Qualitrol 118 ITM Series User manual

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Information in this document is subject to change without notice. This document is provided to purchasers of
QUALITROL®products for use in the installation, operation, and servicing of such products. No other use, nor any
reproduction, distribution, or the making of any derivatives of this document is authorized without the express prior written
permission of QUALITROL.
QUALITROL endeavors to ensure the accuracy and quality of its published materials; however, no warranty, expressed or
implied, is provided. QUALITROL disclaims any responsibility or liability for any direct or indirect damages resulting from
the use of the information in this manual or products described in it. Mention of any product or brand does not constitute
an endorsement by QUALITROL of that product or brand.
This document was originally composed in English and was subsequently translated into other languages. The fidelity of
subsequent translations cannot be guaranteed. In case of conflict between the English version and another language
version
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lish version takes
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Contents
Contents
Overview .........................................................................................................1
1.1.QUALITROL Intelligent Transformer Monitor..............................................1
1.2.QUALITROL....................................................................................................2
1.3.About This Manual ........................................................................................2
Installation and Wiring...................................................................................3
2.1.Mounting of the Transformer Monitor .........................................................3
2.2.Primary Power ...............................................................................................5
2.3.Sensors ..........................................................................................................5
2.3.1.Relay Contacts...................................................................................................6
2.3.2.Analog Output.....................................................................................................7
2.3.3.USB Link.............................................................................................................7
2.3.4.RS-485 Link (Optional).......................................................................................7
Operation ........................................................................................................7
3.1.Temperature Display.....................................................................................7
3.2.Status Lamps.................................................................................................7
3.3.Audible Alarm................................................................................................7
3.4.Push Buttons.................................................................................................8
3.5.Fan Exerciser.................................................................................................9
Functional Specifications............................................................................10
Setup Software .............................................................................................12
5.1.Installation for Window XP *For Win7 refer to Appendix F*.....................12
5.2.Files ..............................................................................................................17
5.3.Configuration...............................................................................................19
Appendix A – Manual Set Point Adjustment..............................................22
Appendix B – Thermocouple Accuracy......................................................23
7.1.Installation Considerations.........................................................................23
7.2.Method for Testing ITM Accuracy..............................................................23
Appendix C – Error Codes...........................................................................24
Appendix D – Using the Model 118 ITM in the European Community.....25
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Contents
9.1.Installation....................................................................................................25
9.2.Fuses............................................................................................................26
Appendix F – Installing Configuration Software on Win7 ........................27
Appendix G – Modbus Communications ...................................................30
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Overview
1
Overview
1.1. QUALITROL Intelligent Transformer Monitor
The Model 118 ITM Intelligent Transformer Monitor (ITM) can monitor up to three
thermocouples in ventilated dry-type transformer windings, display the current winding
temperatures, and operate relays by comparing the highest of the three winding
temperatures to stored set point temperatures.
The ITM provides the following standard features:
Monitors three, type K thermocouples.
Displays each of the three thermocouple temperatures as well as the maximum
temperature stored.
Displays the channel that caused the stored maximum temperature.
Operates high-contact rating SPST relays with fuse-protected contacts to control cooling
FANs.
A Manual Fan Control provides the capability to force the FANs to turn ON.
A yellow LED indicates that the FANs are ON.
A Fan Exerciser Circuit turns the FANs ON for a short time at periodic intervals (ON time
and intervals are programmable).
Operates a relay with an SPDT contact when one of the inputs exceeds the ALARM
setting.
A red LED indicates that the ALARM is ON.
An internal audible device (buzzer) sounds when the ALARM is ON. The audible device
can be silenced by the Front Panel Silence button without changing the state of the
ALARM relay.
The ALARM relay default state is normally energized so that the ALARM is initiated upon
power failure (failsafe). All other relay default states are normally de-energized (non-
failsafe). The normal state of all relays, except for the Fan Control Relays, may be
changed via the USB port and software, allowing for customer configuration.
RELAY 4 and RELAY 5 are available for use depending on application. The normal state
of these relays may be set by the user software. A red LED indicates the status RELAY
4 and 5
If a thermocouple goes open circuit, it is detected, the ALARM operates, and the faulty
channel displays “- - -”. A failed thermocouple will not cause a TRIP.
Operates a relay with an SPDT contact when one of the inputs exceeds the TRIP
setting.
A red LED indicates that the TRIP relay is ON
A TEST function shows the stored set points, shows the internal temperature of the ITM,
and tests the LCD display, relay status LEDs, and the buzzer.
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Overview
2
An analog output is provided that is proportional to the highest of the three input
temperatures. The output can be configured to be 0–1 mA, 0–10 mA, 0–20 mA,
4–20 mA, or 0–5 V
A USB data line is used to set up the programmable parameters of the unit.
Power to the unit is via a Universal Power Supply that can accept as Prime Power 80–
300 VAC 50/60 Hz or 40–280 VDC.
The 118 ITM is a panel mounted through a cutout.
RS-485 data link with Modbus protocol is available as an option that must be specified at
the time of the order.
1.2. QUALITROL
QUALITROL has been a leader in supplying pressure, liquid-level, and temperature controls
since 1945. As an ISO 9001 system-certified company, we are committed to providing you
with quality and reliability, both in our products and in our service.
1.3. About This Manual
This manual provides all the information you will need to install, set up, and operate your
QUALITROL Intelligent Transformer Monitor. It is organized into the following sections:
Installation – Step-by-step, illustrated instructions to guide you through mounting, supplying
power to, and wiring your Transformer Monitor.
Operation – A description of use during transformer operation, as well as easy instructions
on how to perform a system test while the transformer is in service.
Functional Specification – A detailed functional specification of the unit.
Setup Software – Step-by-step instructions to guide you through configuration of the
Transformer Monitor to meet your specific needs.
Appendix A – Step-by-step instructions to guide you through the manual adjustment of set
points of the Transformer Monitor.
Appendix B – Guides you through the installation considerations and the method of testing
a thermocouple-equipped ITM for accuracy.
Appendix C – Guides you through the possible error codes that may be displayed, the
conditions that resulted in the error codes, and the situations’ effects on the Transformer
Monitor.
Appendix D – Guides you through special requirements in order to use the Transformer
Monitor in the European community.
Appendix E – Step-by-step instructions to guide you through set up of the Transformer
Monitor for use with Modbus communications.
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Operation
3
Installation and Wiring
2.1. Mounting of the Transformer Monitor
The 118 ITM mounts in a rectangular cutout for a panel or a hinge mount, which is secured by
four ¼” bolts. See Figure 1; 118 ITM Dimensions.
Figure 1a – 118 ITM-P Dimensions
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Operation
4
Figure 1b – 118 ITM-H Dimensions
Figure 1c – 118 ITM-E Dimensions
°C
MANUAL AUTO
SILENCE TEST
ALARM
MAX TEMP
RESET
FANS
FANS
ALARM
TRIP
RELAY 4
RELAY 5
6.25
[158.8]
.16
[4.1]
.41
[10.5] 8.50
[215.9]
10.50
[266.7]
6.00
[152.4]
10.93
[277.7]
.31 WD x .50 LG
SLOTS (4 PLCS)
VENT
.63
[16.0]
QUICKRELEASE
LATCH(2PLCS)
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Operation
5
2.2. Primary Power
Primary Power is connected to TB1-13 and TB1-14 with an Earth Ground connection to TB1-15.
This connection provides power to the 118 ITM. Power can be 80 to 300Vac or 40 to 280Vdc.
2.3. Sensors
The three thermocouple sensors are connected to TB4-1(+), 2(-); TB4-3(+), 4(-), and
TB4-5(+), 6(-). See Figure 2; Wiring Diagram.
To connect the Type K thermocouples, the YELLOW lead is connected to the positive terminal
(1, 3, or 5), and the RED lead is connected to the negative terminal (2, 4, or 6).
If no thermocouple is connected to an input, those input terminals must be shorted together.
This will prevent the ITM from reporting an alarm condition, due to a failed input, and will cause
that channel to show the internal temperature of the ITM. If the channel is not used, it can be
turned OFF using the setup software, but the terminals still must be shorted together.
Figure 2 – Wiring Diagram
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Operation
6
2.3.1. Relay Contacts
FAN #1 – Power for Fan #1 is connected to TB2-3 (N) and TB2-4 (L). Fan #1 is connected to
TB2-1 and TB2-2. There is a 30 A fuse in series with TB2-1.
FAN #2 – Power for Fan #2 is connected to TB2-7 (N) and TB2-8 (L). Fan #2 is connected to
TB2-5 and TB2-6. There is a 30 A fuse in series with TB2-5. Note that the Fan #2 circuit is
electrically separate from Fan #1.
ALARM – SPDT (form C) contacts are provided at TB1-1, -2, and -3 to indicate an alarm
condition. This relay is usually set to be energized in the normal state so that the power OFF
state will cause an alarm (failsafe). The normal state can be changed by the User Configuration
software via the USB port.
NOTE: Under failsafe conditions below set point, TB1-1 and -2 are closed, and TB1-2 and
-3 are open. Under failsafe alarm conditions, TB1-1 and -2 will open, and TB1-2
and -3 will close. The operation of this relay can be changed to be non-failsafe,
the opposite of that described above, through the software configuration.
TRIP – SPDT (form C) contacts are provided at TB1-4, -5, and -6 to indicate that the
temperature being monitored has reached the trip state. This relay is usually set to be de-
energized n the normal (non-failsafe) state. The normal state of the relay can be changed by
the User Configuration software via the USB port.
NOTE: Under non-failsafe conditions below the set point, TB1-4 and -5 are open, and
TB1-5 and -6 are closed. Under non-failsafe trip conditions, TB1-4 and -5 will
close, and TBI-5 and -6 will open The operation of this relay can be changed to be
failsafe, the opposite of that described above, through the software
configuration.
RELAY 4 (form C) contacts are provided at TB1-7, -8, and -9 to indicate that the temperature
being monitored has exceeded the set point. This AUX relay is usually set to be de-energized in
the normal (non-failsafe) state. The normal state of the relay can be changed by the User
Configuration software via the USB port.
NOTE: Under non-failsafe conditions below the set point, TB1-7 and -8 are open, and
TB1-8 and -9 are closed. When the set point is exceeded, TB1-7 and -8 will close,
and TBI-8 and -9 will open. The operation of this AUX relay can be changed to be
failsafe, the opposite of that described above, through the software
configuration.
RELAY 5 (form C) contacts are provided at TB1-10, -11, and -12 to indicate that the temperature
being monitored has exceeded the set point. This AUX relay is usually set to be de-energized in
the normal (non-failsafe) state. The normal state of the relay can be changed by the User
Configuration software via the USB port.
NOTE: Under non-failsafe conditions below the set point, TB1-10 and -11 are open, and
TB1-11 and -12 are closed. When the set point is exceeded, TB1-10 and -11 will
close, and TBI-11 and -12 will open. The operation of this AUX relay can be
changed to be failsafe, the opposite of that described above, through the
software configuration.
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Operation
7
2.3.2. Analog Output
An analog output is available at TB5-1(+) and TB5-2(–) that provides an analog signal
proportional to the highest temperature. The analog signal can be selected by the User
Configuration software to be 0–1 mA, 0–10 mA, 0–20 mA, 4–20 mA, or 0–5 V.
2.3.3. USB Link
A USB data link is provided for setting up the 118 ITM. A USB plug is provided for this link.
Refer to the Setup Software section of this manual for more detailed information.
NOTE: The USB cable should only be connected when a configuration update is
required. No permanent wires should be connected to this connector.
2.3.4. RS-485 Link (Optional)
The optional RS-485 data link is accessed through a terminal block connector on the back of
the unit. This provides a method of communicating with a remote master station using Modbus
RTU protocol. Convert to a two-wire RS-485 connection jumper TB3-1 (RXD+ (B)) with TB3-3
(TXD+(B)) and jumper TB3-2 (RXD-(A)) with TB3-4 (TXD-(A)) for half duplex operation. Refer to
Appendix E of this manual for additional information.
Operation
3.1. Temperature Display
The temperature display consists of a three-digit, seven-segment, back-lit LCD display that can
show temperatures from 0°C to 250°C, and three individual icons that identify the temperature
being displayed. The display shows each reading for approximately one second and then
automatically steps to the next reading.
The display shows the three winding temperatures and then the maximum stored temperature.
While the maximum stored temperature is displayed, both the MAX icon and the icon
representing the winding that caused the maximum reading turn ON.
3.2. Status Lamps
Five LEDs are provided that indicate the status of the output relays. Refer to Figure 3; Front
Panel.
A yellow FAN LED indicates that the FAN relay is activated.
A red ALARM LED indicates that the ALARM relay is in the ALARM state.
A red TRIP LED indicates that the TRIP relay is in the TRIP state.
A red fourth-relay LED indicates that RELAY 4 is in the active state.
A red fifth-relay LED indicates that RELAY 5 is in the active state.
3.3. Audible Alarm
An internal buzzer sounds each time the ALARM becomes active. The buzzer can be silenced
by pressing the SILENCE/TEST push-button. The buzzer will then turn OFF and remain OFF
until a new ALARM occurs.
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Operation
8
3.4. Push Buttons
Pressing the MANUAL/AUTO FAN button will force the FAN relay to activate. The FANs will
stay ON until the button is pressed again. A MAN icon on the LCD display indicates whether the
manual FAN ON function is active. Pressing the button to release the MANUAL FAN function,
while the temperature is above the FAN ON set point, will turn OFF the MANUAL FAN icon on
the LCD but will NOT turn OFF the FANs. Thus, the MANUAL FAN button can force the FANs
ON but cannot force the FANs OFF.
Pressing the SILENCE/TEST button while the buzzer is sounding will silence the buzzer until
the next new alarm condition occurs.
Pressing the SILENCE/TEST button while the buzzer is not sounding will start a TEST
sequence. The TEST sequence does the following at two-second intervals:
Displays the FAN ON temperature set point and lights the FAN LED.
Displays the ALARM temperature set point and lights the ALARM LED.
Displays the TRIP temperature set point and lights the TRIP LED.
Displays the RELAY 4 temperature set point and lights the RELAY 4 LED.
Displays the RELAY 5 temperature set point and lights the RELAY 5 LED.
Displays the ambient temperature inside the ITM.
Displays 888 on the temperature display, turns on all icons on the display, turns on all relay
status LEDs, and turns on the buzzer.
Pressing the MAX TEMP RESET button will clear the memory of the maximum stored
temperature causing the current winding temperatures to become the new maximum stored
temperature for each channel.
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Operation
9
Figure 3 – Front Panel
3.5. Fan Exerciser
The unit has a built-in Fan Exerciser function that can turn the FANs on for a short period of
time at periodic intervals. The default setting is for one minute every seven days.
The Fan Exerciser can be configured to be active or inactive. When inactive, it will never turn
the FANs ON.
If the Fan Exerciser is active, it will start timing with a FAN run period when the unit is powered
up. Thus, if the Fan Exerciser run time is one minute, the FANs will turn ON for one minute after
power up. If the Fan Exerciser run time is set for 15 minutes, the FANs will turn ON and run for
15 minutes after power up.
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Functional Specifications
10
Functional Specifications
Performance: Input Power:
Power
Consumption:
80 to 300 VAC 50/60 Hz ;
40 to 280 VDC Universal Power Supply
<10Watts
Measurement
Range: 0°C–250°C
Display Resolution: 1°C increments
Input
Measurement
Accuracy:
±3°C
Memory Retention: 40 years (with power OFF)
Contact Ratings
Fans:
Alarm & Trip:
Fan Circuit Rating:
Volts Resistive Horsepower
120 VAC 30 A 1 Hp
240 VAC 30 A 2 Hp
120 VAC 10 A - - - - - - -
240 VAC 8 A - - - - - - -
UL Rated for 20A
Remote Output
Current Loop:
Accuracy:
0 to 1 mA = into 10,000max. load
0 to 10 mA = into a 1000 max. load
0 to 20 mA = into 500max. load
4 to 20 mA = into 500max. load
0 to 5 V
±3°C
Fan Exerciser Fan Run Time – 1 to 120 minutes
Fan Cycle Time – 0.01 to 30.0 days
Time starts at power up.
Optional Modbus
Communications Via electrically isolated 2- or 4-wire RS-485 link
Environment: Operating
Temperature: 30°C to +72°C
Storage
Temperature: 50°C to +72°C
Relative Humidity: 10 to 90% non-condensing
Hi-pot: 1500 VAC 50/60 Hz for 1 minute; relay contacts
and power input to all other terminals and earth
ground
Vibration: 50/180 Hz @ .004"displacement
Shock: 10 G’s in 3 orthogonal planes
Transient
Suppression: Per ANSI 37.90a-1989 oscillatory waveform test
This device is protected against Radio Frequency Interference.
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Functional Specifications
11
Mechanical:
(Panel Mount
Unit)
Front Panel: 6.5"[165.1mm]Wide x 9.10"[231.1mm]HighGraphic
overlay UV resistant for outdoor use.
Mounting: Panel mount through 5.37" [136.4 mm] wide x 7.97"
[202.4 mm] high cutout. Ø.261[6.63mm]
Depth: 2.22" [56.4 mm]
Weight: 3lbs[1.4kg
Terminals: Screw terminal; maximum 12-gauge wire
Mechanical
(Hinge Mount) Mounting Hinge mount through 8.82" [224.03mm] wide x
15.12" [384.05 mm] high cutout. Mounting Holes
7.94"[201.63mm]Wide x 14.25"[361.95mm]High,
Ø.261[6.63mm] x (4)
Depth 4.28"[108.71mm]
Weight 5lbs[2.3kg]
Terminals: Screw terminal; maximum 12-gauge wire
Mechanical
(Wall Mount
Weatherproof
Box)
Mounting Height = 10.5” [267mm]
Width = 8.9” [226mm]
Depth = 6.38” [162mm]
Weight 6.5lbs [2.9kg]
Mounting (4) #1/4 screws on a 10.94” [277.8mm] x 6.00”
[152.4mm] pattern.
Terminals: Screw terminal; maximum 12-gauge wire
Approvals: Registered per UL standard 873.
Registered per Canadian Standard C22.2 No. 24
Declaration of Conformance CE.
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Setup Software
12
Setup Software
Note: The software is NOT supplied with every unit – it can be ordered as a separate
item with USB cable Item number: KIT-207-1
The ITM Configuration software is a Windows-based program that allows the user to set up
parameters in the QUALITROL Model 118 ITM Intelligent Transformer Monitors via the USB
port.
5.1. Installation for Window XP *For Win7 refer to Appendix F*
Run ITM Setup.exe from the software CD, this will create a directory C:\Program
Files\QUALITROL\ITM118 on the hard drive, and it will install the program and default
configuration files in that directory. It will also put an icon on the desktop to start the
program.
Before you can configure the 118 ITM a driver must be installed to allow the configuration
software to talk to a USB port. Do the following to install the USB driver:
Turn ON the ITM and connect to the computer with a USB printer cable (USB male A to
USB Male B) The ITM will display USB
The computer will show “Welcome to the Found New Hardware Wizard” select “Install from
a list or specific location” and click Next (see Figure 4)
Figure 4
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Setup Software
14
Click “Finish” on the next screen completing the driver installation. Figure 7
Figure 7
The windows file usbser.sys needs to be in the Windows\System32\Drivers folder (it usually
is) in order to install the USB drive. If the install program says it can't find the driver file, you
will need to search the computer to find it and copy it to Windows\System32\Driver folder
and repeat the process above.
Once the driver is successfully installed you must find what communication port number was
assigned so that when you start the ITM Configuration program you can enter the correct
communication port number.
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Setup Software
16
Click the + sign next to ports and it will show the communication port number next to “IAR
virtual COM port”. For example (COM7) means the communication port number is 7. (See
Figure 10)
Figure 10
In a Windows 7 machine do the following: Click Start button – Control Panel – System and
Security. Under System click Device Manager. Click the triangle sign next to Ports and it
will show the communication port number next to “IAR virtual COM port”. For example
(COM7) means the communication port number is 7.
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