LumaSense SmartDGA User manual

PRE-INSTALLATION MANUAL
SmartDGA
®

Confidential Information
The material contained herein consists of information that is the property of LumaSense
Technologies, Inc. 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, Inc. 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.
Copyright
© LumaSense Technologies 2016. All rights reserved.
Trademarks
SmartDGA, SmartDGA Guide, SmartDGA Gauge, SmartDGA Guard, SmartDGA EZHub, LumaSMART
iCore, DGA Viewer, SmartDGA Diagnostics Software, and LumaSMART are trademarks of LumaSense
Technologies, Inc. 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
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
Ph: [phone]
Fax: [phone]
Americas, Aust
ralia, & Other Asia
LumaSense Technologies, Inc.
Santa Clara, CA
Ph: [phone]
Fax: [phone]
Europe, Middle East, Africa
LumaSense Technologies GmbH
Frankfurt, Germany
Ph: [phone]
Fax: [phone]
Brazil
LumaSense, Vendas Brasil
Campinas, Brasil
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]
E-mail [e-mail]
[e-mail]
[e-mail]
Website http://www.LumaSenseinc.com
Part No 515-0012-01
Revision A
July 2016

SmartDGA Pre-Installation Manual General ∂3
Contents
1General...........................................................................................................................7
1.1 Information about this Manual ............................................................................ 7
1.2 Legend ...................................................................................................................7
1.3 Limit of Liability and Warranty ............................................................................7
2Verification of Pre-Installation Tasks ...........................................................................8
3System Overview........................................................................................................... 9
3.1 System Components.............................................................................................. 9
3.1.1 SmartDGA® Instruments.....................................................................................9
3.1.2 SmartDGA EZHubTM Unit....................................................................................10
3.1.3 LumaSMART iCoreTM Controller (Optional) .......................................................10
3.1.4 NEMA 4X Enclosure (Optional) .........................................................................10
3.1.5 Sunshade (Optional)..........................................................................................11
4Technical Specifications ..............................................................................................13
5Transformer and LTC Criteria......................................................................................17
5.1 Transformer Criteria............................................................................................17
5.2 LTC Criteria .......................................................................................................... 17
6Plumbing......................................................................................................................20
6.1 Transformer Valves .............................................................................................20
6.1.1 Drain Valve........................................................................................................20
6.1.2 Fill Valve ............................................................................................................20
6.1.3 Ancillary Valves..................................................................................................20
6.2 SmartDGA Valve Kits...........................................................................................21
6.2.1 Single Valve Kit (VA-1) ......................................................................................21
6.2.2 Dual Valve Kit (VA-2).........................................................................................21
6.2.3 Inline Valve Kit (VA-0) ....................................................................................... 22
6.2.4 Optional Extra Valve with Tee ..........................................................................22
7Mounting for the SmartDGA Instrument...................................................................23
7.1 Clearance around the Mounting Location ......................................................... 23
7.1.1 Minimum Clearances (at drain valve or mounting plate location) ...................23
7.2 Criteria for Single Valve Mounting (VA-1).........................................................24
7.2.1 Thread Type of the Drain Valve ........................................................................ 24

SmartDGA Pre-Installation Manual General ∂4
7.3 Criteria for Dual Valve Mounting (VA-2)............................................................ 25
7.3.1 Thread Type of the Drain Valve ........................................................................ 25
7.3.2 Thread Type of the Return Valve......................................................................25
7.3.3 Distance between the Drain Valve and Return Valve....................................... 25
7.4 Criteria for Transformer Inline Mounting (VA-0)............................................... 26
7.4.1 Mounting Plate Support....................................................................................26
7.4.2 Thread Type of the Sample and Return Valves.................................................26
7.4.3 Distances to the Supply and Return Valves....................................................... 26
7.5 Criteria for LTC Inline Mounting (VA-0) ............................................................. 27
7.5.1 Mounting Plate Support....................................................................................27
7.5.2 Thread Type of the Sample and Return Valves.................................................27
8Tubing .......................................................................................................................... 29
9Mounting for the EZHub .............................................................................................31
9.1 Mounting Type and Location.............................................................................. 31
9.2 Distance to the SmartDGA Instrument .............................................................. 32
9.3 Power for the EZHub ...........................................................................................33
10 Mounting for the LumaSMART iCore (optional)........................................................ 35
10.1 Mounting Type and Location.............................................................................. 35
10.2 Distance to the EZHub......................................................................................... 36
10.3 Power for External Computer or iCore ..............................................................37
11 Communications.......................................................................................................... 39
11.1.1 RS845 Connection..............................................................................................40
11.1.2 Ethernet Connection .........................................................................................40
11.1.3 Data Communications ....................................................................................... 42
12 Additional Mounting Examples.................................................................................. 43
13 Overview of Installation Services...............................................................................49
13.1 Installation........................................................................................................... 49
13.1.1 Provided by LumaSense..................................................................................... 49
13.1.2 Not provided by LumaSense..............................................................................49
13.2 Commissioning....................................................................................................50
13.2.1 Provided by LumaSense..................................................................................... 50
13.2.2 Not provided by LumaSense..............................................................................50
14 Tools Needed for Installation ..................................................................................... 51
14.1 Tools Provided by LumaSense ............................................................................ 51
14.2 Tools Not Provided by LumaSense .....................................................................51

SmartDGA Pre-Installation Manual General ∂5
15 Drawings and Diagrams..............................................................................................53
15.1 SmartDGA Instrument Dimensions .................................................................... 53
15.2 Unistrut Stand Drawings & Build of Material .................................................... 54
15.3 NEMA 4X Enclosure with Inline Mount .............................................................. 57
15.4 NEMA 4 Drawings & Build of Material ...............................................................58
15.5 Assy, NEMA 4, EZHub.............................................................................................. 61
15.6 Sunshade Dimensions for SmartDGA Instrument ............................................. 62
15.7 Assy, Sunshade, SmartDGA Instrument .............................................................63
15.8 Inline Mounting Plate ......................................................................................... 64
15.9 Assy, Cable, I/O Instrument, EZHub ....................................................................65
15.10 Wiring Connection ....................................................................................... 66
15.11 Assy, Wall Mount, EZHub............................................................................. 67
15.12 Assy, Panel Mount, EZHub ...........................................................................68
15.13 Assy, Wall Mount, LumaSMART iCore ......................................................... 69
15.14 Assy, Panel Mount, LumaSMART iCore .......................................................70
15.15 iCore RS485 Connections ............................................................................. 71
15.16 iCore Ethernet Connections.........................................................................72
15.17 Multiple EZHub Setup with Ethernet Hub...................................................73
Index ..................................................................................................................................75

SmartDGA Pre-Installation Manual General ∂6
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SmartDGA Pre-Installation Manual General ∂7
1General
1.1 Information about this Manual
This manual provides important information about planning and preparing for the installation of a
SmartDGA monitoring system. It is important that you carefully read the information
contained in this manual in its entirety prior to installation in order to properly prepare
the site and obtain the necessary equipment.
After you receive and review this pre-installation manual, your Regional Sales Manager (RSM) will
work with you to complete a SmartDGA Pre-Order Checklist (for each SmartDGA Instrument),
and in some cases, a form for Verification of Pre-Installation Tasks (included on the next page).
For more information contact your RSM or email [e-mail].
1.2 Legend
Note: Indicates tips and useful information in this manual. All notes should be read to
effectively operate the instrument.
Caution: 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: 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.
1.3 Limit of Liability and Warranty
All general information and notes for handling, maintaining, and cleaning of the instruments 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.
All SmartDGA systems 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 SmartDGA system has only three user-serviceable components: the battery, hydrogen (H 2) sensor,
and oxygen (O2) sensor. The warranty is VOID if the instrument is otherwise 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.

SmartDGA Pre-Installation Manual Verification of Pre-Installation Tasks ∂8
2Verification of Pre-Installation Tasks
If LumaSense Technologies will be performing the installation of your SmartDGA system, you will be
required to verify that you have completed all the necessary pre-installation tasks as explained in
this manual before an installation can be scheduled. Mark the checkbox next to each of the tasks
listed below that you have completed and then sign and submit a copy of this page to your RSM.
Task Description Done N/A
Identified an appropriate mounting location and transformer valve(s) for connecting the SmartDGA
Instrument(s)
If necessary, appropriate reducers and/or adapters have been installed on the transformer valves
Appropriate valve kit(s) has been chosen for mounting/connecting each SmartDGA Instrument(s)
If using an Inline (VA-0) valve kit, installed any necessary hardware (such as Unistrut) for supporting
the mounting plate
If using a Dual Valve (VA-2) or Inline (VA-0) valve kit, appropriate length of stainless steel or flexible
tubing is ready on-site
If necessary, a stainless steel tee and extra valve has been installed on the drain valve
If monitoring an LTC, a Filmax filtration unit is installed and operational
Identified an appropriate mounting location for the EZHub unit(s)
Identified an appropriate mounting location for the iCore (if applicable)
If using a NEMA 4X enclosure, it has been mounted on an appropriate support structure
If using a NEMA 4X enclosure, power is ran to it using conduits
If using a NEMA 4X enclosure, all communication and relay cables are ran to it using conduit
If not using a NEMA 4X enclosure, power is ran to the EZHub location using conduit
If not using a NEMA 4X enclosure, power is ran to the iCore location using conduit
Determined if a sunshade will need to be added to protect the SmartDGA Instrument(s)
Determined if a sunshade will need to be added to protect the NEMA 4X Enclosure
Determined if a sunshade will need to be added to protect the iCore
Determined what protocols and settings are needed for using the DGA ViewerTM software
If necessary, the SCADA system has been configured
If necessary or desired, fiber optical cable is installed from the EZHub to the iCore using an
Ethernet/Serial to Fiber converter and conduit
If necessary or desired, an outage has been scheduled and approved for the installation date
All necessary tools for the installation (not provided by LumaSense) are ready on-site
I confirm that this pre-installation manual has been reviewed and understood in its entirety and
that all necessary site preparation tasks have been completed (as marked above) in order for
LumaSense Technologies to proceed with the installation of our SmartDGA System.
Signature: _________________________________________________ Date: ____________________

SmartDGA Pre-Installation Manual System Overview ∂9
3System Overview
3.1 System Components
A SmartDGA system consists of the following components:
∂SmartDGA instrument(s) with valve mounting kit(s)
∂EZHub(s) with connection cable(s)
∂iCore (optional) or external PC with DGA Viewer software
∂NEMA 4X Enclosure (optional, depending on location)
∂Sunshade (optional, depending on location)
3.1.1 SmartDGA® Instruments
LumaSense offers three SmartDGA Instrument models:
∂The SmartDGA Gauge™ for monitoring a Load Tap Changer (LTC).
∂The SmartDGA Guard™ for monitoring a transformer.
∂The SmartDGA Guide™ for monitoring a transformer.
LumaSense offers three types of valve mounting kits:
∂Single Valve (VA-1) for mounting on a transformer
∂Dual Valve (VA-2) for mounting on a transformer
∂Inline (VA-0) for mounting separately (off-transformer)
Requires connections to the following components:
∂EZHub unit (communications cable)
∂Valves on the transformer or LTC filtration unit

SmartDGA Pre-Installation Manual System Overview ∂10
3.1.2 SmartDGA EZHubTM Unit
LumaSense offers three possible configurations for the EZHub unit:
∂Individual LTC (Gauge)
∂Individual Transformer (Guard or Guide)
∂Combination of LTC (Gauge) & Transformer (Guard or Guide)
LTC
Transformer
LTC & Transformer
Requires connections to the following components:
∂Mounting support (such as NEMA 4x enclosure)
∂SmartDGA instrument(s) (communications cable(s))
∂iCore controller or external PC (RS485 or Ethernet)
∂Power source
3.1.3 LumaSMART iCoreTM Controller (Optional)
LumaSense offers a LumaSMART iCore controller for use in place
of an external PC for running the SmartDGA Viewer software.
Additionally, the iCore controller can provide advanced
communications to external SCADA systems via DNP3, Modbus, or
IEC61850 protocols.
Requires connections to the following components:
∂Mounting support (such as NEMA 4x enclosure)
∂EZHub unit (Ethernet)
∂Ethernet hub (unmangaged) or Ethernet switch
∂Power source
Note: The LumaSMART iCoreTM is not required to operate the SmartDGA system.
3.1.4 NEMA 4X Enclosure (Optional)
To protect the EZHub unit and/or iCore controller, a NEMA 4X
enclosure may be used.
Requires connections to the following components:
∂Mounting support (such as a wall or Unistrut)
∂Cooling Fan (internal)
∂Grounding line
∂Power source

SmartDGA Pre-Installation Manual System Overview ∂11
3.1.5 Sunshade (Optional)
Depending on the mounting location and environment, a sunshade may be needed to protect the
SmartDGA Instrument(s) from direct sunlight and sudden temperature swings.
LumaSense offers a sunshade for SmartDGA Instruments that are installed on a Unistrut H-frame.
These design plans are also available for free to fabricate for different mounting configurations.
Note: The installation of any sunshade(s) must be done by the customer after the
installation of the SmartDGA system.
For more information, email [e-mail].

SmartDGA Pre-Installation Manual System Overview ∂12
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SmartDGA Pre-Installation Manual Technical Specifications ∂13
4Technical Specifications
Instrument Specifications
NDIR Gas Phase Sens
or Accuracy
± 5% or ± LDL, whichever is greater
Reporting Rate
Every 24 hours
-
default, user selectable from approximately 3
hours to 7 days.
Measurement Range
Minimum value is the lower detectable limit after settling
-
in
period after initial installation which may take up to 1 week,
maximum value is the upper limit of accurate response
Moisture Accuracy
± 3 ppm or ± 2% RS
Oil Pressure
up to 45 psig (3 bar)
Enclosure Rating
IP 55
Sunlight visible indicators for condition
codes
Note: Indicators normally flash on for 5 seconds,
off for 15 seconds
Green
-
Normal
Yellow - Caution
Blue - Warning
Red - Alarm
Red/Blue - System Status Error
Green/Yellow - Loss of Communication
Environment
SmartDGA
®
Instrument
SmartDGA EZHub
TM
LumaSMART
i
Core
TM
Operating Temperature*
-
50 to 55 °C
-
50 to 55 °C
-
40 to 70 °C
Storage Temperature
-
50 to 70 °C
-
50 to 70 °C
-
40 to 75 °C
Storage Humidity
(non-condensing) 1 – 99% RH 1 – 99% RH 1 – 99% RH
Dimensions
(L x H x D) 20.9” x 8.6” dia. 10.3” x 5.7” x 6” 8.7” x 7.4” x 6.6”
Weight
18.74 lbs
6.61 lbs
11.02 lbs
* For operating temperatures less than -20 °C, the cold weather cable is required. Additional heating of oil transfer lines may be required
for operation in cold locations. The unit will generate a system fault if the mineral oil temperature is outside of standard fluid limits of
-20 and 120 °C. For operating in environments where the temperature routinely exceeds 40 °C, the high temperature accessory is
recommended to prevent premature aging and reduction of component lifetime. Temperatures are based upon air temperatures for unit
installation in shaded location.

SmartDGA Pre-Installation Manual Technical Specifications ∂14
SmartDGA® Instrument Gas Measurements (Min
-
Max)
Gas
Gauge
Guard
Guide
Acetylene (C
2
H
2
)
0.5
–
50,000 ppm
0.5
–
10,000 ppm
0.5
–
10,000 ppm
Ethylene (C
2
H
4
)
2
–
50,000 ppm
2
–
50,000 ppm
Carbon Monoxide (CO)
10
–
10,000 ppm
10
–
10,000 ppm
Moisture (RS)
1
–
99%
1
–
99%
1
–
99 %
Hydrogen (H
2
)
5
–
10,000 ppm
5
–
10,000 ppm
Carbon
Dioxide (CO
2
)
10
–
20,000 ppm
10
–
20,000 ppm
Methane (CH
4
)
2
–
50,000 ppm
2
–
50,000 ppm
Ethane (C
2
H
6
)
2
–
20,000 ppm
Oxygen (O
2
)
500
–
50,000 ppm
Nitrogen (N
2
)
5,000
–
100,000 ppm
SmartDGA EZHub
TM
& LumaSMART iCore
TM
Specifications
Power Supplied to EZHub & iCore
90 ~ 264 VAC, 127 ~ 370 VDC,
47 ~ 63 Hz, 6.5 A max
Power Supplied to Instrument
48 VDC ~ 4.16 A max
Memory
Up to 40+ years worth of data storage available with optional
iCore
Data Export
(Available with EZHub and iCore/PC)
Export of results to date in a single file onto a USB memory stick.
When using iCore/PC, user can select date range; when using
EZHub port, all data is exported
Available Communications
(Available with EZHub)
Proprietary communications via RS485 and Ethernet connections
to DGA Viewer software
Optional Communications
(Modbus available with PC, others available with iCore)
IEC61850 Edition 2, DNP3 IEEE Std 1815
-
2013, ModBus RTU V1.02,
ModBus TCP/IP 1.0b protocols for up to 3 EZHubs
Alarm Contacts
EZHub:
3 programmable relay outputs (Type
C, NO/NC) for
caution, warning, & alarm
EZHub & iCore: One (1) alarm relay output for system status
(Type C, NO/NC)
Relay Contact Ratings
Single phase alarm relays (
8 A, 250 VAC; 5 A, 30 VDC)

SmartDGA Pre-Installation Manual Technical Specifications ∂15
Certifications and Standards (Instrument & SmartDGA EZHub
TM
)
Emissions / Immunity
EN 61000
-
6
-
2 (2005) +C1
EN 61000-6-4 (2007) +A1
EN 61000-3-2 (2006) +A1
EN 61000-3-3 (2008)
Environmental / Vibration
ETSI EN 300 019
-
2
-
4
Surge Protection
4000V (IEEE C37.90.1
-
2002)

SmartDGA Pre-Installation Manual Technical Specifications ∂16
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SmartDGA Pre-Installation Manual Transformer and LTC Criteria ∂17
5Transformer and LTC Criteria
5.1 Transformer Criteria
∂The electromagnetic fields around the transformer must meet the IEC 61000-6-5 standard.
If the transformer environment is greater than this EMC standard, more discussion is needed
before proceeding any further. Contact [e-mail].
∂If connecting a SmartDGA Instrument to a valve that is within four (4) meters of an energy
source (such as the bushings), an outage will be needed for installation. Otherwise it is up to the
substation manager’s discretion whether or not they want an outage for installation.
Note: If an outage is required or desired for the installation, it needs to be approved
and/or scheduled for the installation date.
5.2 LTC Criteria
∂Oil must be filtered by a Filmax filtration unit. Filmax is the only type of filtration unit that
is compatible with the SmartDGA system.
∂The Filmax filtration unit must be shutdown prior to installation.
Caution: Never sample oil directly from the LTC to the SmartDGA Instrument.
A side stream of oil is connected from the LTC tank to the Filmax filtration unit.
The SmartDGA Instrument will then sample the filtered oil from the FIlmax filtration unit.
Outage needed
if < 4m from an
energy source

SmartDGA Pre-Installation Manual Transformer and LTC Criteria ∂18

SmartDGA Pre-Installation Manual Transformer and LTC Criteria ∂19
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SmartDGA Pre-Installation Manual Plumbing ∂20
6Plumbing
6.1 Transformer Valves
All transformers have different valve configurations so you will need to assess the type, size,
location, and clearance of your transformer valves. This will allow you to determine how you will
connect your SmartDGA instrument to the transformer, as well as determine which valve kit you will
need for mounting it.
6.1.1 Drain Valve
The drain valve is located near the bottom of the transformer tank. This is the ideal valve to use for
sampling oil from the transformer.
6.1.2 Fill Valve
The fill valve is located near the top of the transformer tank. This is the ideal valve to use for
returning oil back to the transformer.
6.1.3 Ancillary Valves
Some transformers have various ancillary valves in random locations. If necessary, these can be used
in place of the drain valve and/or fill valve for sampling and/or returning oil.
Note: This valve should never be used to sample oil from the transformer because there
is no guarantee that oil will always be at this position.
Drain Valve
Fill Valve
Ancillary Valve