Qualitrol 509ITM Series User manual

QUALITROL509ITM Series
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QUALITROL509ITM-100
QUALITROL509ITM-200
QUALITROL509ITM-300
Intelligent Transformer Monitor
Hardware and Software Instructions
Document ID: IST-099-1 ECN-43847

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About Qualitrol®
QUALITROL®manufactures substation and transformer monitoring and protection
devices used by electric utilities and OEM manufacturing companies. It is the global
leader in sales and installations of transformer asset protection equipment, fault
recorders, and fault locators. Established in 1945, QUALITROL®produces different
types of products on demand, customized to meet unique requirements.
Qualitrol, LLC
1385 Fairport Rd.
Fairport, NY 14450
Safety
The following symbols appear throughout the manual and indicate important safety
instructions:
Warning
Indicates information is important for personal shock safety. Failure to follow may result
in personal injury or death.
Caution
Indicates information is important for the proper operation of the equipment. Failure to
follow may result in damage to the equipment.
Operation outside of the intended use shall not be the responsibility of Qualitrol.
©2023 QUALITROL®Company LLC, an ISO 9001 system certified company. All rights reserved. Information subject to change without notice.
All trademarks are properties of their respective companies, as noted herein. IST-099-1.
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, the English version takes precedence.

Contents
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Contents
Hardware Instructions..................................................................................... 8
Overview ...................................................................................................................8
QUALITROL509 Series Intelligent Transformer Monitor ............................................... 8
About Qualitrol.................................................................Error! Bookmark not defined.
About These Hardware Instructions................................................................................ 9
Controls, Indicators, and Modules........................................................................10
Front Panel................................................................................................................... 10
Modules........................................................................................................................ 11
RTD Input Module................................................................................................... 11
CT Input Module ..................................................................................................... 11
AC Voltage Input Module........................................................................................ 11
Tap Position Input Module (509ITM-300)................................................................ 12
Potentiometer Input Module.................................................................................... 12
DC Voltage Input Module........................................................................................ 12
Current Input Module .............................................................................................. 12
Dry Contact Closure Module................................................................................... 12
Powered Contact Closure Module........................................................................... 13
Installation ..............................................................................................................14
Location and Mounting.................................................................................................. 14
Installing the Hardware ........................................................................................... 14
Mounting Styles...................................................................................................... 17
Power Supply ............................................................................................................... 19
Heater Option ............................................................................................................... 21
RTD Input Modules....................................................................................................... 21
CT Input Module........................................................................................................... 22
AC Voltage Input Module.............................................................................................. 22
Tap Position Input Module (509ITM-300)...................................................................... 23
Potentiometer Input Module.......................................................................................... 24
DC Voltage Input Module.............................................................................................. 24
Current Input Module.................................................................................................... 25
Dry Contact Closure Input Module................................................................................ 27
Powered Contact Closure Input Module........................................................................ 27

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Output Contacts............................................................................................................ 28
Remote Output Signals................................................................................................. 29
Communications........................................................................................................... 30
Operation ................................................................................................................31
Automatic Operation..................................................................................................... 31
Viewing Channels or Viewing Mode Scrolling ......................................................... 31
MENU Mode........................................................................................................... 31
Program Mode........................................................................................................ 34
Cooling System Monitor (509ITM-200) .................................................................35
Load Tap Changer Monitor (509ITM-300).............................................................36
Testing the System....................................................................................................... 37
Functional Specifications......................................................................................37
Software Instructions.................................................................................... 39
General Information ...............................................................................................39
Connecting to the 509ITM......................................................................................39
Installing/Running the Software............................................................................39
Desktop Communications Window ......................................................................39
File Menu...................................................................................................................... 40
Establishing Communications with the 509ITM ..................................................41
Troubleshooting the Communications Link ........................................................43
Overview of the 509ITM Tools...............................................................................43
Opening a Tool.......................................................................................................45
Using the Monitor Tool ..........................................................................................45
Using the Simulator Tool.......................................................................................46
Using the Factory Calibrator Tool (Advanced users only) .................................47
Using the Setup Tools ...........................................................................................50
System Settings............................................................................................................ 52
Password Setup...................................................................................................... 53
Installed Features ................................................................................................... 54
Time and Date Setup.............................................................................................. 54
Display Setup.......................................................................................................... 56
Heater Setup........................................................................................................... 57
Communications........................................................................................................... 58

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Front USB - Service Port......................................................................................... 59
Main 485 - Main Port............................................................................................... 60
Aux 485 - Auxiliary Port........................................................................................... 61
Ethernet - Port ........................................................................................................ 63
Cancel and Load Buttons........................................................................................ 63
Input Modules............................................................................................................... 65
Module.................................................................................................................... 66
Custom Scaling....................................................................................................... 67
CT Current Parameters........................................................................................... 68
Winding Temperature Setup (Calculated) ............................................................... 69
Simple Calculation Setup Method ..................................................................... 69
Advanced Calculation Setup Method................................................................. 73
Output Relays............................................................................................................... 78
Relay Tabs.............................................................................................................. 79
Relay Control.......................................................................................................... 79
Seasonal Setpoint................................................................................................... 82
Ambient Temperature Forecast............................................................................... 83
Cooling Equipment Exerciser.................................................................................. 86
Matrix Controlled..................................................................................................... 88
Cancel and Load Buttons........................................................................................ 90
Output Loops................................................................................................................ 91
Loop Parameters .................................................................................................... 92
Custom Range........................................................................................................ 92
Loop Controlled ...................................................................................................... 93
Bank Switching............................................................................................................. 93
TransLife™................................................................................................................... 95
TransLifeTM Control................................................................................................. 96
Consumed Life........................................................................................................ 97
Critical Forecast...................................................................................................... 98
Temperature Profiler............................................................................................. 100
Data Logger................................................................................................................ 102
Event Recorder........................................................................................................... 105
Module.................................................................................................................. 106
Record Type......................................................................................................... 106

509ITM Hardware and Software Instructions
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Event Trigger........................................................................................................ 107
Cooling System Monitor (509ITM-200) ....................................................................... 108
Cooling Bank Setup.............................................................................................. 110
Setup .............................................................................................................. 111
Running Bank Current..................................................................................... 113
Starting Motor Current Value........................................................................... 114
Number of Actuations...................................................................................... 115
Run Time ........................................................................................................ 115
Flow Gauge..................................................................................................... 116
Differential Temperature.................................................................................. 116
Cancel and Load Buttons................................................................................ 116
Cooling Monitor Initialization ................................................................................. 117
Load Tap Changer Monitor (509ITM-300)................................................................... 119
LTC Requirements and Recommendations for Use.............................................. 119
LTC Monitor Setup................................................................................................ 120
Tap Position.................................................................................................... 121
Tap Count....................................................................................................... 122
Tap Motor Sensing.......................................................................................... 122
Load Current................................................................................................... 123
Alarm Setup.................................................................................................... 123
High Priority - LTC Alarm Setup............................................................................ 124
Alarm Relay Setup.......................................................................................... 125
Total Tap Counts............................................................................................. 126
Multiple Tap Movements................................................................................. 126
Tap Run Time................................................................................................. 127
Tap Counts Per Period.................................................................................... 127
Running Motor Current.................................................................................... 128
Starting Motor Current..................................................................................... 128
Motor Actuations............................................................................................. 129
Motor Actuation Time...................................................................................... 129
Differential Temperatures................................................................................ 130
Cancel and Load Buttons................................................................................ 130
Low Priority LTC Alarm Setup............................................................................... 130
Difference Calculation................................................................................................. 131

509ITM Hardware and Software Instructions
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View LTC Values........................................................................................................ 132
QUALITROL®509ITM –DW with Direct Winding ...............................................134
System Overview........................................................................................................ 134
Components............................................................................................................... 134
System Setup............................................................................................................. 135
Using an optical hot spot module with an analog connection ................................ 135
Using an optical hot spot module with a digital connection.................................... 136
Comparing direct and calculated winding temperature methods ........................... 136
Importing and Exporting Configuration Files....................................................138
Expansion Module Option...................................................................................139
Location and Mounting................................................................................................ 140
Input Supply Power:.................................................................................................... 142
Communications......................................................................................................... 142
Input Modules............................................................................................................. 143
Calibrating the 509ITM.........................................................................................146
Calibrating Remote Outputs for Alternate Values........................................................ 157
Overview and Requirements................................................................................. 157
Calibration Procedure ........................................................................................... 157
Calibrating a Level Gauge to the 509ITM.................................................................... 161
Overview............................................................................................................... 161
Before You Begin.................................................................................................. 161
Calibration Procedure ........................................................................................... 161
Calibrating a Tap Position Resistor Bridge to the 509ITM........................................... 165
Overview............................................................................................................... 165
Before You Begin.................................................................................................. 165
Calibration Procedure ........................................................................................... 166
Frequently Asked Questions About the 509ITM................................................173
Appendix....................................................................................................... 178

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Hardware Instructions
Overview
QUALITROL509 Series Intelligent Transformer Monitor
The QUALITROL509 Series Intelligent Transformer Monitor (509ITM) for Liquid-Filled
Transformers offers microprocessor technology and advanced digital signal processing to
accurately assess the health and performance of oil-filled transformers.
The 509ITM can be tailored to suit the application. This complete transformer monitoring
system can monitor up to eight total parameters (up to sixteen if an Expansion Module is
added), such as:
•Liquid Temperatures (Main Tank Top or Bottom, Load Tap Changer)
•Winding Temperatures
•Ambient Temperatures
•Winding Current
•Cooling Bank Currents
•A variety of parameters from transducers, such as Tank Pressure or Dissolved Gas in
Oil analysis
Available 509ITM inputs include:
•Resistance Temperature Detectors (RTDs)
•Current Transformers ( 0 –5 A, 0 –10 A, 0 –20 A, 0 –50 A, 0 –100 A)
•AC Voltage (0 - 140 VAC or 0 - 320 VAC)
•Potentiometer (5K - 15K)
•Current Loops (0 - 1 or 4 - 20 mA DC)
•DC Voltage (0 - 100 mV or 0 - 10 V)
•Tap Position Resistor Bridge
•Switch Contact Closure (powered or dry)

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The 509ITM offers:
•Advanced thermal modeling of winding temperatures
•Superior temperature control for higher loads
•Integrated Load Tap Changer (LTC) temperature monitoring
•Standalone or networked substation monitoring
•Diagnostic tools for condition based maintenance
•Eight, Form C programmable relays to operate cooling equipment, signal alarms, and
provide trip functions, depending on transformer conditions
•Four, 0 - 1 or 4 - 20 mA DC loops for use with SCADA systems
•Digital communication ports RS-232 and RS-485
The device is easy to install and use. It is designed to be mounted outdoors, with a heater
available inside the enclosure, in a transformer control cabinet, and it is powered by a
universal power supply of 100 - 240 VAC 47 - 63 Hz single-phase power or 45 - 260 VDC. It
comes with user-friendly, computer-aided setup software that can be supplied with non-
intrusive, easy-to-retrofit sensors.
About These Hardware Instructions
These Hardware Instructions provide all the information you will need to configure, install,
and operate your 509ITM. They are organized into the following sections:
Controls, Indicators, and Modules - Diagrams and brief descriptions to help you locate
and understand basic functions of each of the controls, indicators, and modules that make
up the 509ITM.
Installation - Illustrated instructions to guide you through mounting, supplying power to, and
wiring your transformer monitor.
Operation - A description of automatic operation, as well as easy instructions on viewing
parameters and set points, resetting memories, programming the 509ITM using the Keypad,
and testing the system.
Functional Specifications - A detailed, functional specification of the monitor.
Appendix - A functional wiring diagram for your reference, an example of the front panel
menu diagram, and a rear cover view.

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Controls, Indicators, and Modules
Front Panel
The functions of the display and the keypad on the front panel are described below. For
operating instructions, refer to the Operation section.
DISPLAY - Every two seconds, the display automatically scrolls through the channels and
displays the channel name and the value of the parameter. It also displays the selected
indications of the keypad control.
KEYPAD - The ENTER key is used to change menu modes or accept changes to values;
the TEST key displays the set point source and value on the DISPLAY; the MENU key is
used to access the programming menu; and the RESET key is used to reset the maximum
and minimum values, while in the program menu, or unlatch any latched relays while in the
normal scrolling mode. The ARROW keys are used to move through the various menus. For
a full operation description, refer to the Operation section.
SET POINT INDICATORS - A red LED illuminates to indicate that the set point for the relay,
indicated on the overlay, has been exceeded.
RS-232 / USB PORT - When used with the Qualitrol software, this port allows for the setup
of all of the parameters of the monitor. See the Software Instructions section for a full
description of this setup procedure.
509ITM Front Panel