489

GENERATOR MANAGEMENT RELAY

Instruction Manual
489 Firmware Revision: 32G140A8.000
489 PC Software Revision: 1.40
Manual P/N: 1601-0071-E7
Copyright 2000 GE Power Management

489 STATUS

GENERATOR STATUS

OUTPUT RELAYS

489 IN SERVICE

BREAKER OPEN

R1 TRIP

SETPOINT ACCESS

BREAKER CLOSED

R2 AUXILIARY

COMPUTER RS232

HOT STATOR

R3 AUXILIARY

COMPUTER RS485

NEG. SEQUENCE

R4 AUXILIARY

AUXILIARY RS485

GROUND

R5 ALARM

ALT. SETPOINTS

LOSS OF FIELD

R6 SERVICE

RESET
POSSIBLE

RESET

VT FAILURE

MESSAGE

NEXT

BREAKER FAILURE

PROGRAM PORT

ACTUAL

ESCAPE

HELP

SETPOINT

MESSAGE

VALUE
ENTER

489 Generator Management Relay

TM

808754E3.CDR

g
NORTH AMERICA
215 Anderson Avenue, Markham, Ontario, L6E 1B3
Tel: (905) 294-6222 Fax: (905) 294-8512
Internet: http://www.ge.com/indsys/pm/

GE Power Management

489 MANUAL

1.

TABLE OF CONTENTS

INTRODUCTION .................................................................................................................. 1-1

1.1 OVERVIEW .........................................................................................................................................................................1-1
1.2 ORDER INFORMATION ......................................................................................................................................................1-3
1.3 489 SPECIFICATIONS ........................................................................................................................................................1-4

2.

INSTALLATION ................................................................................................................... 2-1

2.1 MECHANICAL .....................................................................................................................................................................2-1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5

DESCRIPTION.............................................................................................................................................................................................. 2-1
PRODUCT IDENTIFICATION ....................................................................................................................................................................... 2-2
INSTALLATION ............................................................................................................................................................................................. 2-3
UNIT WITHDRAWAL AND INSERTION ....................................................................................................................................................... 2-4
TERMINAL LOCATIONS .............................................................................................................................................................................. 2-5

2.2 ELECTRICAL.......................................................................................................................................................................2-6
2.2.1 TYPICAL WIRING ......................................................................................................................................................................................... 2-8
2.2.2 CONTROL POWER ...................................................................................................................................................................................... 2-8
2.2.3 PHASE CURRENT INPUTS ......................................................................................................................................................................... 2-9
2.2.4 GROUND CURRENT INPUT...................................................................................................................................................................... 2-10
2.2.5 VOLTAGE INPUTS ..................................................................................................................................................................................... 2-11
2.2.6 DIGITAL INPUTS ........................................................................................................................................................................................ 2-11
2.2.7 ANALOG INPUTS ....................................................................................................................................................................................... 2-11
2.1.8 ANALOG OUTPUTS ................................................................................................................................................................................... 2-12
2.1.9 RTD SENSOR CONNECTIONS ................................................................................................................................................................. 2-12
2.1.10 OUTPUT RELAYS................................................................................................................................................................................. 2-13
2.1.11 IRIG-B .................................................................................................................................................................................................... 2-13
2.1.12 RS485 COMMUNICATIONS PORTS.................................................................................................................................................... 2-14
2.1.13 DIELECTRIC STRENGTH TESTING.................................................................................................................................................... 2-15

489 OPERATION ................................................................................................................. 3-1

3.1 OVERVIEW .........................................................................................................................................................................3-1
3.1.1. 489 FACEPLATE .......................................................................................................................................................................................... 3-1
3.1.2. DISPLAY ....................................................................................................................................................................................................... 3-2
3.1.3. LED INDICATORS ........................................................................................................................................................................................ 3-2
3.1.4. RS232 PROGRAM PORT............................................................................................................................................................................. 3-3
3.1.5. KEYPAD........................................................................................................................................................................................................ 3-4
3.1.6. ENTERING ALPHANUMERIC TEXT............................................................................................................................................................ 3-4
3.1.7. ENTERING +/- SIGNS .................................................................................................................................................................................. 3-4
3.1.8. SETPOINT ENTRY ....................................................................................................................................................................................... 3-5

4.

SETPOINT PROGRAMMING............................................................................................... 4-1

4.1 OVERVIEW .........................................................................................................................................................................4-1
4.1.1
4.1.2
4.1.3
4.1.4

TRIPS / ALARMS / CONTROL FEATURES DEFINED ................................................................................................................................ 4-1

RELAY ASSIGNMENT PRACTICES ............................................................................................................................................................ 4-1
DUAL SETPOINTS ....................................................................................................................................................................................... 4-1
SETPOINT MESSAGE MAP......................................................................................................................................................................... 4-2

4.2 S1 489 SETUP ....................................................................................................................................................................4-3

4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7

PASSCODE .................................................................................................................................................................................................. 4-3

PREFERENCES ........................................................................................................................................................................................... 4-4
SERIAL PORTS ............................................................................................................................................................................................ 4-5
REAL TIME CLOCK ...................................................................................................................................................................................... 4-6
DEFAULT MESSAGES................................................................................................................................................................................. 4-6
MESSAGE SCRATCHPAD........................................................................................................................................................................... 4-7
CLEAR DATA................................................................................................................................................................................................ 4-8

4.3 S2 SYSTEM SETUP............................................................................................................................................................4-9

4.3.1
4.3.2
4.3.3
4.3.4

CURRENT SENSING.................................................................................................................................................................................... 4-9

VOLTAGE SENSING .................................................................................................................................................................................... 4-9
GENERATOR PARAMETERS.................................................................................................................................................................... 4-10
SERIAL START/STOP INITIATION ............................................................................................................................................................ 4-10

4.4 S3 DIGITAL INPUTS .........................................................................................................................................................4-11

4.4.1 ACCESS SWITCH ...................................................................................................................................................................................... 4-11
4.4.2 BREAKER STATUS .................................................................................................................................................................................... 4-11
4.4.3 DIGITAL INPUT FUNCTION: GENERAL INPUT A - G .............................................................................................................................. 4-11

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489 MANUAL

4.4.4 DIGITAL INPUT FUNCTION: REMOTE RESET ........................................................................................................................................ 4-12

4.4.5 DIGITAL INPUT FUNCTION: TEST INPUT................................................................................................................................................ 4-12
4.4.6 DIGITAL INPUT FUNCTION: THERMAL RESET....................................................................................................................................... 4-12
4.4.7 DIGITAL INPUT FUNCTION: DUAL SETPOINTS...................................................................................................................................... 4-13
4.4.8 DIGITAL INPUT FUNCTION: SEQUENTIAL TRIP..................................................................................................................................... 4-14
4.4.9 DIGITAL INPUT FUNCTION: FIELD-BREAKER DISCREPANCY............................................................................................................. 4-14
4.4.10 DIGITAL INPUT FUNCTION: TACHOMETER ...................................................................................................................................... 4-15
4.4.11 WAVEFORM CAPTURE ....................................................................................................................................................................... 4-15
4.4.12 DIGITAL INPUT FUNCTION: GROUND SWITCH STATUS................................................................................................................. 4-16

4.5 S4 OUTPUT RELAYS........................................................................................................................................................4-17

4.5.1 RELAY RESET MODE................................................................................................................................................................................ 4-17

4.6 S5 CURRENT ELEMENTS ................................................................................................................................................4-18

4.6.1 INVERSE TIME OVERCURRENT CURVE CHARACTERISTICS ............................................................................................................. 4-18
ANSI CURVES ................................................................................................................................................................................................. 4-18
IEC CURVES ................................................................................................................................................................................................... 4-19
IAC CURVES ................................................................................................................................................................................................... 4-19
FLEXCURVE .................................................................................................................................................................................................... 4-20
DEFINITE TIME CURVE ..................................................................................................................................................................................... 4-20
4.1.2 OVERCURRENT ALARM ........................................................................................................................................................................... 4-21
4.1.3 OFFLINE OVERCURRENT ........................................................................................................................................................................ 4-21
4.1.4 INADVERTENT ENERGIZATION............................................................................................................................................................... 4-22
4.1.5 VOLTAGE RESTRAINED PHASE OVERCURRENT................................................................................................................................. 4-23
4.1.6 NEGATIVE SEQUENCE OVERCURRENT................................................................................................................................................ 4-24
4.1.7 GROUND OVERCURRENT ....................................................................................................................................................................... 4-26
4.1.8 PHASE DIFFERENTIAL.............................................................................................................................................................................. 4-27
4.1.9 GROUND DIRECTIONAL ........................................................................................................................................................................... 4-28
4.1.10 HIGH-SET PHASE OVERCURRENT ................................................................................................................................................... 4-29

4.7 S6 VOLTAGE ELEMENTS ................................................................................................................................................4-30

4.7.1 UNDERVOLTAGE....................................................................................................................................................................................... 4-30
4.7.2 OVERVOLTAGE ......................................................................................................................................................................................... 4-31
4.7.3 VOLTS/HERTZ............................................................................................................................................................................................ 4-32
4.7.4 PHASE REVERSAL.................................................................................................................................................................................... 4-34
4.7.5 UNDERFREQUENCY ................................................................................................................................................................................. 4-34
4.7.6 OVERFREQUENCY.................................................................................................................................................................................... 4-35
4.7.7 NEUTRAL OVERVOLTAGE (FUNDAMENTAL).............................................................................................................................................. 4-36
4.7.8 NEUTRAL UNDERVOLTAGE (3RD HARMONIC) .......................................................................................................................................... 4-38
4.7.9 LOSS OF EXCITATION .............................................................................................................................................................................. 4-39
4.1.10 DISTANCE ELEMENTS ........................................................................................................................................................................ 4-41

4.8 S7 POWER ELEMENTS....................................................................................................................................................4-41

4.8.1
4.8.2
4.8.3
4.8.4

POWER MEASUREMENT CONVENTIONS .............................................................................................................................................. 4-42

REACTIVE POWER.................................................................................................................................................................................... 4-43
REVERSE POWER .................................................................................................................................................................................... 4-44
LOW FORWARD POWER .......................................................................................................................................................................... 4-45

4.9 S8 RTD TEMPERATURE ..................................................................................................................................................4-46

4.9.1
4.9.2
4.9.3
4.9.4
4.9.5
4.9.6
4.9.7

RTD TYPES ................................................................................................................................................................................................ 4-46

RTDS 1-6 ..................................................................................................................................................................................................... 4-47
RTDS 7 - 10 ................................................................................................................................................................................................. 4-47
RTD 11 ........................................................................................................................................................................................................ 4-48
RTD 12 ........................................................................................................................................................................................................ 4-49
OPEN RTD SENSOR.................................................................................................................................................................................. 4-50
RTD SHORT/LOW TEMP ........................................................................................................................................................................... 4-50

4.10 S9 THERMAL MODEL.......................................................................................................................................................4-51

4.10.1
4.10.2
4.10.3
4.10.4
4.10.5
4.10.6
4.10.7

THERMAL MODEL................................................................................................................................................................................ 4-51

MODEL SETUP ..................................................................................................................................................................................... 4-52
THERMAL MODEL: UNBALANCE BIAS .............................................................................................................................................. 4-61
THERMAL MODEL: MACHINE COOLING ........................................................................................................................................... 4-62
HOT/COLD CURVE RATIO................................................................................................................................................................... 4-63
RTD BIAS .............................................................................................................................................................................................. 4-63
THERMAL ELEMENTS ......................................................................................................................................................................... 4-64

4.11 S10 MONITORING ............................................................................................................................................................4-65

4.11.1
4.11.2
4.11.3
4.11.4
4.11.5
4.11.6
4.11.7

TRIP COUNTER.................................................................................................................................................................................... 4-65

BREAKER FAILURE ............................................................................................................................................................................. 4-65
TRIP COIL MONITOR ........................................................................................................................................................................... 4-66
VT FUSE FAILURE ............................................................................................................................................................................... 4-68
CURRENT, MW, Mvar, MVA DEMAND ................................................................................................................................................ 4-68
PULSE OUTPUT ................................................................................................................................................................................... 4-70
GENERATOR RUNNING HOUR SETUP ............................................................................................................................................. 4-70

4.12 S11 ANALOG I/O...............................................................................................................................................................4-70

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4.12.1
4.12.2

TABLE OF CONTENTS

ANALOG OUTPUTS 1-4 ....................................................................................................................................................................... 4-71

ANALOG INPUTS 1-4 ........................................................................................................................................................................... 4-73

4.13 489 TESTING ....................................................................................................................................................................4-75

4.13.1
4.13.2
4.13.3
4.13.4
4.13.5
4.13.6
4.13.7

5.

SIMULATION MODE ............................................................................................................................................................................. 4-75

PRE-FAULT SETUP.............................................................................................................................................................................. 4-76
FAULT SETUP ...................................................................................................................................................................................... 4-77
TEST OUTPUT RELAYS....................................................................................................................................................................... 4-78
TEST ANALOG OUTPUT...................................................................................................................................................................... 4-78
COMM PORT MONITOR ...................................................................................................................................................................... 4-79
FACTORY SERVICE............................................................................................................................................................................. 4-79

ACTUAL VALUES ............................................................................................................... 5-1

5.1 OVERVIEW .........................................................................................................................................................................5-1
5.1.1 ACTUAL VALUES MESSAGES.................................................................................................................................................................... 5-1

5.2 A1 STATUS .........................................................................................................................................................................5-2

5.2.1
5.2.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7

GENERATOR STATUS ................................................................................................................................................................................ 5-2

LAST TRIP DATA.......................................................................................................................................................................................... 5-2
ALARM STATUS........................................................................................................................................................................................... 5-3
TRIP PICKUPS ............................................................................................................................................................................................. 5-5
ALARM PICKUPS ......................................................................................................................................................................................... 5-8
DIGITAL INPUTS ........................................................................................................................................................................................ 5-10
REAL TIME CLOCK .................................................................................................................................................................................... 5-10

5.3 A2 METERING DATA ........................................................................................................................................................5-11

5.3.1
5.3.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7

CURRENT METERING............................................................................................................................................................................... 5-11

VOLTAGE METERING ............................................................................................................................................................................... 5-12
POWER METERING................................................................................................................................................................................... 5-13
TEMPERATURE ......................................................................................................................................................................................... 5-14
DEMAND METERING................................................................................................................................................................................. 5-15
ANALOG INPUTS ....................................................................................................................................................................................... 5-15
SPEED ........................................................................................................................................................................................................ 5-16

5.4 A3 LEARNED DATA ..........................................................................................................................................................5-17

5.4.1 PARAMETER AVERAGES ......................................................................................................................................................................... 5-17
5.4.2 RTD MAXIMUMS ........................................................................................................................................................................................ 5-17
5.4.3 ANALOG IN MIN/MAX ................................................................................................................................................................................ 5-18

5.5 A4 MAINTENANCE ...........................................................................................................................................................5-19

5.5.1 TRIP COUNTERS ....................................................................................................................................................................................... 5-19
5.5.2 GENERAL COUNTERS .............................................................................................................................................................................. 5-21
5.5.3 TIMERS ....................................................................................................................................................................................................... 5-21

5.6 A5 EVENT RECORDER ....................................................................................................................................................5-22

5.6.1 EVENT RECORDER................................................................................................................................................................................... 5-22

5.7 A6 PRODUCT INFO .........................................................................................................................................................5-25

5.7.1 489 MODEL INFO ....................................................................................................................................................................................... 5-25
5.7.2 CALIBRATION INFO................................................................................................................................................................................... 5-25

5.8 DIAGNOSTICS ..................................................................................................................................................................5-26

5.8.1 DIAGNOSTIC MESSAGES FOR OPERATORS ........................................................................................................................................ 5-26
5.8.2 FLASH MESSAGES.................................................................................................................................................................................... 5-27

6.

COMMUNICATIONS ............................................................................................................ 6-1

6.1 ELECTRICAL INTERFACE..................................................................................................................................................6-1
6.1.1 ELECTRICAL INTERFACE........................................................................................................................................................................... 6-1

6.2 PROTOCOL.........................................................................................................................................................................6-2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5

MODBUS RTU PROTOCOL ......................................................................................................................................................................... 6-2

DATA FRAME FORMAT AND DATA RATE ................................................................................................................................................. 6-2
DATA PACKET FORMAT ............................................................................................................................................................................. 6-2
ERROR CHECKING ..................................................................................................................................................................................... 6-3
TIMING .......................................................................................................................................................................................................... 6-3

6.3 SUPPORTED MODBUS FUNCTIONS ................................................................................................................................6-4

6.3.1
6.3.2
6.3.3
6.3.4
6.3.5

SUPPORTED MODBUS FUNCTIONS ......................................................................................................................................................... 6-4

FUNCTION CODES 03 AND 04 - READ SETPOINTS AND ACTUAL VALUES ......................................................................................... 6-4
FUNCTION CODE 05 - EXECUTE OPERATION......................................................................................................................................... 6-5
FUNCTION CODE 06 - STORE SINGLE SETPOINT .................................................................................................................................. 6-6
FUNCTION CODE 07 - READ DEVICE STATUS ........................................................................................................................................ 6-7

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6.3.6 FUNCTION CODE 08 - LOOPBACK TEST .................................................................................................................................................. 6-8

6.3.7 FUNCTION CODE 16 - STORE MULTIPLE SETPOINTS............................................................................................................................ 6-9
6.3.8 FUNCTION CODE 16 - PERFORMING COMMANDS ............................................................................................................................... 6-10

6.4 ERROR RESPONSES.......................................................................................................................................................6-11

6.4.1 ERROR RESPONSES................................................................................................................................................................................ 6-11

6.5 MEMORY MAP..................................................................................................................................................................6-12

6.5.1
6.5.2
6.5.3
6.5.4
6.5.5
6.5.6

MEMORY MAP INFORMATION ................................................................................................................................................................. 6-12

USER DEFINABLE MEMORY MAP AREA ................................................................................................................................................ 6-12
EVENT RECORDER................................................................................................................................................................................... 6-12
WAVEFORM CAPTURE ............................................................................................................................................................................. 6-13
DUAL SETPOINTS ..................................................................................................................................................................................... 6-13
PASSCODE OPERATION .......................................................................................................................................................................... 6-13

6.6 DNP 3.0 DEVICE PROFILE DOCUMENT..........................................................................................................................6-51

TESTING .............................................................................................................................. 7-1

7.1 TEST SETUP.......................................................................................................................................................................7-1
7.1.1. TESTING ...................................................................................................................................................................................................... 7-1
7.1.2. SECONDARY INJECTION TEST SETUP ................................................................................................................................................... 7-2

7.2 HARDWARE FUNCTIONAL TESTING ................................................................................................................................7-3

7.2.1. OUTPUT CURRENT ACCURACY TEST..................................................................................................................................................... 7-3
7.2.2. PHASE VOLTAGE INPUT ACCURACY TEST ............................................................................................................................................ 7-3
7.2.3. GROUND (1A), NEUTRAL AND DIFFERENTIAL CURRENT ACCURACY TEST ..................................................................................... 7-4
7.2.4. NEUTRAL VOLTAGE (FUNDAMENTAL) ACCURACY TEST..................................................................................................................... 7-5
7.2.5. NEGATIVE SEQUENCE CURRENT ACCURACY TEST............................................................................................................................ 7-6
7.2.6. RTD ACCURACY TEST............................................................................................................................................................................... 7-7
7.2.7. DIGITAL INPUTS AND TRIP COIL SUPERVISION .................................................................................................................................... 7-9
7.2.8. ANALOG INPUTS AND OUTPUTS............................................................................................................................................................ 7-10
7.2.9. OUTPUT RELAYS...................................................................................................................................................................................... 7-11

7.3 ADDITIONAL FUNCTIONAL TESTING .............................................................................................................................7-12

7.3.1. OVERLOAD CURVE TEST........................................................................................................................................................................ 7-12
7.3.2. POWER MEASUREMENT TEST............................................................................................................................................................... 7-13
7.3.3. REACTIVE POWER TEST......................................................................................................................................................................... 7-14
7.3.4. VOLTAGE PHASE REVERSAL TEST....................................................................................................................................................... 7-15
7.3.5. INJECTION TESTSETUP 2........................................................................................................................................................................ 7-16
7.3.6. GE POWER MANAGEMENT HGF GROUND ACCURACY TEST............................................................................................................ 7-17
7.3.7. NEUTRAL VOLTAGE (3RD HARMONIC) ACCURACY TEST.................................................................................................................. 7-17
7.3.8. PHASE DIFFERENTIAL TRIP TEST ......................................................................................................................................................... 7-18
7.3.9. VOLTAGE RESTRAINED OVERCURRENT TEST ................................................................................................................................... 7-21

8.

8489PC PROGRAM ............................................................................................................. 8-1

8.1 INSTALLATION / UPGRADE ...............................................................................................................................................8-1
8.2 CONFIGURATION...............................................................................................................................................................8-3
8.3 UPGRADING RELAY FIRMWARE ......................................................................................................................................8-4
8.4 CREATING A NEW SETPOINT FILE ..................................................................................................................................8-5
8.5 EDITING A SETPOINT FILE................................................................................................................................................8-6
8.6 DOWNLOADING A SETPOINT FILE TO THE 489 ..............................................................................................................8-7
8.7 UPGRADING SETPOINT FILE TO NEW REVISION ...........................................................................................................8-8
8.8 PRINTING............................................................................................................................................................................8-9
8.9 TRENDING ........................................................................................................................................................................8-10
8.10 WAVEFORM CAPTURE....................................................................................................................................................8-12
8.11 PHASORS .........................................................................................................................................................................8-14
8.12 EVENT RECORDING ........................................................................................................................................................8-15
8.13 TROUBLESHOOTING .......................................................................................................................................................8-17

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TABLE OF CONTENTS

APPENDIX A
COMMISSIONING SUMMARY .................................................................................................................................................. A-1

APPENDIX B
STATOR GROUND FAULT PROTECTION USING THE SR489................................................................................................ B-1

APPENDIX C
ANSI / IAC / IEC (BS142) TIME/OVERCURRENT CURVES ..................................................................................................... C-1

APPENDIX D
CURRENT TRANSFORMERS ................................................................................................................................................... D-1