Franklin Electric incon OPTIMIZER3 User manual

incon®OPTIMIZER3 circuit breaker monitor
user guide

The informaon in this publicaon is provided for reference only. While every eort has been made to ensure the reliability and accuracy of
the informaon contained in this manual at the me of prinng, we recommend that you refer to the appropriate website for the most current
version of this manual. All product specicaons, as well as the informaon contained in this publicaon, are subject to change without noce.
Franklin Electric Co., Inc. does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of, or in any way
connected with, installaon, operaon, use, or maintenance by using this manual. Franklin Electric Co., Inc. assumes no responsibility for any
infringement of patents or other rights of third pares that may result from use of this manual or the products. We make no warranty of any kind
with regard to this material, including, but not limited to, the implied warranes of merchantability and tness for a parcular purpose.
Copyright © 2020 Franklin Electric Co., Inc., Madison, WI 53718. All world rights reserved. No part of this publicaon may be stored in a retrieval
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For technical assistance, please contact:
franklinfueling.com
3760 Marsh Rd. • Madison, WI 53718 • USA
Tel: USA & Canada [phone] • Fax: [phone]
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INCON is a registered trademark of Franklin Electric Grid Soluons.
000-1533 r4
Conventions used in this manual
This manual includes safety precauons and other important informaon presented in the following format:
NOTE: This provides helpful supplementary informaon.
IMPORTANT: This provides instrucons to avoid damaging hardware or a potenal hazard to the environment, for example: fuel leakage from
equipment that could harm the environment.
CAUTION: This indicates a potenally hazardous situaon that could result in minor or moderate injury if not avoided. This may also be used to
alert against unsafe pracces.
WARNING: This indicates a potenally hazardous situaon that could result in severe injury or death if not avoided.
DANGER: This indicates an imminently hazardous situaon that will result in death if not avoided.
Operating precautions
WARNING: IMPORTANT SAFETY INSTRUCTIONS. BEFORE INSTALLING ANY FRANKLIN ELECTRIC GRID SOLUTIONS EQUIPMENT, READ THIS GUIDE
AND FOLLOW SAFETY AND OPERATING INSTRUCTIONS. SAVE THESE INSTRUCTIONS.
WARNING: Do not disassemble any equipment; contact Franklin Electric Grid Soluons when a repair is required. Incorrect reassembly may
result in a risk of electric shock or re.
WARNING: To avoid electric shock, abide by your company’s safety pracces and the following guidelines:
WARNING: Perform service work only for which you have been trained.
WARNING: Refer to NFPA 70E for electrical safety requirements.
WARNING: Use of Personal Protecon Equipment (PPE) and Protecve Clothing per NFPA 70E guidelines is required. Some examples of these,
but not limited to, are: Electrical-insulang Protecve gloves, Protecve footwear; Protecve clothing for voltage levels, Insulated rescue hooks or
other means for pulling personnel from live circuits.
WARNING: Before working with electricity, remove personal metal items such as rings, bracelets, necklaces, watches, etc. A short-circuit
current can be high enough to weld such items, causing a severe burn.
WARNING: Always wear safety glasses with side shields.
WARNING: To avoid a risk of serious injury or death, DO NOT come into contact with any source of live, electric current!
WARNING: Avoid simultaneous contact with live conductors and enclosures, racks, or hardware that may be grounded.

CONTENTS
Introduction.................................................................................................................................................................................................................5
Safety overview......................................................................................................................................................................................................5
Hazzard Assessment..........................................................................................................................................................................................5
Working on energized conductions and equipment......................................................................................................................................5
Optimizer3 Overview .............................................................................................................................................................................................6
Sensor Inputs .....................................................................................................................................................................................................8
CT Inputs.............................................................................................................................................................................................................9
Control Inputs.....................................................................................................................................................................................................9
Control Input Logic Monitoring.......................................................................................................................................................................10
Input Power, Grounding, Isolation.................................................................................................................................................................10
Relay..................................................................................................................................................................................................................11
Programming ...............................................................................................................................................................................................11
Communication Ports...................................................................................................................................................................................... 12
Communications Software..............................................................................................................................................................................14
Self-Diagnostics...............................................................................................................................................................................................14
Specifications................................................................................................................................................................................................... 15
Installation ................................................................................................................................................................................................................16
Mounting...............................................................................................................................................................................................................16
Current Pickup Coils..............................................................................................................................................................................................18
Navigation ............................................................................................................................................................................................................ 18
SF₆ Gas Monitoring....................................................................................................................................................................................................24
SF₆ Parameter Set Up...........................................................................................................................................................................................25
SF₆ Alarm Settings................................................................................................................................................................................................26
SF₆ GIL (Gas Insulated Transmission Line) Application......................................................................................................................................27
Pressure/Density Trend, Forecast Planning Alarms...........................................................................................................................................29
Low Gas Alarm Forecast & Forecast Planning Alarm ....................................................................................................................................29
Other Sensor Monitoring..........................................................................................................................................................................................30
Temperature Monitoring......................................................................................................................................................................................30
Voltage Monitoring ..............................................................................................................................................................................................32
Current Monitoring...............................................................................................................................................................................................33
Motor Run-Time Metrics.......................................................................................................................................................................................34
Voltage Mode...................................................................................................................................................................................................34
Current Mode....................................................................................................................................................................................................34

Heater Monitoring................................................................................................................................................................................................35
Generic Pressure Monitoring...............................................................................................................................................................................36
Dew Point Monitoring..........................................................................................................................................................................................36
Circuit Breaker Monitor Function.............................................................................................................................................................................37
Purpose of Circuit Breaker Monitoring ...............................................................................................................................................................37
Operating Modes..................................................................................................................................................................................................38
Choosing the Desired Operating Mode.............................................................................................................................................................. 40
Mode 1.............................................................................................................................................................................................................. 40
Mode 2 ..............................................................................................................................................................................................................42
Mode 3 ..............................................................................................................................................................................................................43
Mode 4............................................................................................................................................................................................................. 44
Mode 5 ............................................................................................................................................................................................................. 46
Mode 6..............................................................................................................................................................................................................49
Mode 7 ...............................................................................................................................................................................................................51
Velocity & Average Velocity Measurements.......................................................................................................................................................52
Current and Voltage Logging..............................................................................................................................................................................54
Use of AUX Inputs for control circuit status monitoring....................................................................................................................................55
DNP3.0 .......................................................................................................................................................................................................................56
Programming for DNP3........................................................................................................................................................................................56
DNP3 Behavior......................................................................................................................................................................................................58
Flag Behavior ...................................................................................................................................................................................................58
Value Behavior.................................................................................................................................................................................................58
Time Stamps.....................................................................................................................................................................................................58
Units Conversion..............................................................................................................................................................................................59

5
INTRODUCTION
SAFETY OVERVIEW
The Optimizer3 Circuit Breaker Performance and SF₆ Gas Density Monitor is intended to be used on high voltage energized circuit
breakers or equipment. Personnel using equipment on energized equipment must be authorized by the relevant regulatory bodies
to carry out such work and must have appropriate training.
The information given in this document is given as a guide only. It is the user’s responsibility to ensure that correct and safe
procedures are followed at the actual worksite. Franklin Electric Grid Solutions oers no warranty or indemnity for accidents that
may occur when following these instructions.
HAZZARD ASSESSMENT
Prior to installing the equipment, the operator must carry out a worksite, pre-job hazard assessment to identify the safety and
environmental needs. This must be done prior to commencing work and prior to recommencing work after leaving and returning
to the worksite. As a minimum, this hazard assessment should:
• Identify possible hazards and risks.
• Identify the safety needs of the job.
• Identify the correct procedures, practices and equipment.
• Eliminate unsafe conditions and actions from the worksite.
• Identify the need for personal protective equipment.
• Inspect equipment before use.
Prior to working with and installing Optimizer3, you should check the following:
• The sheaths of all cables are secured and undamaged.
• Plugs and connectors are properly connected and serviceable.
• There should also be an ongoing risk assessment during the job.
WORKING ON ENERGIZED CONDUCTIONS AND EQUIPMENT
For the correct and safe use of this equipment, it is essential that all operating personnel follow appropriate safety procedures.
Check with your employer and relevant regulatory body’s rules for working with energized equipment.

6
OPTIMIZER3 OVERVIEW
This guide is written for the Optimizer3 with firmware version 1.9.1 and higher.
The Optimizer3 is an on-line continuous performance monitor for high voltage circuit breakers. It provides information for the
process of Condition-Based Maintenance
Optimizer3 performs four main functions:
1. Mechanism Timing.
2. Estimation of interrupter condition as degraded by internal arcing eects.
3. Measurement of SF₆ gas density, pressure, and dew point temperature.
4. Status Monitoring of Auxiliary systems.
The Optimizer3 is designed to be installed in the circuit breaker control cabinet. Usually this is the most convenient place because
there is easy access to SF₆ plumbing for the density sensors, bushing CT circuits, and control circuits. Often the O&M technicians
have no access to the control building where the protective relays are located. If it is not possible to locate the Optimizer3 in the
control cabinet, then it may be installed in the control building. Most often this decision is based on access to communication links
or SCADA RTU access.
For use as a SF₆-only monitor, such as for monitoring compartments of GIS or SF₆ insulated bus, the Optimizer3 may be located up
to 2000 feet from the digital SF₆ density or pressure sensors if AWG 14 wire is used. This makes it feasible to locate the Optimizer3
in a control building, near communications access points.
If access to circuit breaker control cabinets is restricted, Optimizer3 may also be installed in a separate enclosure, mounted to the
frame of the circuit breaker. This way, Optimizer3 can be accessed without opening the circuit breaker control cabinet, without
restriction of the breaker being taken out of service.
Figure 1 – Breaker Timing Measurements

7
Optimizer3 measures and logs the following information:
• Breaker status OPEN/CLOSE • Heater Current • Open Average Velocity
• SF₆ Density • Optimizer3 Line Voltage • Close Average Velocity
• SF₆ Temperature • Ambient Cabinet Temperature • Open Operation Arcing Time
• SF₆ Dew Point • Days since Last Operation • Clearing Time
• Sensor Malfunction • Restrike Occurrence • Opening Travel Time
• Motor Run Time • Contact Life; cumulative I²T or IT • Closing Travel Time
• Motor Runs per Day • Last Trip Coil Energized (TC1/ TC2) • Total Operation Count
• Motor I²T • Open Latch Time • Non-Fault Operation Count
• Motor Total Run Time • Close Latch Time • Fault Operations Count
• Heater Status On/O
The Optimizer3 continuously monitors the SF₆ attributes according to what sensors are used. Available sensors include:
1. Temperature-Compensated Pressure analog 4-20 mA.
2. Temperature-Compensated Pressure and Temperature (Model PSDP Digital Pressure Sensor).
3. SF₆ Density and Temperature (model DSDP Digital True Density Sensor).
4. SF₆ Density analog 4-20 mA.
5. SF₆ Dew Point Temperature analog 4-20 mA.
The Optimizer3 uses these measured attributes to calculate other user-defined properties in desired units. Optimizer3 calculates
density, pressure, trends, trend rates, changes in mass, etc. Most attributes can be compared to static alarm settings for assertion
when they go out-of-tolerance. Optimizer3 issues alarms via contacts, through DNP3.0 points, and via HTTPS web service, locally or
remotely.
The Optimizer3 Installation has been kept simple, with few connections required to the circuit breaker control circuits. Simple
electrical connections are made to trip and close circuits. Split-core Pickup Coils are attached to bushing CT secondary circuits. SF₆
gas sensors may be installed on the gas plumbing in several ways.
The Optimizer3 can be applied to any type of circuit breaker- vacuum, bulk oil, minimum oil, air blast, SF₆, live tank or dead tank.
Optimizer3 is useful on small sub-transmission circuit breakers to large EHV circuit breakers.
Contact wear models vary slightly by manufacturer and technology used. During set up, the manufacturer’s limits for contact wear
and timing should be used. If this information is not available, then IEEE C37.06-1989 standard should be used as a guide.

8
SENSOR INPUTS
The Optimizer3 includes eight inputs for sensors and five inputs for control signals.
Figure 2 – Sensor Field Wiring
Loop-powered (2-wire) digital or analog sensor inputs.
Supports 4-20 mA sensors or digital sensors with up to
18 VDC compliance voltage. 20 AWG twisted-pair wiring
recommended. Digital good to 700m.
Loop-powered (2-wire) analog-only sensor inputs.
Supports 4-20 mA sensors with up to 24 VDC compliance
voltage. 20 AWG twisted-pair wiring recommended.
Sensor 5
Sensor 4
Sensor 3
Sensor 2
Sensor 1
Sensor 5
Sensor 4
Sensor C
Sensor B
Sensor A
Sensor inputs A, B, and C are dual-function. They accept either 2-wire 4-20 mA analog sensors or 2 wire Sensors with a Proprietary
Digital Protocol. Sensor inputs 1-5 are 4-20 mA analog only and do not accept the digital protocol. For each 4-20 mA analog sensor,
there is a corresponding setup area in the CONFIGURATION web pages where the scaling of the input is done. The digital Sensors
require no scaling. The Optimizer3 scales those signals automatically.
• 18 VDC sensor power is provided for sensors A, B, and C.
• 24 VDC sensor power is provided for Sensors 1-5.

9
CT INPUTS
The Optimizer3 measures the current flowing through the bushing CT secondaries of the circuit breaker. These measurements are
used in the contact wear calculations, arc time, and determination of Fault versus Non-Fault operations. Line current is also logged.
During installation, small split-core Pickup Coils are attached to the relevant bushing CT circuits, noting the bushing CT turns ratio.
Depending on the maximum current expected in the bushing CT circuits, an optimal split-core Pickup Coil is selected. INCON® oers
split-core Pickup Coils with the following full-scale ratings:
Table 1 – Pickup Coil Ratings.
INCON® Part Number CT-20 CT-30 CT-50 CT-100 CT-160 CT-250 CT-400 CT-800
Full Scale Rating (A) 20 30 50 100 160 250 400 800
Range (A) 1.4-20 2.1-30 3.5-50 7-100 11.2-160 17.5-250 28-400 56-800
Each “CT-nn” part number is for a set of three Pickup Coils. The Pickup Coils are compatible with 50 or 60 Hertz power systems.
The split-core Pickup Coils snap on over existing insulated bushing CT secondary circuits without tools and are rated 1.0 % accuracy
and 0.05 VA burden at 5 amps. Removal or disruption of bushing CT circuits is not necessary. Although referred to as a CT, these are
sensors that give 0-5 VAC output for 0 to Full Scale current.
CONTROL INPUTS
The use of each input is determined by the circuit breaker application and Mode of operation. Each control input is multi-function
and is defined in the system CONFIGURATION. The control inputs are continuously interrogated to detect when the control circuit
nodes are in the active or inactive state. Each AUX input is fused on both legs, optically isolated from the monitoring processor
circuits, and has an input impedance of 540 kΩ. The O/On voltage threshold is approximately 35 volts.
Figure 3 – Power, Relay, Aux Input, Field Wiring
Power:
110–264 V AC/DC 50/60 Hz
Twisted pair recommended.
Relay Contact Rating:
NO: @ 250 VAC or 30 VDC
NO: @ 250 VAC or 30 VDC
48–250 VDC
Twisted pair
recommended.
AUX 5
AUX 4
AUX 3
AUX 2
AUX 1
GND
L1
L2
LOAD
LOAD

10
CONTROL INPUT LOGIC MONITORING
The logical state of each Control Input is continuously monitored and compared with the Input Polarity settings, in the context of
the Input Mode setting. Based upon these settings, the Optimizer3 knows the normally expected logic state of each Input, when
the breaker is closed or open. If the voltage state of an Input violates its closed or open state for longer than 3 seconds, the A-B
Logic Alarm will activate. This alarm is self-clearing once the provoking condition returns to the normal state. A record of the alarm
is written in the Event History, along with the dates and times the alarm occurred and was cleared.
This A-B Logic alarm serves as a Trip Coil integrity monitor in Input Modes 2, 4, 5, 6 and 7. The normal voltage state of the Control
Input wired across the Trip Coil is low. The low impedance (approximately 50 ohms) of the Trip Coil, energized through the
high-impedance Red Light, will normally produce a very low voltage to the Optimizer3 Control Input. If the Trip Coil impedance
significantly increases or it becomes open-circuited, the voltage drop across the damaged coil will be high, causing the Optimizer3
to assert the A-B Logic alarm.
INPUT POWER, GROUNDING, ISOLATION
The Optimizer3 operates from station battery DC or AC station service. Nominal current draw is 0.5 amp. The power input
automatically accepts either AC or DC. Both power supply legs are fused. If external fuses are used, 3.15 amp slow-blow are
recommended. Power input leads are isolated from chassis and are floating and not referenced to ground.
Ground connection is internally connected to the metal chassis. It is recommended that the ground be connected to the station
ground or ground bar inside the circuit breaker cabinet. Follow the electrical grounding standard in eect at your utility.
All wiring connections are made to removable Phoenix connectors. The Optimizer3 may be electrically isolated by pulling out
all the connectors from their mating sockets. Follow the electrical isolation standard in eect at your utility. If fused-cutouts are
desired, locate them physically near the Optimizer3 with 3.15 Amp Slow-Blow fuses for all input and control wiring. The Optimizer3
uses a switch-mode power supply with universal input. On power-up, it draws more than nominal current for 1 mS. Slow-Blow
fuses are mandatory if external fuses are used.
IMPORTANT: The Optimizer3 contains flash storage (SD card) for booting the device and saving data. Flash storage has the
potential to be corrupted under rare circumstances due to power loss while the software is writing to the SD card. The Optimizer3
has both hardware and software features to prevent corruption from occurring on boot-up or shut down.
The protection features begin working after 20 seconds of operation. It is important to make sure the power to the Optimizer3 is
solidly connected to terminals without the chance of disconnection and loss of power during the first 20 seconds of operation.