GE TOP-FREEZER 16 User manual

GEDE-GA_M-DLIS-TE.MA-001 Rev 3.0 18-Jan-16
GE
Grid Solutions
Kelman TRANSFIX™-family
Installation Manual
Transformer Oil
Dissolved Gas and Moisture Monitor

Contents
1Introduction.................................................................................................................................... 5
1.1 Product Overview................................................................................................................... 5
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
5Compliance................................................................................................................................... 11
6Transformer Criteria..................................................................................................................... 12
7Mounting....................................................................................................................................... 13
8Plumbing....................................................................................................................................... 15
8.1 Transformer Valves.............................................................................................................. 16
8.1.1 Fill Valve........................................................................................................................ 16
8.1.2 Drain Valve ................................................................................................................... 16
8.1.3 Ancillary Valves ............................................................................................................ 16
8.1.4 Cooling Loop Valves..................................................................................................... 17
8.2 Supply & Return Valves........................................................................................................ 17
8.2.1 Oil Supply...................................................................................................................... 17
8.2.2 Oil Return ...................................................................................................................... 18
8.3 Tubing ................................................................................................................................... 18
8.3.1 Fitting Requirements.................................................................................................... 20
8.3.2 Fitting Instructions ....................................................................................................... 22
8.3.3 Connection to Oil Supply Valve.................................................................................... 22
8.3.4 Connection to Oil Return Valve.................................................................................... 23
9Power............................................................................................................................................ 26
9.1 Connections.......................................................................................................................... 26
9.2 Cold Start .............................................................................................................................. 28
9.3 Battery .................................................................................................................................. 28
10 Electronics ................................................................................................................................ 30
10.1 System Board ....................................................................................................................... 30

10.2 Alarm Connections............................................................................................................... 30
10.3 Accessory Power.................................................................................................................. 31
10.4 External Sensors................................................................................................................... 31
11 Communications...................................................................................................................... 32
11.1 Electromagnetic Compatibility (EMC) requirements........................................................... 33
Appendix A Installation Tools and Supplies.................................................................................... 34
Appendix B Customer Checklist ...................................................................................................... 35
Appendix C Installation Record ....................................................................................................... 36
Appendix D Tubing Specification and Ordering Details ................................................................. 40
Appendix E Dielectric fittings........................................................................................................... 43
Appendix F Product Dimensions..................................................................................................... 45
Appendix G Mounting Stand Dimensions ....................................................................................... 48
Appendix H Footprint Dimensions................................................................................................... 50
Appendix I System Board ............................................................................................................... 51
Appendix J Heat Trace Cable.......................................................................................................... 54
Contact & Copyright Details ................................................................................................................ 55
Table of Figures
Figure 8—1: Schematic representation of an installation.................................................................. 15
Figure 8—2: Examples of possible line configurations (three of many)............................................. 15
Figure 8—3: Transformer Valve locations........................................................................................... 16
Figure 8—4: TRANSFIX 1.6 connections - bottom view ...................................................................... 20
Figure 8—5: MULTITRANS connections - bottom view....................................................................... 21
Figure 8—6: TAPTRANS connections - bottom view........................................................................... 21
Figure 8—7: Fitting body and tubing................................................................................................... 22
Figure 8—8: Nut at 6 o'clock position.................................................................................................. 22
Figure 8—9: Nut at 9 o'clock position.................................................................................................. 22
Figure 8—10: Bleed assembly on flange-type oil return valve .......................................................... 23
Figure 8—11: Flange example ............................................................................................................. 24
Figure 8—12: Return Assembly kit....................................................................................................... 24
Figure 8—13: Bleed assembly on threaded-type oil return valve...................................................... 25
Figure 9—1: Location of mains supply ................................................................................................ 27
Figure 9—2: Protective cover............................................................................................................... 27
Figure 9—3: Earth terminal on bottom of enclosure .......................................................................... 28
Figure 9—4: Voltage selector switch................................................................................................... 28
Figure 9—5: Coin cell battery............................................................................................................... 29
Figure 10—1: Accessory power points for 12 V and 24 V .................................................................. 31
Figure 11—1: Ferrite placement on RS-485........................................................................................ 33

Figure F—1: TRANSFIX 1.6 dimensions................................................................................................ 45
Figure F—2: TAPTRANS dimensions..................................................................................................... 46
Figure F—3: MULTITRANS dimensions................................................................................................. 47
Figure G—1: TRANSFIX 1.6 & MULTITRANS mounting stand dimensions –top, front & side............ 48
Figure G—2: TAPTRANS mounting stand dimensions –top, front & side .......................................... 49
Figure H—1: TRANSFIX 1.6 & MULTITRANS footprint dimensions ...................................................... 50
Figure H—2: TAPTRANS footprint dimensions..................................................................................... 50
Figure I—1: System board.................................................................................................................... 51
Figure I—2: RS-232 & RS-485 connections ......................................................................................... 53
List of Tables
Table 4—1: Technical specification ..................................................................................................... 10
Table 5—1: Type tests .......................................................................................................................... 11
Table 11—1: Product communications channels............................................................................... 32
Table I—1: List of terminals.................................................................................................................. 52

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1INTRODUCTION
1.1 Product Overview
The TRANSFIX™family of products (herein referred to as the product, meaning the
TRANSFIX 1.6, MULTITRANS and TAPTRANS) are on-line DGA (Dissolved Gas Analysis)
systems for transformer diagnostics. The products measure the following key fault gases
in the transformer oil: hydrogen, methane, ethane, ethylene, carbon monoxide, carbon
dioxide and acetylene. In addition they also measure oxygen, nitrogen 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.
In addition, the MULTITRANS has the facility to measure oil from three separate oil tanks,
for example, three transformer tanks operating in a single phase bank. The TAPTRANS
has the facility to measure oil from the transformer main tank and on-load tap changer
(OLTC), including both the separate diverter tank and selector tank where one exists.
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.
Six user-configurable relay contacts based on absolute gas and moisture values.
Two user-configurable sunlight-visible LED arrays on the exterior of the enclosure
–one red for alarm, one yellow for caution.
Two standard sunlight-visible LED arrays –green for power, blue for service.
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.

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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. Differences between the products are always qualified
by the use of the respective product name and operational details can be found in the
respective product user guides. 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).

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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.

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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-001 –TRANSFIX-family Installation Manual –Rev 3.0 18-Jan-16 Page 9 of 55
3REQUIREMENTS
3.1 Pre-installation
Ensure that the mains selection switch in the product is set to the relevant voltage range.
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 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: TAPTRANS packages do not include a mounting stand top section, so are unsuitable for stacking.
Note: Customers are fully responsible for ensuring that stacked pallets are stable and, if necessary,
providing additional external support. Damage incurred as a result of poor customer handling or storage
will not be covered under the GE warranty.

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4TECHNICAL SPECIFICATION
The product meets the following technical specification as listed in Table 4—1.
Table 4—1: Technical specification
PARAMETER
VALUE/MEETS
GAS MEASURED
MEASUREMENT RANGE (ppm) and accuracy
Hydrogen (H2)
5 –5,000 Accuracy ± 5% or ± LDL (whichever is greater) *1
Methane (CH4)
2 –50,000 Accuracy ± 5% or ± LDL (whichever is greater) *1
Ethane (C2H6)
2 –50,000 Accuracy ± 5% or ± LDL (whichever is greater) *1
Ethylene (C2H4)
2 –50,000 Accuracy ± 5% or ± LDL (whichever is greater) *1
Acetylene (C2H2)
0.5 –50,000 Accuracy ± 5% or ± LDL (whichever is greater) *1
Carbon Monoxide (CO)
2 –50,000 Accuracy ± 5% or ± LDL (whichever is greater) *1
Carbon Dioxide (CO2)
20 –50,000 Accuracy ± 5% or ± LDL (whichever is greater) *1
Oxygen (O2)
100 –50,000 Accuracy ± 10% or ± LDL (whichever is greater) *1
Nitrogen (N2)
(Available on free-breathing transformers
only)
10,000 –100,000 ppm Accuracy ± 15% or ± LDL (whichever is
greater) *1
Moisture (H2O)
0 –100% RS (given in ppm)
ENVIRONMENTAL
External temperature range
−40 °C to 55 °C
Oil temperature range
−20 °C to 120 °C *2
Altitude
Up to 2000 m
Atmospheric pressure
Up to 1050 mbar
Operating humidity
10 –95% RH non-condensing
Enclosure
IP55
Weight
72 kg (159 lb) TRANSFIX 1.6
88 kg (194 lb) TAPTRANS
76.5 kg (169 lb) MULTITRANS
POWER REQUIREMENTS
110 / 230 V AC*3 (factory set), 50/60 Hz, 8 A Max
Single phase Alarm Relays: NO and NC
provided
3 A 250 V AC, 150 mA 300 V DC*4, 200 mA 125 V DC, 3 A 30 V DC
Fuses *5
10 A 500 V (Cooper Bussmann BAF), 10x38 mm
MEASUREMENT FREQUENCY
Variable –Once per hour to once every 4 weeks
*1 Note: Accuracy quoted is the accuracy of detectors during calibration; gas-in-oil measurement
accuracy may also be affected by sampling and/or oil type.
*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 -20 ºC, GE recommends the use of heat trace
cabling on piping.
*3 Note: Voltage ranges:
Set Voltage (V AC)
Minimum I/P Voltage (V AC)
Maximum I/P Voltage (V AC)
110
100
121
230
207
253
*4 Note: Maximum DC breaking capacity for a resistive load.
*5 Note: Use only the approved and recommended fuse to ensure continued fire protection and
compliance.