MTE HYDROCAL1005 User manual

HYDROCAL 1005 Manual for Installation and Operation Edition 01.2011
HYDROCAL1005
Gas-in-Oil Analysis System with
Transformer Monitoring Functions
Manual for installation and operation

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Copyright MTE Meter Test Equipment AG
All rights reserved.
The contents of this manual are
subject to change without notice.
All efforts have been made to ensure
the accuracy of this publication but
MTE Meter Test Equipment AG can
assume no responsibility for any errors Customs tariff number:
or their consequences 9027.1010

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Summary
1. General.......................................................................................................................................4
2. Mounting of HYDROCAL1005 unit............................................................................................5
2.1 Locations for installation of HYDROCAL1005.......................................................................5
2.2 Security precautions for installation......................................................................................6
2.3 Preparation for installation....................................................................................................8
2.3.1 Power supply for the unit...............................................................................................8
2.3.2 Requested tools: ...........................................................................................................8
2.4 Installation of the HYDROCAL1005 unit...............................................................................8
2.5 Electrical Installation of HYDROCAL1005 unit....................................................................11
2.6 Completion of Installation ...................................................................................................12
3. Hardware components of HYDROCAL 1005..........................................................................14
3.1 Front view of HYDROCAL1005 ..........................................................................................14
3.2 Rear side of HYDROCAL1005 unit.....................................................................................15
3.3 Connections on the measuring and controller card.............................................................17
3.4 Measurement and extraction Components .........................................................................22
4. Software on HYDROCAL unit .................................................................................................24
4.1 General information............................................................................................................24
4.2 Description of Gas measurement Process .........................................................................24
4.3. Operation Cycles................................................................................................................25
4.3.1. Zero measurement......................................................................................................25
4.3.1.1 Safety function and error observation for Zero measurement cycle......................25
4.3.2 Depression..................................................................................................................26
4.3.2.1. Safety function and error observation for depression cycle ..................................26
4.3.3. Leak detection.............................................................................................................27
4.3.3.1. Safety function and error observation for leak detection cycle..............................27
4.3.4. Filling to level 1............................................................................................................28
4.3.4.1. Safety function and error observation for filling to level 1 cycle.............................28
4.3.5. Degassing ...................................................................................................................29
4.3.5.1. Safety function and error observation for degassing cycle....................................29
4.3.6. Filling to level 2............................................................................................................30
4.3.6.1. Safety function and error observation for filling to level 2 cycle.............................30
4.3.7. Measurement ..............................................................................................................31
4.3.7.1. Safety function and error observation for measurement cycle..............................31
4.3.8. Flushing.......................................................................................................................32
4.3.8.1. Safety function and error observation for flushing cycle .......................................32
4.3.9. Draining.......................................................................................................................33
4.3.9.1. Safety function and error observation for draining cycle.......................................33
4.3.10. Wait .........................................................................................................................34
4.3.10.1. Safety function and error observation for wait cycle .............................................34
4.4 Operation of HYDROCAL1005 by its keyboard ..................................................................35
4.4.1 Contrast Set-up...........................................................................................................35
4.5 Main menu..........................................................................................................................36
4.6 Extraction Menu..................................................................................................................37
4.7 Display of stored „Gas-in-oil“measuring values...................................................................37
4.7.1 Graphic display.................................................................................................37
4.7.2 Table presentation............................................................................................38

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4.8 Status of alarms ......................................................................................................39
4.8.1 Acknowledgment of alarms .........................................................................................39
4.9 Device set –up........................................................................................................40
4.9.1 Menu Transformer data setup..........................................................................41
4.9.1.1. DGA Adjustment: Input of correction factor..............................................................41
4.9.1.1 Hot Spot calculation..................................................................................42
4.9.1.2 Ageing Rate / Loss of Life .........................................................................44
4.9.2 Configuration of analogue outputs....................................................................45
4.9.3 Configuration of analogue inputs (external sensors) ........................................45
4.9.4 Configuration of alarms and digital outputs ......................................................48
4.9.5 Unit Setup........................................................................................................51
4.9.5.1 Digital Output Test.....................................................................................52
4.9.5.2 Device options..........................................................................................52
4.9.5.2.1. Configuration of user settings.........................................................................53
4.9.5.3 Date. Time & Clock Settings.....................................................................53
4.9.5.4 Configuration of the communication..........................................................55
4.9.5.5 Ethernet setup...........................................................................................56
4.9.5.6 Alert SMS setup........................................................................................57
4.9.5.7 Internal modem setup ...............................................................................58
4.9.5.8 RS 232 / RS 485 setup.........................................................................................59
4.9.5.9 MODBUS..............................................................................................................66
5. Windows Software HydroSoft ................................................................................................76
5.1 Purpose of the program......................................................................................................76
5.2 Remarks for use of this operation handbook ......................................................................76
5.3 Requirements to the PC .....................................................................................................76
5.4 Installation..........................................................................................................................77
5.4.1 Microsoft .NET .NET Framework 1.1 Redistributable ..................................................77
5.4.2 Microsoft Data Access Components............................................................................77
5.4.3 Adaptation of installation .............................................................................................78
5.5 Functions of HydroSoft program.........................................................................................78
5.6 Start of program .................................................................................................................78
5.7 Preparation / rename of a new customer list.......................................................................79
5.8 Opening a new transformer station.....................................................................................80
5.9 Opening a file for a new transformer ..................................................................................80
5.9.1 Modem settings...........................................................................................................82
5.9.2 RS232 interface settings .............................................................................................82
5.10 Settings of HYDROCAL1005 unit.......................................................................................82
5.10.1 Alert Setup...................................................................................................................83
5.10.2 External sensors (see also chapter 4.7.3) ...................................................................86

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5.10.3 Alert SMS Setup..........................................................................................................87
5.10.4 Input of DGA Level Adjustment ...................................................................................89
5.10.5 Analog Output Setup...................................................................................................90
5.10.6 Digital Output Setup ....................................................................................................91
5.10.7 Device Setup (Clock settings)......................................................................................91
5.10.5.1. Ethernet................................................................................................................92
5.10.5.2. Modbus-TCP........................................................................................................93
5.10.5.3. MODBUS..............................................................................................................93
5.11 Data transmission from / to the HYDROCAL1005 unit........................................................93
5.12 View of results....................................................................................................................96
5.12.1 Sensor selection..........................................................................................................96
5.12.2 Time range selection...................................................................................................96
5.12.3 Result window .............................................................................................................97
5.12.4 Print and export of results............................................................................................97
5.13 View of alarm status...........................................................................................................98
5.13.1 Alarm selection............................................................................................................98
5.13.2 Time range selection...................................................................................................98
5.13.3 Alarm window..............................................................................................................99
5.13.4 Status of alarms ..........................................................................................................99
5.13.5 Print and export of results............................................................................................99
5.14 Online Sensors.................................................................................................................100
6. RS 485 Wiring ........................................................................................................................101
7. HYDROSOFT Scheduler........................................................................................................102
7.1 General ............................................................................................................................102
7.2 Scheduler.........................................................................................................................102
7.2.1 Configuring a Transformer for automatic History Data Update..................................102
7.2.1.1 Connection Scheduler Dialog .............................................................................103
7.2.2 Scheduler Status Visualization ..................................................................................103
7.2.2.1 Status Icons .......................................................................................................103
7.2.2.2 Transformer........................................................................................................104
7.2.2.3 Station................................................................................................................104
7.2.2.4 Customer............................................................................................................104
7.2.2.5 Example .............................................................................................................104
7.2.3 HydroSoft and the Windows Task Scheduler ............................................................105
7.2.3.1 Command Line Options for Windows Task Scheduler........................................106
7.2.3.2 IdleClose ............................................................................................................106
7.2.3.3 Minimized...........................................................................................................106
7.2.4 Internal Operation......................................................................................................106
7.2.5 Data Directory Lock...................................................................................................107
8. Technical data HYDROCAL1005...........................................................................................108
9. Dimensional drawings HYDROCAL1005..............................................................................110

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1. General
The HYDROCAL 1005 is a permanently-installed multi-gas-in-oil analysis system with transformer
monitoring functions. It allows for the individual measurement of moisture and the key gases hydro-
gen (H2), carbon monoxide (CO), acetylene (C2H2) and ethylene (C2H4) dissolved in transformer oil.
As hydrogen (H2) is involved in nearly every fault of the isolation system of power transformers and
carbon monoxide (CO) is a sign of an involvement of the cellulosic / paper isolation the presence and
increase of acetylene (C2H2) and ethylene (C2H4) further classifies the nature of a fault as overheat-
ing, partial discharge or high energy arcing. The device can serve as a compact transformer monitor-
ing system by the integration / connection of other sensors present on a transformer via its analog
inputs:
5 analog outputs 0/4-20mADC
4 analog inputs 0/4-20 mADC (Option)
6 analog inputs 0/4-20 mADC +20% / 0-80 VAC +20% (option)
configurable by jumpers
It is further equipped with digital outputs for the transmission of alarms or the execution of control
functions (e. g. control of a cooling system of a transformer):
5 digital relay outputs
5 digital opto-coupler outputs (Option)
Key Advantages
Hydrogen (H2), Carbon monoxide (CO), acetylene (C2H2) and ethylene (C2H4) measurement
Moisture-in-oil measurement
Communication interfaces ETHERNET 10/100 Mbit/s (copper-wired or fibre-optical) and RS 485
to support proprietary communication protocols and to be open / prepared for substation commu-
nication protocols IEC 61850, MODBUS, DNP 3 etc.
Optional on-board GSM and analog modems for remote communication
6 analog AC current inputs for the connection of capacitive HV bushing sensors for HV bushing
monitoring applications
The present operating instructions are divided in the following sections:
Instructions for mounting the HYDROCAL 1005 unit (chapter 2)
Hardware components of HYDROCAL 1005 (chapter 3)
Description of software of the HYDROCAL 1005 unit (chapter 4)
Description of Windows software HydroSoft (chapter 5)
RS 485 Wiring (chapter 6)
New HydroSoft Scheduler functions (chapter 7)
Technical Data of HYDROCAL 1005 (chapter 8)
HYDROCAL 1005 dimensional drawings (chapter 9)

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2. Mounting of HYDROCAL1005 unit
2.1 Locations for installation of HYDROCAL1005
To ensure the correct function of the HYDROCAL1005 the location of mounting is very important.
For a typical transformer, four places are possible:
Pos. 1
On return side of cooling circuit:
Please install the unit on a straight piece of tube on the cooler output between the cooler
and the main oil tank. In order to avoid negative pressure, the unit must absolutely be
mounted on the downstream side (after the bend) of the oil circulation pump.
Remark: Choose this place only in case of continuous oil flux through the cooler.
Pos. 2
Flange below on the transformer tank:
The flange must be at minimum height of 40 cm in order to allow installation and mounting
of HYDROCAL1005 unit.
Pos. 3
Upper filling valve:
It is possible to mount the Hydrocal 1005 unit on this position, if the filling level of
the oil is min. 100 cm higher than the mounting position. This position is not rec-
ommended, because the filling process is influenced by the hydrostatic pressure of
the oil and it may be difficult to operate and read the data of the unit.
Pos. 4
Never install the HYDROCAL1005 unit on top of the cooler or on the suction face of
the pump. In this case, filling oil step cannot be carried out in the right way.

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2.2 Security precautions for installation
The following security precautions must be strictly observed during the installation. Otherwise no
warranty claims will be accepted.
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 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 close the aeration holes for oxygenation. They are situated in bot-
tom side of the protection cover and at the back plate of the device
Never use or stock chemicals with hydrocarbon contents near the meas-
uring sensor.
Never clean the measuring head with solvents, because its gases will strongly
impair the measuring accuracy and the sensitivity of the sensors.
Never apply a negative pressure to the measuring head.
Negative pressure can cause problem during filling process.
Remove the HYDROCAL1005 unit from the valve every time you degas or
refill the transformer. You can also close the valve of the transformer
Never install the HYDROCAL unit on a valve that is closed for a long pe-
riod of time. Remove the unit if this cannot be avoided. Please refer to
De-installation instructions
Never install the HYDROCAL1005 on the suction side of the cooling
pump!
The HYDROCAL 1005 should be installed on positions located 100 cm be-
low of the oil level inside the transformer
Never install the HYDROCAL1005 unit on an elbow or curve of a tube.
The unit cannot operate by negative pressure produced by turbulences in
curves.

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Never install or remove the HYDROCAL1005 without opening first the
aeration screw.
Never use galvanized fittings or valves to mount the HYDROCAL1005
unit.
Galvanized fittings or valves can react with oil; this will produce incorrect
measuring values.
Never clean the HYDROCAL1005 unit with high pressure cleaning
equipment.
High pressure cleaning equipment used to clean transformers can seriously
damage the HYDROCAL1005 unit.
Never use a chaining key tool for mounting.
Use of such tools can damage the surface of the measuring head and the
threads. Please use an adjustable thin spanner for 1 ½“.
Attention!!!
Faulty or inappropriate handling of the sensor head like malfunction by
negative pressure, paint or solvent liquids make the warranty invalid.

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2.3 Preparation for installation
Before installation, a visual inspection of the unit must be carried out. Remove the protection cover
and check visually the components. All cables and tubes must be connected.
2.3.1 Power supply for the unit
The HYDROCAL1005 unit requires an auxiliary power supply of 110 / 230V close to the unit. The
power needed is max. 350 VA.
2.3.2 Requested tools:
Long Allen key, size 4 for aeration screw
Bucket, oil absorber, cleaning rag
Teflon-band
Drill / screw driver
Digital multimeter
Tin spanner M55 or adjustable tin spanner of 1 ½“ for valve and fittings
To seal the thread of the measuring head, either Teflon band (minimum 4 to 5 layers must be ap-
plied) or an O-Ring must be used.
2.4 Installation of the HYDROCAL1005 unit
Attention!!!
Mount the unit horizontally on the valve. The aeration screw must be in
the 12 o’clock position.
Please mount the HYDROCAL1005 unit on a valve with full opening (full bore valve) or a ball valve
with an internal thread of 1½” (DIN ISO 228: G 1½) . The HYDROCAL unit has a 1½’’ thread (Di-
mensional drawings, see. chapter 8). As an option a valve with NPT 1½ standard can also be used.
A good oil flux should exist on the mounting location. If necessary, use a reduction piece (adapter).
It is recommended to mount the HYDROCAL 1005 unit to valve with a union- or sleeve nut. In this
case the device has not to be turned to fix during the installation. An O-ring should be used as seal-
ing.
In case there exist strong vibrations on the mounting valve, the valve should be relieved by a sup-
port.
Then mount the unit according to the following steps:

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Only remove the protection cap (slowly while turning)
when you are ready to mount the measuring head!
Clean the internal side of the installation valve.
In case you don’t use a union or sleeve nut as connection point with o-ring, wind 4 to 5 layers of
Teflon band on the Hydrocal 1005 connection thread and mount it either directly into the valve or
into an additional adapter. If you use an adapter it should be mounted to the valve, before the Hy-
drocal 1005 will be mounted to the adapter. Wind 4 to 5 layers of Teflon band on the thread of the
adapter and mount it into the valve. Make sure that everything is fixed mechanically.
Turn the unit in order to get 12 o clock position.

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Attention!!!
The following steps must be done according to the company procedures.
Work carefully in order to prevent air entering into the transformer. Use a
bucket to catch oil coming out as described on following drawing.
Unscrew the aeration screw 3 –4 turns with Allen key No. 4. (Aeration is active).
Open the valve slowly until oil comes of the sample tube.
As soon as no air bubbles sort on the sample tube, close the aeration screw. Then fully open the
valve. Remove the oil from the measuring head externally.
Do not use any solvents for cleaning!

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2.5 Electrical Installation of HYDROCAL1005 unit
Use steel protected cables for power supply, alarm-cables and communication cables and con-
nect them to the appropriate connectors.
Recommendations for main supply cable:
Mains supply cable (3-wire)
(1) Phase 230VAC 20%
(2) Neutral
(3) Protection Earth
Wire : 1,5mm2
If optional GSM Modem is used, GSM antenna must be connected to Hydrocal as above draw-
ing:
Recommendations for alarm and external sensor cables:
Cable Specification (or equivalent)
Type: e.g. Ölflex FD855CP
Cable : 13,3mm (of external cable)
Wire : 0,5mm2(of 16 intern. wires)
Connect the power supply to the HYDROCAL1005 unit. The display shows the specified condi-
tions confirming that the HYDROCAL1005 is functioning correctly.
oBrown (L)
oBlue (N)
oGreen - yellow (PE)

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2.6 Completion of Installation
START-SCREEN
At first, date and time must be setup, refer to chapter
4.9.5.3.
The HYDROCAL1005 has a sub menu allowing con-
figuration of time, date as well as clock
MOUNT-BUTTON
The Hydrocal is currently not installed.
After the mount button is activated,
the Detect-Cycle will start.
DETECT-SCREEN
The Hydrocal filled up to level 1.
A circulation is made to remove air from the system.
Finally system is drained to level 0.
UNMOUNT-BUTTON
The Hydrocal is installed in normal operation.
(Currently Sync. Wait)
The selected Button is the unmount button.
(Controlled draining and stopping)

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Then, if everything is working correctly put the housing in correct position and secure it with the
knurled thumbscrews.
The measuring cycle of the HYDROCAL1005 unit is synchronized on the hour mark; this means
the first measuring value is available approx. 2, 22 or 42 min. after the hour mark and can be read
on the display.
After first start-up, in all cases date and time have to be checked on the HYDROCAL1005 display
and eventually have to be adjusted manually in clock settings (chapter 3.7.5.2) or with HydroSoft
(chapter 4.10.7).

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3. Hardware components of HYDROCAL 1005
3.1 Front view of HYDROCAL1005
On the front side of the HYDROCAL1005 unit the following operating elements are available.
[1]
LCD-display with 240 x 320 pixels
[2]
Screw mounting to mount the cover
[3]
Alphanumeric keyboard to enter numbers and text
[4]
Arrow-buttons to move in the menus, for data input and contrast set-up from the main
display (Up an Down)
[5]
Enter button to confirm and stop functions and data

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3.2 Rear side of HYDROCAL1005 unit
[1]
Measuring sensor with an internal thread of 1½ (DIN ISO 228: G 1½) or optionally (NPT
1½)

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[2]
Entrance for power supply 88 VACmin … 276 VACmax
Optional: 88 VDCmin … 390 VDCmax
max. 350 VA, 50/60 Hz
Then, power supply must be connected as follow :
oBrown (L)
oBlue (N)
oGreen - yellow (PE)
[3]
System outlet for digital and analogue inputs and outputs
Communication outlet for communication via analogue or GSM/GPRS-modem
[4]
ETHERNET connector
[5]
Gas Air Outlet

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3.3 Connections on the measuring and controller card
[1]
Connector ST13: 4 x Valve Control
Connection for valve control

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[2]
Connector ST14: Pumps Oil Air
Connection for pumps oil air control
[3]
Connector ST11: Oil Level / Oil-Flow
Connection for oil level / oil flow control
[4]
Connector ST3: Humidity Temperature
Connection for humidity temperature control
[5]
Connector KL1: Power supply
Note: The connection [5] is connected to a filter module from
where the connection to the power supply 88 VACmin …
276 VACmaxand PE is made
As showed on picture on the left side, usually you just need to
connect cables to the main power supply connector
Brown L
Blue N
Green/yellow PE