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

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Modules
The modules comprising the 509ITM include:
•RTD Input Module
•CT Input Module
•AC Voltage Input Module
•Tap Position Input Module (required for the 300 Series)
•Potentiometer Input Module
•DC Voltage Input Module
•Current Input Module (required for the 200 Series)
•Dry Contact Closure Module
•Powered Contact Closure Module
RTD Input Module
RTD Input Modules are used for monitoring liquid, ambient, or if used in a heated well,
winding temperatures. The input to the module is either a 10 ohm copper or a 100 ohm
platinum RTD (factory configured).
For measuring liquid or ambient temperatures, the module is scaled over the range of -40 -
120° C. If it is used in a heated well, the scale is -40 - 200° C. When ordering the 509ITM
from the factory, the temperature requirements need to be specified.
CT Input Module
The CT Input Module is used to monitor winding temperatures, winding currents, motor
currents of LTCs, or fan currents. The input to the module is a clamp on the CT, provided by
Qualitrol, which has an input range of 0 - 5 A, 0 - 10 A, or 0 - 20 A, other ranges are
available, and an output of 0 - 0.333 VAC, can be used as the input to the CT Input Module.
If this module is used for winding temperatures, the scaling is in the range of -40 - 200° C;
for anything other than temperature, the range is scalable to a maximum of 99999.9° C.
AC Voltage Input Module
The AC Voltage Input Module is used to monitor any AC voltages under 320 VAC. The input
module works in conjunction with the Qualitrol Voltage Sensor, TRA-600-1, and measures
ranges of either 0 - 140 VAC or 0 - 320 VAC.
The range is scalable to a maximum of 99999.9 VAC.

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Tap Position Input Module (509ITM-300)
The Tap Position Input Module is used for measuring the movement of the drive mechanism
of the Load Tap Changer. The input to the module is a powered or a non-powered resistor
bridge attached to the drive mechanism. The module can accept up to 33 tap positions, and
if a resistor bridge is used for the sensor, the bridge may be made up of resistors of equal
values from 40.2 - 2500 ohm. The resistor bridge may be powered by 0 - 1 VDC, 0 - 5 VDC,
0 - 10 VDC, -5 - 5 VDC, -10 - 10 VDC, or 0 - 125 VDC. If the resistor bridge is not powered,
a Tap Position Input Module may be configured to supply a sensing voltage to the resistor
bridge. Tap Position Input Modules must be calibrated on site. For more information, see the
Using the Factory Calibrator Tool (Advanced users, only) section in the Software
Instructions.
The scaling for this module varies according to the number of tap positions that exist on the
resistor bridge; but a typical application is -16 - +16.
Potentiometer Input Module
The Potentiometer Input Module is used for monitoring liquid level, flow gauges, or gas
accumulation. The input to the module is a potentiometer that is typically supplied by
Qualitrol. The range of the potentiometer input is up to 15,000 ohm. Typically, the 25° mark
on a liquid level dial is set to the center of the potentiometer range, and the high and low
readings are simply ratios of the angular deflections from the normal setting. Qualitrol
gauges use a 340 angular degree potentiometer on a 2:1 gear ratio from the dial travel to
the potentiometer travel. The Potentiometer Input Module must be calibrated on site. For
more information, see the Using the Factory Calibrator Tool (Advanced users, only) section
in the Software Instructions.
The scaling of the 509ITM for this module is 0 - 100%.
DC Voltage Input Module
The DC Voltage Input Module is used for monitoring transducer outputs with an output
signal in either the 0 - 100 mV DC or 0 - 10 VDC range.
The range for this module is scalable to a maximum of 99999.9 VDC.
Current Input Module
The Current Input Module is used for monitoring transducer output with an output signal in
either the 0 - 1 mA DC or 4 - 20 mA DC range. These can be devices such as pressure
transducers for measuring main tank pressure, bushing pressure, or dissolved gas in oil
transducers.
The input module can be configured to operate with either two-wire loop transducers, which
are powered by the module, or three-wire transducers that are powered by the module or
from the transducer.
The range for this module is scalable to a maximum of 9999.99 mA DC.
Dry Contact Closure Module
The Dry Contact Closure Module is used for monitoring a contact and indicating on a display
if it is open or closed. An open contact means there is no connection between the contacts;

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a closed contact signifies a shorted connection across the contacts. This can be used, for
example, to monitor pumps or fans. The system internally treats closed and opened contacts
as either a 0 or 100 numeric value. Therefore, if the module is used to control a relay, the
relay set point should be set at midrange, e.g., 50.
This module can monitor a non-powered, dry contact.
Powered Contact Closure Module
The Powered Contact Closure Module is used to monitor a powered contact, and it indicates
on the display whether it is opened or closed. An open means there is no connection
between the contacts, and closed indicates a shorted connection across the contacts. This
can be used to monitor alarms or active fans, for example. The system internally treats
closed and open contacts as either a 0 or 100 numeric value. Therefore, if the module is
used to control a relay, the relay set point should be set at midrange, e.g., 50.
The module will register a powered contact of >80 V AC/DC or >130 V AC/DC jumper
selectable as an Open; and a voltage of <50 V AC/DC or < 85 V AC/DC jumper selectable
as Closed.

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Installation
Location and Mounting
Installing the Hardware
1. Unpack the 509ITM.
2. Check that all of the materials on the packing slip are included.
3. Make four holes on the transformer panel for installation of the monitor.
Important:
•Note the mounting differences between the enclosure style and the panel-only style.
•Allow space below the monitor for the wiring harness.
4. Install the monitor.
Important: Ensure that the sensor type matches the input designator labels on the
509ITM dust cover.
509ITM Back Panel (silkscreen for reference only; see product model drawing for latest
revision)

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5. Wire input sensors to the correct inputs, TB3 through TB10.
6. Connect the correct alarm control circuitry, TB1-2 through TB1-13 and TB1-18 through
TB1-32. See the wiring schematics or engineering drawings for your specific
transformer.
Note: The optional heater input is TB1-1 and TB1-17.
Relay contact ratings: 10 A @ 115/230 VAC, 10 A @ 30 VDC
CAUTION: The loops must be connected to an isolated analog input to avoid
potential damage to the 509ITM.
7. If required, connect the current output loops, TB2-1 through TB2-8.
8. Connect the RS-485 communications to TB2-9 through TB2-13.
•4-wire: TB2-9 through TB2-12; signal ground on TB2-13, not an earth ground (used
for DNP, Modbus, IEC 60870 and ASCII protocol communications).
•2-wire RS485: Used only for digital sensors (Hot Spot Modules, DGA sensors, etc.;
not for external communications). TB2-16 is not an earth ground
9. Connect the input power, TB1-14, 15, and earth ground to TB1-16.
•Universal power supply:
100 - 240 VAC, 50/60 Hz
45 - 260 VDC
CAUTION: Installing power outside of the recommended input range will
damage the unit.
10. Energize the 509ITM.
The monitor briefly displays “Qualitrol” and the version of the board firmware.
Important: The following operation can cause the alarm output state to change.
11. On the front panel, press TEST.
Relays 1 through 8 actuate.
Note: Relays that have been configured with the test lockout feature enabled will not
operate, but the corresponding LED will light.
12. Upon commissioning the 509ITM, do the following steps to reset the maximum and
minimum values:
(a) Press MENU.
(b) Scroll to the View Maximum Value column (see menu flowchart).
(c) Press RESET.
(d) Scroll to the View Minimum Value column.
(e) Press RESET.
(f) Press MENU.
When the test is complete; the monitor defaults to the scrolling mode, cycling consecutively
through the display of each input. You are now ready to use the remote software which is

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found on the documentation CD-ROM, to view, change, or modify the settings of the 509ITM
to meet your requirements.
Warning
•Switch off the power supply before performing installation or maintenance.
•Hazardous voltage may still be present at the relay area, even if mains power is
disconnected.

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Mounting Styles
Enclosure (Fiberglass) Style
The 509ITM is a 3R fiberglass enclosure, designed to be back-mounted on any smooth
surface. Four 0.31 × 0.50 in. oval slots are provided for use with fasteners. The monitor
requires an approximate area that is 13 inches in width, 16 inches in height, and 8.5 inches
in depth. An additional area below the monitor should be allowed for the wiring harness.
Also allow a minimum 3 inch clearance area around the vents for proper ventilation. See
Mounting the 509 ITM figure for mounting centers and dimensions.
Panel Mount Style
The 509ITM is designed to be flush-mounted inside a transformer control cabinet on any
smooth surface. Four 0.28 in. square holes are provided for use with the 0.25 in. diameter
carriage bolts. The monitor requires an approximate area of 11 inches in width, 13 inches in
height, and 3 inches in depth. An additional area below the monitor should be allowed for
the wiring harness.
Enclosure (Steel) Style
The 509ITM is a 3R steel enclosure style, designed to be back-mounted on any smooth
surface. Four 0.40 in. round holes are provided for use with fasteners. The monitor requires
an approximate area that is 16 inches in width, 20 inches in height, and 11 inches in depth.
Also allow a minimum 3 inch clearance area around the vents for proper ventilation. An
additional area below the monitor should be allowed for the wiring harness.

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Fiberglass Enclosure and Panel Mount 509ITM
Steel Enclosure 509ITM
14.50 [368]
21.56
[548]
11.06
[281]
20.00
[508]
16.00 [406]
23.06
[586]
(4X) Ø.41 [Ø10]
MOUNTING HOLES
.86 [22]
TYP.

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Power Supply
Supply power is applied to Terminal Block TB1 terminals 14 and 15. For DC input, positive
voltage is applied to terminal 14, and ground or negative voltage is applied to terminal 15.
Chassis ground is applied to terminal 16, as shown in the Power Supply Connection figure.
This non-metallic enclosure does not automatically provide a common grounding lug.
Grounding must be provided as part of the installation, and it must be in accordance with the
requirements of the National Electrical Code (NEC) or any international code that is in effect.
For CSA/UL applications, a switch or circuit breaker must be installed near the
509ITM where the switch/circuit breaker; is clearly marked as they disconnect for the
509ITM; installed to meet the IEC 60947-1 and IEC 60947-3 specifications; must not be
incorporated in a mains supply cord and must not interrupt the protective earth
conductor.
Power Supply Connection
For the optional 5 kV Impulse Unit supply power is applied to Terminal Block TB12 terminals
1, 3, and 5, as shown in the Power Supply Connection for 5 kV Impulse Unit figure.
Power Supply Connection for 5 kV Impulse Unit

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The power supply has an internal removable fuse of GMA 250V/T3.15A (the 5 kV Impulse
Unit has no internal fusing) if it becomes necessary to replace this fuse. The fusing must be
replaced with the same type and rating that was originally installed. Failure to do so may
impact warranty issues.