSAGE CONNECTION is “Wye”.
Vcn: 0 Volts
AVERAGE PHASE Range: 0 to 50000 V. Not seen if VT
VOLTAGE: 0 Volts
LINE A-B VOLTAGE: Range: 0 to 50000 V, 0 to 359°. Not
0 V 0° Lag
“None”.
LINE B-C VOLTAGE: Range: as above
MESSAGE
0 V 0° Lag
LINE C-A VOLTAGE: Range: as above
MESSAGE
0 V 0° Lag
PHASE A-N VOLTAGE: Range: 0 to 50000 V, 0 to 359°. Not
0 V 0° Lag
“Wye”.
PHASE B-N VOLTAGE: Range: as above
MESSAGE
0 V 0° Lag
PHASE C-N VOLTAGE: Range: as above
MESSAGE
0 V 0° Lag
PER UNIT MEASUREMENT Range: 0.00 to 2.00. Not seen if VT
OF V/Hz: 0.00
FREQUENCY: Range: 0.00 to 90.00 Hz. Not seen if VT
0.00 Hz
NEUTRAL VOLTAGE Range: 0.0 to 25000.0 V. Seen only if
FUND: 0.0 V

NEUTRAL VOLTAGE Range: 0.0 to 25000.0 V. Seen only if

3rd HARM: 0.0 V
TERMINAL VOLTAGE Range: 0.0 to 25000.0 V. Seen only if VT
3rd HARM: 0.0 V
IMPEDANCE Vab / Iab Range: 0.0 to 6553.5 Ωsec., 0 to 359°
MESSAGE
0.0 Ω sec. 0°
Measured voltage parameters will be displayed here. The V/Hz measurement is a per unit
value based on Vab voltage/measured frequency divided by generator phase-to-phase
nominal voltage/nominal system frequency. Polar coordinates for measured phase and/or
line voltages are also shown using Va (wye connection) or Vab (open delta connection) as a
zero angle reference vector. In the absence of a voltage signal (Va or Vab), IA output current
is used as the zero angle reference vector.
If VT CONNECTION TYPE is programmed as “None” and NEUTRAL VOLTAGE TRANSFORMER is
“No” in S2 SYSTEM, the THIS FEATURE NOT PROGRAMMED flash message will appear
when an attempt is made to enter this group of messages.
6.3.3 Power Metering

PATH: ACTUAL VALUES ZV A2 METERING DATA ZV POWER METERING
POWER [Z] POWER FACTOR: Range: 0.01 to 0.99 Lead or Lag, 0.00,
METERING 0.00 1.00
REAL POWER: Range: 0.000 to ±2000.000 MW

MESSAGE
0.000 MW
REACTIVE POWER: Range: 0.000 to ±2000.000 Mvar
MESSAGE
0.000 Mvar
APPARENT POWER: Range: 0.000 to 2000.000 MVA
MESSAGE
0.000 MVA
POSITIVE WATTHOURS: Range: 0.000 to 4000000.000 MWh
MESSAGE
0.000 MWh
POSITIVE VARHOURS: Range: 0.000 to 4000000.000 Mvarh
MESSAGE
0.000 Mvarh
NEGATIVE VARHOURS: Range: 0.000 to 4000000.000 Mvarh
MESSAGE
0.000 Mvarh
The values for power metering appear here. Three-phase total power quantities are
displayed here. Watthours and varhours are also shown here. Watthours and varhours will
not update if a digital input programmed as Test Input is shorted.
An induction generator, by convention generates Watts and consumes vars (+W and –
Note
vars). A synchronous generator can also generate vars (+vars).

If the VT CONNECTION TYPE is programmed as “None”, the THIS FEATURE NOT
PROGRAMMED flash message will appear when an attempt is made to enter this group of
messages.

6.3.4 Temperature
PATH: ACTUAL VALUES ZV A2 METERING DATA ZV TEMPERATURE
HOTTEST STATOR RTD Range: –50 to 250°C, No RTD Seen only

TEMPERATURE [Z] RTD#1: 40°C if at least 1 RTD programmed
as Stator
RTD #1 Range: –50 to 250°C, No RTD (open)
MESSAGE --- (shorted)
TEMPERATURE: 40°C
TEMPERATURE: 40°C
TEMPERATURE: 40°C
TEMPERATURE: 40°C
TEMPERATURE: 40°C
TEMPERATURE: 40°C
TEMPERATURE: 40°C
TEMPERATURE: 40°C
TEMPERATURE: 40°C
TEMPERATURE: 40°C
TEMPERATURE: 40°C
TEMPERATURE: 40°C
These messages are seen only if the corresponding RTDs are programmed. The actual
Note
messages reflect the RTD Names as programmed.

The current level of the 12 RTDs will be displayed here. If the RTD is not connected, the
value will be “No RTD”. If the RTD is shorted, then “---” will be displayed. If no RTDs are
programmed in the S7 RTD TEMPERATURE setpoints menu, the THIS FEATURE NOT
PROGRAMMED flash message will appear when an attempt is made to enter this group of
messages.

6.3.5 Demand Metering

PATH: ACTUAL VALUES ZV A2 METERING DATA ZV DEMAND METERING
DEMAND [Z] CURRENT Range: 0 to 999999 A

METERING DEMAND: 0 Amps
MW DEMAND: Range: 0 to 2000.000 MW. Not seen if
MESSAGE VT CONNECTION TYPE is None
0.000 MW
Mvar DEMAND: Range: 0 to 2000.000 Mvar. Not seen if
0.000 Mvar
MVA DEMAND: Range: 0 to 2000.000 MVA. Not seen if
0.000 MVA
PEAK CURRENT Range: 0 to 999999 A
MESSAGE
DEMAND: 0 Amps
PEAK MW DEMAND: Range: 0 to 2000.000 MW. Not seen if
0.000 MW
PEAK Mvar DEMAND: Range: 0 to 2000.000 Mvar. Not seen if
0.000 Mvar
PEAK MVA DEMAND: Range: 0 to 2000.000 MVA. Not seen if
0.000 MVA
The values for current and power demand are shown here. This peak demand information
can be cleared using the S1 489 SETUP ZV CLEAR DATA ZV CLEAR PEAK DEMAND setpoint.
Demand is shown only for positive real and positive reactive power (+Watts, +vars). Peak
demand will not update if a digital input programmed as Test Input is shorted.
6.3.6 Analog Inputs

PATH: ACTUAL VALUES ZV A2 METERING DATA ZV ANALOG INPUTS
ANALOG [Z] ANALOG I/P 1 Range: –50000 to 50000.

INPUTS 0 Units
ANALOG I/P 2 Range: –50000 to 50000.
MESSAGE
0 Units
MESSAGE
0 Units
MESSAGE
0 Units
These messages are seen only if the corresponding Analog Inputs are programmed. The
Note
actual messages reflect the Analog Input Names as programmed.

The values for analog inputs are shown here. The name of the input and the units will
reflect those programmed for each input. If no analog inputs are programmed in the S11
ANALOG I/O setpoints page, the THIS FEATURE NOT PROGRAMMED flash message will
appear when an attempt is made to enter this group of messages.

6.3.7 Speed
PATH: ACTUAL VALUES ZV A2 METERING DATA ZV SPEED
SPEED [Z] TACHOMETER: 0 RPM Range: 0 to 7200 RPM
If the Tachometer function is assigned to one of the digital inputs, its speed be viewed here.
If no digital input is configured for tachometer, the THIS FEATURE NOT PROGRAMMED
flash message will appear when an attempt is made to enter this group of messages.

6.4 A3 Learned Data
6.4.1 Parameter Averages

PATH: ACTUAL VALUES ZV A3 LEARNED DATA Z PARAMETER AVERAGES
PARAMETER [Z] AVERAGE GENERATOR Range: 0 to 2000% FLA

AVERAGES LOAD: 100% FLA
AVERAGE NEG. SEQ. Range: 0 to 2000% FLA
MESSAGE
CURRENT: 0% FLA
AVERAGE PHASE-PHASE Range: 0 to 50000 V. Not seen if VT
VOLTAGE: 0 V
The 489 calculates the average magnitude of several parameters over a period of time.
This time is specified by S1 489 SETUP ZV PREFERENCES ZV PARAMETER AVERAGES CALC.
PERIOD setpoint (default 15 minutes). The calculation is a sliding window and is ignored
when the generator is offline (that is, the value that was calculated just prior to going
offline will be held until the generator is brought back online and a new calculation is
made). Parameter averages will not update if a digital input programmed as Test Input is
shorted.
6.4.2 RTD Maximums

PATH: ACTUAL VALUES ZV A3 LEARNED DATA ZV RTD MAXIMUMS
RTD #1 Range: –50 to 250°C

RTD [Z] MAX. TEMP.: 40°C
MESSAGE
MAX. TEMP.: 40°C
MESSAGE
MAX. TEMP.: 40°C
MESSAGE
MAX. TEMP.: 40°C
MESSAGE
MAX. TEMP.: 40°C
MESSAGE
MAX. TEMP.: 40°C
MESSAGE
MAX. TEMP.: 40°C
MESSAGE
MAX. TEMP.: 40°C
MESSAGE
MAX. TEMP.: 40°C
MESSAGE
MAX. TEMP.: 40°C


MESSAGE
MAX. TEMP.: 40°C
MESSAGE
MAX. TEMP.: 40°C
These messages are seen only if the corresponding RTDs are programmed. The actual
Note
messages reflect the RTD Names as programmed.

The 489 will learn the maximum temperature for each RTD. This information can be
cleared using the S1 489 SETUP ZV CLEAR DATA ZV CLEAR RTD MAXIMUMS setpoint. The
RTD maximums will not update if a digital input programmed as Test Input is shorted. If no
RTDs are programmed in the S7 RTD TEMPERATURE setpoints page, the THIS FEATURE
NOT PROGRAMMED flash message will appear when an attempt is made to enter this
group of messages.
6.4.3 Analog Input Min/Max

PATH: ACTUAL VALUES ZV A3 LEARNED DATA ZV ANALOG INPUT MIN/MAX
ANALOG INPUT [Z] ANALOG I/P 1 Range: –50000 to 50000

MIN/MAX MIN: O Units
ANALOG I/P 1 Range: –50000 to 50000
MESSAGE
MAX: 0 Units
MESSAGE
MIN: O Units
MESSAGE
MAX: 0 Units
MESSAGE
MIN: O Units
MESSAGE
MAX: 0 Units
MESSAGE
MIN: O Units
MESSAGE
MAX: 0 Units
These messages are seen only if the corresponding Analog Inputs are programmed. The
Note
actual messages reflect the Analog Input Names as programmed.

The 489 learns the minimum and maximum values of the analog inputs since they were
last cleared. This information can be cleared using the S1 489 SETUP ZV CLEAR DATA ZV
CLEAR ANALOG I/P MIN/MAX setpoint. When the data is cleared, the present value of each
analog input will be loaded as a starting point for both minimum and maximum. The name
of the input and the units will reflect those programmed for each input. Analog Input
minimums and maximums will not update if a digital input programmed as Test Input is
shorted.

If no Analog Inputs are programmed in the S11 ANALOG I/O setpoints menu, the THIS
FEATURE NOT PROGRAMMED flash message will appear when an attempt is made to
enter this group of messages.

6.5 A4 Maintenance
6.5.1 Trip Counters

PATH: ACTUAL VALUES ZV A4 MAINTENANCE Z TRIP COUNTERS
TOTAL NUMBER OF Range: 0 to 50000

TRIP [Z] TRIPS: 0
DIGITAL INPUT Range: 0 to 50000. Caused by the
MESSAGE General Input Trip feature
TRIPS: 0
SEQUENTIAL Range: 0 to 50000
MESSAGE
TRIPS: 0
FIELD-BKR DISCREP. Range: 0 to 50000
MESSAGE
TRIPS: 0
TACHOMETER Range: 0 to 50000
MESSAGE
TRIPS: 0
OFFLINE OVERCURRENT Range: 0 to 50000
MESSAGE
TRIPS: 0
PHASE OVERCURRENT Range: 0 to 50000
MESSAGE
TRIPS: 0
NEG. SEQ. OVERCURRENT Range: 0 to 50000
MESSAGE
TRIPS: 0
GROUND OVERCURRENT Range: 0 to 50000
MESSAGE
TRIPS: 0
PHASE DIFFERENTIAL Range: 0 to 50000
MESSAGE
TRIPS: 0
GROUND DIRECTIONAL Range: 0 to 50000
MESSAGE
TRIPS: 0
HIGH-SET PHASE O/C Range: 0 to 50000
MESSAGE
TRIPS: 0
UNDERVOLTAGE Range: 0 to 50000
MESSAGE
TRIPS: 0
OVERVOLTAGE Range: 0 to 50000
MESSAGE
TRIPS: 0
VOLTS/HERTZ Range: 0 to 50000
MESSAGE
TRIPS: 0
PHASE REVERSAL Range: 0 to 50000
MESSAGE
TRIPS: 0
UNDERFREQUENCY Range: 0 to 50000
MESSAGE
TRIPS: 0
OVERFREQUENCY Range: 0 to 50000
MESSAGE
TRIPS: 0

NEUTRAL O/V (Fund) Range: 0 to 50000

MESSAGE
TRIPS: 0
NEUTRAL U/V (3rd) Range: 0 to 50000
MESSAGE
TRIPS: 0
LOSS OF EXCITATION 1 Range: 0 to 50000
MESSAGE
TRIPS: 0
LOSS OF EXCITATION 2 Range: 0 to 50000
MESSAGE
TRIPS: 0
DISTANCE ZONE 1 Range: 0 to 50000
MESSAGE
TRIPS: 0
DISTANCE ZONE 2 Range: 0 to 50000
MESSAGE
TRIPS: 0
REACTIVE POWER Range: 0 to 50000
MESSAGE
TRIPS: 0
REVERSE POWER Range: 0 to 50000
MESSAGE
TRIPS: 0
LOW FORWARD POWER Range: 0 to 50000
MESSAGE
TRIPS: 0
STATOR RTD Range: 0 to 50000
MESSAGE
TRIPS: 0
BEARING RTD Range: 0 to 50000
MESSAGE
TRIPS: 0
OTHER RTD Range: 0 to 50000
MESSAGE
TRIPS: 0
AMBIENT RTD Range: 0 to 50000
MESSAGE
TRIPS: 0
THERMAL MODEL Range: 0 to 50000
MESSAGE
TRIPS: 0
INADVERTENT ENERG. Range: 0 to 50000
MESSAGE
TRIPS: 0
ANALOG I/P 1 Range: 0 to 50000. Reflects Analog In
MESSAGE Name/units as programmed
TRIPS: 0
TRIPS: 0
TRIPS: 0
TRIPS: 0
COUNTERS CLEARED: Range: Date in format shown
MESSAGE
Jan 1, 1995

The number of trips by type is displayed here. When the total reaches 50000, all counters
reset. This information can be cleared with the S1 489 SETUP ZV CLEAR DATA ZV
CLEAR TRIP COUNTERS setpoint. Trip counters will not update if a digital input programmed
as Test Input is shorted. In the event of multiple trips, the only the first trip will increment
the trip counters.
6.5.2 General Counters

PATH: ACTUAL VALUES ZV A4 MAINTENANCE ZV GENERAL COUNTERS
GENERAL [Z] NUMBER OF BREAKER Range: 0 to 50000

COUNTERS OPERATIONS: 0
NUMBER OF THERMAL Range: 0 to 50000. Seen only if a
MESSAGE Digital Input is assigned to
RESETS: 0
Thermal Reset.
One of the 489 general counters will count the number of breaker operations over time.
This may be useful information for breaker maintenance. The number of breaker
operations is incremented whenever the breaker status changes from closed to open and
all phase currents are zero. Another counter counts the number of thermal resets if one of
the assignable digital inputs is assigned to thermal reset. This may be useful information
when troubleshooting. When either of these counters exceeds 50000, that counter will
reset to 0.
The NUMBER OF BREAKER OPERATIONS counter can also be cleared using the S1 489 SETUP
ZV CLEAR DATA ZV CLEAR BREAKER INFORMATION setpoint. The NUMBER OF THERMAL
RESETS counter can be cleared using the S1 489 SETUP ZV CLEAR DATA ZV CLEAR
GENERATOR INFORMATION setpoint.
The number of breaker operations will not update if a digital input programmed as Test
Input is shorted.
6.5.3 Timers
PATH: ACTUAL VALUES ZV A4 MAINTENANCE ZV TIMERS
TIMERS [Z] GENERATOR HOURS Range: 1 to 1000000 hrs.

ONLINE: 0 h
The 489 accumulates the total online time for the generator. This may be useful for
scheduling routine maintenance. When this timer exceeds 1000000, it resets to 0. This
timer can be cleared using the S1 489 SETUP ZV CLEAR DATA ZV CLEAR GENERATOR
INFORMATION setpoint. The generator hours online will not update if a digital input

6.6 A5 Event Recorder

PATH: ACTUAL VALUES ZV A5 EVENT RECORDER ZV E001(E256)
E001 [Z] TIME OF E001: Range: hour: minutes: seconds

<Cause> 00:00:00.0
DATE OF E001: Range: month day, year
MESSAGE
Jan. 01, 1992
ACTIVE Range: 1, 2
MESSAGE
GROUP E001: 1
TACHOMETER Range: 0 to 3600 RPM. Seen only if a
MESSAGE Digital Input set as Tachometer
E001: 3600 RPM
A: 0 B: 0 Range: 0 to 999999 A
MESSAGE
C: 0 A E001
a: 0 b: 0 Range: 0 to 999999 NA. Represents
MESSAGE neutral end current.
c: 0 NA E001
NEG. SEQ. CURRENT Range: 0 to 2000% FLA
MESSAGE
E001: 0% FLA
GROUND CURRENT Range: 0 to 20000.0 A. Not seen if
MESSAGE GROUND CT TYPE is “None”.
E001: 0.00 A
Vca: 0 V E001
FREQUENCY Range: 0.00 to 90.00 Hz. Not seen if VT
E001: 0.00 Hz
NEUTRAL VOLT (FUND) Range: 0.0 to 25000.0 V. Seen only if
E001: 0.0 V
NEUTRAL VOLT (3rd) Range: 0.0 to 25000.0 V. Seen only if
E001: 0.0 V
Vab/Iab E001: Range: 0.0 to 6553.5 Ωsec., 0 to 359°.
MESSAGE Seen only if the Loss of
0.0 Ωsec. 0°
Excitation element is Enabled.
REAL POWER (MW) Range: 0 to ±2000.000 MW. Not seen if
MESSAGE VT CONNECTION is “None”
E001: 0.000
REACTIVE POWER Mvar Range: 0 to ±2000.000 Mvar. Not seen
MESSAGE if VT CONNECTION is “None”
E001: 0.000
APPARENT POWER MVA Range: 0 to 2000.000 MVA. Not seen if
MESSAGE VT CONNECTION is “None”
E001: 0.000
HOTTEST STATOR Range: –50 to +250°C. Seen only if 1 or
MESSAGE more RTDs are set as Stator.
RTD#1: 0°C E001
HOTTEST BEARING Range: –50 to +250°C. Seen only if 1 or
MESSAGE more RTDs are set as Bearing.
RTD#7: 0°C E001

HOTTEST OTHER Range: –50 to +250°C. Seen only if 1 or

MESSAGE more RTDs are set as Other.
RTD#11: 0°C E001
AMBIENT Range: –50 to +250°C. Seen only if 1 or
MESSAGE more RTDs are set as Ambient.
RTD#12 0°C E001
ANALOG INPUT 1 Range: –50000 to 50000. Reflects the
MESSAGE Analog Input name. Not seen if
E001: 0.0 Units
Analog Input 1 is disabled.
E001: 0.0 Units
E001: 0.0 Units
E001: 0.0 Units
The 489 Event Recorder stores generator and system information each time an event
occurs. The description of the event is stored and a time and date stamp is also added to
the record.
The event recorder data may be inaccurate if 489 relay power-on time is less than
Note
2 seconds.
The date and time stamping feature allows reconstruction of the sequence of events for
troubleshooting. Events include all trips, any alarm optionally (except Service Alarm, and
489 Not Inserted Alarm, which always records as events), loss of control power, application
of control power, thermal resets, simulation, serial communication starts/stops, and
general input control functions optionally.
E001 is the most recent event and E256 is the oldest event. Each new event bumps the other
event records down until the 256th event is reached. The 256th event record is lost when
the next event occurs. This information can be cleared using S1 489 SETUP ZV CLEAR DATA
ZV CLEAR EVENT RECORD setpoint. The event record will not update if a digital input
Table 6–1: Cause of Events (Sheet 1 of 2)
TRIPS
Ambient RTD12 Trip * Analog I/P 1 to 4 Trip * Bearing RTD 7 Trip * Bearing RTD 8 Trip *
Bearing RTD 9 Trip * Bearing RTD 10 Trip * Differential Trip Distance Zone 1 Trip
Distance Zone 2 Trip Field-Bkr Discr. Trip Gnd Directional Trip Ground O/C Trip
Inadvertent Energization
Hiset Phase O/C Trip Input A to G Trip * Loss of Excitation 1
Trip
Loss of Excitation 2 Low Fwd Power Trip Neg Seq O/C Trip Neutral O/V Trip
Neut. U/V (3rd) Trip Offline O/C Trip Overfrequency Trip Overvoltage Trip
* reflects the name as programmed

Table 6–1: Cause of Events (Sheet 2 of 2)
TRIPS
Phase O/C Trip Phase Reversal Trip Reactive Power Trip Reverse Power Trip
RTD11 Trip * Sequential Trip Stator RTD 1 Trip * Stator RTD 2 Trip *
Stator RTD 3 Trip * Stator RTD 4 Trip * Stator RTD 5 Trip * Stator RTD 6 Trip *
Tachometer Trip Thermal Model Trip Underfrequency Trip Undervoltage Trip
Volts/Hertz Trip
ALARMS (OPTIONAL EVENTS)
Analog I/P 1 to 4 Alarm Bearing RTD 7 Alarm

489 Not Inserted Ambient RTD12 Alarm *
* *
Bearing RTD 8 Alarm * Bearing RTD 9 Alarm * Bearing RTD 10 Alarm * Breaker Failure
Current Demand Alarm Gnd Directional Alarm Ground O/C Alarm Input A to G Alarm *
Low Fwd Power Alarm MVA Demand Alarm Mvar Demand Alarm MW Demand Alarm
NegSeq Current Alarm Neut. U/V 3rd Alarm Neutral O/V Alarm Open RTD Alarm
Overcurrent Alarm Overfrequency Alarm Overvoltage Alarm Reactive Power Alarm
Reverse Power Alarm RTD11 Alarm * Service Alarm Short/Low RTD Alarm
Stator RTD 1 Alarm Stator RTD 2 Alarm Stator RTD 3 Alarm Stator RTD 4 Alarm
Stator RTD 5 Alarm Stator RTD 6 Alarm Tachometer Alarm Thermal Model Alarm
Trip Coil Monitor Trip Counter Alarm Underfrequency Alarm Undervoltage Alarm
Volts Per Hertz Alarm VT Fuse Fail Alarm
OTHER
Control Power Applied Control Power Lost Dig I/P Waveform Trig Input A to G Control *
Serial Comm. Start Serial Comm. Stop Serial Waveform Trip Setpoint 1 Active
Setpoint 2 Active Simulation Started Simulation Stopped Thermal Reset Close
* reflects the name as programmed

6.7 A6 Product Information
6.7.1 489 Model Info

PATH: ACTUAL VALUES ZV A6 PRODUCT INFO Z 489 MODEL INFO
489 MODEL [Z] ORDER CODE: Range: N/A

INFORMATION 489-P5-HI-A20
489 SERIAL NO: Range: N/A
MESSAGE
A3260001
489 REVISION: Range: N/A
MESSAGE
32E100A4.000
489 BOOT REVISION: Range: N/A
MESSAGE
30K401A0.000
All of the 489 model information may be viewed here when the unit is powered up. In the
event of a product software upgrade or service question, the information shown here
should be jotted down prior to any inquiry.
6.7.2 Calibration Info

PATH: ACTUAL VALUES ZV A6 PRODUCT INFO ZV CALIBRATION INFO
CALIBRATION [Z] ORIGINAL CALIBRATION Range: month day year

INFORMATION DATE: Jan 01 1996
LAST CALIBRATION Range: month day year
MESSAGE
DATE: Jan 01 1996
The date of the original calibration and last calibration may be viewed here.

6.8 Diagnostics
6.8.1 Diagnostic Messages

In the event of a trip or alarm, some of the actual value messages are very helpful in
diagnosing the cause of the condition. The 489 will automatically default to the most
important message. The hierarchy is trip and pretrip messages, then alarm messages. In
order to simplify things for the operator, the Message LED (indicator) will flash prompting
the operator to press the MESSAGE X key. When the MESSAGE X key is pressed, the 489
will automatically display the next relevant message and continue to cycle through the
messages with each keypress. When all of these conditions have cleared, the 489 will
revert back to the normal default messages.
Any time the 489 is not displaying the default messages because other actual value or
setpoint messages are being viewed and there are no trips or alarms, the Message LED
(indicator) will be on solid. From any point in the message structure, pressing the
MESSAGE X key will cause the 489 to revert back to the normal default messages. When
normal default messages are being displayed, pressing the MESSAGE X key will cause the
489 to display the next default message immediately.
EXAMPLE:
If a thermal model trip occurred, an RTD alarm may also occur as a result of the overload.
The 489 would automatically default to the CAUSE OF LAST TRIP message at the top of the
A1 STATUS ZV LAST TRIP DATA queue and the Message LED would flash. Pressing the
MESSAGE X key cycles through the time and date stamp information as well as all of the
pre-trip data. When the bottom of this queue is reached, an additional press of the
MESSAGE X key would normally return to the top of the queue. However, because there is
an alarm active, the display will skip to the alarm message at the top of the A1 STATUS ZV
ALARM STATUS queue. Finally, another press of the MESSAGE X key will cause the 489 to
return to the original CAUSE OF LAST TRIP message, and the cycle could be repeated.
LAST TRIP DATA: CAUSE OF LAST TRIP:

Overload
TIME OF LAST TRIP:

12:00:00.0
DATE OF LAST TRIP

Jan 01 2002
↓
↓
↓
ANALOG INPUT 4
PreTrip: 0 Units

ACTIVE ALARMS: STATOR RTD #1

ALARM: 135°C
START BLOCK OVERLOAD LOCKOUT

LOCKOUTS:
BLOCK: 25 min
When the RESET has been pressed and the hot RTD condition is no longer present, the
display will revert back to the normal default messages.
6.8.2 Flash Messages

Flash messages are warning, error, or general information messages that are temporarily
displayed in response to certain key presses. These messages are intended to assist with
navigation of the 489 messages by explaining what has happened or by prompting the
user to perform certain actions.
Table 6–2: Flash Messages
[.] KEY IS USED TO ACCESS DENIED, ACCESS DENIED, ALL POSSIBLE RESETS ARE YOU SURE? PRESS
ADVANCE THE CURSOR ENTER PASSCODE SHORT ACCESS SWITCH HAVE BEEN PERFORMED [ENTER] TO VERIFY
DATA CLEARED DATE ENTRY DATE ENTRY WAS DEFAULT MESSAGE DEFAULT MESSAGE
SUCCESSFULLY OUT OF RANGE NOT COMPLETE HAS BEEN ADDED HAS BEEN REMOVED
DEFAULT MESSAGE DEFAULT MESSAGES END OF LIST END OF PAGE ENTER A NEW
LIST IS FULL 6 TO 20 ARE ASSIGNED PASSCODE FOR ACCESS
INVALID PASSCODE INVALID SERVICE CODE KEY PRESSED IS NEW PASSCODE NEW SETPOINT HAS
ENTERED! ENTERED INVALID HERE HAS BEEN ACCEPTED BEEN STORED
NO ALARMS ACTIVE NO TRIPS OR ALARMS OUT OF RANGE.! ENTER: PASSCODE SECURITY PRESS [ENTER] TO ADD
TO RESET #### TO ##### BY # NOT ENABLED, ENTER 0 DEFAULT MESSAGE
PRESS [ENTER] TO RESET PERFORMED ROUNDED SETPOINT SETPOINT ACCESS IS SETPOINT ACCESS IS
REMOVE MESSAGE SUCCESSFULLY HAS BEEN STORED NOW PERMITTED NOW RESTRICTED
TACHOMETER MUST USE THAT DIGITAL INPUT THAT INPUT ALREADY THIS FEATURE NOT THIS PARAMETER IS
INPUT 4, 5, 6, OR 7 IS ALREADY IN USE USED FOR TACHOMETER PROGRAMMED ALREADY ASSIGNED
TIME ENTRY TIME ENTRY WAS TOP OF LIST TOP OF PAGE

OUT OF RANGE NOT COMPLETE
• NEW SETPOINT HAS BEEN STORED: This message appear each time a setpoint has
been altered and stored as shown on the display.
• ROUNDED SETPOINT HAS BEEN STORED: Since the 489 has a numeric keypad, an
entered setpoint value may fall between valid setpoint values. The 489 detects this
condition and store a value rounded to the nearest valid setpoint value. To find the
valid range and step for a given setpoint, press the HELP key while the setpoint is
being displayed.
• OUT OF RANGE! ENTER: #### TO ##### BY #: If a setpoint value outside the
acceptable range of values is entered, the 489 displays this message and substitutes
proper values for that setpoint. An appropriate value may then be entered.

• ACCESS DENIED, SHORT ACCESS SWITCH: The Access Switch must be shorted to store
any setpoint values. If this message appears and it is necessary to change a setpoint,
short the Access terminals C1 and C2.
• ACCESS DENIED, ENTER PASSCODE: The 489 has a passcode security feature. If this
feature is enabled, not only must the Access Switch terminals be shorted, but a valid
passcode must also be entered. If the correct passcode has been lost or forgotten,
contact the factory with the encrypted access code. All passcode features may be
found in the S1 489 SETUP Z PASSCODE setpoints menu.
• INVALID PASSCODE ENTERED: This flash message appears if an invalid passcode is
entered for the passcode security feature.
• NEW PASSCODE HAS BEEN ACCEPTED: This message will appear as an acknowledge
that the new passcode has been accepted when changing the passcode for the
passcode security feature.
• PASSCODE SECURITY NOT ENABLED, ENTER 0: The passcode security feature is
disabled whenever the passcode is zero (factory default). Any attempts to enter a
passcode when the feature is disabled results in this flash message, prompting the
user to enter “0” as the passcode. When this has been done, the feature may be
enabled by entering a non-zero passcode.
• ENTER A NEW PASSCODE FOR ACCESS: The passcode security feature is disabled if
the passcode is zero. If the CHANGE PASSCODE SETPOINT is entered as yes, this flash
message appears prompting the user to enter a non-zero passcode and enable the
passcode security feature.
• SETPOINT ACCESS IS NOW PERMITTED: Any time the passcode security feature is
enabled and a valid passcode is entered, this flash message appears to notify that
setpoints may now be altered and stored.
• SETPOINT ACCESS IS NOW RESTRICTED: If the passcode security feature is enabled
and a valid passcode entered, this message appears when the S1 489 SETUP Z
PASSCODE ZV SETPOINT ACCESS setpoint is altered to “Restricted”. This message also
appears any time that setpoint access is permitted and the access jumper is removed.
• DATE ENTRY WAS NOT COMPLETE: Since the DATE setpoint has a special format
(entered as MM/DD/YYYY), this message appears and the new value will not be stored
if the ENTER key is pressed before all of the information has been entered. Another
attempt will have to be made with the complete information.
• DATE ENTRY WAS OUT OF RANGE: Appears if an invalid entry is made for the DATE (for
example, 15 entered for the month).
• TIME ENTRY WAS NOT COMPLETE: Since the TIME setpoint has a special format
(entered as HH/MM/SS.s), this message appears and the new value will not be stored if
the ENTER key is pressed before all of the information has been entered. Another
attempt will have to be made with the complete information.
• TIME ENTRY WAS OUT OF RANGE: Appears if an invalid entry is made for the TIME (for
example, 35 entered for the hour).
• NO TRIPS OR ALARMS TO RESET: Appears if the RESET key is pressed when there are
no trips or alarms present.
• RESET PERFORMED SUCCESSFULLY: If all trip and alarm features that are active can
be cleared (that is, the conditions that caused these trips and/or alarms are no longer

present), then this message appears when a reset is performed, indicating that all trips
and alarms have been cleared.
• ALL POSSIBLE RESETS HAVE BEEN PERFORMED: If only some of the trip and alarm
features that are active can be cleared (that is, the conditions that caused some of
these trips and/or alarms are still present), then this message appears when a reset is
performed, indicating that only trips and alarms that could be reset have been reset.
• ARE YOU SURE? PRESS [ENTER] TO VERIFY: If the RESET key is pressed and resetting
of any trip or alarm feature is possible, this message appears to verify the operation. If
RESET is pressed again while this message is displayed, the reset will be performed.
• PRESS [ENTER] TO ADD DEFAULT MESSAGE: Appears if the decimal [.] key,
immediately followed by the ENTER key, is entered anywhere in the actual value
message structure. This message prompts the user to press ENTER to add a new
default message. To add a new default message, ENTER must be pressed while this
message is being displayed.
• DEFAULT MESSAGE HAS BEEN ADDED: Appears anytime a new default message is
added to the default message list.
• DEFAULT MESSAGE LIST IS FULL: Appears if an attempt is made to add a new default
message to the default message list when 20 messages are already assigned. To add
a new message, one of the existing messages must be removed.
• PRESS [ENTER] TO REMOVE MESSAGE: Appears if the decimal [.] key, immediately
followed by the ENTER key, is entered in the S1 489 SETUP ZV DEFAULT MESSAGES
setpoint page. This message prompts the user to press ENTER to remove a default
message. To remove the default message, ENTER must be pressed while this message
is being displayed.
• DEFAULT MESSAGE HAS BEEN REMOVED: Appears anytime a default message is
removed from the default message list.
• DEFAULT MESSAGES 6 of 20 ARE ASSIGNED: Appears anytime the S1 489 SETUP ZV
DEFAULT MESSAGES setpoint page is entered, notifying the user of the number of
default messages assigned.
• INVALID SERVICE CODE ENTERED: Appears if an invalid code is entered in the S12 489
TESTING ZV FACTORY SERVICE setpoints page.
• KEY PRESSED HERE IS INVALID: Under certain situations, certain keys have no
function (for example, any number key while viewing actual values). This message
appears if a keypress has no current function.
• DATA CLEARED SUCCESSFULLY: Confirms that data is reset in the S1 489 SETUP ZV
CLEAR DATA setpoints page.
• [.] KEY IS USED TO ADVANCE THE CURSOR: Appears immediately to prompt the use of
the [.] key for cursor control anytime a setpoint requiring text editing is viewed. If the
setpoint is not altered for 1 minute, this message flashes again.
• TOP OF PAGE: This message will indicate when the top of a page has been reached.
• BOTTOM OF PAGE: This message will indicate when the bottom of a page has been
reached.
• TOP OF LIST: This message will indicate when the top of subgroup has been reached.

• END OF LIST: This message will indicate when the bottom of a subgroup has been
reached.
• NO ALARMS ACTIVE: If an attempt is made to enter the Alarm Status message
subgroup, but there are no active alarms, this message will appear.
• THIS FEATURE NOT PROGRAMMED: If an attempt is made to enter an actual value
message subgroup, when the setpoints are not configured for that feature, this
message will appear.
• THIS PARAMETER IS ALREADY ASSIGNED: A given analog output parameters can only
be assigned to one output. If an attempt is made to assign a parameter to a second
output, this message will appear.
• THAT INPUT ALREADY USED FOR TACHOMETER: If a digital input is assigned to the
tachometer function, it cannot be used for any other digital input function. If an
attempt is made to assign a digital input to a function when it is already assigned to
tachometer, this message will appear.
• TACHOMETER MUST USE INPUT 4, 5, 6, or 7: Only digital inputs 4, 5, 6, or 7 may be
used for the tachometer function. If an attempt is made to assign inputs 1,2,3, or 4 to
the tachometer function, this message will appear.
• THAT DIGITAL INPUT IS ALREADY IN USE: If an attempt is made to assign a digital
input to tachometer when it is already assigned to another function, this message will
appear.
• To edit use VALUE UP or VALUE DOWN key: If a numeric key is pressed on a setpoint
parameter that is not numeric, this message will prompt the user to use the value
keys.
• GROUP 1 SETPOINT HAS BEEN STORED: This message appear each time a setpoint
has been altered and stored to setpoint Group 1 as shown on the display.
• GROUP 2 SETPOINT HAS BEEN STORED: This message appear each time a setpoint
has been altered and stored to setpoint Group 2 as shown on the display.

Digital Energy
Multilin
Chapter 7: Testing
Testing
7.1 Test Setup
7.1.1 Description
The purpose of this testing description is to demonstrate the procedures necessary to
perform a complete functional test of all the 489 hardware while also testing firmware/
hardware interaction in the process. Since the 489 is packaged in a drawout case, a demo
case (metal carry case in which the 489 may be mounted) may be useful for creating a
portable test set with a wiring harness for all of the inputs and outputs. Testing of the relay
during commissioning using a primary injection test set will ensure that CTs and wiring are
correct and complete.
The 489 tests are listed below. For the following tests refer to Secondary Current Injection
Testing on page 7–3:
1. Output Current Accuracy Test
2. Phase Voltage Input Accuracy Test
3. Ground, Neutral, and Differential Current Accuracy Test
4. Neutral Voltage (Fundamental) Accuracy Test
5. Negative Sequence Current Accuracy Test
6. RTD Accuracy Test
7. Digital Input and Trip Coil Supervision Accuracy Test
8. Analog Input and Outputs Test
9. Output Relay Test
10. Overload Curve Test
11. Power Measurement Test
12. Reactive Power Test

CHAPTER 7: TESTING
13. Voltage Phase Reversal Test

14. For the following tests refer to Secondary Injection Setup #2 on page 7–15:
15. GE Multilin (HGF) Ground Current Accuracy Test
16. Neutral Voltage (3rd Harmonic) Accuracy Test
17. Phase Differential Trip Test
18. For the following test refer to Secondary Injection Test Setup #3 on page 7–19:
19. Voltage Restrained Overcurrent Test

CHAPTER 7: TESTING
VC
3 PHASE VARIABLE AC TEST SET
VA
START
VB IN IA IB IC VA VB VC VN
E10 F10 G9 H9 G10 H10 G3 H3 G4 H4 G5 H5 G6 H6 G7 H7 G8 H8 G2 H1 H2 G1
NEUTRAL
AUTOMATIC CT
1A/5A
1A/5A
1A/5A
1A/5A
1A/5A
1A/5A
Vcom
COM
COM
COM
COM
COM
COM
COM
COM
SHORTING
HGF
Vb
Va
Vc
1A
BAR
V
PHASE a PHASE b PHASE c PHASE A PHASE B PHASE C PHASE
GROUND INPUTS
NEUTRAL END CT's OUTPUT CT's VOLTAGE INPUTS
H12
CONTROL
POWER
H11
FILTER GROUND G11
B1 RTD SHIELD SAFETY GROUND G12
A1 HOT
500 Ohms RTD #1
A2 COMPENSATION
A3 RTD RETURN
E12
A4 IRIG - B
COMPENSATION
500 Ohms RTD #2 F12
A5 HOT
SWITCH
E11
A6 HOT TRIP COIL +24VAC
500 Ohms RTD #3 SUPERVISION
F11 SWITCH
A7 COMPENSATION
COMMON
A8 RTD RETURN E2 START
STOP
TRIGGER TRIGGER
A9 COMPENSATION 1 TRIP F1
500 Ohms RTD #4
A10 HOT E1
G
500 Ohms
A11 HOT
RTD #5
F2
R
A12 COMPENSATION 2 AUXILIARY E3
TIMER
A13 RTD RETURN F3
G
RTD 500 Ohms
A14 COMPENSATION
RTD #6
E5
R
SIMULATION A15 HOT 3 AUXILIARY F4
RESISTORS
OR RESISTANCE
DECADE BOX 500 Ohms
D1 HOT
RTD #7
E4
G
D2 COMPENSATION F5
R
D3 RTD RETURN 4 AUXILIARY E6
500 Ohms
D4 COMPENSATION
RTD #8
F6
G
D5 HOT E8
R
D6 HOT 5 ALARM F7
500 Ohms RTD #9
D7 COMPENSATION E7
G
D8 RTD RETURN F8
G
D9 COMPENSATION 6 SERVICE E9
500 Ohms RTD #10
D10 HOT F9
R
D11 HOT
500 Ohms RTD #11
D12 COMPENSATION
D13 RTD RETURN
D14 COMPENSATION
500 Ohms RTD #12
g
D15 HOT
D16 ASSIGNABLE INPUT 1
D17 ASSIGNABLE INPUT 2 GE Multilin

SECONDARY INJECTION
D19 ASSIGNABLE INPUT 4 TEST SETUP
V D20 ASSIGNABLE INPUT 5

DIGITAL INPUTS
D23 COMMON
D24 SWITCH +24Vdc
C1 COMPUTER ANALOG I/O

AUXILIARY
ACCESS COMM.
RS485 ANALOG OUTPUTS ANALOG INPUTS
C2 RS485
SHIELD
COM
COM
COM
COM
VDC
+24
1+
3+
1+
3+
2+
4+
2+
4+
-
C3
BREAKER
STATUS
C4 D25 D26 D27 B2 B3 B4 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 A27
A
A V
RS485 RS485
A
A
808818A3.CDR
FIGURE 7–1: Secondary Current Injection Testing

CHAPTER 7: TESTING
7.2 Hardware Functional Tests
7.2.1 Output Current Accuracy

The specification for output and neutral end current input is ±0.5% of 2 × CT when the
injected current is less than 2 × CT. Perform the steps below to verify accuracy.
Z Alter the following setpoint:
S2 SYSTEM SETUP Z CURRENT SENSING ZV PHASE CT PRIMARY: “1000 A”
Measured values should be ±10 A.

Z Inject the values shown in the table below and verify accuracy of the
measured values.
Z View the measured values in the A2 METERING DATA ZV CURRENT
METERING menu.
Injected Current Expected Measured Current

Current
1 A Unit 5 A Unit Phase A Phase B Phase C
0.1 A 0.5 A 100 A
0.2 A 1.0 A 200 A
0.5 A 2.5 A 500 A
1A 5A 1000 A
1.5 A 7.5 A 1500 A
2A 10 A 2000 A
7.2.2 Phase Voltage Input Accuracy

The specification for phase voltage input accuracy is ±0.5% of full scale (200 V). Perform
the steps below to verify accuracy.
Z Alter the following setpoints in the S2 SYSTEM SETUP ZV VOLTAGE
SENSING menu:
VT CONNECTION TYPE: “Wye”

VOLTAGE TRANSFORMER RATIO: “10.00:1”
Measured values should be ±1.0 V.

Z Apply the voltage values shown in the table and verify accuracy of
the measured values.
Z View the measured values in the A2 METERING DATA ZV VOLTAGE
METERING menu.
Applied Line- Expected Voltage Measured Voltage

Neutral Voltage Reading
A-N B-N C-N
30 V 300 V
50 V 500 V
100 V 1000 V
150 V 1500 V

CHAPTER 7: TESTING
Applied Line- Expected Voltage Measured Voltage

Neutral Voltage Reading
A-N B-N C-N
200 V 2000 V
7.2.3 Ground (1 A), Neutral, and Differential Current Accuracy

The specification for neutral, differential and 1 A ground current input accuracy is ±0.5% of
2 × CT. Perform the steps below to verify accuracy.
Z In the S2 SYSTEM SETUP Z CURRENT SENSING menu, set:
GROUND CT: “1A Secondary”
GROUND CT RATIO: “1000:1”
PHASE CT PRIMARY: “1000 A”
Z In the S5 CURRENT ELEMENTS ZV PHASE DIFFERENTIAL menu, set:

PHASE DIFFERENTIAL TRIP: “Unlatched”
DIFFERENTIAL TRIP MIN. PICKUP: “0.1 x CT”
The last two setpoints are needed to view the neutral and the differential current.
The trip element will operate when differential current exceeds 100 A.
Measured values should be ±10 A.
Z Inject (IA only) the values shown in the table below into one phase
only and verify accuracy of the measured values.
Z View the measured values in the A2 METERING DATA Z CURRENT
METERING menu or press the NEXT key to view the current values
when differential trip element is active.
Table 7–1: Neutral and Ground Current Test Results
Injected Expected Measured Measured Neutral Current

Current Current Ground Current
1 A Unit Phase A Phase B Phase C
0.1 A 100 A
0.2 A 200 A
0.5 A 500 A
1A 1000 A
Table 7–2: Differential Current Test Results
Injected Expected Current Reading Measured Differential Current

Current
Differential Differential Phase A Phase B Phase C
Phase A Phase B,C
0.1 A 200 A 100 A
0.2 A 400 A 200 A
0.5 A 1000 A 500 A
1A 2000 A 1000 A

CHAPTER 7: TESTING
7.2.4 Neutral Voltage (Fundamental) Accuracy

The specification for neutral voltage (fundamental) accuracy is ±0.5% of full scale (100 V).
Perform the steps below to verify accuracy.
Z In the S2 SYSTEM SETUP ZV VOLTAGE SENSING menu, set:
NEUTRAL VOLTAGE TRANSFORMER: “Yes”
NEUTRAL V.T. RATIO: “10.00:1”
Z In the S2 SYSTEM SETUP ZV GEN. PARAMETERS menu, set:

GENERATOR NOMINAL FREQUENCY: “60 Hz”

METERING menu.
Applied Neutral Voltage Expected Neutral Voltage Measured Neutral

at 60 Hz Voltage
10 V 100 V
30 V 300 V
50 V 500 V
7.2.5 Negative Sequence Current Accuracy

The 489 measures negative sequence current as a percent of Full Load Amperes (FLA). A
sample calculation of negative sequence current is shown below. Given the following
generator parameters:
Rated MVA (PA) = 1.04
Voltage Phase to Phase (Vpp): 600 V
We have:
PA 6
× 10 - = 1000 A
- = 1.04
FLA = --------------------- ------------------------- (EQ 7.1)
3 × V pp 3 × 600
With the following output currents:

I a = 780 ∠0°, I b = 1000 ∠113° lag, I c = 1000 ∠247° lag (EQ 7.2)
The negative-sequence current Ins is calculated as:

CHAPTER 7: TESTING
1 2
I ns = --- ( I a + a I b + aI c ) where a = 1 ∠120° = – 0.5 + j0.866
3
1 2
= --- ( 780 ∠0° + ( 1 ∠120° ) ( 1000 ∠– 113° ) + ( 1 ∠120° ) ( 1000 ∠113° ) )
3
1
= --- ( 780 ∠0° + 1000 ∠127° + 1000 ∠233° )
3 (EQ 7.3)
1
= --- ( 780 – 601.8 + j798.6 – 601.8 – j798.6 )
3
= – 141.2
I ns
⇒ %I ns = --------- × 100 = 14%
FLA
Therefore, the negative sequence current is 14% of FLA. The specification for negative-
sequence current accuracy is per output current inputs. Perform the steps below to verify
accuracy.
GENERATOR RATED MVA: “1.04”
VOLTAGE PHASE-PHASE: “600”
Note that setting VOLTAGE PHASE-PHASE to “600” is equivalent to setting FLA = 1000 A. This
is for testing purposes only!
PHASE CT PRIMARY: “1000 A”
Z Inject the values shown in the table below and verify accuracy of the
measured values.
Z View the measured values in the A2 METERING DATA Z CURRENT
METERING menu.
Injected Current Expected Negative Measured Negative

Sequence Current Sequence Current
1 A Unit 5 A Unit
Ia = 0.78 A ∠0° Ia = 3.9 A ∠0°
Ib = 1 A ∠113° lag Ib = 5 A ∠113° lag 14% FLA
Ic = 1 A ∠247° lag Ic = 5 A ∠247° lag
Ia = 1.56 A ∠0° Ia = 7.8 A ∠0°
Ib = 2 A ∠113° lag Ib = 10 A ∠113° lag 28% FLA
Ic = 2 A ∠247° lag Ic = 10 A ∠247° lag
Ia = 0.39 A ∠0° Ia = 1.95 A ∠0°
Ib = 0.5 A ∠113° lag Ib = 2.5 A ∠113° lag 7% FLA
Ic = 0.5 A ∠247° lag Ic = 2.5 A ∠247° lag
7.2.6 RTD Accuracy

The specification for RTD input accuracy is ±2° for Platinum/Nickel and ±5° for Copper.
Perform the steps below.
Z In the S8 RTD TEMPERATURE MENU, set:
RTD TYPE Z STATOR RTD TYPE: “100 Ohm Platinum” (select desired type)
RTD #1 Z RTD #1 APPLICATION: “Stator” (repeat for RTDs 2 to 12)

CHAPTER 7: TESTING
Measured values should be ±2°C / ±4°F for platinum/nickel and ±5°C / ±9°F for
copper.
Z Alter the resistance applied to the RTD inputs as shown below to
simulate RTDs and verify accuracy.
Z View the measured values in A2 METERING DATA ZV TEMPERATURE.
Applied Expected RTD Measured RTD Temperature
Resistance Temperature Reading Select One: ____°C ____°F
100 Ω Platinum
°C °F 1 2 3 4 5 6 7 8 9 10 11 12
84.27 Ω –40°C –40°F
100.00 Ω 0°C 32°F
119.39 Ω 50°C 122°F
138.50 Ω 100°C 212°F
157.32 Ω 150°C 302°F
175.84 Ω 200°C 392°F
194.08 Ω 250°C 482°F

120 Ω Nickel
°C °F 1 2 3 4 5 6 7 8 9 10 11 12
92.76 Ω –40°C –40°F
120.00 Ω 0°C 32°F
157.74 Ω 50°C 122°F
200.64 Ω 100°C 212°F
248.95 Ω 150°C 302°F
303.46 Ω 200°C 392°F
366.53 Ω 250°C 482°F

100 Ω Nickel
°C °F 1 2 3 4 5 6 7 8 9 10 11 12
77.30 Ω –40°C –40°F
100.00 Ω 0°C 32°F
131.45 Ω 50°C 122°F
167.20 Ω 100°C 212°F
207.45 Ω 150°C 302°F
252.88 Ω 200°C 392°F
305.44 Ω 250°C 482°F
Applied Expected RTD Measured RTD Tempeature

10 Ω Copper
°C °F 1 2 3 4 5 6 7 8 9 10 11 12
7.49 Ω –40°C –40°F
9.04 Ω 0°C 32°F
10.97 Ω 50°C 122°F
12.90 Ω 100°C 212°F
14.83 Ω 150°C 302°F
16.78 Ω 200°C 392°F

CHAPTER 7: TESTING
Applied Expected RTD Measured RTD Tempeature

10 Ω Copper
°C °F 1 2 3 4 5 6 7 8 9 10 11 12
18.73 Ω 250°C 482°F
7.2.7 Digital Inputs and Trip Coil Supervision

The digital inputs and trip coil supervision can be verified easily with a simple switch or
pushbutton. Verify the Switch +24 V DC with a voltmeter. Perform the steps below to verify
functionality of the digital inputs.
Z Open switches of all of the digital inputs and the trip coil supervision
circuit.
Z View the status of the digital inputs and trip coil supervision in the A1
STATUS ZV DIGITAL INPUTS menu.
Z Close switches of all of the digital inputs and the trip coil supervision
circuit.
Z View the status of the digital inputs and trip coil supervision in the A1
STATUS ZV DIGITAL INPUTS menu.
Input Expected Status 4 Pass Expected Status 4 Pass

(Switch Open) 8 Fail (Switch Closed) 8 Fail
Access Open Shorted
Breaker Status Open Shorted
Assignable Input 1 Open Shorted
Trip Coil Supervision No Coil Coil
7.2.8 Analog Inputs and Outputs

The specification for analog input and analog output accuracy is ±1% of full scale. Perform
the steps below to verify accuracy. Verify the Analog Input +24 V DC with a voltmeter.
4 to 20 mA Inputs:
Z In the S11 ANALOG I/O ZV ANALOG INPUT 1 menu, set:
ANALOG INPUT 1: “4-20 mA”
ANALOG INPUT 1 MINIMUM: “0”
ANALOG INPUT 1 MAXIMUM: “1000” (repeat all for Analog Inputs 2 to 4)
Analog output values should be ±0.2 mA on the ammeter. Measured analog input
values should be ±10 units.

CHAPTER 7: TESTING
Z Force the analog outputs using the following setpoints from the S12
TESTING ZV TEST ANALOG OUTPUT menu:
FORCE ANALOG OUTPUTS FUNCTION: “Enabled”

ANALOG OUTPUT 1 FORCED VALUE: “0%” (enter %, repeat for Outputs 2 to
4)
Z Verify the ammeter readings and the measured analog input

readings.
For the purposes of testing, the analog input is fed in from the analog
output (see Secondary Current Injection Testing on page 7–3).
Z View the measured values in the A2 METERING DATA Z ANALOG
INPUTS menu.
Analog Expected Measured Ammeter Expected Measured Analog Input

Output Ammeter Reading (ma) Analog Input Reading (units)
Force Value Reading Reading
1 2 3 4 1 2 3 4
0% 4 mA 0 units
25% 8 mA 250 units
50% 12 mA 500 units
75% 16 mA 750 units
100% 20 mA 1000 units
0 to 1 mA Analog Inputs:
Z In the S11 ANALOG I/O ZV ANALOG INPUT 1 menu, set:
ANALOG INPUT 1: “0-1 mA”
ANALOG INPUT 1 MINIMUM: “0”
ANALOG INPUT 1 MAXIMUM: “1000” (repeat for Analog Inputs 2 to 4)
Analog output values should be ±0.01 mA on the ammeter. Measured analog input
values should be ±10 units.
Z Force the analog outputs using the following setpoints in the S12
TESTING ZV TEST ANALOG OUTPUT menu:
FORCE ANALOG OUTPUTS FUNCTION: “Enabled”

ANALOG OUTPUT 1 FORCED VALUE: “0%” (enter %, repeat for
Outputs 2 to 4)
Z Verify the ammeter readings as well as the measured analog input
readings.
Z View the measured values in the A2 METERING DATA ZV ANALOG
INPUTS menu.
Analog Expected Measured Ammeter Expected Measured Analog Input

Output Force Ammeter Reading (mA) Analog Input Reading (units)
Value Reading Reading
1 2 3 4 1 2 3 4
0% 0 mA 0 units
25% 0.25 mA 250 units
50% 0.50 mA 500 units
75% 0.75 mA 750 units
100% 1.00 mA 1000 units

CHAPTER 7: TESTING
7.2.9 Output Relays

To verify the functionality of the output relays, perform the following steps:
Using the setpoint:
S12 TESTING ZV TEST OUTPUT RELAYS ZV FORCE OPERATION OF RELAYS: “1 Trip”
Z Select and store values as per the table below, verifying operation
Force Expected Measurement (4 for short) Actual Measurement (4 for short)
Operation
Setpoint 1 2 3 4 5 6 1 2 3 4 5 6
no nc no nc no nc no nc no nc no nc no nc no nc no nc no nc no nc no nc
1 Trip 4 4 4 4 4 4
2 Auxiliary 4 4 4 4 4 4
3 Auxiliary 4 4 4 4 4 4
4 Auxiliary 4 4 4 4 4 4
5 Alarm 4 4 4 4 4 4
6 Service 4 4 4 4 4 4
All Relays 4 4 4 4 4 4
No Relays 4 4 4 4 4 4
The 6 Service relay is failsafe or energized normally. Operating output relay 6 causes it to
Note
de-energize.

CHAPTER 7: TESTING
7.3 Additional Functional Tests
7.3.1 Overload Curve Accuracy

The specification for overload curve timing accuracy is ±100 ms or ±2% of time to trip.
Pickup accuracy is as per the current inputs (±0.5% of 2 × CT when the injected current is
less than 2 × CT and ±1% of 20 × CT when the injected current is equal to or greater than
2 × CT). Perform the steps below to verify accuracy.
GENERATOR RATED MVA: “1.04”
GENERATOR VOLTAGE PHASE-PHASE: “600”
Note that setting GENERATOR VOLTAGE PHASE-PHASE to “600” is equivalent to setting

FLA = 1000 A. For testing purposes ONLY!
PHASE CT PRIMARY: “1000”
Z In the S9 THERMAL MODEL Z MODEL SETUP menu, set:

SELECT CURVE STYLE: “Standard”
OVERLOAD PICKUP LEVEL: “1.10 x FLA”
UNBALANCE BIAS K FACTOR: “0”
HOT/COLD SAFE STALL RATIO: “1.00”
ENABLE RTD BIASING: “No”
STANDARD OVERLOAD CURVE NUMBER: “4”
ENABLE THERMAL MODEL: “Yes”
Z In the S9 THERMAL MODEL Z THERMAL ELEMENTS menu, set:

THERMAL MODEL TRIP: “Latched” or “Unlatched”
Any trip must be reset prior to each test. Short the emergency restart terminals
momentarily immediately prior to each overload curve test to ensure that the thermal
capacity used is zero. Failure to do so will result in shorter trip times. Inject the current of
the proper amplitude to obtain the values as shown and verify the trip times. Motor load
may be viewed in the A2 METERING DATA Z CURRENT METERING menu.
The thermal capacity used and estimated time to trip may be viewed in the A1 STATUS ZV
GENERATOR STATUS menu.
Average Phase Pickup Level Expected Tolerance Range Measured Time

Current Time to Trip to Trip (sec.)
Displayed
1050 A 1.05 × FLA never n/a
1200 A 1.20 × FLA 795.44 s 779.53 to 811.35 s
1750 A 1.75 × FLA 169.66 s 166.27 to 173.05 s
3000 A 3.00 × FLA 43.73 s 42.86 to 44.60 s
6000 A 6.00 × FLA 9.99 s 9.79 to 10.19 s
10000 A 10.00 × FLA 5.55 s 5.44 to 5.66 s
Generator Rated MVA

Note
FLA = ----------------------------------------------------------------------------------------------------
- (EQ 7.4)
3 × Generator Phase-to-Phase Voltage

CHAPTER 7: TESTING
7.3.2 Power Measurement Test

The specification for reactive and apparent power is ± 1% of 3 × 2 × CT × VTratio × VTfull-
scale at Iavg < 2
× CT. Perform the steps below to verify accuracy.

VOLTAGE TRANSFORMER RATIO: “10.00:1”
Z Inject current and apply voltage as per the table below.

Z Verify accuracy of the measured values.
Z View the measured values in the A2 METERING DATA ZV POWER
METERING menu:
Injected Current / Applied Voltage Power Quantity Power Factor

(Ia is the reference vector)
1 A UNIT 5 A UNIT Expected Tolerance Measured Expected Measured
Ia = 1 A∠0° Ia = 5 A∠0°
Ib = 1 A∠120° lag Ib = 5 A∠120° lag
Ic = 1 A∠240° lag Ic = 5 A∠240° lag
+3424 kW
3355 to
0.95 lag
Va = 120 V∠342° lag Ia = 120 V∠342° lag 3493 kW
Vb = 120 V∠102° lag Vb = 120 V∠102° lag
Vc = 120 V∠222° lag Vc = 120 V∠222° lag
Ia = 1 A∠0° Ia = 5 A∠0°
Ib = 1 A∠120° lag Ib = 5 A∠120° lag
Ic = 1 A∠240° lag Ic = 5 A∠240° lag
+3424 kvar
3355 to
0.31 lag
Va = 120 V∠288° lag Va = 120 V∠288° lag 3493 kvar
Vb = 120 V∠48° lag Vb = 120 V∠48° lag
Vc = 120 V∠168° lag Vc = 120 V∠168° lag
7.3.3 Reactive Power Accuracy

The specification for reactive power is ±1% of 3 × 2 × CT × VTratio × VTfull scale at
Iavg < 2 × CT. Perform the steps below to verify accuracy and trip element.

VOLTAGE TRANSFORMER RATIO: “100:1”
Z In the S2 SYSTEM SETUP ZV GEN. PARAMETERS menu, set

GENERATOR RATED MVA: “100”
GENERATOR RATED POWER FACTOR: “0.85”
–1
The rated reactive power is 100 sin ( cos ( 0.85 ) ) = ± 52.7 Mvar .
Z Alter the following reactive power setpoints in the S7 POWER
ELEMENTS Z REACTIVE POWER menu:

CHAPTER 7: TESTING
REACTIVE POWER ALARM: “Unlatched”

ASSIGN ALARM RELAYS(2-5): “---5”
POSTIVE MVAR ALARM LEVEL: “0.6 x Rated”
NEGATIVE MVAR ALARM LEVEL: “0.6 x Rated”
REACTIVE POWER ALARM DELAY: “5 s”
REACTIVE POWER ALARM EVENT: “On”
REACTIVE POWER TRIP: “Unlatched”
ASSIGN TRIP RELAYS(1-4): “1---”
POSTIVE MVAR TRIP LEVEL: “0.75 x Rated”
NEGATIVE MVAR TRIP LEVEL: “0.75 x Rated”
REACTIVE POWER TRIP DELAY: “10 s”
Z Inject current and apply voltage as per the table below.

Z Verify the alarm/trip elements and the accuracy of the measured
values.
Z View the measured values in the A2 METERING DATA Z POWER
METERING page.
Z View the Event Records in the A5 EVENT RECORD menu.
Current/Voltage Mvar Alarm Trip

Expected Tolerance Measured Expected Observed Delay Expected Observed Delay
Vab=120V∠0°
Vbc=120V∠120°lag
Vca=120V∠240°lag 18
13 to 23 4 N/A 8 N/A
Ian=5 A∠10°lag
Ibn=5 A∠130°lag
Icn=5 A∠250°lag
Vab=120V∠0°
Vbc=120V∠120°lag
Vca=120V∠240°lag –35
–40 to –30 4 8 N/A
Ian=5 A∠340°lag
Ibn=5 A∠100°lag
Icn=5 A∠220°lag
Vab=120V∠0°
Vbc=120V∠120°lag
Vca=120V∠240°lag –52 –57 to –47 4 4
Ian=5 A∠330°lag
Ibn=5 A∠90°lag
Icn=5 A∠210°lag
Vab=120V∠0°
Vbc=120V∠120°lag
Vca=120V∠240°lag 52
47 to 57 4 4
Ian=5 A∠30°lag
Ibn=5 A∠150°lag
Icn=5 A∠270°lag
4: Activated, 8: Not Activated
7.3.4 Voltage Phase Reversal Accuracy

The relay can detect voltage phase rotation and protect against phase reversal. To test the
phase reversal element, perform the following steps:

CHAPTER 7: TESTING
GENERATOR PHASE SEQUENCE: “ABC”
Z In the S3 DIGITAL INPUTS Z BREAKER STATUS menu, set:

BREAKER STATUS: “Breaker Auxiliary a”
Z In the S6 VOLTAGE ELEMENTS ZV PHASE REVERSAL menu, set:

PHASE REVERSAL TRIP: “Unlatched”
ASSIGN TRIP RELAYS: “1---”
Z Apply voltages as per the table below. Verify the operation on voltage
phase reversal
Applied Voltage Expected Result Observed Result

Va = 120 V∠0°
Vb = 120 V∠120° lag No Trip
Vc = 120 V∠240° lag
Va = 120 V∠0°
Vb = 120 V∠240° lag Phase Reversal Trip
Vc = 120 V∠120° lag
7.3.5 Injection Test Setup #2

Set up the 489 device as follows for the GE Multilin HGF Ground Accuracy Test, Neutral
Voltage (3rd Harmonic) Accuracy Test, and the Phase Differential Trip Test.
VC
VA
VB VA VB VC VN IA IB IC IN
NC NC
50:0.25

NEUTRAL
AUTOMATIC CT
1A/5A
1A/5A
1A/5A
1A/5A
1A/5A
1A/5A
Vcom
COM
COM
COM
COM
COM
COM
COM
COM
SHORTING
HGF
Vb
Va
Vc
1A
BAR
V

GROUND INPUTS
808817A1.CDR
FIGURE 7–2: Secondary Injection Setup #2
7.3.6 GE Multilin 50:0.025 Ground Accuracy

The specification for GE Multilin HGF 50:0.025 ground current input accuracy is ±0.5% of
2 × CT rated primary (25 A). Perform the steps below to verify accuracy.

CHAPTER 7: TESTING
GROUND CT: “50:0.025 CT”
Measured values should be ±0.25 A.

Z Inject the values shown in the table below either as primary values
into a GE Multilin 50:0.025 Core Balance CT or as secondary values
that simulate the core balance CT.
Z Verify accuracy of the measured values in the A2 METERING DATA Z
CURRENT METERING menu.
Injected Current Current Reading

Primary 50:0.025 CT Secondary Expected Measured
0.25 A 0.125 mA 0.25 A
1A 0.5 mA 1.00 A
5A 2.5 mA 5.00 A
10 A 5 mA 10.00 A
7.3.7 Neutral Voltage (3rd Harmonic) Accuracy

The 489 specification for neutral voltage (3rd harmonic) accuracy is ±0.5% of full scale
(100 V). Perform the steps below to verify accuracy.
Z In the S2 SYSTEM SETUP ZV VOLTAGE SENSING menu, set
NEUTRAL VOLTAGE TRANSFORMER: “Yes”
NEUTRAL V.T. RATIO: “10.00:1”

GENERATOR NOMINAL FREQUENCY: “60 Hz”

METERING menu.
Applied Neutral Voltage Expected Neutral Voltage Measured Neutral

at 180 Hz Voltage
10 V 100 V
30 V 300 V
50 V 500 V
7.3.8 Phase Differential Trip Accuracy
These tests will require a dual channel current source. The unit must be capable of
Note
injecting prefault currents and fault currents of a different value. Application of

excessive currents (greater than 3 × CT) for extended periods will cause damage to the
relay.

CHAPTER 7: TESTING
Minimum Pickup Check

Z Connect the relay test set to inject Channel X current (Ix) into the G3
terminal and out of H3 terminal (Phase A). Increase Ix until the
differential element picks up.
Z Record this value as pickup.
Z Switch off the current.
The theoretical pickup can be computed as follows:
I XPU = Pickup setting × CT (EQ 7.5)
Single Infeed Fault

Z Set the Ix prefault current equal to 0.
Z Set the fault current equal to CT.
Z Apply the fault.
Z Record the operating time.
Z Set the Ix prefault current equal to 0.
Z Set the fault current equal to 5 × CT.
Z Apply the fault.
Z Record the operating time.
Slope 1 Check
Z Connect the relay test set to inject Channel Y current (IY) into the G6
terminal and out of H6 terminal.
The angle between Ix and IY will be 180°.
Z Set pre-fault current, Ix and IY equal to zero.
Z Set fault current, IY equal to 1½ CT.
At this value the relay should operate according to the following formula:
2 – Slope 1 setting 3 × CT
I XOP1 = ---------------------------------------------- × --------------- (EQ 7.6)
2 + Slope 1 setting 2
Z Set fault current, Ix equal to 0.95 × IXOP1.
Z Apply the fault.
The relay should operate.
Z Apply the fault.
The relay should restrain.

CHAPTER 7: TESTING
Slope 2 Check
Z Set fault current, IY equal to 2.5 × CT.
At this value the relay should operate according to the following formula.
2 – Slope 2 setting
I XOP2 = ---------------------------------------------- × 2.5 × CT (EQ 7.7)
2 + Slope 2 setting
Z Switch on the test set.
The relay should operate.
Directional Check
Z Set pre-fault current, Ix and IY equal to 3.5 × CT.
At this value the conditions for CT saturation detection are set and
the relay will enable the directional check.
Z Repeat steps from Minimum Pickup Check onward for phases B
and C.
Test Results
Test Phase A Phase B Phase C
Calculated Measured Calculated Measured Calculated Measured
Minimum Pickup
CT 5 × CT CT 5 × CT CT 5 × CT
Single Infeed Fault

CHAPTER 7: TESTING
operate restrain operate restrain operate restrain
Ix
Iy
Slope 1
Operation
(OK/not
OK)
Ix
Iy
Slope 2
Operation
(OK/not
OK)
Ix N/A N/A N/A
Iy N/A N/A N/A

Directional
Check
Operation
(OK/not N/A N/A N/A
OK)
7.3.9 Injection Test Setup #3

Setup the 489 device as follows for the Voltage Restrained Overcurrent test.
VC
VA
VB VA VB VC VN IA IB IC IN

NEUTRAL
AUTOMATIC CT
1A/5A
1A/5A
1A/5A
1A/5A
1A/5A
1A/5A
Vcom
COM
COM
COM
COM
COM
COM
COM
COM
SHORTING
HGF
Vb
Va
Vc
1A
BAR
V

GROUND INPUTS
808822A2.CDR
FIGURE 7–3: Secondary Injection Test Setup #3

CHAPTER 7: TESTING
7.3.10 Voltage Restrained Overcurrent Accuracy

Setup the relay as shown in FIGURE 7–3: Secondary Injection Test Setup #3 on page 7–19.
GENERATOR RATED MVA: “100 MVA”

VT CONNECTION TYPE: “Open Delta”
VOLTAGE TRANSFORMER RATIO: “100:1”
Z In the S5 CURRENT ELEMENTS Z OVERCURRENT ALARM menu, set:

OVERCURRENT ALARM: “Unlatched”
O/C ALARM LEVEL: “1.10 x FLA”
OVERCURRENT ALARM DELAY: “2 s”
O/C ALARM EVENTS: “On”
Z In the S5 CURRENT ELEMENTS ZV PHASE OVERCURRENT menu, set:

PHASE OVERCURRENT TRIP: “Latched”
ENABLE VOLTAGE RESTRAINT: “Yes”
PHASE O/C PICKUP: “1.5 x CT”
CURVE SHAPE: “ANSI Extremely Inv.”
O/C CURVE MULTIPLIER: “2.00”
O/C CURVE RESET: “Instantaneous”
The trip time for the extremely inverse ANSI curve is given as:
⎛ ⎞
B
⎜ A + ---------------------------- D E
- + ------------------------------------ -⎟
- + ------------------------------------
Time to Trip = M × ⎜ I -–C ⎛ I 2 I - – C⎞ ⎟ 3 (EQ 7.8)
⎜ ------------------ ------------------- – C⎞ ⎛ ------------------
〈 K 〉 × I ⎝ 〈 K〉 × I ⎠ ⎝ 〈 K〉 × I ⎠ ⎟
⎝ p p p ⎠
where:M = O/C CURVE MULTIPLIER setpoint

I = input current
Ip = PHASE O/C PICKUP setpoint
A, B, C, D, E = curve constants, where A = 0.0399, B = 0.2294, C = 0.5000, D = 3.0094,
and E = 0.7222
K = voltage restrained multiplier <optional>
The voltage restrained multiplier is calculated as:
phase-to-phase voltage -
K = -------------------------------------------------------------------------- (EQ 7.9)
rated phase-to-phase voltage
and has a range of 0.1 to 0.9.
Z Using Secondary Injection Test Setup #3 on page 7–19, inject current
and apply voltage as per the table below.
Z Verify the alarm/trip elements and view the event records in the A5
EVENT RECORD menu.

CHAPTER 7: TESTING
Current/voltage (5 A unit) Alarm Trip Trip Delay

Current Voltage expected observed delay expected observed expected observed
Ian = 5 A∠0° Vab = 120 V∠0° lag

Ibn = 5 A∠120° lag Vbc = 120 V∠120° lag 8 N/A 8 N/A N/A
Icn = 5 A∠240° lag Vca = 120 V∠240° lag
Ian = 6 A∠0° Vab = 120 V∠0°
Ibn = 6 A∠120° lag Vbc = 120 V∠120° lag 4 8 N/A N/A
Icn = 6 A∠240° lag Vca = 120 V∠240° lag
Ian = 10 A∠0° Vab = 120 V∠0°
Ibn = 10 A∠120° lag Vbc = 120 V∠120° lag 4 4 11.8 s
Icn = 10 A∠240° lag Vca = 120 V∠240° lag
Ian = 10 A∠0° Vab = 100 V∠0°
Icn = 10 A∠240° lag Vca = 100 V∠240° lag
Ian = 10 A∠0° Vab = 60 V∠0°
Icn = 10 A∠240° lag Vca = 60 V∠240° lag
4 activated; 8 Not Activated
7.3.11 Distance Element Accuracy

The theoretical impedance on the R-X plane can be calculated as:
2 2
0.875 × Z d × cos ( θ d – θ i ) + ( 0.875 × Z d × cos ( θ d – θ i ) ) + 4 × Z d × 0.125
Z i = -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
- (EQ 7.10)
2
where: Zd = programmed distance impedance
θd = programmed distance characteristic angle
θi = variable angle on the R-X plane at point i for which boundary
impedance is to be calculated
It is recommended that voltage is kept constant while increasing the current magnitude at
certain angles referenced to voltage phase A until element operates.
Then the expected operating current (assuming that current in the two phases are 180°
apart) can be calculated as:
Va – Vb
I i = ----------------- (EQ 7.11)
2Z i
jθ i
where Z i = Z i × e .

CHAPTER 7: TESTING

Digital Energy
Multilin
Appendix
Appendix
A.1 Stator Ground Fault
A.1.1 Description
This application note describes general protection concepts and provides guidelines on
the use of the 489 to protect a generator stator against ground faults. Detailed
connections for specific features must be obtained from the relay manual. Users are
also urged to review the material contained in the 489 manual on each specific
protection feature discussed here.
The 489 Generator Management Relay offers a number of elements to protect a generator
against stator ground faults. Inputs are provided for a neutral-point voltage signal and for
a zero-sequence current signal. The zero-sequence current input can be into a nominal 1 A
secondary circuit or an input reserved for a special GE Multilin type HGF ground CT for very
sensitive ground current detection. Using the HGF CT allows measurement of ground
current values as low as 0.25 A primary. With impedance-grounded generators, a single
ground fault on the stator does not require that the unit be quickly removed from service.
The grounding impedance limits the fault current to a few amperes. A second ground fault
can, however, result in significant damage to the unit. Thus the importance of detecting all
ground faults, even those in the bottom 5% of the stator. The fault detection methods
depend on the grounding arrangement, the availability of core balance CT, and the size of
the unit. With modern full-featured digital generator protection relays such as the 489,
users do not incur additional costs for extra protection elements as they are all part of the
same device. This application note provides general descriptions of each of the elements in
the 489 suitable for stator ground protection, and discusses some special applications.
489 GENERATOR MANAGEMENT RELAY – INSTRUCTION MANUAL A–1

CHAPTER A: APPENDIX
A.1.2 Neutral Overvoltage Element

The simplest, and one of the oldest methods to detect stator ground faults on high-
impedance-grounded generators, is to sense the voltage across the stator grounding
resistor (See References [1, 2] at the end of this section). This is illustrated, in a simplified
form in the figure below. The voltage signal is connected to the Vneutral input of the 489,
terminals E10 and F10. The Vneutral signal is the input signal for the 489 neutral overvoltage
protection element. This element has an alarm and a trip function, with separately
adjustable operate levels and time delays. The trip function offers a choice of timing curves
as well as a definite time delay. The neutral overvoltage function responds to fundamental
frequency voltage at the generator neutral. It provides ground fault protection for
approximately 95% of the stator winding. The limiting factor is the level of voltage signal
available for a fault in the bottom 5% of the stator winding. The element has a range of
adjustment, for the operate levels, of 2 to 100 V.
Generator
R is selected for a
maximum fault current
of 10 A, typically.
Distribution Overvoltage
R Relay
Transformer
808739A1.CDR
FIGURE A–1: Stator Ground Fault Protection
The operating time of this element should be coordinated with protective elements
downstream, such as feeder ground fault elements, since the neutral overvoltage element
will respond to external ground faults if the generator is directly connected to a power grid,
without the use of a delta-wye transformer.
In addition, the time delay should be coordinated with the ground directional element
(discussed later), if it is enabled, by using a longer delay on the neutral overvoltage element
than on the directional element.
It is recommended that an isolation transformer be used between the relay and the
grounding impedance to reduce common mode voltage problems, particularly on
installations requiring long leads between the relay and the grounding impedance.
When several small generators are operated in parallel with a single step-up transformer,
all generators may be grounded through the same impedance (the impedance normally
consists of a distribution transformer and a properly sized resistor). It is possible that only
one generator is grounded while the others have a floating neutral point when connected
to the power grid (see the figure below). This operating mode is often adopted to prevent
circulation of third-harmonic currents through the generators, if the installation is such
that all the star points would end up connected together ahead of the common grounding
impedance (if each generator has its own grounding impedance, the magnitude of the
A–2 489 GENERATOR MANAGEMENT RELAY – INSTRUCTION MANUAL

CHAPTER A: APPENDIX
circulating third harmonic current will be quite small). With a common ground point, the
same Vneutral signal is brought to all the relays but only the one which is grounded should
have the neutral overvoltage element in service.
For these cases, the neutral overvoltage element has been provided with a supervising
signal obtained from an auxiliary contact off the grounding switch. When the grounding
switch is opened, the element is disabled. The grounding switch auxiliary contact is also
used in the ground directional element, as is the breaker auxiliary contact, as discussed
later.
If all the generators are left grounded through the same impedance, the neutral
overvoltage element in each relay will respond to a ground fault in any of the generators.
For this reason, the ground directional element should be used in each relay, in addition to
the neutral overvoltage element.
Common
Grounding G1 Breaker
Impedance Grounding
Switch
Trans. & R
Aux.
Contact Aux.
Isolating
Trans. Contact
489
Vneutral Relay
G2 Breaker
Grounding
Switch
Aux.
Contact Aux.
Contact
489
Vneutral Relay
Other Generators,
as the case may be
808737A1.CDR
FIGURE A–2: Parallel Generators with Common Grounding Impedance
A.1.3 Ground Overcurrent Element

The ground overcurrent element can be used as a direct replacement or a backup for the
neutral overvoltage element, with the appropriate current signal from the generator
neutral point, for grounded generators. This element can also be used with a Core Balance
CT, either in the neutral end or the output end of the generator, as shown below. The use of
the special CT, with its dedicated input to the relay, offers very sensitive current detection,
but still does not offer protection for the full stator. The setting of this element must be
above the maximum unbalance current that normally flows in the neutral circuit. Having
the element respond only to the fundamental frequency component allows an increase in
sensitivity.

CHAPTER A: APPENDIX
The core balance CT can be a conventional CT or a 50:0.025 Ground CT, allowing the
measurement of primary-side current levels down to 0.25 A. Using a Core Balance CT, on
the output side of the transformer will provide protection against stator ground faults in
ungrounded generators, provided that there is a source of zero-sequence current from the
grid.
Though in theory one could use this element with a zero sequence current signal obtained
from a summation of the three phase currents (neutral end or output end), by connecting it
in the star point of the phase CTs, Options 4 and 5 in the figure below, this approach is not
very useful. The main drawback, for impedance-grounded generators is that the zero-
sequence current produced by the CT ratio and phase errors could be much larger than
the zero sequence current produced by a real ground fault inside the generator.
Again the time delay on this element must be coordinated with protection elements
downstream, if the generator is grounded. Refer to Ground Directional on page 5–40 for
the range of settings of the pickup levels and the time delays. The time delay on this
element should always be longer than the longest delay on line protection downstream.
GENERATOR
CORE CORE Phase CTs BREAKER

BALANCE BALANCE
CT CT
Option 2 Option 5
(similar to Option 3 Breaker
Option 4) Aux.
Option 1
489
Option 4
Ground current input Ground

from one of the five Overcurrent
options Element
808736A1.CDR
FIGURE A–3: Ground Overcurrent Element with Different Current Source Signals
A.1.4 Ground Directional Element

The 489 can detect internal stator ground faults using a Ground Directional element
implemented using the Vneutral and the ground current inputs. The voltage signal is
obtained across the grounding impedance of the generator. The ground, or zero sequence,
current is obtained from a core balance CT, as shown below (due to CT inaccuracies, it is
generally not possible to sum the outputs of the conventional phase CTs to derive the
generator high-side zero sequence current, for an impedance-grounded generator).
If correct polarities are observed in the connection of all signals to the relay, the Vneutral
signal will be in phase with the ground current signal. The element has been provided with
a setting allowing the user to change the plane of operation to cater to reactive grounding
impedances or to polarity inversions.
This element’s normal ‘plane of operation’ for a resistor-grounded generator is the 180°
plane, as shown in FIGURE A–4: Ground Directional Element Polarities and Plane of
Operation, for an internal ground fault. That is, for an internal stator-to-ground fault, the Vo
signal is 180° away from the Io signal, if the polarity convention is observed. If the

CHAPTER A: APPENDIX
grounding impedance is inductive, the plane of operation will be the 270° plane, again,
with the polarity convention shown below. If the polarity convention is reversed on one
input, the user will need to change the plane of operation by 180°.
GENERATOR CORE 90°

BALANCE
Io CT Plane of operation
Io
for resistive
grounding impedance
Io
180° 0°
Vo
±
F10 H10
489
Relay Io
E10 G10
270°
±
Isolating
Transformer 808735A1.CDR
FIGURE A–4: Ground Directional Element Polarities and Plane of Operation
GENERATOR
CORE
BREAKER
BALANCE
CT
Aux.
Contact
Grounding
Switch Aux.
To Relay 489 Breaker
Grounding Ground
Ground
Impedance Vneutral Directional
Current
(Trans. & Input Element
Input
Resistor) (or O/C)
Isolating
Transformer
Neutral Ground
O/V O/C
Element Element
Grounding G.S. Breaker

Switch Status Status
Aux. Cont.
808734A1.CDR
FIGURE A–5: Ground Directional Element Conceptual Arrangement
The operating principle of this element is quite simple: for internal ground faults the two
signals will be 180° out of phase and for external ground faults, the two signals will be in
phase. This simple principle allows the element to be set with a high sensitivity, not
normally possible with an overcurrent element.
The current pickup level of the element can be adjusted down to 0.05 × CT primary,
allowing an operate level of 0.25 A primary if the 50:0.025 ground CT is used for the core
balance. The minimum level of Vneutral at which the element will operate is determined by
hardware limitations and is internally set at 2.0 V.
Because this element is directional, it does not need to be coordinated with downstream
protections and a short operating time can be used. Definite time delays are suitable for
this element.

CHAPTER A: APPENDIX
Applications with generators operated in parallel and grounded through a common

impedance require special considerations. If only one generator is grounded and the other
ones left floating, the directional element for the floating generators does not receive a
correct Vneutral signal and therefore cannot operate correctly. In those applications, the
element makes use of auxiliary contacts off the grounding switch and the unit breaker to
turn the element into a simple overcurrent element, with the pickup level set for the
directional element (note that the ground directional element and the ground overcurrent
elements are totally separate elements). In this mode, the element can retain a high
sensitivity and fast operate time since it will only respond to internal stator ground faults.
The table below illustrates the status of different elements under various operating
conditions.
Table A–1: Detection Element Status
Generator Unit Ground Element

Condition Breaker Switch
Ground Neutral Ground
Directional Overvoltage Overcurrent
Shutdown Open Open Out-of-service Out-of-service In-service
Open Circuit In-service (but will

and Open Closed not operate due to In-service In-service
grounded lack of I0)
Loaded and Closed Closed In-service In-service In-service

Grounded
Loaded and In service as a

Not Closed Open simple overcurrent Out-of-service In-service
Grounded element
A.1.5 Third Harmonic Voltage Element

The conventional neutral overvoltage element or the ground overcurrent element are not
capable of reliably detecting stator ground faults in the bottom 5% of the stator, due to
lack of sensitivity. In order to provide reliable coverage for the bottom part of the stator,
protective elements, utilizing the third harmonic voltage signals in the neutral and at the
generator output terminals, have been developed (see Reference 4).
In the 489 relay, the third-harmonic voltage element, Neutral Undervoltage (3rd Harmonic)
derives the third harmonic component of the neutral-point voltage signal from the Vneutral
signal as one signal, called VN3. The third harmonic component of the internally summed
phase-voltage signals is derived as the second signal, called VP3. For this element to
perform as originally intended, it is necessary to use wye-connected VTs.
Since the amount of third harmonic voltage that appears in the neutral is both load and
machine dependent, the protection method of choice is an adaptive method. The following
formula is used to create an adaptive third-harmonic scheme:
V N3
------------------------------- ≤ 0.15 which simplifies to V P3 ≥ 17V N3 (EQ 1.1)
V P3 ⁄ 3 + V N3
The 489 tests the following conditions prior to testing the basic operating equation to
ensure that VN3 is of a measurable magnitude:

CHAPTER A: APPENDIX
Neutral CT Ratio
V P3′ > 0.25 V and V P3′ ≥ Permissive_Threshold × 17 × ---------------------------------------- (EQ 1.2)
Phase CT Ratio
where: VN3 is the magnitude of third harmonic voltage at the generator neutral
VP3 is the magnitude of third harmonic voltage at the generator terminals
VP3' and VN3' are the corresponding voltage transformer secondary values
Permissive_Threshold is 0.15 V for the alarm element and 0.1875 V for the trip
element.
In addition, the logic for this element verifies that the generator positive sequence terminal
voltage is at least 30% of nominal, to ensure that the generator is actually excited.
This method of using 3rd harmonic voltages to detect stator ground faults near the
Note
generator neutral has proved feasible on larger generators with unit transformers. Its
usefulness in other generator applications is unknown.
If the phase VT connection is “Open Delta”, it is not possible to measure the third harmonic
voltage at the generator terminals and a simple third harmonic neutral undervoltage
element is used. In this case, the element is supervised by both a terminal voltage level and
by a power level. When used as a simple undervoltage element, settings should be based
on measured 3rd harmonic neutral voltage of the healthy machine. It is recommended
that the element only be used for alarm purposes with open delta VT connections.
A.1.6 References
1. C. R. Mason, “The Art & Science of Protective Relaying”, John Wiley & Sons, Inc., 1956,
Chapter 10.
2. J. Lewis Blackburn, “Protective Relaying: Principles and Applications”, Marcel Dekker,
Inc., New York, 1987, chapter 8.
3. GE Multilin, “Instruction Manual for the 489 Generator Management Relay”.
4. R. J. Marttila, “Design Principles of a New Generator Stator Ground Relay for 100%
Coverage of the Stator Winding”, IEEE Transactions on Power Delivery, Vol. PWRD-1,
No. 4, October 1986.

CHAPTER A: APPENDIX
A.2 Stator Differential Protection Special Application
A.2.1 Background
The 489 relay is applied in a dual breaker arrangement as shown in the figure below. In this
configuration one breaker is closed at a time eliminating a danger of through fault
conditions. However, the customer prefers not to sum up the two breaker currents to
obtain effectively the terminal-side current of the generator, nor to install an extra CT at
the generator to measure the terminal-side current explicitly. Instead, the customer
applies two 489 relays each spanning its differential zone between the neutral-side CT of
the generator and the CT at the corresponding breaker.
In this application, when a breaker is closed, the other (opposite) relay would measure the
neutral-side current without the matching terminal-side current, as the latter flows via the
other (closed) breaker and it not visible to the opposite relay.
Block 87 when CB closed
489-2 489-1
FIGURE A–6: Considered application of two 489s protecting a dual-breaker generator configura-
tion
When both breakers are opened both relays be operational with the differential function
enabled. The application is based on blocking the differential function using the position of
the opposite breaker via the multiple setting group mechanism of the relay.
When both breakers are opened, both relays are in their setting group 1 with the
differential functions operational. When a breaker is closed, its relay remains in group 1 so
that no setting group switching takes place and therefore continuous uninterrupted
protection is provided for the generator. At the same time the opposite relay is blocked by
switching to group 2 in which the differential function is disabled. This prevents mis-
operation. There is no provision for an “advanced close” signal, and the breaker position
signal is used instead.

CHAPTER A: APPENDIX
In addition, enhanced differential protection algorithm takes care the timing offset
between the main and auxiliary contacts of the breaker. As a result, maximum of 50ms
timing offset between the main and auxiliary contacts of the breaker will block the
differential function.
A.2.2 Stator Differential Logic

The differential function uses an internal timer of 130ms as shown in the figure below. This
timer is a common timer for all three phases of the differential function. Normally, the timer
is not engaged ensuring instantaneous operation and backward compatibility with the
previous firmware revisions of the product.
The timer is engaged only when the terminal-side currents in all three phases are zero. If
any of the terminal currents is above 5% of CT nominal, the timer is by-passed. Also, if any
of the neutral-side current is above 5 times CT nominal, the timer is by-passed as well.
In this logic the current magnitudes are filtered fundamental frequency components (T
stands for terminal-side currents, and N stands for neutral-side currents); PKP denotes the
pickup state of the element prior to any user set delay that may or may not be used in a
particular application; A, B and C designate phases.
The differential element works as follows:
With the machine under load, the terminal currents are above 5% of CT nominal and no
delay is applied to the differential function.
With the machine on-line but with no load (below 5%) the delay is applied. However, should
a fault occur at that time, at least one of the terminal current would get elevated
cancelling the delay and resulting in an instantaneous trip.
With the opposite breaker being closed as in the considered dual-breaker application, a
current is drawn (either transformer inrush or load or both). This will activate the
differential characteristic. However, the timer remains engaged because all the terminal
currents (ABC) are zero, and all the neutral-side currents (ABC) are below 5 times CT
nominal. The timer keeps timing out. However, before it expires the relay switches to group
2 and blocks the differential function. This prevents misoperation.
Normally, no extra
IT mag A > 0.05pu
delay is applied
0ms
OR
IT mag B > 0.05pu

100ms
OR
IT mag C > 0.05pu
IN mag A > 5pu

AND
OR
IN mag B > 5pu
IN mag C > 5pu

OR
87 PKP
87 PKP A
130ms
OR
87 PKP B
0ms
87 PKP C
With no terminal side currents, a
delay of an extra 130ms is applied
to the differential function.
FIGURE A–7: Enhancements to the stator differential logic

CHAPTER A: APPENDIX
Should a fault occur during the first 50-60ms after closing the breaker, the corresponding
relay would trip instantly. Before closing the breaker the corresponding relay too applies a
delay. However, once the load/inrush current exceeds 5% of CT nominal, its timer is by-
passed and instantaneous protection is provided.
Should a fault occur during generator start-up with both breakers opened, both relays
would operate after the extra time delay of 130ms. This delay is acceptable under such
conditions. Even this delay will be eliminated if the fault is heavy enough to draw more
than 5 times CT nominal from the neutral-side of the generator.
For proper implementation, the internal timer is cleared each time the 87 function
becomes enabled (so that a partial time out from the previous “enabled” period does not
affect the intended operation).

CHAPTER A: APPENDIX
A.3 Current Transformers
A.3.1 Ground Fault CTs for 50:0.025 A CT

CTs that are specially designed to match the ground fault input of GE Multilin motor
protection relays should be used to ensure correct performance. These CTs have a
50:0.025A (2000:1 ratio) and can sense low leakage currents over the relay setting range
with minimum error. Three sizes are available with 3½-inch, 5½-inch, or 8-inch diameter
windows.
HGF3C
808840A1

CHAPTER A: APPENDIX
HGF5C
808841A1
HGF8
808842A1

CHAPTER A: APPENDIX
A.3.2 Ground Fault CTs for 5 A Secondary CT

For low resistance or solidly grounded systems, a 5 A secondary CT should be used. Two
sizes are available with 5½” or 13” × 16” windows. Various Primary amp CTs can be chosen
(50 to 250).
GCT5 GCT16
DIMENSIONS DIMENSIONS
808709A1.CDR
A.3.3 Phase CTs

CHAPTER A: APPENDIX
Current transformers in most common ratios from 50:5 to 1000:5 are available for use as
phase current inputs with motor protection relays. These come with mounting hardware
and are also available with 1 A secondaries. Voltage class: 600 V BIL, 10 KV.
808712A1.CDR

CHAPTER A: APPENDIX
A.4 Time Overcurrent Curves
A.4.1 ANSI Curves
489 ANSI
GE Multilin MODERATELY INVERSE
1000
100
MULTIPLIER
10
30.0
TRIP TIME (sec)
20.0
15.0
10.0
8.0
6.0
1
4.0
3.0
2.0
1.0
0.1 0.5
0.01
0.1 1 10 100
CURRENT (I/Ipu) 808802A4.CDR
FIGURE A–8: ANSI Moderately Inverse Curves

CHAPTER A: APPENDIX
489 ANSI
GE Multilin NORMALLY INVERSE
1000
100
10 MULTIPLIER
TRIP TIME (sec)
30.0
20.0
15.0
10.0
1 8.0
6.0
4.0
3.0
2.0
1.0
0.1
0.5
0.01
0.1 1 10 100
FIGURE A–9: ANSI Normally Inverse Curves

CHAPTER A: APPENDIX
489 ANSI
GE Multilin VERY INVERSE
1000
100
10
MULTIPLIER
TRIP TIME (sec)
30.0
20.0
15.0
1 10.0
8.0
6.0
4.0
3.0
2.0
0.1 1.0
0.5
0.01
0.1 1 10 100
CURRENT (I/Ipu) 808800A4.DWG
FIGURE A–10: ANSI Very Inverse Curves

CHAPTER A: APPENDIX
489 ANSI
GE Multilin EXTREME INVERSE
1000
100
10
TRIP TIME (sec)
MULTIPLIER
30.0
20.0
1
15.0
10.0
8.0
6.0
4.0
3.0
2.0
0.1
1.0
0.5
0.01
0.1 1 10 100
808799A4.CDR
CURRENT (I/Ipu)
FIGURE A–11: ANSI Extremely Inverse Curves

CHAPTER A: APPENDIX
A.4.2 Definite Time Curves
489
GE Multilin DEFINITE TIME
1000
100
10
TRIP TIME (sec)
MULTIPLIER
30.0
20.0
15.0
1 10.0
8.0
6.0
4.0
3.0
2.0
0.1 1.0
0.5
0.01
0.1
100
10
1
FIGURE A–12: Definite Time Curves

CHAPTER A: APPENDIX
A.4.3 IAC Curves
489 IAC
GE Multilin
SHORT INVERSE
1000
100
MULTIPLIER
10
TRIP TIME (sec)
30.0
1
20.0
15.0
10.0
8.0
6.0
4.0
3.0
0.1
2.0
1.0
0.5
0.01
0.1
10
100
FIGURE A–13: IAC Short Inverse Curves

CHAPTER A: APPENDIX
489
GE Multilin IAC INVERSE
1000
100
10 MULTIPLIER
30.0
TRIP TIME (sec)
20.0
15.0
10.0
8.0
6.0
1 4.0
3.0
2.0
1.0
0.5
0.1
0.01
1
0.1
10
100
FIGURE A–14: IAC Inverse Curves

CHAPTER A: APPENDIX
489 IAC
GE Multilin VERY INVERSE
1000
100
10
MULTIPLIER
TRIP TIME (sec)
30.0
20.0
15.0
10.0
1 8.0
6.0
4.0
3.0
2.0
1.0
0.1
0.5
0.01
0.1
10
100
1
FIGURE A–15: IAC Very Inverse Curves

CHAPTER A: APPENDIX
489 IAC
GE Multilin
EXTREME INVERSE
1000
100
10
TRIP TIME (sec)
MULTIPLIER
30.0
1
20.0
15.0
10.0
8.0
6.0
4.0
3.0
0.1
2.0
1.0
0.5
0.01
0.1
10
100
FIGURE A–16: IAC Extreme Inverse Curves

CHAPTER A: APPENDIX
A.4.4 IEC Curves
489
GE Multilin IEC CURVE A (BS142)
1000
100
10
TRIP TIME (sec)
MULTIPLIER
1.00
0.80
0.60
0.50
1
0.40
0.30
0.20
0.15
0.10
0.05
0.1
0.01
0.1
10
100
1
FIGURE A–17: IEC Curves A (BS142)

CHAPTER A: APPENDIX
489
GE Multilin IEC CURVE B (BS142)
1000
100
10
TRIP TIME (sec)
MULTIPLIER
1.00
0.80
0.60
0.50
0.40
0.30
0.20
0.1
0.15
0.10
0.05
0.01
0.1
100
10
FIGURE A–18: IEC Curves B (BS142)

CHAPTER A: APPENDIX
489
GE Multilin IEC CURVE C (BS142)
1000
100
10
TRIP TIME (sec)
MULTIPLIER
1.00
0.80
0.60
0.1 0.50
0.40
0.30
0.20
0.15
0.10
0.01
0.05
1
10
0.1
100
FIGURE A–19: IEC Curves C (BS142)

CHAPTER A: APPENDIX
A.5 Revision History
A.5.1 Change Notes
Table A–2: Revision History
MANUAL P/N REVISION RELEASE DATE ECO
1601-0150-A1 3.00 26 April 2004 489-249
1601-0150-A2 3.00 21 May 2004 ---
1601-0150-A3 3.00 22 July 2004 ---
1601-0150-A4
1601-0150-A5 4.0x 21 July 2006
1601-0150-A6 4.0x 9 February, 2007
1601-0150-A7 4.0x 31 March, 2007
1601-0150-A8 4.0x 3 April, 2008
1601-0150-A9 4.0x 12 June, 2008
1601-0150-AA 4.0x 10 September, 2008
1601-0150-AB 4.0x 2 December, 2008
1601-0150-AC 4.0x 23 April, 2009
1601-0150-AD 4.0x 21 July, 2009
A.5.2 Changes to the 489 Manual
Table A–3: Major Updates for 489 Manual Revision AD
SECT SECT CHANGE DESCRIPTION

(AC) (AD)
Title Title Update Manual part number to 1601-0150-AD
3.1.6 3.1.6 Revision Figure 3-9 revised.
3.2.1 3.2.1 Revision Figure 3-10 revised.
Table A–4: Major Updates for 489 Manual Revision AC

(AB) (AC)
Title Title Update Manual part number to 1601-0150-AC

CHAPTER A: APPENDIX
Table A–4: Major Updates for 489 Manual Revision AC

(AB) (AC)
Self-test Warnings table: Relay Not Configured

4.1.7 4.1.7 Revision
revised.
Table A–5: Major Updates for 489 Manual Revision AB

(AA) (AB)
Title Title Update Manual part number to 1601-0150-AB
2.2.5 2.2.5 Revision Power Metering - changes to spec.
7.3.2 7.3.2 Revision Changes to specs.
Table A–6: Major Updates for 489 Manual Revision AA

(A9) (AA)
Title Title Update Manual part number to 1601-0150-AA
5.6.9 5.6.9 Change Note (Pickup Level)
Table A–7: Major Updates for 489 Manual Revision A9

(A8) (A9)
Title Title Update Manual part number to 1601-0150-A9
5.6.5 5.6.5 Fig 5-2: Change graph

(A7) (A8)
2.1.2 2.1.2
Update Changes to DC Power Supply range
2.2.5 2.2.5
fig 5-2 fig 5-2 Change graph
8.2.1 Add New Section: Stator Differential Protection

CHAPTER A: APPENDIX

(A7) (A8)
8.2.1 8.3.1 Update Drawings changed
Equn 7.7 Equn 7.7 Update Change equation
PAGE SECT CHANGE DESCRIPTION

(A5) (A6)
5-31 5.6.8 Correction Changes to step value - Differential Trip Delay
2-9 2.2.6 Correction Changes to Littelfuse SLO-BLO data
2-7,8 2.2.3 Changes to OverFrequency and Underfrequency

Update
5-39,40 5.7.5,6 parameters
PAG PAG CHANGE DESCRIPTION

E E
(A5) (A6)
2-14 2-14 Update Changes to ELECTROSTATIC DISCHARGE value

E E
(A3) (A4)
2- 2- Update Updated ORDERING section
2- 2- Update Updated SPECIFICATIONS section
--- 3-4 Add Added ETHERNET COMMUNICATION section
5- --- Remove Removed SERIAL PORTS section
--- 5- Add Added COMMUNICATIONS section
5-44 5-44 Update Updated DISTANCE ELEMENT section

CHAPTER A: APPENDIX

E E
(A3) (A4)
--- 6-3 Add Added NETWORK STATUS section
--- 7-16 Add Added DISTANCE ELEMENT ACCURACY section

E E
(A2) (A3)
Updated THERMAL MODEL COOLING diagram to

5-67 5-67 Update
808705A2

E E
(A1) (A2)
Additional changes for revision A2 were cosmetic. There was no change to content.

CHAPTER A: APPENDIX
A.6 EU Declaration of Conformity
A.6.1 EU Declaration of Conformity

CHAPTER A: APPENDIX
A.7 Warranty
A.7.1 GE Multilin Warranty

General Electric Multilin Inc. (GE Multilin) warrants each relay it manufactures to be free
from defects in material and workmanship under normal use and service for a period of 24
months from date of shipment from factory.
In the event of a failure covered by warranty, GE Multilin will undertake to repair or replace
the relay providing the warrantor determined that it is defective and it is returned with all
transportation charges prepaid to an authorized service centre or the factory. Repairs or
replacement under warranty will be made without charge.
Warranty shall not apply to any relay which has been subject to misuse, negligence,
accident, incorrect installation or use not in accordance with instructions nor any unit that
has been altered outside a GE Multilin authorized factory outlet.
GE Multilin is not liable for special, indirect or consequential damages or for loss of profit or
for expenses sustained as a result of a relay malfunction, incorrect application or
adjustment.
For complete text of Warranty (including limitations and disclaimers), refer to GE Multilin
Standard Conditions of Sale.

INDEX
Index
Numerics
0-1mA ANALOG INPUT ................................................................................... 3-15
4-20mA ANALOG INPUT ................................................................................. 3-15
50:0.025 CT ...................................................................................................... 3-12
A
ACCESS SWITCH .............................................................................................. 5-21
ACCESSORIES .................................................................................................... 2-5
ACTUAL VALUES
messages .......................................................................................................... 6-3
ALARM PICKUPS ............................................................................................... 6-12
ALARM RELAY .......................................................................................... 3-17, 5-28
ALARM STATUS ................................................................................................. 6-6
ALARMS ....................................................................................................... 5-6, 5-7
ANALOG IN MIN/MAX ...................................................................................... 6-23
ANALOG INPUTS .............................................................................................. 3-14
actual values .......................................................................................... 6-20, 6-23
analog I/P min/max ......................................................................................... 5-17
min/max .......................................................................................................... 6-23
minimums and maximums .............................................................................. 5-23
setpoints .......................................................................................................... 5-98
specifications ................................................................................................... 2-6
testing .............................................................................................................. 7-9
ANALOG OUTPUTS ........................................................................................... 3-15
setpoints .......................................................................................................... 5-96
specifications ................................................................................................... 2-7
table ................................................................................................................ 5-97
testing .............................................................................................................. 7-9
ANSI CURVES .......................................................................................... 5-30, A-15
ANSI DEVICE NUMBERS ................................................................................... 2-2
APPLICATION NOTES
current transformers ...................................................................................... A-11
stator ground fault ........................................................................................... A-1
AUXILIARY RELAY .................................................................................... 3-17, 5-28
B
BAUD RATE .............................................................................................. 2-14, 5-12
setpoints .......................................................................................................... 5-13
BREAKER FAILURE ........................................................................................... 5-90
BREAKER STATUS ............................................................................................. 5-21
BURDEN ............................................................................................................. 2-6
C
CALIBRATION INFO .......................................................................................... 6-31
489 GENERATOR MANAGEMENT RELAY – INSTRUCTION MANUAL I–1

INDEX
CASE ........................................................................................................... 2-15, 3-1

CAUSE OF EVENTS TABLE ............................................................................... 6-29
CERTIFICATIONS .............................................................................................. 2-15
CHANGING SETPOINTS ..................................................................................... 1-9
CLEAR DATA ..................................................................................................... 5-16
CLOCK ...................................................................................................... 5-13, 6-15
COMM PORT MONITOR ................................................................................. 5-104
COMMUNICATIONS
monitoring ..................................................................................................... 5-104
RS232 ............................................................................................ 4-11, 4-15, 4-17
RS485 ............................................................................................ 4-12, 4-15, 4-17
setpoints .......................................................................................................... 5-12
specifications .................................................................................................. 2-14
wiring ...................................................................................................... 4-11, 4-12
CONTROL FEATURES ......................................................................................... 5-6
CONTROL POWER ............................................................................................ 3-10
COOLING .......................................................................................................... 5-85
COOLING TIME CONSTANTS ........................................................................... 5-85
CORE BALANCE ................................................................................................ 3-12
CT RATIO ........................................................................................................... 5-18
CTs
burden ............................................................................................................... 2-6
ground fault .................................................................................................... A-13
phase .............................................................................................................. A-13
setpoints .......................................................................................................... 5-18
withstand ........................................................................................................... 2-6
CURRENT ACCURACY TEST ............................................................................... 7-4
CURRENT DEMAND .......................................................................................... 5-93
CURRENT INPUTS .............................................................................................. 2-7
CURRENT METERING ....................................................................................... 6-16
CURRENT SENSING .......................................................................................... 5-18
CURVES
see OVERLOAD CURVES
CUSTOM OVERLOAD CURVE ........................................................................... 5-76
D
DEFAULT MESSAGES ..................................................................... 5-10, 5-14, 5-15
DEFINITE TIME CURVE ........................................................................... 5-32, A-19
DEMAND DATA ................................................................................................. 5-23
DEMAND METERING ...................................................................... 2-12, 5-93, 6-20
DEMAND PERIOD ............................................................................................. 5-94
DESCRIPTION ..................................................................................................... 2-1
DEVICE NUMBERS .............................................................................................. 2-2
DIAGNOSTIC MESSAGES ................................................................................. 6-32
DIELECTRIC STRENGTH
specifications .................................................................................................. 2-14
testing ............................................................................................................. 3-18
DIFFERENTIAL CURRENT ACCURACY TEST ..................................................... 7-5
DIGITAL COUNTER ........................................................................................... 5-23
DIGITAL INPUTS ............................................................................................... 3-14
actual values ................................................................................................... 6-15
dual setpoints .................................................................................................. 5-24
field-breaker discrepancy ............................................................................... 5-26
general input ................................................................................................... 5-22
I–2 489 GENERATOR MANAGEMENT RELAY – INSTRUCTION MANUAL

INDEX
ground switch status ....................................................................................... 5-27

remote reset .................................................................................................... 5-23
sequential trip ................................................................................................. 5-25
specifications ................................................................................................... 2-6
tachometer ...................................................................................................... 5-26
test input ......................................................................................................... 5-23
testing .............................................................................................................. 7-9
thermal reset ................................................................................................... 5-23
DIMENSIONS ..................................................................................................... 3-2
DISPLAY ............................................................................................................. 4-1
DISTANCE ELEMENTS ...................................................................................... 5-56
DRAWOUT INDICATOR .................................................................................... 3-17
DUAL SETPOINTS ...................................................................................... 5-8, 5-24
E
EMERGENCY RESTARTS ................................................................................... 5-23
ENERVISTA VIEWPOINT WITH THE 489 ......................................................... 4-44
ENTERING TEXT ................................................................................................. 4-5
ENVIRONMENT ................................................................................................. 2-15
ETHERNET
actual values .................................................................................................... 6-4
setpoints .......................................................................................................... 5-13
EU ..................................................................................................................... A-30
EU Declaration of Conformity ...................................................................... A-30
EVENT RECORD
cause of events ............................................................................................... 6-29
EVENT RECORDER .......................................................................... 5-17, 5-23, 6-28
F
FACTORY SERVICE ......................................................................................... 5-104
FAULT SETUP .................................................................................................. 5-102
FEATURES ........................................................................................... 2-2, 2-3, 2-10
FIELD-BREAKER DISCREPANCY ...................................................................... 2-11
FIRMWARE
upgrading via EnerVista 489 setup software .................................................. 4-30
FLASH MESSAGES ............................................................................................ 6-33
FLEXCURVE ....................................................................................................... 5-31
FLOW ................................................................................................................. 3-14
FREQUENCY TRACKING .................................................................................... 2-6
FRONT PANEL
using ................................................................................................................. 1-3
FUSE .................................................................................................................. 2-13
G
GENERAL COUNTERS ....................................................................................... 6-27
GENERAL INPUTS .................................................................................... 2-12, 5-22
GENERATOR INFORMATION ............................................................................ 5-17
GENERATOR LOAD ........................................................................................... 6-22
GENERATOR PARAMETERS ............................................................................. 5-19
GENERATOR STATUS ........................................................................................ 6-4
GETTING STARTED ............................................................................................ 1-1

INDEX
GROUND CT
burden ............................................................................................................... 2-6
setpoint ........................................................................................................... 5-18
withstand ........................................................................................................... 2-6
GROUND CURRENT ACCURACY TEST ..................................................... 7-5, 7-15
GROUND CURRENT INPUT .............................................................................. 3-12
GROUND DIRECTIONAL ........................................................................... 5-40, A-4
GROUND FAULT CTs ....................................................................................... A-13
GROUND OVERCURRENT ........................................................................ 5-38, A-3
GROUND SWITCH STATUS .............................................................................. 5-27
H
HELP KEY .......................................................................................................... 1-10
HIGH-SET PHASE OVERCURRENT .................................................................. 5-42
HI-POT .............................................................................................................. 3-18
HOT/COLD SAFE STALL RATIO ....................................................................... 5-87
I
IAC CURVES ............................................................................................ 5-31, A-20
IDENTIFICATION ................................................................................................. 3-2
IEC CURVES ............................................................................................ 5-30, A-24
IED SETUP ......................................................................................................... 4-13
INADVERTENT ENERGIZATION ................................................................ 2-9, 5-34
INJECTION TEST SETUP .................................................................. 7-3, 7-15, 7-19
INPUTS
analog ...................................................................................................... 2-6, 3-14
current ............................................................................................. 2-7, 3-11, 3-12
digital ....................................................................................................... 2-6, 3-14
general ............................................................................................................ 2-12
RTD ........................................................................................................... 2-7, 3-15
voltage ..................................................................................................... 2-7, 3-14
INSERTION .......................................................................................................... 3-4
INSPECTION CHECKLIST ................................................................................... 1-1
INSTALLATION .................................................................................................... 3-3
IRIG-B ....................................................................................................... 3-17, 5-13
K
KEYPAD ............................................................................................................... 4-3
help .................................................................................................................. 1-10
L
LAST TRIP DATA ............................................................... 5-17, 5-23, 6-5, 6-9, 6-12
LEARNED PARAMETERS .................................................................................. 5-23
LEDs ..................................................................................................... 4-1, 4-2, 4-3
LONG-TERM STORAGE .................................................................................... 2-16
LOOP POWERED TRANSDUCERS .................................................................... 3-14
LOSS OF EXCITATION ............................................................................... 2-9, 5-55
LOSS OF LOAD ................................................................................................... 4-3
LOW FORWARD POWER ................................................................................. 5-63

INDEX
M
MACHINE COOLING ......................................................................................... 5-85
MESSAGE SCRATCHPAD .................................................................................. 5-15
METERING
current ............................................................................................................. 6-16
demand .................................................................................................. 2-12, 6-20
Mvarh ............................................................................................. 5-17, 5-23, 6-18
MWh ............................................................................................... 5-17, 5-23, 6-18
power ............................................................................................................... 2-13
specifications ................................................................................................... 2-4
voltage ............................................................................................................. 6-17
MODEL INFORMATION .................................................................................... 6-31
MODEL SETUP .................................................................................................. 5-71
MOTOR STARTS ................................................................................................ 5-23
MOTOR TRIPS ................................................................................................... 5-23
MVA DEMAND ......................................................................................... 5-93, 6-20
MVAR DEMAND ....................................................................................... 5-93, 6-20
Mvarh METERING ........................................................................... 5-17, 5-23, 6-18
MW DEMAND ........................................................................................... 5-93, 6-20
MWh METERING ............................................................................. 5-17, 5-23, 6-18
N
NAMEPLATE ....................................................................................................... 1-1
NEGATIVE SEQUENCE CURRENT ACCURACY TEST ....................................... 7-6
NEGATIVE SEQUENCE OVERCURRENT .......................................................... 5-36
NEGATIVE-SEQUENCE CURRENT ................................................................... 6-17
NEUTRAL CURRENT ACCURACY TEST ............................................................. 7-5
NEUTRAL OVERVOLTAGE ........................................................................ 5-51, A-2
NEUTRAL UNDERVOLTAGE ............................................................................. 5-53
NEUTRAL VOLTAGE ACCURACY TEST ..................................................... 7-6, 7-16
NUMERICAL SETPOINTS .................................................................................. 1-10
O
OFFLINE OVERCURRENT ................................................................................. 5-33
OPEN DELTA ..................................................................................................... 3-14
OPEN DELTA CONNECTED VTs ....................................................................... 5-54
OPEN RTD SENSOR .......................................................................................... 5-68
ORDER CODES ................................................................................................... 2-6
OUTPUT CURRENT ACCURACY TEST ............................................................... 7-4
OUTPUT RELAY LEDs ........................................................................................ 4-3
OUTPUT RELAYS
1 Trip ................................................................................................................ 3-16
2 Auxiliary ........................................................................................................ 3-17
3 Auxiliary ........................................................................................................ 3-17
4 Auxiliary ........................................................................................................ 3-17
5 Alarm ............................................................................................................ 3-17
6 Service .......................................................................................................... 3-17
setpoints .......................................................................................................... 5-28
specifications ................................................................................................... 2-8
testing ............................................................................................................. 7-11
wiring ............................................................................................................... 3-16

INDEX
OUTPUTS
analog ...................................................................................................... 2-7, 3-15
OVERCURRENT
ground ............................................................................................................. 5-38
ground directional ........................................................................................... 5-40
high-set ........................................................................................................... 5-42
negative-sequence .......................................................................................... 5-36
phase ............................................................................................................... 5-35
phase differential ............................................................................................ 5-39
setpoints .......................................................................................................... 5-33
specifications ........................................................................................... 2-9, 2-10
TOC .................................................................................................................. 5-29
OVERCURRENT ALARM .................................................................................... 5-33
OVERCURRENT CURVES
ANSI ................................................................................................................ A-15
characteristics ................................................................................................. 5-29
definite time ................................................................................................... A-19
graphs ............................................................................................................ A-15
IAC ......................................................................................................... 5-31, A-20
IEC ......................................................................................................... 5-30, A-24
OVERFREQUENCY ................................................................................... 2-10, 5-50
OVERLOAD CURVE MULTIPLIERS ................................................................... 5-75
OVERLOAD CURVES
custom ............................................................................................................. 5-76
definite time .................................................................................................... 5-32
standard multipliers ........................................................................................ 5-75
testing ............................................................................................................. 7-12
OVERVOLTAGE ........................................................................................ 2-10, 5-44
P
PACKAGING ...................................................................................................... 2-15
PARAMETER AVERAGES .................................................................................. 6-22
PARITY ...................................................................................................... 5-12, 5-13
PASSCODE ................................................................................................... 5-9, 6-1
PEAK DEMAND ........................................................................................ 5-17, 6-20
PHASE CT PRIMARY ................................................................................ 5-18, 5-19
PHASE CTs ....................................................................................................... A-13
PHASE CURRENT INPUTS ................................................................................ 3-11
PHASE DIFFERENTIAL ...................................................................................... 5-39
PHASE DIFFERENTIAL TRIP TEST .................................................................... 7-16
PHASE OVERCURRENT .................................................................................... 5-35
PHASE REVERSAL ............................................................................................. 5-48
PHASE REVERSAL TEST ................................................................................... 7-14
POSITIVE-SEQUENCE CURRENT ..................................................................... 6-17
POWER DEMAND ............................................................................................. 5-93
POWER MEASUREMENT CONVENTIONS ....................................................... 5-60
POWER MEASUREMENT TEST ......................................................................... 7-13
POWER METERING .................................................................................. 2-13, 6-18
POWER SUPPLY ...................................................................................... 2-13, 3-11
POWER SYSTEM ...................................................................................... 5-19, 5-20
PRE-FAULT SETUP ......................................................................................... 5-101
PREFERENCES .................................................................................................. 5-10
PRESSURE ......................................................................................................... 3-14
PRODUCT IDENTIFICATION ............................................................................... 3-2

INDEX
PRODUCTION TESTS ........................................................................................ 2-14

PROTECTION FEATURES ................................................................................... 2-3
PROXIMITY PROBE ........................................................................................... 3-14
PULSE OUTPUT ..........................................................................................2-8, 5-94
R
REACTIVE POWER ............................................................................................ 5-61
REACTIVE POWER TEST ................................................................................... 7-13
REAL TIME CLOCK ................................................................................... 5-13, 6-15
RELAY ASSIGNMENT PRACTICES ..................................................................... 5-7
RELAY RESET MODE ......................................................................................... 5-28
REMOTE RESET ................................................................................................. 5-23
RESETTING THE 489 ........................................................................................ 5-28
RESIDUAL GROUND CONNECTION ................................................................ 3-12
REVERSE POWER ............................................................................................. 5-62
REVISION HISTORY ......................................................................................... A-27
RS232 COMMUNICATIONS ...................................................................... 4-3, 5-12
configuring with EnerVista 469 setup ............................................................. 4-17
configuring with EnerVista 750/760 Setup ...................................................... 4-17
connections ..................................................................................................... 4-11
RS485 COMMUNICATIONS .................................................................... 3-17, 5-12
configuring with EnerVista 750/760 Setup ...................................................... 4-17
connections ..................................................................................................... 4-12
RTD
actual values .......................................................................................... 6-19, 6-23
maximums ..................................................................................... 5-17, 5-23, 6-22
sensor connections ......................................................................................... 3-15
setpoints ........................................................................................ 5-65, 5-66, 5-67
specifications ........................................................................................... 2-7, 2-11
testing .............................................................................................................. 7-7
RTD ACCURACY TEST ........................................................................................ 7-7
RTD BIAS ........................................................................................................... 5-87
RTD MAXIMUMS ............................................................................................... 6-22
RTD SENSOR, OPEN ......................................................................................... 5-68
RTD SHORT/LOW TEMPERATURE ................................................................... 5-69
RTD TYPES ........................................................................................................ 5-64
RUNNING HOUR SETUP .................................................................................. 5-95
RUNNING HOURS ............................................................................................ 5-23
S
SEQUENTIAL TRIP ................................................................................... 2-12, 5-25
SERIAL PORTS .................................................................................................. 5-12
SERIAL START/STOP INITIATION .................................................................... 5-20
SERVICE RELAY ................................................................................................ 3-17
SETPOINT ENTRY ............................................................................................... 4-6
SETPOINT MESSAGE MAP ................................................................................ 5-1
SETPOINTS
changing ........................................................................................................... 1-9
dual setpoints ................................................................................................... 5-8

INDEX
entering with EnerVista 489 setup software ................................................... 4-21

loading from a file ........................................................................................... 4-28
messages .......................................................................................................... 5-1
numerical ........................................................................................................ 1-10
saving to a file ................................................................................................. 4-30
text .................................................................................................................. 1-15
SIMULATION MODE ....................................................................................... 5-100
SINGLE LINE DIAGRAM ..................................................................................... 2-1
SLAVE ADDRESS .............................................................................................. 5-13
SOFTWARE
entering setpoints ........................................................................................... 4-21
hardware requirements ................................................................................... 4-10
installation ....................................................................................................... 4-12
loading setpoints ............................................................................................. 4-28
overview .......................................................................................................... 4-10
saving setpoints .............................................................................................. 4-30
serial communications ........................................................................... 4-15, 4-17
SPECIFICATIONS ................................................................................................ 2-6
SPEED ................................................................................................................ 6-21
STANDARD OVERLOAD CURVES
multipliers ........................................................................................................ 5-75
STARTER
information ...................................................................................................... 5-17
operations ....................................................................................................... 5-23
status .............................................................................................................. 5-21
STATOR GROUND FAULT PROTECTION .......................................................... A-1
STATUS LEDs ...................................................................................................... 4-2
T
TACHOMETER ................................................................................. 2-12, 5-26, 6-21
TEMPERATURE ................................................................................................. 6-19
TEMPERATURE DISPLAY .................................................................................. 5-10
TERMINAL LAYOUT ............................................................................................ 3-7
TERMINAL LIST ................................................................................................... 3-8
TERMINAL LOCATIONS ...................................................................................... 3-7
TERMINAL SPECIFICATIONS ........................................................................... 2-15
TEST ANALOG OUTPUT ................................................................................. 5-103
TEST INPUT ....................................................................................................... 5-23
TEST OUTPUT RELAYS ................................................................................... 5-102
TESTS
differential current accuracy ............................................................................ 7-5
ground current accuracy .......................................................................... 7-5, 7-15
list ...................................................................................................................... 7-1
negative-sequence current accuracy ............................................................... 7-6
neutral current accuracy ................................................................................... 7-5
neutral voltage accuracy ......................................................................... 7-6, 7-16
output current accuracy ................................................................................... 7-4
output relays ................................................................................................... 7-11
overload curves ............................................................................................... 7-12
phase current accuracy .................................................................................... 7-4
power measurement ....................................................................................... 7-13
production tests .............................................................................................. 2-14
reactive power ................................................................................................ 7-13
RTD accuracy ..................................................................................................... 7-7
secondary injection setup ................................................................................. 7-3

INDEX
voltage input accuracy ..................................................................................... 7-4

voltage phase reversal .................................................................................... 7-14
TEXT SETPOINTS .............................................................................................. 1-15
THERMAL CAPACITY USED ............................................................................... 6-4
THERMAL ELEMENTS ....................................................................................... 5-89
THERMAL MODEL
machine cooling .............................................................................................. 5-85
setpoints .......................................................................................................... 5-70
specifications .................................................................................................. 2-10
unbalance bias ................................................................................................ 5-84
THERMAL RESET ............................................................................................... 5-23
THIRD HARMONIC VOLTAGE ........................................................................... A-6
TIME .......................................................................................................... 5-13, 6-15
TIME OVERCURRENT CURVES ........................................................................ A-15
TIMERS .............................................................................................................. 6-27
TOC CHARACTERISTICS ................................................................................... 5-29
TOC CURVES .................................................................................................... A-15
TRIP COIL MONITOR ........................................................................................ 5-91
TRIP COIL SUPERVISION .......................................................................... 2-13, 7-9
TRIP COUNTER ............................................................................... 5-17, 5-90, 6-25
TRIP PICKUPS .................................................................................................... 6-9
TRIP RELAY .............................................................................................. 3-16, 5-28
TRIP TIME ON OVERLOAD, ESTIMATED ........................................................... 6-4
TRIPS .................................................................................................................. 5-6
TYPE TESTS ....................................................................................................... 2-15
TYPICAL WIRING DIAGRAM .............................................................................. 3-9
U
UNBALANCE BIAS ............................................................................................ 5-84
UNDERFREQUENCY ......................................................................................... 5-49
UNDERVOLTAGE ..................................................................................... 2-11, 5-43
UNPACKING THE RELAY ................................................................................... 1-1
UPGRADING FIRMWARE .................................................................................. 4-30
V
VIBRATION ........................................................................................................ 3-14
VOLTAGE DEPENDENT OVERLOAD CURVE ................................................... 5-77
VOLTAGE INPUTS
description ....................................................................................................... 3-14
specifications ................................................................................................... 2-6
testing .............................................................................................................. 7-4
VOLTAGE METERING ........................................................................................ 6-17
VOLTAGE RESTRAINED OVERCURRENT
setpoints .......................................................................................................... 5-35
testing ............................................................................................................. 7-20
VOLTAGE SENSING .......................................................................................... 5-18
VOLTS/HERTZ ................................................................................................... 5-45
VT FUSE FAILURE ............................................................................................. 5-92
VT RATIO ........................................................................................................... 5-18
VTFF .................................................................................................................. 5-92
VTs
open delta ....................................................................................................... 5-54

INDEX
setpoints .......................................................................................................... 5-18

wye connected ................................................................................................ 5-53
W
WARRANTY ............................................................................................. A-27, A-31
WAVEFORM CAPTURE ..................................................................................... 5-27
WIRING DIAGRAM ............................................................................................ 3-10
WITHDRAWAL .................................................................................................... 3-4
WYE ................................................................................................................... 3-14
WYE CONNECTED VTs ..................................................................................... 5-53

16 Jalan 51A/225,
Selangor, Malaysia
Documentation:
2.26 PQM-II Power Quality Meter
Digital Energy
Multilin
PQMII Power Quality Meter

Instruction Manual
Software Revision: 2.2x
Manual P/N: 1601-0118-AD
Manual Order Code: GEK-106435M
Copyright © 2010 GE Multilin
GE Multilin
215 Anderson Avenue, Markham, Ontario
Canada L6E 1B3
Tel: (905) 294-6222 Fax: (905) 201-2098
Internet: http://www.GEmultilin.com
GE Multilin's Quality Management

System is registered to ISO9001:2000
*1601-0118-AD* QMI # 005094

UL # A3775
© 2010 GE Multilin Incorporated. All rights reserved.
GE Multilin PQMII Power Quality Meter instruction manual for revision 2.2x.
PQMII Power Quality Meter, is a registered trademark of GE Multilin Inc.
The contents of this manual are the property of GE Multilin Inc. This documentation is
furnished on license and may not be reproduced in whole or in part without the permission
of GE Multilin. The content of this manual is for informational use only and is subject to
change without notice.
Part numbers contained in this manual are subject to change without notice, and should
therefore be verified by GE Multilin before ordering.
Part number: 1601-0118-AD (May 2010)

TABLE OF CONTENTS
Table of Contents
1: OVERVIEW INTRODUCTION TO THE PQMII ................................................................................................... 1-1

DESCRIPTION ........................................................................................................................ 1-1
FEATURE HIGHLIGHTS ......................................................................................................... 1-2
APPLICATIONS OF THE PQMII ........................................................................................... 1-2
STANDARD FEATURES ................................................................................................................... 1-5
METERING ............................................................................................................................. 1-5
ALARMS ................................................................................................................................. 1-5
COMMUNICATIONS .............................................................................................................. 1-5
FUTURE EXPANSION ............................................................................................................ 1-5
OPEN ARCHITECTURE ......................................................................................................... 1-6
OPTIONAL FEATURES ..................................................................................................................... 1-7
TRANSDUCER INPUT/OUTPUTS ......................................................................................... 1-7
CONTROL OPTION ............................................................................................................... 1-7
POWER ANALYSIS OPTION ................................................................................................. 1-8
ENERVISTA PQMII SETUP SOFTWARE ..................................................................................... 1-12
OVERVIEW ............................................................................................................................ 1-12
ORDER CODES ................................................................................................................................... 1-13
ORDER CODE TABLE ........................................................................................................... 1-13
MODIFICATIONS ................................................................................................................... 1-13
ACCESSORIES ....................................................................................................................... 1-13
CONTROL POWER ................................................................................................................ 1-13
SPECIFICATIONS ............................................................................................................................... 1-14
INPUTS/OUTPUTS ................................................................................................................ 1-14
TRACE MEMORY TRIGGER .................................................................................................. 1-15
SAMPLING MODES .............................................................................................................. 1-15
OUTPUT RELAYS .................................................................................................................. 1-15
METERING ............................................................................................................................. 1-16
MONITORING ........................................................................................................................ 1-16
SYSTEM ................................................................................................................................. 1-18
TESTING AND APPROVALS .................................................................................................. 1-18
PHYSICAL .............................................................................................................................. 1-20
2: INSTALLATION PHYSICAL CONFIGURATION ........................................................................................................ 2-1

MOUNTING ........................................................................................................................... 2-1
PRODUCT IDENTIFICATION .................................................................................................. 2-2
REVISION HISTORY .............................................................................................................. 2-2
ELECTRICAL CONFIGURATION ................................................................................................... 2-3
EXTERNAL CONNECTIONS .................................................................................................. 2-3
WIRING DIAGRAMS ............................................................................................................. 2-5
3-WIRE SYSTEM USING TWO CTS .................................................................................... 2-12
CONTROL POWER ................................................................................................................ 2-13
VT INPUTS ............................................................................................................................ 2-13
CT INPUTS ............................................................................................................................ 2-13
OUTPUT RELAYS .................................................................................................................. 2-14
SWITCH INPUTS (OPTIONAL) .............................................................................................. 2-14
ANALOG OUTPUTS (OPTIONAL) ......................................................................................... 2-16
ANALOG INPUT (OPTIONAL) ............................................................................................... 2-17
PQMII POWER QUALITY METER – INSTRUCTION MANUAL TOC–I

TABLE OF CONTENTS
RS485 SERIAL PORTS ........................................................................................................ 2-17

RS232 FRONT PANEL PORT ............................................................................................. 2-19
DIELECTRIC STRENGTH TESTING ........................................................................................ 2-19
3: OPERATION FRONT PANEL AND DISPLAY ....................................................................................................... 3-1

FRONT PANEL ...................................................................................................................... 3-1
DISPLAY ................................................................................................................................. 3-1
LED INDICATORS .............................................................................................................................. 3-2
DESCRIPTION ........................................................................................................................ 3-2
STATUS .................................................................................................................................. 3-2
COMMUNICATE ..................................................................................................................... 3-2
RELAYS .................................................................................................................................. 3-3
KEYPAD ................................................................................................................................................. 3-4
DESCRIPTION ........................................................................................................................ 3-4
MENU KEY ............................................................................................................................ 3-4
ESCAPE KEY .......................................................................................................................... 3-4
ENTER KEY ............................................................................................................................ 3-4
RESET KEY ............................................................................................................................ 3-4
MESSAGE KEYS .................................................................................................................... 3-5
VALUE KEYS ......................................................................................................................... 3-6
DATA ENTRY METHODS ...................................................................................................... 3-6
SETPOINT ACCESS SECURITY ............................................................................................. 3-7
DEFAULT MESSAGES ...................................................................................................................... 3-8
DESCRIPTION ........................................................................................................................ 3-8
ADDING A DEFAULT MESSAGE .......................................................................................... 3-8
DELETING A DEFAULT MESSAGE ....................................................................................... 3-8
DEFAULT MESSAGE SEQUENCE ......................................................................................... 3-9
4: SOFTWARE INTRODUCTION ................................................................................................................................ 4-1

OVERVIEW ............................................................................................................................ 4-1
HARDWARE ........................................................................................................................... 4-2
INSTALLING THE ENERVISTA PQMII SETUP SOFTWARE ................................................ 4-3
CONFIGURING SERIAL COMMUNICATIONS .......................................................................... 4-7
DESCRIPTION ........................................................................................................................ 4-7
UPGRADING FIRMWARE ............................................................................................................... 4-8
DESCRIPTION ........................................................................................................................ 4-8
SAVING SETPOINTS TO A FILE ............................................................................................ 4-8
LOADING NEW FIRMWARE ................................................................................................. 4-8
LOADING SAVED SETPOINTS .............................................................................................. 4-10
USING THE ENERVISTA PQMII SETUP SOFTWARE ............................................................. 4-11
ENTERING SETPOINTS ......................................................................................................... 4-11
VIEWING ACTUAL VALUES .................................................................................................. 4-12
SETPOINT FILES .................................................................................................................... 4-12
GETTING HELP ..................................................................................................................... 4-12
POWER ANALYSIS ............................................................................................................................ 4-13
WAVEFORM CAPTURE ......................................................................................................... 4-13
HARMONIC ANALYSIS ......................................................................................................... 4-13
TRACE MEMORY ................................................................................................................... 4-14
DATA LOGGER ...................................................................................................................... 4-16
VOLTAGE DISTURBANCE RECORDER ................................................................................. 4-18
USING ENERVISTA VIEWPOINT WITH THE PQMII ............................................................... 4-21
PLUG AND PLAY EXAMPLE ................................................................................................. 4-21
TOC–II PQMII POWER QUALITY METER – INSTRUCTION MANUAL

TABLE OF CONTENTS
5: SETPOINTS INTRODUCTION ................................................................................................................................ 5-1

SETPOINT ENTRY METHODS ............................................................................................... 5-1
SETPOINTS MAIN MENU ..................................................................................................... 5-2
S1 PQMII SETUP ................................................................................................................................ 5-5
DESCRIPTION ........................................................................................................................ 5-5
PREFERENCES ....................................................................................................................... 5-5
SETPOINT ACCESS ............................................................................................................... 5-6
SERIAL PORTS ...................................................................................................................... 5-7
DNP 3.0 CONFIGURATION ................................................................................................ 5-8
CLOCK ................................................................................................................................... 5-9
CALCULATION PARAMETERS .............................................................................................. 5-10
CLEAR DATA ......................................................................................................................... 5-12
EVENT RECORDER ............................................................................................................... 5-13
TRACE MEMORY ................................................................................................................... 5-14
PROGRAMMABLE MESSAGE ............................................................................................... 5-17
PRODUCT OPTIONS ............................................................................................................. 5-18
S2 SYSTEM SETUP ............................................................................................................................ 5-19
CURRENT AND VOLTAGE CONFIGURATION ...................................................................... 5-19
ANALOG OUTPUTS .............................................................................................................. 5-21
ANALOG INPUT .................................................................................................................... 5-25
SWITCH INPUTS ................................................................................................................... 5-27
PULSE OUTPUT .................................................................................................................... 5-28
PULSE INPUT ........................................................................................................................ 5-29
DATA LOGGER ...................................................................................................................... 5-30
VOLTAGE DISTURBANCE ..................................................................................................... 5-30
S3 OUTPUT RELAYS ......................................................................................................................... 5-32
DESCRIPTION ........................................................................................................................ 5-32
ALARM RELAY ...................................................................................................................... 5-32
AUXILIARY RELAYS ............................................................................................................... 5-32
S4 ALARMS/CONTROL ................................................................................................................... 5-34
CURRENT/VOLTAGE ALARMS ............................................................................................. 5-34
HARMONIC DISTORTION ..................................................................................................... 5-39
FREQUENCY .......................................................................................................................... 5-40
POWER ALARMS .................................................................................................................. 5-41
POWER FACTOR ................................................................................................................... 5-43
DEMAND ALARMS ................................................................................................................ 5-46
PULSE INPUT ........................................................................................................................ 5-48
TIME ....................................................................................................................................... 5-49
MISCELLANEOUS ALARMS .................................................................................................. 5-50
S5 TESTING ......................................................................................................................................... 5-51
TEST RELAYS AND LEDS .................................................................................................... 5-51
CURRENT/VOLTAGE ............................................................................................................ 5-51
ANALOG OUTPUTS .............................................................................................................. 5-52
ANALOG INPUT .................................................................................................................... 5-53
SWITCH INPUTS ................................................................................................................... 5-53
FACTORY USE ONLY ........................................................................................................... 5-54
6: MONITORING ACTUAL VALUES VIEWING ........................................................................................................... 6-1

DESCRIPTION ........................................................................................................................ 6-1
ACTUAL VALUES MENU ...................................................................................................... 6-2
A1 METERING ..................................................................................................................................... 6-4
CURRENT METERING ........................................................................................................... 6-4
PQMII POWER QUALITY METER – INSTRUCTION MANUAL TOC–III

TABLE OF CONTENTS
VOLTAGE METERING ........................................................................................................... 6-6

PHASORS .............................................................................................................................. 6-8
POWER METERING .............................................................................................................. 6-8
ENERGY METERING .............................................................................................................. 6-12
DEMAND METERING ............................................................................................................ 6-14
FREQUENCY METERING ....................................................................................................... 6-15
PULSE INPUT COUNTERS .................................................................................................... 6-16
ANALOG INPUT .................................................................................................................... 6-17
A2 STATUS ........................................................................................................................................... 6-18
ALARMS ................................................................................................................................. 6-18
SWITCH STATUS ................................................................................................................... 6-20
CLOCK ................................................................................................................................... 6-21
PROGRAMMABLE MESSAGE ................................................................................................ 6-21
A3 POWER ANALYSIS ..................................................................................................................... 6-22
POWER QUALITY .................................................................................................................. 6-22
THD ...................................................................................................................................... 6-22
DATA LOGGER ...................................................................................................................... 6-24
EVENT RECORDER ................................................................................................................ 6-24
VOLTAGE DISTURBANCE ..................................................................................................... 6-28
A4 PRODUCT INFO .......................................................................................................................... 6-30
SOFTWARE VERSIONS ......................................................................................................... 6-30
MODEL INFORMATION ......................................................................................................... 6-30
7: APPLICATIONS EVENT RECORDER ............................................................................................................................ 7-1

LIST OF EVENTS ................................................................................................................... 7-1
ACCESS TO EVENT RECORDER INFORMATION ................................................................. 7-6
INTERFACING USING HYPERTERMINAL .................................................................................. 7-8
UPGRADING FIRMWARE ...................................................................................................... 7-8
CYCLING POWER ................................................................................................................. 7-8
HYPERTERMINAL .................................................................................................................. 7-8
PHASOR IMPLEMENTATION ......................................................................................................... 7-11
THEORY OF PHASOR IMPLEMENTATION ............................................................................ 7-11
TRIGGERED TRACE MEMORY ...................................................................................................... 7-13
DESCRIPTION ........................................................................................................................ 7-13
PULSE OUTPUT ................................................................................................................................. 7-14
PULSE OUTPUT CONSIDERATIONS .................................................................................... 7-14
CONNECTING TO AN END RECEIVER USING KYZ TERMINALS ...................................... 7-14
DATA LOGGER IMPLEMENTATION ............................................................................................ 7-16
DATA LOGGER STRUCTURE ................................................................................................ 7-16
MODES OF OPERATION ....................................................................................................... 7-17
ACCESSING DATA LOG INFORMATION .............................................................................. 7-17
INTERPRETING DATA LOG INFORMATION ......................................................................... 7-17
DATA LOG PARAMETERS ..................................................................................................... 7-20
READING LONG INTEGERS FROM THE MEMORY MAP ..................................................... 7-21
DESCRIPTION ........................................................................................................................ 7-21
EXAMPLE ............................................................................................................................... 7-21
PULSE INPUT APPLICATION ......................................................................................................... 7-23
DESCRIPTION ........................................................................................................................ 7-23
PQMII PULSE INPUT(S) WITH A PULSE INITIATOR USING KYZ TERMINALS ................ 7-23
PULSE TOTALIZER APPLICATION ............................................................................................... 7-24
DESCRIPTION ........................................................................................................................ 7-24
TOTALIZING ENERGY FROM MULTIPLE METERING LOCATIONS ..................................... 7-24
TOC–IV PQMII POWER QUALITY METER – INSTRUCTION MANUAL

TABLE OF CONTENTS
8: WARRANTY GE MULTILIN DEVICE WARRANTY ............................................................................................ 8-1

WARRANTY STATEMENT ..................................................................................................... 8-1
APPENDIX A MOD 506: CAPACITOR BANK SWITCHING ............................................................................ A-1

DESCRIPTION ........................................................................................................................ A-1
SETPOINTS ............................................................................................................................ A-1
ACTUAL VALUES .................................................................................................................. A-3
CONDITIONS REQUIRED TO ENERGIZE A STEP ............................................................... A-4
ADDITIONS TO MODBUS MEMORY MAP .......................................................................... A-5
REVISION HISTORY .......................................................................................................................... A-7
RELEASE DATES ................................................................................................................... A-7
RELEASE NOTES ................................................................................................................... A-7
INDEX
PQMII POWER QUALITY METER – INSTRUCTION MANUAL TOC–V

TABLE OF CONTENTS
TOC–VI PQMII POWER QUALITY METER – INSTRUCTION MANUAL

Digital Energy
Multilin
Chapter 1: Overview
Overview
1.1 Introduction to the PQMII
1.1.1 Description
The GE Multilin PQMII Power Quality Meter is an ideal choice for continuous monitoring of a
single or three-phase system. It provides metering for current, voltage, real power, reactive
power, apparent power, energy use, cost of power, power factor, and frequency.
Programmable setpoints and four assignable output relays allow control functions to be
added for specific applications. This includes basic alarm on over/under current or voltage,
unbalance, demand-based load shedding, and capacitor power factor correction control.
More complex control is possible using the four switch inputs; these can also be used for
status information such as breaker open/closed and flow information.
As a data gathering device for plant automation systems that integrate process,
instrument, and electrical requirements, all monitored values are available via one of two
RS485 communication ports running the Modbus protocol. If analog values are required
for direct interface to a PLC, any of the monitored values can output as a 4 to 20 mA (or 0
to 1 mA) signal to replace up to four (4) separate transducers. A third RS232
communication port connects to a PC from the front panel for simultaneous access of
information by other plant personnel.
With increasing use of electronic loads such as computers, ballasts, and variable
frequency drives, the quality of the power system is important. With the harmonic analysis
option, any phase current or voltage can be displayed and the harmonic content
calculated. Knowledge of the harmonic distribution allows action to be taken to prevent
overheated transformers, motors, capacitors, neutral wires, and nuisance breaker trips.
Redistribution of system loading can also be determined. The PQMII can also provide
waveform and data printouts to assist in problem diagnosis.
PQMII POWER QUALITY METER – INSTRUCTION MANUAL 1–1

CHAPTER 1: OVERVIEW
1.1.2 Feature Highlights

• Monitoring: A, V, VA, W, var, kWh, kvarh, kVAh, PF, Hz
• Demand metering: W, var, A, VA
• Setpoints for alarm or control from most measured values, including: unbalance,
frequency, power factor, voltage, and current
• four (4) output relays / four (4) switch inputs for flexible control configuration
• four (4) isolated analog outputs replace transducers for PLC interface
• one 4 to 20 mA analog input
• Modbus communications
• Three COM ports (two rear RS485 ports and one front RS232 port) for access by
process, electrical, maintenance, and instrument personnel
• Harmonic analysis for power quality review and problem correction
• 40-character display and keypad for local programming
• No-charge EnerVista PQMII Setup Software
• Simulation mode for testing and training
• Compact design for panel mount
• AC/DC control power
1.1.3 Applications of the PQMII

• Metering of distribution feeders, transformers, generators, capacitor banks, and
motors
• Medium and low voltage three-phase systems
• Commercial, industrial, utility
• Flexible control for demand load shedding, power factor, etc.
• Power quality analysis
• System debugging
1–2 PQMII POWER QUALITY METER – INSTRUCTION MANUAL

CHAPTER 1: OVERVIEW
Three-phase
3/4-wire bus
0 to 600 V direct
> 600V CT/VTs CTs VTs
Control PQMII
power –
(AC/DC)
Four switch
inputs for
control
Main
COM 1
SCADA
Four (4)
output Alarm
Instrumentation control
Electrical COM 2 relays
Maintenance
1
4 to 20 mA
RS232 Four (4) PLC
2
PORT transducer 3
or
outputs 4 RTU
PC running
EnerVista PQMII Setup 746701A1.CDR
FIGURE 1–1: Single Line Diagram

CHAPTER 1: OVERVIEW
FIGURE 1–2: Feature Highlights

CHAPTER 1: OVERVIEW
1.2 Standard Features
1.2.1 Metering
True RMS monitoring of Ia, Ib, Ic, In, Van, Vbn, Vcn, Vab, Vbc, Vca, voltage/current
unbalance, power factor, line frequency, watts, vars, VA, Wh, varh, VAh, and demand
readings for A, W, vars, and VA. Maximum and minimum values of measured quantities are
recorded and are date and time stamped.
A 40-character liquid crystal display is used for programming setpoints and monitoring
values and status.
1.2.2 Alarms
Alarm conditions can be set up for all measured quantities. These include overcurrent,
undercurrent, neutral current, current unbalance, voltage unbalance, phase reversal,
overfrequency, underfrequency, power factor, switch inputs, etc. The alarm messages are
displayed in a simple and easy to understand English format.
The PQMII is equipped with one standard RS485 port utilizing the Modbus or DNP
protocols. This can be used to integrate process, instrumentation, and electrical
requirements in a plant automation system by connecting several PQMII meters together
to a DCS or SCADA system. A PC running the EnerVista PQMII Setup Software can change
system setpoints and monitor values, status, and alarms. Continuous monitoring
minimizes process downtime by immediately identifying potential problems due to faults
or changes from growth.
The PQMII also includes a front RS232 port which can be used for the following tasks:
• data monitoring
• problem diagnosis
• viewing event records
• trending
• printing settings and/or actual values
• loading new firmware into the PQMII
1.2.4 Future Expansion

Flash memory is used to store firmware within the PQMII. This allows future product
upgrades to be loaded via the serial port.

CHAPTER 1: OVERVIEW
FIGURE 1–3: Downloading Product Enhancements via the Serial Port
1.2.5 Open Architecture

PQMII units can initially be used as standalone meters. Their open architecture allows
connection to other Modbus compatible devices on the same communication link. These
can be integrated in a complete plant-wide system for overall process monitoring and
control.

CHAPTER 1: OVERVIEW
1.3 Optional Features
1.3.1 Transducer Input/Outputs

Four isolated 4 to 20 mA (or 0 to 1 mA depending on the installed option) analog outputs
are provided that can replace up to eight transducers. The outputs can be assigned to any
measured parameters for direct interface to a PLC.
One 4 to 20 mA analog input is provided to accept a transducer output for displaying
information such as temperature or water level.
An additional rear RS485 communication port is provided for simultaneous monitoring by
process, instrument, electrical, or maintenance personnel.
FIGURE 1–4: Additional Communication Port
1.3.2 Control Option

An additional three dry-contact form “C” output relays and four dry-contact switch inputs
are provided. These additional relays can be combined with setpoints and inputs/outputs
for control applications. Possibilities include:
• undercurrent alarm warnings for pump protection
• overvoltage/undervoltage for generators
• unbalance alarm warnings to protect rotating machines
• dual level power factor for capacitor bank switching
• underfrequency/demand output for load shedding resulting in power cost saving
• kWh, kvarh and kVAh pulse output for PLC interface
• Pulse input for totalizing quantities such as kWh, kvarh, kVAh, etc.

CHAPTER 1: OVERVIEW
FIGURE 1–5: Switch Inputs and Outputs Relays
1.3.3 Power Analysis Option

Non-linear loads (such as variable speed drives, computers, and electronic ballasts) can
cause unwanted harmonics that may lead to nuisance breaker tripping, telephone
interference, and transformer, capacitor or motor overheating. For fault diagnostics such
as detecting undersized neutral wiring, assessing the need for harmonic rated
transformers, or judging the effectiveness of harmonic filters, details of the harmonic
spectrum are useful and available with the power analysis option.
FIGURE 1–6: Harmonic Spectrum

CHAPTER 1: OVERVIEW
Voltage and current waveforms can be captured and displayed on a PC with the EnerVista
PQMII Setup Software or EnerVista Viewpoint. Distorted peaks or notches from SCR
switching provide clues for taking corrective action.
FIGURE 1–7: Captured Waveform
Alarms, triggers, and input/output events can be stored in a 150-event record and time/
date stamped by the internal clock. This is useful for diagnosing problems and system
activity. The event record is available through serial communication. Minimum and
maximum values are also continuously updated and time/date stamped.

CHAPTER 1: OVERVIEW
FIGURE 1–8: Data Logger
Routine event logs of all measured quantities can be created, saved to a file, and/or
printed.
For additional information on waveform sampling and analysis features, see Power
Analysis on page 4–13.
The power analysis option also provides a Trace Memory feature. This feature can be used
to record specified parameters based on the user defined triggers.

CHAPTER 1: OVERVIEW
FIGURE 1–9: Trace Memory Capture

CHAPTER 1: OVERVIEW
1.4 EnerVista PQMII Setup Software
1.4.1 Overview
All data continuously gathered by the PQMII can be transferred to a third party software
program for display, control, or analysis through the communications interface. The
EnerVista PQMII Setup Software allows the user to view and manipulate this data and
assists in programming the PQMII. Some of the tasks that can be executed using the
EnerVista PQMII Setup Software package include:
• reading metered data
• monitoring system status
• changing PQMII setpoints on-line
• saving setpoints to a file and downloading into any PQMII
• capturing and displaying voltage and current waveforms for analysis
• recording demand profiles for various measured quantities
• troubleshooting communication problems with a built in debugger
• printing graphs, charts, setpoints, and actual values
The EnerVista PQMII Setup Software is fully described in Software on page 4–1.
FIGURE 1–10: EnerVista PQMII Setup Software Main Window

CHAPTER 1: OVERVIEW
1.5 Order Codes
1.5.1 Order Code Table

The order code for all options is: PQMII-T20-C-A
Table 1–1: Order Codes

PQMII S S S
| | | Basic unit with display, all current/voltage/power
|
Basic Unit PQMII – – || – || measurements, one (1) RS485 communication port,
|
| | | one (1) RS232 communication port
| | Four (4) isolated analog outputs, 0-20 mA and 4-20
T20 – | – ||
|
mA assignable to all measured parameters, 4-20 mA
| | analog input, 2nd RS485 communication port
Transducer
Option | | Four (4) isolated analog outputs, 0-1 mA assignable
| – |
T1 | | to all measured parameters, 4-20 mA analog input,
| | 2nd RS485 communication port
| Three (3) additional programmable output relays (for
Control C – |
Option | a total of 4), 4 programmable switch inputs
Harmonic analysis, triggered trace memory,
Power Analysis
Option A waveform capture, event recorder, data logger,
voltage disturbance recorder*
* The voltage disturbance recorder is only available with the 25 MHz processor.
1.5.2 Modifications
Consult the factory for any additional modification costs):
• MOD 501: 20 to 60 V DC / 20 to 48 V AC Control Power
• MOD 502: Tropicalization
• MOD 504: Removable Terminal Blocks
• MOD 506: 4-Step Capacitor Bank Switching (Available with Option "C" only)
1.5.3 Accessories
Consult the factory for any additional accessory costs:
• EnerVista PQMII Setup Software (included with the PQMII; also available at http://
www.enerVista.com)
• RS232 to RS485 converter (required to connect a PC to the PQMII RS485 ports)
• GE MultiNET RS485 serial-to-Ethernet converter (required for connection to an
Ethernet network)
• RS485 terminating network
1.5.4 Control Power

• 90 to 300 V DC / 70 to 265 V AC standard
• 20 to 60 V DC / 20 to 48 V AC (MOD 501)

CHAPTER 1: OVERVIEW
1.6 Specifications
Specifications are subject to change without notice.
Note
1.6.1 Inputs/Outputs
CURRENT INPUTS
Conversion:...................................................true RMS, 64 samples/cycle
CT Input: .........................................................1 A and 5 A secondary
Burden: ...........................................................0.2 VA
Overload: .......................................................20 × CT for 1 sec.
100 × CT for 0.2 sec.
Range: .............................................................1 to 150% of CT primary
Full Scale:.......................................................150% of CT primary
Frequency: ....................................................up to 32nd harmonic
Accuracy:.......................................................±0.2% of full scale at <1.20 x CT
VOLTAGE INPUTS
Conversion:...................................................true RMS, 64 samples/cycle
VT pri./sec.:....................................................120 to 72000 : 69 to 240, or Direct
VT Ratio: .........................................................1:1 to 3500:1
Burden: ...........................................................2.2 MΩ
Input Range:.................................................40 to 600 V AC
Full scale:
for VT input ≤150 V AC: ......................150 V AC
for VT input >150 V AC: ......................600 V AC
Frequency: ....................................................up to 32nd harmonic
Accuracy:.......................................................±0.2% of full scale
SWITCH INPUTS
Type:.................................................................dry contacts
Resistance:....................................................1000 Ω max ON resistance
Output:............................................................24 V DC at 2 mA (pulsed)
Duration: ........................................................100 ms minimum
ANALOG OUTPUT (0–1 MA)
Max. load: ......................................................2400 Ω
Max. output: .................................................1.1 mA
Accuracy:.......................................................±1% of full-scale reading
Isolation:.........................................................±36 V DC isolated, active source
ANALOG OUTPUT (4–20 MA)
Max. load: ......................................................600 Ω
Max. output: .................................................21 mA
Accuracy:.......................................................±1% of full-scale reading
Isolation:.........................................................±36 V DC isolated, active source
PULSE OUTPUT
Parameters:..................................................+kWh, –kWh, +kvarh, –kvarh, kVAh
Interval:...........................................................1 to 65000 in steps of 1
Pulse width: ..................................................100 to 2000 ms in steps of 10
Minimum pulse interval: ........................500 ms
Accuracy:.......................................................±10 ms

CHAPTER 1: OVERVIEW
PULSE INPUT
Max. inputs:.................................................. 4
Min. pulse width: ....................................... 150 ms
Min. off time:................................................ 200 ms
1.6.2 Trace Memory Trigger

TRACE MEMORY TRIGGER
Input ................................................................ 2 data cycles (current, voltage)
Time delay:................................................... 0 to 30 cycles
Current input full scale: ......................... 150% of CT primary
Voltage input full scale: ......................... 600 V AC
TRIGGER LEVEL PICKUP ACCURACY
Overcurrent:................................................. ±2% of full scale
Overvoltage: ................................................ ±2% of full scale
Undervoltage: ............................................ ±3% of full scale
1.6.3 Sampling Modes

METERED VALUES
Samples per cycle: ................................... 64
Inputs sampled at a time: .................... all
Duration:........................................................ 2 cycles
TRACE MEMORY
Samples per cycle: ................................... 16
Inputs sampled at a time: .................... all
Duration:........................................................ continuous
HARMONIC SPECTRUM
Samples per cycle: 256
Inputs sampled at a time: 1
Duration:........................................................ 1 cycle
VOLTAGE DISTURBANCE RECORDER
Samples per half-cycle: ......................... 8
Inputs sampled: ........................................ all measured voltages
Duration: ...................................................... 0.5 cycles to 1 minute
1.6.4 Output Relays

MAKE/CARRY
Continuous:.................................................. 5 A
0.1 second: ................................................... 30 A
BREAK
Resistive:........................................................ 5 A at 30 V DC, 125/250 V AC
0.5 A at 125 V DC
0.3 A at 250 V DC
Inductive (L/R = 7 ms): ............................. 5 A at 30 V DC, 125/250 V AC
0.25 A at 125 V DC
0.15 A at 250 V DC

CHAPTER 1: OVERVIEW
1.6.5 Metering
MEASURED VALUES ACCURACY (SPECIFIED FOR 0 TO 40°C)
Voltage:...........................................................±0.2% of full-scale
Current:...........................................................±0.2% of full-scale
Voltage unbalance: ..................................±1% of full-scale
Current unbalance: ..................................±1% of full-scale
kW:....................................................................±0.4% of full scale
kvar: ................................................................±0.4% of full scale
kVA: ..................................................................±0.4% of full scale
kWh: ................................................................±0.4% of full scale
kvarh: ..............................................................±0.4% of full scale
kVAh: ...............................................................±0.4% of full scale
Power factor: ...............................................±1% of full-scale
Frequency: ....................................................±0.02 Hz
kW demand:.................................................±0.4% of full-scale
kvar demand:...............................................±0.4% of full-scale
kVA demand:................................................±0.4% of full-scale
Current demand: .......................................±0.4% of full-scale
Current THD:.................................................±2.0% of full-scale
Voltage THD: ................................................±2.0% of full-scale
Crest factor:..................................................±0.4% of full-scale
MEASURED VALUES RANGE
Voltage:...........................................................20 to 100% of VT
Current:...........................................................1 to 150% of CT
Voltage unbalance: ..................................0 to 100%
Current unbalance: ..................................0 to 100%
Real power:...................................................0 to ±999,999.99 kW
Reactive power: .........................................0 to ±999,999.99 kvar
Apparent power: .......................................0 to 999,999.99 kVA
Real energy:..................................................232 kWh
Reactive energy: ........................................232 kvarh
Apparent energy: ......................................232 kVAh
Power factor: ...............................................0.00 to ±1.00
Frequency: ....................................................20.00 to 70.00 Hz
kw demand:..................................................0 to ±999,999.99 kW
kvar demand:...............................................0 to ±999,999.99 kvar
kVA demand:................................................0 to 999,999.99 kVA
Current demand: .......................................0 to 7500 A
THD (current and voltage): ...................0.0 to 100.0%
Crest factor:..................................................1 to 9.99
1.6.6 Monitoring
UNDERVOLTAGE MONITORING
Req’d voltage: .............................................>20 V applied in all phases
Pickup:.............................................................0.50 to 0.99 × VT in steps of 0.01
Dropout: .........................................................103% of pickup
Time delay: ...................................................0.5 to 600.0 s in steps of 0.5
Phases:............................................................Any 1 / Any 2 / All 3 (programmable) have to be ≤
pickup to operate
Accuracy:.......................................................per voltage input

CHAPTER 1: OVERVIEW
Timing accuracy: ...................................... –0 / +1 sec.

OVERVOLTAGE MONITORING
Pickup: ............................................................ 1.01 to 1.25 × VT in steps of 0.01
Dropout:......................................................... 97% of pickup
Time delay:................................................... 0.5 to 600.0 s in steps of 0.5
Phases:........................................................... Any 1 / Any 2 / All 3 (programmable) must be ≥ pickup
to operate
Accuracy: ...................................................... Per voltage input
Timing accuracy: ...................................... –0 / +1 sec.
UNDERFREQUENCY MONITORING
Req’d voltage: ............................................ >30 V applied in phase A
Pickup: ............................................................ 20.00 to 70.00 Hz in steps of 0.01
Dropout:......................................................... Pickup + 0.03 Hz
Accuracy: ...................................................... 0.02 Hz
Timing accuracy: ±100 ms
OVERFREQUENCY MONITORING
Pickup: ............................................................ 20.00 to 70.00 Hz in steps of 0.01
Dropout:......................................................... Pickup – 0.03 Hz
Accuracy: ...................................................... 0.02 Hz
Timing accuracy: ±100 ms
POWER FACTOR MONITORING
Pickup: ............................................................ 0.50 lag to 0.50 lead step 0.01
Dropout:......................................................... 0.50 lag to 0.50 lead step 0.01
Timing accuracy: ...................................... –0.5/+1 sec.
DEMAND MONITORING
Measured values: ..................................... Phase A/B/C/N Current (A)
3φ Real Power (kW)
3φ Reactive Power (kvar)
3φ Apparent Power (kVA)
Measurement type (programmable):
Thermal Exponential, 90% response time: 5 to 60 min. in steps of 1
Block interval: ............................................ 5 to 60 min. in steps of 1
Rolling Demand Time Interval: .......... 5 to 60 min. in steps of 1
Pickup: ............................................................ 10 to 7500 A in steps of 1
1 to 65000 kW in steps of 1
1 to 65000 kvar in steps of 1
1 to 65000 kVA in steps of 1
VOLTAGE DISTURBANCE RECORDER
Required voltage: ..................................... >20 V or 10% (whichever is greater) applied in each
measured phase
Minimum nominal voltage: .................. 60 V
Phases recorded: ...................................... all three phases recorded independently
Conversion: .................................................. true RMS, 8 samples/half-cycle
Sag:
Pickup level: .............................................. 0.20 to 0.90 × VT in steps of 0.01
Dropout level: .......................................... pickup + 10% of nominal

CHAPTER 1: OVERVIEW
Swell:
Pickup level: ..............................................1.01 to 1.50 × VT in steps of 0.01
Dropout level: ...........................................pickup – 10% of nominal
1.6.7 System
COMMUNICATIONS
COM1/2: .........................................................RS485 2-wire, half duplex, isolated
COM3:..............................................................RS232 9-pin
Baud rate:......................................................1200 to 19200
Protocols:.......................................................Modbus® RTU; DNP 3.0
Functions:......................................................Read/write setpoints, read actual values, execute
commands, read device status
loopback test
CLOCK
Accuracy:.......................................................±1 min. / 30 days at 25±5°C
Resolution:.....................................................1 sec.
CONTROL POWER
Input:................................................................90 to 300 V DC or 70 to 265 V AC at 50/60 Hz
Power: .............................................................nominal 10 VA, max. 20 VA
Holdup: ...........................................................100 ms typical (at 120 V AC / 125 V DC)
It is recommended that the PQMII be powered up at least once per year to avoid
deterioration of the electrolytic capacitors in the power supply.
FUSE TYPE/RATING
5 × 20mm, 2.5 A, 250V
Slow blow, High breaking capacity
1.6.8 Testing and Approvals

TYPE TESTS
TEST REFERENCE STANDARD TEST LEVEL
Dielectric voltage withstand 2300-3700VAC
Impulse voltage withstand EN60255-5 5KV
Insulation resistance 500VDC >100mohm
Damped Oscillatory IEC61000-4-18IEC60255-22-1 2.5KV CM, 1KV DM
Electrostatic Discharge EN61000-4-2/IEC60255-22-2 Level II
RF immunity EN61000-4-3/IEC60255-22-3 10V/m 80-1Ghz
Fast Transient Disturbance EN61000-4-4/IEC60255-22-4 Class A and B
Surge Immunity EN61000-4-5/IEC60255-22-5 4Kv, 2KV
Conducted RF Immunity EN61000-4-6/IEC60255-22-6 10Vrms
Radiated & Conducted Emissions CISPR11 /CISPR22/ IEC60255-25 Class A

CHAPTER 1: OVERVIEW
Sinusoidal Vibration IEC60255-21-1 Class 1
Shock & Bump IEC60255-21-2 Class 1
Power magnetic Immunity IEC61000-4-8 Level 4
Pulse Magnetic Immunity IEC61000-4-9 Level 4
0,40,70,% dips,250/
Voltage Dip & interruption IEC61000-4-11
300cycle interrupts
Ingress Protection IEC60529 IP40 front , IP20 Back
Environmental (Cold) IEC60068-2-1 -10C 16 hrs
Environmental (Dry heat) IEC60068-2-2 70C 16hrs
Relative Humidity Cyclic IEC60068-2-30 6day variant 2
EFT IEEE/ANSI C37.90.1 4KV, 2.5Khz
Damped Oscillatrory IEEE/ANSI C37.90.1 2.5KV,1Mhz
Altitude: 2000m (max)
Pollution Degree: II
Overvoltage Category: II
Ingress protection: IP40 Front , IP20 back
APPROVALS
APPROVALS
Applicable Council Directive According to
Low voltage directive EN60255-5
CE compliance EMC Directive EN61000-6-2
UL508
North America cULus e83849 NKCR/7 UL1053
C22.2.No 14
Manufactured under a registered

ISO ISO9001
quality program
ENVIRONMENTAL
Ambient temperatures:
Operating range: -10C to 60C
Operating up to 95% (non condensing) @ 55C (As per

Humidity:
IEC60068-2-30 Variant 2, 6days)

CHAPTER 1: OVERVIEW
No special ventilation required as long as ambient

temperature remains within specifications.
Ventillation:
Ventilation may be required in enclosures exposed to
direct sunlight.
Cleaning: May be cleaned with a damp cloth.
1.6.9 Physical
PACKAGING
Shipping box: ..............................................8½” × 6” × 6” (L × H × D)
21.5cm × 15.2cm × 15.2 cm

Digital Energy
Multilin
Chapter 2: Installation
Installation
2.1 Physical Configuration
2.1.1 Mounting
Physical dimensions and required cutout dimensions for the PQMII are shown below. Once
the cutout and mounting holes are made in the panel, use the eight #6 self-tapping screws
provided to secure the PQMII. Mount the unit on a panel or switchgear door to allow
operator access to the keypad and indicators.
FIGURE 2–1: Physical Dimensions

2.1.2 Product Identification

Product attributes vary according to the configuration and options selected on the
customer order. Before applying power to the PQMII, examine the label on the back and
ensure the correct options are installed.
The following section explains the information included on the label shown below:
g PQM II MODEL NO.: PQMII-T20-C-A VERSION: 100.000
MAXIMUM CONTACT RATING 90-300VDC 20VA

CONTROL VOLTAGE: 70-265VAC 50/60HZ 20VA SERIAL No.: C7360001
250 VAC 10A RESISTIVE
1/4HP 250VAC 1/2HP 125VAC
MADE IN
CANADA
CUSTOMER TAG No.: 1234-567-89
9 10 11 12 13 14 15 16 17 18 19 20
FIGURE 2–2: Product Label
• Model No: Shows the PQMII configuration. The model number for a basic panel
mount PQMII is “PQMII”. T20, C, and A appear in the model number only if the
Transducer, Control, or Power Analysis options are installed.
• Supply Voltage: Indicates the power supply input configuration installed in the
PQMII. The PQMII shown in this example can accept any AC 50/60Hz voltage from
70 to 265 V AC or DC voltage from 90 to 300 V DC.
• Tag#: An optional identification number specified by the customer.
• Mod#: Indicates if any unique features have been installed for special customer
orders. This number should be available when contacting GE Multilin for technical
support.
• Version: An internal GE Multilin number that should be available when contacting
us for technical support.
• Serial No.: Indicates the serial number in numeric and barcode formats. Record
this number when contacting GE Multilin for technical support.
2.1.3 Manual and Firmware Revisions

Each instruction manual revision corresponds to a particular firmware revision. The
manual revision is located on the title page as part of the manual part number (the format
is 1601-nnnn-revision). The firmware revision is located on that same page, just above the
manual part number, and is also loaded in the PQMII, where it can be viewed by scrolling
to the A4 PRODUCT INFO ÖØ SOFTWARE VERSIONS ÖØ MAIN PROGRAM VERSION message.
When using the instruction manual to determine PQMII features and settings, ensure that
the instruction manual revision corresponds to the firmware revision installed in the PQMII.

2.2 Electrical Configuration
2.2.1 External Connections

Signal wiring is to Terminals 21 to 51. These terminals accommodate wires sizes up to 12
gauge. Please note that the maximum torque that can be applied to terminals 21 to 51 is
0.5 Nm (or 4.4 in ·lb.). CT, VT, and control power connections are made using Terminals 1 to
20. These #8 screw ring terminals accept wire sizes as large as 8 gauge. Consult the wiring
diagrams for suggested wiring. A minimal configuration includes connections for control
power, phase CTs/VTs, and the alarm relay; other features can be wired as required.
Considerations for wiring each feature are given in the sections that follow.
Table 2–1: PQMII External Connections
VT / Control Power Row (1 to 8) 25 Analog out 4+
1 V1 Voltage input 26 Analog out 3+
4 Vn Voltage input 29 Switch 4 input
5 Filter ground 30 Switch 3 input
6 Safety ground 31 Switch 2 input
7 Control neutral (–) 32 Switch 1 input
8 Control live (+) 33 +24 V DC switch com
CT Row (9 to 20) 34 Aux3 relay NC
9 Phase A CT 5A 35 Aux3 relay COM
10 Phase A CT 1A 36 Aux3 relay NO
11 Phase A CT COM 37 Aux2 relay NC
12 Phase B CT 5A 38 Aux2 relay COM
13 Phase B CT 1A 39 Aux2 relay NO
14 Phase B CT COM 40 Aux1 relay NC
15 Phase C CT 5A 41 Aux1 relay COM
16 Phase C CT 1A 42 Aux1 relay NO
17 Phase C CT COM 43 Alarm relay NC
18 Neutral CT 5A 44 Alarm relay COM
19 Neutral CT 1A 45 Alarm relay NO
20 Neutral CT COM 46 Comm 1 COM

Table 2–1: PQMII External Connections
Signal Upper Row (21 to 51) 47 Comm 1 –
21 Analog shield 48 Comm 1 +
22 Analog in – 49 Comm 2 COM
23 Analog in + 50 Comm 2 –
24 Analog out com 51 Comm 2 +

2.2.2 Wiring Diagrams

This wiring diagram below shows the typical 4-wire wye connection which will cover any
voltage range. Select the S2 SYSTEM SETUP ÖØ CURRENT/VOLTAGE CONFIGURATION ÖØ VT
WIRING: “4 Wire Wye (3 VTs)” setpoint
FIGURE 2–3: Wiring Diagram 4-wire Wye (3 VTs)

The 2½ element 4-wire wye connection can be used for situations where cost or size
restrictions limit the number of VTs to two. With this connection, Phase Vbn voltage is
calculated using the two existing voltages. Select the S2 SYSTEM SETUP ÖØ CURRENT/VOLTAGE
CONFIGURATION ÖØ VT WIRING: “4 WIRE WYE (2 VTs)” setpoint.
This wiring configuration will only provide accurate power measurements if the voltages
are balanced.

FIGURE 2–4: Wiring Diagram 4-wire Wye (2 VTs)
Four-wire systems with voltages 347 V L-N or less can be directly connected to the PQMII
without VTs. Select the S2 SYSTEM SETUP ÖØ CURRENT/VOLTAGE CONFIGURATION ÖØ VT WIRING: “4
WIRE WYE DIRECT” setpoint.

The PQMII voltage inputs should be directly connected using HRC fuses rated at 2 A to
ensure adequate interrupting capacity.
FIGURE 2–5: Wiring Diagram 4-wire Wye Direct (No VTs)

This diagram shows the typical 3-wire delta connection which will cover any voltage range.
Select the S2 SYSTEM SETUP ÖØ CURRENT/VOLTAGE CONFIGURATION ÖØ VT WIRING: “3 WIRE DELTA (2
VTs)” setpoint.
FIGURE 2–6: Wiring Diagram 3-wire Delta (2 VTs)

Three-wire systems with voltages 600 V (L-L) or less can be directly connected to the PQMII
without VTs. Select the S2 SYSTEM SETUP ÖØ CURRENT/VOLTAGE CONFIGURATION ÖØ VT WIRING: “3
WIRE DIRECT” setpoint.
The PQMII voltage inputs should be directly connected using HRC fuses rated at 2 amps to
ensure adequate interrupting capacity.
FIGURE 2–7: Wiring Diagram 3-wire Direct (No VTs)

For a single-phase connection, connect current and voltage to the phase A inputs only. All
other inputs are ignored. Select the S2 SYSTEM SETUP ÖØ CURRENT/VOLTAGE CONFIGURATION ÖØ VT
WIRING: “SINGLE PHASE” setpoint.
FIGURE 2–8: Single Phase Connection

2.2.3 3-wire System using Two CTs

The figure below shows two methods for connecting CTs to the PQMII for a 3-wire system.
The top drawing shows the standard wiring configuration using three CTs. An alternate
wiring configuration uses only two CTs. With the two CT method, the third phase is
measured by connecting the commons from phase A and C to the phase B input on the
PQMII. This causes the phase A and phase C current to flow through the PQMII’s phase B CT
in the opposite direction, producing a current equal to the actual phase B current.
Ia + Ib + Ic = 0 for a three wire system.
Ib = – (Ia + Ic)
For the CT connections above, the S2 SYSTEM SETUP ÖØ CURRENT/VOLTAGE CONFIGURATION ÖØ
PHASE CT WIRING ÖØ PHASE CT PRIMARY setpoint must be set to PHASE A, B, AND C.
FIGURE 2–9: Alternate CT Connections for 3-wire System

2.2.4 Control Power
The control power supplied to the PQMII must match the installed power supply. If the
applied voltage does not match, damage to the unit may occur. Check the product
identification to verify the control voltage matches the intended application.
A universal AC/DC power supply is standard on the PQMII. It covers the range 90 to 300 V
DC and 70 to 265 V AC at 50/60 Hz. It is not necessary to adjust the PQMII if the control
voltage is within this range. A low voltage power supply is available as an option. It covers
the range 20 to 60 V DC and 24 to 48 V AC at 50/60 Hz. Verify from the product
identification label that the control voltage matches the intended application. Connect the
control voltage input to a stable source for reliable operation. A 2.5 A HRC fuse is
accessible from the back of the PQMII via the fuse access door. Consult the factory for
replacement fuses, if required. Using #12 gauge wire or ground braid, connect Terminals 5
and 6 to a solid system ground, typically a copper bus in the switchgear. The PQMII
incorporates extensive filtering and transient protection to ensure reliable operation under
harsh industrial operating environments. Transient energy must be conducted back to the
source through Filter Ground Terminal (5). The Filter Ground Terminal (5) is separated from
the Safety Ground Terminal (6) to allow dielectric testing of switchgear with the PQMII
wired up. Filter Ground Terminal connections must be removed during dielectric testing.
When properly installed, the PQMII meets the interference immunity requirements of IEC
801 and ANSI C37.90.1.
2.2.5 VT Inputs
The PQMII accepts input voltages from 0 to 600 V AC between the voltage inputs (V1, V2,
V3) and voltage common (Vn). These inputs can be directly connected or supplied through
external VTs. If voltages greater than 600 V AC are to be measured, external VTs are
required. When measuring line-to-line quantities using inputs V1, V2, and V3, ensure that
the voltage common input Vn is grounded. This input is used as a reference for measuring
the voltage inputs.
All connections to the PQMII voltage inputs should be connected using HRC fuses rated at
2 Amps to ensure adequate interrupting capacity.
2.2.6 CT Inputs
Current transformer secondaries of 1 A or 5 A can be used with the PQMII for phase and
neutral sensing. Each current input has 3 terminals: 5 A input, 1 A input, and common.
Select either the 1 A or 5 A terminal and common to match the phase CT secondary.
Correct polarity as indicated in the wiring diagrams is essential for correct measurement of
all power quantities.
The CTs selected should be capable of supplying the required current to the total
secondary load, including the PQMII burden of 0.1 VA at rated secondary current and the
connection wiring burden.
All PQMII internal calculations are based on information measured at the CT and VT inputs.
The accuracy specified in this manual assumes no error contribution from the external CTs
and VTs. To ensure the greatest accuracy, Instrument class CTs and VTs are recommended.

2.2.7 Output Relays

The basic PQMII comes equipped with one output relay; the control option supplies three
additional output relays. The PQMII output relays have form C contacts (normally open
(NO), normally closed (NC), and common (COM)). The contact rating for each relay is 5 A
resistive and 5 A inductive at 250 V AC. Consult 1.6: Specifications for contact ratings under
other conditions. The wiring diagrams show the state of the relay contacts with no control
power applied; that is, when the relays are not energized. Relay contact wiring depends on
how the relay operation is programmed in the S3 OUTPUT RELAYS setpoint group (see 5.4: S3
Output Relays for details).
• Alarm Relay (Terminals 43/44/45): A selected alarm condition activates the alarm
relay. Alarms can be enabled or disabled for each feature to ensure only desired
conditions cause an alarm. If an alarm is required when control power is not present,
indicating that monitoring is not available, select “Fail-safe” operation for the alarm
relay through the S3 OUTPUT RELAYS ÖØ ALARM RELAY ÖØ ALARM OPERATION setpoint. The NC/
COM contacts are normally open going to a closed state on an alarm. If “Unlatched”
mode is selected with setpoint S3 OUTPUT RELAYS ÖØ ALARM RELAY ÖØ ALARM ACTIVATION, the
alarm relay automatically resets when the alarm condition disappears. For “Latched”
mode, the key must be pressed (or serial port reset command received) to reset the
alarm relay. Refer to 6.3.1: Alarms for all the displayed alarm messages.
• Auxiliary Relays 1,2,3 (Optional; Terminals 34 to 42): Additional output relays can be
configured for most of the alarms listed in 6.3.1 Alarms. When an alarm feature is
assigned to an auxiliary relay, it acts as a control feature. When the setpoint is
exceeded for a control feature, the output relay changes state and the appropriate
Aux LED lights but no indication is given on the display. The auxiliary relays can also be
programmed to function as kWh, kvarh, and kVAh pulse outputs.
2.2.8 Switch Inputs (Optional)

With the control (C) option installed the PQMII has four programmable switch inputs that
can be used for numerous functions. The figure below shows the internal circuitry of the
switches.
PQM II
TYPICAL
ISOLATED SWITCH
POWER TERMINALS
SUPPLY +24VDC
COM
EXTERNAL
SWITCH
FILTER IN
TO LOGIC
OPTO
ISOLATION
10mA
PULSED
FIGURE 2–10: Switch Input Circuit

Each switch input can be programmed with a 20-character user defined name and can be
selected to accept a normally open or normally closed switch. A list of various functions
assignable to switches is shown below, followed by a description of each function.
• Alarm Relay: When a switch input is assigned to the alarm relay, a change in the
switch status produces an alarm condition and the alarm relay activates.
• Pulse Input 1/2/3/4: When a switch input is assigned as a pulse input counter, the
PQMII counts the number of transitions from open to closed when the input is
configured as normally open and closed to open when the input is configured as
normally closed. The minimum pulse width required for the PQMII to read the switch is
150 ms. Therefore, for the PQMII to read one pulse, the switch input must be in its
inactive state (closed/open) for a minimum of 150 ms then in its active state (open/
closed) for another 150 ms. See 1.6: Specifications for more details.
• New Demand Period: The PQMII can be used for load shedding by assigning a switch
input to a new demand period. This allows the PQMII demand period to be
synchronized with the utility meter. One of the billing parameters used by a utility is
peak demand. By synchronizing the PQMII to the utility meter, the PQMII can monitor
the demand level read by the utility meter and perform load shedding to prevent the
demand from reaching the penalty level. The utility meter provides a dry contact
output which can be connected to one of the PQMII switch inputs. When the PQMII
senses a contact closure, it starts a new demand period (with Block Interval Demand
calculation only).
• Setpoint Access: The access terminals must be shorted together in order for the
faceplate keypad to have the ability to store new setpoints. Typically the access
terminals are connected to a security keyswitch to allow authorized access only. Serial
port commands to store new setpoints operate even if the access terminals are not
shorted. When the access terminals are open, all actual and setpoint values can still
be accessed for viewing; however, if an attempt is made to store a new setpoint value,
the message SETPOINT ACCESS DISABLED is displayed and the previous setpoint
remains intact. In this way, all of the programmed setpoints remain secure and
tamper proof.
• Select Analog Output: This switch selection allows each analog output to be
multiplexed into two outputs. If the switch is active, the parameter assigned in
setpoint S2 SYSTEM SETUP ÖØ ANALOG OUTPUT 1 ÖØ ANALOG OUTPUT 1 ALT determines the
output level. If the switch is not active, the parameter assigned in setpoint S2 SYSTEM
SETUP ÖØ ANALOG OUTPUT 1 ÖØ ANALOG OUTPUT 1 MAIN is used. See the following section
and 5.3.2: Analog Outputs for additional details.
• Select Analog Input: This switch selection allows the analog input to be multiplexed
into two inputs. If the switch is active, the parameter assigned in setpoint S2 SYSTEM
SETUP ÖØ ANALOG INPUT ÖØ ANALOG INPUT ALT is used to scale the input. If the switch is not
active, the parameter assigned in setpoint S2 SYSTEM SETUP ÖØ ANALOG INPUT ÖØ ANALOG
INPUT MAIN is used. If a relay is assigned in S2 SYSTEM SETUP ÖØ ANALOG INPUT ÖØ ANALOG IN
MAIN/ALT SELECT RELAY, that relay energizes when the switch is active and de-energizes
when the switch is not active, thus providing the ability to feed in analog inputs from
two separate sources as shown in the figure below. See the 2.2.10: Analog Input
(Optional) section below for details. Refer to 5.3.3: Analog Input for additional details.

FIGURE 2–11: Analog Input Multiplexing
• Aux 1/2/3 Relay: When a switch input is assigned to an Auxiliary relay, a closure on
the switch input causes the programmed auxiliary relay to change state. This
selection is available only if the Control (C) option is installed.
• Clear Energy: When a switch input is assigned to “Clear Energy”, a closure on the
switch input will clear all Energy data within the PQMII.
• Clear Demand: When a switch input is assigned to “Clear Demand”, a closure on the
switch input will clear all Demand data within the PQMII.
2.2.9 Analog Outputs (Optional)

The PQMII has four current outputs when the transducer option is installed (T20 = 4 to 20
mA, T1 = 0 to 1 mA in the order code). These outputs can be multiplexed to produce 8
analog transducers. This output is a current source suitable for connection to a remote
meter, chart recorder, programmable controller, or computer load. Use the 4 to 20 mA
option with a programmable controller that has a 2 to 40 mA current input. If only a
voltage input is available, use a scaling resistor at the PLC terminals to scale the current to
the equivalent voltage. For example, install a 500 Ω resistor across the terminals of a 0 to
10 V input to make the 4 to 20 mA output correspond to 2 to 10 V (R = V/I = 10 V / 0.02 A =
500 Ω). Current levels are not affected by the total lead and load resistance which must not
exceed 600 Ω for the 4 to 20 mA range and 2400 Ω for the 0 to 1 mA range. For readings
greater than full scale the output will saturate at 22 mA (4 to 20 mA) or 1.1 mA (0 to 1 mA).
These analog outputs are isolated and since all output terminals are floating, the
connection of the analog output to a process input will not introduce a ground loop. Part of
the system should be grounded for safety, typically at the programmable controller. For
floating loads (such as a meter), ground Terminal 24 externally.
The outputs for these transducers can be selected from any of the measured parameters
in the PQMII. The choice of output is selected in the S2 SYSTEM SETUP ÖØ ANALOG OUTPUT 1(4)
setpoints group. See 5.3.2: Analog Outputs for a list of available parameters. Each analog
output can be assigned two parameters: a main parameter and an alternate parameter.
Under normal operating conditions, the main parameter will appear at the output
terminals. To select the alternate parameter, one of the switch inputs must be assigned to
“SELECT ANALOG OUT” and the switch input must be closed (assuming normally closed
activation). By opening and closing the switch input, two analog output parameters can be
multiplexed on one output. This effectively achieves 8 analog outputs for the PQMII.

PQMII
823700A1.CDR
FIGURE 2–12: Analog Output
As shown in wiring diagrams, these outputs are at Terminals 25 to 28 and share Terminal
24 as their common. Shielded cable should be used, with only one end of the shield
grounded, to minimize noise effects.
Signals and power supply circuitry are internally isolated, allowing connection to devices
(PLCs, computers, etc.) at ground potentials different from the PQMII. Each terminal,
however, is clamped to ±36 V to ground.
2.2.10 Analog Input (Optional)

Terminals 22(–) and 23(+) are provided for a current signal input. This current signal can be
used to monitor any external quantity, such as transformer winding temperature, battery
voltage, station service voltage, transformer tap position, etc. Any transducer output
ranges within the range of 0 to 20 mA can be connected to the analog input terminals of
the PQMII. See 5.3.3: Analog Input for details on programming the analog input.
2.2.11 RS485 Serial Ports

A fully loaded PQMII is equipped with three serial ports. COM1 is a RS485 port available at
the rear terminals of the PQMII which is normally used as the main communications
interface to the system. COM2, which is also a rear RS485 port, can be used for data
collection, printing reports, or problem analysis without disturbing the main
communications interface. COM3 is a front panel RS232 port that can be used for setpoint
programming or recording using the EnerVista PQMII Setup Software.
A serial port provides communication capabilities between the PQMII and a remote
computer, PLC, or distributed control system (DCS). Up to thirty-two PQMIIs can be daisy
chained together with 24 AWG stranded, shielded, twisted-pair wire on a single
communication channel. Suitable wire should have a characteristic impedance of 120 W
(such as Belden #9841). These wires should be routed away from high power AC lines and
other sources of electrical noise. The total length of the communications wiring should not
exceed 4000 feet for reliable operation. Correct polarity is essential for the
communications port to operate. Terminal (485+) of every PQMII in a serial communication
link must be connected together. Similarly, the (485–) terminal of every PQMII must also be
connected together. These polarities are specified for a 0 logic and should match the
polarity of the master device. If the front panel RX1 or RX2 lights are flashing, this indicates
that the PQMII is receiving data. If the front panel TX1 or TX2 lights are flashing, this

indicates that the PQMII is transmitting data. Each PQMII must be daisy-chained to the
next one as shown in the figure below. Avoid star or stub connected configurations. If a
large difference in ground potentials exists, communication on the serial communication
link will not be possible. Therefore, it is imperative that the serial master and PQMII are both
at the same ground potential. This is accomplished by joining the RS485 ground terminal
(Terminal 46 for COM1; Terminal 49 for COM2) of every unit together and grounding it at the
master only.
The last PQMII in the chain and the master computer require a terminating resistor and
terminating capacitor to ensure proper electrical matching of the loads and prevent
communication errors. Using terminating resistors on all the PQMIIs would load down the
communication network while omitting them at the ends could cause reflections resulting
in communication errors. Install the 120 Ω, ¼ watt terminating resistor and 1 nF capacitor
externally. Although any standard resistor and capacitor of these values are suitable, these
components can also be ordered from GE Multilin as a combined terminating network.
Each communication link must have only one computer (PLC or DCS) issuing commands
called the master. The master should be centrally located and can be used to view actual
values and setpoints from each PQMII called the slave device. Other GE Multilin relays or
devices using the Modbus RTU protocol can be connected to the communication link.
Setpoints in each slave can also be changed from the master. Each PQMII in the link must
be programmed with a different slave address prior to running communications using the
S1 PQMII SETUP ÖØ COM1 RS485 SERIAL PORT ÖØ MODBUS COMMUNICATION ADDRESS setpoint. The GE
Multilin EnerVista PQMII Setup Software may be used to view status, actual values, and
setpoints. See 4.4: Using the EnerVista PQMII Setup Software for more information on the
EnerVista PQMII Setup Software.
48
47
46
PQM II
PQM II
GE Multilin
IED
SR Series
GE Multilin
Protection Relay
RS485.CDR
FIGURE 2–13: RS485 Communication Wiring

2.2.12 RS232 Front Panel Port

A 9-pin RS232C serial port provided on the front panel allows the user to program the
PQMII with a personal computer. This port uses the same communication protocol as the
rear terminal RS485 ports. To use this interface, the personal computer must be running
the EnerVista PQMII Setup Software provided with the relay. Cabling to the RS232 port of
the computer is shown below for both 9-pin and 25-pin connectors.
PQMII
PQMII
RS232.CDR
FIGURE 2–14: RS232 Connection
2.2.13 Dielectric Strength Testing

It may be required to test the complete switchgear for dielectric strength with the PQMII
installed. This is also known as “flash” or “hipot” testing. The PQMII is rated for 1500 V AC
isolation between relay contacts, CT inputs, VT inputs, control power inputs and Safety
Ground Terminal 6. Some precautions are necessary to prevent damage to the PQMII
during these tests.
Filter networks and transient protection clamps are used between the control power, serial
port, switch inputs, analog outputs, analog input, and the filter ground terminal 5 to filter
out high voltage transients, radio frequency interference (RFI) and electromagnetic
interference (EMI). The filter capacitors and transient absorbers could be damaged by the
continuous high voltages relative to ground that are applied during dielectric strength
testing. Disconnect the Filter Ground (Terminal 5) during testing of the control power
inputs. Relay contact and CT terminals do not require any special precautions. Do not
perform dielectric strength testing on the serial ports, switch inputs, analog input or analog
output terminals or the PQMII internal circuitry will be damaged.

GE Multilin
PQMII
POWER QUALITY METER
746702A1.CDR
FIGURE 2–15: Hi-Pot Testing

Digital Energy
Multilin
Chapter 3: Operation
Operation
3.1 Front Panel and Display
3.1.1 Front Panel

The local operator interface for setpoint entry and monitoring of measured values is
through the front panel as shown in the figure below. Control keys are used to select the
appropriate message for entering setpoints or displaying measured values. Alarm and
status messages are automatically displayed when required. Indicator LEDs provide
important status information at all times. An RS232 communications port is also available
for uploading or downloading information to the PQMII.
3.1.2 Display
All messages are displayed in English on the 40-character liquid crystal display. This
display is visible under varied lighting conditions. When the keypad and display are not
actively being used, the screen displays a default status message. This message appears if
no key has been pressed for the time programmed in the S1 PQMII SETUP Ö PREFERENCES Ö
DEFAULT MESSAGE TIME setpoint. Note that alarm condition messages automatically override
the default messages.
819761A6.CDR
FIGURE 3–1: Display (example)

CHAPTER 3: OPERATION
3.2 LED Indicators
3.2.1 Description
The LED status indicators provide a quick indication of the overall status of the PQMII.
These indicators illuminate if an alarm is present, if setpoint access is enabled, if the PQMII
is in simulation mode, or if there is a problem with the PQMII itself.
FIGURE 3–2: LED Indicators
3.2.2 Status
• Alarm: When an alarm condition exists, the Alarm LED indicator will flash.
• Program: The Program LED indicator is on when setpoint access is enabled.
• Simulation: The Simulation LED indicator will be on when the PQMII is using
simulated values for current, voltage, analog input, switches and analog outputs.
While in simulation mode, the PQMII will ignore the measured parameters
detected at its inputs and will use the simulated values stored in the S5 TESTING ÖØ
SIMULATION setpoints group.
• Self-Test: Any abnormal condition detected during PQMII self-monitoring, such as

a hardware failure, causes the Self Test LED indicator to be on. Loss of control
power to the PQMII also causes the Self Test LED indicator to turn on, indicating
that no metering is present.
3.2.3 Communicate
The Communicate LED indicators monitor the status of the RS485 communication ports.
When no serial data is being received through the rear serial ports terminals, the RX1/2
LED indicators are off. This situation occurs if there is no connection, the serial wires
become disconnected, or the master computer is inactive. If there is activity on the serial
port but the PQMII is not receiving valid messages for its internally programmed address,
the TX1/2 LED indicators remain off. This condition can be caused by incorrect message
formats (such as baud rate or framing), reversed polarity of the two RS485 twisted-pair
connections, or the master not sending the currently programmed PQMII address. If the
PQMII is being periodically addressed with a valid message, the RX1/2 LED indicator will
turn on followed by the TX1/2 LED indicator.
• TX1: The PQMII is transmitting information via the COM1 RS485 communications
port when lit.
• RX1: The PQMII is receiving information via the COM1 RS485 communications port
when lit.

• TX2: The PQMII is transmitting information via the COM2 RS485 communications
port when lit.
• RX2: The PQMII is receiving information via the COM2 RS485 communications port
when lit.
3.2.4 Relays
The status of the output relays is displayed with these LED indicators.
• Alarm: The Alarm relay is intended for general purpose alarm outputs. This
indicator will be on while the Alarm relay is operating. When the condition clears,
the Alarm LED indicator turns off. If the alarm relay has been programmed as
“Latched”, the alarm condition can only be cleared by pressing the RESET key or by
issuing a computer reset command.
• Aux1: The Aux 1 relay is intended for control and customer specific requirements.
The Aux1 LED indicator is on while the Auxiliary 1 relay is operating.

3.3 Keypad
3.3.1 Description
The front panel keypad allows direct access to PQMII functionality. The keys are used to
navigate through message pages, allowing the user to modify settings and view actual
values from the device location.
3.3.2 Menu Key

Setpoints and actual values are arranged into two distinct groups of messages. The MENU
key selects the main setpoints or actual values page. Pressing MENU while in the middle of
a setpoints or actual values page returns the display to the main setpoints or actual values
page. The MESSAGE keys select messages within a page.
3.3.3 Escape Key

Pressing the ESCAPE key during any setpoints or actual values message returns the user to
the previous message level. Continually pressing ESCAPE will return the user back to the
main setpoints or actual values page.
3.3.4 Enter Key

When programming setpoints, enter the new value by using the VALUE keys, followed by
the ENTER key. Setpoint programming must be enabled for the ENTER key to store the
edited value. An acknowledgment message will flash if the new setpoint is successfully
saved in non-volatile memory. The ENTER key is also used to add and remove user defined
default messages. Refer to 3.4: Default Messages for details.
3.3.5 Reset Key

The RESET key is used to clear the latched alarm and/or auxiliary conditions. Upon
pressing the key, the PQMII will perform the appropriate action based on the condition
present as shown in the table below.
Table 3–1: Reset Key Actions
Condition Present Message Displayed PQMII Action Performed
None None No action taken
Alarm LED indicators and

RESET NOT POSSIBLE alarm relay remain on
Alarm ALARM STILL PRESENT because condition is still
present

Table 3–1: Reset Key Actions
Auxiliary LED indicator(s) and

RESET NOT POSSIBLE aux relay(s) remain on
Aux Relay AUX CONDITION
because condition is still
EXISTS
present
Auxiliary and Alarm LED

RESET NOT POSSIBLE indicators and alarm and aux
Alarm and Aux Relay AUX CONDITION
relays remain on because
EXISTS
condition is still present
Latched Alarm No message displayed, and

(condition no longer None Alarm LED indicators and the
exists) alarm relay turned off
No message displayed, and

Latched Aux Relay
appropriate Auxiliary LEDs
(condition no longer None
exists) and auxiliary relay(s) turned
off
No message displayed, and

Alarm and Latched Aux
Relay (Aux condition no appropriate Auxiliary LEDs
None and auxiliary relay(s) turned
longer exists)
off
Aux Relay and Latched No message displayed, and

Alarm (alarm condition None Alarm LEDs and alarm relay
no longer exists) turned off
The RESET key, along with the ENTER key, is also used to remove user defined default
messages. Refer to 3.4: Default Messages further details.
3.3.6 Message Keys

Use the MESSAGE keys to move between message groups within a page. The MESSAGE
DOWN key moves toward the end of the page and the MESSAGE UP key moves toward the
beginning of the page. A page header message will appear at the beginning of each page
and a page footer message will appear at the end of each page. To enter a subgroup,
press the MESSAGE RIGHT key. To back out of the subgroup, press the MESSAGE LEFT key.

Moves back to the Moves forward to

previous menu level MESSAGE the next menu level
MENU MESSAGE MESSAGE MESSAGE
1. SETPOINTS [ w] n SETPOINTS [ w] n PREFERENCES [ w] DEFAULT MESSAGE TIME

Press [ w] for more S1 PQMII SETUP 1.0 MINUTES
DISPLAY FILTER
▲ ▲ CONSTANT: 4
MESSAGE MESSAGE
▼ ▼
MESSAGE
n SETPOINT [ w] SETPOINT ACCESS:

ACCESS DISABLE
ENCRYPTED SETPOINT
▲ ACCESS CODE: 376
▲
MESSAGE MESSAGE
▼
▼
n COM1 RS485 [ w]
Moves back
SERIAL PORT
MESSAGE within a
subgroup
n SETPOINTS [ w]
MESSAGE
S2 SYSTEM SETUP
Moves
MENU forward within
a subgroup
2. ACTUAL VALUES
Press [ w] for more
MSGKEYOP.CDR
FIGURE 3–3: Message Key Operation
3.3.7 Value Keys

Setpoint values are entered using the VALUE keys. When a setpoint is displayed calling for
a yes/no response, each time a VALUE key is pressed, the “Yes” becomes a “No,” or the
“No” becomes a “Yes.” Similarly, for multiple choice selections, each time a VALUE key is
pressed, the next choice is displayed. When numeric values are displayed, each time
VALUE UP is pressed, the value increases by the step increment, up to the maximum. Hold
the key down to rapidly change the value.
3.3.8 Data Entry Methods

• Keypad Entry: Press the MENU key once to display the first page of setpoints Press the
MESSAGE RIGHT key to select successive setpoints pages. The page number and
page title appear on the second line. All setpoint page headers are numbered with an
‘S’ prefix. Actual value page headers are numbered with an ‘A’ prefix.
The messages are organized into logical subgroups within each Setpoints and Actual
Values page as shown below.

Press the MESSAGE keys when displaying a subgroup to access messages within that
subgroup. Otherwise select the MESSAGE keys to display the next subgroup.
1. SETPOINTS n SETPOINTS [w] n PREFERENCES [w] DISPLAY FILTER

Press [w] for more S1 PQMII SETUP CONSTANT:
MAIN MENU PAGE HEADER SUBGROUP HEADER SUBGROUP MESSAGE

MESSAGE MESSAGE MESSAGE
FIGURE 3–4: Message Hierarchy Example
• Computer Entry: When running the EnerVista PQMII Setup Software, setpoint values
are accessed through the menu bar and displayed in a series of windows. See Chapter
4: Software for further details.
• SCADA Entry: Details of the complete communication protocol for reading and writing
setpoints are given in 7.4: DNP 3.0 Communications. A SCADA system connected to the
RS485 terminals can be custom programmed to make use of any of the
communication commands for remote setpoint programming, monitoring, and
control.
3.3.9 Setpoint Access Security

The PQMII incorporates software security to provide protection against unauthorized
setpoint changes. A numeric access code must be entered to program new setpoints using
the front panel keys. To enable the setpoint access security feature, the user must enter a
value in the range of 1 to 999. The factory default access code is 1. If the switch option is
installed in the PQMII, a hardware jumper access can be assigned to a switch input.
Setpoint access can then only be enabled if the switch input is shorted and the correct
software access code entered. Attempts to enter a new setpoint without the electrical
connection across the setpoint access terminals or without the correct access code will
result in an error message. When setpoint programming is via a computer, no setpoint
access jumper is required. If a SCADA system is used for PQMII programming, it is up to the
programmer to design in appropriate passcode security.

3.4 Default Messages
3.4.1 Description
Up to 10 default messages can be selected to display sequentially when the PQMII is left
unattended. If no keys are pressed for the default message time in the S1 PQMII SETUP Ö
PREFERENCES Ö DEFAULT MESSAGE TIME setpoint, then the currently displayed message will
automatically be overwritten by the first default message. After three seconds, the next
default message in the sequence will display if more than one is selected. Alarm messages
will override the default message display. Any setpoint or measured value can be selected
as a default message.
Messages are displayed in the order they are selected.
3.4.2 Adding a Default Message

Use the MESSAGE keys to display any setpoint or actual value message to be added to the
default message queue and follow the steps shown below. When selecting a setpoint
message for display as a default, do not modify the value using the VALUE keys or the
PQMII will recognize the ENTER key as storing a setpoint instead of selecting a default
message
ENTER ENTER ENTER
THREE PHASE REAL TO ADD THIS DEFAULT NEW DEFAULT

POWER = 1000 kW MESSAGE PRESS ENTER MESSAGE SELECTED
ACTUAL VALUE OR SETPOINT DISPLAYED FOR 3 SECONDS DISPLAYED FOR 3 SECONDS
TO BE STORED AS DEFAULT WHEN STORE KEY PRESSED WHEN STORE KEY PRESSED
MESSAGE TWICE
ADEFMSG.CDR
If 10 default messages are already selected, the first message is erased and the new
message is added to the end of the queue.
3.4.3 Deleting a Default Message

Use the MESSAGE keys to display the default message to be erased. If default messages
are not known, wait until the PQMII starts to display them and then write them down. Use
the MESSAGE keys to display the setpoint or actual value message to be deleted from the
default message queue and follow the steps below.

ENTER RESET VALID DEFAULT

ENTER
STORE
MESSAGE
RESET
THREE PHASE REAL TO DELETE THIS DEFAULT MESSAGE
POWER = 1000 kW MESSAGE PRESS ENTER REMOVED
DISPLAYED FOR 3 SECONDS
ACTUAL VALUE OR SETPOINT DISPLAYED FOR 3 SECONDS WHEN THE ENTER KEY IS
TO BE REMOVED FROM THE WHEN ENTER KEY AND RESET PRESSED
DEFAULT MESSAGE QUEUE KEY ARE PRESSED IN SEQUENCE
NOT A DEFAULT
MESSAGE
NOT A SELECTED
DEFAULT MESSAGE
REDEFMSG.CDR
DISPLAYED FOR 3 SECONDS WHEN
ENTER KEY AND RESET KEY ARE
PRESSED IN SEQUENCE
3.4.4 Default Message Sequence

Each PQMII is pre-programmed with five default messages as shown below. Note, each
time the factory setpoints are reloaded the user programmed default messages are
overwritten with these messages.
The PQMII will scroll through the default messages in the sequence shown.
A= 100 B= 100
Location: A1 METERING ð CURRENT
C= 100 AMPS
Van = 120 Vbn = 120

Location: A1 METERING ðò VOLTAGE
Vcn = 120 V
FREQUENCY = 60.00 Hz
Location: A1 METERING ðò FREQUENCY
TIME: 12:00:00am
Location: A2 STATUS ðò CLOCK
DATE: JAN 01 1996
Phone: 905-294-6222
Location: A2 STATUS ðò PROGRAMMABLE MESSAGE
www.GEmultilin.com


Digital Energy
Multilin
Chapter 4: Software
Software
4.1 Introduction
4.1.1 Overview
Although setpoints can be manually entered using the front panel keys, it is far more
efficient and easier to use a computer to download values through the communications
port. The no-charge EnerVista PQMII Setup Software included with the PQMII makes this a
quick and convenient process. With the EnerVista PQMII Setup Software running on your
PC, it is possible to:
• Program and modify setpoints
• Load/save setpoint files from/to disk
• Read actual values and monitor status
• Perform waveform capture and log data
• Perform harmonic analysis
• Trigger trace memory
• Get help on any topic
The EnerVista PQMII Setup Software allows immediate access to all the features of the
PQMII through pull-down menus in the familiar Windows environment. The software can
also run without a PQMII connected. This allows you to edit and save setpoint files for later
use. If a PQMII is connected to a serial port on a computer and communication is enabled,
the PQMII can be programmed from the setpoint screens. In addition, measured values,
status and alarm messages can be displayed with the actual screens.

CHAPTER 4: SOFTWARE
4.1.2 Hardware
Communications from the EnerVista PQMII Setup Software to the PQMII can be
accomplished three ways: RS232, RS485, and Ethernet (requires the MultiNET adapter)
communications. The following figures below illustrate typical connections for RS232 and
RS485 communications. For details on Ethernet communications, please see the MultiNET
manual.
FIGURE 4–1: Communications using The Front RS232 Port

CHAPTER 4: SOFTWARE
FIGURE 4–2: Communications using Rear RS485 Port
4.1.3 Installing the EnerVista PQMII Setup Software

The following minimum requirements must be met for the EnerVista PQMII Setup Software
to operate on your computer.
• Microsoft Windows 95 or higher operating system
• 64 MB of RAM (256 MB recommended)
• Minimum of 50 MB hard disk space (200 MB recommended)
After ensuring these minimum requirements, use the following procedure to install the
EnerVista PQMII Setup Software from the enclosed GE EnerVista CD.
Z Insert the GE EnerVista CD into your CD-ROM drive.
Z Click the Install Now button and follow the installation instructions to
install the no-charge EnerVista software on the local PC.

CHAPTER 4: SOFTWARE
Z When installation is complete, start the EnerVista Launchpad

application.
Z Click the IED Setup section of the Launch Pad window.
Z In the EnerVista Launch Pad window, click the Install Software button
Z Select the “PQMII Power Quality Meter” from the Install Software
window as shown below.
Z Select the “Web” option to ensure the most recent software release, or
select “CD” if you do not have a web connection.
Z Click the Check Now button to list software items for the PQMII.
Z Select the PQMII software program and release notes (if desired) from
the list.
Z Click the Download Now button to obtain the installation program from
the Web or CD.
EnerVista Launchpad will obtain the installation program.

CHAPTER 4: SOFTWARE
Z Once the download is complete, double-click the installation program to

install the EnerVista PQMII Setup Software.
The program will request the user to create a backup 3.5" floppy-disk
set. If this is desired, click on the Start Copying button; otherwise,
Z Click on the CONTINUE WITH PQMII VERSION 1.O1
INSTALLATION button.
Z Select the complete path, including the new directory name, where the
EnerVista PQMII Setup Software will be installed.
Z Click on Next to begin the installation.
The files will be installed in the directory indicated and the installation
program will automatically create icons and add EnerVista PQMII
Setup Software to the Windows start menu.

CHAPTER 4: SOFTWARE
Z Click Finish to end the installation.

The PQMII device will be added to the list of installed IEDs in the
EnerVista Launchpad window, as shown below.

CHAPTER 4: SOFTWARE
4.2 Configuring Serial Communications
4.2.1 Description
Before starting, verify that the serial cable is properly connected to either the RS232 port
on the front panel of the device (for RS232 communications) or to the RS485 terminals on
the back of the device (for RS485 communications). See 4.1.2: Hardware for connection
details.
Z Install and start the latest version of the EnerVista PQMII Setup
Software (available from the GE EnerVista CD). See the previous
section for the installation procedure.
Z Enter the desired site name in the Site Name field. If desired, a short
description of site can also be entered along with the display order of
devices defined for the site.
The new site will appear in the upper-left list in the EnerVista PQMII
Setup Software window.
Z Select “Serial” from the Interface drop-down list.
This will display a number of interface parameters that must be entered
for proper RS232 functionality.
Z Enter the relay slave address and COM port values (from the S1 PQMII
SETUP ÖØ FRONT PANEL RS232 SERIAL PORT setpoints menu) in the Slave
Address and COM Port fields.
Z Enter the physical communications parameters (baud rate and parity
settings) in their respective fields.
Z Click the Read Order Code button to connect to the PQMII device and
If a communications error occurs, ensure that the PQMII serial
communications values entered in the previous step correspond to the
relay setting values.
window) located in the top left corner of the main EnerVista PQMII
The PQMII Site Device has now been configured for serial communications.

CHAPTER 4: SOFTWARE
4.3 Upgrading Firmware
4.3.1 Description
To upgrade the PQMII firmware, follow the procedures listed in this section. Upon
successful completion of this procedure, the PQMII will have new firmware installed with
the original setpoints.
The latest firmware files are available from the GE Multilin website at
http://www.GEmultilin.com.
4.3.2 Saving Setpoints to a File

Before upgrading firmware, it is important to save the current PQMII settings to a file on
your PC. After the firmware has been upgraded, it will be necessary to load this file back
into the PQMII.
Z To save setpoints to a file, select the File > Read Device Settings menu
item.
The EnerVista PQMII Setup Software will read the device settings and
prompt the user to save the setpoints file.
Z Select an appropriate name and location for the setpoint file.
Z Click OK.
The saved file will be added to the “Files” pane of the EnerVista PQMII
Setup Software main window.
4.3.3 Loading New Firmware

Z Select the Commands > Upgrade Firmware menu item.
A warning will appear.
Z Select Yes to proceed or No the abort the process.
Do not proceed unless you have saved the current setpoints as shown in
the previous section.

CHAPTER 4: SOFTWARE
Z Locate the firmware file to load into the PQMII.

The firmware filename has the following format:
73 D 210 C4 . 000
Modification number (000 = none)

For GE Multilin use only
Product firmware revision (e.g. 100 = 1.00). This number

must be larger than the current number of the PQMII. This
number is found in actual values page A4 under SOFTWARE
VERSIONS MAIN PROGRAM VERSION
Required product hardware revision. This letter must match

the first character of the serial number located on the PQMII
product label (on the back of the unit)
Product Name (73 = PQMII)
Z Select the required file.

Z Click on OK to proceed or Cancel to abort the firmware upgrade.
One final warning will appear. This will be the last chance to abort the firmware
upgrade.
Z Select Yes to proceed, No to load a different file, or Cancel to abort the
process.
The EnerVista PQMII Setup Software now prepares the PQMII to receive the new
firmware file. The PQMII will display a message indicating that it is in Upload Mode.
While the file is being loaded into the PQMII, a status box appears showing how
much of the new firmware file has been transferred and how much is remaining.
The entire transfer process takes approximately five minutes.

CHAPTER 4: SOFTWARE
The EnerVista PQMII Setup Software will notify the user when the PQMII has
finished loading the file.
Z Carefully read any displayed messages and click OK to return the main
screen.
If the PQMII does not communicate with the EnerVista PQMII Setup Software,
ensure that the following PQMII setpoints correspond with the EnerVista PQMII
Setup Software settings:
MODBUS COMMUNICATION ADDRESS
BAUD RATE
PARITY (if applicable)
Also, ensure that the correct COM port is being used.
4.3.4 Loading Saved Setpoints

Z Select the previously saved setpoints file from the File pane of the
EnerVista PQMII Setup Software main window.
Z Select the setpoint file to be loaded into the PQMII.
Z Click OK.
Z Select the File > Edit Settings File Properties menu item and change
the file version of the setpoint file to match the firmware version of the
PQMII.
Z With the updated setpoint file selected in the File pane, select the File >
Write Settings to Device menu item and select the target PQMII to
receive the previously saved settings file.
A dialog box will appear to confirm the request to download setpoints.
Z Click Yes to send the setpoints to the PQMII or No to end the process.
The EnerVista PQMII Setup Software will load the setpoint file into the PQMII. If new
setpoints were added in the firmware upgrade, they will be set to factory defaults.

CHAPTER 4: SOFTWARE
4.4 Using the EnerVista PQMII Setup Software
4.4.1 Entering Setpoints

The System Setup page will be used as an example to illustrate the entering of setpoints.
Z Select the Setpoint > System Setup menu item. The following window
will appear:
When a non-numeric setpoint such as CT WIRING is selected, EnerVista PQMII Setup

Software displays a drop-down menu:
When a numeric setpoint such as PHASE CT PRIMARY is selected, EnerVista PQMII

Setup Software displays a keypad that allows the user to enter a value within the
setpoint range displayed near the top of the keypad:
Z Click Accept to exit from the keypad and keep the new value. Click on
Cancel to exit from the keypad and retain the old value.
Z In the Setpoint / System Setup dialog box, click on Store to save the
values into the PQMII.
Z Click OK to accept any changes and exit the window.
Z Click Cancel to retain previous values and exit.

CHAPTER 4: SOFTWARE
4.4.2 Viewing Actual Values

If a PQMII is connected to a computer via the serial port, any measured value, status and
alarm information can be displayed. Use the Actual pull-down menu to select various
measured value screens. Monitored values will be displayed and continuously updated.
4.4.3 Setpoint Files

To print and save all the setpoints to a file follow the steps outlined in 4.3.2: Saving
Setpoints to a File.
To load an existing setpoints file to a PQMII and/or send the setpoints to the PQMII follow
the steps outlined in 4.3.4: Loading Saved Setpoints.
4.4.4 Getting Help

A detailed Help file is included with the EnerVista PQMII Setup Software.
Select the Help > Contents menu item to obtain an explanation of any feature,
specifications, setpoint, actual value, etc. Context-sensitive help can also be activated by
clicking on the desired function.
For easy reference, any topic can be printed by selecting File > Print Topic item from the
Help file menu bar.

CHAPTER 4: SOFTWARE
4.5 Power Analysis
4.5.1 Waveform Capture

Two cycles (64 samples/cycle) of voltage and current waveforms can be captured and
displayed on a PC using the EnerVista PQMII Setup Software or third party software.
Distorted peaks or notches from SCR switching provides clues for taking corrective action.
Waveform capture is also a useful tool when investigating possible wiring problems due to
its ability to display the phase relationship of the various inputs. The waveform capture
feature is implemented into EnerVista PQMII Setup Software as shown below.
Select the Actual > Power Analysis > Waveform Capture menu item. The EnerVista PQMII
Setup Software will open the Waveform Capture dialog box.
Select the buttons on the left to display the desired waveforms. The waveform values for
the current cursor line position are displayed to the right of the selected buttons.
Numerical values are displayed directly below the button.
4.5.2 Harmonic Analysis

Non-linear loads such as variable speed drives, computers, and electronic ballasts can
cause harmonics which may lead to problems such as nuisance breaker tripping,
telephone interference, transformer, capacitor or motor overheating. For fault diagnosis
such as detecting undersized neutral wiring, need for a harmonic rated transformer or
effectiveness of harmonic filters; details of the harmonic spectrum are useful and available
with the PQMII and the EnerVista PQMII Setup Software.
The EnerVista PQMII Setup Software can perform a harmonic analysis on any of the four
current inputs or any of the three voltage inputs by placing the PQMII in a high speed
sampling mode (256 samples/cycle) where it will sample one cycle of the user defined

CHAPTER 4: SOFTWARE
parameter. EnerVista PQMII Setup Software then takes this data and performs a FFT (Fast
Fourier Transform) to extract the harmonic information. The harmonic analysis feature is
implemented into EnerVista PQMII Setup Software as shown below.
Z Select the Actual > Power Analysis > Harmonic Analysis >
Harmonic Spectrum menu item.
The EnerVista PQMII Setup Software can display the Harmonic
Analysis Spectrum window including the harmonic spectrum up to and
including the 62nd harmonic.
Z Enter the trigger parameter for the Select Trigger setting.
Z Click the Select button for the Trigger setting.
The Waveform capture window will appear.
Z To display the harmonic spectrum, click the Harmonics button ( )
on the top of the screen.
FIGURE 4–3: Harmonic Spectrum Display
The window includes details of the currently selected harmonic and other
harmonic analysis-related data (for example, THD, K Factor, etc.).
Z Select Read Last Trigger From Device to load previous acquired
spectra from the PQMII.
4.5.3 Trace Memory

The trace memory feature allows the PQMII to be setup to trigger on various conditions.
The trace memory can record maximum of 36 cycles of data (16 samples per cycle) for all
voltage and current inputs simultaneously. A Total Trace Triggers Counter has been
implemented in the PQMII Memory Map at Register 0x0B83. This register will keep a

CHAPTER 4: SOFTWARE
running total of all valid Trace Memory Triggers from the last time power was applied to
the PQMII. The Total Trace Triggers counter will rollover to 0 at 65536. The trace memory
feature is implemented into the EnerVista PQMII Setup Software as shown below.
Z Select the Setpoint > PQMII Setup > Trace Memory Setup menu
item to setup the trace memory feature.
The Trace Memory Usage parameter is set as follows:

• 1 x 36 cycles: upon trigger, the entire buffer is filled with 36 cycles of data
• 2 x 18 cycles: 2 separate 18-cycle buffers are created and each is filled upon a
trigger
• 3 x 12 cycles: 3 separate 12 cycle buffers are created and each is filled upon a
trigger
If the Trace Memory Trigger Mode is set to “One-Shot”, then the trace memory is triggered
once per buffer; if it is set to “Retrigger”, then it automatically retriggers and overwrites the
previous data.
The Trace Memory Trigger Delay delays the trigger by the number of cycles specified. The
Voltage, Current, and Switch Inputs selections are the parameters and levels that are used
to trigger the trace memory. Clicking Save sends the current settings to the PQMII.

CHAPTER 4: SOFTWARE
Z Select the Actual > Power Analysis > Trace Memory menu item to
view the trace memory data.
This launches the Trace Memory Waveform window.
4.5.4 Data Logger

The data logger feature allows the PQMII to continuously log various specified parameters
at the specified rate. The data logger uses the 64 samples/cycle data. This feature is
implemented into EnerVista PQMII Setup Software as shown below.
Z Select the Setpoint > System Setup > Data Log menu item to setup the
data logger feature.
This launches the Data Log settings box shown below. The state of each
data logger and percent filled is shown.
Z Use the Start Log 1(2) and Stop Log 1(2) buttons to start and stop the
logs.

CHAPTER 4: SOFTWARE
FIGURE 4–4: Data Logger Setup Window
1. The Log 1(2) Mode parameters are set as follows:

• “Run to Fill”: when the data logger is full (100%) it will stop logging
• “Circulate”: when the data logger is full, it will start from the beginning
and overwrite the previous data.
2. The Log 1(2) Interval parameters determine how frequently the PQMII logs
each piece of data.
3. The total log size is approximately 192KB. The allotment of this memory can
be varied between the two logs to maximize the overall log time. Set the Log
Size Determination to let the PQMII automatically optimize the memory. If
desired, the optimization can also be performed manually by the user.
4. The Log 1(2) Fill Time parameters represent the amount of time the data
logger takes to fill to 100%. This time is dependent on the logging interval and
the number of parameters being logged.
Z Set the parameters to be logged by setting the various Log Assignment
parameters to the desired log.
Z Select the Actual > Power Analysis > Data Logger > Log 1 (or Log 2)
item to view the respective data logger.

CHAPTER 4: SOFTWARE
FIGURE 4–5: Data Logger Window
5. The Data Log 1(2) dialog box displays the record numbers, data log start time,
the current time, and parameter values for the current cursor line position.
4.5.5 Voltage Disturbance Recorder

The Voltage Disturbance Recorder allows the PQMII to monitor and record sag and swell
disturbances. This function can record up to 500 sag/swell events for all voltages
simultaneously. The events roll-over and old events are lost when more than 500 events
are recorded.
PQMII VDR events are stored in volatile memory. Therefore, all voltage disturbance
Note
events will be cleared when control power is cycled to the meter.
The operation of the voltage disturbance recorder as implemented in the EnerVista PQMII
Setup Software is shown below:
Z Select the Setpoint > System Setup > System Config menu item.
Z Select the Voltage Disturbance Recorder Setup tab.
Z The Sag Level % Nominal should be set to the level to which a voltage
input must fall before a sag event is to be recorded. The Swell
Level % Nominal should be set to the level to which a voltage input
must rise before a swell event is to be recorded.
Z Click Save to send the current settings to the PQMII.

CHAPTER 4: SOFTWARE
Z Select the Actual > Power Analysis > Voltage Disturbance Recorder
menu item to view the voltage disturbance recorder events.
Within the voltage disturbance recorder window, each event is listed and can be selected.
When the event is selected the following values are displayed:
• Dist. Number: The event number. The first event recorded (after the event recorder
is cleared) will be given the event number of “1”. Each subsequent event will be
given an incrementing event number. If the event number reaches 65535, the
event number will rollover back to 1.
• Dist. Type: The type refers to the classification of the event (i.e. Sag, Swell,
Undervoltage or, Overvoltage)
• Dist. Source: The source of the disturbance is the line/phase voltage that the
disturbance was measured on.
• Dist. Time/Date: The time that the disturbance was recorded. Each disturbance is
recorded at the end of the disturbance event.
• Dist. Dur.: The duration of the event in cycles.
• Dist. Average Voltage: The average RMS voltage recorded during the disturbance.
The Clear Events button clears the voltage disturbance recorder. Events are overwritten
when the event recorder reaches 500 events.
The Save button exports the events to a CSV format file. A text file viewer can open and
read the file.

CHAPTER 4: SOFTWARE
FIGURE 4–6: Voltage Disturbance Recorder

CHAPTER 4: SOFTWARE
4.6 Using EnerVista Viewpoint with the PQMII
4.6.1 Plug and Play Example

EnerVista Viewpoint is an optional software package that puts critical PQMII information
onto any PC with plug-and-play simplicity. EnerVista Viewpoint connects instantly to the
PQMII via serial, ethernet or modem and automatically generates detailed overview,
metering, power, demand, energy and analysis screens. Installing EnerVista Launchpad
(see previous section) allows the user to install a fifteen-day trial version of EnerVista
Viewpoint. After the fifteen day trial period you will need to purchase a license to continue
using EnerVista Viewpoint. Information on license pricing can be found at
http://www.enervista.com.
Z Install the EnerVista Viewpoint software from the GE EnerVista CD.

Z Ensure that the PQMII device has been properly configured for either
serial or Ethernet communications (see previous sections for details).
Z Click the Viewpoint window in EnerVista to log into EnerVista
Viewpoint.
At this point, you will be required to provide a login and password if
you have not already done so.
FIGURE 4–7: EnerVista Viewpoint Main Window
Z Click the Device Setup button to open the Device Setup window.

CHAPTER 4: SOFTWARE

If desired, a short description of site can also be entered along with the
display order of devices defined for the site.
The new site will appear in the upper-left list in the EnerVista PQMII
Z Select the appropriate communications interface (Ethernet or Serial) and
fill in the required information for the PQMII.
FIGURE 4–8: Device Setup Screen (Example)
Z Click the Read Order Code button to connect to the PQMII device and
If a communications error occurs, ensure that communications values
entered in the previous step correspond to the relay setting values.
Z Click OK when complete.
Z From the EnerVista main window, select the IED Dashboard item to
open the Plug and Play IED dashboard.
An icon for the PQMII will be shown.

CHAPTER 4: SOFTWARE
FIGURE 4–9: ‘Plug and Play’ Dashboard
Z Click the Dashboard button below the PQMII icon to view the device
information.
We have now successfully accessed our PQMII through EnerVista
Viewpoint.

CHAPTER 4: SOFTWARE
FIGURE 4–10: EnerVista Plug and Play Screens

CHAPTER 4: SOFTWARE
For additional information on EnerVista viewpoint, please visit the EnerVista website at
http://www.enervista.com.

CHAPTER 4: SOFTWARE

Digital Energy
Multilin
Chapter 5: Setpoints
Setpoints
5.1 Introduction
5.1.1 Setpoint Entry Methods

Prior to operating the PQMII, it is necessary to program setpoints to define system
characteristics and alarm settings by one of the following methods:
• Front panel, using the keys and display.
• Rear terminal RS485 port COM1 or COM2, or front RS232 port and a computer
running the EnerVista PQMII Setup Software included with the PQMII, or from a
SCADA system running user-defined software.
Either of the above methods can be used to enter the same information. However, a
computer makes information entry considerably easier. Moreover, a computer allows
setpoint files to be stored and downloaded for fast, error-free entry. The EnerVista PQMII
Setup Software included with the PQMII facilitates this process. With this software,
setpoints can be modified remotely and downloaded at a later time to the PQMII. Refer to
4.4: Using the EnerVista PQMII Setup Software for additional details.
Setpoint messages are organized into logical groups or pages for easy reference.
Messages may vary somewhat from those illustrated because of installed options, and
messages associated with disabled features will be hidden. This context sensitive
operation eliminates confusing detail. Before accurate monitoring can begin, the setpoints
on each page should be worked through, entering values either by local keypad or
computer.
The PQMII leaves the factory with setpoints programmed to default values. These values
are shown in all setpoint message illustrations. Many of these factory default values can be
left unchanged. At a minimum, however, setpoints that are shown shaded in 5.3.1: Current
and Voltage Configuration must be entered for the system to function correctly. As a
safeguard, the PQMII will alarm and lock-out until values have been entered for these
setpoints. The CRITICAL SETPOINTS NOT STORED alarm message will be displayed until the
PQMII is programmed with these critical setpoints.

5.1.2 Setpoints Main Menu
SETPOINTS [Z] PREFERENCES [Z]

See page 5–5.
S1 PQMII SETUP
SETPOINT [Z]
ACCESS
COM1 RS485 [Z]
SERIAL PORT
COM2 RS485 [Z]
SERIAL PORT
FRONT PANEL [Z]
RS232 SERIAL PORT
DNP 3.0 [Z]
CONFIGURATION
CLOCK [Z]
CALCULATION [Z]
PARAMETERS
CLEAR DATA [Z]
EVENT RECORDER [Z]

TRACE MEMORY [Z]

PROGRAMMABLE [Z]
MESSAGE
PRODUCT [Z]
OPTIONS
END OF PAGE S1 [Z]
MESSAGE
MESSAGE
SETPOINTS [Z] CURRENT/ [Z]

See page 5–19.
S2 SYSTEM SETUP VOLTAGE CONFIG.
ANALOG [Z]
OUTPUT 1
ANALOG [Z]
OUTPUT 2
ANALOG [Z]
OUTPUT 3
ANALOG [Z]
OUTPUT 4

ANALOG INPUT [Z]

SWITCH INPUT A [Z]

SWITCH INPUT B [Z]

SWITCH INPUT C [Z]

SWITCH INPUT D [Z]

PULSE OUTPUT [Z]

PULSE INPUT [Z]

DATA LOGGER [Z]

VOLTAGE DIST. [Z]

RECORDER
END OF PAGE S2 [Z]
MESSAGE
MESSAGE
SETPOINTS [Z] ALARM RELAY [Z]

See page 5–32.
S3 OUTPUT RELAYS
AUXILIARY [Z]
RELAY 1
AUXILIARY [Z]
RELAY 2
AUXILIARY [Z]
RELAY 3
END OF PAGE S3 [Z]
MESSAGE
MESSAGE
SETPOINTS [Z] CURRENT/ [Z]

See page 5–34.
S4 ALARMS/CONTROL VOLTAGE
TOTAL HARMONIC [Z]
DISTORTION
FREQUENCY [Z]
POWER [Z]

POWER FACTOR [Z]

DEMAND [Z]
PULSE INPUT [Z]

TIME [Z]
MISCELLANEOUS [Z]
END OF PAGE S4 [Z]

MESSAGE
MESSAGE
SETPOINTS [Z] TEST RELAYS & [Z]

See page 5–51.
S5 TESTING LEDS
CURRENT/ [Z]
VOLTAGE SIMULATION
ANALOG OUTPUTS [Z]
SIMULATION
ANALOG INPUT [Z]
SIMULATION
SWITCH INPUTS [Z]
SIMULATION
FACTORY USE [Z]
ONLY
END OF PAGE S5 [Z]
MESSAGE

5.2 S1 PQMII Setup
5.2.1 Description
General settings to configure the PQMII are entered on this page. This includes user
preferences, the RS485 and RS232 communication ports, loading of factory defaults, and
user-programmable messages.
5.2.2 Preferences
PATH: SETPOINTS Ö S1 PQMII SETUP Ö PREFERENCES
PREFERENCES [Z] DEFAULT MESSAGE TIME: Range: 0.1 to 120.0 minutes in steps of
1.0 MINUTES 0.1 or OFF
DISPLAY FILTER Range: 1 to 10 in steps of 1

MESSAGE
CONSTANT: 4
• DEFAULT MESSAGE TIME: Up to 10 default messages can be selected to scan

sequentially when the PQMII is left unattended. If no keys are pressed for the interval
defined by the DEFAULT MESSAGE TIME setting, then the currently displayed message is
automatically overwritten by the first default message. After 3 seconds, the next
default message in the sequence is displayed. Alarm messages will always override
the default message display. Note that any setpoint or measured value can be
selected as a default message.
See 3.4: Default Messages for details on default message operation and programming.
• DISPLAY FILTER CONSTANT: Display filtering may be required in applications where
large fluctuations in current and/or voltage are normally present. This setpoint allows
the user to enter the PQMII filter constant to average all metered values. If the DISPLAY
FILTER CONSTANT setpoint is set to 1, the PQMII updates the displayed metered values
approximately every 400 ms. Therefore, the display updating equals DISPLAY FILTER
CONSTANT × 400 ms.

5.2.3 Setpoint Access

PATH: SETPOINTS Ö S1 PQMII SETUP ÖØ SETPOINT ACCESS
SETPOINT [Z] SETPOINT ACCESS: Range: Disable, Enable

ACCESS DISABLE
ENTER SETPOINT Range: 1 to 999 in steps of 1
MESSAGE
ACCESS CODE: 1
SETPOINT ACCESS ON Range: 1 to 300 min. in steps of 1 or
MESSAGE Unlimited
FOR: 5 min.
CHANGE SETPOINT Range: No, Yes
MESSAGE
ACCESS CODE: No
ENTER NEW ACCESS Range: 1 to 999 in steps of 1
MESSAGE
CODE: 0
RE-ENTER NEW ACCESS Range: 1 to 999 in steps of 1
MESSAGE
CODE: 0
ENCRYPTED SETPOINT Range: N/A
MESSAGE
ACCESS CODE: 376
To enable setpoint access, follow the steps outlined in the following diagram:
ENTER ENTER
STORE STORE
SETPOINT ACCESS: ENTER SETPOINT SETPOINT ACCESS ON

ENABLE ACCESS CODE: 1 FOR: 5 min.
CORRECT
CODE
INCORRECT
CODE
INCORRECT CODE
SETACCEN.CDR
The factory default access code for the PQMII is 1.

If three attempts are made to enable setpoint access with an incorrect code, the value of
the setpoint access setpoint changes to “Disabled” and the above procedure must be
repeated.
Once setpoint access is enabled, the Program LED indicator turns on. Setpoint alterations
are allowed as long as the Program LED indicator remains on. Setpoint access is be
disabled and the Program LED indicator turns off when:
• The time programmed in S1 PQMII SETUP Ö SETPOINT ACCESS ÖØ SETPOINT ACCESS ON FOR
is reached
• The control power to the PQMII is removed
• The factory setpoints are reloaded
To permanently enable the setpoint access feature, enable setpoint access and then set
SETPOINT ACCESS ON FOR to “Unlimited”. Setpoint access remains enabled even if the control
power is removed from the PQMII.

Setpoints can be changed via the serial ports regardless of the state of the setpoint
Note
access feature or the state of an input switch assigned to setpoint access.

To change the setpoint access code, enable setpoint access and perform the steps as
outlined below:
ENTER ENTER
CHANGE SETPOINT ENTER SETPOINT RE-ENTER SETPOINT

ACCESS CODE: YES ACCESS CODE: 4 ACCESS CODE: 4
SAVCCCD.CDR
If an attempt is made to change a setpoint when setpoint access is disabled, the SETPOINT
ACCESS: DISABLED message is displayed to allow setpoint access to be enabled. Once
setpoint access has been enabled, the PQMII display will return to the original setpoint
message.
If the control option is installed and one of the switches is assigned to “Setpoint Access”,
the setpoint access switch and the software setpoint access will act as a logical ‘AND’. That
is, both conditions must be satisfied before setpoint access will be enabled. Assuming the
setpoint access switch activation is set to closed, the following flash messages will appear
depending upon the condition present when the ENTER key is pressed.
Table 5–1: Setpoint Access Conditions
Condition Displayed Message
Access Code Switch Input
SETPOINT ACCESS OFF

Incorrect Open ENTER ACCESS CODE
SETPOINT ACCESS OFF

Incorrect Closed ENTER ACCESS CODE
CANNOT ALTER SETTING

Correct Open ACCESS SW. DISABLED
NEW SETPOINT
Correct Closed STORED
5.2.4 Serial Ports

PATH: SETPOINTS Ö S1 PQMII SETUP ÖØ COM1 RS485 SERIAL PORT
COM1 RS485 [Z] MODBUS COMMUNICATION Range: 1 to 255 in steps of 1

SERIAL PORT ADDRESS: 1
COM1 BAUD RATE: Range: 1200, 2400, 4800, 9600, and
MESSAGE 19200 baud
19200 BAUD
COM1 PARITY: NONE Range: None, Even, Odd
MESSAGE

COM2 RS485 [Z] COM2 BAUD RATE: Range: 1200, 2400, 4800, 9600, and
SERIAL PORT 19200 BAUD 19200 baud
COM2 PARITY: NONE Range: None, Even, Odd

MESSAGE
FRONT PANEL [Z] RS232 BAUD RATE: Range: 1200, 2400, 4800, 9600, and
RS232 SERIAL PORT 9600 Baud 19200 baud
RS232 PARITY: None Range: None, Even, Odd

MESSAGE
• MODBUS COMMUNICATION ADDRESS: Enter a unique address from 1 to 255. The

selected address is used for all serial communication ports. Address 0 represents a
broadcast message to which all PQMIIs will listen but not respond. Although addresses
do not have to be sequential, no two PQMIIs can have the same address or there will
be conflicts resulting in errors. Generally, each PQMII added to the link uses the next
higher address, starting from address 1.
• BAUD RATE: Enter the baud rate for each port: 1200, 2400, 4800, 9600, or 19200 baud.
All PQMIIs and the computer on the RS485 communication link must run at the same
baud rate. The fastest response is obtained at 19200 baud. Use slower baud rates if
noise becomes a problem. The data frame consists of 1 start bit, 8 data bits, 1 stop bit
and a programmable parity bit. The baud rate default setting is 9600.
• PARITY: Enter the parity for each communication port: “Even”, “Odd”, or “None”. All
PQMIIs on the RS485 communication link and the computer connecting them must
have the same parity.
5.2.5 DNP 3.0 Configuration

PATH: SETPOINTS Ö S1 PQMII SETUP ÖØ DNP 3.0 CONFIGURATION
DNP 3.0 [Z] DNP PORT: None Range: None, COM1, COM2
CONFIGURATION
▲
DNP SLAVE ADDRESS: Range: 0 to 255 in steps of 1
▼
0
DNP TURNAROUND TIME: Range: 0 to 100 ms in steps of 10
▲
0 ms
• DNP PORT: Select the appropriate PQMII port to be used for DNP protocol. The COM2
selection is only available if T1 or T20 option is installed in the PQMII. Each port is
configured as shown in 5.2.4: Serial Ports.
• DNP SLAVE ADDRESS: Enter a unique address from 0 to 255 for this particular PQMII.
The address selected is applied to the PQMII port currently assigned to communicate
using the DNP protocol. Although addresses do not have to be sequential, no two
PQMIIs that are daisy chained together can have the same address or there will be
conflicts resulting in errors. Generally each PQMII added to the link will use the next
higher address.
• DNP TURNAROUND TIME: The turnaround time is useful in applications where the
RS485 converter without RTS or DTR switching is being employed. A typical value for
the delay is 30 ms to allow the transmitter to drop in the RS485 converter.

5.2.6 Clock
PATH: SETPOINTS Ö S1 PQMII SETUP ÖØ CLOCK
CLOCK [Z] SET TIME hh:mm:ss Range: time format as shown

12:00:00 am DATE Z
SET DATE dd:mm:yyyy Range: date format as shown
MESSAGE
Nov 21, 2003
• SET TIME/DATE: These messages are used to set the time and date for the PQMII
software clock.
The PQMII software clock is retained for power interruptions of approximately thirty
days. A Clock Not Set alarm can be enabled so that an alarm will occur on the loss of
clock data. The time and date are used for all time-stamped data. If the clock has not
been set, a “?” will appear on the right-hand side of the displayed time for all time-
stamped data. Follow the steps shown below to set the new time and date.
USE THE VALUE

KEYS TO CHANGE
VALUE
THE UNDERLINED
QUANTITIES
MESSAGE MESSAGE
SET TIME hh:mm:ss SET TIME hh:mm:ss SET TIME hh:mm:ss

12:00:00 am DATE-> 03:00:00 am DATE-> 03:35:00 am DATE->
MESSAGE ENTER MESSAGE

MESSAGE
SET DATE mm:dd:yyyy NEW TIME SET TIME hh:mm:ss

Jan 01, 1996 HAS BEEN STORED 03:35:55 am DATE->
MESSAGE MESSAGE ENTER

STORE
SET DATE mm:dd:yyyy SET DATE mm:dd:yyyy NEW DATE

Oct 01, 1996 Jan 01, 1997 HAS BEEN STORED
FIGURE 5–1: Setting the Date and Time
The time and date can also be set via Modbus communications. Refer to Broadcast
Command (Function Code 10h) on page 7–10 as an example.

5.2.7 Calculation Parameters

PATH: SETPOINTS Ö S1 PQMII SETUP ÖØ CALCULATION PARAMETERS
CALCULATION [Z] EXTRACT FUNDAMENTAL: Range: Disable, Enable

PARAMETERS DISABLE
CURRENT DEMAND TYPE: Range: Thermal Exponential, Rolling
MESSAGE Interval, Block Interval
THERMAL EXPONENTIAL
CURRENT DEMAND TIME Range: 5 to 180 min. in steps of 1
MESSAGE
INTERVAL: 30 min.
POWER DEMAND TYPE: Range: Thermal Exponential, Rolling
MESSAGE Interval, Block Interval
THERMAL EXPONENTIAL
POWER DEMAND TIME Range: 5 to 180 min. in steps of 1
MESSAGE
INTERVAL: 30 min.
ENERGY COST PER kWh Range: 0.01 to 500.00 cents in steps of
MESSAGE 0.01
10.00 cents
TARIFF PERIOD 1 Range: 0 to 1439 min. in steps of 1
MESSAGE
START TIME: 0 min.
TARIFF PERIOD 1 COST Range: 0.01 to 500.00 cents in steps of
MESSAGE 0.01
PER kWh: 10.00 cents
MESSAGE
START TIME: 0 min.
MESSAGE 0.01
MESSAGE
START TIME: 0 min.
MESSAGE 0.01
The PQMII can be programmed to calculate metering quantities and demand by various
methods.
• EXTRACT FUNDAMENTAL: The PQMII can be programmed to calculate all metering
quantities using true RMS values or the fundamental component of the sampled data.
When this setpoint is set to “Disable”, the PQMII will include all harmonic content, up to
the 32nd harmonic, when making metering calculations. When this setpoint is set to
“Enable”, the PQMII will extract the fundamental contribution of the sampled data only
and use this contribution to calculate all metering quantities. Many utilities base their
metering upon fundamental, or displacement, values. Using the fundamental
contribution allows one to compare the quantities measured by the PQMII with the
local utility meter.
• CURRENT DEMAND TYPE: Three current demand calculation methods are available:
thermal exponential, block interval, and rolling interval (see the Demand Calculation
Methods table below). The current demand for each phase and neutral is calculated
individually.
• CURRENT DEMAND TIME INTERVAL: Enter the time period over which the current
demand calculation is to be performed.

• POWER DEMAND TYPE: Three real/reactive/apparent power demand calculation

methods are available: thermal exponential, block interval, and rolling interval (see the
Demand Calculation Methods table below). The three phase real/reactive/apparent
power demand is calculated.
• POWER DEMAND TIME INTERVAL: Enter the time period over which the power
demand calculation is to be performed.
Table 5–2: Demand Calculation Methods
Method Description
This selection emulates the action of an analog peak-recording

thermal demand meter. The PQMII measures the average quantity
(RMS current, real power, reactive power, or apparent power) on each
phase every minute and assumes the circuit quantity remains at this
value until updated by the next measurement. It calculates the
“thermal demand equivalent” based on the following equation:
– kt
d(t) = D(1 – e ) (EQ 5.1)
where: d = demand after applying input quantity for time t (in min.)
D = input quantity (constant)
k = 2.3 / thermal 90% response time
100
Thermal
Exponential 80
Demand (%)
60
40
20
0
0 3 6 9 12 15 18 21 24 27 30
Time (min)
The graph above shows the thermal response characteristic for a

thermal 90% response time of 15 minutes. A setpoint establishes the
time to reach 90% of a steady-state value, just as the response time
of an analog instrument (a steady-state value applied for twice the
response time will indicate 99% of the value).
This selection calculates a linear average of the quantity (RMS

Block Interval current, real power, reactive power, or apparent power) over the
programmed demand TIME INTERVAL . Each new value of demand
becomes available at the end of each time interval.
This selection calculates a linear average of the quantity (RMS

current, real power, reactive power, or apparent power) over the
Rolling Interval programmed demand TIME INTERVAL (in the same way as Block
Interval). The value is updated every minute and indicates the
demand over the time interval just preceding the time of update.
• ENERGY COST PER kWh: Enter the cost per kWh that is charged by the local utility.
• TARIFF PERIOD START TIME: Enter the start time for each of the three tariff period
calculations.
• TARIFF PERIOD COST PER kWh: Enter the cost per kWh for each of the three tariff
periods.

5.2.8 Clear Data

PATH: SETPOINTS Ö S1 PQMII SETUP ÖØ CLEAR DATA
CLEAR DATA [Z] CLEAR ENERGY Range: Yes, No

VALUES: NO
CLEAR MAX DEMAND Range: Yes, No
MESSAGE
VALUES: NO
CLEAR ALL DEMAND Range: Yes, No
MESSAGE
VALUES: NO
CLEAR MIN/MAX Range: Yes, No
MESSAGE
CURRENT VALUES: NO
MESSAGE
VOLTAGE VALUES: NO
MESSAGE
POWER VALUES: NO
MESSAGE
FREQUENCY VALUES: NO
CLEAR MAX THD Range: Yes, No
MESSAGE
VALUES: NO
CLEAR PULSE INPUT Range: Yes, No
MESSAGE
VALUES: NO
CLEAR EVENT RECORD: Range: Yes, No
MESSAGE
NO
CLEAR VOLTAGE DIST. Range: Yes, No
MESSAGE
RECORD: NO
LOAD FACTORY DEFAULT Range: Yes, No
MESSAGE
SETPOINTS: NO
• CLEAR ENERGY VALUES: Enter “Yes” to clear all the energy used data in the A1
METERING ÖØ ENERGY actual values subgroup. The TIME OF LAST RESET date under
the same subgroup is updated upon issuing this command.
• CLEAR MAX DEMAND VALUES: Enter “Yes” to clear all the maximum power and
current demand data under the actual values subgroup A1 METERING ÖØ DEMAND.
The time and date associated with each message will be updated to the current date
upon issuing this command.
• CLEAR ALL DEMAND VALUES: Enter “Yes” to clear all the power and current demand
data under the actual values subgroup A1 METERING ÖØ DEMAND. The time and date
associated with each message will be updated to the current date upon issuing this
command.
• CLEAR MIN/MAX CURRENT VALUES: Enter “Yes” to clear all the minimum/maximum
current data under the actual values subgroup A1 METERING ÖØ CURRENT. The time
and date associated with each message will be updated to the current date upon
issuing this command.
• CLEAR MIN/MAX VOLTAGE VALUES: Enter “Yes” to clear all the minimum/maximum
voltage data under the actual values subgroup A1 METERING ÖØ VOLTAGE. The time

and date associated with each message will be updated to the current date upon
• CLEAR MIN/MAX POWER VALUES: Enter “Yes” to clear all the minimum/maximum
power data under the actual values subgroup A1 METERING ÖØ POWER. The time and
date associated with each message will be updated to the current date upon issuing
this command.
• CLEAR MIN/MAX FREQUENCY VALUES: Enter “Yes” to clear all the minimum/maximum
frequency data under the actual values subgroup A1 METERING ÖØ FREQUENCY. The
time and date associated with each message will be updated to the current date upon
• CLEAR MAX THD VALUES: Enter “Yes” to clear all the max THD data under the actual
values subgroup A3 POWER ANALYSIS ÖØ TOTAL HARMONIC DISTORTION. The time and
date associated with each message will be updated to the current date upon issuing
this command.
• CLEAR PULSE INPUT VALUES: Enter “Yes” to clear all the pulse input values under the
actual values subgroup A1 METERING ÖØ PULSE INPUT. The time and date associated
with this message will be updated to the current date upon issuing this command.
• CLEAR EVENT RECORD: Enter “Yes” to clear all of the events in the Event Record. This
will eliminate all previous events from the Event Record and create a Clear Events
event as the new event number 1. The Event Recorder can be cleared only if it is
enabled in S1 PQMII SETUP ÖØ EVENT RECORDER ÖØ EVENT RECORDER OPERATION.
The CLEAR EVENT RECORD command takes six seconds to complete, during which no new
events will be logged. Do not cycle power to the unit while the event record is being
cleared.
• CLEAR VOLTAGE DIST. RECORD: Enter “Yes” to clear all of the events in the Voltage
Disturbance Record.
• LOAD FACTORY DEFAULT SETPOINTS: When the PQMII is shipped from the factory all
setpoints will be set to factory default values. These settings are shown in the setpoint
message reference figures. To return a PQMII to these known setpoints select “Yes”
and press the key while this message is displayed. The display will then warn that all
setpoints will be lost and will ask whether to continue. Select yes again to reload the
setpoints. It is a good idea to first load factory defaults when replacing a PQMII to
ensure all the settings are defaulted to reasonable values.

PATH: SETPOINTS Ö S1 PQMII SETUP ÖØ EVENT RECORDER
EVENT RECORDER [Z] EVENT RECORDER Range: Enable, Disable

OPERATION: DISABLE
The Event Recorder can be disabled or enabled using the EVENT RECORDER OPERATION
setpoint. When the Event Recorder is disabled no new events are recorded. When the
Event Recorder is enabled new events are recorded with the 150 most recent events
displayed in A3 POWER ANALYSIS ÖØ EVENT RECORDER . Refer to 6.4.4 Event Recorder for
the list of possible events. All data within the Event Recorder is stored in non-volatile
memory.

5.2.10 Trace Memory

PATH: SETPOINTS Ö S1 PQMII SETUP ÖØ TRACE MEMORY
TRACE MEMORY [Z] TRACE MEMORY USAGE: Range: 1 x 36, 2 x 18, 3 x 12 cycles
1 x 36 cycles
TRACE MEMORY TRIGGER Range: One Shot, Retrigger
MESSAGE
MODE: ONE SHOT
Ia OVERCURRENT TRIG Range: 1 to 150% of CT in steps of 1 or
MESSAGE OFF
LEVEL: OFF % CT
Ib OVERCURRENT TRIG Range: 1 to 150% of CT in steps of 1 or
MESSAGE OFF
LEVEL: OFF % CT
Ic OVERCURRENT TRIG Range: 1 to 150% of CT in steps of 1 or
MESSAGE OFF
LEVEL: OFF % CT
In OVERCURRENT TRIG Range: 1 to 150% of CT in steps of 1 or
MESSAGE OFF
LEVEL: OFF % CT
Va OVERVOLTAGE TRIG Range: 20 to 150% of Nominal in steps
MESSAGE of 1 or OFF
LEVEL: OFF % NOMINAL
Vb OVERVOLTAGE TRIG Range: 20 to 150% of Nominal in steps
MESSAGE of 1 or OFF
Vc OVERVOLTAGE TRIG Range: 20 to 150% of Nominal in steps
MESSAGE of 1 or OFF
Va UNDERVOLTAGE TRIG Range: 20 to 150% of Nominal in steps
MESSAGE of 1 or OFF
Vb UNDERVOLTAGE TRIG Range: 20 to 150% of Nominal in steps
MESSAGE of 1 or OFF
Vc UNDERVOLTAGE TRIG Range: 20 to 150% of Nominal in steps
MESSAGE of 1 or OFF
SWITCH INPUT A TRIG: Range: Off, Open-to-Closed,
MESSAGE Closed-to-Open
OFF
SWITCH INPUT B TRIG: Range: Off, Open-to-Closed,
OFF
SWITCH INPUT C TRIG: Range: Off, Open-to-Closed,
OFF
SWITCH INPUT D TRIG: Range: Off, Open-to-Closed,
OFF
TRACE MEMORY TRIGGER Range: 0 to 30 cycles in steps of 2
MESSAGE
DELAY: 0 cycles
TRACE MEMORY TRIGGER Range: Off, Aux1, Aux2, Aux3, Alarm
MESSAGE
RELAY: OFF
The Trace Memory feature involves a separate sampling data stream. All input channels
are sampled continuously at a rate of 16 times per cycle. Using a single-cycle block
interval, the input samples are checked for trigger conditions as per the trigger setpoints
below. Note that the normal sampling burst (64 samples/cycle, 2 cycles) used for all

metering calculations is done on top of the trace memory sampling. The harmonic analysis
sampling (256 samples/cycles, 1 cycle) causes the trace memory sampling to stop for one
cycle whenever a harmonic analysis is requested. Refer to 4.5.3 Trace Memory for details
on trace memory implementation in the EnerVista PQMII Setup Software.
• TRACE MEMORY USAGE: The trace memory feature allows the user to capture
maximum of 36 cycles. The TRACE MEMORY USAGE setpoint allows the buffer to be divided
into maximum of 3 separate buffers as shown in table below.

Setpoint Value Result

1 x 36 cycles Upon a trigger, the entire buffer is filled with 36 cycles of data.
The buffer is split into 2 separate buffers and upon a trigger, the
2 x 18 cycles first buffer is filled with 18 cycles of data and upon a second
trigger, the second buffer is filled with 18 cycles of data.
The buffer is split into 3 separate buffers and upon a trigger, the
first buffer is filled with 12 cycles of data, upon a second trigger,
3 x 12 cycles
the second buffer is filled with 12 cycles of data and upon a
third trigger, the third buffer is filled with 12 cycles of data.
• TRACE MEMORY TRIGGER MODE: The trace memory can be configured to trigger in
two different modes as described in the table below.
Setpoint Value Result
The trace memory will be triggered once per buffer as defined
in the TRACE MEMORY USAGE setpoint above. In order for it to
One Shot re-trigger, it must be re-armed through the serial port using the
EnerVista PQMII Setup Software or other software. Once re-
armed the trace memory will default back to the first buffer.
The trace memory will automatically re-trigger upon each
Retrigger
condition and overwrite the previous buffer data.
• Ia/Ib/Ic/In OVERCURRENT TRIG LEVEL: Once the phase A/B/C/neutral current equals
or increases above this setpoint value, the trace memory is triggered and data on all
inputs are captured in the buffer. The number of cycles captured depends on the value
specified in the TRACE MEMORY USAGE setpoint.
• Va/Vb/Vc OVERVOLTAGE TRIG LEVEL: Once the phase A/B/C voltage equals or
increases above this setpoint value, the trace memory is triggered and data on all
inputs are captured in the buffer. The number of cycles captured depends on the value
specified in the TRACE MEMORY USAGE setpoint. Phase to neutral levels are used
regardless of the VT wiring.
• Va/Vb/Vc UNDERVOLTAGE TRIG LEVEL: Once the phase A/B/C voltage is equal to or
less than this setpoint value, the trace memory is triggered and data on all inputs are
captured in the buffer. The number of cycles captured depends on the value specified
in the TRACE MEMORY USAGE setpoint.
• SWITCH INPUT A(D) TRIG: If the setpoint is set to “Open-to-Closed”, the trace memory
is triggered and data on all inputs are captured in the buffer on a Switch A(D) close
transition. If the setpoint is set to “Closed-to-Open”, the trace memory is triggered and
data on all inputs are captured in the buffer on a Switch A(D) open transition. The
number of cycles captured depends on the value specified in the TRACE MEMORY USAGE
setpoint.
• TRACE MEMORY TRIGGER DELAY: In some applications it may be necessary to delay
the trigger point to observe the data before the fault occurred. The PQMII allows the
trigger to be delayed by the amount of cycles set in this setpoint. Therefore, buffer will
always contain the number cycles specified in this setpoint before the trigger point
and the remaining space in the buffer is filled with the cycles after the trigger point.
• TRACE MEMORY TRIGGER RELAY: The relay selected here will be activated upon the
occurrence of a Trace Memory Trigger. This relay will be cleared once the Trace
Memory is re-armed.
See 7.4 Triggered Trace Memory for additional details on this feature.

5.2.11 Programmable Message

PATH: SETPOINTS Ö S1 PQMII SETUP ÖØ PROGRAMMABLE MESSAGE
PROGRAMMABLE [Z] PHONE: 905-294-6222 Range: 40 alphanumeric characters

MESSAGE www.GEmultilin.com
A 40-character message can be programmed using the keypad, or via a serial port using
the EnerVista PQMII Setup Software. An example of writing a new message over the
existing one is shown below:
MESSAGE ENTER Displayed for 3 seconds when

ENTER key pressed
n PROGRAMMABLE PHONE: 905-294-6222 NEW SETPOINT

n MESSAGE GEindustrial.com STORED
ENTER
STORE
USE THE VALUE

KEYS TO SELECT NEW SETPOINT PHONE: 905-294-6222
VALUE
THE UNDERLINED STORED GEindustrial.com
QUANTITIES
Displayed for 3 seconds when
ENTER key pressed
TIPS:
• The setpoint access must be enabled in order to alter the characters.
• To skip over a character press the ENTER key.
• If a character is entered incorrectly, press the ENTER key repeatedly until the
cursor returns to the position of the error, and re-enter the character.
• See 3.4 Default Messages for details on selecting this message as a default
message
A copy of this message is displayed in actual values page A2 STATUS ÖØ PROGRAMMABLE
MESSAGE.

5.2.12 Product Options

PATH: SETPOINTS Ö S1 PQMII SETUP ÖØ PRODUCT OPTIONS
PRODUCT [Z] SELECT ORDER: Range: see range in PQMII Modbus

OPTIONS PQMII-T20-C-A memory format code F116
SELECT MOD1 TO Range: 0 to 999 in steps of 1

MESSAGE
ENABLE: 0
MESSAGE
ENABLE: 0
MESSAGE
ENABLE: 0
MESSAGE
ENABLE: 0
MESSAGE
ENABLE: 0
ENTER PASSCODE: _ Range: consult the factory
MESSAGE
The PQMII can have options and certain modifications upgraded on-site via use of a
passcode provided by GE Multilin. Consult the factory for details on the use of this feature.

5.3 S2 System Setup
5.3.1 Current and Voltage Configuration
The shaded setpoints below must be set to a value other than “Off” to clear the Critical
Note
Setpoints Not Stored alarm.
PATH: SETPOINTS ÖØ S2 SYSTEM SETUP Ö CURRENT/VOLTAGE CONFIG.
CURRENT/ [Z] PHASE CT WIRING: Range: A, B, and C, A and B only, A and

VOLTAGE CONFIG. Phases A, B, AND C C only, A only
PHASE CT PRIMARY: Range: 5 to 12000 A in steps of 5 or Off

MESSAGE
OFF A
NEUTRAL CURRENT Range: Off, Separate CT, Calculated
MESSAGE
SENSING: OFF
NEUTRAL CT PRIMARY: Range: 5 to 6000 A in steps of 5
MESSAGE
100 A
VT WIRING: Range: Off, 4 Wire Wye / 3 VTs, 4 Wire
MESSAGE Wye / Direct, 4 Wire Wye / 2
OFF
VTs, 3-Wire Delta / 2 VTs, 3
Wire Direct, Single Phase Direct
VT RATIO: Range: 1.0 to 3500.0 in steps of 0.1
MESSAGE
1.0 : 1
VT NOMINAL SECONDARY Range: 40 to 600 V in steps of 1
MESSAGE
VOLTAGE: 120 V
NOMINAL DIRECT INPUT Range: 40 to 600 V in steps of 1
MESSAGE
VOLTAGE: 600 V
NOMINAL SYSTEM Range: 50 Hz, 60 Hz
MESSAGE
FREQUENCY: 60 Hz
• PHASE CT WIRING: The table below indicates the required connection per setpoint
setting.
Setpoint Value Required CT Connection
A,B, and C CTs are connected to phase A, B and C inputs.
CTs are connected to phase A and B only. Phase C input is left
A and B Only
open. The value for phase C is calculated by the PQMII.
CTs are connected to phase A and C only. Phase B input is left
A and C Only
open. The value for phase B is calculated by the PQMII.
CT is connected to phase A only. Phase B and C inputs are left
A Only
open. The values for phase B and C are calculated by the PQMII.
If the “A and B Only”, “A and C Only”, or “A Only” connection is selected, the neutral
sensing must be accomplished with a separate CT.
• PHASE CT PRIMARY: Enter the primary current rating of the phase current
transformers. All three phase CTs must have the same rating. For example, if 500:5 CTs
are used, the PHASE CT PRIMARY value is entered as “500”. The PHASE CT PRIMARY factory
default is “Off”. While set to “Off”, the PQMII is forced to an alarm state as a safety

precaution until a valid CT value is entered. Ensure that the CT is connected to the
correct 1 or 5 A terminals to match the CT secondary.
• NEUTRAL CURRENT SENSING: Neutral current sensing can be accomplished by using
a separate external CT connection or by calculations. Select “Separate CT” when using
an external CT. If “Calculated” is selected, the PQMII calculates the neutral current
using the vector sum of Ia + Ib + Ic = In. If a residual connection is required using the
PQMII internal CT, the neutral CT primary must be the same as the phase CT primary to
ensure correct readings.
• NEUTRAL CT PRIMARY: This message is visible only if the neutral current sensing
setpoint is set to “Separate CT”. Enter the CT primary current. For example, if a 50:5 CT
is installed for neutral sensing enter 50. One amp CTs can also be used for neutral
sensing.
• VT WIRING: Enter the VT connection of the system in this setpoint. The three possible
wiring configurations are Wye, Delta, and Single Phase.
If the system to be measured is a Wye connection, the selections are “4 Wire Wye
Direct”, “4 Wire Wye / 3 VTs”, and “4 Wire Wye /2 VTs”. The “4 Wire Wye Direct” value is
used for systems that are 600 V or less and directly connected to the PQMII. The VT
NOMINAL SECONDARY VOLTAGE setpoint is replaced by NOMINAL DIRECT INPUT VOLTAGE. With
external VTs (depending upon how many external VTs are used), the “4 Wire Wye / 3
VTs” or “4 Wire Wye / 2 VTs” value must be selected. Note that when using the “4 Wire
Wye / 2 VTs” value, only two voltages are measured; the third voltage is calculated on
the assumption that Van + Vbn + Vcn = 0. This assumption is valid only for balanced
system voltages.
If the system to be measured is a Delta connection, the values are “3 Wire Direct” and
“3 Wire Delta / 2 VTs”. The “3 Wire Direct” value should be used for systems that are
600 V or less and directly connected to the PQMII. With external VTs, “3 Wire Delta / 2
VTs” must be selected.
The PQMII accepts input voltages from 0 to 600 V AC between any two of the voltage
terminals (V1, V2, V3, and Vn). These inputs can be directly connected or supplied via
external VTs. External VTs are required for input voltages greater than 600 V AC (line-
to-line). When measuring line-to-line quantities using inputs V1, V2 and V3, ensure
that the voltage common input Vn is grounded. This input is used as a reference for
measuring the voltage inputs.
All connections to the PQMII voltage inputs should be connected using HRC fuses
rated at 2 amps to ensure adequate interrupting capacity.
• VT RATIO: Enter the voltage transformer ratio. All three voltage inputs must be of the
same rating. For example, if 4200:120 VTs are used, the VT RATIO should be 4200 / 120 =
35.0:1. This setpoint is not visible if VT WIRING is set to “3 Wire Direct”, “4 Wire Direct”, or
“Single Phase Direct”.
• VT NOMINAL SECONDARY VOLTAGE: Enter the nominal secondary of the VTs. If the
voltage inputs are directly connected, enter the nominal system voltage that will be
applied to the PQMII. This setpoint is not visible if the VT WIRING is set to “3 Wire Direct”,
“4 Wire Direct”, or “Single Phase Direct”. This value is used to scale an analog output
that is assigned to display voltage as a percentage of nominal.
• NOMINAL DIRECT INPUT VOLTAGE: This setpoint is displayed only if VT WIRING is
selected as a direct connection. The nominal direct input voltage must be entered in

this message. This value will be used to scale an analog output that is assigned to
display voltage as a percentage of nominal.
• NOMINAL SYSTEM FREQUENCY: Enter the nominal system frequency. The PQMII
measures frequency from the Van voltage and adjusts its internal sampling to best fit
the measured frequency. If the Van input is unavailable, the PQMII will assume the
frequency entered here.

PATH: SETPOINTS ÖØ S2 SYSTEM SETUP ÖØ ANALOG OUTPUT 1(4)
ANALOG [Z] ANALOG OUTPUT RANGE: Range: 0-20 mA, 4-20 mA. Seen only in
OUTPUT 1 4-20 mA the Analog Output 1 menu.
ANALOG OUTPUT 1 MAIN: Range: refer to the Analog Output

MESSAGE Parameters table below
Not Used
MAIN 4 mA VALUE: Range: refer to the Analog Output
0
MAIN 20 mA VALUE: Range: refer to the Analog Output
0
ANALOG OUTPUT 1 ALT: Range: refer to the Analog Output
NOT USED
ALT 4 mA VALUE: Range: refer to the Analog Output
0
ALT 20 mA VALUE: Range: refer to the Analog Output
0
The PQMII has four (4) Analog Outputs configured through four setpoints pages. The
ANALOG OUTPUT RANGE setpoint appears in the Analog Output 1 setpoints page only and
applies to all four outputs.
• ANALOG OUTPUT RANGE: If the T20 option is installed, the Analog Outputs can be
configured to operate as 4 to 20 mA current sources or 0 to 20 mA current sources. All
four Analog Outputs will operate in the range defined by this setpoint.
• ANALOG OUTPUT 1(4) MAIN / ANALOG OUTPUT 1(4) ALT: If the PQMII is used in
conjunction with programmable controllers, automated equipment, or a chart
recorder, the analog outputs can be used for continuous monitoring. Although
parameters can be selected for continuous analog output, all values are available
digitally through the communications interface. Applications include using a
computer to automatically shed loads as the frequency decreases by monitoring
frequency or a chart recorder to plot the loading of a system in a particular process.
Each of the analog outputs can be assigned to two of the parameters listed in the
Analog Output Parameters table. The analog output main selection is the default
selection and a programmable switch input can be programmed to multiplex the
ANALOG OUTPUT 1(4) ALT selection to the same output depending upon the open or closed
state of the switch input. See 5.3.4 Switch Inputs for details about configuring a switch
input. If no switch input is assigned as an analog output multiplexer, the analog output
main selection will be the only parameter which appears at the analog output
terminals. The ability to multiplex two different analog output quantities on one

analog output effectively gives the PQMII eight analog outputs. The table below shows
the criteria used by the PQMII to decide whether the output is based on MAIN or ALT
settings.
• MAIN/ALT 4 mA VALUE: This message appears for each analog output and allows the
user to assign a numeric value which corresponds to the 4 mA end of the 4 to 20 mA
signal range (T20 option) or the 0 mA end of the 0 to 1 mA signal range (T1 option). The
numeric value range will depend upon which parameter is selected. See the Analog
Output Parameters table below for details. Note that if the T20 option is installed and
the ANALOG OUTPUT RANGE setpoint is set to “0-20 mA”, this message represents the 0 mA
end of the signal range.
Table 5–3: Analog Output Selection Criteria
Condition Present ‘Main’ ‘Alt’ Parameter Output

Parameter Based On
Any condition “Not Used” “Not Used” Main
Control option ‘C’ not installed any not available Main
Switch assigned to SELECT ANALOG any “Not Used” Main

OUTPUT and is disabled
Switch assigned to SELECT ANALOG any “Not Used” Main

OUTPUT and is enabled
anything other
Any condition “Not Used” than “Not Alt
Used”
anything other
Switch assigned to SELECT ANALOG “Not Used” than “Not Alt
OUTPUT and is disabled
Used”
anything other
Switch assigned to SELECT ANALOG
any than “Not Alt
OUTPUT and is enabled
Used”
• MAIN/ALT 20 mA VALUE: This message appears for each analog output and allows
the user to assign a numeric value which corresponds to the 20 mA end of the 4 to 20
mA signal range (T20 option) or the 1 mA end of the 0 to 1 mA signal range (T1 option).
The numeric value range will depend upon which parameter is selected. See the
Analog Output Parameters table below.
If the 4 mA (or 0 mA) value is programmed to be higher than the 20 mA (or 1 mA) value,
the analog output will decrease towards 4 mA (or 0 mA) as the value increases and the
analog output will increase towards 20 mA (or 1 mA) as the value decreases. If the 4
mA (or 0 mA) and 20 mA (or 1 mA) values are programmed to an identical value, the
output will always be 4 mA (or 0 mA).

Table 5–4: Analog Output Parameters (Sheet 1 of 2)
Parameter Range Step
Phase A Current 0 to 150% 1%
Phase B Current 0 to 150% 1%
Phase C Current 0 to 150% 1%
Neutral Current 0 to 150% 1%
Average Phase Current 0 to 150% 1%
Current Unbalance 0 to 100.0% 0.1%
Voltage Van 0 to 200% 1%
Voltage Vbn 0 to 200% 1%
Voltage Vcn 0 to 200% 1%
Voltage Vab 0 to 200% 1%
Voltage Vbc 0 to 200% 1%
Voltage Vca 0 to 200% 1%
Average Phase Voltage 0 to 200% 1%
Average Line Voltage 0 to 200% 1%
Voltage Unbalance 0 to 100.0% 0.1%
Frequency 00.00 to 75.00 Hz 0.01 Hz
3 Phase PF 0.01 lead to 0.01 lag 0.01
3 Phase kW –32500 to +32500 1 kW
3 Phase kvar –32500 to +32500 1 kvar
3 Phase kVA 0 to 65400 1 kVA
3 Phase MW –3250.0 to +3250.0 0.1 MW
3 Phase Mvar –3250.0 to +3250.0 0.1 Mvar
3 Phase MVA 0 to 6540.0 0.1 MVA
Phase A PF 0.01 lead to 0.01 lag 0.01
Phase A kW –32500 to +32500 1 kW
Phase A kvar –32500 to +32500 1 kvar
Phase A kVA 0 to 65400 1 kVA
Phase B PF 0.01 lead to 0.01 lag 0.01
Phase B kW –32500 to +32500 1 kW
Phase B kvar –32500 to +32500 1 kvar

Table 5–4: Analog Output Parameters (Sheet 2 of 2)
Parameter Range Step
Phase B kVA 0 to 65400 1 kVA
Phase C PF 0.01 lead to 0.01 lag 0.01
Phase C kW –32500 to +32500 1 kW
Phase C kvar –32500 to +32500 1 kvar
Phase C kVA 0 to 65400 1 kVA
3 Phase +kWh Used 0 to 65400 1 kWh
3 Phase +kvarh Used 0 to 65400 1 kvarh
3 Phase –kWh Used 0 to 65400 1 kWh
3 Phase –kvarh Used 0 to 65400 1 kvarh
3 Phase kVAh Used 0 to 65400 1 kVAh
Phase A Current Demand 0 to 7500 1A
Phase B Current Demand 0 to 7500 1A
Phase C Current Demand 0 to 7500 1A
Neutral Current Demand 0 to 7500 1A
3 Phase kW Demand –32500 to +32500 1 kW
3 Phase kvar Demand –32500 to +32500 1 kvar
3 Phase kVA Demand 0 to 65400 1 kVA
3 Phase Current THD 0.0 to 100% 0.1%
3 Phase Voltage THD 0.0 to 100% 0.1%
Phase A Current THD 0.0 to 100% 0.1%
Phase B Current THD 0.0 to 100% 0.1%
Phase C Current THD 0.0 to 100% 0.1%
Voltage Van THD 0.0 to 100% 0.1%
Voltage Vbn THD 0.0 to 100% 0.1%
Voltage Vcn THD 0.0 to 100% 0.1%
Voltage Vab THD 0.0 to 100% 0.1%
Voltage Vbc THD 0.0 to 100% 0.1%
Neutral Current THD 0.0 to 100% 0.1%
Serial Control –32500 to +32500 1 Unit

When the Analog Output parameter is set to “Serial Control”, the analog output(s)
reflect a value in proportion to the serial value written to a specific register within the
PQMII memory map. The locations are as described in the table below.
Analog Output Modbus Register Register

Analog Output 1 Analog Output 1 Serial Value 1067
Analog Output 2 Analog Output 2 Serial Value 106F
Analog Output 3 Analog Output 3 Serial Value 1077
Analog Output 4 Analog Output 4 Serial Value 107F
5.3.3 Analog Input

PATH: SETPOINTS ÖØ S2 SYSTEM SETUP ÖØ ANALOG INPUT
ANALOG INPUT [Z] ANALOG IN MAIN/ALT Range: Aux1, Aux2, Aux3, Off.
SELECT RELAY: OFF
ANALOG IN MAIN NAME: Range: 20 alphanumeric characters
MESSAGE
MAIN ANALOG INPUT
ANALOG IN MAIN Range: 10 alphanumeric characters
MESSAGE
UNITS: Units
MAIN 4 mA VALUE: Range: 0 to 65000 in steps of 1
MESSAGE
0
MAIN 20 mA VALUE: Range: 0 to 65000 in steps of 1
MESSAGE
0
ANALOG IN MAIN: Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
ANALOG IN MAIN LEVEL: Range: 0 to 65000 in steps of 1
MESSAGE
100 Units
ANALOG IN MAIN Range: 0.5 to 600.0 s in steps of 1
MESSAGE
DELAY: 10.0 s
ANALOG IN ALT NAME: Range: 20 alphanumeric characters
MESSAGE
ALT ANALOG INPUT
ANALOG IN ALT Range: 10 alphanumeric characters
MESSAGE
UNITS: Units
ALT 4 mA VALUE: Range: 0 to 65000 in steps of 1
MESSAGE
0
ALT 20 mA VALUE: Range: 0 to 65000 in steps of 1
MESSAGE
0
ANALOG IN ALT: Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
ANALOG IN ALT LEVEL: Range: 0 to 65000 in steps of 1
MESSAGE
100
ANALOG IN ALT Range: 0.5 to 600.0 s in steps of 1
MESSAGE
DELAY: 10.0 s

• ANALOG IN MAIN/ALT SELECT RELAY: Select the output relay that is to be used to
multiplex two analog input signals to the PQMII. If this setpoint is “Off”, the MAIN analog
input setpoints will be used unless a switch input assigned to SELECT ANALOG INPUT is
activated. For more information on multiplexing two analog inputs using one of the
PQMII output relays, refer to 2.2.8 Switch Inputs (Optional).
• ANALOG IN MAIN/ALT NAME: This message allows the user to input a user defined 20
character alphanumeric name for the MAIN and ALT analog inputs. To enter the names,
perform the following steps:
Z Allow access to setpoints by enabling setpoint access.
Z Select the Analog Input name message display under the S2 SYSTEM SETUP
ÖØ ANALOG INPUT setpoints group.
Z Use the VALUE keys to change the blinking character over the cursor. A
space is selected like a character.
Z Press the ENTER key to store the character and advance the cursor to the
next position. To skip over a character press the ENTER key.
Z Continue entering characters and spaces until the desired message is
displayed. If a character is entered incorrectly, press the ENTER key
repeatedly until the cursor returns to the incorrect position and re-enter
the character.
• ANALOG IN MAIN/ALT UNITS: This message allows the user to input a user defined 10
character alphanumeric name for the MAIN and ALT units. To enter the units, perform
the same steps as shown for analog input name.
• MAIN/ALT 4 mA VALUE: This message appears for each analog input and allows the
signal range.
• MAIN/ALT 20 mA VALUE: This message appears for each analog input and allows the
signal range.
• ANALOG IN MAIN/ALT RELAY: Analog input MAIN and ALT detection can either be
disabled, used as an alarm or as a process control. Set this setpoint to OFF if the
feature is not required. Selecting “Alarm” causes the alarm relay to activate and
displays an alarm message whenever a MAIN or ALT analog input condition exists.
Selecting an auxiliary relay causes the selected auxiliary relay to activate with no
message displayed. This is intended for process control.
• ANALOG IN MAIN/ALT LEVEL: When the measured MAIN or ALT analog input meets or
exceeds the level set by this setpoint, a MAIN or ALT analog input condition will occur.
• ANALOG IN MAIN/ALT DELAY: If the MAIN or ALT analog input meets or exceeds the
ANALOG IN MAIN/ALT LEVEL setpoint value and remains this way for the time delay
programmed in this setpoint, an analog input condition will occur. If the ANALOG IN
MAIN/ALT RELAY setpoint is set to “Alarm”, the alarm relay will activate and the ANALOG
IN MAIN/ALT ALARM message will be displayed. If the setpoint ANALOG IN MAIN/ALT RELAY
is set to “Aux1”, “Aux2”, or “Aux3”, the respective auxiliary relay will activate and no
message will be displayed after the delay expires.

5.3.4 Switch Inputs

PATH: SETPOINTS ÖØ S2 SYSTEM SETUP ÖØ SWITCH INPUT A(D)
SWITCH INPUT A [Z] SWITCH A NAME: Range: 20 alphanumeric characters

Switch Input A
SWITCH A FUNCTION: Range: see description below
MESSAGE
NOT USED
SWITCH A ACTIVATION: Range: Open, Closed
MESSAGE
OPEN
SWITCH A TIME DELAY: Range: 0.0 to 600.0 s in steps of 1
MESSAGE
0.0 s
There are four (4) Switch Inputs, denoted as Switch Input A, B, C, and D.
• SWITCH A(D) NAME: This message allows the user to input a user defined 20-
character alphanumeric name for each switch input. To enter a switch name, perform
the following steps:
Z Select the switch input message display under the subgroup S2 SYSTEM
SETUP ÖØ SWITCH INPUT A.
repeatedly to return the cursor to the position of the error, and re-enter
the character.
• SWITCH A(D) FUNCTION: Select the required function for each switch input. See
Switch Inputs (Optional) on page 2–12 for a description of each function. The “New
Demand Period”, “Setpoint Access”, “Select Analog Out”, “Select Analog In”, “Pulse Input
1", “Pulse Input 2", “Pulse Input 3", “Pulse Input 4", “Clear Energy” and “Clear Demand”
functions can be assigned to only one switch input at a time. If an attempt is made to
assign one of these functions to more than one input, the THIS SWITCH FUNCTION
ALREADY ASSIGNED flash message will be displayed. If an attempt is made via the
serial port, no flash message will appear but an error code will be returned.
The range of functions for the SWITCH A(D) FUNCTION setpoint is: Not Used, Alarm, Aux1,
Aux2, Aux3, New Demand Period, Setpoint Access, Select Analog Out, Select Analog In,
Pulse Input 1, Pulse Input 2, Pulse Input 3, Pulse Input 4, Clear Energy, Clear Demand.
• SWITCH A(D) ACTIVATION: This setpoint determines the operating sequence of the
switch. Select “Open” if a switch activation is required for a switch input transition of
closed to open. Select “Closed” if a switch activation is required for a switch input
transition of open to closed.
• SWITCH A(D) TIME DELAY: If the switch input function is assigned to “Alarm”, “Aux1”,
“Aux2”, or “Aux3”, this message will be displayed. Enter the required time delay in this
message.

5.3.5 Pulse Output

PATH: SETPOINTS ÖØ S2 SYSTEM SETUP ÖØ PULSE OUTPUT
PULSE OUTPUT [Z] POS kWh PULSE OUTPUT Range: Alarm, Aux1, Aux2, Aux3, Off
RELAY: OFF
POS kWh PULSE OUTPUT Range: 1 to 65000 kWh in steps of 1
MESSAGE
INTERVAL: 100 kWh
NEG kWh PULSE OUTPUT Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: Off
NEG kWh PULSE OUTPUT Range: 1 to 65000 kWh in steps of 1
MESSAGE
INTERVAL: 100 kWh
POS kvarh PULSE OUTPUT Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
POS kvarh PULSE OUTPUT Range: 1 to 65000 kvarh in steps of 1
MESSAGE
INTERVAL: 100 kvarh
NEG kvarh PULSE OUTPUT Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
NEG kvarh PULSE OUTPUT Range: 1 to 65000 kvarh in steps of 1
MESSAGE
INTERVAL: 100 kvarh
kVAh PULSE OUTPUT Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
kVAh PULSE OUTPUT Range: 1 to 65000 kVAh in steps of 1
MESSAGE
INTERVAL: 100 kVAh
PULSE WIDTH: Range: 100 to 2000 ms in steps of 10
MESSAGE
100 ms
• kWh / kvarh / kVAh PULSE OUTPUT RELAY: Five pulse output parameters can be
assigned to the alarm or auxiliary relays. They are positive kWh, negative kWh, positive
kvarh, negative kvarh, and kVAh. Enter the desired relay to which each parameter is
assigned. Select “Off” if a particular output parameter is not required.
• KWh / kvarh / kVAh PULSE OUTPUT INTERVAL: Enter the interval for the appropriate
quantity at which the relay pulse will occur. The pulse width is set by the PULSE WIDTH
setpoint described below. If the pulse interval is set to “100 kWh”, one pulse will
indicate that 100kWh has been accumulated.
• PULSE WIDTH: This setpoint determines the duration of each pulse as shown in the
figure below.

STATUS STATUS STATUS
Normally Open (NO) Contact OPEN CLOSED OPEN
Normally Closed (NC) Contact CLOSED OPEN CLOSED
PULSE
WIDTH
FIGURE 5–2: Pulse Output Timing
5.3.6 Pulse Input

PATH: SETPOINTS ÖØ S2 SYSTEM SETUP ÖØ PULSE INPUT
PULSE INPUT [Z] PULSE INPUT Range: 10 alphanumeric characters

UNITS: Units
PULSE INPUT 1 VALUE: Range: 0 to 65000 in steps of 1
MESSAGE
1 Units
MESSAGE
1 Units
MESSAGE
1 Units
MESSAGE
1 Units
PULSE INPUT TOTAL: Range: 1+2, 1+3, 1+4, 2+3, 2+4, 3+4,
MESSAGE 1+2+3, 1+3+4, 1+2+4, 2+3+4,
1+2+3+4
1+2+3+4
• PULSE INPUT UNITS: This message allows the user to input a user defined 10
character alphanumeric unit for the pulse inputs (i.e. kWh). The unit will be used by all
pulse inputs including the totalized value. To enter the unit, perform the following
steps:
Z Select the PULSE INPUT UNITS setpoint.


repeatedly until the cursor returns to the incorrect position and re-enter
the character.
• PULSE INPUT 1(4) VALUE: Enter a value in this setpoint that will be equivalent to 1
pulse input on the switch input assigned to Pulse Input 1(4); i.e., 1 pulse = 100 kWh. The
accumulated value is displayed in actual values under A1 METERING ÖØ PULSE INPUT
COUNTERS ÖØ PULSE INPUT 1(4).
• PULSE INPUT TOTAL: This setpoint defines which pulse inputs to add together. For
example, if the selection is this setpoint is “1+2+3”, the PULSE INPUT 1, PULSE INPUT 2
and PULSE INPUT 3 values shown in A1 METERING ÖØ PULSE INPUT COUNTERS ÖØ
PULSE INPUT 1(4) will be added together and displayed in A1 METERING ÖØ PULSE
INPUT COUNTERS ÖØ PULSE IN 1+2+3.
5.3.7 Data Logger

PATH: SETPOINTS ÖØ S2 SYSTEM SETUP ÖØ DATA LOGGER
DATA LOGGER [Z] STOP DATA LOG 1: Range: No, Yes

NO (STOPPED)
STOP DATA LOG 2: Range: No, Yes
MESSAGE
NO (STOPPED)
The data logger operation is only configurable using the EnerVista PQMII Setup Software.
On occasions it may be necessary to stop the data loggers using the PQMII keypad and
then a computer to extract the logged information. The STOP DATA LOG 1(2) setpoints allow
the user to stop the respective data log. These setpoints also display the current status of
the respective data logger. Refer to 7.6 Data Logger Implementation for a detailed
implementation description.
5.3.8 Voltage Disturbance

PATH: SETPOINTS ÖØ S2 SYSTEM SETUP ÖØ VOLTAGE DIST. RECORDER
VOLTAGE DIST. [Z] SAG Range: 20 to 90% of Nominal VT in

RECORDER LEVEL ≤ 80% Nominal steps of 1
SWELL Range: 110 to 150% of Nominal VT in

MESSAGE steps of 1
LEVEL ≥ 130% Nominal
• SAG LEVEL: When the voltage on any phase drops below this level a Sag condition
occurs. During this condition, the average voltage and duration of the disturbance are
calculated. The condition ends when the level increases to at least 10% of nominal
plus pickup of the SAG LEVEL setting. This hysteresis is implemented to avoid nuisance
alarms due to voltage fluctuations. If the duration logged was less then or equal to 1
minute an event with a sag type will be logged. If the duration was greater then 1
minute an event with an undervoltage type will be logged when this feature is
configured.
• SWELL LEVEL: When the voltage on any phase increases above this level a swell
condition occurs. During a swell condition the average voltage and duration of the

disturbance are calculated. To end a Swell condition the level must decrease to pickup
minus 10% of nominal of the SWELL LEVEL setting. This hysteresis is implemented to
avoid nuisance alarms due to voltage fluctuations. If the duration logged was less
then or equal to 1 minute an event with a swell type will be logged. If the duration was
greater then 1 minute an event with an overvoltage type will be logged when this
feature is configured.

5.4 S3 Output Relays
5.4.1 Description
Output relay operation in the PQMII occurs in either ‘failsafe’ or ‘non-failsafe’ modes, as
defined below:
• Non-failsafe: The relay coil is not energized in its non-active state. Loss of control
power will cause the relay to remain in the non-active state. That is, a non-failsafe
alarm relay will not cause an alarm on loss of control power. Contact configuration in
the Wiring Diagrams is shown with relays programmed non-failsafe and control
power not applied.
• Failsafe: The relay coil is energized in its non-active state. Loss of control power will
cause the relay to go into its active state. That is, a failsafe alarm relay will cause an
alarm on loss of control power. Contact configuration is opposite to that shown in the
Wiring Diagrams for relays programmed as failsafe when control power is applied.
5.4.2 Alarm Relay

PATH: SETPOINTS ÖØ S3 OUTPUT RELAYS Ö ALARM RELAY
ALARM RELAY [Z] ALARM OPERATION: Range: Non-failsafe, Failsafe

NON-FAILSAFE
ALARM ACTIVATION: Range: Unlatched, Latched
MESSAGE
UNLATCHED
• ALARM OPERATION: The terms ‘failsafe’ and ‘non-failsafe’ are defined above as
implemented in the PQMII. If an alarm is required when the PQMII is not operational
due to a loss of control power, select failsafe operation. Otherwise, choose non-
failsafe.
• ALARM ACTIVATION: If an alarm indication is required only while an alarm is present,
select unlatched. Once the alarm condition disappears, the alarm and associated
message automatically clear. To ensure all alarms are acknowledged, select latched.
Even if an alarm condition is no longer present, the alarm relay and message can only
be cleared by pressing the key or by sending the reset command via the computer.
5.4.3 Auxiliary Relays

PATH: SETPOINTS ÖØ S3 OUTPUT RELAYS Ö AUXILIARY RELAY 1(3)
AUXILIARY [Z] AUX1 OPERATION: Range: Non-failsafe, Failsafe

RELAY 1 NON-FAILSAFE
AUX1 ACTIVATION: Range: Unlatched, Latched
MESSAGE
UNLATCHED
The PQMII contains three (3) auxiliary relays, denoted as Aux1 through Aux3. The terms
‘failsafe’ and ‘non-failsafe’ are defined in the previous section.

• AUXILIARY 1(3) OPERATION: If an output is required when the PQMII is not operational
due to a loss of control power, select failsafe auxiliary operation, otherwise, choose
non-failsafe.
• AUXILIARY 1(3) ACTIVATION: If an auxiliary relay output is only required while the
selected conditions are present, select “Unlatched”. Once the selected condition
disappears, the auxiliary relay returns to the non-active state. To ensure all conditions
are acknowledged, select “Latched”. If the condition is no longer present, the auxiliary
relay can be reset by pressing the key or by sending the reset command via the
computer.
The PQMII uses a priority system to determine which function will control the relays if they
Note
happen to be assigned to more than one function.

The Pulse Output function has the highest activation priority, followed by the Analog Input
Main/Alt Select functions. The alarm functions have the lowest priority. For example, if a
relay is assigned to an alarm function and also assigned to one of the pulse output
parameters, it only responds to the pulse output function.

5.5 S4 Alarms/Control
5.5.1 Current/Voltage Alarms

PATH: SETPOINTS ÖØ S4 ALARMS/CONTROL Ö CURRENT/VOLTAGE
CURRENT/ [Z] DETECT I/V ALARMS Range: No, Yes

VOLTAGE USING PERCENTAGE: NO
PHASE UNDERCURRENT Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
PHASE UNDERCURRENT Range: 1 to 12000 A in steps of 1, or
MESSAGE 1 to 100% of CT in steps of 1,
LEVEL ≤ 100 A
set by the DETECT I/V ALARMS
USING PERCENTAGE value.
PHASE UNDERCURRENT Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
DETECT UNDERCURRENT Range: No, Yes
MESSAGE
WHEN 0A: NO
PHASE OVERCURRENT Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
PHASE OVERCURRENT Range: 1 to 12000 A in steps of 1, or
LEVEL ≥ 100 A
PHASE OVERCURRENT Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
PHASE OVERCURRENT Range: Average, Maximum
MESSAGE
ACTIVATION: AVERAGE
NEUTRAL OVERCURRENT Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
NEUTRAL OVERCURRENT Range: 1 to 12000 A in steps of 1, or
LEVEL ≥ 100 A
NEUTRAL OVERCURRENT Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
UNDERVOLTAGE Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
UNDERVOLTAGE Range: 20 to 65000 V in steps of 1, or
MESSAGE 20 to 100% of VT in steps of 1,
LEVEL ≤ 100 V
UNDERVOLTAGE Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
PHASES REQ’D FOR U/V Range: Any One, Any Two, All Three.
MESSAGE Not seen when VT WIRING is set
OPERATION: ANY ONE
to “Single Phase Direct”

DETECT UNDERVOLTAGE Range: No, Yes

MESSAGE
BELOW 20V: NO
OVERVOLTAGE Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
OVERVOLTAGE Range: 20 to 65000 V in steps of 1, or
MESSAGE 20 to 150% of VT in steps of 1,
LEVEL ≥ 100 V
OVERVOLTAGE Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
PHASES REQ’D FOR O/V Range: Any One, Any Two, All Three.
MESSAGE Not seen when VT WIRING is set
OPERATION: ANY ONE
to “Single Phase Direct”
CURRENT UNBALANCE Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
CURRENT UNBALANCE Range: 1 to 100% in steps of 1
MESSAGE
LEVEL ≥ 100%
CURRENT UNBALANCE Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
VOLTAGE UNBALANCE Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
VOLTAGE UNBALANCE Range: 1 to 100% in steps of 1
MESSAGE
LEVEL ≥ 100%
VOLTAGE UNBALANCE Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
VOLTS PHASE REVERSAL Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
VOLTS PHASE REVERSAL Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 1.0 s
• DETECT I/V ALARMS USING PERCENTAGE: When “Yes” is selected, all current and
voltage alarms can be set in percentages of CT and VT. When “No” is selected, all
current and voltage alarms are actual voltage and current levels.
• PHASE UNDERCURRENT RELAY: Undercurrent can be disabled, used as an alarm, or
as a process control feature. Set this setpoint to “Off” if the feature is not required.
Selecting “Alarm” activates the alarm relay and displays an alarm message whenever
an undercurrent condition exists. Selecting an auxiliary relay activates the selected
auxiliary relay for an undercurrent condition but no message will be displayed. This is
intended for process control.
• PHASE UNDERCURRENT LEVEL: When the average three phase current drops to or
below the level set by this setpoint, a phase undercurrent condition will occur. Refer to
the DETECT UNDERCURRENT WHEN 0A setpoint description below to enable/disable
undercurrent detection below 5% of CT.
• PHASE UNDERCURRENT DELAY: If the average phase current is less than or equal to
the PHASE UNDERCURRENT LEVEL setpoint value for the time delay programmed in this
setpoint, a phase undercurrent condition will occur.

• DETECT UNDERCURRENT WHEN 0A: If this setpoint is set to “Yes”, undercurrent will be
detected if the average phase current drops below 5% of CT. If the setting is “No”, the
undercurrent detection is only enabled if the average phase current is equal to or
above 5% of CT.
• PHASE OVERCURRENT RELAY: Overcurrent can either be disabled, used as an alarm
or as a process control. Set this setpoint to “Off” if the feature is not required. Selecting
“Alarm” activates the alarm relay and displays an alarm message whenever an
overcurrent condition exists. Selecting an auxiliary relay activates the auxiliary relay
for an overcurrent condition but no message will be displayed. This is intended for
process control.
• PHASE OVERCURRENT LEVEL: When the average (or maximum, see below) three
phase current equals or exceeds the level set by this setpoint, a phase overcurrent
condition will occur.
• PHASE OVERCURRENT DELAY: If the average (or maximum, see below) phase current
equals or exceeds the PHASE OVERCURRENT LEVEL setpoint value and remains this way for
the time delay programmed in this setpoint, a phase overcurrent condition will occur.
• PHASE OVERCURRENT ACTIVATION: The Phase Overcurrent function can use either
the average phase current or the maximum of the three phase currents. This setpoint
determines which is used.
• NEUTRAL OVERCURRENT RELAY: Neutral overcurrent can be disabled, used as an
alarm, or used as a process control. Set this setpoint to “Off” if the feature is not
required. Selecting “Alarm” activates the alarm relay and displays an alarm message
whenever a neutral overcurrent condition exists. Selecting an auxiliary relay activates
the auxiliary relay for a neutral overcurrent condition but no message will be
displayed. This is intended for process control.
• NEUTRAL OVERCURRENT LEVEL: When the neutral current equals or exceeds the level
set by this setpoint, a neutral overcurrent condition will occur.
• NEUTRAL OVERCURRENT DELAY: If the neutral current greater than or equal to the
NEUTRAL OVERCURRENT LEVEL setpoint value for the time delay programmed in this
setpoint, a neutral overcurrent condition will occur.
• UNDERVOLTAGE RELAY: Undervoltage can either be disabled, used as an alarm, or as
a process control. Set this setpoint to “Off” if the feature is not required. Selecting
undervoltage condition exists. Selecting an auxiliary relay activates the auxiliary relay
for an undervoltage condition but no message will be displayed. This is intended for
process control.
• UNDERVOLTAGE LEVEL: When the voltage on one, two, or three phases drops to or
below this level, an undervoltage condition occurs. The required number of phases is
determined by the PHASES REQUIRED FOR U/V OPERATION setpoint. To clear the
undervoltage condition, the level must increase to 103% of the UNDERVOLTAGE LEVEL
setting. For example, if the UNDERVOLTAGE LEVEL is “4000 V”, the condition clears when
the voltage in the appropriate phase(s) increases above 4120 V (4000 × 1.03). This
hysteresis is implemented to avoid nuisance alarms due to voltage fluctuations.
• UNDERVOLTAGE DELAY: If the voltage drops to or below the UNDERVOLTAGE LEVEL
setpoint value and remains this way for the time delay programmed in this setpoint,
an undervoltage condition will occur.

• PHASES REQ’D FOR U/V OPERATION: Select the minimum number of phases on which
the undervoltage condition must be detected before the selected output relay will
operate. This setpoint is not visible if VT WIRING is set to “Single Phase Direct”.
• DETECT UNDERVOLTAGE BELOW 20V: If an indication is required for loss of voltage,
select “Yes”. If “No” is selected and any one of the voltage inputs has less than 20 V
applied, the undervoltage feature will be disabled.
• OVERVOLTAGE RELAY: Overvoltage can either be disabled, used as an alarm, or as a
process control. Set this setpoint to “Off” if the feature is not required. Selecting
overvoltage condition exists. Selecting an auxiliary relay activates the auxiliary relay
for an overvoltage condition but no message will be displayed. This is intended for
process control.
• OVERVOLTAGE LEVEL: When the voltage on one, two, or three phases equals or
exceeds the level determined with this setpoint, an overvoltage condition occurs. The
required number of phases is determined by the PHASES REQUIRED FOR O/V OPERATION
setpoint. To clear the overvoltage condition, the level must decrease to 97% of the
OVERVOLTAGE LEVEL setting. For example, if the OVERVOLTAGE LEVEL is set to “4200 V”, the
condition clears when the voltage in the appropriate phase(s) goes below 4074 V
(4200 × 0.97). This hysteresis is implemented to avoid nuisance alarms due to voltage
fluctuations.
• OVERVOLTAGE DELAY: If the voltage equals or exceeds the OVERVOLTAGE LEVEL setpoint
value for the time delay programmed in this setpoint, an overvoltage condition will
occur.
• PHASES REQ’D FOR O/V OPERATION: Select the minimum number of phases on which
the overvoltage condition must be detected before the selected output relay operates.
This setpoint is not visible if VT WIRING is set to “Single Phase Direct”.
• CURRENT UNBALANCE RELAY: Current unbalance is calculated as the maximum
deviation from the average divided by the average three phase current. Current
unbalance can either be disabled, used as an alarm, or as a process control. Set this
setpoint to “Off” if the feature is not required. Selecting “Alarm” activates the alarm
relay and displays an alarm message whenever a current unbalance condition exists.
Selecting an auxiliary relay activates the auxiliary relay for a current unbalance
condition but no message will be displayed. This is intended for process control.
• CURRENT UNBALANCE LEVEL: When the current unbalance equals or exceeds this
level, a current unbalance condition will occur. See 6.2.1 Current Metering for details on
the method of calculation.
• CURRENT UNBALANCE DELAY: If the current unbalance equals or exceeds the
CURRENT UNBALANCE LEVEL value for the time delay programmed in this setpoint, a
current unbalance condition occurs.
• VOLTAGE UNBALANCE RELAY: Voltage unbalance is calculated as the maximum
deviation from the average divided by the average three phase voltage. Voltage
unbalance can either be disabled, used as an alarm, or as a process control. Set this
relay and displays an alarm message whenever a voltage unbalance condition exists.
Selecting an auxiliary relay activates the auxiliary relay for a voltage unbalance
condition but no message will be displayed. This is intended for process control.

• VOLTAGE UNBALANCE LEVEL: When the voltage unbalance equals or exceeds this
level, a voltage unbalance condition occurs. See 6.2.2 Voltage Metering for details on
the method of calculation.
• VOLTAGE UNBALANCE DELAY: If the voltage unbalance equals or exceeds the VOLTAGE
UNBALANCE LEVEL setpoint value and remains this way for the time delay programmed in
this setpoint, a voltage unbalance condition will occur.
• VOLTAGE PHASE REVERSAL: Under normal operating conditions, the PQMII expects to
see the voltages connected with a 1-2-3 or A-B-C sequence. If the voltages are
connected with the wrong sequence (e.g. 2-1-3 or B-A-C), a voltage phase reversal
condition will occur. A minimum of 20 V must be applied to the PQMII on all voltage
inputs before the phase reversal feature will operate.
A phase reversal condition is determined by looking at the phase angle at the
occurrence of the peak sample of phase B voltage and subtracting it from the phase
angle at the peak sample of phase A voltage (phase A angle – phase B angle). This
angle is averaged over several cycles before deciding on the condition to avoid any
false triggering of the feature. Only two phases are required to detect phase reversal
because all phase reversal conditions can be covered without the use of the third
phase. The angle to detect phase reversal will vary depending on the connection
being used as described below.
For “4-Wire Wye / 3 VTs”, “4 Wire Wye / 2 VTs”, “4 Wire Direct”, and “3 Wire Direct”
connections, the phase reversal function operates when the angle between phase A and B
becomes ≤ –150° or ≥ –90° as shown below.
Vc(a or n) = –240°
Va(b or n) = 0° (reference)
Vb(c or n) – 30°
Vb(c or n) = –120°
shaded area = angle tolerance allowed
Vb(c or n) + 30° before phase reversal will occur
FIGURE 5–3: Phase Reversal for 4-wire and 3-wire Direct Connections
For the “3 Wire Delta / 2 VTs” connection, the phase reversal function operates when the
angle between phase A and B is ≤30° or ≥90° as shown below.
Vcb + 30°
shaded area = angle tolerance
allowed before phase reversal Vcb = 60°
will occur
Vcb – 30°
Vab = 0° (reference)
Vbc = –120°
FIGURE 5–4: Phase Reversal for 3-wire Delta (2 VTs Open-Delta) Wiring

When the “Single Phase Direct” connection is used the phase reversal feature will never
operate.
• VOLTAGE PHASE REVERSAL DELAY: If a voltage phase reversal exists for the time
programmed in this setpoint a voltage phase reversal condition will occur.
Please note that the terms undervoltage and overvoltage used for alarm, are generic
Note
regardless of sag/swell or undervotlage/overvoltage conditions based on duration of the

voltage disturbance
5.5.2 Harmonic Distortion

PATH: SETPOINTS ÖØ S4 ALARMS/CONTROL ÖØ TOTAL HARMONIC DISTORTION
TOTAL HARMONIC [Z] AVERAGE CURRENT THD Range: Alarm, Aux1, Aux2, Aux3, Off
DISTORTION RELAY: OFF
AVERAGE CURRENT THD Range: 0.5 to 100.0% in steps of 0.5
MESSAGE
LEVEL ≥ 10.0 %
AVERAGE CURRENT THD Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
AVERAGE VOLTAGE THD Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
AVERAGE VOLTAGE THD Range: 0.5 to 100.0% in steps of 0.5
MESSAGE
LEVEL ≥ 10.0 %
AVERAGE VOLTAGE THD Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
• AVERAGE CURRENT THD RELAY: Excessive phase current THD detection can either be
disabled, used as an alarm, or as a process control. Set this setpoint to “Off” if the
feature is not required. Selecting “Alarm” activates the alarm relay and displays an
alarm message whenever an excessive average current THD condition exists.
Selecting an auxiliary relay activates the auxiliary relay, but no message will be
• AVERAGE CURRENT THD LEVEL: When the measured average current THD exceeds
this setpoint value, an average current THD condition occurs.
• AVERAGE CURRENT THD DELAY: If the average current THD exceeds the AVERAGE
CURRENT THD LEVEL for the time delay programmed in this setpoint, an average current
THD condition occurs.
• AVERAGE VOLTAGE THD RELAY: Average voltage THD detection can either be
disabled, used as an alarm or as a process control. Set this setpoint to off if the feature
is not required. Selecting alarm relay will cause the alarm relay to activate and display
an alarm message whenever an average voltage THD condition exists. Selecting
auxiliary relay will cause the auxiliary relay to activate, but no message will be
• AVERAGE VOLTAGE THD LEVEL: When the measured average voltage THD equals or
exceeds this setpoint value, an Average Voltage THD condition occurs.

• AVERAGE VOLTAGE THD DELAY: If the average voltage THD equals or exceeds the
AVERAGE VOLTAGE THD LEVEL value and remains this way for the time delay programmed
in this setpoint, an Average Voltage THD condition will occur.
5.5.3 Frequency
PATH: SETPOINTS ÖØ S4 ALARMS/CONTROL ÖØ FREQUENCY
FREQUENCY [Z] UNDERFREQUENCY Range: Alarm, Aux1, Aux2, Aux3, Off

RELAY: OFF
MESSAGE 0.01
LEVEL ≤ 40.00 Hz
MESSAGE
DELAY: 1.0 s
UNDERFREQUENCY WHEN Range: Yes, No
MESSAGE
FREQUENCY=0 Hz: NO
OVERFREQUENCY Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
MESSAGE 0.01
LEVEL ≥ 70.00 Hz
MESSAGE
DELAY: 1.0 s
• UNDERFREQUENCY RELAY: Underfrequency detection can either be disabled or used

as an alarm, or process control. Set this setpoint to “Off” if the feature is not required.
Selecting alarm relay will cause the alarm relay to activate and display an alarm
message whenever an underfrequency condition exists. Selecting an auxiliary relay
activates the auxiliary relay for an underfrequency condition, but no message will be
• UNDERFREQUENCY LEVEL: When the measured frequency drops to or below the level
set by this setpoint, an underfrequency condition will occur.
• UNDERFREQUENCY DELAY: If the underfrequency drops to or below the
UNDERFREQUENCY LEVEL value for the time delay programmed in this setpoint, an
underfrequency condition will occur.
• UNDERFREQUENCY WHEN FREQ=0 Hz: A voltage greater than 20 V is required on
phase AN (AB) voltage input before frequency can be measured. If no voltage is
applied or if the voltage applied is less than 20 V, the displayed frequency will be 0 Hz.
If “No” is selected in this setpoint, an underfrequency condition will not occur when
the displayed frequency is 0 Hz.
• OVERFREQUENCY RELAY: Overfrequency detection can either be disabled, used as an
alarm or as a process control. Set this setpoint to off if the feature is not required.
Selecting alarm relay will cause the alarm relay to activate and display an alarm
message whenever an overfrequency condition exists. Selecting auxiliary relay will
cause the auxiliary relay to activate for an overfrequency condition, but no message
will be displayed. This is intended for process control.
• OVERFREQUENCY LEVEL: When the measured frequency equals or exceeds the level
set by this setpoint, an overfrequency condition will occur.

• OVERFREQUENCY DELAY: If the overfrequency equals or exceeds the OVERFREQUENCY

LEVEL setpoint value for the time delay programmed in this setpoint, an overfrequency
5.5.4 Power Alarms

PATH: SETPOINTS ÖØ S4 ALARMS/CONTROL ÖØ POWER
POWER [Z] POWER ALARMS LEVEL Range: kW/kvar, MW, Mvar

BASE UNIT(s): kW/kvar
POSITIVE REAL POWER Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
POSITIVE REAL POWER Range: 1 to 65000 kW in steps of 1, or
MESSAGE 0.01 to 650.00 MW in steps of
LEVEL ≥ 1000 kW
0.01
POSITIVE REAL POWER Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
NEGATIVE REAL POWER Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
NEGATIVE REAL POWER Range: 1 to 65000 kW in steps of 1, or
MESSAGE 0.01 to 650.00 MW in steps of
LEVEL ≥ 1000 kW
0.01
NEGATIVE REAL POWER Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
POSITIVE REACT POWER Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
POSITIVE REACT POWER Range: 1 to 65000 kvar in steps of 1, or
MESSAGE 0.01 to 650.00 Mvar in steps of
LEVEL ≥ 1000 kvar
0.01
POSITIVE REACT POWER Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
NEGATIVE REACT POWER Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
NEGATIVE REACT POWER Range: 1 to 65000 kvar in steps of 1, or
MESSAGE 0.01 to 650.00 Mvar in steps of
LEVEL ≥ 1000 kvar
0.01
NEGATIVE REACT POWER Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
• POWER ALARMS LEVEL BASE UNIT(S): This setpoint is used to select the base unit
multiplier for all power alarms. When set to kW/kvar, all power alarm levels can be set
in terms of kW and kvar with a step value of 1 kW/kvar. When set to MW/Mvar, all
power alarm levels can be set in terms of MW and Mvar with a step value of 0.01 MW/
Mvar.
• POSITIVE/NEGATIVE REAL POWER RELAY: The positive and negative real power level
detection can be disabled, used as an alarm, or used as a process control. The “Off”
setting disables this feature. Selecting “Alarm” activates the alarm relay and displays
an alarm message whenever a positive/negative real power level exceeds the
selected level. Selecting an auxiliary relay activates the auxiliary relay for a set level of

positive/negative real power but no message will be displayed. This is intended for
process control.
• POSITIVE/NEGATIVE REAL POWER LEVEL: When the three phase real power equals or
exceeds the level defined by this setpoint, an excess positive/negative real power
• POSITIVE/NEGATIVE REAL POWER DELAY: If the positive/negative real power equals
or exceeds the POSITIVE/NEGATIVE REAL POWER LEVEL setpoint value for the time delay
programmed in this setpoint, an excessive positive/negative real power condition will
occur.
• POSITIVE/NEGATIVE REACTIVE POWER RELAY: Positive and negative reactive power
level detection can either be disabled, used as an alarm, or as a process control. Set
this setpoint to “Off” if the feature is not required. Selecting “Alarm” activates the alarm
relay and displays an alarm message whenever a positive/negative reactive power
level exceeds the selected level. Selecting an auxiliary relay activates the auxiliary
relay for a set level of positive/negative reactive power but no message will be
• POSITIVE/NEGATIVE REACTIVE POWER LEVEL: When the three phase reactive power
equals or exceeds the level set by this setpoint, an excess positive/negative reactive
power condition will occur.
• POSITIVE/NEGATIVE REACTIVE POWER DELAY: If the positive reactive power equals or
exceeds the POSITIVE/NEGATIVE REACTIVE POWER LEVEL setpoint value for the time delay
programmed in this setpoint, an excessive positive reactive power condition will occur.

5.5.5 Power Factor

PATH: SETPOINTS ÖØ S4 ALARMS/CONTROL ÖØ POWER FACTOR
POWER FACTOR [Z] POWER FACTOR LEAD 1 Range: Alarm, Aux1, Aux2, Aux3, Off
RELAY: OFF
POWER FACTOR LEAD 1 Range: 0.50 to 1.00 in steps of 0.01
MESSAGE
PICKUP ≤ 0.99
MESSAGE
DROPOUT ≥ 1.00
POWER FACTOR LEAD 1 Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
POWER FACTOR LAG 1 Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: Off
POWER FACTOR LAG 1 Range: 0.50 to 1.00 in steps of 0.01
MESSAGE
PICKUP ≤ 0.99
MESSAGE
DROPOUT ≥ 1.00
POWER FACTOR LAG 1 Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
POWER FACTOR LEAD 2 Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
MESSAGE
PICKUP ≤ 0.99
MESSAGE
DROPOUT ≥ 1.00
POWER FACTOR LEAD 2 Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
POWER FACTOR LAG 2 Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
MESSAGE
PICKUP ≤ 0.99
MESSAGE
DROPOUT ≥ 1.00
POWER FACTOR LAG 2 Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
It is generally desirable for a system operator to maintain the power factor as close to
unity as possible (that is, to make the real power of the system as close as possible to the
apparent power) to minimize both costs and voltage excursions. On dedicated circuits
such as some large motors, with a near-fixed load, a capacitor bank may be switched on
or off with the motor to supply leading vars to compensate for the lagging vars required by
the motor. Since the power factor is variable on common non-dedicated circuits, it is

advantageous to compensate for low (lagging) power factor values by connecting a

capacitor bank to the circuit when required. The PQMII provides power factor monitoring
and allows two stages of capacitance switching for power factor compensation.
FIGURE 5–5: Capacitor Bank Switching
The PQMII calculates the average power factor in the three phases, according to the
following equation:
Total 3-phase Real Power
Average Power Factor = ---------------------------------------------------------------------------- (EQ 5.2)
Total 3-phase Apparent Power
Two independent ‘elements’ are available for monitoring power factor, Power Factor 1 and
Power Factor 2, each having a pickup and a dropout level. For each element, when the
measured power factor is equal to or becomes more lagging than the pickup level (i.e.
numerically less than), the PQMII will operate a user-selected output relay. This output can
be used to control a switching device which connects capacitance to the circuit, or to
signal an alarm to the system operator. After entering this state, when the power factor
becomes less lagging than the power factor dropout level, the PQMII will reset the output
relay to the non-operated state.
Both Power Factor 1 and 2 features are inhibited from operating unless all three voltages
are above 20% of nominal and one or more currents is above 0. Power factor 1 and 2 delay
timers will be allowed to time only when the 20% threshold is exceeded on all phases (and,
of course, only while the power factor remains outside of the programmed pickup and
dropout levels). In the same way, when a power factor condition starts the power factor 1
or 2 delay timer, if all three phase voltages fall below the 20% threshold before the timer
has timed-out, the element will reset without operating. A loss of voltage during any state
will return both Power Factor 1 and 2 to the reset state.
• POWER FACTOR LEAD 1(2) RELAY: Power factor detection can either be disabled, used
as an alarm or as a process control. Set this setpoint to “Off” if the feature is not
when the power factor is more leading than the level set. Selecting “Aux1”, “Aux2”, or
“Aux3” activates the respective auxiliary relay when the power factor is equal to or
more leading than the level set, but no message will be displayed. This is intended for

process control. A minimum of 20 V applied must exist on all voltage inputs before this
feature will operate.
• POWER FACTOR LEAD 1(2) PICKUP: When a leading power factor equals or exceeds
the level set by this setpoint, a Power Factor Lead 1(2) condition will occur.
• POWER FACTOR LEAD 1(2) DROPOUT: When a leading power factor drops below this
level, the Power Factor Lead 1(2) condition will drop out.
• POWER FACTOR LEAD 1(2) DELAY: If the power factor equals or exceeds the POWER
FACTOR LEAD 1(2) PICKUP setpoint value and remains this way for the time delay
programmed in this setpoint, a Power Factor Lead 1(2) condition will occur.
If the power factor drops below the POWER FACTOR LEAD 1(2) DROPOUT setpoint value, the
power factor lead 1(2) condition will drop out. If the POWER FACTOR LEAD 1(2) RELAY
setpoint is set to “Alarm”, the alarm relay will deactivate and the POWER FACTOR LEAD
1(2) ALARM message will be cleared. If the POWER FACTOR LEAD 1(2) RELAY setpoint is set to
“Aux1”, “Aux2”, or “Aux3,” the respective auxiliary relay deactivates.
• POWER FACTOR LAG 1(2) RELAY: Power factor detection can either be disabled, used
as an alarm or as a process control. Set this setpoint to “Off” if the feature is not
when the power factor is more lagging than the level set. Selecting “Aux1”, “Aux2”, or
“Aux3” activates the respective auxiliary relay when the power factor is equal to or
more lagging than the level set, but no message will be displayed. This is intended for
process control. A minimum of 20 V applied must exist on all voltage inputs before this
feature will operate.
• POWER FACTOR LAG 1(2) PICKUP: When a lagging power factor equals or exceeds the
level set by this setpoint, a Power Factor Lag 1(2) condition will occur.
• POWER FACTOR LAG 1(2) DROPOUT: When a lagging power factor drops below this
level, the Power Factor Lag 1(2) condition will drop out.
• POWER FACTOR LAG 1(2) DELAY: If the power factor equals or exceeds the POWER
FACTOR LAG 1/2 PICKUP setpoint value and remains this way for the time delay
programmed in this setpoint, a Power Factor Lag 1(2) condition will occur.
If the power factor drops below the POWER FACTOR LAG 1(2) DROPOUT setpoint value, the
Power Factor 1(2) lag condition will drop out. If the POWER FACTOR LAG 1(2) RELAY setpoint
is set to “Alarm”, the alarm relay will deactivate and the POWER FACTOR LAG 1(2)
ALARM message will be cleared. If the POWER FACTOR LAG 1(2) RELAY setpoint is set to
“Aux1”, “Aux2”. or “Aux3”, the respective auxiliary relay will deactivate.

5.5.6 Demand Alarms

PATH: SETPOINTS ÖØ S4 ALARMS/CONTROL ÖØ DEMAND
DEMAND [Z] PHASE A CURRENT DMD Range: Alarm, Aux1, Aux2, Aux3, Off
RELAY: OFF
PHASE A CURRENT DMD Range: 10 to 7500 A in steps of 1
MESSAGE
LEVEL ≥ 100 A
PHASE B CURRENT DMD Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
PHASE B CURRENT DMD Range: 10 to 7500 A in steps of 1
MESSAGE
LEVEL ≥ 100 A
PHASE C CURRENT DMD Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
PHASE C CURRENT DMD Range: 10 to 7500 A in steps of 1
MESSAGE
LEVEL ≥ 100 A
NEUTRAL CURRENT DMD Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
NEUTRAL CURRENT DMD Range: 10 to 7500 A in steps of 1
MESSAGE
LEVEL ≥ 100 A
3Φ POS REAL PWR DMD Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
3Φ POS REAL PWR DMD Range: 1 to 65000 kW in steps of 1
MESSAGE
LEVEL ≥ 1000 kW
3Φ POS REACT PWR DMD Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
3Φ POS REACT PWR DMD Range: 1 to 65000 kvar in steps of 1
MESSAGE
LEVEL ≥ 1000 kvar
3Φ NEG REAL PWR DMD Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
3Φ NEG REAL PWR DMD Range: 1 to 65000 kW in steps of 1
MESSAGE
LEVEL ≥ 1000 kW
3Φ NEG REACT PWR DMD Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
3Φ NEG REACT PWR DMD Range: 1 to 65000 kvar in steps of 1
MESSAGE
LEVEL ≥ 1000 kvar
3Φ APPARENT PWR DMD Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
3Φ APPARENT PWR DMD Range: 1 to 65000 kVA in steps of 1
MESSAGE
LEVEL ≥ 1000 kVA
• PHASE A/B/C/NEUTRAL CURRENT DMD RELAY: Phase/neutral current demand

detection can either be disabled or used as an alarm or process control. Set this
relay and displays an alarm message whenever a phase/neutral current demand level

is equalled or exceeded. Selecting “Aux1”, “Aux2”, or “Aux3” activates the respective

auxiliary relay with no message displayed. This is intended for process control.
• PHASE A/B/C/NEUTRAL CURRENT DMD LEVEL: When the phase A/B/C/ or neutral
current demand equals or exceeds this setpoint, a phase A/B/C or neutral demand
alarm or process control indication occurs.
• 3Φ POS/NEG REAL PWR DMD RELAY: Three-phase positive/negative real power
demand detection can either be disabled or used as an alarm or process control. Set
this setpoint to “Off” if the feature is not required. Selecting “Alarm” activates the alarm
relay and displays an alarm message whenever the positive/negative three-phase
real power demand level is equalled or exceeded. Selecting “Aux1”, “Aux2”, or “Aux3”
activates the respective auxiliary relay with no message displayed. This is intended for
process control.
• 3Φ POS/NEG REAL PWR DMD LEVEL: When the three-phase real power demand
exceeds this setpoint, a three-phase positive/negative real power demand alarm or
process control indication will occur.
• 3Φ POS/NEG REACT PWR DMD RELAY: Three-phase positive/negative reactive power
demand detection can either be disabled or used as an alarm or process control. Set
to “Off” if this feature is not required. Selecting “Alarm” activates the alarm relay and
displays an alarm message whenever the positive/negative three-phase reactive
power demand level is equalled or exceeded. Selecting “Aux1”, “Aux2”, or “Aux3”
activates the respective auxiliary relay with no message displayed. This is intended for
process control.
• 3Φ POS/NEG REACT PWR DMD LEVEL: When the three-phase reactive power demand
equals or exceeds this setpoint, a three-phase positive/negative reactive power
demand alarm or process control indication will occur.
• 3Φ APPARENT POWER DEMAND RELAY: Three-phase apparent power demand
detection can be disabled or used as an alarm or process control. Set to “Off” if this
feature is not required. Selecting “Alarm” activates the alarm relay and displays an
alarm message if the three-phase apparent power demand level is equalled or
exceeded. Selecting “Aux1”, “Aux2”, or “Aux3” activates the respective auxiliary relay
with no message displayed. This is intended for process control.
• 3Φ APPARENT POWER DEMAND LEVEL: When the three-phase apparent power
demand equals or exceeds this setpoint, a three-phase apparent power alarm or
process control indication will occur.

5.5.7 Pulse Input

PATH: SETPOINTS Ø S4 ALARMS/CONTROL Ö PULSE INPUT
PULSE INPUT [Z] PULSE INPUT 1 Range: Alarm, Aux1, Aux2, Aux3, Off
RELAY: OFF
PULSE INPUT 1 LEVEL Range: 1 to 65000 in steps of 1
MESSAGE
≥ 100 Units
PULSE INPUT 1 Range: 0.5 to 600.0 s in steps of 0.5
MESSAGE
DELAY: 10.0 s
PULSE INPUT 2 Range: Alarm, Aux1, Aux2, Aux3, Off
MESSAGE
RELAY: OFF
MESSAGE
≥ 100 Units
MESSAGE
DELAY: 10.0 s
MESSAGE
RELAY: OFF
MESSAGE
≥ 100 Units
MESSAGE
DELAY: 10.0 s
MESSAGE
RELAY: OFF
MESSAGE
≥ 100 Units

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CH10003 - Operating & Maintenance Manual PDF

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Jebsen & Jessen Technology (M) Sdn Bhd

Order number CH10003

Customer JC Chang (Pte) Ltd.

Location Lahad Datu – Melewar Properties

Turbine Model NG DME-700 8’/16’ MVA-III

Gearbox Model Triveni HSG-360

Generator Model TDPS TD110

Contents: Master Table of Contents

Section 1: Equipment Manuals

Section 2: Auxiliary Equipment

2.6 Adjustable Orifice

Section 3: Contract Documents

PROJECT NAME: MELEWAR PROPERTIES

PROJECT NUMBER: CH10003

APPROVED SCALE DIMENSION

Steam Conditions Normal UNITS

Steam Conditions Normal UNITS

Driven equipment Generator

Turbine type DME – 700

Power (Normal) (kW) 3500

Speed (Normal) (rpm) 5000

Output speed – reducer (rpm) -

Trip speed (rpm) 5500

Steam conditions NORMAL

Inlet pressure (bara) 30

Inlet temperature (°C) 293

Exhaust pressure (bara) 4,1

Steam rate (Normal) (kg/kW.h) 14,42

Steam consumption (Normal) (kg/kW.h) 50.500

PROJECT NAME: MELEWAR PROPERTIES

PROJECT NUMBER: CH10003

APPROVED SCALE DIMENSION

Forced-Lubrication System for NG Hydraulic Governor

The forced lubrication system is composed of the following parts:

Main Oil Pump (Not supplied by NG)

Lubrication auxiliary pump (Not supplied by NG)

Oil filter (Not supplied by NG)

Oil pressure reducer

Relief valve (Not supplied by NG)

General description of lubricating oil

Characteristics of Turbine oil (DIN 51515, equivalent to classification ISO VG 68)

Kinetic viscosity at 50oC 44 ± 4cSt

Maintenance of turbine oil

Oil inspection during operation

Criteria for oil changes

Nozzles and Diaphragms

Shaft sealing (Drawings nbrs. 4, 5, 6 and 7)

Automatic overload valves (Drawing nbr. 8)

Speed Regulator and Hydraulic Actuator (Drawing nbr. 11)

Trip valve (Drawing nbr. 8)

Trip valve operation

Safety device (Drawing nbr. 3)

Shutdown trip device (Drawing nbr. 9)

How to start-up turbine

Start up after long shutdown period

Mechanical-type safety device

Inspection of over speed safety device

Disassembly of safety device (Drawing nbr. 4.080.03067.9)

Disassembly of shutdown trip device (Drawing nbr. 3.080.01640.1)

Inspection of shutdown trip device

TRIP VALVE (Drawing nbr. 3.080.01644.9)

Check of the angular misalignment

Lubricate all bearings before trying to move or rotate the shafts