LumaSense LumaSMART User manual

USER MANUAL
LumaSMART®
Fiber Optic Winding Hot Spot Temperature Monitor and Controller for Power
Transformers

Confidential Information
The material contained herein consists of information that is the property of LumaSense Technologies | An
Advanced Energy Company and intended solely for use by the purchaser of the equipment described in this
manual.
All specifications are subject to change without notice. Changes are made periodically to the information in this
publication, and these changes will be incorporated in new editions.
LumaSense Technologies prohibits the duplication of any portion of this manual or the use thereof for any purpose
other than the operation or maintenance of the equipment described in this manual, without the express written
permission of LumaSense Technologies or Advanced Energy Industries, Inc. Any unauthorized use of this manual or
its contents is strictly prohibited.
Copyright
© 2018 LumaSense Technologies, Inc. All rights reserved. LumaSense Technologies, Inc. is a subsidiary of Advanced
Energy Industries, Inc.
Trademarks
LumaSMART, LUXTRON, and Fluoroptic are trademarks of LumaSense Technologies.
All other trademarks are trademarks, registered trademarks, and/or service marks of their respective holders.
Service Centers
LumaSense Technologies, Inc.
North America
Sales & Service
Santa Clara, CA, USA
Ph: [phone]
Ph: [phone]
Fax: [phone]
LumaSense Technologies GmbH
Other Than North America
Sales & Support
Frankfurt, Germany
Ph: [phone]
Fax: [phone]
Global and Regional Centers
Our Headquarters
LumaSense Technologies, Inc.
Santa Clara, CA, USA
Ph: [phone]
Fax: [phone]
Americas, Australia, & Other Asia
LumaSense Technologies, Inc.
Santa Clara, CA, USA
Ph: [phone]
Fax: [phone]
Europe, Middle East, Africa
LumaSense Technologies GmbH
Frankfurt, Germany
Ph: [phone]
Fax: [phone]
France
LumaSense Technologies Sarl Erstein,
France
Ph: [phone]
Fax: [phone]
India
LumaSense Technologies, India
Mumbai, India
Ph: + 91 22 67419203
Fax: + 91 22 67419201
China
LumaSense Technologies, China
Shanghai, China
Ph: [phone]
Ph: [phone]
Email [e-mail]
[e-mail]
[e-mail]
Website http://www.lumasenseinc.com
Part No 38-15207-01
Revision J
September 2018

LumaSMART®User Manual Contents •iii
Contents
1General .................................................................................................................................................... 9
1.1 Information about the User Manual............................................................................................... 9
1.2 Software Upgrade Release Notes ................................................................................................... 9
1.3 Legend............................................................................................................................................ 9
1.4 Limit of Liability and Warranty ....................................................................................................... 9
1.5 Unpacking and Inspection ............................................................................................................ 10
1.6 Malfunction or Service Request.................................................................................................... 10
1.7 Shipments to LumaSense for Repair............................................................................................. 10
1.8 Disposal / Decommissioning......................................................................................................... 11
2Introduction........................................................................................................................................... 13
2.1 System Overview.......................................................................................................................... 13
2.1.1 System Organization .............................................................................................................14
2.2 Theory of Operation..................................................................................................................... 14
2.2.1 Temperature Sensor..............................................................................................................14
2.2.2 Extracting Temperature from Phosphorescent Decay Time .................................................15
2.3 System Components..................................................................................................................... 15
2.3.1 LumaSMART®Controller........................................................................................................15
Internal Components.......................................................................................................16
Display .............................................................................................................................16
SBC and Comm Board......................................................................................................16
Power Supply...................................................................................................................16
Fiber Optic Thermometer Module ..................................................................................16
Relay Module...................................................................................................................17
Interconnect Board..........................................................................................................17
Analog Output .................................................................................................................17
Front Features .................................................................................................................18
Back Features ..................................................................................................................19
Bottom Features..............................................................................................................20
Base Unit FOT Connections .............................................................................................20
Base Unit Relay Connections ...........................................................................................21
Base Unit Communications and Power Connections ......................................................22
Base Unit Access Panel ....................................................................................................22
FOT Module Connections ................................................................................................23
Control Module Connections ..........................................................................................23
Operating Specifications..................................................................................................24
Configuration Options .....................................................................................................26
2.3.2 Probes ...................................................................................................................................26
Probe Design ...................................................................................................................26
Service Life.......................................................................................................................27
2.3.3 Diagnostic Instrument...........................................................................................................27
2.4 User Benefits................................................................................................................................ 27
2.4.1 Transformer Design Integrity and Manufacturing Quality Verification ................................27

LumaSMART®User Manual Contents •iv
2.4.2 Transformer Protection and Life Extension with Real-Time Cooling Control .......................27
2.4.3 Increased Transformer Loading to the Safe Maximum.........................................................28
2.4.4 External Communication and Monitoring Connections........................................................28
2.4.5 Extract Additional MVA Rating Existing Inherently in Every Transformer Design.................28
3Installation of Probes and Accessories ................................................................................................... 29
3.1 Pre-Installation Planning .............................................................................................................. 29
3.2 Installation Philosophy................................................................................................................. 30
3.2.1 General Guidelines for FOT Installation ................................................................................30
3.2.2 FOT Installation Guidelines for Common Designs.................................................................31
Three Phase Wye-Wye or Delta-Wye Sub-Transmission Transformers Feeding
Distribution Systems........................................................................................................31
Loaded Tertiary (3rd Winding) ........................................................................................31
Buried Tertiary that is Delta Connected ..........................................................................31
Three Phase Wye-Wye, Delta-Wye, Autotransformer Used for Transmission Step Down
or Step Up and Generator Step-Up Unit (GSU) Transformers.........................................31
Single Phase Transformers—Autotransformer and GSU.................................................32
Top Oil Measurement......................................................................................................32
3.3 Handling the Fiber ........................................................................................................................ 32
3.3.1 Fiber Optic Cable Handling Precautions................................................................................33
3.4 Installing the Probes..................................................................................................................... 34
3.4.1 Sensor Installation Guidelines...............................................................................................35
Sensor Tip Placement ......................................................................................................35
3.4.2 Installing Probe Tip in a Core Form Transformer ..................................................................35
Radial Spacer Design .......................................................................................................36
3.4.3 Installing Probe Tip in a Shell Form Transformer ..................................................................38
3.4.4 Alternate Probe Tip Installation Methods.............................................................................39
3.4.5 Probe Routing inside the Transformer..................................................................................40
3.5 Installing the Tank Wall Adapter Plate ......................................................................................... 40
3.6 Installing the Tank Wall Plate Assembly ....................................................................................... 42
4Installation of the LumaSMART® Controller ............................................................................................ 43
4.1 Mounting and Installing the LumaSMART Controller.................................................................... 44
4.1.1 Installing the Wall-Mount LumaSMART Controller...............................................................44
4.1.2 Installing the Panel-Mount LumaSMART ..............................................................................45
4.2 Installing the External Fiber Optic Extension Cable....................................................................... 46
4.3 Installing the Electrical Wiring ...................................................................................................... 47
4.3.1 Power Wiring.........................................................................................................................48
4.3.2 Analog Output Wiring ...........................................................................................................48
Current Loop Considerations...........................................................................................49
4.3.3 Relay Output Wiring..............................................................................................................50
System Status Relay.........................................................................................................50
4.3.4 Optional Communication Wiring ..........................................................................................51
4.4 Starting up the Instrument ........................................................................................................... 52
4.5 Testing the Probe Signal Strength................................................................................................. 52
5Using the Software ................................................................................................................................ 53
5.1 Home Screen ................................................................................................................................ 53
5.1.1 Viewing All Relays .................................................................................................................53
5.1.2 Viewing All Temperatures .....................................................................................................54
5.1.3 Viewing Signal Strength.........................................................................................................54

LumaSMART®User Manual Contents •v
5.2 Main Menu................................................................................................................................... 55
5.2.1 Setup .....................................................................................................................................55
Transformer Info Setup ...................................................................................................57
Date & Time.....................................................................................................................58
Administrator Tools.........................................................................................................58
Download Firmware ........................................................................................................59
Change Authentication Code...........................................................................................61
Export/Import Configuration File ....................................................................................61
Stop Watchdog for 5 minutes..........................................................................................62
Relay Tests.......................................................................................................................62
Serial Number..................................................................................................................62
Relay & Control................................................................................................................62
Status System Relay.........................................................................................................63
Relay Setup......................................................................................................................63
Analog Outputs................................................................................................................65
Channel Setup .................................................................................................................67
5.2.2 Transformer Info ...................................................................................................................67
5.2.3 Battery Life ............................................................................................................................68
5.2.4 Display ...................................................................................................................................69
5.2.5 Data Log Export.....................................................................................................................69
5.2.6 Diagnostics ............................................................................................................................71
Sensor Channel Diagnostics.............................................................................................71
Relay Testing/Simulation.................................................................................................72
Erase Data Log .................................................................................................................72
File Viewer .......................................................................................................................73
System Status Viewer ......................................................................................................73
System Status Relay History ............................................................................................74
Configuration...................................................................................................................74
Service Diagnostic Log .....................................................................................................74
Data Graph Log................................................................................................................74
Data Graph Zoom Feature...............................................................................................76
Communication and Protocols ........................................................................................77
Select Interface................................................................................................................77
Setup RS485 Interface Parameters..................................................................................78
Setup TCP/IP Ethernet Interface Parameters ..................................................................78
Setup DNP3......................................................................................................................79
Setup Modbus .................................................................................................................80
Setup IEC61850 over Ethernet TCP/IP.............................................................................80
6Modbus Protocol Testing ....................................................................................................................... 81
6.1 Configuring Modbus Poll in LumaSMART over RS485 ................................................................... 81
6.2 Configuring the Modbus Poll program on a PC ............................................................................. 82
6.3 Testing Modbus Functions............................................................................................................ 83
6.3.1 Read Coils (0x01) ...................................................................................................................83
6.3.2 Read Discrete Input Status (0x02).........................................................................................84
6.3.3 Holding Registers (0x03, 0x06, 0x16) ....................................................................................84
6.3.4 Input Registers (0x04) ...........................................................................................................86
6.4 Sample Relay Setup over Modbus ................................................................................................ 87
6.5 Modbus Register Map .................................................................................................................. 89
6.5.1 Modbus Coil Status ...............................................................................................................89
6.5.2 Modbus Input Status.............................................................................................................90
6.5.3 Modbus Holding Register......................................................................................................90

LumaSMART®User Manual Contents •vi
6.5.4 Modbus Input Register..........................................................................................................96
7IEC 61850 Protocol Testing..................................................................................................................... 99
7.1.1 Test Setup..............................................................................................................................99
7.2 Configuring IEC 61850 in LumaSMART and TMW Hammer ......................................................... 100
7.3 Connecting the LumaSMART and TMW Hammer ....................................................................... 102
7.4 Sample Relay Setup.................................................................................................................... 103
7.5 Report Control............................................................................................................................ 105
7.6 IEC61580 Channel Temperature Alarm....................................................................................... 106
7.6.1 Example for Channel 4 alarm ..............................................................................................106
7.7 IEC61850 Channel Signal Strength Alarm.................................................................................... 108
7.7.1 Example for Channel 4 alarm ..............................................................................................108
7.8 IEC61580 Register Maps ............................................................................................................. 109
7.8.1 IEC61850 Temperature Channel Control and Supervision..................................................109
7.8.2 IEC61850 Relay Channel Control and Supervision ..............................................................111
7.8.3 IEC61850 FOT Setup and Status Monitoring .......................................................................112
7.8.4 IEC61850 System Status Relay Report ................................................................................113
7.8.5 IEC61850 General System Configuration Information ........................................................114
7.8.6 IEC61850 Report Contents - Temperatures and Relays ......................................................115
7.8.7 IEC61850 Reports Channel Temperature and Probe Signal Strength Alarms .....................116
7.8.8 IEC61850 Probe Signal Strength levels................................................................................116
8DNP3 Protocol Testing ......................................................................................................................... 117
8.1 Configuring DNP3 in LumaSMART (Ethernet TCP/IP) .................................................................. 118
8.2 Testing Harness Window Components ....................................................................................... 119
8.3 DNP3 Enable Unsolicited Reports............................................................................................... 121
8.4 Binary Inputs Data...................................................................................................................... 121
8.5 Binary Outputs ........................................................................................................................... 122
8.6 Analog Inputs ............................................................................................................................. 124
8.7 Analog Output Statuses.............................................................................................................. 126
8.7.1 Configuring FOT Analog Outputs.........................................................................................126
8.7.2 Configuring Relay Operation ...............................................................................................128
8.8 DNP3 Register Map .................................................................................................................... 131
8.8.1 DNP 3 Binary Output Map...................................................................................................131
8.8.2 DNP 3 Binary Input Map......................................................................................................132
8.8.3 DNP 3 Analog Output Map..................................................................................................133
8.8.4 DNP 3 Analog Input Map.....................................................................................................137
9Data Manager ...................................................................................................................................... 139
9.1 Data Report Content .................................................................................................................. 139
9.2 Data Retrieval ............................................................................................................................ 139
9.3 Operation During Data Retrieval Mode ...................................................................................... 140
10 User Commands................................................................................................................................... 141
10.1 Command Rules, Syntax, and Returns ........................................................................................ 141
10.2 rtrv Command ............................................................................................................................ 142
11 Maintenance........................................................................................................................................ 143
11.1 Battery Replacement.................................................................................................................. 143

LumaSMART®User Manual Contents •vii
12 Appendix ............................................................................................................................................. 145
12.1 Third Party Suppliers .................................................................................................................. 145
12.2 List of Tables .............................................................................................................................. 146
Index........................................................................................................................................................... 147

LumaSMART®User Manual Contents •viii
To ensure consistent document formatting, this page was intentionally left blank.

LumaSMART®User Manual General •9
1General
1.1 Information about the User Manual
This manual provides important information that can be used as a work of reference for installing, operating, and
maintaining your LumaSense Fiber Optic Winding Hot Spot Temperature Monitor and Controller (LumaSMART®
controller). This manual is for software version 3.2.3.0 and above.
It is important that you carefully read the information contained in this manual and follow all safety procedures
before you install or operate the system. To avoid handling or configuration errors, keep this manual in a location
where it will be readily accessible.
1.2 Software Upgrade Release Notes
This software package is also being released as an upgrade for existing LumaSMART installations. Changes in the
4.1.0.4 release of software effect the operation of the communications protocols – Chapter 7 IEC61850, Chapter 8
DNP3, and Chapter 6 ModBus. If you are upgrading an existing version of the software prior to Version 4.0.0.0 and
use any of those protocols, please review those sections of the manual as the mapping of functions and registers
has changed.
The control of the System Status Relay has changed and the logic has been inverted. Please see Section 4.3.3.1
System Status Relay for proper wiring instructions.
In addition, the contents of the user stored values of configuration have changed. If you are upgrading from a
version prior to 3.2.2.0, use Data Log Export (Section 5.2.5) to get a list of your current configuration prior to
upgrading. It may be needed to manually restore the selected operational parameters.
1.3 Legend
Note: The note symbol indicates tips and useful information in this manual. All notes should be read
to effectively operate the instrument.
Caution: The caution symbol denotes information critical to avoiding instrument damage or a severe
impact to processing. When this symbol is found on the instrument it indicates a potential hazard.
Consult the documentation before proceeding with any actions.
Warning: The warning symbol denotes information critical to avoiding personal injury, such as when
an electrical hazard is present. When this symbol is found on the instrument it indicates a
potential hazard. Consult the documentation before proceeding with any actions.
1.4 Limit of Liability and Warranty
All general information and notes for handling, maintenance, and cleaning of this instrument are offered according
to the best of our knowledge and experience.
LumaSense Technologies is not liable for any damages that arise from the use of any examples or processes
mentioned in this manual or in case the content of this document should be incomplete or incorrect. LumaSense
Technologies reserves the right to revise this document and to make changes from time to time in the content
hereof without obligation to notify any person or persons of such revisions or changes.

LumaSMART®User Manual General •10
All LumaSMART®instruments from LumaSense Technologies have a regionally effective warranty period. Please
check our website at http://info.lumasenseinc.com/warranty for up-to-date warranty information. This warranty
covers manufacturing defects and faults which arise during operation, only if they are the result of defects caused
by LumaSense Technologies.
A LumaSMART instrument only has one user-serviceable component: the clock battery. Disassembly of the
instrument otherwise is not allowed. The warranty is VOID if the instrument is disassembled, tampered with,
altered, or otherwise damaged without prior written consent from LumaSense Technologies; or if considered by
LumaSense Technologies to be abused or used in abnormal conditions.
1.5 Unpacking and Inspection
Save all packing materials, including the carrier’s identification codes, until you have inspected the system
components and find that there is no obvious or hidden damage. Before shipment, the system components were
examined and tested.
When unpacking and inspecting your system components:
1. Check all materials in the container against the enclosed packing list.
2. Carefully unpack and inspect all components for visible damage.
3. If you note any damage or suspect damage, immediately contact the carrier and LumaSense Technologies,
Inc.
LumaSense Technologies cannot be responsible for shortages against the packing list unless a claim is
immediately filed with the carrier. Final claim and negotiations with the carrier must be completed by the
customer.
1.6 Malfunction or Service Request
Contact LumaSense Technologies Technical Support in case of a malfunction or service request. Provide clearly
stated details of the problem as well as the instrument model number and serial number. Upon receipt of this
information, Technical Support will attempt to locate the fault and, if possible, solve the problem over the
telephone.
If Technical Support concludes that the instrument must be returned to LumaSense Technologies for repair, they
will issue a Return Material Authorization (RMA) number.
Return the instrument upon receipt of the RMA number, transportation prepaid. Clearly indicate the assigned RMA
number on the shipping package exterior. Refer to Section 1.6, Shipments to LumaSense for Repair, for shipping
instructions.
Technical Support can be contacted by telephone or email:
Santa Clara, California
Frankfurt, Germany
Telephone: [phone]
[phone]
Email: [e-mail]
Telephone: [phone]
Email: [e-mail]
1.7 Shipments to LumaSense for Repair
All RMA shipments of LumaSense Technologies instruments are to be prepaid and insured by way of preferred
carrier. For overseas customers, ship units air-freight, priority one.
The instrument must be shipped in the original packing container or its equivalent. LumaSense Technologies is not
responsible for freight damage to instruments that are improperly packed.
Clearly indicate the assigned RMA number on the shipping package exterior. If no RMA is indicated, shipment will
not be accepted.