online transformer monitor installation guide - march 2010

On-Line Transformer Monitor Installation Guide

Model TM Series 810-1644-02 Rev A

March 10

www.serveron.com 3305 NW Aloclek Drive Hillsboro, OR 97124 USA +1 (503) 924-3200 phone +1 (503) 924-3290 fax

Serveron Corporation, A BPL Global Company 3305 NW Aloclek Drive Hillsboro, OR 97124-7101 Phone: (503) 924-3200 Toll-free: (800) 880-2552 (USA and Canada only) Fax: (503) 924-3290

Technical Support: +1 (866) 273-7763 E-mail: [email protected]

http://www.serveron.com

For more information, contact your nearest Serveron Representative or Serveron Corporation Serveron and LoadGuide are registered trademarks of Serveron Corporation. All other trademarks, registered trademarks, service marks, and trade names are the property of their respective owners.

810-1644-02 Rev A On-Line Transformer Monitor Installation Guide

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Table of Contents Product Overview ................................................................................................................................................... 3 Product Symbols ...................................................................................................................................................... 4 Environmental Conditions ..................................................................................................................................... 5 Warranty ................................................................................................................................................................... 5 Items Needed for Installation ................................................................................................................................ 6 Optional Accessories ............................................................................................................................................... 7 Preparatory Tasks for Installation ......................................................................................................................... 8 Site Preparation Guide Checklist .......................................................................................................................... 8 Installation Procedures ........................................................................................................................................... 9 Mounting and Assembly ...................................................................................................................................... 10

Mounting the Pedestal Stand ........................................................................................................................... 10 Assembling the Stand (Standard Installation) ............................................................................................... 11 Junction Box Mounting ..................................................................................................................................... 12 Optional Oil Cooler ........................................................................................................................................... 13 Mounting the Transformer Monitor ............................................................................................................... 14 Mounting to the Pedestal Stand ...................................................................................................................... 14

Tank/Wall Mount ................................................................................................................................................. 15 Tank/Wall Mount Assembly ........................................................................................................................... 15

With Optional Oil Cooler .............................................................................................................................................. 15 Without Optional Oil Cooler ........................................................................................................................................ 16

Junction Box Mounting ..................................................................................................................................... 17 Attaching the Sunshield .................................................................................................................................... 18

Oil Connections ...................................................................................................................................................... 19 In-Line Oil Filter ................................................................................................................................................ 19 Oil Plumbing ...................................................................................................................................................... 20

Oil Moisture and Temperature (Optional) ......................................................................................................... 22 Oil Moisture and Temperature Transmitter Unit ......................................................................................... 23

Gas Connections .................................................................................................................................................... 24 Helium Gas Cylinder and Dryer Mounting .................................................................................................. 24 Verification Gas Cylinder ................................................................................................................................. 26

Cable Connections ................................................................................................................................................. 27 Power Cable ........................................................................................................................................................ 27 Sensor Cable (black) .......................................................................................................................................... 28 Communication Cable (gray) ........................................................................................................................... 28

External Sensors ..................................................................................................................................................... 30 Oil Moisture and Temperature Connections ..................................................................................................... 30 LoadGuide .............................................................................................................................................................. 30 Relays ...................................................................................................................................................................... 31 Aux Inputs .............................................................................................................................................................. 31 Pedestal Stand Assembly Drawing ..................................................................................................................... 32 Tank/Wall-Mount Assembly Drawing .............................................................................................................. 33 Installation Checklist ............................................................................................................................................. 34 Verification Cylinder Data Sheet ......................................................................................................................... 35


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Table of Figures Figure 1: Oil Circulation and Gas Extraction Schematic .................................................................................... 3 Figure 2: Installation Schematic ............................................................................................................................. 9 Figure 3: Pedestal Stand ........................................................................................................................................ 10 Figure 4: Stand Assembly ..................................................................................................................................... 11 Figure 5: Junction Box Mounting ........................................................................................................................ 12 Figure 6: Oil Cooler Mounting ............................................................................................................................. 13 Figure 7: Transformer Monitor Mounting ......................................................................................................... 14 Figure 8: Unistrut Mounting ................................................................................................................................ 15 Figure 9: Grounding Strap ................................................................................................................................... 16 Figure 10: Junction Box Mounting ...................................................................................................................... 17 Figure 11: Helium Bracket Assembly ................................................................................................................. 17 Figure 12: Sunshield Mounting .......................................................................................................................... 18 Figure 13: In-Line Oil Filter .................................................................................................................................. 19 Figure 14 : Oil Supply Port Assy ......................................................................................................................... 20 Figure 15 : Oil Return Port Assy /Bleed Fixture ............................................................................................... 20 Figure 16: Sample Port/Secondary Shutoff Assy ............................................................................................. 21 Figure 17: Oil Moisture and Temperature Sensor ............................................................................................. 22 Figure 18: Transmitter Unit .................................................................................................................................. 23 Figure 19: Base and Transmitter .......................................................................................................................... 23 Figure 20: Rain Shield Installed ........................................................................................................................... 23 Figure 21: Helium Dryer ....................................................................................................................................... 24 Figure 22: Helium Regulator ................................................................................................................................ 25 Figure 23: Installed Verification Cylinder .......................................................................................................... 26 Figure 24: Wiring Terminations........................................................................................................................... 29 Figure 25: Pedestal Stand Assembly ................................................................................................................... 32 Figure 26: Wall/Tank Mount ............................................................................................................................... 33

Table of Tables Table 1: Product Symbols ....................................................................................................................................... 4 Table 2: Items Shipped ............................................................................................................................................ 6 Table 3: Items Shipped ............................................................................................................................................ 7 Table 4: Optional Accessories ................................................................................................................................ 7 Table 5: Oil Moisture and Temperature Connections ...................................................................................... 30 Table 6: Verification Cylinder Data Sheet .......................................................................................................... 35


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Product Overview This section describes the basic operational essentials for the Serveron On-Line Transformer Monitor TM series and the most common methods of collecting data.

The On-Line Transformer Monitor technology from Serveron Corp. is a remotely deployed laboratory grade gas chromatograph which can be safely installed onto an energized or non-energized transformer. The purpose of this monitor is to detect and measure fault gases found in an electrical power transformer‘s insulating oil. The monitor is designed and constructed to resist environmental conditions relevant to a transformer substation.

The On-Line Transformer Monitor is a precision device. The heart of the monitor is a specially constructed gas chromatograph designed to measure fault gases. Serveron offers three versions of products, application dependant. The TM8 measures eight IEEE recommended fault gases: hydrogen (H2), oxygen (O2), carbon dioxide (CO2), carbon monoxide (CO), methane (CH4), ethylene (C2H4), ethane (C2H6), and acetylene (C2H2). The TM5 measures five of the eight gases: acetylene (C2H2), ethylene (C2H4), methane (CH4), carbon monoxide (CO), and carbon dioxide (CO2). The TM3 measures the three Duval Triangle fault gases: methane (CH4), ethylene (C2H4), and acetylene (C2H2). The On-Line Transformer Monitor may be used on conservator or nitrogen-blanketed transformers. However, in all cases, the sample of gas is extracted directly from the oil within the transformer.

Oil is circulated from the transformer, to the monitor and then returned to the transformer through ¼-inch O.D. stainless-steel tubing. Stainless-steel tubing is used in conjunction with compression fittings to minimize the risk of leaks. The monitor is outfitted with an internal gas-extraction system which removes dissolved gases from the circulating transformer oil. Helium is used as a carrier gas to help transport the extracted sample gases through the gas chromatograph. The oil circulation and gas- extraction paths in the On-Line Transformer Monitor are shown below.

Data is collected in the monitor each time a gas chromatograph (GC) analysis is completed. The GC analysis takes approximately 43 minutes. Once an analysis has been completed, the optional Serveron Monitoring Service (SMS) or TM View software can be used to view the monitor’s data. The monitor is set up to perform a sample analysis once every four hours (default). All data captured during an analysis is stored on compact flash memory within the monitor. The compact flash memory holds approximately (2) years of data. The TM View software or Serveron Monitoring Service (SMS) will allow the end user to track the gas ppm levels over time and monitor the gas levels against user- defined caution and alarm settings.

The On-Line Transformer Monitor includes ambient temperature and LoadGuide® sensor devices. An optional Oil Moisture and Temperature sensor is available along with spare 4-20ma inputs for use with other external devices. External sensor information can also be correlated with fault gas information to allow a complete diagnostic overview of the transformer’s condition.

Figure 1: Oil Circulation and Gas Extraction Schematic

Gas Chromatograph

Oil Return toTransformer

Oil Supply fromTransformer

GasSide

OilSide

Gas supply to GC

Gas ExtractorUnit

Gas supply to GC


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Product Symbols The following symbols are used throughout the Transformer Monitor or accessories. They are defined by the International Electrotechnical Commission, IEC 878 and IEC 417A. It is important for safety reasons to have an understanding of their representation.

Voltage Output

Voltage Input

Fuse

High Voltage

Caution: Refer to On-Line Transformer Monitor Installation Guide and accompanying documentation.

Protective Earth (ground)

V~ Alternating Current and Voltage H Connect to mains live conductor (brown) L Connect to mains neutral conductor (blue)

__I__ O

The I position indicates the power switch is ON The O position indicates the power switch is OFF

This device has been tested and certified by the Canadian Standards Association International to comply with applicable U.S. and Canadian safety standards.

Table 1: Product Symbols

WARNING statements in this manual identify conditions or practices that could result in personal injury. CAUTION statements in this manual identify conditions or practices that could result in damage to the equipment or other property. NOTE statements provide additional important information.


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Environmental Conditions The TM series is designed to operate within the following outdoor conditions:

Altitude up to 4572 m Humidity Range 5% to 95% Temperature Range -50C to 55C Installation Category II Pollution Degree 2

Please note that the altitude, humidity, and temperature ranges indicated are considered extended environmental conditions from the minimum ranges required by UL 61010-1, Clause 1.4.1.

Warranty Serveron warrants its Goods to be free from latent defects in materials or workmanship for 12 months from the date of shipment. Serveron will repair or replace, at Serveron’s option and without cost to Buyer, any Goods furnished hereunder that are found to contain defects in materials or workmanship during that period. Serveron uses new and reconditioned parts in performing warranty repairs and building replacements. Serveron owns all Goods it has replaced and all parts removed from repaired Goods. It is Buyer’s responsibility to return the Goods to Serveron for warranty coverage. This warranty does not cover items damaged in shipment or damages resulting from misuse, neglect, abuse, acts of war, or acts of God. Serveron recommends only using the provided shipping material and packing inserts for transportation. The TMx is designed for pad or tank mount in normal transformer operation. It is not designed to be mounted or affixed to the transformer or any other device during transportation, doing so is subject to void all and any warranties. Prior to returning any item (whether during the warranty period or out of warranty), Buyer must obtain a Return Material Authorization (RMA) number from Serveron Corporation by calling (800) 880-2552 Monday through Friday, 8 am to 5 pm, Pacific Time, or by sending a facsimile request to (503) 924-3290. Serveron makes no warranties, expressed or implied, other than the warranties expressly stated in this paragraph. All other warranties, expressed or implied, arising by law or otherwise, including, but not limited to, the implied warranties of title, merchantability, noninfringement and fitness for a particular purpose, are expressly disclaimed. Serveron’s product operations manuals and product installation guides describe approved accessories, options, operating materials, and installation methods. Use of accessories, options, operating materials, and installation methods not as described will void the warranty.


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Items Needed for Installation Note: As each transformer is different, some items may need to be provided by the installer.

Upon receipt of your On-Line Transformer Monitor, it is important to verify the contents of the shipping carton with the packing list. After inspection of the contents, please notify Serveron directly if there are any signs of damage that may have occurred in transit.

Part # Description

140-0170-XX Sunshield

250-0130-XX (1) In-line Oil Filter, 1/4” SS Swagelok

250-0144-XX (2) Nut and Ferrule Set, 1/4” OD, SS

252-0013-XX (3) 10-32 Nut

253-0066-XX (6) 10-32x3/8” Screw

270-0004-XX (1) Helium Dryer, Q5 Copper Catalyst

290-0017-XX

(1) Verification gas cylinder

Note: The verification gas cylinder is shipped separately from the monitor

because of UN1956 classified non-flammable gas shipping requirements and

may ship at a later date depending upon installation.

291-0014-XX (2) Helium Dryer Mounting Clips

292-0018-XX (1) Helium Regulator, high purity, for cylinder valve type CGA-580

300-0004-XX (1) LoadGuide, Current Transformer

456-0022-XX (1) Valve, Oil Return Assy.

456-0023-XX (1) Valve, Sample Port / Secondary Shutoff Assy.

456-0026-XX (1) Oil Supply Port Assy.

610-0110-XX (1) Cable, 14’, RJ45, 8 Cond.

610-0121-XX (1) Adapter Assy., RS232

610-0192-XX (1) Serial Adapter, USB RS-232 DB-9 Male

750-0088-XX (1) 10” Helium Supply Line

750-0089-XX (1) 120” Helium Supply Line

900-0055-XX

900-0112-XX

900-0075-XX

900-0070-XX

900-0113-XX

900-0077-XX

(1) On-Line Transformer Monitor, Model TM8 OR



(1) On-Line Transformer Monitor, Model TM8 (Chinese) OR

(1) On-Line Transformer Monitor, Model TM5 (Chinese) OR

(1) On-Line Transformer Monitor, Model TM3 ( Chinese)

900-0053-XX (1) Bleed Fixture

910-0018-XX (1) TM View Transformer Monitor Software CD

Table 2: Items Shipped


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Part # Description

900-0064-XX

900-0059-XX

610-0179-XX

610-0180-XX

610-0181-XX

(1) Kit, Junction Box with Cables

(1) Junction Box

(1) AC Power Cable (black 3-wire)

(1) Sensor Cable (black)

(1) Communication Cable (gray)

900-0057-XX

900-0066-XX

(1) Transformer Pad Mount OR

(1) Transformer Tank Mount

900-0062-XX Kit, Fiber Optic Ethernet

Table 3: Items Shipped

Optional Accessories

Part # Description

900-0082-XX Kit , Oil Moisture and Temperature Sensor

900-0063-XX

610-0182-XX

610-0183-XX

610-0184-XX

(1) Kit, External 23 ft. Cables

(1) AC Power Cable 23 ft. (black 3-wire)

(1) Sensor Cable, 23 ft. (black)

(1) communication Cable 23ft (gray)

900-0058-XX Oil Inlet Cooler

900-0106-XX GSM Cellular Modem, T-Mobile (Worldwide)

900-0105-XX CDMA Cellular Modem, Verizon (US Only)

700-0052-XX Kit, Copper Ethernet

900-0068-XX TM Configuration Utility Kit

900-0103-XX TMx Internal Display

Table 4: Optional Accessories


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Preparatory Tasks for Installation CAUTION: Do not attempt to install your Serveron On-Line Transformer Monitor until you have read and fully understand the procedures outlined in this document.

There are certain tasks that must be completed prior to installation of the Transformer Monitor. These tasks are outlined in the “On-Line Transformer Monitor Site Preparation Guide” that was sent to you upon acceptance of your order. Additionally, a copy of the guide can be downloaded from www.serveron.com. Please review the Site Preparation Guide and ensure all items on the Site Preparation Guide checklist below have been completed.

Site Preparation Guide Checklist

The following is a checklist that will help ensure that all the proper steps have been completed.

Customer Information form filled out and returned to Serveron A location for mounting the On-Line Transformer Monitor has been identified, and the

monitor mounting stand is secured in place The transformer oil supply valve (On-Line Transformer Monitor oil supply port) and the

transformer oil return valve (On-Line Transformer Monitor oil return port) have been selected

Note: Serveron recommends a minimum size of ½”for the oil supply valve

Bleed fixture and oil supply fittings installed (additional fittings required if Oil Moisture sensor is to be installed)

Power is present and available at the installation site for the monitor Transformer is oil filled Communication is available to the monitor A cylinder of chromatographic grade helium (99.9999% pure with < 0.2 ppm of H2O)

has been purchased and is on location A 0-5 Amp CT has been identified for the LoadGuide sensor All shipped items and optional accessories have been located Electrical conduit and enclosures have been installed (as required) 1/4” (or 3/8” as required) stainless steel tubing (SS-316), 0.035 wall thickness , 20 ft

lengths onsite, enough for each tubing run


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Installation Procedures Installation consists of completing the following steps:

Stand Mounting and Assembly Mounting the Transformer Monitor Oil Connections Gas Connections Cable Connections External Sensors Installation Checklist

Figure 2: Installation Schematic


Page 10 of 35

Mounting and Assembly

There are two types of mounting for the TMx monitors; pedestal mounting stand or transformer tank-mounting kit. The monitor should be located in a position where it will not interfere with transformer maintenance or access requirements. The front of the monitor must be accessible for commissioning and maintenance. There should be adequate room behind the monitor to access the junction box and helium cylinder. The location should also minimize the length of supply and return tubing runs.

Items to consider when choosing a location for the monitor are:

Location of oil supply and oil return ports Location of power supply Transformer maintenance points Access to the monitor Mounting of the monitor stand

NOTE: The monitor must be mounted and operated in an upright position. Failure to do so will void the warranty.

Mounting the Pedestal Stand

1) Remove the pedestal stand from the shipping container. 2) Position the stand on the transformer pad or the dedicated Transformer Monitor pad. The

mounting location should have been determined during completion of the “On-Line Transformer Monitor Site Preparation Guide”

3) Use the stand as a template and mark the four mounting holes onto the pad. Orientation of the four mounting holes is not important.

4) Temporarily move the stand. Using a hammer drill, drill a 3/8-in x 2-in (5 cm) deep hole at each of the marked locations.

5) Insert the four 3/8-in concrete anchors supplied with the stand. 6) Reposition the stand over the four anchors and install a flat-washer,

split-washer and 3/8-in nut onto each of the four anchors and tighten evenly.

7) Using a level, verify the stand-post is within ± 5˚ of plumb in all directions. Use 3/8-in stainless steel washers as spacers under the four corners if leveling is required.

Figure 3: Pedestal Stand


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Assembling the Stand (Standard Installation)

1) Locate stand hardware, items 2-through-16 (refer to the “Mounting Stand Assembly Drawing” in the back of this guide) and assemble the stand per the figure below.

2) Attach (1) unistrut (item 5) using (1) U-bolt assembly (item 4) with (2) lock washers (item 9) to the stand approx. 3-in (7.6 cm) from the top. Using a 9/16-in deep socket and a level, secure the items to the stand with (2) 3/8 nuts (item 7) without over-tightening and ensure the channel is ± 5˚ of plumb. (Note: over-tightening will crush the aluminum post.)

3) On the back side of the stand, mark from the top of the U-bolt assembly 20-in down and attach the second unistrut (item 5) using (1) U-bolt assembly (item 4) with (2) lock washers (item 9) and (2) 3/8 nuts (item 7) to post. (Note: If the optional Oil Cooler will be installed, fully tighten the lower U-bolt nuts to the stand at this time. Otherwise, wait until the Transformer Monitor is installed and secured before tightening the nuts.)

4) Insert (2) spring nuts (item 2) in the top unistrut channel using (2) fully-threaded bolts (item 3) from the rear of channel.

5) Insert (2) spring nuts (item 2) in the bottom unistrut channel. 6) Attach (2) mounting straps (item 13) to the back of the unistrut using (4) screws, (4) lock

washers and (4) nuts (items 14, 15 and 16). 7) Attach helium tank support bracket and strap to the back of the lower unistrut (items 11 and

12) using (2) bolts, (2) washers and (2) nuts (items 20, 7 and 9).

Figure 4: Stand Assembly

8) If the optional oil cooler was purchased, proceed to the “Optional Oil Cooler” section. If the oil cooler was not purchased, continue with step (9).

9) Position (1) helium dryer mounting clip (291-0014-XX) provided with the monitor hardware to the front of the outside mounting strap (item 13), lower through-hole (the front of the strap is opposite the side that it is attached to the unistrut). Attach the clip to the strap using (1) screw (253-0066-XX) and (1) nut (252-0013-XX) contained in the monitor hardware.

Note: If a Junction Box will not be installed, attach the second clip (291-0014-XX) using (1) screw (253-0066-XX) and (1) nut (252-0013-XX) to the second through-hole from the top of the same outside mounting strap (item 13).


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Junction Box Mounting

The junction box must be mounted prior to mounting the optional oil cooler or Transformer Monitor.

1) Remove the junction box from the shipping container taking care not to damage the cable glands protruding from the bottom of the box.

2) Attach the junction box to the stand mounting straps as illustrated in the figure below. Use the mounting hardware included with the junction box.

3) If the optional oil cooler will be installed, skip to the next section on “Optional Oil Cooler”. Otherwise, attach (1) helium dryer mounting clip (291-0014-XX) opposite to the junction box’s top-right mounting position using the junction box mounting hardware.

Figure 5: Junction Box Mounting


Page 13 of 35

Optional Oil Cooler

The cooler must be installed on the stand prior to mounting the Transformer Monitor and helium dryer retaining clips. If you have purchased the transformer pad mount stand, follow the instructions below. If the tank/wall mount will be used, go to the section “Tank/Wall Mount”, step 3.

1) Remove the oil cooler from its shipping container. 2) Mount the oil cooler to the upper Transformer Monitor stand mounting bolts. The oil cooler

will be secured using the same hardware used to secure the Transformer Monitor. 3) Position (1) helium dryer mounting clip (291-0014-XX) to the predrilled and tapped hole

located on the upper right hand side of the cooler. Attach the clip to the cooler using (1) screw (253-0066-XX) contained in the monitor hardware. Position a second helium dryer mounting clip (291-0014-XX) to the predrilled and tapped hole located on the lower right hand side of the cooler. Attach the clip using (1) screw (253-0066-XX) contained in the monitor hardware. Discard (2) nuts (252-0013-XX) contained in the monitor mounting hardware.

CAUTION: If the oil cooler will not be mounted to the transformer pad mount stand, the oil cooler must still be secured by the cooler frame. Oil line fittings and oil tubing cannot support the cooler weight.

Figure 6: Oil Cooler Mounting


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Mounting the Transformer Monitor

CAUTION: The monitor must be mounted and operated in an upright position. Failure to do so will VOID the warranty.

Mounting to the Pedestal Stand

1) Remove the Transformer Monitor from the shipping container taking care not to damage the ambient temperature sensor or cable glands protruding from the bottom of the monitor enclosure.

2) Attach the monitor to the upper unistrut using the (2) mounting bolts (item 3) and secure with (2) strut washers (item 21 – only if oil cooler will NOT be used), (2) flat washers, (2) lock washers and (2) nuts (items 8, 9 and 7) provided with the stand hardware.

3) Position the spring nuts in the lower unistrut so they are in line with the lower monitor mounting tabs. Loosely secure the monitor using (2) strut washers (item 21 – only if oil cooler will NOT be used), (2) bolts, (2) lock washers and (2) flat washers (items 6, 8 and 9) to the spring nuts.

4) Using a 9/16-in deep socket, tighten the lower channel on the post if not already done. (Note: Over-tightening will crush the aluminum post.)

5) Verify monitor is plumb and level, within ± 5˚ and all mounting hardware is tight.

Figure 7: Transformer Monitor Mounting


Page 15 of 35

Tank/Wall Mount

The tank/wall mount kit comes with all the necessary hardware to mount the monitor to either 1 5/8” unistrut or mounting tabs located directly on tanks. If unistrut is required for the tank or wall mount, Serveron recommends using deep channel 1 5/8” unistrut which is not provided with the mounting kit.

Tank/Wall Mount Assembly

1) If unistrut is required, mount (2) 4ft pieces approx 40 “ from the ground or pad level (depending on where the helium cylinder will sit) as shown in the figure below:

Figure 8: Unistrut Mounting

With Optional Oil Cooler

2) Locate (2) 3/8” unistrut spring nuts (item 1) (refer to the “Tank/Wall Mounting &Assembly Drawing” in the back of this guide). Install one on each unistrut rung approx. 2” from the left end.

3) Locate and unpack the oil cooler. Position the cooler over the unistrut, aligning the mounting holes on the left with the spring nuts previously installed and mark the mounting hole positions on the right side with a Sharpie Marker. Set the cooler aside.

4) Install the other (2) 3/8” spring nuts in the locations identified in step 3. 5) Locate (4) 3/8” lock washers, (4) vibration dampers and the grounding strap (items 11, 12

and 14). Align the oil cooler over all (4) installed spring nuts. Insert a vibration damper (item 12) into each of the top cooler mounting holes to loosely hold it in place. Position one end of the grounding strap (item 14) over the lower-left mounting hole between the spring nut and the oil cooler, placing a lock washer (item 11) in front of, and behind the strap (see Figure 9). Use the other two vibration dampers to attach the bottom of the cooler to the unistrut. Ensure that all 4 vibrations dampers are tight against the oil cooler.

6) Mount the monitor on the vibration dampers and secure with (4) flat washers, (4) lock washers and (4) nuts (items 10, 11 and 9) provided with the tank/wall-mount hardware.

7) Position (1) helium dryer mounting clip (291-0014-XX) to the predrilled and tapped hole located on the upper right hand side of the cooler. Attach the clip to the cooler using (1) screw (253-0066-XX) contained in the monitor hardware. Position a second helium dryer mounting clip (291-0014-XX) to the predrilled and tapped hole located on the lower right hand side of the cooler. Attach the clip using (1) screw (253-0066-XX) contained in the monitor hardware. Discard (2) nuts (252-0013-XX) contained in the monitor mounting hardware.


Page 16 of 35

Without Optional Oil Cooler

8) Locate (4) 3/8” unistrut spring nuts (item 1) (refer to the “Tank/Wall Mounting &Assembly Drawing” in the back of this guide). Install one on the upper unistrut rung approx. 2” from the left end and another one 21 ¼-in to the right of the first one.

9) Install a third spring nut on the lower unistrut rung approx. 3 ½-in from the left end and another one 18 ¼-in to the right of the third one.

10) Install and tighten a vibration damper (item 12) on each of the spring nuts on the upper unistrut.

11) Position one end of the grounding strap (item 14) over the lower-left spring nut, placing a lock washer (item 11) in front of, and behind the strap. Insert a vibration damper through the strap and the lock washers and secure to the spring nut (see the figure below). Position the other end of the grounding strap over the end of the vibration damper. This will be held in place when the monitor is mounted. Install the last vibration damper in the lower-right spring nut.

12) Position the monitor over the vibration dampers and secure with (4) flat washers, (4) lock washers and (4) nuts (items 10, 11 and 9) provided with the tank/wall-mount hardware.

13) Locate hardware items 2, 3, 5 and 6 (3/16”spring nut, #10 lock washer, #10 screw, mounting straps) in the accessories box.

14) Insert (1) spring nut (item 2) in the upper unistrut, next to the right vibration damper and another spring nut directly below in the lower unistrut. Attach one of the mounting straps (item 6) to the spring nuts with (2) of the lock washers and screws (items 3 and 5).

15) Attach (1) helium dryer mounting clip (291-0014-XX) provided with the monitor hardware to the strap at the second through-hole from the top with (1) screw (253-0066-XX) and (1) nut (252-0013-XX), contained in the monitor hardware. Attach the second clip to the bottom through-hole in the strap with another screw and nut.

Figure 9: Grounding Strap


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Junction Box Mounting

16) Locate hardware items 2, 3, 5 and 6 (3/16”spring nut, #10 lock washer, #10 screw, mounting straps) in the accessories box.

17) Remove the junction box from its packing. Open the junction box and locate the mounting tabs and screws. The mounting tabs can be discarded.

18) Turn the junction box face down and secure both mounting straps using the (4) screws provided with the junction box.

19) Approx. 6 to 8 inches to the right of the oil cooler (or the monitor, if cooler is not installed), insert two spring nuts into each unistrut. Align the spring nuts with the holes in the mounting straps and secure the junction box to the unistrut with the screws and lock washers. Please refer to the figure below.

Figure 10: Junction Box Mounting

20) Locate items 1, 4, 7, 8, 10 and 11 (3/8”spring nut, 3/8”x 1.5” bolts, helium support bracket,

helium strap, 3/8” flat washer, 3/8” lock washer and assemble as shown in the figure below.

Figure 11: Helium Bracket Assembly


Page 18 of 35

Attaching the Sunshield

1) Locate the sunshield and the (4) 10x32 retaining screws (253-0066-XX), included in the monitor hardware.

2) Position the sun shield over the monitor, see the figure below. 3) Install the four screws in pre-drilled and tapped mounting holes.

Figure 12: Sunshield Mounting


Page 19 of 35

Oil Connections

There are several steps that must be followed specifically when connecting the oil supply and return lines. The monitor must be connected to the transformer’s main tank in two locations. The first connection supplies oil from the transformer to the monitor (Oil Supply Port). The second connection returns oil from the monitor back to the transformer (Oil Return Port). Refer to the Site Preparation Guide for recommended transformer oil connection locations.

To guard against oil leaks, Extra High Density, 1.45 SG or higher Teflon tape (PTFE) or Teflon paste should be applied to all NPT-type connections prior to assembly.

CAUTION: Ensure all fittings, valves, and fixtures are clean prior to installing. De-burr all tubing ends prior to swaging on fittings.

CAUTION: Maximum Oil Inlet Pressure to the analyzer is 45 psi (3 bar)

In-Line Oil Filter

One (1) in-line oil filter (250-0130-XX) is supplied with the monitor to be used on the oil-supply line. The preferred mounting location is at the Oil In monitor bulkhead, see the figure below. If this location is not convenient, the filter must be mounted in a location that will allow easy access for filter service.

1) Identify the location for oil filter mounting. 2) Install the filter in the oil-supply line with the flow arrow oriented toward the monitor. 3) Swage the two fittings onto the ¼-in oil tubing, supporting the filter housing with a wrench.

Figure 13: In-Line Oil Filter


Page 20 of 35

Oil Plumbing

Locate the two bulkhead fittings for oil connections labeled Oil In and Oil Out on the left side of the Transformer Monitor.

1) Secure the Serveron Oil Supply Port Assy (456-0026-XX) to the transformer oil supply valve (see the figure below), as specified in the Site Preparation Guide.

Figure 14 : Oil Supply Port Assy

2) Secure the Serveron-supplied Bleed Fixture (900-0053-XX) to the oil return port (see the figure below), as specified in the Site Preparation Guide. Please note that the bleed fixture is ready to mount to a 2” NPT nipple. If your valve size differs, the necessary adapters and fittings should have been outlined in the Site Preparation procedure (minimum ½” recommended).

3) Secure the Serveron Oil Return Valve Assy (456-0022-XX) to the Bleed Fixture (see the figure below), as specified in the Site Preparation Guide.

Figure 15 : Oil Return Port Assy /Bleed Fixture

4) Using ¼-in stainless steel tubing, join the Serveron Oil Supply valve assembly and the Serveron oil return valve assembly to their respective Oil In and Oil Out bulkhead fittings on the Transformer Monitor. Ensure that the in-line oil filter is installed as described in the previous section (preferably as close to the Oil In bulkhead fitting as possible).


Page 21 of 35

CAUTION: Oil lines, valves, and fixtures should not be used as a step! Make sure all tubing is positioned out of the way of any foot traffic or maintenance areas.

5) Using the supplied helium and regulator, purge fitted oil lines with helium for one minute prior to final tubing connection to the monitor.

6) Select a convenient location in the oil-supply line, no higher than 6 feet (183 cm) above ground level, to mount the Serveron Sample Port/Secondary Shut-Off Valve assembly (456-0023-XX). The flow arrow on the Secondary Shut-Off valve (dark green handle) should face toward the monitor.

Figure 16: Sample Port/Secondary Shutoff Assy

Note: The sample port/secondary shut-off valve is used when performing manual DGA testing or for stopping oil supply to the transformer monitor.


Page 22 of 35

Oil Moisture and Temperature (Optional)

An optional sensor is available to provide oil moisture in parts per million (ppm) and percent relative saturation (%RS) and oil temperature in °C. Depending on sensor location, the oil temperature data can be representative of transformer top oil temperature.

Note: Serveron recommends the Oil Moisture/Temperature Sensor be installed on the top oil supply port of the transformer.

To install the sensor, use the fittings identified in the Site Preparation Guide. All fittings must be stainless steel, brass, or black iron. Please refer to the figure below for the Moisture/Temperature Sensor fixture configuration.

1) Install the male nipple (B) and the Serveron Oil Supply Port Assy (C) (456-0026-XX) on the transformer oil supply valve with the tee orientation as shown below.

2) Install the provided 2”x ½” reducing bushing packaged with the Serveron Oil Moisture and Temperature Sensor (900-0082-XX).

3) Install the Serveron Oil Moisture and Temperature Sensor (D).

For proper installation of the Oil Moisture and Temperature sensor, it is important that the tip of the sensor is positioned in the oil flow. The position should be adjusted before inserting the sensor into the end of the bushing. Please refer to the highlighted yellow section in the figure below.

Note: The Serveron Oil Supply Port Assy (456-0026-XX) and Serveron Oil Moisture/Temperature Sensor (900-0082-XX) come standard with fittings for 2” NPT valves. If your valve is different from 2” NPT, additional fittings may be required. Serveron recommends ½” as a minimum size for the oil supply valve.

Figure 17: Oil Moisture and Temperature Sensor


Page 23 of 35

Oil Moisture and Temperature Transmitter Unit

The moisture sensor is designed for industrial applications. The sensor assembly consists of (5) elements:

Probe with Cable (5m), Transmitter Unit, Mounting Base, Rain Shield, Interface Cable (20m) There are a few options to mount the transmitter unit depending on the valve location in which the sensor will be installed. The transmitter unit is secured with two 3-mm hex screws to the mounting base (refer to the figure below). If the transmitter is installed in an unprotected outside environment, the rain shield must be installed. The base and rain shield are mounted together.

Figure 18: Transmitter Unit

Figure 19: Base and Transmitter

Figure 20: Rain Shield Installed

3mm hex screws to remove transmitter unit from mounting base


Page 24 of 35

Gas Connections

CAUTION: Use of helium other than 99.9999% pure research or chromatographic grade with less than 0.2-ppm H2O content will VOID the Transformer Monitor warranty.

Two gas sources must be connected to the monitor- Helium and Verification gas.

WARNING: When full, the helium gas cylinder is pressurized to greater than 2000psi (138 bar). Helium is regulated to 80psi (5.5 bar), nominal, before entering the monitor. Always follow Compressed Gas Association (CGA) guidelines when handling and transporting compressed gases.

Helium Gas Cylinder and Dryer Mounting

WARNING: Never leave the helium input to the monitor or the helium dryer inlet and outlet ports exposed to the atmosphere.

The helium gas cylinder must be securely mounted. The Transformer Monitor stand includes a mounting bracket that meets all Compressed Gas Association (CGA) cylinder restraining requirements.

The helium dryer is mounted vertically to the Transformer Monitor mounting stand using the retaining brackets included with the monitor mounting stand.

A 10-ft (305 cm) x 1/8-in O.D. stainless-steel tube is provided to connect the helium cylinder regulator to the top of the helium dryer. A 10-in (25.4 cm) x 1/8-in O.D. stainless-steel tube is provided to connect the bottom of the helium dryer to the monitor.

CAUTION: Do not uncap or connect helium gas lines to the helium dryer at this time.

1) Install the provided helium regulator onto the helium cylinder. Do not use Teflon tape or pipe dope.

2) Orient the gauge vertically and tighten the CGA fitting.

Figure 21: Helium Dryer

3) Orient the helium cylinder so that the gauges on the regulator can be clearly seen. 4) Mount the helium dryer to the stand in the vertical orientation as indicated in Figure 21 on

the previous page, using the supplied retaining clips (291-0014-XX). 5) Install one end of the 10-ft stainless steel tubing onto the regulator. Do not over-tighten the

7/16-in. nut on the regulator. 6) Verify the helium regulator shutoff valve (black knob) is closed and slowly turn the valve on

top of the helium cylinder fully counterclockwise (open).


Page 25 of 35

7) Slowly turn helium regulator shutoff valve counterclockwise (open) until helium begins to flow. At this point, gas should be escaping from the stainless steel tubing.

CAUTION: Do not open the regulator shutoff valve completely to regulate the helium flow.

8) With the helium flowing, attach the other end of the 10-ft. tubing to the top of the helium dryer.

9) Remove the cap from the bottom of the helium dryer. While the helium is continuing to flow, install the one end of the 10-in stainless-steel tubing onto the bottom of the helium dryer.

10) Let the helium continue to purge through the dryer and tubing for one (1) minute. 11) While the helium is still purging, attach the remaining end of the 10-in stainless-steel tubing

to the bulkhead fitting on the right side of the monitor labeled Helium In. 12) Now turn the regulator shutoff valve fully counterclockwise (open). 13) Confirm all four helium connections and the helium regulator-to helium tank connections

are leak-tight by applying a leak-check solution to the fittings.

Figure 22: Helium Regulator

Note: The leak-check is very important, as even the smallest leak can substantially reduce the life of the helium cylinder.


Page 26 of 35

Verification Gas Cylinder

WARNING: When full, the verification gas cylinder is pressured to greater than 500psi (34 bar). Verification gas is regulated to 8psi (0.5 bar), nominal, before entering the monitor. Always follow Compressed Gas Association (CGA) guidelines when handling and transporting compressed gases.

The verification gas cylinder is used to automatically verify and calibrate the monitor. The cylinder contains a certified NIST-traceable concentration of the eight transformer fault-gases measured by the monitor.

1) Open the analyzer door and locate the Verification cylinder mounting bracket and regulator. 2) Install the Verification cylinder into the mounting bracket and secure using the Velcro strap. 3) Connect the cylinder to the regulator union and tighten. 4) Turn the knob on the top of the Verification cylinder counterclockwise until it is fully open. 5) Confirm that the bottle-to-regulator connection is leak-tight by applying a leak-check

solution to the fitting. Wipe away any excess leak-check solution.

Note: The leak check is very important, as even the smallest leak can substantially reduce the life of the Verification cylinder.

6) Complete and return the Verification cylinder data sheet found in the appendix to Serveron.

Figure 23: Installed Verification Cylinder


Page 27 of 35

Cable Connections

The Transformer Monitor has three primary electrical cable connections: Power, Sensor, and Communication. Each cable comes with a preinstalled connector on one end and is marked with an identifying part number and a description.

CAUTION: Ensure monitor power switch is off before connecting cables.

Power Cable

The monitor has a variable-input power supply capable of receiving input of 115VAC or 230VAC ±15%, 50/60 Hz. Current draw is 6A max at 115VAC and 3A max at 230VAC. There are two 4A/250V type 3AG (T) fuses installed for the power supply (line and neutral) and two 2.5A/250V type GMD fuses for the monitor’s enclosure heater (line and neutral).

Note: Monitors with previous versions of the power supply will have three fuses (4A/250V type 3AG (T)). Replace fuses with same type and rating only. Serveron recommends installing a properly rated and marked switch or circuit breaker in close proximity to the monitor as a mains voltage disconnect device.

1) Locate the cable gland on the bottom of the monitor labeled Power. 2) Starting from the inside of the monitor housing, route the power cable through the cable

gland until the ferrite core contacts the cable gland. 3) Locate the white connector from the power supply and attach it to the matching connector

on the power cable. 4) Tighten the cable gland onto the power cable. 5) Attach the green/yellow ground wire to one of the two ground lugs and secure with the

3/8-in ground nut. 6) Route the blunt end of the cable into the Junction Box or control cabinet for termination. Pull

enough cable through and trim cable to length. When using the Serveron Junction Box, pull approx 10-in through and remove the black cable jacket.

7) Terminate per the wiring termination diagram located on the following pages.


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Sensor Cable (black)

1) Locate the cable gland on the bottom of the monitor labeled Sensor. 2) Starting from the inside of the monitor housing, route the sensor cable through the cable

gland until the ferrite core contacts the cable gland. 3) Locate socket J100 on the system board and insert the matching connector on the cable. 4) Tighten the cable gland onto the sensor cable. 5) Attach the shield drain wire to the open ground lug and loosely attach the ground nut until

the next cable is installed. 6) Route the blunt end of the cable into the Junction Box or control cabinet for termination. Pull

enough cable through and trim cable to length. When using the Serveron Junction Box, pull approx 10-in through and remove the black cable jacket.

7) Terminate per the wiring termination diagram on the next page.

Communication Cable (gray)

1) Locate the cable gland on the bottom of the monitor labeled Communication. 2) Starting from the inside of the monitor housing, route the gray communication cable

through the cable gland until the ferrite core contacts the cable gland. 3) Locate socket J101 on the system board and insert the matching connector on the cable. 4) Tighten the cable gland onto the communication cable. 5) Attach the shield drain wire to the same ground lug as the sensor cable and securely tighten

the ground nut. 6) Route the blunt end into the Junction Box or control cabinet for termination. Pull enough

cable through and trim cable to length. When using the Serveron Junction Box, pull approx 10-in (25.4 cm) through and remove the gray cable jacket.

7) Terminate per the wiring termination diagram on the next page.


Page 29 of 35

Figure 24: Wiring Terminations


Page 30 of 35

External Sensors Oil Moisture and Temperature Connections

The Oil Moisture and Temperature sensor can be configured for 4-20mA or RS-232 output; the recommended configuration is 4-20mA. The sensor can also be wired as moisture only or moisture and temperature. When using the 4-20ma inputs, always wire temperature to Aux 3 and moisture to Aux1. Please refer to the table below for the wiring configurations.

Sensor Type Sensor Signal Name

Sensor Wire Color

Monitor Signal Name Monitor Wire Color

Moisture Only Supply (-) GREY Signal GND BLK

Supply (+) 24VDC PINK CH 1 (+) 24VDC ORG

CH 2 GRN CH 1 Input WHT/ORG Moisture/Temperature Supply (-) GREY Signal Ground BLK Supply (+)

24VDC PINK CH 1 (+) 24VDC ORG

CH 2 GRN CH 1 Input WHT/ORG CH 1 YEL CH 3 Input WHT/BLK/BRN

Table 5: Oil Moisture and Temperature Connections

LoadGuide

WARNING: High voltage can be induced by the LoadGuide sensor. Do not clamp the LoadGuide around the transformer CT winding until its wires have been terminated to the Transformer Monitor.

1) Locate the 0 to 5-amp CT winding identified in the Site Preparation Guide within the transformer control panel.

2) Pull the LoadGuide leads from the transformer panel to the monitor junction box. A wire size of 22 AWG or larger can be used to extend the length of the leads.

3) Connect the black and white wires of the LoadGuide to the brown and blue sensor cable leads. Polarity is not significant.

4) Unscrew the white screws from the LoadGuide and remove the back plate from device. 5) Place the clamp around the 0 to 5-amp tap. 6) Reinstall back plate and finger-tighten the screws.


Page 31 of 35

Relays

There are two dry-contact relays (Programmable and Power) which can be wired for normally-open (NO) or normally-closed (NC) configuration. Programmable relay - typically configured for critical events such as gas alarms but can be programmed for; gas alarm, gas caution, service LED and aux input alarms Power relay - will always report loss of AC power. It can also be configured for non-critical events such as; gas caution, service LED and aux inputs.

Note: Only revision -04 system boards have a configurable Power relay. For all revisions lower than -04, the Power relay will only report loss of AC Power.

Note: The relay contact ratings for resistive loads are: Max switched Power 100W or 600VA Max switched Current 3A Max switched Voltage 150VDC or 300VAC

Aux Inputs

The TMx has three 4-20ma self-powered (24VDC) auxiliary inputs (Aux1, Aux2 and Aux3). The inputs can be labeled for name, units and are scalable. If the moisture/temperature sensor is installed, only one input is available (Aux2). The aux inputs can be configured using either the TM Config Utility Tool or the Command Line Interface (CLI).


Page 32 of 35

Pedestal Stand Assembly Drawing

Figure 25: Pedestal Stand Assembly

Part

/Des

crip

tion

140-

0190

-00

CM

P, S

tand

Pos

t

291-

0011

-00

Nut

Mou

nt w

/spr

ing

253-

0144

-00

3/8

Bol

ts x

3”

291-

0010

-00

U-B

olt A

ssy

291-

0009

-00

Uni

stru

t – 2

feet

253-

0071

-00

3/8

Bol

ts x

1.5

”

252-

0014

-00

3/8

Nut

254-

0070

-00

3/8

Fla

t Was

her

254-

0071

-00

3/8

Loc

k W

ashe

r

253-

0076

-00

3/8

Anc

hor B

olts

140-

0062

-00

He

Supp

ort B

rack

et

190-

0001

-00

He

Tank

Stra

p

140-

0193

-00

¾ x

1/8

Stra

p

252-

0013

-00

#10

-32

Nut

254-

0023

-00

#10

Loc

k W

ashe

r

253-

0070

-00

#10

-32

x ½

Scr

ew

010-

0047

-00

Pac

kagi

ng S

et

140-

0203

-00

Bra

cket

Bul

khea

d

253-

0148

-00

#10

-16

x ¾

” Scr

ew

253-

0151

-00

3/8

Bol

ts x

.875

”

254-

0094

-00

Stru

t Was

her,

Qty

1 4 2 2 2 2 4 4 10

4 1 1 2 4 8 8 1 1 2 2 4

Item

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

18

19

20

21


Page 33 of 35

Tank/Wall-Mount Assembly Drawing

Figure 26: Wall/Tank Mount


Page 34 of 35

Installation Checklist The following is a checklist to help ensure that all the proper steps have been completed prior to filling the Transformer Monitor with oil.

Transformer Monitor securely mounted

Helium cylinder securely mounted

Helium regulator installed

Helium dryer installed in the vertical orientation

Helium system leak-checked

Verification cylinder securely mounted

Verification cylinder system leak-checked

All oil-plumbing components secure

(Optional) Oil Cooler securely mounted to stand

All compression fittings securely tightened and leak-checked

All cabling securely routed and safely out of the way

Electrical conduit and or termination strip enclosures installed, secured, and grounded as necessary

Sensor connections established

Communication connections established

Power connections established (power is OFF in the analyzer)

CAUTION: DO NOT apply power to the analyzer! Power will be applied as part of the commissioning procedure.


Page 35 of 35

Verification Cylinder Data Sheet Upon successful installation of your Transformer Monitor verification cylinder, please complete and fax or e-mail this Verification Cylinder Data Sheet to Technical Support at: +1 (503) 924-3290 fax [email protected] e-mail

Attention: Serveron Product Support

From:

Customer Information

Company:

Site:

Site Address:

City, State and Zip:

Country:

Transformer Monitor and Verification Cylinder Information

Installer’s Name:

Installation Date:

Transformer Monitor Serial Number:

Helium high pressure gauge (psig):

Helium low pressure

gauge (psig):

Verification high pressure gauge (psig):

Verification low pressure

gauge (psig): N/A

Verification Cylinder Lot Number:

Analysis Date

Verification Cylinder Components Certified Concentrations

Hydrogen H2 ppm Oxygen O2 ppm Methane CH4 ppm

Carbon Monoxide CO ppm Carbon Dioxide CO2 ppm

Ethylene C2H4 ppm Ethane C2H6 ppm

Acetylene C2H2 ppm

Table 6: Verification Cylinder Data Sheet

online transformer monitor installation guide - march 2010

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