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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TransformerCare Unit Transporting the TCU
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Training and Instruction of Personnel
The Unit may only be operated by properly trained and instructed personnel.
The areas of responsibility of your staff must be established in a clear-cut manner.
Staff undergoing training may not use the unit unless supervised by an experienced
staff member.
Individuals
Persons undergoing training
I
n
di
v
id
ua
l
s w
ith
technical training/ engineering background Electrician Supervisor with the appropriate authority
Activity
Packing
Transportation X X X
Commissioning X X X
Operation X X X X
Troubleshooting/
locating the source of malfunction X X X
Troubleshooting, mechanical
problem X X
Troubleshooting, electrical problem X X
Maintenance X X X X
Repair work X
Shutdown /
decommissioning X X X X
Transporting the TCU
For transportation, lay the TCU with the rear side facing down onto a pallet.

TransformerCare Unit Storing the TCU
Storing the TCU
Make sure to store the CM-RE in a clean, dry place, in the original packing, if
possible. Do not remove the packing until you are ready to install the unit.
Storage conditions
Storage temperature: -20°C … +40°C
Relative humidity: max. 80%, non-condensing
Decoding the model code label
For identification details of the TransformerCare Unit, see the type label. This is
located on the top of the unit and contains the exact product description and the
serial number.
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TransformerCare Unit Checking the scope of delivery
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Checking the scope of delivery
The TransformerCare Unit comes packed and ready for operation. Before
commissioning the unit, check the contents of the package to make sure everything
is present.
The following items are supplied:
Item Qty. Designation
1 1 TransformerCare Unit
1 1 Ball valve
- 1 Wiring diagram
- 1 Operating and maintenance instructions
To be provided on-site
Please have the following items at hand for installing and starting up the TCU:
Qty. Designation
1 Bucket (at least 10 liter capacity) to catch the insulating oil when filling
and bleeding the TCU and hoses
1 Canister (at least 25 liter capacity) for transporting the oil quantity
gathered.
1 Funnel for pouring the oil.
1 Suction hose
1 Return hose
1 1 bar check valve for connecting the return line to the transformer
- Fastening material such as anchors, screws, bolts and nuts for
mounting the TCU and the switch box.
- Threaded connections, flanges etc. for connection to the transformer
Items supplied
NOTICE
Impermissible operating media
The unit will be damaged
►Operate the TCU with transformer oils only.

TransformerCare Unit TCU Features
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TCU Features
The Transformer Care Unit TCU is a maintenance system for extending the service
life of transformers and reactors filled with oil.
Continuous degassing, draining and filtration of the insulating oil keeps the oxygen
content, water content and particle contamination in the transformer at a constantly
low level, increases the breakdown voltage of the insulating oil and thus improves
the operational safety and extends the service life of the insulation.
The residual service life of the transformer (open expansion vessel) can typically be
tripled.
The throughput is only ~ 15 m³ / week, preventing harmful turbulence in the
transformer.
The TCU is used during the service life, while the transformer is operational and
connected to the grid.
Effective degasification and dewatering is achieved at high oil temperatures in the
degasification and dewatering unit and at low ambient temperatures.
Increased safety: Facilitated by the monitoring function in the TCU. The operating
pressure of the degasification and dewatering unit (vacuum) is monitored. It can be
used to calculate the gas content in the oil and changes proportionally to the total
gas content in the oil.
An increase in the pressure therefore indicates increasing gas content in the oil. The
pressure switch is connected to two separate floating monitoring circuits.
Connection to a central alarm means that a warning signal is sent whenever
anything occurs in the transformer which requires a more thorough investigation.
Precise status control: After a period of continuous degasification, a stable
condition occurs in which the gas content of the oil is stabilized at a constant low
level. In this status, the error gases removed with the TCU correspond to the gas
formation rate in the transformer, which makes a clearer interpretation possible than
with a standard DGA (dissolved gas analysis).
Optimized service life:. The TCU reduces the chemical deterioration of the oil and
the solid insulation (cellulose). Permanent degasification keeps the oxygen content
at a constantly low level. As oxygen is the transformer's worst enemy, degasification
has a key influence on reducing the aging rate.
Why are water and air/oxygen dissolved in the oil?
At a natural balance, insulating oil dissolves approximately 10 percent volume of the
air on contact with atmospheric air. One third of this is oxygen. The atmospheric air
has the effect that the oil also absorbs water until it reaches the same relative
moisture as the air. In the same way, the cellulose insulation reaches the same
saturation level as the surrounding oil by diffusion.
Optimized : The TCU is equipped with a particle filter which also removes very
small particles (from 3 μm). This not only increases the dielectric strength, but also
increases the service life of the insulating oil.

TransformerCare Unit TCU components
TCU components
The TCU consists of the following components mounted on a common wall bracket
with a bottom trough. It is protected against weathering by a cover made of ABS
plastic. The electrical switching unit is to be mounted outside the cover depending
on model.
The components are as follows:
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TransformerCare Unit TCU components
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Item Designation
1 Electrical switch box. Depending on the type, not installed on the console
and must be installed outside the cover. Units built after 08/2010 must
always be installed separately and externally.
2 Motor-pump assembly
3 Patented dewatering and degasification unit
4 Clogging indicator
5 Fluid filter
6 Electronic pressure switch (EDS) for monitoring the pressure (vacuum) in
the dewatering and degasification unit, and thus indirectly the total content
in the insulating oil.
7 Pressure control valve to build up the required pressure for the
degasification and dewatering unit (20 bar)
8 Bleed screw for dewatering and degasification unit
9 Automatic shut-off valve
10 Measurement point upstream of the fluid filter for taking oil samples, e.g. for
DGA
14 Safety switch reports leaks and full safety drip tray reports problems and
deactivates the TCU
17 Filter unit bleed screw
18 Measurement point in front of the differential pressure relief valve
20 Drip tray
21 Main switch
22 AquaSensor AS 1000 (optional) for continuous measurement of the water
saturation level (relative moisture) as a percentage.
23 Gas withdrawal connection for taking gas samples. A small quantity of
insulating oil required to lubricate and seal the internal vacuum pump is
ejected here.

TransformerCare Unit Hydraulic functions
Hydraulic functions
The TCU is connected to the transformer via two hoses.
Warm oil fed from the upper section of the transformer passes through the hose (15)
to the ball valve (5) of the TCU.
The oil is returned to the transformer via the hose (16) and the check valve (19).
The check valve (19) needs to be mounted at the lower connecting point of the
transformer. This ensures that no transformer oil can run out of the transformer.
Valves (19) and (22) only allow the oil to flow in one direction.
The oil flows through the ball valve (5) and the automatic shut-off valve (9). If there
is a malfunction or if the pressure in the dewatering and degasification unit (8) rises
above 600 mbar (absolute), the shut-off valve (9) closes automatically.
The oil passes through to the suction side of the pump (2) via the fluid filter (4). The
oil flow rate of the pump is ~ 7.2 l/min (50Hz), 8.7 l/min (60Hz).
The pressure required for the degasification and dewatering unit is approx. 18 bar
and is preset using a pressure control valve (22).
The volume flow at the inlet of the degasification and dewatering unit (8) is
~ 4.5 l/min.
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TransformerCare Unit Hydraulic functions
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Depending on the cycle phase, the volume flow at the outlet of the dewatering and
degasification unit (8) varies between 0 - 7.2 l/min (50Hz), 8.7l/min (60Hz).
The volume flow fed through the valve (22) is ~ 1.5 l/min (~ 15m³ / week).
The safety switch (14) monitors the oil level in the safety drip tray.
The filter unit is equipped with a filter clogging indicator (13), which shows the
differential pressure in the filter housing via the filter element, to monitor the degree
of contamination.
The electronic pressure switch EDS (6) monitors the pressure in the dewatering and
degasification unit and is the key component of the monitoring function of the TCU,
as it allows the total gas content in the insulating oil to be monitored.
Two monitoring pressures are preset in the pressure sensor:
The 'Alarm pressure' (SP2) is used to monitor a possible increase in the
overall gas content in the insulating oil. As the total gas content decreases
continuously during the first months after installation, the 'alarm pressure'
must be adapted to the current pressure.
The TCU is not deactivated automatically when the alarm pressure is
reached. The signal lamp in the switch box illuminates, and a signal can be
sent to an external location via the alarm interfaces in the switch cabinet.
The stopping pressure (SP1) acts as a safety function, e.g. in the event of a
malfunction of the degasification and dewatering unit and corresponding
increasing pressure in the unit.
The TCU is not deactivated automatically when the stopping pressure (SP1)
is reached.

TransformerCare Unit Hydraulic functions
7
Item Designation Example
mbar
(absolute)
1 Normal operating pressure level fluctuates
between a lower (minimum oil level in the
degasification and dewatering unit) and an
upper pressure (maximum oil level).
110 … 230
2 The alarm pressure (SP2) should be ~ 20 %
above the pressure currently shown (upper
pressure).
At least 20 mbar higher than the actual
pressure.
270
3 Stopping pressure (SP1): 600 mbar. After
expiry of a preset delay (K1), the TCU
deactivates automatically.
600
4 Atmospheric pressure 1013
5 The signal lamp illuminates
6 Absolute pressure
7 Absolute vacuum 0
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TransformerCare Unit Electric functions
Electric functions
The control module is split into a main circuit and a control circuit:
The main circuit powers the electric motor via gates which are operated by
the control circuit.
The control circuit is a 24 V DC circuit supplied by the main circuit via the
fuse (F1) and the transformer (T1).
After switching on the main circuit, the motor-pump assembly starts the supply and
the time relay (K1) begins counting down the preset, adjustable time delay from ~ 5
minutes.
This delay time is required so that the TCU has enough time to build up a pressure
level inside the degasification and dewatering unit which is below the preset
stopping pressure (SP1) on the electronic pressure switch EDS (6) at 600 mbar.
This avoids early deactivation of the system.
The signal at the switching output is permanently voltage-carrying.When the delay
time has expired, the stopping pressure (SP1) of the electronic pressure switch EDS
(6) is not reached and the safety switch (14) of the safety drip tray or of the optional
float switch in the collecting canister (optional) is not switched, the gate (K3)
switches the electric motor of the pump on permanently.
Make sure the alarm functions, for example, the stopping pressure (SP1) or the
safety switch (14) in the safety drip tray, are deactivated for the duration of the delay
time. Similarly, after power failure or resumption of the power supply and a restart of
the delay time, the alarm functions must be deactivated.
The gate (K3) remains activated thanks to the electronic pressure switch EDS (6),
the safety switch (14) in the safety drip tray and in the optional float switch in the
collecting canister. It is deactivated as soon as the stopping pressure (SP1) of the
EDS is reached, the safety switch in the drip tray or the float switch in the collecting
canister (optional) is switched.
If the TCU stops because the stopping pressure (SP1) of the EDS (6) is reached,
you must restart the TCU manually. This is done by deactivating and reactivating the
main switch. The TCU is then restarted with a new delay time. If the system stops
after restarting, this indicates a fault in the system. See chapter Measures to be
taken if operation is stopped in this connection.
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