SM6-0 GAS DENSITY MONITOR

INSTALLATION &

OPERATION MANUAL

Alotek LLC 3915 E. Francis Avenue, Suite B-1

Spokane, WA 99217 800-845-2908

August 6, 2008

TABLE OF CONTENTS

CHAPTER 1  OVERVIEW ....................................................................................................................................... 1 

1.1 INTRODUCTION ................................................................................................................................................ 1 1.2 WHAT THE SM6-0 MEASURES ........................................................................................................................ 1 1.3 SM6-0 RELAY LOGIC ......................................................................................................................................... 1 1.4 DATA STORAGE AND ANALYSIS ................................................................................................................... 3 

CHAPTER 2  MOUNTING THE SM6-0 ................................................................................................................ 4 

2.1 MOUNTING LOCATION .................................................................................................................................... 4 2.2 FRONT-MOUNTING THE SM6-0 ..................................................................................................................... 4 2.3 REAR MOUNTING THE SM6-0 ........................................................................................................................ 4 2.4 CONDUIT INSTALLATION ............................................................................................................................... 5 

CHAPTER 3  INSTALLING THE TEMPERATURE SENSOR ......................................................................... 7 

3.1 SENSOR LOCATION .......................................................................................................................................... 7 3.1.1 Single Tank Breakers .................................................................................................................................... 7 3.1.2 Three-Tank, Common-Gas Breakers ............................................................................................................. 7 

3.2 MOUNTING THE TEMPERATURE SENSOR ................................................................................................... 9 3.3 WIRING THE SENSOR TO THE SM6-0 ............................................................................................................. 9 3.4 CHANGING THE TEMPERATURE SENSOR .................................................................................................. 9 

CHAPTER 4  ELECTRICAL POWER ................................................................................................................. 10 

4.1 POWER REQUIREMENTS ............................................................................................................................... 10 4.1.1 Pigtails ....................................................................................................................................................... 10 4.1.2 Input Power ................................................................................................................................................ 11 4.1.3 Heater Power ............................................................................................................................................. 12 4.1.4 Earth Ground ............................................................................................................................................. 12 4.1.5 Connectors ................................................................................................................................................. 12 

CHAPTER 5  RELAY WIRING AND COMMUNICATIONS .......................................................................... 14 

5.1 WIRING THE SIGNAL CIRCUITS .................................................................................................................. 14 5.2 WIRING THE COMMUNICATION LINES ..................................................................................................... 16 

5.2.1 Connecting to the RS-232 (TERMINAL PORT) .......................................................................................... 16 5.2.2 Wiring to the RS-485 Port ........................................................................................................................... 17 5.2.3 Wiring the Motor Monitor Relay (option discontinued after January 2004) ............................................. 17 

CHAPTER 6  SF6 PLUMBING .............................................................................................................................. 19 

6.1 PLUMBING TO THE SM6-0 ............................................................................................................................. 19 6.2 PRESSURIZING THE SM6-0 ........................................................................................................................... 21 

CHAPTER 7  CONNECTING AND STARTING ................................................................................................ 22 

7.1 OVERVIEW ....................................................................................................................................................... 22 7.2 SETTING THE BAUD RATE ............................................................................................................................ 22 7.3 COMMUNICATING WITH THE SM6-0 .......................................................................................................... 23 

7.3.1 RS-232 ......................................................................................................................................................... 23 7.3.2 RS-485 (Version 3.7) .................................................................................................................................. 23 

CHAPTER 8  CONFIGURING AND USING THE SM6-0 ................................................................................... 25 

8.1 OVERVIEW ....................................................................................................................................................... 25 8.1.1 Main Menu ................................................................................................................................................. 25 8.1.2 Display Messages ....................................................................................................................................... 26 

8.2 SETUP ................................................................................................................................................................ 29 

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8.2.1 Setting the Date and Time .......................................................................................................................... 29 8.2.2 Setting Measurement Units ......................................................................................................................... 30 8.2.3 Setting SM6-0 Configuration ...................................................................................................................... 31 8.2.4 Disabling the Saturation Proximity Alarm (recommended) ....................................................................... 33 8.2.5 Network Setup .............................................................................................................................................. 33 8.2.6 Motor Monitor (Specified on version 3.4 units purchased after April 1, 1995) ......................................... 34 

8.3 MONITOR MENU ............................................................................................................................................. 35 8.3.1 SF6 Density .................................................................................................................................................. 35 8.3.2 Relay Monitoring ......................................................................................................................................... 36 8.3.3 SM6-0 Heater Monitoring .......................................................................................................................... 37 8.3.4 Motor Monitoring ....................................................................................................................................... 37 

8.4 HISTORY MENU .............................................................................................................................................. 38 8.4.1 Monthly Record ........................................................................................................................................... 38 8.4.2 Daily Record ................................................................................................................................................ 39 8.4.3 Event Log .................................................................................................................................................... 39 8.4.4 Data Download ........................................................................................................................................... 40 

8.5 SERVICE MENU ............................................................................................................................................... 42 8.5.1 Vacuum Test ................................................................................................................................................ 42 8.5.2 Test Mode .................................................................................................................................................... 43 8.5.3 Ending Your Session .................................................................................................................................... 44 

CHAPTER 9  GRAPHING AND TRENDING (SMSOFT) ................................................................................. 45 

9.1 OVERVIEW ....................................................................................................................................................... 45 9.2 GRAPH ............................................................................................................................................................... 45 9.3 PRINTING THE GRAPH ................................................................................................................................... 48 9.4 ALARM PROJECTION/TRENDING SUMMARY .......................................................................................... 48 9.5 VIEWING EVENT LOG OR DOWNLOAD DATA ......................................................................................... 50 

CHAPTER 10  TROUBLESHOOTING .............................................................................................................. 51 

APPENDIX A  MODBUS ..................................................................................................................................... 53 

ILLUSTRATIONS

FIGURE 1: Mounting Bracket and Hardware........................................................................................................... 5 FIGURE 2: Temperature Sensor ................................................................................................................................. 8 FIGURE 3: Input Power ............................................................................................................................................ 11 FIGURE 4: 120 VAC Heater Power .......................................................................................................................... 11 FIGURE 5: Standard Configuration Wiring ........................................................................................................... 13 FIGURE 6: Signal Wiring .......................................................................................................................................... 14 FIGURE 7: RS-232 Port Pinout ................................................................................................................................ 16 FIGURE 8: RS-485 Port ............................................................................................................................................. 17 FIGURE 9: Motor Monitor Relay ............................................................................................................................. 18 FIGURE 10: SM6-0 Pressure Transducer ................................................................................................................ 19 FIGURE 11: Compression Fitting ............................................................................................................................. 20 FIGURE 12: INCORRECT plumbing ...................................................................................................................... 20 FIGURE 13: CORRECT plumbing .......................................................................................................................... 21 FIGURE 14: RS-232/574 serial port baud rate settings .......................................................................................... 22 FIGURE 15: RS-485 Communications ..................................................................................................................... 24

TABLES

TABLE 1: Wiring ........................................................................................................................................................ 10

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TABLE 2: Truth Table ............................................................................................................................................... 15 TABLE 3: SM6-0 Message Lights ............................................................................................................................. 28

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1

CHAPTER 1 0OVERVIEW

1 11.1 INTRODUCTION The SM6-0 is a microprocessor-based gas density monitor for SF6-filled high-voltage equipment. It continuously displays the specific density of sulfur hexafluoride (SF6) gas in percentage (%) form on its frontal LCD display. It also continuously updates recorded data and stores it in memory for up to ten years. Through use of Alotek's SMPLUS software, users can access that data in numeric or graph form to trend the performance of the equipment being monitored, and thus predict when the gas density will achieve user-programmed alarm levels of low gas. By utilizing relay contacts provided in the SM6-0, it is also possible to trip and lock a breaker at a pre-determined level. In addition, the SM6-0 gives users advance notice that a breaker's SF6 will soon liquefy (and its pressure drop). The SM6-0 is programmed upon installation with the charge specifications for the equipment it will monitor. This is done by using SMPLUS or a terminal emulation program such as Microsoft's HyperTerminal. The SM6-0 has a heated NEMA 4X enclosure and mounts near the equipment to be monitored. A dedicated temperature sensor attaches to the outside of the pressure vessel, insulated from the ambient air temperature by the insulation blanket provided in the installation kit. The unit obtains accurate pressure readings via the SF6 gas line plumbed to a pipe fitting at the bottom of the SM6-0. The SM6-0's electronics operate on either AC or DC power (100-370 VDC, or 85-265 VAC), with 48VDC available upon request. The unit also has an internal heater which operates whenever the internal temperature drops below 20o C. The standard heater unit requires 120 VAC power.

1 21.2 WHAT THE SM6-0 MEASURES The SM6-0 measures both the pressure and the temperature of the SF6 gas at the breaker. The gas density percentage displayed on the LCD is actually a temperature-compensated pressure reading, achieved by dividing the pressure by the temperature to compensate for the effects of temperature on the gas. The reference standard used by the SM6-0 to calculate density is defined by the user upon installation, i.e. the normalized pressure and temperature settings entered to define “full” for that breaker. EXAMPLE: 75 PSI-gauge at 20o C = 100% SF6

1 31.3 SM6-0 RELAY LOGIC

Firmware version 3.2 (purchased prior to April 1995): All SM6-0 units of this model will have the following three relays:

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SIGNAL 1: (First incidence of low gas)

• The Signal 1 setting will activate the Signal 1 relay and could be used to trip at set points programmed by the user at installation (see Chapter 9).

• Provides a single pole with one normally open (N.O.) contact and one normally closed (N.C.) contact.

SIGNAL 2: (Second incidence of low gas)

• The Signal 2 setting will activate the Signal 2 relay and could be used to block operation at set points programmed by the user at installation (see Chapter 9).

• Provides two poles, each with its own set of N.O. and N.C. contacts. The second pole and its set of contacts are labeled "AUX.SIGNAL 2".

TROUBLE:

• The Trouble indicator on the front of the SM6-0 lights under the following conditions: 1. If the self-diagnostics program detects a problem. 2. If the outer door is unlatched when there isn't a PC plugged into the RS-232 port. 3. If a PC running SMSOFT has put the SM6-0 into a mode where it can't monitor

SF6 density (such as when a vacuum test or test mode is running).

NOTE: If the DC power to the SM6-0 has failed, the TROUBLE indicator will not light, but the TROUBLE alarm will be tripped.

Firmware Version 3.4 (Specified at purchase after April 1, 1995) Motor monitor capable

TROUBLE:

Same as above, with the following addition: The trouble relay will now operate for SM6-0 self-test warnings, and for the first entry level of low gas warning. This could be used for alarm-only to the SCADA system.

SIGNAL 1:

Same as above.

SIGNAL 2: Same as above.

NOTE: If only two alarm levels are required, disable the Trouble alarm by entering “0” on the

SM6-0 configuration screen. The SM6-0 will now operate with only Signal 1 and Signal 2. Firmware version 3.41 (Standard version as of December 15, 1995)

Same as above. Saturation proximity alarm tagged to SIGNAL 1 can be disabled in accordance with Section 8.2.4. This model is motor-monitor capable as well.

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Firmware version 3.41D (No longer available)

Same as standard 3.41 with the exception that an alarm will register if the SM6-0 door is opened.

Firmware version 3.6 (October 10, 1996 and later)

Same as Version 3.41 above, in addition to network capability using the Modbus communications protocol (Appendix A).

Firmware version 3.7 (Standard on units manufactured after January 2004)

Same as Version 3.6 above, with improved MODBUS support and higher speed communication.

The Signal 1 and Signal 2 relays are kept de-energized whenever the breaker is properly pressurized—its "normal" state. Pressure losses below the programmed set points activate the two Signal relays. The Trouble relay is normally kept energized. The SM6-0 relays are rated at 130 VDC, 1 amp maximum load. It may be necessary to use an interposing relay in order to operate the breaker via the SM6-0.

1 41.4 DATA STORAGE AND ANALYSIS The SM6-0 logs observed data for trending analysis and records signal events. A standard SM6-0 stores 10 years of such data. If data has not been downloaded and the memory cleared it will be deleted on a first-in, first-out basis. Information is retrieved via the SM6-0's RS-232 port, using the included SMPLUS software. SMPLUS can graphically display the recorded numeric readings of raw gas pressure, temperature, temperature-compensated pressure, and density. Its trending feature uses logged data to predict when SIGNAL 1 and SIGNAL 2 alarm levels will be reached.

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CHAPTER 2 1MOUNTING THE SM6-0 The SM6-0 comes with all parts and accessories required for installation on most breakers. For help with specialized fittings, please contact Alotek LLC or the breaker manufacturer.

1 52.1 MOUNTING LOCATION The SM6-0 has a heated, NEMA 4X enclosure and can be mounted outdoors at any convenient location on or near the breaker. The mounting location should take into account the following:

• Station power is required to run the unit. • Ideally, the unit should be mounted in such a way that it is possible to observe both the SM6-0

display and the PC screen during servicing operations such as filling the breaker.

• The location of the temperature sensor is important for accuracy in density calculation. Site the SM6-0 to accommodate the length of cable run to the sensor (20 feet).

1 62.2 FRONT-MOUNTING THE SM6-0 Use the Hoffman 29560066 MTG FOOT KIT A-48 included with your SM6-0 and follow the instructions included with the kit.

1 72.3 REAR MOUNTING THE SM6-0

For rear mounting, use the four internally-threaded brass inserts in the back of the SM6-0 enclosure. The SM6-0 shipping carton contains two SM6-0 mounting "L" brackets and associated hardware (Figure 1).

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SM6-0 Enclosure

Mounting Bracket

FIGURE 1: MOUNTING BRACKET AND HARDWARE

1 82.4 CONDUIT INSTALLATION The SM6-0 requires three runs of conduit:

• Signal and communication lines (SM6-0 to breaker control cabinet) • AC and DC power and earth ground (SM6-0 to breaker control cabinet) • The temperature sensor (SM6-0 to termination in free air near sensor mount)

The three conduit fittings at the bottom of the SM6-0 are aluminum ½" female NPT pipe threads. There is also a ¼" stainless steel fitting for plumbing the SF6 gas line to the SM6-0 (see Chapter 6). Standard SM6-0 units come with the wiring connectors ready to install. All wires and connectors are labeled (see page 10). Wire in accordance with Chapter 5. Exercise care when working inside the SM6-0 box itself.

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After all wires have been pulled through the conduit DO NOT seal the conduit's internal wire way with insulation or sealing materials of any sort. The SM6-0 has a heated enclosure and requires a small free-flowing air path to drive off moisture which might be introduced when the outer door is opened.

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CHAPTER 3 2INSTALLING THE TEMPERATURE SENSOR The brass temperature sensor included with the SM6-0 must be securely affixed to the side of the pressure vessel of the monitored breaker. The effectiveness of the SM6-0 depends in large part upon the fact that its temperature sensor is reading, to the greatest degree possible, the temperature of the SF6 gas rather than the ambient air temperature. Proper use of the insulation blanket included in the installation kit and careful placement of the sensor itself are key elements of accurate readings. Each SM6-0 is individually calibrated at the factory to a matching temperature sensor. If the number on the sensor does not match the SM6-0 serial number located inside the front panel, notify Alotek LLC.

1 93.1 SENSOR LOCATION Accuracy of the temperature sensor is affected by its location on the breaker. Alotek LLC recommends the following configurations:

4 13.1.1 Single Tank Breakers

The sensor should be mounted midway up the side that receives the least amount of early morning or midday sun. There should sufficient space at the chosen location to accommodate the entire insulation blanket provided with the sensor. Direct exposure of the sensor to sun or cold will affect the accuracy of the density readings.

4 23.1.2 Three-Tank, Common-Gas Breakers

The sensor should be mounted wherever it will receive the least amount of early morning or midday sun. This is generally the center phase. Mount the temperature sensor midway up the side of the tank.

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FIGURE 2: TEMPERATURE SENSOR

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2 03.2 MOUNTING THE TEMPERATURE SENSOR Alotek LLC recommends permanently affixing the temperature sensor to the pressure vessel using the Loctite 330 adhesive provided. This provides the optimum installation.

CAUTION: The Loctite 330 is an eye and skin irritant. Caution should be exercised when handling

it. Use in accordance with the directions provided on the package.

1. Clean both bonding surfaces with fine sandpaper or Scotch-Brite and any commercial metal cleaner.

2. Apply a bead of RTV (silicon glue) around the perimeter of the underside of the insulation blanket, approximately 1-2" from the outside edge.

3. Apply the Loctite 330 (or other quick-drying epoxy) directly to the black temperature puck in the center of the insulation blanket.

4. Secure the temperature pad to the breaker using tie wraps until the RTV and epoxy have had sufficient time to cure. Use of tape is not recommended, as it can damage the insulation blanket when removed.

2 13.3 WIRING THE SENSOR TO THE SM6-0

1. The orange 2-pole plug required for installation is shipped with the temperature sensor. Run the wires through whatever conduit you are using and into the SM6-0. Wire to the connector in accordance with FIGURE 2, page 8.

2. Coil the excess cable in such a way that it will not drip moisture into the SM6-0 enclosure.

Excess cable may be trimmed as required. Leave enough cable to attach the drain wire.

3. Attach the drain wire to the grounding stud located in the lower right corner of the SM6-0 interior.

NOTE: The drain wire should be insulated and routed so as to avoid contacting the power

supply or the fuse block. 4. Plug the orange connector into the rectangular hole on the right side of the "PRES/TEMP

MODULE" mounted at the rear of the SM6-0 interior. The header and the plug are polarized and will only mate one way.

2 23.4 CHANGING THE TEMPERATURE SENSOR If for any reason it becomes necessary to change the temperature sensor, contact Alotek LLC for directions on how to proceed.

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CHAPTER 4 3ELECTRICAL POWER

2 34.1 POWER REQUIREMENTS The SM6-0 utilizes a universal power supply for its electronics, operating between 100-370 VDC and 85-265 VAC. It requires no manual switching for varying incoming voltage. However, the unit does require separate 120VAC 50-60 Hz power for its internal heater. The power module is located on the right interior wall of the SM6-0.

4 34.1.1 Pigtails Upon request, Alotek LLC provides units with all connectors solidly fastened to the electronics modules, with “pigtails” provided for direct wiring to the breaker. These wires are numbered sequentially 1 through 18 and correspond to the following table. Ground wires are marked with green tape.

FUNCTION WIRE #Trouble Relay 1 Trouble Relay 2 Trouble Relay 3

Signal 1 4 Signal 1 5 Signal 1 6 Signal 2 7 Signal 2 8 Signal 2 9

Auxiliary Signal 10 Auxiliary Signal 11 Auxiliary Signal 12 120 VAC Line 13

120 VAC Neutral 14 125 VDC 15 125 VDC 16

TABLE 1: WIRING

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4 44.1.2 Input Power

Incoming power is wired to the fuse block located beside the universal power supply on the right interior wall of the unit.

FIGURE 3: INPUT POWER

The power supply uses two 3-amp, 250 volt fuses.

FIGURE 4: 120 VAC HEATER POWER

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4 54.1.3 Heater Power

The internal heater will operate whenever the unit’s internal temperature drops below 20o Celsius (68o F). Use one of the orange 3-pole connectors included with the installation kit to wire incoming 120VAC power in accordance with Figure 4. Protect the AC line to the SM6-0 with a three ampere fuse.

4 64.1.4 Earth Ground Route the earth ground through the SM6-0’s power conduit to the grounding stud in the lower right-hand corner of the rear interior wall of the unit.

4 74.1.5 Connectors

The orange connectors provided with the installation kit are compatible with wire ranging from 26 to 14 AWG (0.1 to 2.5 mm2).

Connectors are labeled as below:

AUXILIARY SIGNAL 2

10 11 12

120 VAC

L N 13 14

125 VDC

– + 15 16

TROUBLE SIGNAL 1 SIGNAL 2 1 2 3 4 5 6 7 8 9

A wiring diagram specific to the unit’s specifications (Figure 5) is found inside the door panel of the SM6-0. It may vary in accordance with the unit’s function, as specified at the time of order (i.e. motor monitoring may be included). Take particular note when wiring the unit of the power supply voltage indicated both on the wiring diagram and on the voltage specification sticker located beside the fuse block inside the unit.

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DISPLAY MODULE(On Front Panel)

CONTROL MODULE(On Left Side)

PRES/TEMP MODULE(On the Back)

RELAY MODULE(On the Back)

P/T DATA

RELAYCONTROL

DISPLAY CONTROLCONTROL POWER

PRES/TEMP POWER

TO TERMINAL PORTD-SHELL CONNECTOR

(On Front Panel)

104-120 VAC50-60 Hz875 mA

EARTHGROUND

L N

BLACK

TEMP.SENSOR

AUX SIGNAL 2

TROUBLE SIGNAL

SIGNAL 1

SIGNAL 2

RS-485SCADA

SM-6 WIRING SCHEMATIC (Standard)

FIELD WIRINGCONNECTOR

LEGEND

RELAY CONTACTSIN NORMAL

(100% DENSITY) STATE

RED

DRAINSIGNAL 1 & 2TROUBLE

FACTORYWIRING

GROUNDINGSTUD

TO POWERSUPPLY

TO CONTROL MODULE

TO PRES/TEMPMODULE

AC/DC POWER SUPPLY

UNINTERRUPTABLE100vdc-370vdc or85vac-265vac

50-60hz, 7 W Max.

L

POWER MODULE

N

  

FIGURE 5: STANDARD CONFIGURATION WIRING

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CHAPTER 5 4RELAY WIRING AND COMMUNICATIONS

2 45.1 WIRING THE SIGNAL CIRCUITS Wire all signal lines to the provided orange, multi-pole connectors in accordance with Figure 8, opposite, and Figure 9 below.

} } } }

TROUBLE (ENERGIZED)

SIGNAL 1 (DE-ENERGIZED)

SIGNAL 2 (DE-ENERGIZED)

AUX SIGNAL 2 (DE-ENERGIZED)

SM6-0 IN ‘NORMAL’ STATE (100% DENSITY)

3/16 Inch (5mm)

FIGURE 6: SIGNAL WIRING

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Table 2 below shows relay configurations when the SM6-0 is wired through normally open contacts. Boxed figures indicate a change of state from normal.

TABLE 2: TRUTH TABLE

TROUBLE SIG-1 SIG-2 AUX

NORMAL STATE o o o o o o o o o o o o When SM6-0 has power and gas pressure is above all set alarm levels. TROUBLE relay coil is energized; SIGNAL relay coils are de-energized.

NO POWER No gas o o o o o o o o o o o o Gas o o o o o o o o o o o o

POWER No Gas o o o o o o o o o o o o POWER (ver. 3.4 and higher)

GAS PRESSURE Above all set alarm levels o o o o o o o o o o o o

At or below low gas warning level o o o o o o o o o o o o

Below low gas warning and at or below o o o o o o o o o o o o

Signal 1 At or below Signal 2 level o o o o o o o o o o o o

SELF DIAGNOSTICS SM6-0 internal problem. Requires power. o o o

SATURATION PROXIMITY o o o o o o

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2 55.2 WIRING THE COMMUNICATION LINES The SM6-0 has two communication ports:

• RS-232 “TERMINAL PORT" on the SM6-0's front panel • RS-485 port inside the SM6-0.

Telephone modems in differing configurations can attach to either the RS-232 port or the RS-485 (see Section 7.5, “Communicating with the SM6-0”, for more information). The RS-485 port can also be wired to SCADA systems such as MODICON.

4 85.2.1 Connecting to the RS-232 (TERMINAL PORT)

The Terminal Port uses a standard DB-9 female connector (FIGURE 10, below) and a 5-circuit subset of EIA RS-232C. It also conforms to the IBM "AT" serial port standard. It is used in conjunction with SMPLUS for system set-up and system tests as well as data retrieval and analysis. Any DB-9 straight-through extension cable can connect a PC to the SM6-0. If the PC does not have a serial port, you will need a USB-to-RS232 adapter. If you are using a modem you will need a null modem adapter.

6789

5 4 3 2 1

PIN PIN CIRCUIT EIA # NAME FUNCTION CIRCUIT 2 RD RECEIVE DATA BB 3 TD TRANSMIT DATA BA 5 SG SIGNAL GROUND AB 7 RTS REQUEST TO SEND CA 8 CTS CLEAR TO SEND CB

THE SM6-0 IS PINNED AS DCE USING THE IBM “AT” SERIAL PORT STANDARD

FIGURE 7: RS-232 PORT PINOUT

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4 95.2.2 Wiring to the RS-485 Port

Wire two twisted-pairs to the provided orange, 4-pole connector.

Back of connector Left to right 1 2 3 4

3/8 Inch(10m m )

Pai rs m ust be t w ist ed

1 TX A 2 TX B 3 RX A 4 RX B

FIGURE 8: RS-485 PORT

Networks running a variety of protocols attach to the RS-485 port inside the SM6-0. Contact Alotek LLC for your networking needs.

5 05.2.3 Wiring the Motor Monitor Relay (option discontinued after January 2004)

In order to use this feature, units manufactured prior to April 1, 1995, or any ordered after that date which did not specify this feature, will require a hardware upgrade to utilize this function. An auxiliary contact from the motor starter relay is needed, to be wired to the SM6-0 terminal block located on the CPU metal can (left side of the SM6-0 interior). The auxiliary contact will be supplied with 120 VAC tapped from the heater power supply plug in the SM6-0. The two

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wires from the motor auxiliary contact should be terminated on the two wire terminals as shown below.

Red

White to 120 VAC

Black to 120 VAC

Red

Black

TO A

UX

.C

ON

TAC

TSO

F M

OTO

RS

TAR

TER

17 1

8{

CPU Can (Left side insideSM6-0)

Dip Switches

RS-485

  

FIGURE 9: MOTOR MONITOR RELAY

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CHAPTER 6 5SF6 PLUMBING The SM6-0 uses a bulkhead-mounted, stainless steel pressure transducer. SF6 pressure must be plumbed to a bulkhead fitting at the bottom of the SM6-0.

SM-6 BULKHEAD

RIBBON CABLE

FIGURE 10: SM6-0 PRESSURE TRANSDUCER

2 66.1 PLUMBING TO THE SM6-0 1. Plumb SF6 to the SM6-0's bulkhead fitting using the compression fittings provided in the

installation kit and ¼" stainless steel tubing. 2. The compression fittings use a Swagelok twin ferrule system. Assemble the ferrules properly

according to Figure 11. 3. When assembling the compression fitting, insert the tubing all the way into the fitting.

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FIGURE 11: COMPRESSION FITTING If the SM6-0 must tap into a line that is the flow path during filling you MUST tap into the line perpendicular to the gas flow (FIGURES 12 and 13). Tap into tank pressure at a point that is completely isolated from where filling is performed to avoid exposing the SM6-0 to damaging pressure transients during filling. On 3-tank, common-gas breakers a preferred location may be at a fitting outside the breaker cabinet.

SM -6 reads f alse addi t ionalSF6 pressure at “ T” dur ingf i l l ing.

TA NK SM -6

FILL VA LVE

FILL FITTING

SM -6

BREA KER

175

FIGURE 12: INCORRECT PLUMBING

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FILL FITTING

BREA KER

TA NK FILLVA LVE

SM -6

SM -6 reads on lyst at ic t ank pressuredur ing f i l l ing , p lus

sm al l w ork ingpressure.

105

SM -6

FIGURE 13: CORRECT PLUMBING

2 76.2 PRESSURIZING THE SM6-0 Raise the line pressure slowly to allow the SM6-0 microprocessor to register the changing pressure. Purge the line of any accumulated moisture by loosening the compression fitting. IF YOU HAVE ANY TECHNICAL QUESTIONS REGARDING INSTALLATION OF THE SM6-0, PLEASE CALL ALOTEK LLC AT 1-800-845-2908 (Canada: 509-927-8837).

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CHAPTER 7 6CONNECTING AND STARTING

2 87.1 OVERVIEW Either SMPLUS or a terminal program may be used to communicate with and configure the SM6-0. SMPLUS is required to download data and for graphing and trending. SMPLUS is provided with each SM6-0 purchased, or may be downloaded at www.con-elec.com. A minimum of thirty days’ worth of historical information is required on any download of recorded data or events in order for SMPLUS to be able to perform its graphing and trending functions.

2 97.2 SETTING THE BAUD RATE

The maximum communication speed of the SM6-0 is 19,200 bps and is defaulted to this speed at the factory. On all units using SMPLUS version 2.5 and higher, the baud rate setting on the SM6-0 is matched automatically at startup to the modem transmission speed of the computer being used. The dip switches inside the SM6-0 control module control the communications speed. If the unit does not respond to software override, reset the switches in accordance with Figure14 below.

1 2

3 4

OFF

DIP SWITCH #1 #2 #3 #4 19.2k ON OFF OFF OFF 9600 ON OFF OFF ON 4800 ON OFF ON OFF 2400 ON OFF ON ON 1200 ON ON OFF OFF 600 ON ON OFF ON 300 ON ON ON OFF

The #1 switch controls the SM6-0’s relay logic. Leave it in its default “ON” position. To turn a DIP switch “ON”, press down on the numbered side.

 

CONTROL MODULE Inside SM6-0 on

the left side

FIGURE 14: RS-232/574 SERIAL PORT BAUD RATE SETTINGS

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3 07.3 COMMUNICATING WITH THE SM6-0 The SM6-0 is configured to communicate using SMPLUS or any terminal emulation program such as HyperTerminal.

5 17.3.1 RS-232

The RS-232 port can be used in conjunction with a modem or HyperTerminal to access a single SM6-0 remotely. Default settings are:

Baud rate : 19200 Data bits : 8 Stop bits : 1 Parity : None Flow Control : X on/X off

Baud: If 19200 proves to be too fast, reset to a more common rate such as 9600 or 4800. If the SM6-0 baud rate has been changed previously and not recorded, try different settings until it answers to the [TAB] key with the main menu.

Data bits: This value is factory set and non-user adjustable. It must equal 8 or the SM6-0 will respond with gibberish. Change the setting without hanging up to correct the error.

Stop bits: Must be set to 1 or the data will be garbled. Change as with data bits above. Parity: Must be set to none. Change as above.

5 27.3.2 RS-485 (Version 3.7)

Unlike the RS-232, the RS-485 can be used to talk to multiple devices on the same network. It is possible to run a network line from Point A to B and to attach network members by tapping in at any point between A and B. The RS-485 drivers in the SM6-0 will drive two 18 gauge twisted pairs about 1000 yards. This length limitation is sufficient for most breaker yards (see Figure 16). The SM6-0 RS-485 port is configured as a four-wire, or “full duplex” or “multidrop” type network. See Appendix A for MODBUS registers.

The SM6-0 is configured to communicate via MODBUS as stated below:

Baud : 2400bps – 19.2kbps Protocol : ASCII MODBUS Parity : None Data Bits/Stop Bits : 7/2 Slave Addressing Style : 584/984 Maximum Coil Read Block Size : 1000

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Maximum Read Block Size : 32 Resistor Type : Binary String Variable Style : Full Length (padded with spaces)

M A STER

R

T

+-

+-

R R RT T T+ - + - + - + - + - + -

SM -6 SM -6 SM -6

A B C

   

FIGURE 15: RS-485 COMMUNICATIONS Node Name

Node name is used to identify a particular SM6-0. When configuring the SM6-0 (Setup, Section 8.2.5), at the Network menu, type in a node name of up to eight characters.

Node Number The slave address used by each SM6-0 in the network. Valid slave addresses may be any number in the range 1-247, limiting the maximum number of units on the network to 246. To prevent bus contention, no two SM6-0s should have the same node number on the network.

Wiring

See Section 5.2.2

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CHAPTER 8 7CONFIGURING AND USING THE SM6-0

3 18.1 OVERVIEW Through use of the alarm levels configured at setup, the SM6-0 can forecast the next incidence of low gas, along with the predicted number of days until the gas level reaches each alarm setting. Maintenance may then be scheduled in accordance with the philosophy of preventive, rather than reactive, maintenance. For more about this feature, see Chapter 9. The optimal reading to be achieved on the SM6-0 display is 100%, indicating a fully charged breaker. All setup values entered in Section 8.2 are designed to produce this reading for each breaker to be monitored. One hundred percent "full" is defined by the normalized temperature and pressure settings entered by the user. Subsequent deviations from this optimum reading indicate actual changes in gas density inside the breaker pressure vessel, rather than the effect of ambient temperature on the SM6-0’s temperature sensor. The various alarm levels are triggered when the density reading reaches pre-set limits. All menus shown in this chapter apply to connections using either SMSOFTTM or a terminal program. SMPLUS, the current software shipped with the SM6-0, is a Windows-based program with easy-to-use menus and its own help file. However, information in this section is relevant to all methods of communicating with the SM6-0.

5 38.1.1 Main Menu

All SM6-0 setup configurations are accessed through the main menu screen. Briefly, the four categories cover:

1. MONITORING

• SF6 Density: Displays configuration settings and current real time readings

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• Relay: Displays current condition of SIGNAL 1, SIGNAL 2, and TROUBLE relays, as well as the density percentage level they are set at. Go to this screen first when the unit alarms.

• Heater: Displays the current internal temperature and heater performance of the SM6-0.

• Motor: Displays the motor monitoring screen 2. HISTORY

• Displays the daily and monthly data summaries and event log and allows access to data downloads.

3. SERVICE

• Provides access to the vacuum test procedure and SM6-0 self-test. 4. SETUP

• Date and Time • Measurement Units: temperature, pressure, vacuum, etc. • SM6-0 Configuration: elevation, normalized temperature/pressure, relay set points,

etc. • Network • Motor Alarm Limits

5 4 8.1.2 Display Messages

The SM6-0 has four indicators above the LCD on the front panel: NORMAL (green), SIGNAL 1 (amber), SIGNAL 2 (amber), and TROUBLE (amber).

- Su -

NORMAL TROUBLE SIGNAL 2SIGNAL 1

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• The green NORMAL indicator will remain lit whenever the SM6-0 is functioning normally and the gas density remains above all set alarm levels.

• The amber SIGNAL 1 will light when the level of gas in the breaker has reached the first density alarm set point. Both the TROUBLE and SIGNAL 1 indicators will be lit, and the LCD will display the current density, which will correspond to the alarm set point or below. For example, if the Signal 1 alarm is set at 89% density, the percentage displayed at the time the indicator lights will read 89% or below.

This signal will also light when the gas reaches the saturation proximity set-point described in Sections 8.2.3 and 8.2.4.

• The red SIGNAL 2 will light when the level of gas has reached the second density alarm set-point (lockout).

• The TROUBLE indicator will light in conjunction with the low gas warning (first density alarm set point), or any condition discovered by the SM6-0’s self-diagnostics (see table below). It will also light to indicate user activity such as door open, vacuum test, setup, etc. The diagram above shows a TROUBLE indicator because the SM6-0 is in setup mode.

Table 3 indicates the possible display messages and the indicator light(s) for each.

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TABLE 3: SM6-0 MESSAGE LIGHTS SM6-0

DISPLAY MESSAGE

NAME SIGNAL

1 SIGNAL

2 TROUBLE EXPLANATION

-A- Alarm X X Second alarm set point (Signal 1) -ar- Average Run

Time X (Version 3.4 and higher). Indicates

that the average run time per start as determined by the SM6-0 for the past 30-day window has exceeded the limit set in the motor alarm limits screen.

-do- Door Open X User activity, indicates front door is not latched (disabled on version 3.4 and higher)

-HP- High Pressure X Activated if the pressure is higher than 150 PSIA, or possible sensor malfunction

-Ht- High Temperature

X Activated when gas temperature is above 60o C (140o F), the cable is shorted, or there is a problem with the temperature sensor

-L- Lockout X X X Third alarm set point (Signal 2: lockout)

- Lo- Low Gas X First low gas set point -LP- Low Pressure X Possible internal problem in the

SM6-0 pressure transducer -Lt- Low

Temperature X Indicates gas temperature is below -

50o C (-58o F). Also activated if the temperature sensor is malfunctioning or the cable is cut.

-op- Operations X Indicates the allowable number of motor starts per 30-day window has been exceeded.

-rt- Run Time X Indicates the allowable run time per start has been exceeded.

-St- Self Test X Indicates the SM6-0 is running its self-diagnostic program.

-Su- Setup X User is accessing setup program -T- Trouble X First incidence of low gas, or

problems pinpointed by the self-diagnostics

-Vt- Vacuum Test X User is running vacuum test

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3 28.2 SETUP All setup functions are accessed through the screen below. To reach this screen, at the SM6-0 MAIN MENU, press 4 (SETUP MENU).

5 58.2.1 Setting the Date and Time

1. At the SETUP screen, press 1. This screen will appear:

2. To insure that the SM6-0 memory is clear, start by using the down arrow [ ] to go to the DATE. Type eight zeros (00000000), and press [ENTER] three times. If there is data you want to save, download to a disk or skip this procedure. Proceed with setting the new date and time.

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3. Use the up [ ] or down [ ] arrow keys to move within this screen. Input the correct time in military-style 24 hour format. Use the period or decimal keys (.) to separate both time and date; the SM6-0 will not accept colons or slashes. Though you must enter a value for seconds, the SM6-0 will convert the entry to zero, zero (00) regardless of what is entered. If you accidentally input an incorrect number, press left arrow [ ].

4. After you have finished inputting the new time, press [ENTER]. This sets the new time. 5. Press the down arrow [ ] key to move the cursor to the date line. Input the date. Press

[ENTER].

6. Press the [TAB] key to return to the SETUP menu.

5 68.2.2 Setting Measurement Units

1. At the SETUP menu screen, press 2. At this screen, values are chosen at each line by pressing the [SPACE] bar.

2. The flashing cursor will be on the Temperature Units line. Options for this line are:

C: Celsius F: Fahrenheit K: Kelvin R: Rankin cal: Calibration units. This is for factory calibration only N2: N2 or CF4

Alotek LLC recommends using the same units as listed on the breaker's nameplate.

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3. Press the [SPACE] bar until the desired option appears. Use the down arrow [ ] to move to the next line.

4. Press the [SPACEBAR] key to toggle to the desired pressure measurement unit. Options:

bar: millibars cal: calibration units kgf: kilogram force kPa: kilopascal Mpa: megapascal PSI: pounds per square inch

5. Vacuum Units: There is not normally a vacuum unit listed on the breaker nameplate. If you don't know what vacuum unit will be used, select "mmHg". Options:

cal: calibration units iH2O: inches water column inHg: inches mercury kPa: kilopascal mbar: millibar mmHg: millimeters mercury

Torr: = millimeters mercury 6. Pressure Base Options: Gauge: Gauge abs: Absolute

If you selected "PSI" for your pressure units, selecting “gauge” will give you PSIG. Selecting "abs" will give you PSIA. Your breaker's nameplate pressure rating will specify the pressure as being either a gauge or absolute rating. This is important because the difference between the two can be as great as 14.7 PSI (0.101 Mpa).

7. Set Pressure Vessel to either "steel" or "alum." (aluminum) depending on what the

breaker's pressure vessel is made of. 8. Select either N2 or CF4 if the breaker uses mixed gas.

9. Use the [TAB] key to return to the SETUP menu screen.

5 78.2.3 Setting SM6-0 Configuration

1. Press 3 to go to the SM6-0 CONFIGURATION screen. Correct settings here are critical to the SM6-0’s accuracy and ability to properly recognize alarm levels.

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2. Input the proper yard elevation for the breaker being monitored, using the numeric keys.

Press the [ENTER] key and then the down arrow [ ] to move to the next set point.

3. Normalized Temperature: The temperature the breaker manufacturer used to specify the breaker's rated charge pressure. For instance, if the breaker were rated for a charge of 75 PSIG @ 68 °F, you would set the normalized temperature to "68".

4. Normalized Pressure: The rated charge pressure. Using the above example, if the breaker

were rated for a charge of 75 PSIG normalized to a temperature of 68° F, you would set the normalized pressure to "75".

5. Low Gas Set Point: On version 3.4 and higher units this is the first incidence of low gas

warning point. It will light the TROUBLE led indicator on the front panel. If this alarm level is not desired, set this value to “0”.

6. When normalized pressure is entered the SM6-0 will automatically calculate and enter the

Low Gas warning, Relay 1 and Relay 2 set points. If your system requirements demand higher or lower alarm levels, you can manually set these at any level. Move the cursor to the function you want to reset, key in the value and press [ENTER].

7. If the breaker is filled with an SF6/nitrogen blend, set N2 Content to the proper value. The SM6-0 will factor that value into the compensation process. If not, leave it at "0.00%".

8. Saturation Proximity: This setting determines how much advance notice (in degrees of

temperature) the SM6-0 will give that a breaker's SF6 is about to liquefy, i.e. the gas is 6o C above liquefaction. The SIGNAL 1 alarm will trip when this value is reached. Acceptable values:

Celsius: Any value between 0o and 6o Fahrenheit: Any value between 3.6o and 10.8o

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8. Record all settings on the faceplate of the SM6-0. To determine what the PSI settings equal in percent (%), press [TAB] until the MAIN MENU screen appears. Low gas warning, SIGNAL 1 and SIGNAL 2 settings are listed at the RELAY MONITORING screen.

5 88.2.4 Disabling the Saturation Proximity Alarm (recommended) Units sold after December 15, 1995 have an override command for this setting (version 3.41). Customers operating in extremely cold climates may wish to disable the proximity alarm for liquefaction. The following procedure will move the alarm algorithm to follow the saturation curve 20o C (36o F) below the actual curve. This insures this alarm will not occur. To disable the proximity alarm, while running SMSOFT from a PC or laptop:

• Connect to the SM6-0. At the MAIN MENU select 4 SETUP. • Select 2 CHANGE UNITS. • Press space bar to toggle through Temperature, Pressure, and Vacuum settings until

“cal” units is displayed on each. • Pres [TAB] to return to the SETUP menu. • Select 3 CONFIGURATION. • Use down arrow to move to the SATURATION PROX alarm item. • Enter “64896”, press [ENTER]. The SM6-0 will return a value of “-640” cal units.

This corresponds to -20o C or -36o F. To verify this, return to the SETUP menu and select CHANGE UNITS again.

• Select the “C” or “F” temperature units. Return to the CONFIGURATION menu in SETUP to view the new saturation proximity alarm.

To re-enable the alarm:

• Select SETUP at the MAIN MENU, then CHANGE UNITS. • Select “cal” units as above. • Press [TAB] to return to the SETUP menu. Select CONFIGURATION. • Again select the SATURATION PROX. alarm. • Enter the number of degrees prior to liquefaction desired for the alarm setting (2-6o C,

3.6-10.8o F), and press [ENTER]. The SM6-0 will return the same number. The unit will now generate a SIGNAL 1 alarm when the saturation proximity is reached.

5 98.2.5 Network Setup The RS-485 ports in the SM6-0 is available for networking as described in Section 7.5.2. Contact Alotek LLC for help in configuring your system.

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6 08.2.6 Motor Monitor (Specified on version 3.4 units purchased after April 1, 1995)

This screen sets the alarm levels for the motor monitor feature, which allows the SM6-0 to monitor the stored energy system of the breaker closing mechanism. Do not set alarm levels at “0”, even if the motor monitor function is not engaged. If left at “0”, it will trigger an alarm. If motor monitoring is not being used, enter any number above “0” as shown.

1. From the SETUP screen, press 5 (Motor Alarm Limits)

2. Run Time: Sets the allowable time for the motor to run before triggering an alarm. Time is recorded in minutes. Enter any value above zero and press [ENTER]. Use the down arrow [ ] to move to the next line.

3. Starts/Month: Sets a limit for the permissible motor operations per 30-day window.

4. Avg. Run Time/Start: Sets an alarm point based upon the average run time per start

for the previous 30 days’ operations. Time is recorded in minutes.

The run time analysis covers a thirty-day window, updated daily at midnight. At that time the computer analyzes the most recent 24 hours of data and adds this to the stored data for the previous 29 days, with the oldest 24-hour period being automatically dropped from memory.

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3 38.3 MONITOR MENU

At the MAIN MENU, press 1 for MONITOR MENU. This series of screens displays all of the SM6’s configuration settings and the current readings for each area of interest.

6 18.3.1 SF6 Density

This screen displays the normalized settings entered for the equipment being monitored, and the SM6-0’s realtime readings.

1. Press 1 to go to the SF6 DENSITY MONITORING screen. The following example is based

on a breaker charged to 100%. Current density, compensated pressure,

temperature and pressure values.

} The breaker's specification for rated charge, as determined by values entered at the SM6-0 Configuration screen, section 9.2.3; in this case, 15 PSIA at 68o F.

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This screen displays actual readings in comparison to setup values. The unit continuously calculates changing pressure and temperature readings to achieve the temperature-compensated pressure from which density is calculated.

2. Press [TAB] to return to the MONITOR SCREEN.

6 28.3.2 Relay Monitoring

This screen shows the current density set points and the real time state of the relays. If the SM6-0 should show an alarm, check this screen first to determine why. A partial list of trouble indicators is given at the bottom of the screen.

1. From the MONITOR SCREEN, press 2 to go to the Relay Monitoring screen:

2. The screen looks like this when a breaker is properly pressurized and the SM6-0 is functioning properly. The Signal relays are both de-energized (OFF), because the current readings are at or higher than the alarm set-points. The Trouble relay is energized (ON) because:

a. The SM6-0 is running. b. The SM6-0 is making density calculations c. The user is logged on even though the outer door is open. d. The unit has been configured with the Trouble relay normally open.

3. Also shown are definitions for events that may occur and be logged in the event recorder.

4. Press [TAB] to return to the MONITOR MENU.

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6 38.3.3 SM6-0 Heater Monitoring

1. Press 3 to go to the Heater Monitoring screen.

The SM6-0 was designed to maintain an internal temperature of 68o F or above. "WATTS" is the power presently being drawn by the SM6-0 internal heater. The constant is 3 watts.

2. Press [TAB] to return to the Monitor Menu. Press [TAB] again to return to the Main

Menu.

6 48.3.4 Motor Monitoring (Found only on version 3.4 units specified after April 1, 1995. Older SM6-0s can be upgraded to accommodate this feature.)

1. At the MONITOR MENU, press 4. The following screen will display:

2. To clear alarms, at the above screen press the [SPACE] bar. The event log retains all of the alarms and the time when the alarm is cleared.

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If an alarm is generated, simply clearing the alarm will not resolve the cause. If a 30-day alarm such as ‘Average Run Time” or “Starts per Month” is occurring, then the alarm value must be reset at a higher level. Otherwise, additional alarms could occur daily until the cause of the alarm is overcome and the effect of the high value has migrated through the 30-day window.

3 48.4 HISTORY MENU This series of screens displays the data recorded by the SM6-0 since it was activated. The SM6-0 is capable of storing up to ten years’ worth of daily information. Each download performed during that time will access ALL of the information in memory. When the SM6-0 memory reaches capacity, information is deleted on a first-in, first-out basis. At the MAIN MENU, press 3 (History).

6 58.4.1 Monthly Record

1. Press 1 to go to the Monthly Record screen.

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This screen displays an average, by month, of the following for any given year:

• DENS (Density) • TEMP (Temperature) • PRES (Pressure) • TCMP (Temperature Compensated Pressure)

3. Press the [SPACE] bar to toggle between the above-listed data types. 4. Press the [ ] up or [ ] down arrow keys to toggle through the years. 5. Press [TAB] to return to the History Menu.

6 68.4.2 Daily Record

1. Press 2 to go to the Daily Record screen.

This screen presents the daily averages for density, pressure, temperature, and temperature compensated pressure for any given month, any recorded year 2. Use the [SPACE] bar to toggle between data records.

3. Use the [ ] up or [ ] down arrow keys to toggle between months.

6 78.4.3 Event Log

This screen shows the dates and times of any event such as an Alarm 1, Alarm 2 or Trouble Relay and the explanation for the event if it is a trouble relay. For example, "-do-" means the door is open when a PC is not communicating with the SM6-0. For more information on viewing and editing event log data, see section 10.5.

1. Press 3 to go to the Event Log screen.

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If you are logged onto SMPLUS, the messages displayed at this screen may also be viewed in the "Relay Monitoring" screen:

Ht = HighTemperature Su = Setup Mode A = Signal 1 Op = Operation St = Self Test L = Signal 2 LP = Low Pressure do = Door Open T = Trouble HP = High Pressure Vt = Vacuum Test rt = Run Time Lt = Low Temperature

2. Press [TAB] to return to the History Menu.

NOTE: The SM6-0 correctly logs the passage of time even when the date and time have not been

properly set. However, all records will appear as above, logged to a null time and date.

6 88.4.4 Data Download

This screen allows access to the recorded data in the SM6-0 memory. Information can be downloaded directly to the PC hard drive, or to a floppy disk for later analysis. It is not possible to download only part of the SM6-0’s memory. Any download will recover all of the information stored since the SM6-0 was activated. It is possible to clear the memory by zeroing out the date and time in the setup menu (section 8.2.1). This will remove all data, including setup configurations. If the data download files become too large for convenient editing or downloading to a disk, this action may be desirable. It is recommended that users keep backup files of all downloads performed. Only data files may be graphed, using the graph/trending feature described in Chapter 9. Event log files can only be viewed and edited in MS-DOS.

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A minimum of 30 days’ worth of recorded data is required on a download in order for SMPLUS to produce trending data (see Chapter 9).

1. Press 4 to go to the Data Download screen.

2. Press [D] to Download Daily Averages or [E] to Download Events. SMPLUS will ask for a filename.

3. Type in a filename of up to eight characters. The program will add the extension .SM6

when writing to the database. Press [ENTER]. If you are downloading both the event log and the data, be sure to give them different file names, such as 123E for events, 123D for downloads. This will prevent accidental overwriting of information from the same breaker.

SMPLUS assumes you are downloading to the C:\SMPLUS directory on your PC hard

drive unless otherwise specified. To download to a floppy disk, specify the drive when typing in the filename.

EXAMPLE: Enter Filename: A:\>2617d.sm6 DO NOT interrupt the download. When the transfer of information is complete, the

History Menu will display again. If the file transfer is interrupted, press [END] and return to the /SMSOFT> prompt in MS-DOS and type "SM6" to return to the main menu. You can then return to this screen and try again.

4. If you have downloaded "Daily Average" and want to use the History Graph and Alarm

Projection/Trending summary you will need to be at the DOS prompt. See Chapter 9 for detailed instructions.

Versions 3.2 and earlier of the program sometimes fail to create headers for download data, resulting in an abortive download or gibberish. Software versions after 17 June 1996 correct the

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problem by automatically searching for setup parameters to create a header file prior to commencing the download. Note that this version displays the message “Downloading Header…”. If your software version does not display this message or you experience download problems, contact Alotek LLC about upgrading the software.

3 58.5 SERVICE MENU This screen allows use of the SM6-0 to determine the present vacuum of the breaker, as well as to test your system’s response to the SM6-0. At the MAIN MENU, press 3 for the SERVICE MENU.

6 9 8.5.1 Vacuum Test

This test is used during servicing of a breaker when it is necessary to draw a vacuum on the SF6 gas chamber. It presents a real-time display of each item. For best results the vacuum test should be conducted over a period of four hours.

The SM6-0 is accurate to within 1 Torr (1mmHg).

1. At the SERVICE MENU, Press 1 to go to the Vacuum Test screen. The Trouble relay

will light. The present vacuum is displayed.

2. To start or stop the test press the [S] key on the keyboard.

3. To change the unit parameter you will need to go to the SETUP MENU. Refer to section 8.2.2 (Setting Measurement Units).

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7 08.5.2 Test Mode WARNING: Exercise of the relays will affect the breaker. It could cause the

breaker to trip or lock-out, depending on the manner in which the relays are connected.

1. From the Service Menu press 2 to go to the Test Mode screen. This test allows you to

check alarm set points, to exercise the SM6-0 hardware and software, and to test your system's response to relay contact closures. Check the SM6-0 faceplate or RELAY MONITORING in the MONITOR MENU to verify what the alarm set points are.

Test temperature = normalized temperature Test pressure = normalized pressure

The normalized settings define 100% as entered in Section 8.2.3 (CONFIGURATION). When the test mode is "on" the SM6-0 is not monitoring.

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2. To test the settings for SIGNAL 1 and SIGNAL 2, use the up [ ] and down [ ]

arrow keys to move to the Test Temp. and Test Pres. settings. Enter the SIGNAL 1 normalized pressure and temperature settings established during setup (section 8.2.3).

3. Move the cursor up to the ON/OFF line and press the [SPACE] bar to turn the test on.

The SM6-0’s SIGNAL 1 light should come on.

4. Press the [SPACE] bar again to turn test mode off.

5. Repeat the test using the SIGNAL 2 pressure setting. Both the SIGNAL 1 and SIGNAL 2 indicators should light. Turn the test off to return the unit to normal monitoring. The SM6-0 will reset to monitoring automatically in ten minutes if not turned off after testing.

6. The test mode must be turned "OFF" before exiting.

7 18.5.3 Ending Your Session

To exit the program, press "END."

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CHAPTER 9 8GRAPHING AND TRENDING (SMSOFT)

3 69.1 OVERVIEW One difference between the SM6-0 and other gas monitoring systems is the SM6-0’s ability to trend breaker performance and predict alarms. The values entered in the setup process, the accuracy of the temperature sensor, and the care taken at installation, all combine to produce information which accurately tracks the leak rate, if any, of the specific breaker, and uses that information to predict the exact date at which the level of gas density reaches the preset alarm points (SIGNAL 1 and SIGNAL 2). The graph displays the density, temperature, pressure, and compensated pressure values in relation to the alarm set points, allowing the user to see several months’ worth of data at once. The trending screen shows at a glance the predicted date for the next alarm. Maintenance may be scheduled accordingly. In order to graph or trend data for the actual equipment being monitored, the user must first perform a data download in accordance with Section 8.4.4. A minimum of 30 days’ worth of historical data is required. It is not necessary for the unit to be connected to the SM6-0 in order to graph the information. Users may download data for later analysis. On color monitors graphic data is represented as follows:

DENS (density) Purple PRES (pressure) Red TEMP (temperature) Blue TCMP (temperature compensated pressure) Green Leak Trend Summary Yellow (top yellow line) SIGNAL 1 and 2 Yellow (bottom two yellow lines) Past daily averages are represented on the four data lines. Alarm levels will be reached when the TCMP line intersects the SIGNAL lines. The leak trend summary shows the actual leak rate of the monitored equipment. Grids for each measurement can be added, using the function keys (F1-F10) on your computer keyboard, to refine the data represented in the daily averages. For example, the temperature grid will tell you at what temperature the density fell. (See Section 9.2.1).

3 79.2 GRAPH 1. At the DOS prompt (C:\SMSOFT> type "GRAPH" (versions of SMSOFT sold prior to April

1, 1995 may require that the type of monitor be entered also; i.e. GRAPHCGA, GRAPHVGA, GRAPHEGA, and ask for a file name). Version 2.5 allows direct access to download files

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from either DOS or WINDOWS. Type “Graph” or click on the “Graph.exe” file in the program directory.

2. When starting GRAPH from either DOS or Windows, the program takes you to a directory screen:

When accessing a drive with subdirectories available (a hard drive or a floppy with more than one directory), you will see a [ ..] on the left (directory) side of the screen, and a list of files on the other. With the cursor on the up [ ..] arrow, press [ENTER] to move back one directory level. Use the other arrow keys as follows:

• Left [ ] to move to the directory window. • Up [ ] or Down [ ] to scroll through files or directories. Press [ENTER] on a

highlighted file or directory to access it. • Right [ ] moves the cursor from the directory window to the file window. • When a file is selected by pressing [ENTER], it automatically begins the graph

program. The graph screen will appear.

All recorded values are graphed together on this screen for immediate comparison. In versions of SMSOFT distributed after June 1996 (Version 2.5 and higher), the download file name is displayed at the top of the screen and a help file was added. Press “H” to access the help file from the graph screen. Press any key to exit Help. The program automatically filters download data to remove any misplaced information which would prevent obtaining a readable graph or trending screen.

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4. The dates of the download range are displayed at the bottom of the graph grid. Use the

space bar to change the date format from MMM/YY to MM/YY, i.e Jun94 to 06/94. download range are displayed at the bottom of the graph grid. Use the

space bar to change the date format from MMM/YY to MM/YY, i.e Jun94 to 06/94.

5. Note that the yellow leak summary and alarm projection lines are not displayed. To add the alarm projection lines, press [F9]. To see the 100% density average line, press [F8] for the density grid.

5. Note that the yellow leak summary and alarm projection lines are not displayed. To add the alarm projection lines, press [F9]. To see the 100% density average line, press [F8] for the density grid.

6. All grids may be displayed on the graph screen simultaneously. To add or remove data lines or grids:

6. All grids may be displayed on the graph screen simultaneously. To add or remove data lines or grids:

ODD-numbered function keys add or remove data lines. ODD-numbered function keys add or remove data lines. EVEN-numbered function keys add or remove grids. EVEN-numbered function keys add or remove grids.

TEMP PRES TCMP DENS PROJ (red) (blue) (green) (purple) (yellow) Data Line F1 F3 F5 F7 F9 Grid F2 F4 F6 F8 F10

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5. To magnify the grid, use the up [ ] up and down [ ] arrow keys. The screen can be magnified to 32x. There must be at least two months’ data stored to use the magnify function.

6. Use the left [ ] and right [ ] arrow keys to move through the magnified grid (forward or backward chronologically).

NOTE: In order to use this function the grid must first have been magnified in accordance with step 5, this section.

7. To exit the graph program from the graph screen, press [END]. This will return you to the

DOS prompt (C:\SMSOFT>). To return to the SM6-0 MAIN MENU screen, type “SM6”.

3 89.3 PRINTING THE GRAPH To print the current graph or trending screen, simply press “P” in either screen. This screen will appear:

PRINT GRAPH

Press E for an Epson-compatible dot matrix printer. Press H for a Hewlett-Packard LaserJet printer.

Press I for an IBM Proprinter-compatible printer.

Press Escape to cancel printing Select whichever printer emulation best suits your printer from those displayed. If there is a printer connection error or if the printer is off-line, a message will display indicating that there is a problem.

3 99.4 ALARM PROJECTION/TRENDING SUMMARY This function is accessed from the graph screen. A minimum of 30 days’ data is required in order for the SM6-0 to project alarm signals.

1. Start the GRAPH program in accordance with Section 9.2 above. When the graph appears, press [F10]. Attempting to trend with insufficient information will return the user to MS-DOS at this point.

2. The “Alarm Projection/Trending Summary” screen appears:

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ALARM PROJECTIONS: The starting and ending dates of the download data are

displayed. All predicted alarm dates are displayed for planning purposes.

SETUP: Values entered into the SM6-0 at original setup. MIN/MAX VALUES: The minimum and maximum values for each data

line recorded during the period of the download. DAILY/ANNUAL LEAK RATE: Calculated based on the data presented in the period of the

download. SUMMARY: Shows the minimum and maximum values of density,

temperature compensated pressure, raw pressure, and temperature over the service period of the SM6-0. . Use the [ ] and [ ] arrow keys or the [Pg Up] and [Pg Dn] keys to move through the data, one line or one screen at a time. The current line is highlighted by the data color used in the graph screen (ie. the temperature data will be highlighted in red).

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3. To return to the graph, press [F10] again. This key also activates the alarm and leak projection inputs on the graph screen.

4. To quit the trending feature, press any key other than an arrow key to return to the graph

screen. Press [ESC] to exit the graph program.

4 09.5 VIEWING EVENT LOG OR DOWNLOAD DATA Event logs cannot be graphed. They simply record the date and time a signal event occurred, so that the user can cross-reference specific alarm or event messages to a precise time of occurrence. To view and edit event log data:

1. Download an event log in accordance with section 8.4.4 (Data Download). 2. At the DOS prompt (C:\SMSOFT>), type “edit” and the event log filename: EXAMPLE: C:\SMSOFT>edit 123E.sm6

3. This brings up the DOS EDIT screen. A few seconds later the event log data will appear. 4. To view or edit download data, follow the procedure show above, using data download file

names. The first line of data is the header, and should look like this: PSIG F , 70, 65, 60 This indicates the normalized settings for the SM6-0. If the header is missing, you may have an older version of SMSOFT. Check the

normalized settings for your SM6-0 and enter them as the first line in the edit screen in the format listed above. The data will then appear in column form under the headers. ContactAlotek LLC to obtain updated software.

5. Use the arrow keys or the page up [Pg Up] and page down [Pg Dn] keys to scroll through

the data.

6. Print the data and exit the program in accordance with the menus across the top of the EDIT program screen.

IF YOU HAVE ANY TECHNICAL QUESTIONS REGARDING THE OPERATION OF THE SM6-0 OR ITS SOFTWARE, CALL ALOTEK LLC AT 800-845-2908.

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CHAPTER 10 9TROUBLESHOOTING

AREA OF CONCERN

PROBLEM SOLUTION CHAPTER

SMSOFT Program does not start Check version of SMSOFT and type the correct start command (i.e. SMSOFT2 = “sm6”)

7.2 7.3

When you start the SM6-0 Setup program you get a message stating “Please check all cables and Baud Rate Settings”.

The SM6-0 may not be connected to the PC.

7.2

There may be a cabling problem between the PC and the SM6-0. The required cable is a 9-to-9 pin D-shell, straight through extension cable. Check your cable with a VOM. Pins 2, 3, 5, 7, and 8 should have straight through continuity (refer to Figure 11, p. 19). Pin 2 at one end of the cable should have continuity with pin 2 at the other end and the same for the other pins.

5.2.1

You may be using a null modem cable. Be aware that pins 2 & 3 and pins 7 & 8 will swap positions between one end and the other.

5.2.1 7.1

You may be using a null modem cable without a null modem adapter. An adapter is required in order to swap the pins again andproduct a straight through cable assembly.

5.2.1 7.1

Check that the toggle switches in the SM6-0 have not been changed.

7.4

Recycle power to the laptop and the SM6-0.

7.3 7.4

Run terminal program 7.5 Check the communications port 7.4

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AREA OF CONCERN

PROBLEM SOLUTION CHAPTER

you are using SMSOFT You attempt to graph a file

and receive a “File or path not found” message in MS-DOS.

List the directory files to insure the file name is correct. (C:\SMSOFT>dir [ENTER])

9.2

You attempt to graph a download file and the DOS prompt appears unexpectedly.

There was insufficient data for SMSOFT to trend

9.3

DISPLAY The SM6-0 Display is locked.

Recycle power to the SM6-0.

DOWNLOAD The screen is jumbled when a Data Download is attempted.

A prior Data Download was probably interrupted. Press [END] to go to the \SMSOFT> prompt and type "SM6" to return to the Main Menu.

8.4.4

OPERATION Computer screen displays gibberish or odd characters

The baud rate is probably mismatched. Check that the DIP switches on the SM6-0 are set in accordance with the PC’s modem.

7.4

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1 0APPENDIX A MODBUS The Modbus communications protocol is supported by SMSOFT via firmware version 3.7. Below is the registry map for using this protocol. 01 COIL STATUS

Address Description Data = 0 Data = 1 00001 Trouble Light Off On* 00002 Signal 1 Light Off On* 00003 Signal 2 Light Off On* 00004 Normal Light Off On 00005 Trouble Relay Alarm Normal 00006 Signal 1 Relay Alarm Normal 00007 Signal 2 Relay Alarm Normal 00008 Heater Off On 00009 Motor Runtime Alarm Off On 00010 Motor Operations Alarm Off On 00011 Motor Runtime Average Alarm Off On 00012 Reserved 00013 Reserved

* Data toggles with flash of light 02 INPUT STATUS

Address Description Data = 0 Data = 1 00001 Relay Logic Indicator True Inverted 00002 RS-232 Baud Rate, Bit 1 0 1 00003 RS-232 Baud Rate, Bit 2 0 1 00004 RS-232 Baud Rate, Bit 3 0 1 00005 Reserved 00006 Motor Runtime Indicator On Off 00007 Reserved 00008 Reserved 00009 Condensation Alarm Off On

03 INPUT REGISTERS Raw Data

Address Description Min Max Units 00001 SF6 Temperature 0 4095 Cal 00002 SF6 Pressure 0 4095 Cal 00003 SF6 Density 0 65535 % 00004 SF6 TCMP 0 4095 Cal 00005 Current or Last Motor Runtime 0 20000 Minutes 00006 30 Day Motor Operations Count 0 20000 Counts 00007 30 Day Average Motor Runtime 0 20000 Minutes 00008 Trouble Codes and Motor Seconds 0 100000 BCD

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00009 Reserved 00010 Reserved 00011 Reserved 00012 Reserved 00013 Reserved 00014 Reserved

04 HOLDING REGISTERS Raw Data

Address Description Min Max Units00001 Installation Elevation 0 12800 Feet 00002 SF6 Normalized Temperature 0 4095 Cal 00003 SF6 Normalized Pressure 0 4095 Cal 00004 Alarm 1 Set Point (Trouble) 0 65535 Decimal 00005 Alarm 2 Set Point (Signal 1) 0 65535 Decimal 00006 Alarm 3 Set Point (Signal 2) 0 65535 Decimal 00007 Nitrogen/CF4 Percentage 0 100 % 00008 SF6 Condensation Set Point 64 192 Cal 00009 Motor Runtime Alarm Set Point 0 20000 Minutes 00010 30 Day Motor Operation Alarm Set Point 0 20000 Counts 00011 30 Day Avg Motor Runtime Set Point 0 20000 Minutes 00012 SF6 Temperature 0 4095 Cal 00013 SF6 Pressure 0 4095 Cal 00014 SF6 Density 0 65535 % 00015 SF6 TCMP 0 4095 Cal 00016 Current or Last Motor Runtime 0 20000 Minutes 00017 30 Day Motor Operations Count 0 20000 Counts 00018 30 Day Average Motor Runtime 0 20000 Minutes 00019 Trouble Codes and Motor Seconds 0 100000 BCD 00020 Front panel lights, relays, and heater* 00000000b 11111111b Bits 00021 Reserved 00022 Reserved 00023 Reserved 00024 Reserved 00025 Reserved 00026 Reserved 00027 Reserved 00028 Reserved 00029 Reserved 00030 Reserved 00031 Reserved 00032 Reserved

Note: units labeled ‘Cal’ are calibration units for the SM6-0. For temperatures, 0 cal = -50C and 4095 cal = 78C. For pressures, 0 cal = 0 PSIA and 4095 cal = 150 PSIA. * Bit positions and values are copied from 01 coils 1 through 8, with 1 being the LSB.