ABB CoreSense User manual

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USER GUIDE
CoreSense™
Hydrogen and Moisture Sensor

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Disclaimer
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and documentation, may not be copied, photocopied, reproduced,
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or machine-readable format without prior written consent from
ABB.
This document contains product specifications and performance
statements that may be in conflict with other ABB published
literature, such as product fliers and catalogs. All specifications,
product characteristics, and performance statements included
in this document are given as indications only. In case of
discrepancies between specifications given in this document and
specifications given in the official ABB product catalogs, the latter
take precedence.
ABB reserves the right to make changes to the specifications
of all equipment and software, and contents of this document,
without obligation to notify any person or organization of such
changes. Every effort has been made to ensure that the information
contained in this document is current and accurate. However, no
guarantee is given or implied that the document is error-free or that
the information is accurate.
ABB makes no representations or warranties with regard to the
product and instructional and reference materials, including, but
not limited to, all implied warranties of merchantability and fitness
for a particular purpose.
ABB does not warrant, guarantee, or make any representations
regarding the use, or the results of the use, of any software or
written materials in terms of correctness, accuracy, reliability,
currentness, or otherwise. ABB shall not be liable for errors or
omissions contained in its software or manuals, any interruptions
of service, loss of business or anticipatory profits and/or for
incidental or consequential damages in connection with the
furnishing, performance or use of these materials, even if ABB has
been advised of the possibility of such damages.
All equipment, software, and manuals are sold as is. The entire risk
as to the results and performance of the equipment and software is
assumed by the user.
The software or hardware described in this document is furnished
under a license and may be used, copied, or disclosed only in
accordance with the terms of such license.
© ABB, Inc., 2018

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Table of Contents
1 Safety Information
Symbol definitions ..................................................1
General........................................................................3
Electrical.....................................................................3
Handling .................................................................... 4
2 Introducing the CoreSense
3 Preparing for installation
Tools for installation ...............................................7
Tools supplied by ABB ......................................7
Spare Parts ..........................................................7
Additional tools (not supplied by ABB)........7
Necessary protection equipment.................8
Unpacking..................................................................9
Handling .....................................................................9
Siting on the transformer......................................9
Planning your cabling ...........................................11
Planning your communications.........................11
Password protection........................................... 14
4 Installing the sensor head
Installation on transformer valve ..................... 15
Bleeding the sensor ............................................. 18
Removing the cover.............................................. 20
Establishing the connections ............................21
AC power line terminal block ........................22
RS-485 to SCADA .............................................23
Ethernet to SCADA...........................................23
Optical Ethernet to SCADA (optional)....... 24
Wiring the alarm relays (dry-contact) ....... 24
Analog 4–20 mA outputs.............................. 25
Analog 4–20 mA inputs................................. 26
Reinstalling the cover .......................................... 27
5 Configuring the sensor head
Connecting a laptop for the first time ........... 29
Tabs of the CoreSense web interface ..............31
Hydrogen settings.......................................... 34
Moisture settings............................................ 35
Administration settings................................ 36
Communication settings...............................37
Demo mode ...................................................... 38
About dialog box............................................. 39
Configuring alarm levels.....................................40
Rate-of-Change (RoC) trigger level ...........40
Latched alarms ................................................40
Visual indications and alarms ........................... 41
Meanings of the visual indicators ...............41
In case of WARNING or ALARM.................... 42
6 Post-installation check list
7 Maintenance
Replacing the fuse................................................45
Taking an oil sample.............................................46
Cleaning...................................................................46
Before sending a spectrometer to ABB.... 46
8 FAQ and troubleshooting
A Technical specifications...................A51
Description...........................................................A51
Measurement specifications ..........................A51
Mechanical specifications................................A51
Electrical specifications .................................. A52
Communication specifications ..................... A52
Environmental specifications........................ A52
Default RS-485 configuration........................ A53
Application TCP ports table ........................... A53
B CoreSense Hub option ......................B55
Overview............................................................... B55
Visual indicators............................................B56
CoreSense Hub Web user interface...............B57
Dashboard tab...............................................B57
History tab ......................................................B58
Settings tab....................................................B58
Automatic detection of Modbus sensors.....
........................................................................... B60
Configuring calculated values...................B62
Configuring 4–20 mA output channels. B64
Risks of overloading a transformer .........B65
SCADA communication...............................B65

iv Installation Guide
Device configuration .........................................B73
eDevices model descriptions....................B73
eDevices parameters................................... B74
C Modbus table......................................C77
Default RS-485 configuration.........................C77
Default TCP configuration port......................C77
Modbus parameters ......................................... C78
D DNP3 .....................................................D81
Default RS-485 configuration........................ D81
Default TCP configuration port..................... D81
E IEC 61850 (CoreSense only) .............E83
PIXIT........................................................................E83
PIXIT for Association Model.......................E83
PIXIT for Server Model .................................E84
PIXIT for Data Set Model.............................E85
PIXIT for Substitution Model .....................E85
PIXIT for Setting Group Control Model...E86
PIXIT for Reporting Model..........................E86
PIXIT for Logging Model .............................E87
PIXIT for GOOSE Publish Model................E87
PIXIT for GOOSE Subscribe Model...........E88
PIXIT for GOOSE Performance..................E88
PIXIT for Control Model ...............................E89
PIXIT for Time Synchronization Model....E92
PIXIT for File Transfer Model......................E93
PIXIT for Service Tracking Model..............E93
MICS....................................................................... E94
Logical Nodes List ........................................E94
SIML–Insulation medium supervision
(liquid) ..............................................................E94
PICS.........................................................................E95
ACSI Basic Conformance Statement.......E95
ACSI Models Conformance Statement ...E96
ACSI Service Conformance Test ...............E97
TICS Mandatory IntOp TISSUES .................. E100
F Sensor software update ................. F103
G CoreSense default factory values G105
H System events ..................................H107
I Definition of exported values.........I109
Hydrogen.csv ..................................................... I109
Moisture.csv ....................................................... I109
Events.csv ........................................................... I109
J Third party legal notices ................. J111

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CHAPTER 1
Safety Information
To ensure personal safety and optimal performance, make sure you thoroughly read and understand
the contents of this manual before installing or using the instrument.
This equipment intended for field installation by qualified service personnel according to
manufacturer’s installation instructions and local/national wiring requirements.
Users must comply with all safety indications (danger, warning, caution and notices) given in this
manual.
Symbol definitions
This document uses the following symbols to bring attention to key technical and safety-related
information.
DANGER–SERIOUS DAMAGE TO HEALTH/RISK TO LIFE
Indicates a hazardous situation that, if not avoided will result in death or serious injury.
WARNING–DAMAGE TO HEALTH/RISK TO LIFE
Indicates a hazardous situation that, if not avoided could result in death or serious
injury.
CAUTION–DAMAGE TO HEALTH
Indicates a hazardous situation that, if not avoided, could result in minor or moderate
injury..
NOTICE
Indicates information considered important, but not hazard related, that could impact
things
other than personal injury, like property damage.
WARNING–HIGH VOLTAGE
Indicates the presence of electrical energy at voltages high enough to inflict harm on
living organisms.

2Installation Guide
LASER RADIATION
Indicates the presence of a laser related hazard. It also indicates the type of laser in
use, its wavelength and its safety class.
SHARP EDGES
Indicates the presence of sharp edges that could cause personal injury if touched.
HOT SURFACES
Indicates the presence of heat sufficient enough to cause burns.
ELECTROSTATIC DISCHARGES
Indicates a device or part of a device that is susceptible to electrostatic discharges.
Identifies any terminal intended for connection to an external conductor for protection
against electrical shock in case of a fault, or the terminal of a protective earth (ground)
electrode.
Identifies protective earth conductor terminals.
Indicates the presence of direct current.

Safety Information 3
General
DANGER
Failing to comply with any of the instructions, precautions or warnings contained in
this manual is in direct violation of the standards of design, manufacture, and intended
use of the equipment.
ABB assumes no liability for the user’s failure to comply with any of these safety
requirements which may result in personal injuries and/or equipment damages.
WARNING
Do not, under any circumstances, remove the warning and caution labels. Information
must be available at all times for the security of the user.
Read this manual thoroughly before using this equipment. If you do not fully
understand the information contained in this manual or if the equipment shows any
sign of damage, please contact ABB. Refer to the back cover of this manual for contact
information.
If the equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.
Electrical
The CoreSense is an overvoltage category II instrument.
Use only fuse(s) specified as appropriate for this equipment (see “Technical specifications” on
page A51.)
In accordance with international safety standards, the sensor uses a three-wire power cord typically
connected to an electrical panel that provides grounding for the sensor chassis.
DANGER
Disconnect power at the distribution panel circuit breaker before opening the sensor.
Ensure that the equipment and all devices or power cords connected to the sensor are
properly grounded. Make sure that the sensor ground is at the same potential as the
transformer ground.
Protective earthing connection (grounding) must be active at all times.
The absence of grounding can lead to a potential shock hazard that could result in
serious personnel injury. If an interruption of the protective earthing is suspected, cut
the power to the sensor at the plant’s distribution panel and have the electrical circuit
tested.

4Installation Guide
DANGER
An external circuit breaker with a maximum rating of 15 amps must be installed on the
AC source and labeled accordingly, in compliance with your country’s national electrical
code.
In accordance with IEC61010-1 edition 3.0, to prevent contamination of the electronics by outside
elements, the sensor cover shall be removed only under controlled environmental conditions defined as:
• Temperature shall be between 5 °C and 40 °C
• Maximum relative humidity shall be 80% for temperatures up to 31 °C, decreasing linearly to 50%
relative humidity at 40 °C.
Do not expose the interior of the sensor to rain or snow.
For configuration purposes, the sensor can be powered when empty, but the thermal pump must
be turned off (this can be done in the web interface in Settings/administration settings). To prevent
accidents, the CoreSense is delivered with the thermal pump turned off.
When the installation is complete and the sensor is in contact with oil, make sure the thermal pump is
enabled in the web interface.
NOTICE
Operating the heater in air will result in failure of the thermal pump.
Handling
The CoreSense hydrogen and moisture sensor weighs approximately 8 kg. To avoid personal injuries,
make sure to use proper body mechanics (bend your knees) when lifting the sensor.
WARNING
Do not grab the sensor by the threaded NPT interface. The threaded edges are sharp
and there is a risk of personal injury.
WARNING
• During operation, the NPT port interface becomes hot. Avoid touching the surface
of the adapter.
• The sensor contains an internal heater. Thus, some parts of the sensor may be hot
when powered, i.e. all parts that contain hot oil. Always manipulate the sensor with
caution.

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CHAPTER 2
Introducing the CoreSense
The CoreSense continuously monitors hydrogen and moisture levels in oil and alerts the user when
either one starts increasing beyond a predefined threshold. Real-time monitoring complements
periodic off-line dissolved gas analysis (DGA) by alerting the user much sooner to evolving conditions.
The CoreSense can be mounted at multiple locations on the transformer including on the drain valve
because it uses a heating element to induce forced convection and ensure that fresh representative oil
is always reaching the solid state sensing elements.
The CoreSense user interface is designed as a series of simple web pages that can be accessed through
most web browsers. The web interface allows viewing of the current CoreSense status and settings.
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Figure 1 CoreSense sensor head
Cabling port
(½ NPT)
Oil sampling
access panel
1.5 NPT port interface to
transformer valve
Ground lug connection
System LED
Moisture LED
Hydrogen LED

Page intentionally left blank

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CHAPTER 3
Preparing for installation
This chapter provides information relevant to the steps that should be performed prior to installing the
CoreSense sensor.
Tools for installation
Here are the various tools necessary to install the CoreSense system.
Tools supplied by ABB
4 mm Allen key
5 mm Allen key
Spare Parts
O-ring No. 1 (Sensor enclosure) Buna-N o-ring no: AS568A DASH NUMBER 269, A50 durometer
O-ring No. 2 (Sensor brass fitting)
already installed on sensor
Metric Buna-N o-ring 3 mm width, 50 mm inside diameter
Plugs To cover unused cable gland ports
 For sampling
Additional tools (not supplied by ABB)
Laptop with Internet
Explorer 9 or above (for
sensor commissioning)
Straight Ethernet cable (for
sensor commissioning)

8Installation Guide
2 in wrench or adjustable
wrench (50.8 mm)
8 mm wrench or adjustable
wrench (0.31 in)
Roll of PTFE tape Bucket and rags
Wire stripper Wire cutter
Flat head screwdriver
Optical termination
equipment if installing the
optional optical Ethernet
port
Torque wrench
Transformer valve adapter
(when applicable).
Necessary protection equipment
Safety shoes
Gloves
Protective
glasses

Preparing for installation 9
Unpacking
The sensor is supplied in a cardboard box with internal shock absorbing packaging. Always transport
the sensor in the packaging supplied to minimize the risk of damage.
Handling
The product is designed to withstand many industrial environmental conditions. However, a few
handling precautions will ensure reliable operation of the unit for years to come:
• DO NOT DROP the sensor.
• It is not recommended to open the CoreSense if it is raining or snowing.
• Always turn off power at the electrical panel before doing any installation or adjustment.
• Do not expose the sensor internal electronics to any liquids or dirt.
• Ensure that the cable glands are tight after connection and that all 4 cable glands contain a cable.
• Make sure the cover is well secured with the supplied o-ring once connections inside the sensor have
been completed (see "Removing the cover" on page 20).
NOTICE
While the initial (cold start) accuracy of the sensor is likely to be within specifications,
a settling period of approximately 12 hours is strongly recommended to allow the
electronic components to fully warm up and the internal temperature to stabilize.
Siting on the transformer
On the transformer, several mounting locations may be available for installing the sensor. Care should
be taken to select a mounting location where the sensor will be exposed to maximal oil flow and
minimal oil temperature. The following table and Figure 2 can be used to help select the best location.
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Table 1 Typical instrument locations
Location Benefits Issues
(A) Radiator Return • Good oil flow
• Low operating temperature
• Ease of access
• Connection flange rarely present
(B) Drain valve • Low operating temperature
• Ease of access
• Permanent availability
• Low oil flow may increase reaction time
• Sludge could accumulate here
(C) Top tank (fill valve) • Good oil flow from thermal
convection
• Temperature may exceed 100 °C
• Access is difficult
• Installation requires working at height
• Mandatory power down of transformer during
installation

10 Installation Guide
Location Benefits Issues
(D) Top of radiator • Good oil flow • Temperature may exceed 100 °C
• Access is difficult
• Installation requires working at height
• Connection flange rarely present
• Mandatory power down of transformer during
installation
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Best
installation
location
Acceptable
installation
location
Acceptable
installation
location
Good
installation
location
Figure 2 Recommended installation locations
A
D
C
B

Preparing for installation 11
Planning your cabling
Select cabling according to your communication needs. Refer to the table below for recommended
cable gauge or cable type.
Always comply with national codes and electrical standards.
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Table 2 Recommended cable gauge and type
Cable Gauge/Type Maximum length
Power 12 AWG 15 m (50 ft)
14 AWG 10 m (33 ft)
Ground 10 or 6 AWG 15 m (50 ft)
RS-485 24 AWG 1220 m (4003 ft)
Alarm relays 16 or 14 AWG N/A
4–20 mA 18 AWG N/A
Ethernet (SCADA) Category 5 cable 100 m (328 ft)
Ethernet (SERVICE) Category 5 cable 3 m (10 ft)
Ethernet (optical) ST-ST Plenum Duplex

2000 m (6562 ft)
USB (service port) USB key only N/A
WARNING
To maintain the sensor IP67 rating, all cables must have a diameter of 10 to 14 mm
when used with the supplied cable glands. All four cable glands must contain a cable.
If necessary, tape can be used to adjust for the minimum required diameter. Failure to
comply may result in water infiltration and the presence of electrical shock hazards.
Planning your communications
The digital protocols supported by the sensor are Modbus, DNP3, and IEC 61850. Modbus and DNP3 are
available on the RS-485 serial interface, the Ethernet SCADA port or the optical Ethernet port. IEC 61850
is available on the Ethernet SCADA port or the optical Ethernet port.
Table 3 below shows the default RS-485 serial configuration. These default values can be modified at
any time using the built-in web interface.
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Table 3 Default RS-485 configuration
Baud rate 9600
Data bit 8
Stop bits 1
Parity None
Flow control None
When using Modbus, the default slave ID is 1, and when using the DNP3, the default outstation ID is 4.

12 Installation Guide
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Table 4 Summary of communication parameters
Port Default communication setup Setting options from web page
(see x-ref)
Protocol
RS-485
Baud rate 9600 Baud rate 110; 300;
600; 1200;
2400;
4800;
9600;
19200;
38400;
57600;
115200;
230400;
576000;
921600;
11520000
Modbus (point to
point only):
default slave ID = 1
Default DNP3
outstation ID = 4
Data bit 8 Data bit 7; 8
Stop bit 1 Stop bit 1; 2
Parity None Parity None;
Even; Odd
Flow control None Flow control None
Ethernet (SCADA)
DHCP client
Static IP; DHCP client
Administrator settings on
SCADA port can be enabled or
disabled using the web interface.
When the fiber optic port is in
use, the Ethernet SCADA port
must not be used.
Web http port
80/tcp
Modbus TCP port
502/tcp
DNP3 port
20000/tcp
IEC61850 MMS
port
102/tcp
Ethernet (optical)
Ethernet (SERVICE)
DHCP server
Default IP address range
172.16.100.x for PC
Default IP address for
CoreSense 172.16.100.1
Static IP; DHCP server.
ABB remote access can be
enabled or disabled using the
web interface.
NOTICE
For best results it is recommended to configure the Modbus or DNP3 master with a
timeout of 10000 ms and 5 retries.
Minimum delay between polls shall be at least 100 ms.
The DNP3 cold restart function is not supported for cybersecurity reasons.
NOTICE
Do not connect your internal network to the SERVICE port.

Preparing for installation 13
NOTICE – CYBERSECURITY
This product is designed to be connected to and to communicate information
and data via a network interface. It is the user’s sole responsibility to provide and
continuously ensure a secure connection between the product and the user network
or any other network (as the case may be). Users shall establish and maintain any
and all appropriate measures (such as, but not limited to, the installation of firewalls,
application of authentication measures, encryption of data, installation of anti-virus
programs, etc.) to protect the product, the network, its system, and the interface
against any kind of security breaches, unauthorized access, interference, intrusion,
leakage and/or theft of data or information. ABB Inc. and its affiliates are not liable for
damages and/or losses related to such security breaches, any unauthorized access,
interference, intrusion, leakage and/or theft of data or information.
ABB strives to maintain cybersecurity for its products and services. By visiting the web
page, you will find notifications about newly found software vulnerabilities and options
to download the latest software. It is recommended that you visit this web page
regularly:
http://new.abb.com/about/technology/cyber-security
Information about your product is also available on the product page:
http://new.abb.com/products/transformers/service/advanced-services/coresense
If you are planning on connecting to the Ethernet port or the optional optical Ethernet port, contact
your network administrator to confirm the network settings and check that the service ports described
in the table below are accessible. The SCADA Ethernet port and the optional optical Ethernet port are
configured at the factory as DHCP clients. Ethernet ports may also be configured with static IP settings.
The service Ethernet port is configured as a DHCP server and will automatically assign an IP address to
your laptop/PC in the 172.16.100.x range. The default server address on the service port is 172.16.100.1.
—
Table 5 Application TCP ports
Application Port
Web interface 80/tcp
IEC61850 MMS 102/tcp
Modbus TCP 502/tcp
DNP3 20000/tcp
ABB diagnostic port 22/tcp
DHCP 67/udp & 68/udp
NOTICE
The ABB TCP diagnostic port can be enabled and disabled using the web interface.

14 Installation Guide
NOTICE
Do not connect your internal network to the SERVICE port.
Password protection
The sensor is secured by a password for the operator role and a password for the administrator role.
For cybersecurity reasons, it is absolutely mandatory to change the default password. Not doing so
could expose your entire network to cyberattacks.
Passwords should comply with your company’s policies and meet minimal complexity requirements to
avoid security breaches.
—
Table 6 Default passwords
User role Default password
Acknowledge Ack
Administrator Admin
Default passwords can be modified using the web interface.

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CHAPTER 4
Installing the sensor head
This chapter explains the various steps necessary to physically install the CoreSense on the transformer.
NOTICE
In accordance with IEC61010-1 edition 3.0, to prevent contamination of the electronics
by outside elements the sensor cover shall be removed only under controlled
environmental conditions defined as:
Temperature shall be 5 °C to 40 °C.
Maximum relative humidity 80% for temperatures up to 31 °C, decreasing linearly to
50% relative humidity at 40 °C.
Do not expose the interior of the sensor to rain or snow.
Installation on transformer valve
The sensor is designed to be installed on a 1.5 NPT transformer valve, as explained below:
1 Loosen the eight rotating flange screws with the 5 mm Allen key.

16 Installation Guide
2 Wrap the sensor male fitting thread with PTFE tape.
3 Install the sensor on the transformer valve. An optional adapter can be used if the valve fitting is not
1.5 in. (e.g., most North American fittings are 2 in.).
WARNING
During operation, the NPT port interface becomes hot. Avoid touching the surface of
the adapter.
4 Tighten with a 2 in. (50.8 mm) wrench or use an adjustable wrench.