RUGGED MONITORING H2SENS User manual

Model 5000 Gen5 Transformer Sensor
Operating Manual
90000177 R0, 3/24/2020 ECO 20-032 Page 2 of 18
MISSION STATEMENT
Our Mission
Deliver unsurpassed value and optimize green initiatives with our one of a kind continuous hydrogen-specific sensing
technology worldwide.
Our Value Propositions
Enable end-user customers to efficiently and effectively optimize:
Electric utility power transformer fleet and other oil-filled assets (Grid)
Petroleum refinery and other industrial process control
Facility and equipment safety to minimize downtime
...at a much lower total costs of ownership than the competition.
Our Strategic Objectives
H2scan's technology accepted as the new gold standard in hydrogen sensors.
H2scan's business recognized for innovation and ingenuity, high quality products and systems, application -specific
solutions, and exceptional customer service and satisfaction.
H2scan's success results from teamwork, strategic partnerships and market leadership leading to sales growth and
improved profitability.

Model 5000 Gen5 Transformer Sensor
Operating Manual
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CONTENTS
1 INTRODUCTION............................................................................................................................5
2 FEATURES ....................................................................................................................................5
2.1 SENSOR ................................................................................................................................. 5
2.2 MECHANICAL .......................................................................................................................... 5
2.3 ELECTRICAL............................................................................................................................ 6
3 ELECTRICAL INTERFACE ...........................................................................................................7
3.1 6V POWER ............................................................................................................................. 7
3.2 GROUND ................................................................................................................................ 7
3.3 DATA+ ................................................................................................................................... 7
3.4 DATA- .................................................................................................................................... 7
4 INSTALLATION .............................................................................................................................7
4.1 HANDLING PRECAUTIONS......................................................................................................... 7
5 OPERATION ..................................................................................................................................8
5.1 STARTUP................................................................................................................................ 8
6 MODBUS ....................................................................................................................................... 8
6.1 COMMUNICATION SETTINGS ..................................................................................................... 8
6.1.1 RS485 Connection .......................................................................................................................................... 8
6.2 PROTOCOL ............................................................................................................................. 8
6.2.1 Exception Response ..................................................................................................................................... 10
6.2.2 Modbus Command Register Definitions........................................................................................................ 11
6.2.3 Unit Status..................................................................................................................................................... 16
6.2.4 Error Status ................................................................................................................................................... 16
6.2.5 User-Defined Oil Type Configuration Window .............................................................................................. 17
7 COMMAND LINE INTERFACE....................................................................................................17
8 FIRMWARE UPGRADE............................................................................................................... 18
8.1 MAIN SENSOR BOARD FIRMWARE UPGRADE PROCEDURE ........................................................ 18

Model 5000 Gen5 Transformer Sensor
Operating Manual
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IMPORTANT NOTICES
LIMITED WARRANTY
H2scan Limited Warranty
specifications set from
the ship date for such Product.
Must Provide Notice of Defect: If you believe a Product that you believe is defective, you must notify H2scan in writing, within ten (10) days of
receipt of such Product, of your claim regarding any such defect.
Return Product to H2scan for Repair, Replacement or Credit nder this
warranty is to either (i) repair the Product, (ii) replace the Product, or (iii) issue a credit for the purchase price for such Product, the particular
remedy to be determined by H2scan on a case-by-case basis.
Voided Warranty th Limited Warranty is void for any of the following:
The unit is opened and the manufacturing seal is broken
chnicians
Equipment or parts that have been tampered with, misused, neglected, mishandled, improperly adjusted, or modified in any way without the
written consent of H2scan.
Equipment or parts that have been damaged due to shipping, misuse, accidents, mishandling, neglect, or problems with electrical power sources.
Repair work performed during the warranty period does not prolong the warranty period past the original period.
System operation in incorrect or inappropriate environments.
LIMITATION OF WARRANTY: THE ABOVE IS A LIMITED WARRANTY AS IT IS THE ONLY WARRANTY MADE BY H2SCAN. H2SCAN
MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED AND EXPRESSLY EXCLUDES ALL WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE. YOUR SOLE REMEDY HEREUNDER IS REPAIR OR REPLACEMENT OF THE PRODUCT OR A
CREDIT FOR THE PURCHASE PRICE FOR SUCH PRODUCT, THE PARTICULAR REMEDY TO BE DETERMINED BY H2SCAN ON A CASE-
BY-CASE BASIS. H2SCAN SHALL HAVE NO LIABILITY WITH RESPECT TO ITS OBLIGATIONS UNDER THIS AGREEMENT FOR
CONSEQUENTIAL, EXEMPLARY, OR INCIDENTAL DAMAGES EVEN IF IT HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.
THE STATED EXPRESS WARRANTY IS IN LIEU OF ALL LIABILITIES OR OBLIGATIONS OF H2SCAN FOR DAMAGES ARISING OUT OF OR
IN CONNECTION WITH THE DELIVERY, USE OR PERFORMANCE OF THE PRODUCTS.
LIMITATION OF LIABILITY - SELLER SHALL UNDER NO CIRCUMSTANCES BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL,
SPECIAL, PUNITIVE, OR OTHER DAMAGES, INCLUDING, BUT NOT LIMITED TO, LOSS OF BUSINESS OR PROFIT, PROMOTIONAL OR
MANUFACTURING EXPENSES, INJURY TO REPUTATION, OR LOSS OF CUSTOMER, BASED ON ANY ALLEGED NEGLIGENCE,
BREACH OF WARRANTY, STRICT LIABILITY, BREACH OF CONTRACT, OR ANY OTHER LEGAL THEORY ARISING OUT OF THE USE,
MISUSE, PURCHASE, SALE OR POSSESSION OF ITS GOODS OR ITS PERFORMANCE OF THIS CONTRACT TO THE EXTENT THAT
SUCH CLAIM IS BASED. SELLER ADVISES BUYER TO PERFORM ACCEPTABLE TESTS ON ALL HARDWARE PRIOR TO
DEPLOYME
CIRCUMSTANCES SHALL THE EQUIPMENT PROVIDED HEREUNDER BE USED IN A MANNER WHERE IT IS THE SOLE PROTECTIVE
SYSTEM FOR FACILITIES, EQUIPMENT AND PERSONNEL SAFETY; THE EQUIPMENT IS INTENDED FOR USE IN CONJUNCTION
WITH OTHER APPROPRIATE PROTECTIVE SYSTEMS.

Model 5000 Gen5 Transformer Sensor
Operating Manual
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1 Introduction
The Gen5 Hydrogen Sensor is designed to detect and/or measure hydrogen as a component of
transformer oil. The hydrogen specific solid-state sensing element is designed for ease of use
and interface flexibility. The Gen5 Hydrogen Sensor is an online hydrogen monitoring sensor for
distribution class transformers. This enclosure provides 6VDC power to the Gen5 Hydrogen
Sensor and communicates over a UART interface. 5th generation electronics,
the Gen5 Hydrogen Sensor contains all the circuitry necessary to operate the sensor and present
calibrated hydrogen readings through Modbus protocol over a 2-wire RS485 bus. The measured
hydrogen is reported as ppmH2 dissolved in oil and is comparable to industry standard DGA
measurements. Oil temperature at the sensing element is measured and available through the
digital interfaces.
This document has been updated for use with firmware revision 0:82:A.
2 Features
2.1 Sensor
Gen5 Hydrogen Sensor hydrogen
alloy sensor.
Calibrated to measure hydrogen dissolved in transformer oil
Periodic reference cycles are automatically run to eliminate offsets affecting long term
stability
No maintenance, long life sensing element
WARNING: The sensor element may be damaged if exposed to hydrogen
concentrations above 5,000 ppm.
2.2 Mechanical
The Gen5 Hydrogen Sensor is a rugged water proof mechanical assembly design for
distribution transformer applications. -14 NPT fitting is provided for attachment of the
sensor to a transformer. Overall dimensions are shown below.

Model 5000 Gen5 Transformer Sensor
Operating Manual
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2.3 Electrical
The Gen5 Hydrogen Sensor uses a single M12 4-pin connector for power and communications.
DC power input of 9 to 48 volts, 10 watts
2-wire RS485 for Modbus RTU communications

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Operating Manual
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3 Electrical Interface
All electrical connections are supplied through a 4-pin M12 connector. The key location and pin
numbers are shown below.
3.1 6V Power
Connect a DC power source rated for 9 to 48 volts,10 watts to pin 1.
3.2 Ground
Connect DC ground to pin 2.
3.3 Data+
Connect the RS485 Data+ signal to pin 3.
3.4 Data-
Connect the RS485 Data- signal to pin 4.
4 Installation
-14 NPT fitting on the oil tank. Adapter bushing for larger ID fittings can
be used however, do not use adapters to smaller ID fittings or pipe. The sensor should be
mounted in a horizontal position prevent an air bubble forming around the sensor element. Any
and the total length less than 8 . Additional installation notes are listed below.
Do not allow debris to accumulate around the sensor element
Use thread sealing tape
Provide means to evacuate gas bubbles in pipe fittings between sensor and oil tank
Do not install sensor in turbulent oil flow
4.1 Handling Precautions
The following precautions must be followed to ensure the sensor assembly is not damaged
during handling.
Do not poke anything into the open end around the sensor element
Place wrench close the threaded end when tightening
Do not over tighten

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Operating Manual
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5 Operation
5.1 Startup
After connecting the cable and turning on the power supply the sensor executes a warm-up
sequence lasting several minutes. The following operations are done during the warm-up
sequence:
Perform system self-test
Restore configuration settings from non-volatile memory
Start the sampling system to measure hydrogen and oil temperature
Approximate hydrogen readings will be reported by the sensor within 15 minutes. On new
installations the sensor will take up to 16 hours to reach equilibrium and report an accurate
hydrogen reading.
Modbus will indicate Not Ready until the first valid hydrogen measurement then reports the most
recent measurements. If an error is reported turn off power to the sensor; double check the
electrical connections; and power supply voltage before turning on power again. If the error
condition persists, contact H2scan customer service for assistance.
During normal operation the sensor will periodically measure oil temperature (approximately
once/hour) to provide temperature compensated dissolved gas readings. The unit will also
periodically go through an internal calibration check (called reference cycle). These are
automatic activities and no user interaction is required.
6 Modbus
6.1 Communication Settings
Modbus protocol is configured to operate on the RS485. The device supports RTU packets and
the default device ID is 1.
6.1.1 RS485 Connection
The following communication settings are used on the RS485, 2-wire, half-duplex connection.
Baud Rate:
19,200
Data bits: 8
Stop bits:
1
Parity:
None
Flow Control:
None
6.2 Protocol
The following tables comprise the list of Modbus packets, values, registers, and register
definitions.
The maximum
should be set to 10,000 milliseconds or greater.

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Operating Manual
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Table 1: Modbus Read Request Packet
Byte Modbus Parameter Range Meaning
1 Slave address 1 247 Unit ID Address
2 Function Code 03 Read Holding Register
3 Starting Address Hi 0x00 0xFF Holding Register Hi Byte
4 Starting Address Lo 0x00 0xFF Holding Register Lo Byte
5 Number of registers Hi 0 Limited by Modbus spec V1.1b
6 Number of Registers Lo 1 125 Number of 16-bit registers Lo Byte
7 CRC Lo 0x00 0xFF CRC Low Byte
8 CRC Hi 0x00 0xFF CRC High Byte
Table 2: Modbus Read Response Packet
Byte # Modbus Parameter Range Meaning
1 Slave address 1 247 Unit ID Address
2 Function Code 03 Returning Holding Registers
3 Byte Count 7 255 Number of data bytes returned = N
4 1st Data Value Hi 0x00 0xFF
5 1st Data Value Lo 0x00 0xFF
6 2nd Data Value Hi 0x00 0xFF
7 2nd Data Value Lo 0x00 0xFF
2N+4 CRC Lo 0x00 0xFF CRC Low Byte
2N+5 CRC Hi 0x00 0xFF CRC High Byte
N is the number of bytes returned based on the number of registers requested. If
N registers are requested, then 2N+5 bytes are returned.
Table 3: Modbus Write Request Packet
Byte Modbus Parameter Range Meaning
1 Slave address 1 247 Unit ID Address
2 Function Code 06 Write Holding Registers
3 Register Address Hi 0x00 0xFF Unit Register Address Hi byte
4 Register Address Lo 0x00 0xFF Unit Register Address Lo byte
5 Data Value Hi Byte 0x00 0xFF
6 Data Value Lo Byte 0x00 0xFF
7 CRC Lo 0x00 0xFF CRC Low Byte
8 CRC Hi 0x00 0xFF CRC High Byte
Table 4: Modbus Write Response Packet
Byte Modbus Parameter Range Meaning
1 Slave address 1 247 Unit ID Address
2 Function Code 06
3 Register Address Hi Byte 0x00 0xFF Unit Register Address Hi byte
4 Register Address Lo Byte 0x00 0xFF Unit Register Address Lo byte
5 Data Value Hi Byte 0x00 0xFF
6 Data Value Lo Byte 0x00 0xFF
7 CRC Lo 0x00 0xFF CRC Low Byte
8 CRC Hi 0x00 0xFF CRC High Byte

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6.2.1 Exception Response
In a normal communications query and response due to a communication error, the master
device sends a query to the slave device. Upon receiving the query, the slave processes the
request and returns a response to the master device. An abnormal communication between
the two devices produces one of four possible events:
1. If the slave does not receive the query due to a communications error, then no response
is returned from the slave and the master device will eventually process a timeout
condition for the query.
2. If the slave receives the query but detects a communication error (UART or CRC), then
no response is returned from the slave and the master device will eventually process a
timeout condition for the query.
3. If the slave receives the query without a communications error, and takes longer than
response is returned from the slave. The master
device eventually processes a timeout condition for the query. To prevent this
condition, the master timeout must be set longer than the maximum response time of
the slave (10,000 milliseconds).
4. If the slave receives the query without a communications error but cannot process it due
to reading or writing to a non-existent slave command register, then the slave returns an
exception response message informing the master of the error.
The exception response message has two fields that differentiate it from a normal response.
The first is the function code byte 2. This code will have the high order bit set to a one (i.e.
0x83 for a read exception and 0x86 for a write exception). The second differentiating field is
the exception code byte 3. In addition, the total exception response length is 5 bytes rather
than the normal message length.
Table 5: Exception Response Packet
Byte Modbus Parameter Range Meaning
1 Slave Address 1 247
2 Function Code 0x83 or 0x86 Read or Write
3 Exception Code See Table Below
4 CRC High 0x00 0xFF
5 CRC Low 0x00 0xFF