Direct Winding Temperature Measurement for LiquidFilled Transformers

509DW

Installation and Operation Manual

IST-090-1

QualiTROL Direct Winding Temperature Measurement for Liquid-Filled Transformers Installation and Operation Manual

TABLE OF CONTENTS
Table of Contents _______________________________________________________ i Overview ______________________________________________________________1
QualiTROL ETM With Direct Winding Temperature Measurement ............................. 1 QualiTROL......................................................................................................................... 2 About This Manual ............................................................................................................ 2 Modifying Radial Spacers .................................................................................................. 3 Fiber Optic Probes ............................................................................................................. 4 Transformer Tank Feed-Thru Plates ................................................................................ 4 Feed-Thru Connectors ....................................................................................................... 6 Feed-Thru Plate Cover and Extension Cable .................................................................... 6 Fiber Optic Transmitters and the 509 ............................................................................... 8 Care of the Fiber Optic Cables ........................................................................................ 10 Wiring the Fiber Optic Transmitters............................................................................... 10 Current Input Module in the 509..................................................................................... 12

Functional Specification of the 509 etm ____________________________________13 Product Specifications for fiber optic option ________________________________14
Temperature Measurement Performance ....................................................................... 14 Probe Specifications ......................................................................................................... 14 Fiber Optic to Current Loop Converter Specifications................................................... 14 Converter Power Supply Specifications........................................................................... 14 Fiber Optic Extension Cable Specifications..................................................................... 15 Bulkhead Fitting ............................................................................................................... 15 General Environmental Requirements ............................................................................ 15

Regulatory Certification_________________________________________________15
Certification Approvals .................................................................................................... 16 Product Electrical Safety .............................................................................................. 16 Product Electro-Magnetic Compatibility (EMC)........................................................... 16 Dielectric and Vapor Therm Testing ............................................................................... 16

NMI- 26195

March 23, 2007

QualiTROL Direct Winding Temperature Measurement for Liquid filled Transformers Installation and Operations Manual
OVERVIEW QualiTROL ETM With Direct Winding Temperature Measurement
The QualiTROL Electronic Transformer Monitor (ETM) for Liquid-Filled Transformers (Model #509-100 Series) is an Intelligent Electronic Device (IED) that combines microprocessor technology and advanced digital signal processing, to accurately assess the health, and performance of three phase or autotransformers. The 509 can be tailored to suit the application. The ETM can monitor up to eight total parameters. Requiring inputs from Resistance Temperature Detectors (RTDs), Current Transformers, AC Voltage (0-140 VAC or 0-320 VAC), Current loops (0-1 or 4-20 ma DC), Voltage (0-100 mv or 0-10V), Switch Contact Closure, or Fiber Optic Probes; this complete transformer monitoring system can monitor parameters such as: Liquid Temperatures (Main Tank Top or Bottom, Load Tap Changer), Direct Winding Temperatures, Ambient Temperatures, Winding Current, Cooling Bank Currents, and a variety of parameters from transducers such as Tank Pressure, or Dissolved Gas in Oil analysis. The 509 Transformer Monitor offers:
n n n n n n

Direct measurements of winding temperatures Superior temperature control for higher loads Integrated Load Tap Changer temperature monitoring Stand alone or networked substation monitoring Diagnostic tool for condition based maintenance Eight (8) form C adjustable relays to operate cooling equipment, signal alarms, and provide trip functions, depending on transformer conditions Up to four (4) 0-1 or 4-20 ma DC loops for use with SCADA systems Digital communication ports RS-232, RS-485

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The ETM with direct winding measurement is extremely easy to install and use. It is designed to be mounted outdoors (heater available inside enclosure), in the transformer control cabinet or in a 19 inch control rack. The ETM is powered by a universal power supply of 90-264 VAC 47-63 Hz single phase power or 40-290 VDC while the Converters for the fiber optic probes uses 100-240 VAC. It comes with user-friendly computer aided setup software and can be supplied with a wide array of customer selected sensors. For hardware specific questions concerning the 509 see the 509 Operations Manual IST-072-X and for configuring the software of the 509 see the 509 Software Manual IST-073-X.

QualiTROL
QualiTROL has been a leader in supplying pressure, liquid level, and temperature controls since 1945. An ISO 9001 system certified company; we are committed to providing you with quality and reliability, both in our products and in our service.

About This Manual

This manual provides all the information you will need to install the fiber optic probes, connect the converts to the probes and 509 ETM and configure your QualiTROL Electronic Transformer Monitor. It is organized into the following sections: Modifying Radial Spacers Explanation of how to modify the transformer winding spacers to accept the fiber optic probes. Fiber Optic Probes Information and dimensional characteristics concerning the Fiber Optic Probes. Transformer Tank Feed-Thru Plates Drawings and instructions for mounting the Feed-Thru Plates. Feed-Thru Connectors Where to install the Feed-Thru Connectors. Feed-Thru Plate Cover and Extension Cable How to mount the Cover and run the Fiber Optic Extension Cable. Fiber Optic Transmitters and the 509 Mechanical package choices for the 509 Direct Winding Temperature System. Care of the Fiber Optic Cables Cleaning the fiber optic connection ends. Wiring the Fiber Optic Transmitter Wiring instructions for the Fiber Optic Transmitter, the power supply and connecting to the 509. Current Input Module in the 509 Shows the settings for configuring the Current Input Module of the 509 to accept an input from a Fiber Optic Transmitter. Functional Specification of the 509 ETM Functional specifications for the 509 Intelligent Electronic Device. Product Specifications for Fiber Optic Option Specifications for all the individual components of the Direct Winding Measurement System.

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Installing Fiber Optic Probes in the Radial Spacers

Modifying Radial Spacers

The Qualitrol Fiber Optic Probes come equipped with a keyed tip. This tip once placed inside the modified radial spacer will lock itself in place for the life of the probe. For an example of a modified spacer and the appropriate dimensions see below.

If the customer prefers they can contact Qualitrol about supplying the modified spacers for their application. The Fiber Optic Probe needs to be securely fastened inside the modified radial spacer. Depending on spacer thickness this may take more than one modified spacer to contain the fiber optic probe tip (see Fiber Optic Probe dimensions below). Once the tip is placed inside the modified spacer it can be sandwiched by adhering additional spacers or insulating paper to the modified spacers. The probe tip should be secured such that there is no movement of the probe inside the spacer assembly. Once the probe and spacer assemblies are completed they can then be installed directly between the windings in the location directed by the design engineer. The fiber optic probes are then secured inside the transformer tank and connected to the feed-thru connectors on the Transformer Tank FeedThru Plate. Note: The Fiber Optic Probes should be dressed at a radius of not less than 0.5 inches to prevent probe breakage.

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Fiber Optic Probes

Transformer Tank Feed-Thru Plates

The Transformer Tank Feed-Thru Plates come in two sizes; one that allows up to six fiber optic feed-thru connections and the other that has the capacity for twelve feed-thru connections. Both Feed-Thru Plates can be ordered to be populated with as many feed-thru connections or plugs as required by the application. The Plates are secured to the transformer tank on welded bolts and sealed with a gasket supplied by the customer. For the smaller, six connector feed-thru plate the recommended diameter tank cutout is 4.5 inches while for the larger twelve connector plate the recommended cutout diameter is 6.5 inches.

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Six hole Transformer Tank Feed-Thru Plate Dimensions

Twelve hole Transformer Tank Feed-Thru Plate Dimensions

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Before the Feed-Thru Plate can be bolted into place on the transformer tank the fiber optic probes that are installed in the tank must be connected to the FeedThru connectors located on the underside of the plate. Dress the fiber optic cables in such a fashion that once the plate is bolted in place, the cables will not be strained nor should they be placed in a position to cause a dielectric hazard. It should be remembered that while fiber optic cables are more rugged than they were years ago they still are not as forgiving as copper wire. Therefore care should always be taken when dressing and securing fiber optic cables. The ends of the fiber optic probes are secured to the feed-thru connectors using ST connections.

Feed-Thru Connectors

The Feed-Thru Connectors should be installed in the Feed-Thru Plate before attaching the Fiber Optic Probe. One Feed-Thru Connector is required for each Fiber Optic Probe. Any holes not filed with a Feed-Thru Connector should be plugged. Note: The Feed-Thru Connector should not be used as a plug. Once the Fiber Optic Probes, Feed-Thru Connectors and Feed-Thru Plate are installed on the transformer tank then the Extension Cable can be attached.

Feed-Thru Plate Cover and Extension Cable

The fiber optic extension cable has approximately eighteen inches of fiber optic cable extending beyond the end of the conduit. This allows the installation or removal of the Feed-Thru Plate Cover to the Feed-Thru Plate without loosening the connection of the conduit to the cover. To install the fiber optic extension cable to the Feed-Thru Plate, first connect the Extension Cable conduit to the Feed-Thru Plate Cover and secure using the appropriate hardware. There are three screws that fasten the cover onto the Feed-Thru Plate which allows three and only three different orientations for the cover. Keep this in mind when dressing the fiber optic cables. Next connect the individual fiber optic cables to the appropriate Feed-Thru connectors in the Feed-Thru Plate. A written record
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should be maintained documenting the path from the probe to the Feed-Thru Connector to the fiber optic cable so that the user knows what temperature parameters of the transformer he is measuring with what converter. Once all the fiber optic connections are made then secure the Cover to the Feed-Thru Plate using the three mounting screws. In some applications more Direct Temperature Fiber Optic Probes will be connected to the Feed-Thru plate than will be measured with the 509 system. In these instances the customer can select which probes they would like to measure. The advantage of this is multiple probes could be installed during the heat run tests and the customer may pick and choose which ones to continue to monitor.

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Fiber Optic Transmitters and the 509

There are three styles of mechanical packaging for the Fiber Optic Transmitters; an all encompassing weather proof enclosure for the 509 and fiber optic converters, an auxiliary weather proof enclosure for just the fiber optic transmitters and a bracket assembly of the fiber optic converters. Enclosure Style The all encompassing weather proof enclosure (shown below) is approximately 17 by 19 by 10.5 inches in size and designed to be back-mounted to any smooth surface. Four 0.31 by 0.50 oval slots are provided for use with suitable fasteners to accomplish this. This packaging style has the 509 ETM assembled with the fiber optic transmitters in the same box. If the Data Logging System is purchased then it can also be installed in the same enclosure. While this enclosure is slightly larger than the standard 509 enclosure it does have the advantage of all its components in one package. Note additional area below the Temperature Monitor should be allotted for the wiring harness. See below for mounting centers and dimensions.

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Auxiliary Enclosure Style The auxiliary weather proof enclosure is approximately 8.5 by 10.5 by 6.5 inches in size and designed to be back-mounted to any smooth surface. Four 0.31 by 0.50 oval slots are provided for use with suitable fasteners to accomplish this. It is designed to house the fiber optic transmitters and optional heater in a separate enclosure from the 509 itself. This packaging style has two advantages; should a customer already have a 509 unit installed and wants to upgrade to direct winding temperature system they dont have to remove their original unit. Or if a customer wants to mount the transmitters separately from the 509 unit itself due to mounting considerations then this offers that flexibility. Note additional area below the Temperature Monitor should be allotted for the wiring harness. See below for mounting centers and dimensions.

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Bracket Mount The third mechanical package for the fiber optic transmitters is designed to fit in a 19-inch rack. This package works in conjunction with the 509 Rack Mount unit. It would also be an option if the customer had a 509 panel mount unit where they were installing the 509 and the fiber optic transmitters in their own control cabinet. The bracket is 4U high, approximately 5.0 deep and requires four screws to mount it in the control rack. Additional area behind the Temperature Monitor should be allotted for the wiring harness. See below for the mounting centers and dimensions.

Care of the Fiber Optic Cables

All of the fiber optic connections are shipped from the factory free of contaminants. Care must be exercised when removing the protective caps and securing the connections of all the fiber optic connectors. If there is a question to the cleanliness of the connections, they can be cleaned by applying a small amount isopropyl to a lint free cloth and gently rubbing the affected area.

Wiring the Fiber Optic Transmitters

The 509 Direct Winding Temperature System consists of two transmission elements. The first is the optical path that entails the Fiber Optic Probes installed in the transformer tank, connected to the Feed-Thru Connectors in the transformer tank wall, continues on through the Fiber Optic Extension Cable and finishes at the SMT connector on the Fiber Optic Transmitter. The Fiber Optic Transmitter converts the optic signal to an electrical signal that is the second transmission element of the Direct Winding Temperature System.
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Universal Power Supply The Universal Power Supply for the Fiber Optic Transmitter is DIN rail mountable and should be located near the Fiber Optic Transmitters. The Power Supply will accept an input power supply range of 85 to 264 VAC (50-60 Hz) or 90 to 350 VDC. The output of the power supply is 24 VDC. The 24 VDC is then wired to each Fiber Optic Transmitter as shown above. The Power Supply is capable of powering 8 Fiber Optic Transmitters at the same time. Fiber Optic Transmitter The Fiber Optic Transmitter converts the optic signal from the Fiber Optic Probe to a proportional electrical signal that is sent to the Current Input Module of the 509. One side of the Fiber Optic Transmitter has a SMT connector to secure the Fiber Optic Extension Cable. The other side has four screws; two screws are to accept the input power from the Universal Power Supply and the other two screws are for the 4-20 milliamp output to the 509 IED. Connect both sets of wires as shown above. It takes one Fiber Optic Transmitter for each Fiber Optic Probe the customer intends to monitor. 509 Intelligent Electronics Device The 509 IED is capable of accepting up to 8 Fiber Optic Transmitters. Each Fiber Optic Transmitter needs to be paired with a Current Input Module in the 509. The 4-20 milliamp remote output of the Fiber Optic Transmitter is wired to positions 1 and 2 of the 509 Current Input Module as shown above. Additional information concerning the 509 may be found in the Operations Manual (IST072-X) and the Software Manual (IST-073-X).

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Current Input Module in the 509

The Current Input Module needs to be configured to accept the 4-20 mA DC signal from the Fiber Optic Transmitter. This will usually be done at the factory unless this is an upgrade item. For the Fiber Optic Transmitter application the jumpers on the Current Input Module should be set as follows:
CONNECTOR JP1 JP2 JP3 JP4 POSITION 2-3 2-3 2-3 1-2

509 Current Input Module

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FUNCTIONAL SPECIFICATION OF THE 509 ETM

Power Supply: Front Panel and Interface Display: Universal, 90-264 VAC, 47-63 Hz and 40-290 VDC; (< 10 watts) Type: 1 Easy to read 2-line, 16 character alphanumeric Liquid Crystal Display (LCD) Character size: 0.38 (9.66 mm) high x 0.19 (4.84 mm) wide per line Backlight: Optional 8, Light Emitting Diode (LED) 8 Large keys for programable settings and user interaction UV stabilized polyester +/-0.5% full scale input range 100 ohm platinum (Pt100) or 10 ohm copper (Cu10) RTD sensors;-40 to 120C or 40 to 200C range Clamp on CT 0-5A, 0-10A, 0-20A and others available 0-1 or 4-20 ma DC 0-140 VAC or 0-320 VAC; 50/60 Hz 1500 to 15,000 ohms Open/Closed

Status Indicators: Controls: Front Panel Membrane: Input Parameters: Accuracy: Temperature: Current: Current loop: AC Voltage: Potentiometer: Switch Contact Closure (isolated dry): Switch Contact Closure (powered) (powered, low current) Control/Alarm Contacts: Diagnostics Alarm: Heater control: Contact Rating: Remote (SCADA) Output: Data Communication: Immunity Dielectric Isolation (hi pot): Surge Withstand Capability: Conducted/Radiated Emissions: Conducted/Radiated Radio Frequency Immunity: Safety: Temperature Range: Storage Temperature Humidity: Vibration: Shock: Weatherproof Enclosure: Weight Approx:

Outputs

>80 Volts AC/DC open, 0 volts closed; optically isolated >130 Volts AC/DC open, 0 volts closed; optically isolated 8 form C (changeover) relay contacts for cooling control, alarms, trip, etc. 1 relay for sensors, power and internal instrument circuitry diagnostics 1 relay 10A @ 115/230 VAC, 10A @ 30VDC 0-1 ma, 4-20 ma, (other options available) maximum allowable load resistance: 10,000 ohms for 0-1 ma, 450 ohms for 4-20 ma RS-232, RS-485 (optically isolated), optional fiber optic interface with ST connector; 820 nm wavelength; max distance 1500 meters. 2500 VAC, 60 seconds to ground IEEE C37.90.1 IEC 61000-6-1 IEC 61000-6-2

Environment:

IEC 61010-1 -40C to +72C -50C to +80C 90% non-condensing 60/120 Hz @ .004 inch displacement. 10 Gs half-sine, in three orthogonal planes NEMA #3R (vented), UV stabilized, Corrosion proof fiberglass Weatherproof enclosure version 11.5 lb. (5.2 kg) Panel mount version: 4.5 lb. (2 kg) 19 inch rack mount version 6.5 lb. (3 kg) Accepts wire sizes from 24 to 12 AWG
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All Terminal Connections:

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PRODUCT SPECIFICATIONS FOR FIBER OPTIC OPTION Temperature Measurement Performance

Measurement range: -40C to + 200C (what is the tradeoff to go to 225C) Accuracy: 1C Resolution: 0.1C Response Time: 5s maximum Sampling rate: 0.5 seconds minimum Calibration requirements: none

Probe Specifications
Operating Temperature range: -40C to + 200C Response time: 5 sec Construction: Fiber-optic cable with built in probe tip and connector in 3 configurations Fiber Length: available in standard lengths 2m, 4m, 6m, 8m, 10m Fiber-optic Connector: Stainless Steel ST Fiber Optic Connector Testing Standards: ASTM D 149-97A, ASTM D 2413-99 Cable tensile strength: 10 lbs.

Fiber Optic to Current Loop Converter Specifications

Temperature range: Input Power of Converter: Fiber-optic Interface: Configuration Port: Output Analog Output (optional): Accuracy of (4-20mA): Packaging: -40C to + 85C 9 30VDC (powered from the converter power supply) SMA Connector receptacle RS-232 stereo jack connector 4 20 mA <0.05 mA +/- 0.002 * I reading + 150 ppm/C DIN Rail mounted standard enclosure

Converter Power Supply Specifications

Input Power Range: Output Power (to converter): Operating Temperature: Terminal Block: Electromagnetic Compatibility: 85 264 VAC; 45 65 Hz 24 VDC (22.5 28.5 VDC) -25 60 C 24 14 awg EN 61000-4-2 EN 61000-4-3 EN 61000-4-5 EN 61000-4-6 EN 61000-4-11 ENV 50204 EN 50081-2

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Fiber Optic Extension Cable Specifications

Environmental rating: Number of fibers: Construction: -40C to + 100C maximum 12 inch diameter stainless steel flexible conduit PVC liquid tight jacket Pre-terminated to customer specified length Orange (standard color for fiber-optic cable) 1mm diameter Plastic Optical Fiber with 2 mm diameter nylon jacket Liquid tight compression fittings with elastomeric seals 5m, 10m, 15m, 20m, 25m, 35m (depending on probe length)

Color: Optical Fiber: Conduit Connectors: Maximum Length:

PROBE LENGTH 2 METERS 4 METERS 6 METERS 8 METERS 10 METERS

MAXIMUM EXTENSION CABLE LENGTH 18 METERS 16 METERS 14 METERS 12 METERS 10 METERS

Bulkhead Fitting
Type: Seals: Pressure Rating: Connector Type: Transformer Tank Feed-Thru Plates: Operating Temperature Range: inch standard NPT fitting Viton O-rings 35 psi standard ST fiber optic connector 2 configurations 6 hole or 12 hole -40C to 100C 120C Survivability

General Environmental Requirements

Operating Ambient: Storage Temperature Relative Humidity: Vibration: Shock: Time Duration: -40C to +85C -55C to +85C 90% Non-condensing 0.1 mm @ 30 to 200 Hz 10g in any plane 10 millisecond

REGULATORY CERTIFICATION
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Certification Approvals
These represent mandatory design objectives, which must be satisfied to permit product sales in target markets (Canada, USA, Europe, other international markets).

Product Electrical Safety

q q q

CSA/UL Class I Div I Explosion Proof rating for Probe and Extension Cable CSA/UL Class I Div II Explosion Proof rating for the Fiber Optic Transmitter CE EN61010-1

Product Electro-Magnetic Compatibility (EMC)

q

q q

EN61326:1997+A1:1998 o EN61000-3-2:1995+A1:1998+A2:1998 o EN61000-4-2 o EN61000-4-3 o EN61000-4-4 o EN61000-4-5 o EN61000-4-6 o EN61000-4-8 o EN61000-4-11 CISPR 16-1 CISPR 16-2

Dielectric and Vapor Therm Testing

Passed:

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Multi-Phase Electronic Temperature Monitor

TB1
VAC LINE HEATER

TB1
17 18 19
10 A

1 2 3 4 5 21 22
10 A

VACC NEUT HEATER

RELAY 1
INPUT MODULE 1
10 A

RELAY 5

1 2 3

TB3

20
RELAY 6

RELAY 2
10 A

6 7 8 24 25
10 A

23 2
RELAY 7

1
INPUT MODULE 2

TB4

RELAY 3
10 A

9 10 11 27 28
10 A

3 1 TB5
INPUT MODULE 3

26
RELAY 8

RELAY 4
10 A

12 13 29 30 31 32
10 A

2 3 1 2 3 1 TB7
INPUT MODULE 5

VAC LINE INPUT (+) VACC NEUT INPUT (-) EARTH GROUND

14 15 16
SYSTEM STATE RELAY

TB6
INPUT MODULE 4

INPUT POWER: (UNIVERSAL) 90-264 VAC, 47-63 Hz 40-290 VDC

MODEL NO. SERIAL NO. MFG. DATE

2 3 1 2 3
TXD+(B)

RELAY CONTACTS: 10 A @ 115/230 VAC 10 A @ 30 VDC

TB8
INPUT MODULE 6

TB2
CURRENT LOOP 1 (-) (+) (-) (+) (-) (+) (-) (+)

TB2
9 10 11 12 13 14 15 16 RS-485
TXD-(A) RXD+(B) RXD-(A) GND T/RXD+(B) T/RXD-(A) GND

1 2 3 4 5 6 7 8

CURRENT LOOP 2

1 2 3 1 2 3

TB9
INPUT MODULE 7

CURRENT LOOP 3

TB10
INPUT MODULE 8

CURRENT LOOP 4

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Multi-Phase Electronic Temperature Monitor

Wiring Label (below)

Rear Cover (below)

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