Overspeed Monitor – User’s Manual

This User’s Manual describes the Overspeed Monitor (OSM), P/N 1053832-xxx,
1053834-xxx and 1053835-xxx to be used in Solar Control Systems for Gas Turbine
applications. To the extent possible, the monitor is interchangeable with previous Solar
Turbines speed monitors in operation, mechanical mounting, connectors, and wiring. The
monitor conforms to Hazardous Location and safety standards for U.S., Canadian, and
European applications.

Primary Functions

• Responds to an overspeed condition by issuing a shutdown command via relay.

• Provides excitation to and accepts frequency input from a speed sensor.
• Provides a 4 to 20 mA analog output of the speed signal.
• Provides a programmable Health Monitor Set Point via an RS-232 port.
• Allows user diagnostics and set-point review via an RS-232 port.
• Provides system test capability.
• Provides self-diagnostics to determine OSM health and reports fault conditions.
Operational Overview
Overspeed Relay Operation –
• Normally Open (NO) contact - Trip Chain
• Normally Closed (NC) contact - Control System Annunciation / Trip
Normal Operation:
With no power applied to the OSM, the Overspeed relay is de-energized, and the
relay Trip Chain contact is open. With the application of power and a Reset
Command, the relay is energized, and the relay Trip Chain contact is closed.
Overspeed or Loss of Power:
With the event of an overspeed condition or loss of power, the relay is de-energized
and the relay Trip Chain contact is opened. The Overspeed relay will remain in the
de-energized state with the Trip Chain contact open until the frequency is less than
5% of the Frequency (Hz) Equivalent to 100% or 153 Hz whichever is greater and a
Reset command is received.
Low-speed / Open Probe Detection Relay Operation –
• NO Contact – Enable contact
• NC Contact –
Normal Operation:
With no power applied to the OSM, the Low-speed / Open Probe relay is de-
energized, and the relay Enable contact is open. With the application of power, the
Low-speed / Open Probe relay remains de-energized, and Enable contact is open.
With a speed signal greater than the Open Probe Detection Set Point, the relay is
energized, and the relay Enable contact is closed.
Low-speed / Open Probe:
If speed is reduced to below the Open Probe Detection Set Point, the Lowspeed /
Open Probe Relay is de-energized, and the Enable contact opens. The relay will re-
energize and close the Enable contact if the speed signal is increased above the Open
Probe Detection Set Point.
Hysteresis:
Approximately 1% of the Frequency (Hz) Equivalent to 100%. This minimizes relay
oscillations when crossing through the Open Probe Detection Set Point.
NOTES: Relay Operation has been modified to insure FAIL-SAFE Operation.
The relay is energized when the speed signal is greater than the Low Speed Set
Point. The relay also functions as an OSM Diagnostic / Fault Indicator.

2
OSM Diagnostics / Fault
Diagnostics are provided to determine faults within the OSM in the event of a failure.
A CRC/Checksum of the NV PROM and the NV EEPROM are included.
The OSM diagnostic / fault will cause the Lowspeed / Open Probe relay to de-
energize, opening the Enable contact, and a red LED located on the exterior of the
OSM module will illuminate. The Low-speed / Open Probe relay will remain de-
energized with the contact open until the frequency is less than 5% of the Frequency
(Hz) Equivalent to 100% or 153 Hz, whichever is higher, and a Reset command is
received.
Health Indicator
• NO Contact
With a speed signal greater than the Health Indicator Set Point, the relay is energized,
and the normally open contact is closed. A green LED, located on the OSM modules
exterior will illuminate.
Hysterisis
Approximately 1% of Frequency (Hz) Equivalent to 100%. This minimizes relay
oscillations when crossing through the Health Indicator Set Point.
Set Point – The Health Indicator Set Point can be modified using the User Interface
Menu.
• Allowable Set Point Range 5.00 to 115.00 % of the Frequency (Hz)
Equivalent to 100%.
Analog Output
The OSM provides a linear 4 to 20 mA source - analog output indicating speed.
• 4 mA is equal to 0 Hz
• 20 mA is 120% of the Frequency (Hz) Equivalent to 100%

Conversion of current to percent is given by:

P = 7.5(A – 4),
where P is percent of full speed and A is current in milliamps. For example if the
current is 17.27 mA, the engine speed is 99.52% of full speed.

3
Processor Test Function
The Processor Test Function provides verification of processor integrity during normal
engine operation. The 4 to 20 mA analog output is reduced to 50% of the running speed
with a Reset command.
The new output A in milliamps is given by
I -4
A = + 4,
2
where I is the initial output current in milliamps. The current output will remain in
this state until the voltage is removed from the Reset input. If the current does not
change, there is a problem with the OSM, and appropriate steps should be taken.

System Test / Over Speed Trip Set Point

During engine operation, when the OSM receives a +18 V dc to +33 V dc System
Test command, the Overspeed Trip Set Point is reduced at a rate of 1% per second
until it reaches 40% of the Frequency Equivalent to 100%. When the command is
removed, the normal Overspeed Trip Set Point is restored.
The System Test function will allow the OSM to trigger a full Backup Overspeed
System Test.
Calculations can be made using the time elapsed from the application of the System
Test input until the Backup Overspeed Trip is initiated. For example:

• Running Speed = 98.0%

• Elapsed Time = 10.5 Seconds = 10.5%
Calculated - Overspeed Trip Set Point: 98.0% + 10.5% = 108.5%
User Interface Menu
The menu is accessed from the RS-232 port via an IBM PC compatible computer
using WIN9x, NT, WIN2000, or WIN XP operating system. Communication with the
OSM is accomplished using the HyperTerminal program distributed with Microsoft
Windows.

o The User Interface Menu allows the user to view all set-point
information in both Hz and % of Frequency (Hz) Equivalent to 100%.
o Allows modification of the Health Indicator Set Point
o Provides event and status indications and data.
o Provides High-level diagnostics for module failures.

4
HyperTerminal Setup Instructions

To access the user OSM interface, connect J-4 (RS-232) to any serial port on the
PC. Run the Windows HyperTerminal program by going to the Start menu, then
Programs / Accessories / Communications / HyperTerminal and the appropriate
Setup File (FileName.ht).

If a Setup File has not been defined, follow the steps listed below.

1. Run the Windows HyperTerminal program by going to the Start menu, then
Programs / Accessories / Communications / HyperTerminal.

2. Enter a name, such as OSM, for the

program that will be used and select
an icon that will be associated with
that program. Click OK.

3. Enter the serial port, such as Com1,

to which the OSM will be connected.
Click OK.

5
4. Enter the following settings and click OK.
• Bits per second: 19200
• Data bits: 8
• Parity: None
• Stop bits: 1
• Flow Control None

5. At the next screen, which will be blank, select SAVE on the FILE menu. The
HyperTerminal program for the OSM is now ready to use.

6. Connect the powered-up OSM to the computer using the serial port
connection selected in Step 11 from the DE-9SV connector on the OSM.

7. Once the HyperTerminal program is installed and set up, use it by going to
Start then Programs / Accessories / Communications / HyperTerminal. Then
highlight and double click the HyperTerminal program that has been set up
for the OSM. It will have an .ht file-name extension.

8. With HyperTerminal on line and connected to the OSM, press the ESCAPE
key. This will both access and update the User Interface screen.

NOTE: HyperTerminal is Microsoft Windows program that is supplied but not necessarily
installed when Windows is installed. If the HyperTerminal Program is not installed on your
PC please contact your Systems Administrator.

6
 HyperTerminal Menu / Display
HyperTerminal Setup File Name
Software Version

Module Errors will not be displayed unless an Error Code is Actively Set.

NOTE: To Update the User Interface Screen press the ESCAPE KEY.

7
Installation / Wiring

Wiring
J1 – Control Male 10-Pin Cage Clamp
PIN FUNCTION
1 4 – 20 mA Output, Return
2 Chassis Ground
3 4 – 20 mA Output, + Signal
4 System Test Input (18 – 33 VDC)
5 Reset / Processor Test (18 – 33 VDC)
6 Filter Common
7 + Probe Excitation (9.0 VDC)
8 - Probe Excitation Return
9 24 VDC Return
10 24 VDC Power

Note: Pin 6 - Filter Common. The filter common is an LC network used with the 24 V dc Power
and should be connected to a point with low RF impedance to ground. Wiring lengths should
be kept to a minimum.

J2 – Relays Male 9-Pin Cage Clamp

PIN FUNCTION
1 Overspeed Relay N.O.
2 Overspeed Relay COM
3 Overspeed Relay N.C.
4 N/A
5 Lowspeed Relay N.C.
6 Lowspeed Relay COM
7 Lowspeed Relay N.O.
8 Health Monitor Relay COM
9 Health Monitor Relay N.O.

J3 – Signal Input Male 5 Pin Cage Clamp

PIN FUNCTION
1 + Signal Input
2 Shield
3 - Signal Input
4 Shield
5 - Signal Input

Note: Pins 2 and 4 (Shields) are internally connected.

Pins 3 and 5 (- Signal Input) are internally connected.

J4 – Com Port RS-232 DE-9SV Female D-subminiature

PIN FUNCTION
2 RxD – Receive Data
3 TxD – Transmit Data
5 Gnd - Signal Ground

8
Mounting Options

o Flange Mount

Dimensions:

o DIN-Rail Mount Adapter: DIN Type 35

Assembly:
The DIN rail adapter is mounted to the Overspeed Monitor using 4,
10-32 screws and washers. The required hardware is included in the
DIN-rail Adapter Kit.

9
Performance

1) Response Time Maximum: 6 ms + 6 ms relay time to trigger the Overspeed

Shutdown discrete output. 153Hz to 25KHz

2) Frequency Range: 153 Hz to 25 kHz.

3) Input Impedance 10 kΩ resistive.

4) Input Signal: 600 mV Peak to Peak

5) Accuracy:
• 0.40 % of measurement below 305 Hz
• 0.10% of measurement from 305 Hz to 20 kHz
• 0.15% of measurement from 20 KHz to 25 kHz

6) Operating Temperature: −25°C to 85°C

7) Stability: ± 5 ppm / °C over operating range ± 40 ppm @ 25°C

8) Conversion Algorithm: Running Median (median depth = 11) & Median

Averaging Filter (15 samples).

General Specifications

Input Sensors

• Active Variable Reluctance Sensor

• Passive Variable Reluctance Speed Sensor
• IS Passive Variable Reluctance Speed Sensor

Grounds and Shielding

• The monitors electronics grounds, commons, and filters are isolated from the
monitor’s case. Pins on the I/O connector are available to allow selection of a
grounding scheme that best suits the application.
• A separate chassis ground pin is available for grounding of the OSM case.

CAUTION: Do not use for DIN Rail mounted applications. Chassis

ground for DIN-rail applications is provided through the DIN-rail
mount.

• For DIN-rail-mounted applications the OSM chassis is grounded to the DIN

rail.

10
 • The Speed Sensor Shield is isolated from the Electronics and the OSM case. A
pin on the I/O connector is available to allow select of a shielding scheme that
best suits the application.

Loss of Power

• The OSM requires a Reset command to return to normal operation upon the
restoration of power.

Memory

• Configuration Data: Nonvolatile (NV) EEPROM – No Batteries

• Program: NV PROM – No Batteries

I/O

• Reset / Processor Test Function Command - 18 to 33 Vdc input

• Reduced Set Point – 18 V dc to 33 V dc input
• Discrete Output Relays:
o Overspeed Relay - 3 Amperes, 32 V dc.
o Low-speed Relay / Diagnostic Fault - 1 Ampere, 32 V dc.
o Health Indicator - 1 Ampere, 32 V dc.
• Analog Output – 4 to 20 mA Source
o Maximum Resistive Load: 550 Ω.
o Accuracy: ± 0.25% of full scale.
• RS232 Port – Configuration, testing, and review of set-point data
• Health Indicator
o Green LED on Monitor Exterior
• OSM Diagnostics / Fault
o Red LED on Monitor Exterior

Environmental / Mechanical
Storage Temperature: −55°C to 120°C
Humidity: 95%, non-condensing
Encapsulation: The circuit boards and components are
protected from humidity and fungus.
Case Size: 4.28” by 2.68” by 2.36” (LWH) excluding
terminals, mounting base and connectors.
Connectors:
o RS-232 Link: DB9 Connector
o I/O Cage-Clamp Design

Mounting Options:
o Flange: Foot Print - 5.25” X 2.68”
o DIN-Rail: DIN Type 35

11
Power
Available Power: 24 V dc nominal battery voltage with battery charger
output of up to 33 V dc.
Range: 18 V dc to 33 V dc.
Protection: Reverse Polarity: −42 V dc continuous

12