Mte Hydrocal 1002 Specification sheet

HYDROCAL HYDROCAL

1002-1003: 1002-1003:

Manual Manual

for for

Installation Installation

and and

Operation Operation

Edition Edition

01.201001.2010

HYDROCAL 1002-1003HYDROCAL 1002-1003

Gas-in-Oil Analysis System withGas-in-Oil Analysis System with

Transformer Monitoring FunctionsTransformer Monitoring Functions

Manual for installation and operationManual for installation and operation

HYDROCAL HYDROCAL

1002-1003: 1002-1003:

Manual Manual

for for

installation installation

and and

operation operation

Page Page

1 1

of of

9797

The contents of this manual areThe contents of this manual are

subject to change without notice.subject to change without notice.

All efforts have been made to ensureAll efforts have been made to ensure

the accuracy of this the accuracy of this

publication butpublication but

MTE Meter Test Equipment AG canMTE Meter Test Equipment AG can

assume assume

no no

responsibility responsibility

for for

any any

errors errors

Customs Customs

tariff tariff

number:number:

or or

their their

consequences consequences

9027.10109027.1010

HYDROCAL HYDROCAL

1002-1003: 1002-1003:

Manual Manual

for for

installation installation

and and

operation operation

Page Page

1 1

of of

9797

The contents of this manual areThe contents of this manual are

subject to change without notice.subject to change without notice.

All efforts have been made to ensureAll efforts have been made to ensure

the accuracy of this the accuracy of this

publication butpublication but

MTE Meter Test Equipment AG canMTE Meter Test Equipment AG can

assume assume

no no

responsibility responsibility

for for

any any

errors errors

Customs Customs

tariff tariff

number:number:

or or

their their

consequences consequences

9027.10109027.1010

HYDROCAL HYDROCAL

1002-1003: 1002-1003:

Manual Manual

for for

installation installation

and and

operation operation

Page Page

1 1

of of

9797

SummarySummary

1. 1.

GeneGene

ral ral

..........................

................................

..............................

................................

............................

................................

. .

2. Mounting of HYDROCAL 1002-1003 unit ........................................................................................ 52. Mounting of HYDROCAL 1002-1003 unit ........................................................................................ 5

2.1 Locations for installation of HYDROCAL 1002-1003 .................................................................. 52.1 Locations for installation of HYDROCAL 1002-1003 .................................................................. 5

2.2 Security precautions for installation ........................................................................................... 62.2 Security precautions for installation ........................................................................................... 6

2.3 Preparation for installation ......................................................................................................... 82.3 Preparation for installation ......................................................................................................... 8

2.3.1 Power supply for the unit ..................................................................................................... 82.3.1 Power supply for the unit ..................................................................................................... 8

2.3.2 Requested tools:2.3.2 Requested tools:

..............................

................................

............................

................................

..............................

................................

...... ......

2.4 Installation of the HYDROCAL 1002-1003 unit .......................................................................... 92.4 Installation of the HYDROCAL 1002-1003 unit .......................................................................... 9

Note: For additional information for mounting and un-mounting, please refer to the documentNote: For additional information for mounting and un-mounting, please refer to the document

named: “HC named: “HC

1002-1003 Special Additional Instructions Mounting & 1002-1003 Special Additional Instructions Mounting &

Un-mounting 01-2010.doUn-mounting 01-2010.do

c”. .. 11c”. .. 11

2.5 Front view of HYDROCAL 1002-1003...................................................................................... 122.5 Front view of HYDROCAL 1002-1003...................................................................................... 12

2.6 Rear side of HYDROCAL 1002-1003 unit ................................................................................ 132.6 Rear side of HYDROCAL 1002-1003 unit ................................................................................ 13

2.7 Connections on the measuring and controller card .................................................................. 142.7 Connections on the measuring and controller card .................................................................. 14

2.7.1 HYDROCAL 1002 .............................................................................................................. 142.7.1 HYDROCAL 1002 .............................................................................................................. 14

3. Software on Hydrocal unit ............................................................................................................. 183. Software on Hydrocal unit ............................................................................................................. 18

3.1. General information ................................................................................................................ 183.1. General information ................................................................................................................ 18

3.2. Operation of HYDROCAL 1002-13.2. Operation of HYDROCAL 1002-1

003 by its keyboard 003 by its keyboard

..................

....................

..................

....................

... ...

1919

3.2.1. Contrast Set-up ................................................................................................................ 193.2.1. Contrast Set-up ................................................................................................................ 19

3.3. 3.3.

Main Main

menu ..................menu ..................

................................

..............................

................................

............................

............... ...............

2020

3.4.3.4.

Configuration of user settings ...................................................................................... 21Configuration of user settings ...................................................................................... 21

3.5.3.5.

Display of stored „Gas-in-oil“ measuriDisplay of stored „Gas-in-oil“ measuri

ng values ng values

......................

....................

..................

......................

....... 22....... 22

3.5.13.5.1

Graphic display ...................................................................................................... 22Graphic display ...................................................................................................... 22

3.5.2.3.5.2.

Table Table

presentation presentation

..................

....................

..................

......................

....................

..................

....................

........ ........

2323

3.6.3.6.

History of alarms ......................................................................................................... 24History of alarms ......................................................................................................... 24

3.6.1. Acknowledgment of alarms ............................................................................................... 243.6.1. Acknowledgment of alarms ............................................................................................... 24

3.7. 3.7.

Device Device

set set

– –

up up

................

......................

..................

......................

....................

..................

....................

..................

....................

.. ..

2525

3.7.1.3.7.1.

Menu Transformer data setup ............................................................................... 26Menu Transformer data setup ............................................................................... 26

3.7.1.2. 3.7.1.2.

Hot Hot

Spot Spot

calculation calculation

................

....................

......................

..................

......................

..................

....................

........ ........

2727

3.7.1.3. 3.7.1.3.

Ageing Ageing

Rate Rate

/ /

Loss Loss

of of

Life Life

..................

......................

..................

......................

..................

....................

........ ........

2929

3.7.2. 3.7.2.

Configuration Configuration

of of

analogue analogue

outputs outputs

..................

....................

......................

..................

......................

..................

..... .....

2929

3.7.3. 3.7.3.

Configuration Configuration

of of

analogue analogue

inputs inputs

(external (external

sensors) sensors)

..................

......................

..................

..... .....

3030

3.7.4.3.7.4.

Configuration of alaConfiguration of ala

rms and digital outputs rms and digital outputs

....................

..................

....................

..................

....................

.. ..

3333

3.7.5. 3.7.5.

Unit Unit

Setup Setup

..................

......................

..................

......................

....................

..................

....................

..................

......................

. .

3636

3.7.5.1. 3.7.5.1.

Flange Flange

Heating Heating

Base Base

Temperature Temperature

..................

......................

....................

..................

....................

........ ........

3737

3.7.5.2. 3.7.5.2.

Flange Flange

Heating Heating

Base Base

Temperature Temperature

..................

....................

..................

....................

..................

......................

. .

3737

3.7.5.3. 3.7.5.3.

Device Device

options options

......................

..................

......................

....................

..................

....................

..................

....................

.. ..

3737

3.7.5.4. 3.7.5.4.

Clock Clock

settings settings

................

....................

..................

....................

......................

..................

......................

..................

..... .....

3939

HYDROCAL

1002-1003:

Manual

for

installation

and

operation

Page

3.7.5.5.

Configuration of the communication ................................................................... 40

3.7.5.5.1.

Alert

SMS

setup

.........

...........

..........

.........

..........

.........

..........

3.7.5.5.2.

Internal

modem

setup

..........

.........

..........

...........

.........

...........

.........

.....

3.7.5.5.2.1 Analog Modem ......................................................................................................... 42

3.7.5.5.2.2 GSM Modem ............................................................................................................ 42

3.7.5.5.2.3 IP Modem ................................................................................................................. 43

3.7.5.5.3.

232

485

setup

.........

...........

..........

.........

..........

.........

...........

Poin

t .................

................

...............

................

..............

............... 44

RS23

.............

..............

................

...............

................

......

II.

RS48

.............

..............

................

...............

................

..............

........

III.

Mode

..............

................

..............

................

...............

................

....

RS48

5-Bu

.............

..............

................

...............

................

..............

........

Bridg

...............

................

..............

................

..............

................

.................

...........

Bridg

Setup ...........................

..............

.................

................

..............

...............

RS485-Bus Setup ............................................................................................................... 50

MODB

...............

..............

................

.................

..............

................

..............

........

Test / Debug Options at the HydroCal Device ............................................................................ 52

Function, Register and Address Mapping ........................................................................... 53

MODBUS Communication Examples ............................................................................................. 55

MODBUS/RTU via RS232 (using QuickMod) ..................................................................... 55

MODBUS/ASCII via RS232 (using Modpoll) ....................................................................... 57

III

MODBUS/RTU via RS485 (using QuickMod) ..................................................................... 57

MODBUS/RTU on RS485-Bus (using Modpoll) .................................................................. 59

Windows Software HydroSoft ................................................................................................. 62

4.1. Purpose of the program .......................................................................................................... 62

4.2. Remarks for use of this operation handbook ........................................................................... 62

4.3. Requirements to the PC.......................................................................................................... 62

4.4.

Insta

llati

................

...............

................

..............

................

...............

4.4.1. Microsoft .NET .NET Framework 1.1 Redistributable

.........

..........

.........

..........

...........

....... 63

4.4.2. Microsoft Data Access Components ................................................................................. 63

4.4.3. Adaptation of installation ................................................................................................... 64

4.5. Functions of HydroSoft program ............................................................................................. 64

4.6. Start of program ...................................................................................................................... 64

4.7. Preparation / rename of a new customer list ........................................................................... 65

4.8. Opening a new transformer station ......................................................................................... 66

4.9. Opening a file for a new transformer ....................................................................................... 66

4.9.1. Modem settings ................................................................................................................ 68

4.9.2. RS232 interface settings ................................................................................................... 68

4.10. Settings of HYDROCAL 1002-1003 unit ............................................................................... 68

4.10.1. Alert Setup ...................................................................................................................... 69

4.10.2. External sensors (see also chapter 3.7.3) ....................................................................... 72

4.10.3. Alert SMS Setup ............................................................................................................. 73

4.10.4. Input of DGA Level Adjustment ....................................................................................... 75

4.10.5. Analog Output Setup ...................................................................................................... 76

4.10.6. Digital Output Setup........................................................................................................ 77

HYDROCAL HYDROCAL

1002-1003: 1002-1003:

Manual Manual

for for

installation installation

and and

operation operation

Page Page

3 3

of of

9797

4.10.7. Device Setup (Clock settings) ......................................................................................... 784.10.7. Device Setup (Clock settings) ......................................................................................... 78

4.11. Data transmission from / to the HYDROCAL 1002-1003 un4.11. Data transmission from / to the HYDROCAL 1002-1003 un

it it

......................

..................

....................

........ 79........ 79

4.12. View of results ...................................................................................................................... 814.12. View of results ...................................................................................................................... 81

4.12.1. Sensor selection ............................................................................................................. 814.12.1. Sensor selection ............................................................................................................. 81

4.12.2. Time range selection ...................................................................................................... 814.12.2. Time range selection ...................................................................................................... 81

4.12.3. Result window ................................................................................................................ 824.12.3. Result window ................................................................................................................ 82

4.12.4. Print and export of results ............................................................................................... 824.12.4. Print and export of results ............................................................................................... 82

4.13. View of alarm status ............................................................................................................. 834.13. View of alarm status ............................................................................................................. 83

4.13.1. Alarm selection ............................................................................................................... 834.13.1. Alarm selection ............................................................................................................... 83

4.13.2. Time range selection ...................................................................................................... 834.13.2. Time range selection ...................................................................................................... 83

4.13.3. Alarm window ................................................................................................................. 844.13.3. Alarm window ................................................................................................................. 84

4.13.4. Status of alarms .............................................................................................................. 844.13.4. Status of alarms .............................................................................................................. 84

4.13.5. Print and export of results ............................................................................................... 844.13.5. Print and export of results ............................................................................................... 84

4.14. Online Sensors ..................................................................................................................... 854.14. Online Sensors ..................................................................................................................... 85

5. RS232 / RS 485 Wiring ................................................................................................................. 865. RS232 / RS 485 Wiring ................................................................................................................. 86

6. Vaisala sensors connection on HYDROCAL 1002 ........................................................................ 876. Vaisala sensors connection on HYDROCAL 1002 ........................................................................ 87

6.1 6.1

MMTMMT

318 318

............................

................................

..............................

................................

............................

........ ........

8787

6.2 6.2

MMTMMT

338 338

..............................

............................

................................

..............................

................................

............................

........ ........

8888

7. HYDROSOFT Scheduler .............................................................................................................. 897. HYDROSOFT Scheduler .............................................................................................................. 89

7.1 7.1

GeneGene

ral ral

..............................

................................

............................

................................

............................

................................

..................................

........... ...........

8989

7.2 7.2

SchedSched

uler uler

................................

............................

................................

..............................

................................

............................

........ ........

8989

7.2.1 Configuring a Transformer for automatic History Data Update 7.2.1 Configuring a Transformer for automatic History Data Update

....................

......................

..................

....... 89....... 89

7.2.1.1 Connection Scheduler Dialog ......................................................................................... 897.2.1.1 Connection Scheduler Dialog ......................................................................................... 89

7.2.2 Scheduler Status Visualization7.2.2 Scheduler Status Visualization

..............................

................................

............................

................................

..............................

.. ..

9090

7.2.2.1 Status Icons .................................................................................................................... 907.2.2.1 Status Icons .................................................................................................................... 90

7.2.27.2.2

.2 .2

ExamExam

ple ple

..........................

................................

............................

..................................

................................

............................

................................

............... ...............

9191

7.2.3 Hydrosoft and the 7.2.3 Hydrosoft and the

Windows Task Scheduler Windows Task Scheduler

..................

......................

....................

..................

....................

......................

.. ..

9292

7.2.3.1 Command Line Op7.2.3.1 Command Line Op

tions for Windows Task Scheduler tions for Windows Task Scheduler

....................

..................

....................

... ...

9393

7.2.4 Internal Operation ................................................................................................................. 937.2.4 Internal Operation ................................................................................................................. 93

7.2.5. Data Directory Lock ............................................................................................................. 947.2.5. Data Directory Lock ............................................................................................................. 94

8. Technical data HYDROCAL 1002-1003 ........................................................................................ 958. Technical data HYDROCAL 1002-1003 ........................................................................................ 95

9. Dimensional Drawings HYDROCAL 1002-1003 ............................................................................ 979. Dimensional Drawings HYDROCAL 1002-1003 ............................................................................ 97

HYDROCAL HYDROCAL

1002-1003: 1002-1003:

Manual Manual

for for

installation installation

and and

operation operation

Page Page

4 4

of of

9797

1. General1. General

HYDROCAL 1002-1003 is an on-line Gas-in-Oil Monitoring System for continuous analysis of theHYDROCAL 1002-1003 is an on-line Gas-in-Oil Monitoring System for continuous analysis of the

dissolved gases hydrogen (Hdissolved gases hydrogen (H

) and carbon monoxide (CO) of ) and carbon monoxide (CO) of

power transformers. HYDROCAL 1003power transformers. HYDROCAL 1003

allows also in addition Analysis of moisture (Hallows also in addition Analysis of moisture (H

O) dissolved in transformer oil (absolute humidity inO) dissolved in transformer oil (absolute humidity in

ppm). The possibility to connect additional sensors with an analogue output signal (0..10V or (0-ppm). The possibility to connect additional sensors with an analogue output signal (0..10V or (0-

4..20mA), e.g. for temperature or oil humidity complete the product. The HYDROCAL 1002-10034..20mA), e.g. for temperature or oil humidity complete the product. The HYDROCAL 1002-1003

system together with the Windows-based software HydroSoft is a powerful tool for detection and di-system together with the Windows-based software HydroSoft is a powerful tool for detection and di-

agnosis of incipient fagnosis of incipient f

aults in power transformers.aults in power transformers.

The present operating instructions are divided in The present operating instructions are divided in

the following sections:the following sections:

••

Instructions for Instructions for

mounting the mounting the

HYDROCAL 100HYDROCAL 100

2-1003 un2-1003 un

it (chapter it (chapter

2)2)

••

Description oDescription o

f software of f software of

the HYDROCAL the HYDROCAL

1002-1003 1002-1003

unit (chapunit (chap

ter 3)ter 3)

••

Description Description

of of

Windows soWindows so

ftware Hyftware Hy

droSoft (chdroSoft (ch

apter apter

4)4)

••

RS 232 RS 232

/ RS / RS

485 485

Wiring (chaWiring (cha

pter 5pter 5

))

••

VAISALA sensoVAISALA senso

rs conners conne

ction on ction on

HYDROCAL 1HYDROCAL 1

002 (chap002 (chap

ter 6)ter 6)

••

HYDROSOFT HYDROSOFT

Scheduler Scheduler

(Chapter (Chapter

7)7)

••

Technical Technical

data of Hdata of H

YDROCAL 1YDROCAL 1

002-1003 002-1003

system (chasystem (cha

pter 8)pter 8)

••

HYDROCAL HYDROCAL

1002-1003 1002-1003

dimensional dimensional

drawingdrawing

s (chaps (chap

ter 9)ter 9)

HYDROCAL HYDROCAL

1002-1003: 1002-1003:

Manual Manual

for for

installation installation

and and

operation operation

Page Page

5 5

of of

9797

2. Mounting of HYDROCAL 1002-1003 unit2. Mounting of HYDROCAL 1002-1003 unit

2.1 Locations for installation of HYDROCAL 1002-10032.1 Locations for installation of HYDROCAL 1002-1003

To ensure the correct function of the HYDROCAL 1002-1003 the location of mounting is very impor-To ensure the correct function of the HYDROCAL 1002-1003 the location of mounting is very impor-

tant. For a typical transformer, three places are possible:tant. For a typical transformer, three places are possible:

Pos. Pos.

1 1

On On

return return

side side

of of

cooling cooling

circuit:circuit:

Please install the unit on a Please install the unit on a

straight piece of tube on the cooler output between the straight piece of tube on the cooler output between the

coolercooler

and the main oil tank. In and the main oil tank. In

order to avoidorder to avoid

negative pressurenegative pressure

, the unit must, the unit must

absolutelyabsolutely

bebe

mountedmounted

on theon the

downstream sidedownstream side

(after the bend) of the oil circulation pump.(after the bend) of the oil circulation pump.

Remark: Choose this place only in case of continuous oil flux through the cooler.Remark: Choose this place only in case of continuous oil flux through the cooler.

Pos. Pos.

2 2

Flange Flange

below below

on on

the the

transformer transformer

tank:tank:

The flange must be at minimum height of The flange must be at minimum height of

30 cm in order to allow installation and mounting30 cm in order to allow installation and mounting

of HYDROCAL 1002-1003 unit.of HYDROCAL 1002-1003 unit.

Pos. Pos.

3 3

Upper Upper

filling filling

valve:valve:

It is possible to mount theIt is possible to mount the

HYDROCAL 1002-1003 unit in this position, however it may beHYDROCAL 1002-1003 unit in this position, however it may be

difficult to operate and read the data of difficult to operate and read the data of

the unit.the unit.

Remark: Should the unit be mounted on the wall of the cooler, then make sure thatRemark: Should the unit be mounted on the wall of the cooler, then make sure that

the unit is mounted below the oil lthe unit is mounted below the oil l

evel.evel.

Pos. 4 Pos. 4

Never insNever ins

tall the tall the

HYDROCAL HYDROCAL

1002-1003 1002-1003

unit on unit on

top of top of

the coolethe coole

r or r or

on the on the

suctionsuction

face of the pump.face of the pump.

HYDROCAL

1002-1003:

Manual

for

installation

and

operation

Page

2.2 Security precautions for installation

The following security precautions must be strictly observed during the installation. Otherwise no war-

ranty claims will be accepted.

Never connect the sensor head to another HYDROCAL 1002-1003 elec-

tronic unit other than the delivered one.

The components are delivered as a

matched pair and have been c

alibrated

together in our works. You will f

ind the serial numbers on the units, on the

packing material and /or on the data sheets. Please ensure you note down

these serial numbers for fut

ure reference.

Never remove the protection cap from the sensor before you are ready to

mount the unit on the valve of the transformer

The protection cap protects the membrane of the sensor against dust and other

foreign bodies. Additionally it protects

the thread of the

measuring head and/or

adapters.

Note: Use the protection cap also after dismounting of the unit.

Never touch the membrane with fingers or other objects.

Never close the aeration hole f

or oxygenation

Never use or stock chemicals with hydrocarbon contents near the mea-

suring sensor.

Never clean the measuring head with solvents, because its gases

will strongly

impair the measuring accuracy and the sensivity of the sensors.

HYDROCAL

1002-1003:

Manual

for

installation

and

operation

Page

Never apply a negative pressure to the measuring head.

Negative pressure can damage the

unit.

Remove the HYDROCAL 1002-1003 unit from the valve every time you

degas or refill the transformer.

Never install the HYDROCAL unit on a

valve that is closed for a long pe-

riod of time. Remove the unit i

f this cannot be avoided

Never install the HYDROCAL 1002-1003 on the suction side of the cooling

pump!

Never install the HYDROCAL 1002-1003 unit on an elbow or curve of a

tube.

The unit can

be damaged by negative pressure produced by turbulences in

curves.

Never install or

remove the HYDROCAL 1002-1003 without opening first

the aeration screw.

Never use galvanized fittings or valves to mount the HYDROCAL 1002-

1003 unit.

Galvanized fittings or valves can react with

oil, this will produce incorect mea-

suring values.

Never clean the HYDROCAL

1002-1003 unit with high pressure cleaning

equipment.

High pressure cleaning equipment used to

clean transformers can seriously

damage the HYDROCAL 1002-1003 unit.

This manual suits for next models

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