GE Digital Energy Kelman MINITRANS User manual

GEDE-GA_M-DLIS-SE.MA-005 Rev 3.1 29-Sep-15
GE
Digital Energy
Kelman MINITRANS™
Installation Manual
Transformer Oil
Dissolved Gas and Moisture Monitor

Contents
1Introduction.................................................................................................................................... 6
1.1 Product Overview................................................................................................................... 6
1.2 Manual Scope......................................................................................................................... 6
2Safety.............................................................................................................................................. 7
2.1 Symbols .................................................................................................................................. 7
2.2 Warnings ................................................................................................................................ 7
3Requirements ................................................................................................................................. 9
3.1 Pre-installation ....................................................................................................................... 9
3.2 Handling & Storage................................................................................................................ 9
4Technical Specification ................................................................................................................10
5Design Criteria..............................................................................................................................11
6Transformer Criteria..................................................................................................................... 12
7Mounting.......................................................................................................................................13
7.1 Mounting Stand Installation ................................................................................................14
7.1.1 Mounting the Product to the Stand.............................................................................15
7.2 Direct Mount Cradle .............................................................................................................16
7.2.1 Locking mechanism.....................................................................................................16
7.3 Sun Canopy ..........................................................................................................................17
8Plumbing.......................................................................................................................................18
8.1 Transformer Valves..............................................................................................................19
8.1.1 Fill Valve........................................................................................................................ 19
8.1.2 Drain Valve ................................................................................................................... 19
8.1.3 Ancillary Valves ............................................................................................................19
8.1.4 Cooling Loop Valves..................................................................................................... 20
8.2 Supply & Return Valves........................................................................................................ 20
8.2.1 Oil Supply...................................................................................................................... 20
8.2.2 Oil Return ......................................................................................................................21
8.3 Tubing ...................................................................................................................................21
8.3.1 Fitting Requirements.................................................................................................... 23
8.3.2 Fitting Instructions .......................................................................................................24
8.3.3 Connection to Oil Supply Valve....................................................................................24
8.3.4 Connection to Oil Return Valve....................................................................................25
9Power............................................................................................................................................28

9.1 Connections..........................................................................................................................28
9.2 Battery ..................................................................................................................................30
10 Electronics ................................................................................................................................32
10.1 Input Board...........................................................................................................................32
10.2 Alarm Connections...............................................................................................................32
10.3 Accessory Power..................................................................................................................33
10.4 External Sensors...................................................................................................................33
11 Communications......................................................................................................................34
Installation Tools and Supplies....................................................................................35Appendix A
Customer Checklist ...................................................................................................... 36Appendix B
Installation Record ....................................................................................................... 37Appendix C
Tubing Specification and Ordering Details .................................................................41Appendix D
Product Dimensions.....................................................................................................44Appendix E
Mounting Stand Dimensions .......................................................................................45Appendix F
Footprint Dimensions...................................................................................................46Appendix G
Sun Canopy Dimensions.............................................................................................. 47Appendix H
Input Board...................................................................................................................49Appendix I
Heat Trace Cable..........................................................................................................52Appendix J
Direct Mount Cradle Vibration Levels..........................................................................53Appendix K
Direct Mount Cradle Installation.................................................................................. 55
Appendix L
Direct Mount Cradle Locking Mechanism...................................................................67Appendix M
Contact & Copyright Details ................................................................................................................85
Table of Figures
Figure 7—1: The product mounted on a stand...................................................................................15
Figure 7—2: Direct mount cradle......................................................................................................... 16
Figure 7—3: Cradle-mount sun canopy ..............................................................................................17
Figure 8—1: Schematic representation of an installation.................................................................. 18
Figure 8—2: Examples of possible line configurations (three of many).............................................18
Figure 8—3: Possible valve locations of a transformer ......................................................................19
Figure 8—4: Product connections - bottom view ............................................................................... 23
Figure 8—5: Fitting body and tubing................................................................................................... 24
Figure 8—6: Nut at 6 o'clock position..................................................................................................24
Figure 8—7: Nut at 9 o'clock position..................................................................................................24
Figure 8—8: Bleed assembly on flange-type oil return valve.............................................................25
Figure 8—9: Flange example ...............................................................................................................26

Figure 8—10: Return Assembly kit....................................................................................................... 26
Figure 8—11: Bleed assembly on threaded-type oil return valve......................................................27
Figure 9—1: Bottom plate connections............................................................................................... 29
Figure 9—2: Mains fuse holders with fuses (front - inside)................................................................. 29
Figure 9—3: Mains fuse holders with terminal connections (top - outside) ......................................29
Figure 9—4: Earth terminal on bottom of enclosure ..........................................................................30
Figure 9—5: Coin cell battery............................................................................................................... 30
Figure 10—1: Accessory power points for 12 V and 24 V ..................................................................33
Figure E—1: Front and side dimensions..............................................................................................44
Figure E—2: Base dimensions..............................................................................................................44
Figure F—1: Front and side dimensions with stand ...........................................................................45
Figure G—1: Footprint dimensions ......................................................................................................46
Figure H—1: Mounting-stand canopy front dimensions.................................................................... 47
Figure H—2: Mounting-stand canopy side dimensions .....................................................................47
Figure H—3: Cradle-mount canopy front dimensions........................................................................48
Figure H—4: Cradle-mount canopy side dimensions......................................................................... 48
Figure I—1: Input board .......................................................................................................................49
Figure I—2: RS-232 & RS-485 connections .........................................................................................51
Figure K—1: Product vibration limits ................................................................................................... 54
Figure L—1: Direct mount cradle.........................................................................................................55
Figure L—2: Clearance requirements..................................................................................................56
Figure L—3: Foam skid......................................................................................................................... 58
Figure L—4: Product positioned on the foam skid.............................................................................. 58
Figure L—5: Bracket tools and fittings ................................................................................................ 59
Figure L—6: Attach bracket fittings to the product ............................................................................59
Figure L—7: Tighten the fittings........................................................................................................... 60
Figure L—8: Top isolators tools and fittings........................................................................................60
Figure L—9: Fitting the support bracket.............................................................................................. 61
Figure L—10: Support bracket with top isolators fitted...................................................................... 61
Figure L—11: Mounting slot dimensions .............................................................................................61
Figure L—12: Bottom isolators tools and fittings................................................................................ 62
Figure L—13: The product positioned over the isolators.................................................................... 62
Figure L—14: Isolator with O ring ........................................................................................................63
Figure L—15: Attach fittings to isolators ............................................................................................. 64
Figure L—16: Failsafe tools and fittings ..............................................................................................64
Figure L—17: Fitting the failsafe mechanism......................................................................................65
Figure L—18: Misalignment and skew distance ................................................................................. 66
Figure L—19: Isolators used in compression and compression distance ......................................... 66
Figure M—1: Isolator ............................................................................................................................68
Figure M—2: Misalignment and skew distance ..................................................................................68
Figure M—3: Isolators used in compression and compression distance.......................................... 69
Figure M—4: Product LCD and Power Switch .....................................................................................70
Figure M—5: Tools & fittings ................................................................................................................ 71
Figure M—6: Top isolators with fittings & failsafe items removed.....................................................71
Figure M—7: Locking Piece Top ...........................................................................................................72

Figure M—8: Locking piece with fittings (left) ¦¦ tightened with a nut spinner (right) ........................ 72
Figure M—9: Bottom isolators with partially unscrewed fittings....................................................... 73
Figure M—10: Isolator with fittings (left) ¦¦ tightened with spanner (right)......................................... 73
Figure M—11: Clockwise: Isolators with fittings ¦¦ back fittings tightened with spanner ¦¦ front
fittings tightened with nut spinner............................................................................... 74
Figure M—12: Tools & fittings ..............................................................................................................75
Figure M—13: Inner panel.................................................................................................................... 75
Figure M—14: Rear view of LCD display board with cable attached.................................................75
Figure M—15: Fitting PGA locks ........................................................................................................... 76
Figure M—16: Reconnect LCD display board cable............................................................................ 77
Figure M—17: Inner panel.................................................................................................................... 77
Figure M—18: Loosen isolator front nut with nut spinner................................................................. 78
Figure M—19: Loosen isolator rear outer nut with spanner .............................................................. 78
Figure M—20: Bottom isolator with fittings removed.........................................................................78
Figure M—21: Unscrew the failsafe bolt .............................................................................................79
Figure M—22: Loosen the isolator M6 nut using a nut spinner .........................................................79
Figure M—23: Inverted top locking piece............................................................................................80
Figure M—24: Bottom locking piece.................................................................................................... 80
Figure M—25: Surplus nuts & washers stored securely on bracket bolts .........................................80
Figure M—26: Inner panel.................................................................................................................... 81
Figure M—27: Rear view of LCD display board with cable attached.................................................82
Figure M—28: Slide out PGA lock.........................................................................................................82
Figure M—29: Threaded inserts........................................................................................................... 83
Figure M—30: Stored PGA locks...........................................................................................................83
Figure M—31: PGA locks secured using Allen key ..............................................................................83
Figure M—32: Reconnect LCD board cable ........................................................................................84
Figure M—33: Inner panel.................................................................................................................... 84
List of Tables
Table 4—1: Technical specification .....................................................................................................10
Table 5—1: Type tests ..........................................................................................................................11
Table 11—1: Product communications channels............................................................................... 34
Table I—1: List of terminals..................................................................................................................50
Table L—1: MINI DM-Cradle retrofit kit —KITT00071 .........................................................................57
Table L—2: Bracket tools and fittings.................................................................................................. 59
Table L—3: Top isolators tools and fittings .........................................................................................60
Table L—4: Bottom isolators tools and fittings ................................................................................... 62
Table L—5: Failsafe tools and fittings.................................................................................................. 64
Table M—1: Tools & fittings.................................................................................................................. 71
Table M—2: Tools & fittings.................................................................................................................. 75

MA-005 - MINITRANS Installation Manual - Rev 3.1 29-Sep-15 Page 6 of 85
1INTRODUCTION
1.1 Product Overview
The MINITRANS™(herein referred to as the product) is an on-line DGA (Dissolved Gas
Analysis) system for transformer diagnostics. The product measures the following key
fault gases in transformer oil: hydrogen, carbon monoxide and acetylene as well as
moisture in the oil and the transformer load current. Such data provides insight on
transformer condition criteria, such as developing faults, paper degradation and
electrical arcing. Once installed, operation is straightforward. All results are stored within
the product, but can be downloaded to a PC for analysis.
The key features and characteristics are summarised as follows:
Utilises dynamic headspace sampling to extract target gases from the oil sample.
No consumables, such as carrier gases are required.
Accurate results are available as often as once per hour.
Minimal maintenance.
Uses highly accurate and stable Photo-acoustic Spectrographic technology.
Fully embedded microprocessor with non-volatile internal memory storage for
10,000 records.
Stainless steel outdoor-rated IP55 enclosure connected to the transformer by
robust stainless steel tubing.
All gas sensing is carried out internally –no external gas sensors.
Transformer load tracking is available.
One user-configurable relay contact based on absolute gas and moisture values.
Two sunlight-visible LED arrays on the exterior of the enclosure –one green for
power, one red for alarm.
Communication options include: Ethernet, RS-232, Cellular modem (GSM/GPRS),
PSTN modem, RS-485 and Fibre Optic. Other options may be available on request.
Internal USB connection provided for commissioning and service, or local data
download.
1.2 Manual Scope
This manual details the installation requirements and procedure, including important pre-
installation tasks to be considered when planning and preparing for the installation. It
examines mounting, plumbing, power, electronics and communications —including tools,
supplies and items to purchase. This manual must be read in its entirety prior to
installation so as to prepare the site and obtain the necessary equipment. Refer to the
appendices for details and record site details in the Installation Record (see Appendix C).

MA-005 - MINITRANS Installation Manual - Rev 3.1 29-Sep-15 Page 7 of 85
2SAFETY
2.1 Symbols
General Warning or Caution. Refer to the Installation Manual / User
Guide to prevent injury or damage to equipment.
Electrical Hazard. Risk of electric shock.
Primary Protective Earth connection.
Hot surfaces may be present.
2.2 Warnings
The minimum ambient temperature for installation and service activities is
−10 °C.
If the equipment is installed or used in a manner not specified by the
manufacturer, the protection provided by the equipment may be impaired.
If working at height, third parties must have received appropriate training for
working at height prior to work commencing. This includes, but is not limited to
"Working at height training".
If working at a height greater than 4 feet or at a height greater than that
stipulated by national or site regulatory requirements, it is the responsibility of
the installer to ensure that planned work complies with those requirements.
The installer shall also ensure that any third-party equipment, such as an
approved platform, scaffold or lift is suitable and safe before commencing
work. Ladders or improvised platforms do not meet GE service engineer
requirements.
Once installed, the product may have more than one source of supply.
Disconnect all supplies at their source before accessing the cabinet for
servicing. Follow the site lockout-tagout (LOTO) procedure.

MA-005 - MINITRANS Installation Manual - Rev 3.1 29-Sep-15 Page 8 of 85
Only GE-trained and certified personnel may commission GE products.
Commissioning tasks include making any connections and/or performing any
work within the enclosure, or performing tasks such as purging the oil circuit
between the transformer and the product, and/or all first start-up procedures
relating to equipment or firmware/software.

MA-005 - MINITRANS Installation Manual - Rev 3.1 29-Sep-15 Page 9 of 85
3REQUIREMENTS
3.1 Pre-installation
The product can be safely connected to an energised or non-energised transformer.
However, if installation personnel are required to work in an energised environment they
must be made aware of this prior to work commencing and must observe all health and
safety practices, especially when working with conductive materials such as stainless
steel installation tubing. If either of the oil supply or return valves to be utilised brings
personnel within restricted approach boundaries then the transformer must be de-
energised and isolated before such work is performed.
To ensure success, careful planning and proper execution of the tasks outlined in this
manual are essential. In addition, the GE Customer Service Centre representative will
need specific information in order to provide recommendations for a trouble-free
installation. If GE is to perform the installation, the installation will not be scheduled until
all pre-installation tasks outlined in this manual are complete (as performed by the
customer and GE).
The appendices to this manual contain additional information, such as drawings, forms
and checklists that need to be reviewed and completed prior to the installation. This
relates to materials and facilities that need to be ordered, acquired and in place well in
advance of the scheduled installation date. Confirmation of this needs to reach GE as
soon as possible, at a minimum four weeks prior to the installation date, unless prior
arrangements have been made with the GE Installation Group. This aids in planning and
supporting the installation thereby ensuring a trouble-free commissioning process.
3.2 Handling & Storage
For short-term storage (defined as less than one week), it is acceptable to store the
products in the open air, provided that they are protected from wet weather and direct
sunlight by a suitable customer-supplied waterproof covering and also provided that the
outside temperature does not exceed 45 °C or fall below 0 °C. For storage periods
exceeding one week, customers are requested to store the product in a fully enclosed
building that is free from damp and extremes in ambient temperature (defined as above
30 °C or below 2 °C).
Note: Product packages are not suitable for stacking. Damage incurred as a result of poor customer
handling or storage will not be covered under the GE warranty.

MA-005 - MINITRANS Installation Manual - Rev 3.1 29-Sep-15 Page 10 of 85
4TECHNICAL SPECIFICATION
The product meets the following technical specification as outlined in Table 4—1.
Table 4—1: Technical specification
PARAMETER
VALUE/MEETS
GAS MEASURED
MEASUREMENT RANGE (ppm)
Hydrogen (H2)
5 –5,000 *1
Acetylene (C2H2)
3 –50,000 *1
Carbon Monoxide (CO)
10 –50,000 *1
ACCURACY OF GAS MEASUREMENTS
± 10% or ± LDL (whichever is greater)
Moisture (H2O)
0 –100% RS (given in ppm)
ENVIRONMENTAL
External temperature range
−35 °C to 55 °C
Oil temperature range
−10 °C to 100 °C*2
Operating humidity
10 –95% RH non condensing
Altitude
Up to 2000 m
Atmospheric pressure
Up to 1050 mbar
Enclosure
IP55
Weight
30.5 kg (68 lb)
POWER REQUIREMENTS
90 V AC to 264 V AC, 47 Hz to 63 Hz, 6 A max
Single phase Alarm Relays: NO and NC provided
1 A 250 V AC, 300 mA 110 V DC, 1 A 30 V DC
Fuses *3
Mains:
10 A 500 V (Cooper Bussmann BAF), 10 x 38 mm
Accessories:
2 × 2 A 250 V (Littelfuse 392 T)
MEASUREMENT FREQUENCY
Variable –Once per hour to once every 4 weeks
*1 Note: Accuracy quoted based on accuracy of detectors during calibration.
*2 Note: Based on testing carried out using VOLTESSO™ 35 mineral oil over a ¼ in. pipe run of 10 metres
or less from oil supply or return valve to product connection point, and on transformer oil supply valve
volumes of 200ml or less. For oil temperatures colder than -10 ºC, GE recommends the use of heat trace
cabling on piping.
*3 Note: Use only the approved and recommended fuse to ensure continued fire protection and
compliance.