Vaisala Optimus OPT100 User manual

M211858EN-K
User Guide
Vaisala Optimus™DGA Monitor for
power transformers
OPT100

PUBLISHED BY
Vaisala Oyj
Vanha Nurmijärventie 21, FI-01670 Vantaa, Finland
P.O. Box 26, FI-00421 Helsinki, Finland
[phone]
Visit our Internet pages at www.vaisala.com.
© Vaisala 2021
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Table of contents
1. About this document.....................................................................................7
1.1 Version information.......................................................................................... 7
1.2 Related manuals................................................................................................8
1.3 Documentation conventions........................................................................... 8
1.4 Trademarks........................................................................................................ 9
1.5 Patent notice..................................................................................................... 9
2. Product overview.......................................................................................... 10
2.1 Overview of OPT100 DGA Monitor............................................................... 10
2.2 Basic features and options.............................................................................10
2.3 Measured parameters.....................................................................................10
2.3.1 Total gas pressure measurement............................................................12
2.3.2 Calculating relative moisture saturation inside transformer...............12
2.4 Notes for normal operation............................................................................13
2.5 Parts with Ground Mounting Set................................................................... 14
2.6 Parts with Wall Mounting Set.........................................................................16
2.7 OPT100 cable glands and connectors.......................................................... 18
2.8 OPTPSU1 cable glands and connectors........................................................ 19
2.9 Interior parts................................................................................................... 20
2.10 Status LEDs...................................................................................................... 21
2.11 Gas level alerts................................................................................................ 22
2.12 Modbus protocol.............................................................................................22
2.13 DNP3 protocol.................................................................................................23
2.14 IEC 61850 protocol......................................................................................... 24
2.15 Protocol test mode.........................................................................................24
2.16 Autocalibration............................................................................................... 25
3. User interface................................................................................................. 27
3.1 Overview of user interface.............................................................................27
3.1.1 Connecting to user interface..................................................................27
3.1.2 User interface basics...............................................................................29
3.1.3 Measurements page................................................................................32
3.1.4 DGA diagnostics page............................................................................ 35
3.1.5 Alerts page...............................................................................................37
3.1.6 Control pages.......................................................................................... 39
3.1.7 Settings pages..........................................................................................41
3.1.8 About page............................................................................................... 41
3.2 Changing administrator password............................................................... 42
3.3 Starting measurement...................................................................................43
3.4 Setting device name...................................................................................... 44
3.5 Setting date and time.................................................................................... 45
3.6 Configuring unit settings...............................................................................46
3.7 Configuring autocalibration.......................................................................... 47
3.8 Configuring gas level alerts...........................................................................48
3.9 Muting gas level alerts...................................................................................49
3.10 Configuring network connection................................................................. 50
Table of contents
1

3.11 Configuring user interface security...............................................................51
3.12 Configuring Modbus protocol.......................................................................53
3.13 Configuring DNP3 protocol...........................................................................54
3.14 Configuring IEC 61850 protocol....................................................................56
3.15 Using protocol test mode.............................................................................. 57
3.16 Configuring relays.......................................................................................... 58
4. Maintenance................................................................................................... 60
4.1 Maintenance safety........................................................................................60
4.2 Cleaning DGA monitor.................................................................................. 60
4.3 Maintenance..................................................................................................... 61
4.4 Updating DGA monitor software...................................................................61
4.5 Starting autocalibration manually................................................................64
4.6 Repair.............................................................................................................. 64
4.6.1 Stopping measurement..........................................................................64
4.6.2 Turning o the DGA monitor for maintenance....................................65
4.6.3 Verifying safety after repair...................................................................65
4.6.4 Turning on DGA monitor after maintenance....................................... 65
4.6.5 Starting measurement............................................................................66
4.7 Uninstalling DGA monitor............................................................................. 66
5. Troubleshooting............................................................................................70
5.1 Problem situations......................................................................................... 70
5.2 System statuses............................................................................................... 71
5.3 Device alerts....................................................................................................72
5.4 Resolving a measurement cycle fault.......................................................... 74
6. Technical specification............................................................................... 76
6.1 OPT100 technical specification.....................................................................76
6.2 OPT100 accessories and spare parts........................................................... 82
6.3 Dimensions with Ground Mounting Set.......................................................83
6.4 Dimensions with Wall Mounting Set............................................................ 84
Appendix A: Modbus reference.................................................................. 86
A.1 Default Modbus communication settings................................................... 86
A.2 Function codes............................................................................................... 86
A.3 32-bit floating point or 32-bit integer format.............................................86
A.4 Modbus registers............................................................................................ 87
A.4.1 Measurement data registers.................................................................. 87
A.4.2 Alert registers.......................................................................................... 92
A.4.3 Status registers........................................................................................95
A.4.4 Test value registers................................................................................. 95
A.5 Exception responses......................................................................................96
A.6 Modbus communication examples...............................................................97
Index...................................................................................................................99
Maintenance and calibration services....................................................... 101
OPT100 User Guide M211858EN-K
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Technical support........................................................................................... 101
Warranty........................................................................................................... 101
Recycling.......................................................................................................... 101
Table of contents
3

List of figures
Figure 1 OPT100 front parts with Ground Mounting Set...................................... 14
Figure 2 OPT100 rear parts with Ground Mounting Set........................................ 15
Figure 3 OPT100 front parts with Wall Mounting Set............................................ 16
Figure 4 OPT100 rear parts with Wall Mounting Set.............................................. 17
Figure 5 Cable glands and connectors on OPT100 cabinet..................................18
Figure 6 Cable glands and connectors on OPTPSU1 power supply unit...........19
Figure 7 Inside OPT100 DGA Monitor cabinet........................................................ 20
Figure 8 Inside OPTPSU1 Power Supply Unit cabinet.............................................21
Figure 9 Status LEDs........................................................................................................21
Figure 10 Protocol test mode enabled........................................................................ 24
Figure 11 Elements of the DGA monitor user interface..........................................29
Figure 12 Alert summary message being shown.......................................................31
Figure 13 Measurement graph....................................................................................... 32
Figure 14 Measurement graph for 1 day rate of change values............................ 33
Figure 15 Total gas pressure graph.............................................................................. 34
Figure 16 Table of latest values......................................................................................35
Figure 17 Duval triangles on the DGA diagnostics page........................................36
Figure 18 Alerts page with active gas caution alert.................................................37
Figure 19 Event details for a gas caution alert..........................................................38
Figure 20 DGA monitor Control page.......................................................................... 39
Figure 21 Autocalibration page.....................................................................................40
Figure 22 Settings page....................................................................................................41
Figure 23 About page.......................................................................................................42
Figure 24 Changing administrator password.............................................................43
Figure 25 General settings page................................................................................... 44
Figure 26 Date and time settings page....................................................................... 45
Figure 27 Unit settings page.......................................................................................... 46
Figure 28 Autocalibration page..................................................................................... 47
Figure 29 Alert limits settings page............................................................................. 48
Figure 30 Alert page with methane caution alert visible....................................... 50
Figure 31 IP address settings page.............................................................................. 50
Figure 32 Network security settings page...................................................................51
Figure 33 Modbus settings page................................................................................... 53
Figure 34 DNP3 settings page....................................................................................... 54
Figure 35 IEC 61850 settings page............................................................................... 56
Figure 36 Protocol test mode enabled.........................................................................57
Figure 37 Relay settings page........................................................................................58
Figure 38 About page with current software version and update button.........62
Figure 39 Measurement cycle fault active...................................................................74
Figure 40 OPT100 dimensions with Ground Mounting Set....................................83
Figure 41 OPT100 dimensions with Wall Mounting Set..........................................84
Figure 42 Mounting dimensions of installation beams............................................85
OPT100 User Guide M211858EN-K
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List of tables
Table 1 Document versions (English)........................................................................... 7
Table 2 Related manuals.................................................................................................. 8
Table 3 Applicable patents or applications.................................................................9
Table 4 Measured parameters.......................................................................................10
Table 5 Calculated parameters.......................................................................................11
Table 6 Meaning of status LEDs....................................................................................21
Table 7 Modbus TCP communication settings.........................................................22
Table 8 Default Modbus RTU communication settings......................................... 23
Table 9 Types of autocalibration..................................................................................26
Table 10 Data point selection criteria...........................................................................37
Table 11 Troubleshooting table......................................................................................70
Table 12 System statuses..................................................................................................71
Table 13 Device alerts....................................................................................................... 73
Table 14 OPT100 measurement specification............................................................76
Table 15 OPT100 measurement operation..................................................................76
Table 16 OPT100 field performance..............................................................................77
Table 17 OPT100 calculated parameters..................................................................... 77
Table 18 OPT100 operating environment....................................................................78
Table 19 OPT100 power supply......................................................................................78
Table 20 OPT100 outputs.................................................................................................78
Table 21 OPT100 mechanical specifications...............................................................79
Table 22 OPT100 type tests............................................................................................ 80
Table 23 OPT100 compliance...........................................................................................81
Table 24 OPT100 accessories..........................................................................................82
Table 25 OPT100 spare parts..........................................................................................82
Table 26 Modbus TCP communication settings.........................................................86
Table 27 Default Modbus RTU communication settings.........................................86
Table 28 Supported function codes..............................................................................86
Table 29 Measurement data registers (read-only)....................................................87
Table 30 Alert registers (read-only)..............................................................................92
Table 31 Status registers (read-only)........................................................................... 95
Table 32 Test value registers (read-only).................................................................... 95
Table 33 Modbus exception responses........................................................................ 96
List of tables
5

OPT100 User Guide M211858EN-K
6

1. About this document
1.1 Version information
Table 1 Document versions (English)
Document code Date Description
M211858EN-K January 2021 Applicable from software version 1.13.0 onwards.
Updated sections:
•Total gas pressure measurement (page 12)
•Gas level alerts (page 22)
•Configuring gas level alerts (page 48)
•Configuring unit settings (page 46)
•System statuses (page 71)
•Alert registers (page 92)
•Measurement data registers (page 87)
M211858EN-J November 2020 Applicable from software version 1.12.0 onwards.
Added sections:
•Total gas pressure measurement (page 12)
•Alert indicator (page 30)
•System statuses (page 71)
•Configuring unit settings (page 46)
•Device alerts (page 72)
•Dimensions with Wall Mounting Set (page 84)
Updated sections:
•OPT100 cable glands and connectors (page 18)
•OPTPSU1 cable glands and connectors (page 19)
•Status indicator (page 29)
•Messages (page 30)
•Measurements page (page 32)
•Alerts page (page 37)
•Configuring gas level alerts (page 48)
•Updating DGA monitor software (page 61)
•Problem situations (page 70)
•Resolving a measurement cycle fault (page 74)
•OPT100 technical specification (page 76)
•Measurement data registers (page 87)
•Status registers (page 95)
Chapter 1 – About this document
7

Document code Date Description
M211858EN-H July 2020 Applicable from software version 1.11.0 onwards.
Added sections:
•Protocol test mode (page 24)
•Using protocol test mode (page 57)
•Configuring autocalibration (page 47)
Updated sections:
•Autocalibration (page 25)
•Uninstalling DGA monitor (page 66)
•OPT100 technical specification (page 76)
1.2 Related manuals
Table 2 Related manuals
Document code Name
M211857EN OPT100 Installation Guide
1.3 Documentation conventions
Warning alerts you to a serious hazard. If you do not read and
follow instructions carefully at this point, there is a risk of injury or even death.
WARNING!
Caution warns you of a potential hazard. If you do not read and
follow instructions carefully at this point, the product could be damaged or
important data could be lost.
CAUTION!
Note highlights important information on using the product.
Tip gives information for using the product more eciently.
OPT100 User Guide M211858EN-K
8

Lists tools needed to perform the task.
Indicates that you need to take some notes during the task.
1.4 Trademarks
Vaisalaâis a registered trademark of Vaisala Oyj.
OPTIMUS™is a trademark of Vaisala Oyj.
Modbusâis a registered trademark of Schneider Automation Inc.
All other product or company names that may be mentioned in this publication are trade
names, trademarks, or registered trademarks of their respective owners.
1.5 Patent notice
This product is protected by the following patents and patent applications and their
corresponding national rights:
Table 3 Applicable patents or applications
Issuing oce Patent number
Chinese Patent Oce ZL 201480064015.2
United States Patent and Trademark Oce US 10429371
US 10101266
Finnish Patent Oce 125907
127084
Chapter 1 – About this document
9

2. Product overview
2.1 Overview of OPT100 DGA Monitor
OPT100 is a device for monitoring the internal condition of an electrical transformer using
dissolved gas analysis (DGA), also known as fault gas analysis. OPT100 is intended to be
installed next to the transformer, and connected to it by two oil lines. OPT100 draws oil from a
transformer, measures the concentrations of hydrogen, moisture, and several hydrocarbons in
the oil, and returns the oil back to the transformer.
Measurement results can be transferred via communication interfaces to the substation's
SCADA (Supervisory Control And Data Acquisition) system. The data is also available for
viewing by human operators through the browser-based user interface.
More information
‣OPT100 technical specification (page 76)
2.2 Basic features and options
• Measurement of seven fault gases, moisture in oil, and total gas pressure
• Several calculated parameters and gas ratios available
• Ethernet and RS-485 interfaces for SCADA integration
• Modbus protocol (RTU and TCP)
• Protocol test mode for verifying SCADA integration
• Three configurable relay outputs
• Gas level alerts for measured values and rate of change (ROC)
• IP66 rated cabinet
• Optional software features:
• DGA diagnostics using Duval triangles
• DNP3 (Distributed Network Protocol) over Ethernet or RS-485
• IEC 61850 protocol over Ethernet
• Installation options:
• Ground mounting set
• Wall mounting set
• Weather shield
2.3 Measured parameters
Table 4 Measured parameters
Parameter Output unit(s) Description
Methane (CH4) ppmvMeasured from extracted gas
OPT100 User Guide M211858EN-K
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Parameter Output unit(s) Description
Ethane (C2H6) ppmvMeasured from extracted gas
Ethylene (C2H4) ppmvMeasured from extracted gas
Acetylene (C2H2) ppmvMeasured from extracted gas
Carbon monoxide (CO) ppmvMeasured from extracted gas
Carbon dioxide (CO2) ppmvMeasured from extracted gas
Hydrogen (H2) ppmvMeasured in-oil
Moisture (H2O) ppmwand %RS Measured in-oil as relative
saturation (%RS). See
Calculating relative moisture
saturation inside transformer
(page 12).
Total gas pressure hPa and psi Measured from the sampled oil
volume
Table 5 Calculated parameters
Property Output unit(s) Description
Total dissolved combustible
gases (TDCG)
ppmvCombined total of H2, CO, CH4, C2H6, C2H4, and
C2H2.
24 h average ppmvfor
gases
ppmwfor
moisture
hPa and psi for
total gas
pressure
Available for single gases, moisture, TDCG, and
total gas pressure
Rate of change (ROC) ppmvAvailable for single gases and TDCG for 24 h,
7 d, and 30 d periods
Gas ratios for:
• CH4/H2
• C2H2/C2H4
• C2H2/CH4
• C2H6/C2H2
• C2H4/C2H6
• CO2/CO
Ratio Ratio is calculated from 24 h average values of
the gases
Chapter 2 – Product overview
11

2.3.1 Total gas pressure measurement
Total gas pressure (TGP) is measurement parameter introduced in software version 1.12.0. Total
gas pressure is the total dissolved gas pressure of the sampled oil volume, measured by the
DGA monitor as part of its normal measurement cycle. The primary use of the TGP parameter
is to determine if there is an air leak into a sealed transformer. In case of a leak, majority of the
dissolved gases are nitrogen and oxygen, and the proportion of fault gases in the pressure
value is negligible. The pressure trend of the dissolved gasses gives reliable indication of leak,
as nitrogen is the dominant component, and it is not formed or consumed in reactions inside
the transformer.
From software version 1.13.0 onward TGP measurement results (current value and 24 hour
average) are available through output protocols, and TGP measurement can be used for gas
alerts. TGP has its own separate graph view on page Measurements > Total gas pressure.
2.3.2 Calculating relative moisture saturation inside transformer
DGA monitor measures relative oil moisture (%RS) inside its
cabinet. The temperature of the moisture sensor location does not represent the
temperature inside the transformer tank or inside the oil circulation pipes.
Additionally, oil sampling through the steel pipes changes the oil temperature.
As relative moisture saturation is strongly temperature dependent, the %RS
measured and output by DGA monitor is not equal to %RS inside the
transformer tank.
CAUTION!
However, DGA monitor does output both the measured %RS and the temperature where it was
measured. To calculate the %RS in the true temperature inside the transformer, use the
following equation.
%RST2= % RST1× 10
A T2− T1
T1 + 273.15 × T2 + 273.15
%RS(T1) Relative moisture saturation output by DGA monitor
T1 Temperature of the in-oil measurement chamber inside DGA monitor
T2 Temperature at location where new relative moisture saturation is needed at
A-1662.70
A is a water solubility coecient. Vaisala uses this standard value in all of its oil
moisture transmitters. You can also use this equation with an oil-specific
coecient if it has been determined for your oil.
OPT100 User Guide M211858EN-K
12

2.4 Notes for normal operation
In normal operation the DGA monitor performs measurement cycles automatically without any
operator involvement. Integration with a SCADA system is recommended for convenient
monitoring of measurement results and system status. Status LEDs on the cabinet door
indicate system status on a general level, and detailed status is available from the browser-
based user interface.
Note the following for successful operation:
• Keep the doors of the DGA monitor cabinets closed and locked during normal operation.
This is important for keeping the inside of the DGA monitor clean and the measurement
environment stable.
• Keep the measurement running continuously to achieve the best measurement
performance.
• If the DGA monitor will be unpowered for a long time (for example, due to a transformer
maintenance), set the system to Standby. See Stopping measurement (page 64).
Chapter 2 – Product overview
13

2.5 Parts with Ground Mounting Set
1
2
3
4
5
6
7
Figure 1 OPT100 front parts with Ground Mounting Set
1Status LEDs
2OPT100 DGA Monitor
3Door lock (3 pcs)
4Power supply unit
5Door lock
6Mounting stand
7Wedge anchors (6 pcs)
OPT100 User Guide M211858EN-K
14

1
2
3
Figure 2 OPT100 rear parts with Ground Mounting Set
1Weather shield
2Cable glands and oil connections for DGA Monitor
3Cable glands for power supply unit
More information
‣Dimensions with Ground Mounting Set (page 83)
Chapter 2 – Product overview
15

2.6 Parts with Wall Mounting Set
1
2
3
4
5
Figure 3 OPT100 front parts with Wall Mounting Set
1Status LEDs
2OPT100 DGA Monitor
3Door lock (3 pcs)
4Power supply unit
5Door lock
OPT100 User Guide M211858EN-K
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1
2
3
4
5
6
Figure 4 OPT100 rear parts with Wall Mounting Set
1Installation beam (upper)
2Weather shield
3Installation beam (lower)
4Cable glands for DGA Monitor
5Cradle for power supply unit
6Cable glands for power supply unit
More information
‣Dimensions with Wall Mounting Set (page 84)
Chapter 2 – Product overview
17

2.7 OPT100 cable glands and connectors
1 2 3 4 5 6 7
8 9
Figure 5 Cable glands and connectors on OPT100 cabinet
#Label Description Cable/pipe
diameter
Wrench
size
1Oil Out Oil return to transformer. 10 mm (0.39 in) 19 mm
2Oil In Oil intake from transformer. 10 mm (0.39 in) 19 mm
3 Ground connection. 4 … 16 mm2
(12 … 5 AWG)
conductor
13 mm
4RS-485 RS-485 connection. 5 … 10 mm
(0.20 … 0.39 in)
20 mm
5Relay control
out
Relay control to OPTPSU1. Use Vaisala
cable CBL210539.
7 … 12 mm
(0.28 … 0.47 in)
24 mm
6DC in DC input from OPTPSU1. Use Vaisala cable
CBL210544.
9 … 16 mm
(0.35 … 0.63 in)
30 mm
7Ethernet Ethernet connection. Use shielded outdoor
Ethernet cable. Assemble the included
protection shell on the RJ45 connector.
- -
8Spare Not reserved. 5 … 10 mm
(0.20 … 0.39 in)
20 mm
9Spare Not reserved. 7 … 12 mm
(0.28 … 0.47 in)
24 mm
OPT100 User Guide M211858EN-K
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