HYDAC FILTER SYSTEMS TCU Series Manual

TCU
TransfomerCare Unit
Operating and maintenance instructions
English (translation of original instructions)
Document no.: 3472805b

TransformerCare Unit Trademarks
Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2011 by
HYDAC FILTER SYSTEMS GMBH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
express written consent of HYDAC FILTER SYSTEMS GMBH. Contraventions are
liable to compensation.
Exclusion of Liability
We made every endeavor to ensure the accuracy of the contents of this document.
However, errors cannot be ruled out. Consequently, we accept no liability for such
errors as may exist nor for any damage or loss whatsoever which may arise as a
result of such errors. The content of the manual is checked regularly. Any
corrections required will be incorporated in future editions. We welcome any
suggestions for improvements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC FILTER SYSTEMS GMBH
Postfach 12 51
66273 Sulzbach / Saa
r
Germany
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GMBH, Industriegebiet, 66280 Sulzbach / Saar
Telephone: ++49 (0)6897 509 1511
Telefax: ++49 (0)6897 509 1394
E-mail: [email protected]
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TransformerCare Unit Content
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Content
Trademarks ...............................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ...................................................................................................................... 5
Technical Support...................................................................................................6
Modifications to the Product ...................................................................................6
Warranty .................................................................................................................6
Using the Documentation .......................................................................................7
Safety Information and Instructions....................................................................... 8
Obligations and Liability.......................................................................................... 8
Explanation of Symbols and Warnings, etc. ...........................................................9
Proper/Designated Use .......................................................................................... 9
Improper Use .......................................................................................................... 9
Informal Safety Precautions.................................................................................. 10
Electrical Hazards.................................................................................................10
Training and Instruction of Personnel ...................................................................11
Transporting the TCU ............................................................................................11
Storing the TCU ...................................................................................................... 12
Storage conditions ................................................................................................12
Decoding the model code label ............................................................................12
Checking the scope of delivery ............................................................................13
To be provided on-site........................................................................................... 13
Items supplied....................................................................................................... 13
TCU Features ..........................................................................................................14
TCU components.................................................................................................... 15
Hydraulic functions ................................................................................................ 17
Electric functions ...................................................................................................20
TCU Dimensions / Drilling Template..................................................................... 21
Installing the TCU................................................................................................... 22
Notes on piping / hosing .......................................................................................23
Connecting the suction line................................................................................... 24
Connecting the return line.....................................................................................24
Collecting the lubricating and sealing oil...............................................................25
Accessories "Collecting canister with float switch"............................................ 26
Electrical connection of the TCU .......................................................................... 27
Floating contacts...................................................................................................28
Connections with potential ................................................................................28
Connecting the collecting canister float switch (optional).................................. 29
Filling and bleeding the TCU and connections ................................................... 30
Bleeding the suction hose..................................................................................... 30
Filling and bleeding the TCU ................................................................................ 31

TransformerCare Unit Content
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Bleeding the return connection on the transformer............................................... 31
Bleeding the return hose.......................................................................................32
Starting up the TCU................................................................................................33
TCU in operation ....................................................................................................34
Start / Stop............................................................................................................ 34
Settings.................................................................................................................34
Setting the time relay (K1)................................................................................. 34
Setting the electronic pressure switch (EDS).................................................... 35
EDS operating elements................................................................................ 35
EDS digital display......................................................................................... 35
Setting EDS switchpoints for the alarm and stopping pressure.....................36
EDS factory settings ...................................................................................... 36
Setting EDS hysteresis and switchpoint ........................................................ 37
EDS error messages ..................................................................................... 38
Status monitoring................................................................................................... 39
Monitoring the overall gas content in the oil continuously ....................................39
Continuous water content monitoring (optional) ...................................................40
Checking the gas and water content in the oil ......................................................41
Oil samples for gas analysis (DGA) .................................................................. 41
Specifying the gas formation rate of the transformer............................................ 43
Checking the TCU / Servicing ............................................................................... 47
Periodical check-up - monthly............................................................................... 48
Maintenance - annual ...........................................................................................48
Checking the degasification and dewatering unit for function ...........................49
Cleaning the check valve of the degasification and dewatering unit.................50
Changing the Filter Element.............................................................................. 52
Checking the safety switch of the drip tray for function..................................... 54
General overhaul .................................................................................................. 54
Troubleshooting and measures after an alarm/failure........................................ 55
Measures when the alarm pressure level is reached............................................55
Measures to be taken if operation is stopped .......................................................56
Checking the pump pressure / pressure restriction valve..................................... 57
Setting the differential pressure relief valve.......................................................... 58
Draining and decommissioning the TCU ............................................................. 59
Disposing of the TCU............................................................................................. 60
Spare parts and accessories................................................................................. 61
Technical Data ........................................................................................................62
Customer Service................................................................................................... 62

TransformerCare Unit Preface
Preface
For you, as the owner of a product manufactured by us, we have produced this
manual, comprising the most important instructions for its operation and
maintenance.
It will acquaint you with the product and assist you in using it as intended in an
optimal manner.
Keep it in the vicinity of the product so it is always available.
Note that the information on the unit's engineering contained in the documentation
was that available at the time of publication.There may be deviations in technical
details, figures, and dimensions as a result.
If you discover errors while reading the documentation or have additional comments
or suggestions, contact us at:
HYDAC FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
The editorial department looks forward to receiving your input.
“Putting experience into practice”
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TransformerCare Unit Preface
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Technical Support
Contact our technical sales department if you have any questions on our product.
When contacting us, please always include the model/type designation, serial no.
and part-no. of the product:
Telefax: ++49 (0)6897 509 846
E-mail: [email protected]
Modifications to the Product
We would like to point out that changes to the product (e.g. purchasing additional
options, etc.) may mean that the information in the operating instructions is no
longer applicable or adequate.
After modification or repair work that affects the safety of the product has been
carried out on components, the product may not be returned to operation until it has
been checked and released by a HYDAC technician.
Please notify us immediately of any modifications made to the product whether by
you or a third party.
Warranty
For the warranty provided by us, please refer to the General Terms of Sale and
Delivery of HYDAC FILTER SYSTEMS GMBH.
Refer to these at www.hydac.com General terms and conditions.

TransformerCare Unit Preface
Using the Documentation
Note that the method described for locating specific information does
not release you from your responsibility of carefully reading these
instructions prior to starting the unit up for the first time and at
regular intervals in the future.
What do I want to know?
I determine which topic I am looking for.
Where can I find the information I’m looking for?
The documentation has a table of contents at the beginning. There, I select
the chapter I'm looking for and the corresponding page number.
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Chapter description
Page number
Edition date
Document language
Documentation no.
with index/
file name
The documentation number with its index enables you to order another copy of the
operating and maintenance instructions. The index is incremented every time the
manual is revised or changed.

TransformerCare Unit Safety Information and Instructions
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Safety Information and Instructions
These operating instructions contain the key instructions for properly and safely
operating the Unit.
Obligations and Liability
The basic prerequisite for the safe and proper handling and operation of the unit is
knowledge of the basic safety instructions and safety regulations.
These operating instructions in general, and the safety precautions in particular, are
to be adhered to by all those who work with the Unit.
Adherence is to be maintained to pertinent accident prevention regulations
applicable at the site where the product is used.
The safety instructions listed here are restricted to use of the unit.
The TCU is built to be state of the art and in compliance with the technical safety
regulations. Nevertheless, hazards may be posed to the life and limb of the
individual using the product or to third parties. Risk of damage may be posed to the
product or other equipment and property.
The Unit is to be used only:
solely for its designated use
only when in a safe, perfect condition
Immediately remedy any malfunctions that might impair safety.
Our General Terms and Conditions apply. They are made available to the owner
upon concluding purchase of the unit at the latest. Warranty and liability claims for
personal injuries and damage to property shall be excluded in the event they are
attributable to one or more of the following causes:
Improper use of the unit or use deviating from its designated use
improper assembly/installation, start up, operation and maintenance of the unit
modifications to the Unit made by the user or purchaser
Improper monitoring of unit components that are subject to wear and tear
improperly performed repair work

TransformerCare Unit Safety Information and Instructions
Explanation of Symbols and Warnings, etc.
The following designations and symbols are used in this manual to designate
hazards, etc.:
DANGER
DANGER denotes situations
which can lead to death if
safety precautions are not
observed.
WARNING
WARNING indicates
hazardous situations which
can result in fatal injuries if
not complied with.
CAUTION
CAUTION denotes situations
which can lead to severe
injuries if safety precautions
are not observed.
NOTICE
NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
Proper/Designated Use
The TransformerCare Unit was designed for stationary, continual degassing and
dewatering of transformer oil.
Any other use shall be deemed to be improper and not in keeping with the product's
designated use.
Proper or designated use of the product extends to the following:
Permanent degassing and dewatering of transformer oil
Maintaining adherence to all the instructions contained herein.
Improper Use
Improper use may result in hazard to life and limb.
Examples of improper use:
Improper connection of the Unit voltage and sensor cables.
Operation with non-approved fluids.
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TransformerCare Unit Safety Information and Instructions
Informal Safety Precautions
Apart from the operating instructions, any and all general and local regulations
pertaining to accident prevention and environmental protection are to be made
available and observance is to be maintained to them.
Make sure that the safety and hazard symbols and warnings on the unit are always
in a legible condition. Replace them if necessary.
Check the connection parts for leaks on a daily basis.
Check the TCU electrical equipment on a monthly basis. Immediately replace loose
connections, damaged cables and hoses with original spare parts.
WARNING
Hydraulic systems are under pressure
Danger of bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.
Electrical Hazards
DANGER
Electric shock
Danger of fatal injury
►Any work involving electrical equipment may only
be done by a properly trained, certified electrician.
Only install the TCU in transformers which are disconnected from the grid and
grounded.
Make the changes to the connections to the transformer only when the transformer
has been shut down and grounded.
Service work and sampling on the TCU can be performed with the transformer
running.
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