SmartDGA®
L A U N A M
Confidential Confidential Information Information The material contained herein consists of information that is the property of LumaSense Technologies, Inc. and intended solely for use by the purchaser of the equipment described in this manual. All specifications are subject to change without notice. Changes are made periodically to the information in this publication, and these changes will be incorporated in new editions. LumaSense Technologies, Inc. prohibits the duplication of any portion of this manual or the use thereof for any purpose other than the operation or maintenance of the equipment described in this manual, without the express written permission of LumaSense Technologies. Copyright © LumaSense Technologies 2017. All rights reserved. Trademarks SmartDGA, SmartDGA Guide, SmartDGA Gauge, SmartDGA Guard, SmartDGA EZHub, LumaSMART i Core, Core, DGA Viewer, and LumaSMART are trademarks of LumaSense Technologies, Inc. All other trademarks are trademarks, registered trademarks, and/or service marks of their respective holders. Service Centers LumaSense Technologies, Inc. North America 3301 Leonard Court Santa Clara, CA, 95054 Ph: +1 800 631 0176 Ph: +1 408 727 1600 Fax: +1 408 727 1677
LumaSense Technologies GmbH Other Than North America Kleyerstrasse Kleyerstrasse 90 60326 Frankfurt, Germany Ph: +49 (0) 69 97373 0 Fax: +49 (0) 69 97373 167
Global and Regional Centers Our Headquarters LumaSense Technologies, Inc. 3301 Leonard Court Santa Clara, CA, 95054 Ph: +1 800 631 0176 Fax: +1 408 727 1677
Americas, Australia, & Other Asia LumaSense Technologies, Inc. 3301 Leonard Court Santa Clara, CA, 95054 Ph: +1 800 631 0176 Fax: +1 408 727 1677
Europe, Middle East, Africa LumaSense Technologies GmbH F Kleyerstrasse 90 60326 Frankfurt, Germany Ph: +49 (0) 69 97373 0 Fax: +49 (0) 69 97373 167
Brazil LumaSense, Vendas Brasil Rua Ataliba Camargo Andrade, 172/sl 112 Campinas, SP � 13025-290 Brasil Ph: +55 19 3367 6533 Fax: +55 19 3367 6533
India LumaSense Technologies, India 514, A Wing, Sagar Tech Plaza, Sakinaka Junction, Andheri Kurla Road Andheri East, Mumbai 400072 India Ph: + 91 22 22 67419203 67419203 Fax: + 91 22 67419201 67419201
China LumaSense Technologies, China Rm 1004, No. 1607 South Pudong Rd Pudong New Area Shanghai, 200122 China Ph: +86 133 1182 7766 Ph: +86 21 5877 2383
E-mail E-mail
[email protected] [email protected] [email protected]
Website Website http://www.LumaSenseInc.com Part No 515-0009-01 EN Revision H March 2017
Confidential Confidential Information Information The material contained herein consists of information that is the property of LumaSense Technologies, Inc. and intended solely for use by the purchaser of the equipment described in this manual. All specifications are subject to change without notice. Changes are made periodically to the information in this publication, and these changes will be incorporated in new editions. LumaSense Technologies, Inc. prohibits the duplication of any portion of this manual or the use thereof for any purpose other than the operation or maintenance of the equipment described in this manual, without the express written permission of LumaSense Technologies. Copyright © LumaSense Technologies 2017. All rights reserved. Trademarks SmartDGA, SmartDGA Guide, SmartDGA Gauge, SmartDGA Guard, SmartDGA EZHub, LumaSMART i Core, Core, DGA Viewer, and LumaSMART are trademarks of LumaSense Technologies, Inc. All other trademarks are trademarks, registered trademarks, and/or service marks of their respective holders. Service Centers LumaSense Technologies, Inc. North America 3301 Leonard Court Santa Clara, CA, 95054 Ph: +1 800 631 0176 Ph: +1 408 727 1600 Fax: +1 408 727 1677
LumaSense Technologies GmbH Other Than North America Kleyerstrasse Kleyerstrasse 90 60326 Frankfurt, Germany Ph: +49 (0) 69 97373 0 Fax: +49 (0) 69 97373 167
Global and Regional Centers Our Headquarters LumaSense Technologies, Inc. 3301 Leonard Court Santa Clara, CA, 95054 Ph: +1 800 631 0176 Fax: +1 408 727 1677
Americas, Australia, & Other Asia LumaSense Technologies, Inc. 3301 Leonard Court Santa Clara, CA, 95054 Ph: +1 800 631 0176 Fax: +1 408 727 1677
Europe, Middle East, Africa LumaSense Technologies GmbH F Kleyerstrasse 90 60326 Frankfurt, Germany Ph: +49 (0) 69 97373 0 Fax: +49 (0) 69 97373 167
Brazil LumaSense, Vendas Brasil Rua Ataliba Camargo Andrade, 172/sl 112 Campinas, SP � 13025-290 Brasil Ph: +55 19 3367 6533 Fax: +55 19 3367 6533
India LumaSense Technologies, India 514, A Wing, Sagar Tech Plaza, Sakinaka Junction, Andheri Kurla Road Andheri East, Mumbai 400072 India Ph: + 91 22 22 67419203 67419203 Fax: + 91 22 67419201 67419201
China LumaSense Technologies, China Rm 1004, No. 1607 South Pudong Rd Pudong New Area Shanghai, 200122 China Ph: +86 133 1182 7766 Ph: +86 21 5877 2383
E-mail E-mail
[email protected] [email protected] [email protected]
Website Website http://www.LumaSenseInc.com Part No 515-0009-01 EN Revision H March 2017
Contents 1
General........................................................................................................................... 7 1.1 Informat Information ion about about this Manual Manual ........... ................. ............ ............ ........... ........... ............. ............. ............ ........... ........... ............ ......7 7 1.2 Conventi Conventions ons............ .................. ............ ............ ........... ........... ............ ............ ............ ............ ............ ............ ............ ........... ........... ............. ............. ......7 7 1.3 System System Require Requiremen ments ts ............ .................. ............. ............. ............ ............ ............ ............ ............ ............ ........... ........... ............. ............. ......7 7 1.4 Limit of Liabili Liability ty and Warrant Warranty y .................. ........................ ............ ........... ........... ............. ............. ............ ............ ........... .......... .....8 8 1.5 Malfunction or Service Request............................................................................ Request............................................................................ 8 1.6 Shipments Shipments to LumaSen LumaSense se for Repair Repair ........... ................. ............ ........... ........... ............. ............. ............ ........... ........... .......... ....8 8 1.7 Disposal and Decommissioning Decommissioning............................................................................ 9
2
System System Ove Overvie rview w ............ .................. ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ......... ... 11 2.1 System Components.......................................................................... Components............................................................................................ .................. 12 ®
2.1.1
SmartDGA Instruments .................................................................................... 12
2.1.2
SmartDGA EZ EZHubTM Unit.................................................................................... Unit.................................................................................... 13
2.1.3
LumaSMART i Core Core Controller (Optional) (Optional) ....................................................... ................................................ ....... 14
TM
2.2 Theory Theory of Operation Operation.............. .................... ............ ............ ............ ............ ............ ............ ........... ........... ............ ............ ............ ............. .......14 14
3
2.2.1 2.2.1
Non-Dispe Non-Dispersive rsive Infrared Infrared (NDIR) (NDIR) Theory Theory ................ ....................... ............... ................ ................ ............... .............. ....... 14
2.2.2 2.2.2
Other Other Gas Measure Measuremen ments ts ............... ....................... ............... ............... ................ ................ ............... ............... ................ ............. ..... 15
2.2.3 2.2.3
Sampling Sampling Sequen Sequence ce ........ ................ ................ ............... ............... ................ ................ ............... ............... ................ ................ ............. ..... 15
2.2.4 2.2.4
Oil-Gas Oil-Gas Separat Separating ing Membran Membrane e ................ ....................... ............... ................ ................ ............... ............... ................ ............ .... 16
Pre-Ins Pre-Install tallation ation Verific Verification ation............ .................. ............. ............. ........... ........... ............ ............ ............ ............ ........... ............ ............. .......... ....17 17 3.1 Unpacki Unpacking ng and Verify Verifying ing Contents Contents...... ............ ............ ........... ........... ............. ............. ........... ........... ............ ............ .......... ....17 17 3.2 Confirming Installation Installation Locations Locations ...................................................................... 17 3.2.1 3.2.1
Confirm Confirm Mount Mounting ing for Smart SmartDGA DGA Instrum Instrument ent ................ ........................ ............... ............... ................ ........... ... 17
3.2.2 3.2.2
Confirm Confirm Valve Valve Kit Kit ............... ....................... ................ ............... ............... ................ ................ ............... ............... ................ ................ .......... 18
3.2.3 3.2.3
Confirm Confirm Mounting/ Mounting/Loca Location tion for EZHub EZHub ................ ........................ ............... ............... ................ ................ ............. ..... 20
3.2.4 3.2.4
Confirm Confirm EZHub EZHub Mount Mounting ing ............... ....................... ................ ............... ............... ................ ................ ............... ............... ............ .... 21
3.2.5 3.2.5 Confirm Confirm Mount Mounting ing Locati Location/ on/Type Type for Exte External rnal Comp Compute uterr or LumaS LumaSMART MART i Core Core (Optional) ....................................................................................................................... 21 3.3 Verify Verify Power Power and Commun Communic ication ations s ........... ................. ............ ............ ............ ............ ............ ........... ............ ............. ......... ...23 23
4
3.3.1 3.3.1
Verify Verify Power Power Supply Supply ............... ....................... ................ ............... ............... ................ ................ ............... ............... ................ ............. ..... 23
3.3.2 3.3.2
Verify Verify Commun Communicat ications ions ............... ....................... ................ ................ ............... ............... ................ ................ ............... ............... ........ 23
Valve Valve Installa Installation tion ........... ................. ............ ............ ............ ............ ............ ........... ............ ............. ............ ............ ............ ........... ........... ............ .......... .... 25 4.1 Single Single Valve Valve (VA-1) (VA-1)............... ..................... ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ............ ........ 26 4.1.1 4.1.1
VA-1 Parts Parts and and Tools Tools ............... ....................... ............... ............... ................ ................ ............... ............... ................ ................ ............ .... 26
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4.1.2
VA-1 Installation................................................................................................ 27
4.2 Dual Valve (VA-2) ................................................................................................35 4.2.1
VA-2 Parts and Tools ......................................................................................... 35
4.2.2
VA-2 Installation................................................................................................ 36
4.3 Inline (Off-Transformer) Mounting (VA-0) .........................................................40
5
4.3.1
VA-0 Parts and Tools ......................................................................................... 41
4.3.2
VA-0 Installation................................................................................................ 42
SmartDGA System Installation ...................................................................................49 5.1 SmartDGA Instrument......................................................................................... 49 5.1.1
Parts and Tools for the SmartDGA Instrument ................................................. 49
5.1.2
Mounting the SmartDGA Instrument................................................................ 49
5.2 EZHub ................................................................................................................... 50 5.2.1
Parts and Tools for the EZHub........................................................................... 50
5.2.2
Mounting the EZHub......................................................................................... 52
5.2.3
Connecting the EZHub ...................................................................................... 54
5.3 i Core or External Computer ................................................................................ 59
6
5.3.1
Parts and Tools for the i Core............................................................................. 59
5.3.2
Mounting the i Core ........................................................................................... 60
5.3.3
Connecting the i Core ........................................................................................ 63
SmartDGA Commissioning.......................................................................................... 67 6.1 Installing the DGA Commissioning Tool ............................................................67 6.2 Connecting the SmartDGA System .....................................................................70 6.3 Using the Commissioning Tool ...........................................................................71
7
6.3.1
Setup.................................................................................................................. 71
6.3.2
Preparation........................................................................................................ 75
6.3.3
Pump Setup ....................................................................................................... 77
6.3.4
Priming .............................................................................................................. 78
6.3.5
Final Test............................................................................................................ 78
Maintenance ................................................................................................................81 7.1 Field Replaceable Unit (FRU) List ........................................................................ 81 7.2 Battery Replacement........................................................................................... 81 7.2.1
Replacing the EZHub Battery ............................................................................ 81
7.2.2
Replacing the LumaSMART i Core Battery ...................................................... 84
TM
7.3 Sensor Replacement ............................................................................................ 86 7.3.1
Replacing the H2 Sensor..................................................................................... 87
7.3.2
Replacing the O2 Sensor .................................................................................... 88
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8
Troubleshooting ..........................................................................................................91 8.1 Visual Light Indicators ........................................................................................ 91
9
®
8.1.1
SmartDGA Instrument...................................................................................... 91
8.1.2
SmartDGA EZHubTM Controller .......................................................................... 93
Diagrams & Drawings..................................................................................................95 TM
9.1 Multiple SmartDGA EZHub Setup with Ethernet Hub or Switch ....................95 TM
RS485 Connections ............................................................ 96
TM
Ethernet Connections ........................................................ 97
9.2 LumaSMART i Core 9.3 LumaSMART i Core
9.4 Unistrut Stand .....................................................................................................98 9.5 SmartDGA NEMA 4 Enclosure .............................................................................99 9.6 Inline Mounting Plate ....................................................................................... 100 9.7 Wiring Connection............................................................................................. 101 TM
9.8 Assy, Wall Mount, SmartDGA EZHub ............................................................. 102 TM
9.9 Assy, Panel Mount, SmartDGA EZHub ............................................................ 104 TM
9.10 Assy, Wall Mount, LumaSMART i Core ............................................................ 106 TM
9.11 Assy, Panel Mount, LumaSMART i Core .......................................................... 108 9.12 SmartDGA Instrument Sun Shade .................................................................... 110 9.13 SmartDGA Instrument Dimensions .................................................................. 112 Index ................................................................................................................................ 113
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1 General 1.1
Information about this Manual ®
Congratulations on choosing this high quality and highly efficient SmartDGA system. This manual provides important information about the system and can be used as a work of reference for installing, operating, and maintaining the SmartDGA system. It is important that you carefully read the information contained in this manual and follow all safety procedures before installing or operating the instrument. This manual assumes you have a working knowledge of the Windows™ Operating System and its conventions; including how to use a mouse, standard menus and commands, and how to open, save, and close files. For help with any of these functions, refer to the documentation that came with your computer.
1.2
Conventions large Frutiger type.
·
Section headings appear in
·
Instruction sets appear with Bold headings.
·
Menu, display, and keyboard options appear in Bold Title Case. (i.e., File, Open, etc.) Note: Indicates tips and useful information in this manual. All notes should be read to effectively operate the instrument. Caution: Denotes information critical to avoiding instrument damage or a severe impact to processing. When this symbol is found on the instrument it indicates a potential hazard. Consult the documentation before proceeding with any actions. Warning: Denotes information critical to avoiding personal injury, such as when an electrical hazard is present. When this symbol is found on the instrument it indicates a potential hazard. Consult the documentation before proceeding with any actions.
1.3
System Requirements TM
To operate the SmartDGA instruments you will need to use the DGA Viewer software, which TM requires either a PC or an i Core controller installed and connected through Ethernet or RS485 to the EZHub device. If using a PC to operate the DGA Viewer software, ensure it is a Windows-based computer with the following (minimum) components: · ·
· · ·
Processor: 1 GhZ, 32-bit or 64-bit Operating System: Windows XP Embedded, Windows Server 2003, Windows 7, Windows 8, and Windows Server 2008 Hard Disk Memory: 100 MB for installation files, 10 MB for normal use System Memory: 512 MB or more ® Microsoft .NET Framework
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1.4
Limit of Liability and Warranty
All general information and notes for handling, maintaining, and cleaning of the instruments are offered according to the best of our knowledge and experience. LumaSense Technologies is not liable for any damages that arise from the use of any examples or processes mentioned in this manual or in case the content of this document should be incomplete or incorrect. LumaSense Technologies reserves the right to revise this document and to make changes from time to time in the content hereof without obligation to notify any person or persons of such revisions or changes. All SmartDGA systems from LumaSense Technologies have a regionally effective warranty period. Please check our website at http://info.LumaSenseinc.com/warranty for up-to-date warranty information. This warranty covers manufacturing defects and faults which arise during operation, only if they are the result of defects caused by LumaSense Technologies. A SmartDGA system has only three user-serviceable components: the battery, hydrogen (H 2) sensor, and oxygen (O2) sensor. The warranty is VOID if the instrument is otherwise disassembled, tampered with, altered, or otherwise damaged without prior written consent from LumaSense Technologies; or, if considered by LumaSense Technologies, to be abused or used in abnormal conditions.
1.5
Malfunction or Service Request
Contact LumaSense Technologies Technical Support in case of a malfunction or service request. Provide clearly stated details of the problem as well as the instrument model number and serial number. Upon receipt of this information, Technical Support will attempt to locate the fault and, if possible, solve the problem over the telephone. If Technical Support concludes that the instrument must be returned to LumaSense Technologies for repair, they will issue a Return Material Authorization (RMA) number. Return the instrument upon receipt of the RMA number, transportation prepaid. Clearly indicate the assigned RMA number on the shipping package exterior. Refer to Section 1.6, Shipments to LumaSense for Repair, for shipping instructions. Technical Support can be contacted by telephone or email: Santa Clara, California
Frankfurt, Germany
Telephone:
+1 408 727 1600 +1 800 631 0176
Telephone:
+49 69 97373 0
Email:
[email protected]
Email:
[email protected]
1.6
Shipments to LumaSense for Repair
All RMA shipments of LumaSense Technologies instruments are to be prepaid and insured by way of preferred carrier. For overseas customers, ship units air-freight, priority one. The instrument must be shipped in the original packing container or its equivalent. LumaSense Technologies is not responsible for freight damage to instruments that are improperly packed. Clearly indicate the assigned RMA number on the shipping package exterior. If no RMA is indicated, shipment will not be accepted.
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Send RMA Shipments to your nearest technical service center: Santa Clara, California
Frankfurt, Germany
LumaSense Technologies, Inc. 3301 Leonard Court Santa Clara, CA 95054 USA
LumaSense Technologies GmbH Kleyerstr. 90 60326 Frankfurt, Germany
Telephone:
+1 408 727 1600 +1 800 631 0176
Telephone:
+49 69 97373 0
Email:
[email protected]
Email:
[email protected]
1.7
Disposal and Decommissioning Inoperable instruments must be disposed of in compliance with local regulations for electronic materials. Sensors must be disposed of in compliance with local regulations .
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2 System Overview The LumaSense SmartDGA ® system was designed with the environmental conditions of a transformer substation in mind and utilizes a specially constructed Non-Dispersive Infrared Sensor (NDIR) detection system to measure fault gases. LumaSense offers three SmartDGA Instrument models: Gauge, Guard, and Guide. A SmartDGA system includes the instrument itself (Gauge, Guard, or Guide), necessary mounting hardware for a transformer single or dual valve mounting or an inline adapter mounting which can be applied to a transformer or a LTC filtering system, power and/ or + I/O connection cable to an EZHub device, and an optional LumaSMART i Core which contains the SmartDGA Viewer software. Installations can be accomplished within hours (less than 4 hours in most cases) and requires no carrier gases, consumables, or scheduled calibration. The SmartDGA EZHub has a battery backed-up Real-Time-Clock-Calendar (RTC). The RTC allows the EZHub to be programmed to report measurements at a selectable rate. The first measurement cycle can be programmed to start at a specific time of day. The rates that can be programmed are: 3 hours, 6 hours, 9 hours, 12 hours, 24 hours, 48 hours, and weekly. ®
When a measurement cycle starts, the LumaSense SmartDGA instrument flushes the old oil within it and returns it to the transformer and/or LTC. The instrument then pulls a fresh oil sample to run the measurement cycle and uses a membrane gas separator to extract a sample of the dissolved gases from the transformer oil. The instrument measures the dissolved gases using an NDIR gas sensor. After the NDIR measurement, the gas sample is sent past the oxygen and hydrogen sensors to determine those gas concentrations. Oxygen and hydrogen cannot be measured by (nondispersive) infrared spectroscopy, but instead are measured using sensors which consume oxygen and hydrogen, which is why it is done as a single step at the end. The instrument also performs a background gas measurement which serves as a reference measurement. The SmartDGA system collects the results of each gas analysis cycle and stores the data in memory within the SmartDGA EZHub controller. At the end of each measurement cycle, the EZHub stores the results on the internal memory and sends them to the DGA Viewer software. The EZHub can also be configured to give an indication of the fault condition in the oil by comparing the gas results to programmable thresholds for the gases in level, rate, and ratio. The indications and conditions are: Normal Caution Warning Alarm
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The SmartDGA Viewer software enables the user to configure the SmartDGA instrument and EZHub. The software can be installed on a Windows based PC or on the optional LumaSmart i Core device. The software also displays results and other data from the EZHub and SmartDGA instrument. This allows the user to track the dissolved gas as parts per million (ppm) levels over time and monitor gas levels against user defined warning, caution, and alarm settings. As an option, a LumaSMART i Core device is available to allow local display of DGA values and provide data to external SCADA systems via DNP3, Modbus, and IEC61850 protocols.
2.1
System Components
A SmartDGA system typically consists of: · · ·
SmartDGA instrument(s) with valve mounting kit(s) (VA-0, VA-1, or VA-2) EZHub(s) with connection cable(s) i Core (optional) or PC with DGA Commissioning Tool and DGA Viewer software ®
2.1.1 SmartDGA Instruments The SmartDGA family of instruments is the industry’s most cost effective Dissolved Gas Analysis (DGA) solution, designed to be the most flexible and to provide the best user experience available. Each model has been designed using Non-Dispersive Infrared (NDIR) technology, which LumaSense Technologies incorporated in over 400,000 instruments spanning the last 45 years. The SmartDGA suite of products is designed to continuously monitor the condition of electrical transformers and Load Tap Changers (LTC). The SmartDGA instrument provides DGA values in order to develop a comprehensive analysis of potential fault conditions through specific key gases being monitored. Installations are accomplished within hours (less than 4 hours in most cases) and require no carrier gases, consumables, or scheduled calibration. The resulting online DGA information is made available with user friendly software that allows convenient viewing of all measured and recorded information. The ability to trigger corrective actions is provided by user programmable alarms for individual gases plus real time indicators that are sunlight visible. ·
·
·
The SmartDGA Gauge™ is the industry's first dedicated online Load Tap Changer (LTC) condition monitor. The Gauge measures and records acetylene, methane, and ethylene plus moisture to assess LTC health. The SmartDGA Guard™ measures and reports four (4) critical gases that results in a cost effective reliable early warning online monitoring system to prevent transformer failures. The Guard measures and records hydrogen, acetylene, carbon dioxide, and carbon monoxide plus moisture to provide an early warning diagnostic tool. Each gas indicates that a specific potential failure type could be pending, hydrogen indicates that a potential fault is pending, acetylene indicates that there has been arcing or sparking within the transformer, and a carbon dioxide/monoxide ratio is an indicator that there is a potential failure or fault associated with the insulation within the transformer. The SmartDGA Guide™ measures and reports nine (9) DGA gases plus moisture and vastly reduces total cost of ownership due to its differentiated design and installation scheme. The Guide provides comprehensive online DGA results that enable diagnostic techniques that are essential in protecting critical assets and helping to prevent unplanned outages. The DGA values and diagnostics are available via user friendly software that allows complete access to all measured and recorded values.
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TM
2.1.2 SmartDGA EZHub Unit Light Indicators
Light Indicators
Relay Connections
Relay Connections
LTC Power
RS485 LTC
USB
RS485 OUT Ethernet
RS485 Transformer
Transformer Power
Note: The EZHub pictured above is configured for both an LTC (Gauge) and Transformer (Guide/Guard). Your EZHub may only be configured with an LTC or a transformer side, depending on your setup. The SmartDGA EZHub unit is the central node for the SmartDGA system. A fully configured EZHub is capable of handling the power and communication needs of a pair of SmartDGA instruments, either one Guard or one Guide in combination with an individual LTC (Gauge) simultaneously. All interface functions and interconnects are provided in the EZHub unit as well as internal memory and four (4) relays and bright LED indicators for Caution, Warning, and Alarm conditions. The fourth relay is a system status relay to notify of a SmartDGA system failure or abnormality as measured by several components internal to the instrument and EZHub. The SmartDGA instrument collects DGA gas level data and stores it in the EZHub. The data can be transferred (via RS485 or Ethernet connections) from the EZHub and displayed on the DGA Viewer software running on a computer or on an i Core controller. In addition, each EZHub provides a USB interface for fast data downloading or firmware uploading.
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TM
2.1.3 LumaSMART i Core Controller (Optional) The LumaSMART i Core controller provides a local interactive touch screen display of DGA data collected from the SmartDGA system and EZHub using the SmartDGA Viewer software. This software allows you to set-up your system, create alarm conditions and notifications, and view data collected by the SmartDGA instrument(s). The controller has its own battery backed-up Real-TimeClock-Calendar. The i Core stores up to 40+ years of date and time stamped memory storage when connected to external power. Additionally, the i Core controller provides advanced communications to external systems using standard communications connections. Each i Core controller enables connectivity to multiple EZHub units (up to a maximum of 4). Front View
Bottom View
5.7-inch Interactive Touch Screen
Power Indicator
Unused Connection
USB
AC In Ethernet Unused Serial Connection RS 485
TM
Note: The LumaSMART i Core is not required to operate the SmartDGA system.
2.2
Theory of Operation
With traditional technologies, widespread condition monitoring of transformers has been unattainable, mostly due to high costs and excessive installation times. LumaSense is the industry leader in the use of Non-Dispersive Infrared (NDIR) technologies and has redefined the way gases are measured. The following sections provide a brief overview of the technology behind our products that makes widespread condition monitoring of transformers possible.
2.2.1 Non-Dispersive Infrared (NDIR) Theory The SmartDGA instrument utilizes Non-Dispersive ) . u Infrared (NDIR) absorption to measure the partial . CO2 a ( pressure of the gases: Acetylene (C 2H2), Ethylene (C 2H4), e c n a Methane (CH4), Ethane (C 2H6), Carbon Monoxide (CO) b r CO o s and Carbon Dioxide (CO 2). The NDIR measurement is b A based on Infrared (IR) Absorption. The light from a black body emitter is directed at a gas sample. The 4 4.2 4.4 4.6 4.8 5 Wavelength (mm) light that passes through the gas sample is then incident on a narrow band IR filter and detector. There is an IR filter/detector pair for each gas to be measured. The detectors in the SmartDGA instrument are thermopiles. The filters are each designed to be band pass filters with the band being at a
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wavelength the gas of interest absorbs. The amount of that wavelength absorbed is proportional to the concentration of the gas of interest. By quantifying the amount of light transmitted to the detectors with and without the gas of interest, the concentration of gas can be determined.
2.2.2 Other Gas Measurements The SmartDGA utilizes various independent sensors and calculations to measure Oxygen (O 2), Hydrogen (H2), Moisture, and Nitrogen (N 2). Hydrogen is measured using a metal oxide sensor, Oxygen is measured with a galvanic cell type sensor, and Moisture is measured in-oil using a thermoset polymer capacitive sensing element. All sensors are individually calibrated by LumaSense Technologies for optimal performance and accuracy. Nitrogen gas values are calculated as a residual based on temperatures, gas pressures, and other gas measurements
2.2.3 Sampling Sequence 1. All of the oil valves are defaulted to their normally closed state between measurement cycles. 2. A pressure equalization routine runs continuously between measurement cycles. If the pressure inside the instrument gets too far away from the oil tank pressure (due to temperature changes), the routine will open the oil valves and equalize the pressure. 3. When the Real-Time-Clock-Calendar of the EZHub unit reaches the time of the next measurement cycle, it sets the instrument’s state to �Go�. 4. As a safeguard against the transformer/LTC being degassed when a cycle starts, if the measured inlet oil pressure is not 0.1 psi above the measured ambient pressure, the cycle will abort. 5. The instrument flushes the oil within its oil loops with fresh oil from the transformer/LTC. This takes approximately 3 minutes. 6. At the end of the flush, the instrument will circulate the fresh oil sample through its inner oil loop. The oil loop contains approximately 35 mL of oil. 7. As the sample of oil circulates past the membrane gas separator, the gas migrates across the membrane to establish partial pressure equilibrium with the gas collection volume. 8. While the oil is circulating past the gas separator on the oil side, the gas collection volume is circulating past the gas separator on the gas side. 9. Gas is allowed to equilibrate for a predetermined period of time. SmartDGA® Manual
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10. Once the gas has equilibrated, its absorption levels are collected for about 10 minutes for data processing. 11. Ambient air is passed across the Hydrogen and Oxygen sensors, conditioning them for reading gas levels. 12. The Zero level for the Hydrogen and Oxygen is read for about 1 minute. 13. Ambient air is used to push the gas collection volume past the Hydrogen and Oxygen sensors. The sensors read their gases for 1 minute. 14. As ambient air continues to be pushed through the instrument, the NDIR absorption levels for ambient air is collected for about 10 minutes. 15. The data is processed. 16. The cycle is completed and the oil valves are closed. 17. The EZHub unit reads the results from the SmartDGA instrument. 18. The pressure equalization routine starts.
2.2.4 Oil-Gas Separating Membrane Gases dissolved in the Transformer/LTC insulating oil are sampled by the SmartDGA instrument via an amorphous polymer membrane. The non-porous membrane absorbs gases dissolved in the oil and transfers them to a closed gas sample space while preventing large oil molecules from passing. A porous metal frit support prevents distortion of the membrane into the gas sample space allowing it to withstand high oil pressures. To protect the membrane against the application of negative pressure, the oil pressure is continuously monitored and the oil valves can isolate the membrane from the oil tank. There is a metal plate with a grid of holes on the side of the membrane to add further support. At the beginning of each SmartDGA measurement cycle, a flow-controlled pump refreshes an internal reservoir with oil from the transformer/LTC system. During gas collection, the same pump is used to continuously replenish oil at the surface of the oil-gas separation membrane to expedite gas transfer. Measurements of gas in the sample space as well as oil temperatures and pressures are used to conduct the dissolved gas analysis of the oil.
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3 Pre-Installation Verification This chapter involves verifying that you have all system components, confirming the installation locations are ready, and verifying power supply and communications setup. Also, please ensure all valves are properly shut with limited to no oil leakage.
3.1
Unpacking and Verifying Contents
When unpacking and inspecting your system components: 1. Check all materials in the container against the enclosed packing list. 2. Carefully unpack and inspect all components for visible damage. 3. Save all packing materials, including the carrier’s identification codes, until you have inspected all components and find that there is no obvious or hidden damage. Note: LumaSense Technologies cannot be responsible for shortages against the packing list unless a claim is immediately filed with the carrier. If you note any damage or suspect damage, immediately contact the carrier and LumaSense Technologies, Inc. Final claim and negotiations with the carrier must be completed by the customer.
3.2
Confirming Installation Locations
Confirm that the mounting locations for the SmartDGA instrument and associated mounting requirements are complete and the site is ready for installation. Power supply should already be ready for connections and communication systems should be set up for installation.
3.2.1 Confirm Mounting for SmartDGA Instrument Confirm that the dimensions of the instrument work for the selected installation location and that the valve kit included is suitable for installation. Instrument Dimensions Verify that the installation location is suitable for the dimensions of the SmartDGA instrument: 10.765� 273.43 mm
12.152� 308.66 mm
20.918� 531.32 mm
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Note: The SmartDGA Instrument is designed for vertical installation. Horizontal installation is not recommended.
Caution: The SmartDGA Instrument must be installed in a location that is shaded throughout the day. Rapid sunlight induced heating will negatively affect SmartDGA measurements. See the LumaSense offered sun shade in Section 9.12 and contact us for more information.
Caution: The SmartDGA instrument is designed to withstand typical vibration levels found on transformers. Certain combinations of drain valve pipe diameter and length, combined with line frequency, may result in a mechanical harmonic which amplifies the inherent line frequency of the transformer. This can occur in the range of 180240 Hz. The SmartDGA instrument continues to function but it will experience increased noise and is subject to accelerated wear due to high �g’ forces. If this behavior is observed, the installation must be modified. Changes in the pipe extension length and/or diameter or additional mechanical support can be used to shift the harmonic frequency higher. Alternatively, the SmartDGA instrument can be mounted off transformer.
3.2.2 Confirm Valve Kit Review your site setup and the items you received from LumaSense alongside the charts below. You may need additional reducers to connect the equipment, so please review closely.
VA-1 (Single Valve) Description
Thread Type
Use this kit when separate points for oil sampling and return are not available on the transformer. This should only be used when VA-2 and VA-0 options are not available. This valve kit is compatible with ball, gate, and plug valves.
Confirm that the thread type for the valve is female 1� NPT. If it is not a 1� NPT thread type, you will need an NPT reducer. Verify that you have a reducer on hand.
Not compatible with Globe or Butterfly valves.
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Clearance (Distance) To Left of the Valve
> 18� (45.7 cm)
To Right of the Valve
> 18� (45.7 cm)
Bottom to Ground
> 12� (30 cm)
Top to Obstruction
> 17� (43.2 cm)
Clearance gives the installation team easier access to the valves for workmanship. If there is not enough free space and obstructions cannot be moved, a new location may need to be chosen.
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VA-2 (Dual Valve) Description Use this kit when there is a bottom drain valve and a return valve available on the transformer. This valve kit is compatible with ball, gate, plug, globe, and butterfly valves
Clearance (Distance)
Thread Type Mount (Bottom) Valve Confirm that the thread type for the valve is female 1� NPT. If it is not a 1� NPT thread type, you will need an NPT reducer. Verify that you have a reducer on hand. Return (Top) Valve Confirm that return valve accepts 3/8� tubing. If it is not, you may need an NPT reducer and adapter to decrease the present transformer return valve size to accept 3/8� tubing. You can also purchase a Swagelok adapter (PN SS-600-116) that will thread into the female 1� reducer and accept 3/8� tubing.
To Left of the Valve
> 18� (45.7 cm)
To Right of the Valve
> 18� (45.7 cm)
Bottom to Ground
> 12� (30 cm)
Top to Obstruction
> 17� (43.2 cm)
Vertical distance from the drain valve to the return valve
3’ to 20’ (0.91 m to 6.1 m)
Piping distance from the drain valve to the return valve
< 32.8’ (10.0 m)
Number of right angles to the return valve for piping
< 5 turns
VA-0 (Inline or Off-Transformer) Description Use this kit any time the SmartDGA instrument cannot be mounted directly on the transformer valve or when connecting the SmartDGA Gauge instrument to a LTC tank. Mounting Plate The support for the mounting plate must be capable of holding at least 50 pounds (22 kg) and mounted near the transformer or LTC filter. The typical support will either be the transformer wall or a Unistrut post supported by concrete. The location chosen must be appropriate for the support and allow for oil lines to and from the transformer or LTC filter. If installing in a cold climate where the oil will reach a temperature of -10 °C or less in the lines, the lines must be heated, otherwise the oil will be too viscous to be pumped by the SmartDGA instrument.
Clearance (Distance) Left of the mounting plate
> 18� (45.7 cm)
Right of the mounting plate
> 18� (45.7 cm)
Mounting plate to the ground Mounting plate to the top obstruction Vertical distance from the instrument to the oil ports Piping distance from the instrument to the outlet/return port Number of right angles to the outlet/return port for piping Piping distance from the instrument to the inlet/feed port Number of right angles to the inlet/feed port for piping
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> 12� (30 cm) > 17� (43.2 cm) 3’ to 20’ (0.91 m � 6.1 m) < 32.8’ (10.0 m) < 5 turns < 32.8’ (10.0 m) < 5 turns
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Warning: Do not cross the top of the tank when routing piping.
3.2.3 Confirm Mounting/Location for EZHub The EZHub unit provides power and communications for the SmartDGA system. The EZHub can be mounted in a substation control building, a transformer control cabinet, or a NEMA4X enclosure mounted on a wall or on a Unistrut stand. Note: If mounting in a NEMA4X enclosure, keep environmental conditions in mind. Direct sunlight can cause temperatures to reach above the maximum rated ambient temperature of 55 °C. Examples of EZHub mounting:
EZHub mounted in NEMA 4X enclosure on a wall
EZHub mounted in NEMA 4X enclosure on a Unistrut Stand
Confirm EZHub Type & Location 1. Confirm that the EZHub shipped for your system is correct by verifying that it has LTC, Transformer, or both sets of connections.
LTC
Transformer
LTC & Transformer
2. Confirm distance from the EZHub installation location to the SmartDGA instrument installation location is less than 30 m (98 ft). Note: A standard 10 m (32 ft) outdoor weather (-20 °C to 150 °C) cable is provided with the SmartDGA system. The EZHub may be located up to 30 m (98 ft) away from the SmartDGA instrument. Additional lengths (20 m and 30 m) as well as cold weather (rated -50 °C to 125 °C) cables of 10 m, 20 m, and 30 m are available to order from LumaSense. 3. Ensure the conduit for the connection cable between the EZHub and SmartDGA instrument is present.
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3.2.4 Confirm EZHub Mounting 1. Verify that the enclosure is rated IP55 and provides enough space for the EZHub (per dimensions shown in section 9.8 or 9.9, depending on mounting style). Check for USB stick clearance where the EZHub will be installed. 2. Locate the mounting brackets match the type of mounting (panel or wall) planned. EZHub Location
EZHub Mounting Type
Transformer Control Cabinet
Wall or Panel
Substation Control Building
Panel
NEMA 4X Enclosure
Wall
Notes
Ensure the enclosure is properly mounted to wall or Unistrut stand.
Caution: Direct sunlight will cause heating of the enclosure and may cause overheating beyond the temperature rating of the EZHub.
3.2.5 Confirm Mounting Location/Type for External Computer or LumaSMART i Core (Optional) In order to configure and operate your SmartDGA system with the software, you will need an external computer or an i Core. Confirm Mounting Location 1. Confirm distance from the external computer or i Core installation location to the EZHub location to ensure the cable (Ethernet or RS485) is long enough. Note: If using Ethernet with copper wire, this distance should be less than 100 m (328 ft). If longer distances are required, a fiber optic connection should be used. Note: If using the included RS485 to USB converter, the distance between the EZHub and the external computer cannot be longer than 50 m (164 ft). Use a shielded 18 AWG cable. 2. Ensure the conduit for the connection cable between the EZHub and SmartDGA instrument is present. Confirm Mounting Type External Computer: If using an external computer, verify that it uses a supported Windows operating system. Mounting is configuration dependent. LumaSMART i Core: 1. Verify that the enclosure is rated IP55 and provides enough space for the i Core (per dimensions shown in section 9.10 or 9.11, depending on mounting style.) Check for USB stick clearance where the i Core will be installed. Caution: The mounting position and location chosen for the i Core should ensure that the vents on the top of the i Core box will not be blocked during normal operation. Blocked vents could cause the i Core to overheat.
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Note: If mounting in a NEMA4X enclosure, keep environmental conditions in mind. Direct sunlight can cause temperatures to reach above the maximum rated ambient temperature of 70 °C. Direct sunlight will greatly reduce the apparent contrast of the i Core LCD display and make it difficult to operate. A shaded installation location is recommended. 2. Locate the mounting brackets for the type of mounting (panel or wall) planned (both are included with your shipment). i Core Location
i Core Mounting Type
Transformer Control Cabinet
Wall or Panel
Substation Control Building
Panel
NEMA 4X Enclosure
Wall
Notes
Ensure the enclosure is properly mounted to wall or Unistrut stand.
Caution: Direct sunlight will cause heating of the enclosure and may cause overheating beyond the temperature rating of the i Core. Examples of LumaSMART iCore mounting:
Wall or Panel Mount
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NEMA 4X Enclosure
Substation Panel
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3.3 3.3
Veri Verify fy Pow Power er and and Com Commu muni nica cati tion ons s
3.3.1 3.3.1 Verify Verify Power Power Supp Supply ly Note: LumaSense supplies the connector but does not supply a power cable for the EZHub or i Core. Core. Ensure the cables you are using are the right length for the planned installation locations. Ensure input power is available for the EZHub by identifying a VAC/VDC source and installing any necessary power cables using an appropriate conduit. The EZHub requires 90 to 264 Volts AC, 127 VDC to 370 VDC, 47-63 Hz, 2.5 A max. Use size 14 AWG wire for the included crimps and connectors to bring power to the EZHub. Each EZHub must have a 10 A circuit breaker for system isolation and protection (customer-provided).
EZHub
In addition, both the EZHub and SmartDGA Instrument must have a lowimpedance path to a trusted grounding source. Ensure a grounding source is available for the EZHub at the mounting location. External Computer
LumaSMART i Core Core Controller
Verify computer has power supply (battery or otherwise). Ensure input power is available for the i Core Core by identifying a VAC/VDC source and installing any necessary power cables using an appropriate conduit. The i Core Core requires 90 to 264 Volts AC, 127 VDC to 370 VDC, 4763 Hz, 2.5 A max. Use size 18 AWG wire for the included crimps and connectors to bring power to the i Core. Core. Each i Core Core must have a 10 A circuit breaker for system isolation and protection (separate from any other i Core Core or EZHub units).
3.3.2 Verify Verify Commun Communicati ications ons Verify Ethernet or RS485 equipment available: o
o
If Ethernet, verify that a switch is available if installed on a corporate network or that a hub is available if installed on a standalone network. If RS485 to USB, locate included converter.
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4 Valv Valve e Inst Instal alla lati tio on Once complete with Pre-Installation Verification, proceed with installation of the SmartDGA ® system. Recommended installation order is installing the valve kits, then the instruments, followed by the EZHub and computer/ i Core. Core. There are three types of valve installations. Follow instruction for the valve kit and configuration you are using: · · ·
For Single Valve (VA-1) installation instructions, see section 4.1. For Dual Valve (VA-2) installation instructions, see section 4.2. For Off-Transformer/Inline (VA-0) installation instructions, see section 4.3. Note: To avoid leaks, tape, grease, and tighten. Use tape and grease on all NPT threads throughout the installation process. Starting from the bottom, wrap the tape in the opposite direction as the threads so that when connecting, the tape is not torn off. Once taped, apply enough grease to cover the threads. Then connect and tighten. Tightening Swagelok Fittings ® Many of the provided connectors are Swagelok fittings. Follow these steps to ensure a proper fit: 1. Insert the tube tube into the the fitting fitting as far as as it will go and rotate the nut until until it is hand tight. 2. Mark the nut at the 6 o’clock position. position. Hold the fitting fitting body body steady steady with a second wrench and tighten the marked nut 1.25 turns to the 9 o’clock position. As you assemble and attach the valve kits, tighten as you go, but be careful not to overtighten. Overtightening can cause the part to distort and not properly seal when retightened. Visit Swagelok’s website for more information on tightening fittings (page 62): http://www.swagelok.com/downloads/WebCatalogs/en/MS-01-140.PDF
Warning: All oil wetted metal components of the SmartDGA system are made of 316 stainless steel to avoid corrosion and interaction with dissolved gases. SmartDGA performance and reliability are only guaranteed when all oil wetted connections use 316 stainless steel, including any customer supplied tubing or adapter components for the following reasons: ·
·
Components other than stainless steel will likely experience accelerated corrosion. Different metals in direct contact with each other will undergo galvanic corrosion even under mild ambient conditions. Copper and copper containing alloys react with dissolved gases such as acetylene to form unstable potentially explosive compounds and reduce the apparent concentration of analyte gases.
·
Galvanized components can release hydrogen and cause false readings.
·
Copper tubing is soft and does not form a reliable long term seal.
·
Polymer based flexible hoses are gas permeable and allow ambient oxygen into the oil and dissolved gases to escape. Use stainless steel lined flexible hoses such as Swagelok FL hoses. Tubing should have an appropriate inner diameter for flow while maintain enough wall thickness for strength for 1/4" OD tubing the wall thickness should be 0.035�.
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Note: Before beginning the installation process, ensure that there are no leaks and that all the valves are turned off on the transformer and/or LTC. Note: Examples and pictures in this manual use a test set-up to display configurations and installation. Actual installation will vary on location and setup of valves.
4.1
Single Valve (VA-1)
The single valve (part number VA-1) is intended for installation on the bottom/drain of the transformer. Oil is drawn out of the bottom drain valve and returned to the same region. This option is intended for use in situations where separate points for oil sampling and return are not available. Note: This mounting approach has inherent limitations and risks and should only be used when the VA-0 and VA-2 options are not viable.
4.1.1 VA-1 Parts and Tools Ensure you have the following parts and tools on hand prior to starting installation: PROVIDED BY LUMASENSE Qty Description 1 Mounting Ring (included as part of SmartDGA instrument) 1 Single Valve (VA-1) Kit 1 Adapter, 1� Valve-Tube, DGA (Drain Valve Side Adapter) 1 Assy, Adapter, Tube, Single Valve, DGA (Instrument Side Adapter) ® 1 O-ring, Viton , 3 1/8� ID (Large O-ring) ® 1 O-ring, Viton , 1 3/16� ID (Medium O-ring) ® 1 O-ring, Viton , 5/16� ID (Small O-ring) 1 Valve, Bleed, 1/8� MNPT (1/8� Bleed Valve) PROVIDED BY CUSTOMER (or ordered separately) QTY Description 1 NPT Reducer to 1� ID (optional, from LumaSense): 1 1 1 1 1 1 1 1 1 1
Part # 115-0044-01 815-0029-02 115-0120-02 915-0027-03 99-10559 90-2378 99-10558 90-2395 Part #
2� to 1� NPT Reducer 1.5� to 1� NPT Reducer Soft polymer tubing for bleed valve (3/16� ID, 10 cm L, clear) Tee (stainless steel) and an extra valve (optional, for drain valve) Pipe cutter 1/4’’ to 1/2’’ Hacksaw (optional alternative if no pipe cutter is available) Pipe bender 1/4’’ to 1/2’’ Set of Allen (hex) keys (9/64� & 3/16�) (ball end or stubby recommended) Wrench, pipe (adjustable 1� to 3�) 2-4’’ Channel lock pliers (optional alternative if no pipe wrench is available) Teflon (PTFE) pipe thread sealant tape, 0.0032 inch or greater thickness, density 1.2 g/cc PTFE containing pipe thread sealant such as:
90-2382 90-2381
Leak Lock, Part #HS10001 by Highside Chemicals or Harvey’s, TFE paste, Part # 023015 or TM Rectorseal, Tru-Blu Vibration resistant or similar
1 1 1 1
Screw driver, Phillips (#3, 3/16�) Deburring tool Oil cleaner and wiping rag (to clean any potential spills) Compressed air
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PROVIDED BY CUSTOMER (or ordered separately) 3-4 Cotton swabs (to clean grooves for O-rings) 1 Container (at least 3 Liters for waste oil)
Bottom/Drain Valve
Part #
Adapter (Instrument Side) 915-0027-03 Small Bleed Valve 90-2395
3/8� Stainless Steel Pipe (SSP)
NPT Reducer
Adapter (Drain Valve Side) 115-0120-02
Mounting Ring 115-0044-01 (O-rings are part of VA-1 kit)
Machine Screws (QTY = 6) 99-10064
4.1.2 VA-1 Installation 1. Ensure that the drain valve is completely shut and that there is no oil leakage. 2. If you need to preserve the ability to use this drain valve to sample oil directly from the transformer, install a stainless steel tee and another valve with plug onto the drain valve. Extra valve
Tee
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Plug
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27
3. If necessary, attach an appropriate NPT reducer to the drain valve or tee. Be sure to tape, grease, and tighten.
NPT Reducer 2� to 1�
4. Remove the 3 protective caps from the single valve adapter. Save them for future use. Remove protective caps
5. Remove the 6 machine screws from the Drain Valve Side Adapter (PN 115-0120-02) with an Allen wrench. Save them (you will need them in a later step).
Remove machine screws
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6. Slide the Drain Valve Side Adapter off of the stainless steel pipe (SSP). Drain Valve Side Adapter PN 115-0120-02
Note: This may take some effort due to the friction from the already installed O-rings on the Drain Valve Side Adapter. 7. Remove one Plate Cover screw over the OUT port on the Drain Valve Side Adapter using the Phillips screwdriver. Save the screw; you will reattach it during the commissioning process.
Note: Instead of removing both screws, you may instead remove one screw and leave the plate cover hanging by the other screw to reduce the likelihood of lost hardware. 8. Check to ensure that the plug is closed. If not, tighten the isolation plug on the Drain Valve Side Adapter with an Allen wrench until it is fully closed.
Closed Plug
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9. Tape and grease the threads on the Drain Valve Side Adapter. Thread and secure it into the drain valve or previously installed NPT reducer. Tighten with the wrench. Note: To prevent leaks, use tape and grease on all NPT threads. Starting from the bottom, wrap the tape in the opposite direction as the threads so that when attaching, the tape is not torn off. Once taped, apply enough grease to cover the threads.
Drain Valve Side Adapter 115-0120-02
Drain Valve
NPT Reducer
10. Place absorbent towels under or around the drain valve assembly as there may be a minor amount of leakage from the drain valve in later steps. 11. Determine the proper length of the stainless steel pipe (SSP) needed using a measuring tape. The SSP has to reach from the inside wall of the transformer tank to the outside of the Drain Valve Side Adapter to make sure that the SmartDGA instrument gets fresh oil at all times. Total required length is the transformer wall thickness + X as marked below.
Drain Valve Side Adapter
l l a W r e m r o f s n a r T
�X� Distance
Transformer Wall Thickness
Warning: DO NOT extend the SSP beyond the transformer wall. If the SSP extends too far into the transformer it may come into contact with internal electrical components and short the internal components to the transformer housing causing severe damage to the transformer and endangering any personnel working in the area. Always consult "as built" transformer drawings and verify dimensions whenever possible.
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12. Cut the SSP to the length (�X� + transformer wall thickness) as determined in the previous step.
�X� + transformer wall thickness
13. Completely deburr and smooth the cut end of the SSP. Use compressed air to remove any shavings that may have fallen into the adapter. Caution: Any sharp edges or shavings left on the SSP will damage sealing O-rings when the SSP is used in later steps. This will cause oil to leak from the transformer! 14. Clean the grooves for the three O-rings using cotton swabs.
15. Install the three O-rings to the Instrument Side Adapter (PN 915-0027-03). Large O-Ring PN 99-10559
Medium O-Ring PN 90-2378 Small O-Ring PN 99-10558
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16. Place the mounting ring (PN 115-0044-01) over the stainless steel pipe and the Instrument Side Adapter as shown below. Note: The mounting ring is shipped with the SmartDGA instrument packaging.
17. Remove the plate cover over the IN port on the instrument side adapter by removing the two screws with a Phillips screwdriver. Save the plate cover and the two screws for use during the commissioning process.
Note: Instead of removing both screws, you may instead remove one screw and leave the plate cover hanging by the other screw to reduce the likelihood of lost hardware. 18. Check to ensure that the plug is closed. If not, tighten the isolation plug on the Instrument Side Adapter with an Allen wrench until it is fully closed. Closed Plug
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19. Locate the 1/8� Bleed Valve (PN 90-2395) and remove the protective cap and save it for future use. Tape, grease, and tighten.
Remove protective cap
20. Attach the 1/8� Bleed Valve to the port on the Instrument Side Adapter. Use an adjustable wrench to fully tighten. Verify that the Bleed Valve is closed and pointing away from the mounting ring.
21. Carefully insert the SSP pipe with attached Instrument Side Adapter into the open port on the Drain Valve Side Adapter and gently slide it through until the SSP reaches the gate.
22. Fully open the drain valve.
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23. With the drain valve fully open, carefully slide the SSP extension tube further into the drain valve until the Instrument Side Adapter meets the Drain Valve Side Adapter. Ensure that all the holes correctly line up and that the Bleed Valve is pointing down.
24. Reattach 2 machine screws diagonally from one another first. Use an Allen wrench to tighten and ensure a flat surface/tight fit of the adapters. Install the remaining 4 screws.
Secure with 2 diagonal screws first. Then tighten remaining 4 screws
Note: Due to the tight space, a Ball End Allen Wrench or Stubby Allen Wrench is recommended, but a standard Allen Wrench will also work. 25. Check for leaks. If you encounter leaks, remove the 6 machine screws from the previous step to pull out the SSP just past the gate and close the valve. Fix any leaks and reinstall. 26. Chain and lock the drain valve open. Install a tag on the drain valve warning individuals that there is an extension going through the valve and to not close the valve without removing the extension. Caution: Failure to remove the extension before closing the valve could potentially damage the valve. 27. Install a tag on the bleed valve warning individuals to keep the bleed valve fully closed unless sampling oil. 28. Proceed to Chapter 5 to install the SmartDGA instrument.
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4.2
Dual Valve (VA-2)
In this installation, the adapter and SmartDGA instrument are mounted on the bottom drain valve of the transformer. Oil is drawn out of the bottom drain valve and returned to the top/fill valve using 3/8� stainless steel tubing.
4.2.1 VA-2 Parts and Tools Ensure you have the following parts and tools on hand prior to starting installation: PROVIDED BY LUMASENSE Qty Description 1 Mounting Ring (included as part of SmartDGA instrument) 1 Dual Valve (VA-2) Kit 1 Adapter, Two-valve, DGA (Dual Valve Adapter) 1 O-ring, Viton®, 3 1/8� ID (Large O-ring) ® 1 O-ring, Viton , 1 3/16� ID (Medium O-ring) ® 1 O-ring, Viton , 5/16� ID (Small O-ring) 1 Valve, Bleed, SS 1/8� MNPT (1/8� Bleed Valve) 1 Valve, Bleed, SS 1/4� MNPT (1/4� Bleed Valve) 1 Female branch tee, 3/8� TUBE OD X 3/8� TUBE OD X ¼� FEMALE NPT (3/8� Female Branch Tee) 1 Conn, Male 3/8� Tube 1/8� Male NPT (3/8� Male Connector) PROVIDED BY CUSTOMER (or ordered separately) QTY Description 1 NPT Reducer to 1� ID (optional, from LumaSense): 2� to 1� NPT Reducer 1.5� to 1� NPT Reducer 1 NPT Reducer to female 3/8� ID (if needed) Available from Swagelok Tubing, SS, 3/8� ID (length will vary) 2 Soft polymer tubing for bleed valves (3/16� ID, 10 cm L, clear) 1 Tee (stainless steel) and an extra valve (optional, for drain valve) 1 Pipe cutter 1/4’’ to 1/2’’ 1 Hacksaw (optional alternative if no pipe cutter is available) 1 Pipe bender 1/4’’ to 1/2’’ 1 Wrench, pipe (adjustable 1� to 3�) 1 2-4’’ Channel lock pliers (optional alternative if no pipe wrench is available) 1 Teflon (PTFE) pipe thread sealant tape, 0.0032 inch or greater thickness, density 1.2 g/cc 1 PTFE containing pipe thread sealant such as:
Part # 115-0044-01 815-0027-01 115-0043-03 99-10559 90-2378 99-10558 90-2395 99-10160 99-10158 99-10159 Part #
90-2382 90-2381 SS-600-1-16
Leak Lock, Part #HS10001 by Highside Chemicals or Harvey’s, TFE paste, Part # 023015 or TM Rectorseal, Tru-Blu Vibration resistant or similar
1 1 3-4 1
Screw driver, Phillips (#3, 3/16�) Oil cleaner and wiping rag (to clean any potential spills) Cotton swabs (to clean grooves for O-rings) Container (at least 3 Liters for waste oil)
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Top/ Fill Valve
3/8� Male Connector 3/8� Stainless Steel Tubing Adapter for 3/8� tubing 3/8� Female Branch Tee PN 99-10158
1/4� Bleed Valve PN 99-10160
Bottom/Drain Valve
3/8� Connector PN 99-10159
Mounting Ring PN 115-0044-01 NPT Reducer 2� to 1� Valve Dual Valve Adapter 1/8� PN 115-0043-03 Bleed Valve PN 90-2395
4.2.2 VA-2 Installation Note: To prevent leaks, use tape and grease on all NPT threads. Starting from the bottom, wrap the tape in the opposite direction as the threads so that when attaching, the tape is not torn off. Once taped, apply enough grease to cover the threads. 1. Ensure that the drain valve and top/fill valve are properly shut and that there is not excessive oil leakage or obstructions to prevent installation. 2. If you need to preserve the ability to use this drain valve to sample oil directly from the transformer, install a stainless steel tee and another valve with plug onto the drain valve. Extra valve
Tee
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Plug
Valve Installation
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3. If necessary, attach an appropriate NPT reducer to the drain valve or tee. Be sure to tape, grease, and tighten.
NPT Reducer 2� to 1�
4. Remove the 2 protective caps from the dual valve adapter. Save them for future use.
Remove protective caps
5. Clean the grooves for the three O-rings using cotton swabs.
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6. Install the three O-rings onto the Dual Valve Adapter (PN 115-0043-03).
Large O-Ring PN 99-10559
Medium O-Ring PN 90-2378 Small O-Ring PN 99-10558
7. Place the mounting ring (PN 115-0044-01) over the Dual Valve Adapter as shown below. Note: The mounting ring is shipped with the SmartDGA instrument packaging.
8. Install a 3/8� Male Connector (PN 99-10159) to outlet port. Be sure to tape, grease, and tighten.
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9. Remove the protective cap from the 1/8� Bleed Valve (PN 90-2395) and save for future use. Attach the bleed valve to the open BLEED port on the adapter. Be sure to tape, grease, and tighten.
10. Thread and secure the completed dual valve assembly into the drain valve or previously installed NPT reducer. Be sure to tape, grease, and tighten with wrench.
11. 12. 13. 14.
If needed, attach a SS tee to the top/fill valve. If needed, attach 3/8� reducer to the top/fill valve. Install a 3/8� Connector to the top/fill valve or reducer. Attach 3/8� stainless steel tubing from the end of the outlet port to up near the top/fill valve. Attach the 3/8� Female Branch Tee to the stainless steel tubing. Caution: When the oil level is above the top/fill valve, install the 3/8� Female Branch Tee and 1/4"Bleed Valve as close as possible to the top/fill valve where the oil is returned to. Whenever the oil level is above this return valve point it is possible for air to enter the transformer which creates the risk of transformer damage. Placing the bleed valve as close as possible to the return point and purging the line before opening the top/fill valve will minimize the potential amount of air. Observe safety procedures when accessing valves within proximity of live electrical lines.
15. Remove the protective cap from the 1/4" bleed valve (PN 99-10160) and save for future use. Be sure to tape and grease. Attach the bleed valve to the tee. Remove protective cap
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16. Attach the rest of the tubing from the 3/8� connector on the top/fill valve to the top of the tee to complete the connection. Tighten with wrench. 17. Install a tag on the bleed valves warning individuals to keep the bleed valve fully closed unless sampling oil. 18. Proceed to Chapter 5 to install the SmartDGA instrument.
4.3
Inline (Off-Transformer) Mounting (VA-0)
In this installation, the adapter and SmartDGA instrument are connected to a plate adapter and mounted on a wall, Unistrut, or other appropriate flat surface. Oil is brought from the transformer or LTC to the SmartDGA unit and then returned back using 3/8� stainless steel tubing. Caution: The installation of the SmartDGA Gauge instrument for Load Tap Changers (LTCs) requires the use of an oil filtration system before oil enters the instrument. If no filter is used, metal particulates which are generated during normal LTC operation will enter the instrument and cause component failure. Use of the unit with unfiltered LTC oil will void the warranty of the SmartDGA instrument. Connection to LTC Filter Systems The interface between the SmartDGA and LTC filter system is based on sampling a separate side stream of the filtered oil. While this approach is used with all LTC filter systems, the details of the oil lines and connections vary by manufacturer and model. LumaSense can provide further technical details and provide the most relevant examples of interfaces with specific models of the Filmax and Velcon filtration systems upon request with relevant technical information. Please contact your local LumaSense representative for further details. Note: The LTC filter system must be running at the time the SmartDGA is extracting an oil sample. LumaSense recommends leaving the filtration system on at all times. Alternatively, the time when the filtration system is on must be synchronized with the SmartDGA sampling time (a 20 minute window every 3 hours with starting time as defined by user/installer in DGA Viewer/Commissioning Tool software). The clock between the filtration system timer and i Core or EZHub must be synchronized occasionally to prevent drift of respective starting times. The SmartDGA pump is not capable of generating enough suction to pull oil through the filtration system on its own. If drawing oil through a large pressure drop filter/closed valve or pushing oil against a closed valve, the internal safeguards on the SmartDGA will automatically stop the measurement cycle.
Warning: LTC filters have significantly higher flow rates than the SmartDGA instrument allows. The filter oil sent to the instrument should be sampled using a side stream off of the main line. Contact your local LumaSense representative for information on installation.
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4.3.1 VA-0 Parts and Tools Ensure you have the following parts and tools on hand prior to starting installation. Qty 1 1
Description Mounting Ring (included as part of SmartDGA instrument) Inline (VA-0) Kit 1 Adapter, Inline DGA (Inline Adapter) 1 Plate LTC Adapter (Mounting Plate) 6 Nut, with Spring (for Mounting Plate) 6 Screw, 1/4-20 x 1.25� (for Mounting Plate) 6 Washer (for Mounting Plate) 1 Tubing 0.25 OD 90 D Elbow (1/4� Elbow Tubing Connector) 2 Tubing 0.25 OD 1.30�L,Straight (1/4� Straight Tubing Connector) (Typically only one required) ® 1 O-ring, Viton , 3 1/8� ID (Large O-ring) ® 1 O-ring, Viton , 1 3/16� ID (Medium O-ring) ® 1 O-ring, Viton , 5/16� ID (Small O-ring) 2 Valve, Bleed, SS 1/8� MNPT (1/8� Bleed Valve) 1 Female branch tee 1/4� tube (1/4� Female Branch Tee) 2 Conn, Male, 1/4"Tube 1/8 M (1/4� Male Connector) 2 Tube Fitting Plug Valve 1/4 (1/4� Shut-Off Plug Valve) 2 Tube Fitting Reducer 3/8 x 1/4 (3/8� Tube Reducer)
PROVIDED BY CUSTOMER (or ordered separately) QTY Description 1 NPT Reducer to 1� ID (optional, from LumaSense): 2� to 1� NPT Reducer 1.5� to 1� NPT Reducer 4 Reducers/adapters as required to convert to 3/8� tubing Tubing, SS, 3/8� ID (length will vary) 1 NEMA Unistrut Stand (optional, to secure the mounting plate) 2 Soft polymer tubing for bleed valves (3/16� ID, 10 cm L, clear) 1 Tee (stainless steel) and an extra valve (optional, for drain valve) 1 Pipe cutter 1/4’’ to 1/2’’ 1 Hacksaw (optional alternative if no pipe cutter is available) 1 Pipe bender 1/4’’ to 1/2’’ 1 Wrench, pipe (adjustable 1� to 3�) 1 Wrench, hex 3/16� 1 2-4’’ Channel lock pliers (optional alternative if no pipe wrench is available) 1 Teflon (PTFE) pipe thread sealant tape, 0.0032 inch or greater thickness, density 1.2 g/cc 1 PTFE containing pipe thread sealant such as:
Part # 115-0044-01 815-0028-01 115-0146-03 115-0047-01 99-10341 99-10342 99-10343 115-0191-01 115-0192-01 99-10559 90-2378 99-10558 90-2395 99-10086 99-10088 99-10219 99-10220
90-2382 90-2381
Leak Lock, Part #HS10001 by Highside Chemicals or Harvey’s, TFE paste, Part # 023015 or TM Rectorseal, Tru-Blu Vibration resistant or similar
1 1 3-4 1
Screw driver, Phillips (#3, 3/16�) Oil cleaner and wiping rag (to clean any potential spills) Cotton swabs (to clean grooves for O-rings) Container (at least 3 Liters for waste oil)
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Oil Return Port 1/4� Female Branch Tee PN 99-10086
3/8� Connectors 1/8� Bleed Valve PN 90-2395
Inline Valve Adapter PN 115-0146-03
3/8� Connector 3/8� Stainless Steel Tubing
Mounting Plate PN 115-0047-01
Mounting Ring PN 115-0044-01
1/8� Bleed Valve PN 90-2395
Oil Inlet Port
4.3.2 VA-0 Installation The VA-0 Adapter is designed with 1� male NPT thread to mount to the provided mounting plate. The Inline Adapter provides three ports (one OUT port and two IN/BLEED ports). Plugs are used to control flow through these ports. Note: The support for the mounting plate must be capable of holding at least 50 pounds (22 kg) and mounted near the transformer or LTC filter. The typical support will either be the transformer wall or a Unistrut post supported by concrete. The location chosen must be appropriate for the support and allow for oil lines to and from the transformer or LTC filter. If installing in a cold climate where the oil will reach a temperature of -10 °C or less in the lines, the lines must be heated, otherwise the oil will be too viscous to be pumped by the SmartDGA instrument. 1. If needed, mark drilling holes for mounting plate. 2.50�
2.50�
(63.50 mm)
(63.50 mm)
8x Ø 0.281±0.002 THRU ALL
2.50� (63.50 mm)
2.50� (63.50 mm)
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2. Drill holes in chosen vertical structure/surface for mounting plate and secure the plate using the included screws and the 3/16� hex wrench.
Note: The mounting plate has 8 holes for installation flexibility. Use at least 4 of the screws for installation. 3. Remove the two protective caps and save for future use. Remove
4. Clean the grooves for the three O-rings using cotton swabs.
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5. Attach the three O-rings to the Inline Valve Adapter.
Large O-Ring PN 99-10559
Medium O-Ring PN 90-2378 Small O-Ring PN 99-10558
6. Place the mounting ring (PN 115-0044-01) over the Inline Valve Adapter as shown below. Note: The mounting ring is shipped with the SmartDGA instrument packaging.
7. Install the inlet port using the following steps: Caution: Do not overtighten Swaglok 3/8� connectors as this can cause part distortion.
Note: To prevent leaks, use tape and grease on all NPT threads. Starting from the bottom, wrap the tape in the opposite direction as the threads so that when attaching, the tape is not torn off. Once taped, apply enough grease to cover the threads. a. Install a 1/4" Male Connector (PN 99-10088) into the IN/BLEED port (tape, grease, and tighten). Note: When selecting an IN/BLEED port, choose a position that allows for a �clean� final installation alignment. We recommend the IN port at 12 o’clock, OUT at 3 o’clock, and SAMPLE at 6 o’clock.
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b. Slide one 1/4" Straight Tubing Connector (PN 99-1092-01) to the other end of the 1/4"Male Connector. Tighten with wrench.
c.
Attach 1/4" Shut-Off Plug Valve (PN 99-10219) to the 1/4� Straight Tubing Connector. Tighten with wrench.
Note: Make sure this is attached facing the correct direction. The arrow should be pointing in toward the adapter and in the same direction as the oil flow.
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d. Attach the 3/8� Tube Reducer (PN 99-10220) to the other end of the 1/4� Shut-Off Plug Valve. Tighten with wrench.
8. Install outlet port using the following steps. a. Install a 1/4"Male Connector (PN 99-10088) into the OUT port (tape, grease, and tighten).
b. Slide 1/4"Elbow Tubing Connector (PN 115-0191-01) into the other end of the 1/4" Male Connector. Tighten with wrench.
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c.
Attach 1/4" Shut-Off Plug Valve (PN 99-10219) to the 1/4" Straight Tubing Connector. Tighten with wrench.
Note: Make sure Shut-Off Plug Valve is facing the correct direction. The arrow should be pointing away from the adapter and in the direction of the oil flow. d. Slide the 3/8� Tube Reducer (PN 99-10220) into the open end of the Shut-Off Plug Valve. Tighten with wrench.
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9. Install the 1/8� Bleed Valve (PN 90-2395) into the other IN/BLEED port on the adapter. This valve will serve as the sample valve.
Sample Valve
Oil Inlet
Oil Outlet
10. Attach the completed assembly, with all fittings, to the installed mounting plate. 11. If needed, attach a 3/8� reducer to the feed port on the transformer or side stream of LTC. 12. Attach 3/8� stainless steel tubing from the inlet port on the adapter to the feed port or reducer on the transformer or stream side of the LTC. 13. If needed, attach a 3/8� reducer to return port on the transformer or side stream of LTC. 14. Remove the protective cap and attach a 1/8� Bleed Valve (PN 90-2395) to the middle section of the 1/4"Female Branch Tee (tape, grease, and tighten). 15. Install customer-provided 3/8� to 1/4"reducer/connectors to the open ends of the tee. 16. Attach stainless steel tubing from the oil return port on the transformer or side stream of the LTC to the female tee. Tighten with wrench. Caution: When the oil level is above the return point, install the 1/4� Female Branch Tee and 1/8"Bleed Valve as close as possible to the where the oil is returned to. Whenever the oil level is above this return valve point it is possible for air to enter the transformer which creates the risk of transformer damage. Placing the bleed valve as close as possible to the return point and purging the line before opening the top/fill valve will minimize the potential amount of air. Observe safety procedures when accessing valves within proximity of live electrical lines
Note: If safety regulations prohibit installing the air bleed valve at the oil return point, please contact LumaSense for installation alternatives. 17. To complete the connection, attach 3/8� stainless steel tubing from the tee to the oil outlet on the adapter. Tighten with wrench. 18. Install tags on the bleed valves warning individuals to keep the sample valve fully closed unless sampling oil. 19. Proceed to Chapter 5 to install the SmartDGA instrument.
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5 SmartDGA System Installation 5.1
SmartDGA Instrument
5.1.1 Parts and Tools for the SmartDGA Instrument Ensure you have the following items on hand prior to starting installation. PROVIDED BY LUMASENSE Qty Description 1 SmartDGA Instrument (Guard) or SmartDGA Instrument (Guide) or SmartDGA Instrument (Gauge) 1 DGA Custom Flash Drive with S/W and Manuals 1 Ring, Mounting, Adapter (Mounting Ring)
Part # 015-0004-04 015-0003-04 015-0005-04 815-0191-01 115-0044-01
PROVIDED BY CUSTOMER (or ordered separately) Qty Description 1 3 3/4" face spanner wrench (Available from LumaSense)
Part # SPN-01
5.1.2 Mounting the SmartDGA Instrument Now that the valve installation is complete, you are ready to install the SmartDGA instrument. 1. Remove the protective cap and two plugs (do not remove serial tag). Save for future use.
Remove Plugs
2. Position the SmartDGA instrument vertically so that the mounting ring can align and fasten onto the SmartDGA instrument. Note: Although not required, an additional person is helpful for this step. One person can hold the SmartDGA instrument into position while the other fastens the mounting ring onto the SmartDGA instrument. 3. Fasten the mounting ring onto the SmartDGA instrument until hand-tight.
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4. After hand-tightening, use a 3-3/4� face spanner wrench to tighten the mounting ring until it cannot move any further. Use these holes for the spanner wrench
5. Proceed to installing additional SmartDGA instruments or the EZHub (section 5.2).
5.2
EZHub
5.2.1 Parts and Tools for the EZHub Ensure you have the following items on hand prior to starting installation. PROVIDED BY LUMASENSE � Single Instrument Qty Description 1 EZHub, LTC (EZ0003) or EZHub, XFMR (EZ0004) 1 Kit, EZHub, LTC or XFMR 1 Power and Communications Cable DGA-EZHub, STD, 10m 1 Kit, Conn, 1 Relay, Facility, EZHub 4 Connector, Relay MC 15/3 1 Connector, System RS485 Out 1 Connector, Unit RS485 1 Connector, Unit Power 1 Connector, EZHub Power 1 Adapter-Male Micro B to Female A 1 Lug Ring, Blue (for power to the EZHub) 1 Lug Ring, Red (shield ground for cable to instrument) 28 Ferrule (Small Crimp Pins) (You will have extra) 3 Ferrule (Large Crimp Pins for EZHub Power Connector) 1 Kit, EZHub Mounting Hardware 8 Screw, Pan Head 6-32X.50 (4 for wall mount or 8 for panel mount) 8 Washer, #6, Flat (4 for wall mount or 8 for panel mount) 8 Washer, #6, Split (4 for wall mount or 8 for panel mount) 1 Kit, Bracket, Wall Mount, EZHub 2 Bracket, Wall Mount 1 Kit, Bracket, Panel Mount, EZHub 1 Bracket, EZHub Panel Mount L-Side 1 Bracket, EZHub Panel Mount R-Side 1 Kit, Fuse, EZHub (this is a spare) 1 Kit, USB-ISO-485 / Cable Assembly (RS485 to USB Converter) (used for connection with a PC)
SmartDGA® Manual
Part # 015-0009-01 015-0007-01 915-0030-01 815-0236-01 815-0042-01 47-1407 47-1408 47-1409 47-1410 47-1411 57-0045 95-1970 90-2249 99-10043 99-10352 815-0044-01 02615-08SS1 99-10000 99-39908-100 815-0045-01 115-0074-01 815-0046-01 115-0087-01 115-0097-01 815-0209-01 815-0052-01
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PROVIDED BY LUMASENSE � Two Instruments (TRF & LTC) Qty Description 1 EZHub, LTC and XFMR (EZ0010) 1 Kit, EZHub, LTC and XFMR 2 Power and Communications Cable DGA-EZHub, STD, 10m 1 Kit, Conn, 1 Relay, Facility, EZHub 8 Connector, Relay MC 15/3 1 Connector, System RS485 Out 2 Connector, Unit RS485 2 Connector, Unit Power 1 Connector EZHub Power 1 Adapter-Male Micro B to Female A 1 Lug Ring, Blue (for power to the EZHub) 2 Lug Ring, Red (shield ground for cable to instrument) 50 Ferrule, AL 0.75-8 GY (Crimp Pins) (You will have extra) 3 Ferrule, (Large Crimp Pins for EZHub Power Connector) 1 Kit, EZHub Mounting Hardware 8 Screw, Pan Head 6-32X.50 (4 for wall mount or 8 for panel mount) 8 Washer, #6, Flat (4 for wall mount or 8 for panel mount) 8 Washer, #6, Split (4 for wall mount or 8 for panel mount) 1 Kit, Bracket, Wall Mount, EZHub 2 Bracket, Wall Mount 1 Kit, Bracket, Panel Mount, EZHub 1 Bracket, EZHub Panel Mount L-Side 1 Bracket, EZHub Panel Mount R-Side 1 Kit, Fuse, EZHub (this is a spare) 1 Kit, USB-ISO-485 / Cable Assembly (RS485 to USB Converter) (used for connection with a PC) PROVIDED BY CUSTOMER (or ordered separately) Qty Description 1 Screw driver, Phillips (#3, 3/16�) 1 Screw driver, Phillips (#1, 1/16�) 1 Screw driver, Flat Head (small) 4 Sets of hardware for attaching EZHub brackets to wall, panel, etc. 1 Drill to fasten the EZHub brackets to the main vertical support 1 Power cable (AC IN) 1 Conduit to insulate the shield drain wire Gland seal for cable at conduit Crimper and Stripper (for terminating cables)
SmartDGA® Manual
Part # 015-0010-01 915-0031-01 815-0236-01 815-0043-01 47-1407 47-1408 47-1409 47-1410 47-1411 57-0045 95-1970 90-2249 99-10043 99-10352 815-044-01 02615-08SS1 99-10000 99-39908-100 815-0045-01 115-0074-01 815-0046-01 115-0087-01 115-0097-01 815-0209-01 815-0052-01
Part #
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5.2.2 Mounting the EZHub The EZHub is mounted either on a flat surface (wall mount) or in a hole/slot (panel mount). Both types of brackets and hardware are sent with each order.
Example of wall mount in NEMA enclosure EZHub Wall Mount 1. Remove 4 screws on the back of the EZHub with a Phillips screw driver. Save the screws.
2. Line up the provided EZHub wall mount brackets (PN 115-0074-01) with the holes on the back of the EZHub.
3. Fasten the brackets with the 4 provided screws/washer/split-washer.
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4. Determine the location of the 4 mounting holes to be drilled into the vertical mounting surface. 11.37� (288.80 mm)
5.00� (127 mm)
12.07� 307.58 mm 5. Drill the four holes and attach the EZHub to the wall with customer-provided hardware (#10 or M5 screws). EZHub Panel Mount 1. Remove 8 screws (4 on the back and 2 on each side). Save the screws.
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2. Line up the provided EZHub panel mount brackets (PN Left - 115-0087-01 and Right � 115-0097-01) with the holes on the back of the EZHub.
3. Fasten with the 8 screws/washer/split-washer provided. Note: The screw heads on the yellow band will cause some spacing between the brackets and the EZHub enclosure. Use your judgement to align the brackets properly. 4. Determine location for the 4 panel holes and drill. 11.58� (294.13 mm)
5.00� (127 mm)
12.33� 313.18 mm 5. Install customer-provided fasteners (#10 or M5 screws) to secure the SmartDGA EZHub to the front panel.
5.2.3 Connecting the EZHub Communications Cable ®
The SmartDGA system requires a power/communications cable with multi-pin connector to be connected from the TM SmartDGA device to the SmartDGA EZHub controller. The standard connection cable length is 10 meters and longer cables (up to 30 meters (98 ft)) are also available. The standard connection cable is outdoor weather rated for -20 °C to 150 °C. If extreme weather conditions exist, an extended weather rated cable is available (rated for -50 °C to 125 °C.) SmartDGA® Manual
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Warning: The communications cable completes the sealing mechanism of the housing. The SmartDGA Instrument (Gauge, Guard, Guide) housing is not water tight when the communications cable is not attached and locked in place. Failure to properly connect this cable will invalidate the IP55 rating. The power/communications cable is provided unterminated on the SmartDGA EZHub controller end so that it can be cut to length and then terminated with provided two Phoenix connectors. The communications cable connects to the RS485 Transformer (or LTC) connector and the Transformer Power (or LTC Power) connector. The communications between the instrument and the SmartDGA EZHub controller are proprietary ASCII binary communications. Note: In order to better protect the SmartDGA power/communications cable, you can run the cable through a 1� flexible conduit from the SmartDGA Instrument to the EZHub location. Be sure to seal the point of entry on the cable into the conduit with a gland seal or similar part. To install the communications cable: Note: Ensure that the Phoenix connectors are not installed on the cable until after the routing is completed. It is easier to route the cable through cable trays and conduit without the Phoenix connectors installed. Also, note that the exterior cable should be adequately protected from extreme conditions in the outside environment. 1. Connect the power/communications cable multi-pin connector to the mating receptacle on the SmartDGA instrument. Since this is a key connection, gently turn the plug until key slots line up and then push the plug into the receptacle until you hear a click. Then tighten the thread until it locks into place.
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2. Route the power/communications connection cable to the SmartDGA EZHub location. 3. Once the cable has been routed, cut the cable to the appropriate length and terminate per the following table/diagram. We recommend cutting at least 0.5 m (1.6’) longer than needed to ensure there is enough cable when completing the connection. Trim as needed.
SmartDGA Connector Pin
Wire Color EZHub RS485 pin (1-4 from left to right)
A C E G J M N P R S
Brown Yellow Black Green White Purple (Violet) Grey Red Blue Orange
SmartDGA® Manual
EZHub Power Pin (1-6 from left to right) 6 5 2
3 4 4 3 1 1 2
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4. Insert the connectors into the appropriate slots:
Left � LTC Side SmartDGA Gauge Instrument
Right � Transformer Side SmartDGA Guide or Guard Instrument
To connect an LTC (Gauge) Instrument (Left Side of EZHub): a. Connect the 6-pin into the LTC Power slot located on the bottom left of the EZHub. Tighten the 2 connector screws with a small Flathead screwdriver. b. Connect the 4-pin Phoenix connector into the RS485 LTC slot located next to the Transformer Instrument Power slot on the bottom left of the EZHub. Tighten the 2 connector screws with a small Flathead screwdriver. To connect a transformer - SmartDGA Guard/Guide instrument (Right Side of EZHub): a. Connect the 6-pin Phoenix connector into the Transformer Power slot located on the bottom right of the EZHub. Tighten the 2 connector screws with a small Flathead screwdriver. b. Connect the 4-pin Phoenix connector into the RS485 Transformer Power slot located next to the Transformer Instrument Power slot on the bottom right of the EZHub. Tighten the 2 connector screws with a small Flathead screwdriver. 5. The shield drain wire should be insulated and terminated with the supplied ring lug. Fasten the ring lug to the SmartDGA EZHub controller’s ground terminal. Note: The ring lug should be between the star washer and securing nut (pictured on the right). Tighten fully so the star washer cuts through the paint to make a good electrical contact with the EZHub housing. The cable is not grounded at the DGA unit side and must be grounded at the EZHub side.
Securing nut Ring lug Star washer
Power Supply Wiring No input power cable is provided with the SmartDGA EZHub controller. However, the connector and pins are provided.
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Note: The EZHub requires 90 to 264 Volts AC, 127 VDC to 370 VDC, 47-63 Hz, 2.5 A max. Use size 14 AWG wire for the included crimps and connectors to bring power to the EZHub. We recommend a power cable with the following characteristics: AWG 14, CU type TFFN or MTW or gasoline and oil resistant II. Note: Each EZHub must have a 10 A circuit breaker for system isolation and protection (customer-provided).
Warning: Exercise proper electrical procedures when wiring the electrical input power connectors to ensure complete insulation of electrical conductors. 1. Route the EZHub power cable to the SmartDGA EZHub location. 2. Once the cable has been routed, cut the cable to the appropriate length and connect. The AC/DC pin connections are as follows: Pin N Middle L
Use Return line used by AC or DC Not used (prior to SN XYZ) or earth ground Input line voltage (AC) or DC voltage
DC Polarity - negative + positive
3. Wire the ground to the system’s grounding terminal on the bottom of the unit using the Blue Lug Ring (PN 95-1970).
AC/DC Power Connector
Grounding terminal
Relay Outputs There are four optional relay outputs for status, caution, warning, or alarm. Use of these is optional and they may be used to connect to things such as SCADA systems, alarms, etc. Configuration of the settings and thresholds for using these relays is done with the DGA Viewer software. Refer to the SmartDGA Software Manual. Note: Relays are intended for enunciation use, not for control purposes. The connectors and pins are provided, but wires are not.
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Status
Caution
Warning
Alarm
Relay #
Name
Meaning
When normal
When alert is triggered
1
Status
SmartDGA system status
Com-NO
Com-NC
2
Caution
Com-NC
Com-NO
3
Warning
Com-NC
Com-NO
4
Alarm
Com-NC
Com-NO
5.3
Gas Level/Rate/Ratio exceeds user defined normal threshold Gas Level/Rate/Ratio exceeds user defined caution threshold Gas Level/Rate/Ratio exceeds user defined warning threshold
i Core or External Computer
5.3.1 Parts and Tools for the i Core Ensure you have the following items on hand prior to starting installation. PROVIDED BY LUMASENSE Qty Description 1 i Core Assembly (IC-0012) 1 Kit, Wall Mount, LumaSMART 2 Bracket, Wall Mount 4 Screw, 10-32 X 1/2,Phillips, Pan Head 4 Washer, #10, Flat 4 Washer, #10, Split 1 Kit, Panel Mount, i Core 1 Bracket, Panel Mount, L, i Core 1 Bracket, Panel Mount, R, i Core 1 Kit, Ship i Core 8 Ferrule (Small Crimp Pins for i Core Power Connector) 1 Connector, AC IN (Power) 1 Connector, RS485 1 Lug Ring, Red
SmartDGA® Manual
Part # 015-0002-01 01-15046-01 02-15-226-01 99-11061-308 99-31020-300 99-31040-300 815-0040-01 115-0151-01 115-0152-01 815-0214-01 99-10043 47-1302 47-1303 90-2249
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PROVIDED BY CUSTOMER (or ordered separately) Qty Description 1 Screw driver, Phillips (#3, 3/16�) 1 Screw driver, Phillips (#1, 1/16�) 4 Sets of hardware for attaching i Core brackets to wall, panel, etc. 1 Drill to fasten the i Core brackets to the main vertical support PROVIDED BY CUSTOMER (or ordered separately) 1 Power cable (AC IN) Conduit to insulate the shield drain wire 1 Ethernet Cable (optional, for i Core or PC) 1 Serial Cable (RS485) (optional, for i Core)
Part #
5.3.2 Mounting the i Core The i Core is mounted either on a flat surface (wall mount) or in a hole/slot (panel mount). When ordering, an i Core configuration is provided (wall or panel) and the appropriate brackets are sent with the system.
Wall Mount
NEMA 4 Enclosure
Substation Panel
Rack Mount
i Core Wall Mount 1. Line up the provided brackets (PN 01-15046-01) with the 4 holes on the back of the i Core.
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2. Fasten the brackets with the 4 screws, washers and split-washers provided.
3. Determine the location of the four mounting holes to be drilled into the vertical mounting surface. Mark the holes for drilling. 9.43� (239.52 mm)
6.58� (167.13 mm)
5.58� 141.73 mm
10.07� (255.78 mm)
4. Drill the four holes and attach the i Core to the wall with customer-provided hardware (#10 or M5). i Core Panel Mount 1. Remove the sides of the i Core. Save the screws (8 total).
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2. Rest the provided brackets on the back of the i Core so that the brackets are flush with the sides and back of the i Core.
3. Use the 8 screws saved from Step 1 and the 4 screws provided to fasten the brackets.
4. Determine location for and drill 4 holes into panel. 8.76� (222.50 mm)
5.74� (145.80 mm)
5.25� (133.35 mm)
9.4� (238.76 mm)
5. Install customer-provided fasteners (#10 or M4) to secure the i Core to the front panel.
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5.3.3 Connecting the i Core The following are directions to electrically wire the LumaSMART i Core unit power, outputs, and communication. The following sections outline the provided connections on the rear of the LumaSMART i Core. Communications Output The SmartDGA system requires a communication connection from the EZHub to either an i Core or PC. This can be done via Ethernet or RS485 connection.
USB Unused Connection
Ethernet
AC In
Serial (RS485)
Unused Connection
RS485 Out
Ethernet
Ethernet Connection
The Ethernet connector is the normal RJ45 (CAT5) standard cable. A shielded Ethernet cable must be used. This cable is not provided as the required length will vary. The IP address for the Ethernet connection can be supplied statically or by a DHCP server. Note: For an EZHub using a static IP, you could change the IP address using the Commissioning Tool via RS485 or Ethernet. The new EZHub IP address will take affect only after you power cycle the EZHub. It is recommended to power cycle the EZHub immediately after you change the IP address. Note: The USB connection is only for uploading and downloading functions (such as downloading data or uploading a new version of firmware). When using Ethernet to communicate between the SCADA and the i Core, as well as between the i Core and EZHub(s), the use of an Ethernet switch (not provided) is required. An example of the network topology in such a case is shown in the following figure:
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Note: DGA Viewer supports Modbus protocol on a PC. DNP3 and IEC require an i Core to run DGA Viewer software. Serial (RS485) Connection
If using RS485 with an i Core, use the Phoenix 3-pin (EZHub PN 47-1408) and Phoenix 5-pin ( i Core PN 47-1303) connectors. Phoenix 3-pin connector (for EZHub connector) ·
Pin 1 is TXD+ for RS485
·
Pin 2 is TXD- for RS485
·
Pin 3 is ground
i Core connector
EZHub connector
Phoenix 5-pin connector (for i Core connector) ·
Pin 1 is RS485 TXD-
·
Pin 2 is RS485 TXD+
·
Pin 5 is ground
To connect RS485 to the iCore: 1. Locate the 3-pin connector (PN 47-1408) shipped with the EZHub and the 5-pin connector (PN 47-1303) shipped with the i Core. 2. Use a customer-provided connection cable and the included crimp pins to terminate the ends of the cable for the EZHub and i Core. 3. Insert the 3-pin connector into the EZHub RS485 OUT port and the 5-pin connector into the i Core SERIAL (RS485) port.
EZHub RS485 OUT port & 3-pin connector
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To connect RS485 to the PC: If using RS485 with a PC, you will need to connect the RS485-USB converter:
1. Plug in 3-pin connector from the converter cable into the EZHub RS485 Out port. 2. Plug in the 6-pin connector from the converter cable into the Converter Serial Comm Port. 3. Plug the �square� USB side into the converter box and the standard USB side into your computer USB port. Note: Power for the connector is drawn from the computer. 4. Once powered, your computer may take a few minutes to identify and may install some driver software. If your computer does not automatically install the software, use the enclosed CD to install the software. Power Supply Wiring No power cord is supplied with the LumaSMART i Core unit. However, the connector and pins are provided. Note: The i Core requires 90 to 264 Volts AC, 127 VDC to 370 VDC, 47-63 Hz, 2.5 A max. Use size 18 AWG wire for the included crimps and connectors to bring power to the EZHub. We recommend a power cable with the following characteristics: 18 AWG and UL 1061 (300V, 80C) approved.
Note: Each i Core unit requires that there be a 10A circuit breaker (separate from any other i Core or EZHub units) on the power line that feeds it as a secondary line. This circuit breaker is used to power the unit ON and OFF. The LumaSMART i Core unit does not include any external switches or circuit breakers. Consult local building codes for the appropriate switch or circuit breaker to install. Externally fuse for 200W.
Warning: Exercise proper electrical procedures when wiring the electrical input power connectors to ensure complete insulation of electrical conductors. 1. Route the i Core power cable from the circuit breaker to the i Core location. 2. Once the cable has been routed, cut the cable to the appropriate length. The connection for the AC/DC input is located at the bottom of the LumaSMART i Core unit.
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3. Connect a cable appropriate for the provided connector (PN 47-1302) with the provided crimp pins (PN 99-10043). The AC/DC pin connections are as follows: Pin N Middle L
Use Return line used by AC or DC Not used Input line voltage (AC) or DC voltage
DC Polarity - negative + positive
*Ground wire goes to grounding terminal on the side. Note: Color convention for line power wiring varies by country. 4. Wire the ground to the system’s grounding terminal using the Red Lug Ring (PN 99-2249).
Power Wiring Diagram Caution: To protect the instrument, do not operate the LumaSMART i Core unit above the factory default voltage levels. System Status Relay Unused connection.
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6 SmartDGA Commissioning After everything is installed, you need to check the SmartDGA system to ensure everything is connected and working properly. Use the DGA Commissioning Tool on the PC or iCore. Caution: The on-board protection mechanisms will prevent the SmartDGA system from running a measurement cycle if the pressure exceeds the following pressure limits: ·
minimum oil inlet pressure 2 psig (0.14 bar gauge)
·
maximum oil outlet pressure 45 psig (3.1 bar gauge)
·
The height of the oil level in an operational transformer provides sufficient pressure for SmartDGA operation (approximately 0.4 psi per vertical foot or 0.09 bar per vertical meter).
If the SmartDGA is connected to a laboratory simulated transformer, the minimum pressure threshold may not be reached. In this case, a different mounting location or use of a pressure generating booster pump may be required. If the SmartDGA is connected to the outlet of LTC filter which exceeds the maximum pressure threshold, then use of a pressure reducing stage such as a needle valve or orifice is required. The SmartDGA is capable of generating up to 45 psig (3.1 bar gauge) of pressure on the oil outlet to return the oil to the transformer or LTC. Caution: Do not turn off power to the SmartDGA instrument unless it has been prepared for storage. The instrument requires power to protect the gas separation membrane from pressure changes induced by outside environmental changes even if no measurements are being made. If you need to turn off power to the SmartDGA instrument, please contact LumaSense for instructions on how to properly prepare the instrument for safe storage.
6.1 Installing the DGA Commissioning Tool Check to see if the DGA Commissioning Tool is installed. If not, proceed with the following instructions to install the DGA Commissioning Tool onto the i Core or personal computer (PC). Note: If you previously installed the DGA Commissioning Tool on a personal computer and would like to install an updated version, please uninstall it using the Control Panel before proceeding with installation. To install the DGA Commissioning Tool: Note: We recommend using a personal computer to install the DGA Commissioning Tool software. To install the software on the i Core, you will need to use remote desktop or a keyboard. 1. Close all programs. If using the USB stick, insert it into the USB drive. 2. Locate the DGA Commissioning Tool Installer package on the USB or download the file from Box.com. SmartDGA® Manual
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3. Double-click DGA Commissioning Tool to run the installer.
4. Acknowledge the warning and click Next > to continue with installation.
5. If desired, click Browse� to change the folder for software installation. Click Next >.
Note: If you would like everyone on your computer to use the DGA Commissioning Tool, be sure to select Everyone below the folder selection.
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6. Click Next > .
7. Once installed, the installer will display a success message. Click Close.
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6.2 Connecting the SmartDGA System In order for the DGA Commissioning Tool to communicate with the SmartDGA EZHub TM, you must set up your SmartDGA EZHub to connect via Ethernet/IP or by RS485 COM. Check to ensure all necessary cables and/or adapters are properly connected. If using a PC, you will also need to verify that the firewall is turned off and that it is set to a static IP address that is slightly different than the connected EZHub. For example, you might have your computer IP address set to 192.168.0.10 and the EZHub IP address set to 192.168.0.8. Use the information below for reference (blue indicates default value) and consult your IT support team for assistance. Parameter
EZHub 1
EZHub 2
EZHub 3
EZHub 4 **
i Core/PC
Board ID
48
49
50
51
Use per EZHub
IP Address
192.168.0.8
192.168.0.9
192.168.0.10
192.168.0.11
192.168.0.7
Subnet Mask
255.255.255.0
Same for all
Same for all
Same for all
Same for all
Gateway Address*
192.168.0.1
Same for all
Same for all
Same for all
Same for all
ID LTC (Gauge)
64
66
68
70
N.A. for DGA Viewer software
ID TRF (Guard or Guide)
65
67
69
71
N.A. for DGA Viewer software
Com Port (for RS-485)
N.A.
N.A.
N.A.
N.A.
COM2 for i Core, per PC
Notes
Use Commissioning Tool to set values
Network
Enter Board ID(s) and Device ID(s) used into DGA Viewer Software Firewall=disabled DHCP=disabled Use hub/switch between the i Core/PC and EZHubs***
* Leave Gateway Address blank if unsure. Incorrect address will cause the unit not to function. ** A maximum of 3 EZHubs are supported for protocols (DNP3, Modbus, and IEC61850). *** A network switch is preferred. A hub is acceptable if installed on a standalone network. If connected to a corporate network without a switch (to route appropriately), the network traffic will overwhelm.
Notes: ·
Duplicate IP addresses are not allowed on the same network.
·
Duplicate EZHub Board IDs are not allowed on the same i Core/PC
·
Duplicate SmartDGA Instrument IDs are not allowed on the same i Core/PC (If the instrument on the LTC or TRF side is not present in the current configuration, the checkbox for this instrument should be unchecked in the DGA Commissioning Tool. Default addresses may be kept for the not present instrument. If the instrument will be added to configuration later, modify the address at that time).
·
If using Ethernet for communication between the EZHub(s) and iCore/PC, a dedicated private network is recommended.
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Example Topology
6.3 Using the Commissioning Tool Once the software is successfully installed, a DGA Commissioning Tool icon should appear on your desktop. Double click the icon to start the software. Note: We recommend using the DGA Commissioning Tool on a laptop due to the limited memory of the i Core (you can use the i Core, but it takes longer to run.)
6.3.1 Setup 1. Click the START button to begin.
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2. Select the connection type you are using for your system and click Next >.
If using RS485, select the correct COM port (when using the i Core, this is always COM2) from the drop down. If you are using a PC and do not know the COM port associated with the RS485 converter, start with COM1 and use trial and error until you find the correct COM. If using Ethernet, select the appropriate IP address for the EZHub. The default EZHub IP Address is 192.168.0.8 and EZHub ID is 48. Note: If using Ethernet and a personal computer in a docking station, connect the Ethernet cable in the docking station’s Ethernet port.
Note: If you wish to turn off the animations used throughout the DGA Commissioning Tool, uncheck the Use Animations checkbox. 3. The software will attempt to locate the SmartDGA EZHub unit. If it is unsuccessful, check your connections and retry. If still unsuccessful, please check your connections and try again.
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If successful, you will see a screen similar to the following:
4. If needed, edit any of the device settings. Click Save Settings. Any changes you made will then be saved to the EZHub. If you change the IP Address, you then need to reboot the EZHub. Make sure the lights are off before supplying power back to the EZHub. Note: If installing multiple EZHub controllers, the EZHub ID should be changed to the next value (i.e. start at 48, then use 49, 50, 51, …). The Transformer ID or LTC ID should be unique for each unit connected. 5. The software will then search for SmartDGA instruments located connected to the EZHub and save the information to the instrument(s). If one is not found, or you are still unable to connect to the instrument, please check your connections and try again.
6. After you save your settings, click Next > to continue. The information will be loaded onto the EZHub(s) and SmartDGA instrument(s). Note: The information is not carried over into the DGA Viewer software. Make note of the IP Address and ID.
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7. The software will identify the connected SmartDGA instrument(s). Select the first instrument type (Gauge, Guide, or Guard) you would like to commission and click Next > to continue.
Note: Outlined instruments (such as Gauge and Guard in the above example) are not selectable for commissioning since only a Guide instrument is connected to the EZHub. Indicate your selection by clicking on the grayscale icon (Guide).
Note: You can only commission one SmartDGA instrument at a time and must repeat the process for each additional instrument. 8. Verify the communications by clicking on each of the color boxes. The selected light will flash for 5 seconds every 15 seconds on the SmartDGA instrument. After testing, select Green again and click Next > to continue.
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9. Select the type of valve installation used for your SmartDGA instrument (Single, Dual, or Inline (Off-Transformer)) and click Next > to continue.
10. Acknowledge the information about the icons and click OK to continue.
6.3.2 Preparation 1. Confirm that you have completed the actions by clicking the gray checkmark next to each item to turn it green. Click Next > to continue. Single
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Inline
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2. Prepare a container (at least 3 quarts) for bleeding the valves. Single
Dual
Inline
Note: Ensure the soft polymer bleed tubes are clear enough so that you can see the oil/bubbles in a later step. 3. Open bleed valves and valve/ plugs. Single
Dual
Inline
Note: For dual and inline installations, the bleed valves are on the tees.
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6.3.3 Pump Setup 1. The default flow rate is 190. DO NOT change the flow rate. Click Next > to continue. If for some reason you feel the flow rate needs to be adjusted, contact LumaSense.
2. When ready, click Next > to continue. The oil pump will turn on and begin streaming oil.
3. Stream oil until no bubbles are visible and click Next > to continue and begin priming.
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6.3. 6.3.4 4 Prim Primin ing g The system/instrument will automatically prime the SmartDGA instrument. When finished, click Next > to > to continue.
6.3. 6.3.5 5 Fina Finall Tes Testt 1. Close Close bleed bleed valve valve and and plugs/ plugs/valve valvess and and click click Next > to > to continue. Single
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2. Select No when No when given the option to run a test cycle, as this will be done later using the Viewer Software.
3. SmartDG SmartDGA A Commiss Commission ioning ing is comple complete. te. Click Next > to > to return to the beginning of the DGA Commissioning Tool to commission additional SmartDGA instruments or close the program and refer to the Software Manual to configure the DGA Viewer software.
4. Remove Remove contai container ners. s. Leave Leave tubing tubing on bleed bleed valves valves.. Once you complete commissioning of all SmartDGA instruments, your SmartDGA system will be ready for use. Refer to the SmartDGA Software manual for more information on obtaining gas information. Caution: Do not turn off power to the DGA instrument unless it has been prepared for storage. The instrument requires power to protect the gas separation membrane from pressure changes induced by outside environmental changes even if no measurements are being made. If you need to turn off power to the DGA instrument, please contact LumaSense for instructions on how to properly prepare the instrument for safe storage.
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7 Maintenance To ensure the highest level of performance of DGA Instrument, the following procedures and list of Field Replaceable Units (FRU) have been generated so that periodic maintenance can successfully be performed.
7.1
Field Replaceable Unit (FRU) List
Battery - EZHub
A standard non-rechargeable CR1632 coin-type lithium battery purchased directly from most electronic outlets
Battery - i Core
A standard non-rechargeable CR2032 coin-type lithium battery purchased directly from most electronic outlets
O2 Sensor
Part number O2-DGA that can be purchased by contacting LumaSense customer care at
[email protected]
H2 Sensor
Part number H2-DGA that can be purchased by contacting LumaSense customer care at
[email protected]
7.2
Battery Replacement
7.2.1 Replacing the EZHub Battery Ensure you have the following parts and tools on hand prior to starting installation: PROVIDED BY CUSTOMER Qty Description 1 New Replacement Battery 1 Small Phillips Head Screwdriver 1 Medium Phillips Head Screwdriver 1 Small Flat Head Screwdriver The battery life span will be approximately 8 years. After this period, the battery needs to be replaced. The SmartDGA EZHub controller uses a standard non-rechargeable CR1632 coin-type lithium battery. The battery is located on the left side of the SmartDGA EZHub controller (LTC Side) and is clipped in directly on the main board. Caution: Battery replacement should only be performed by authorized personnel. There is danger of explosion if the battery is mishandled or incorrectly replaced. Replace the battery only with one of the same manufacturer and type or equivalent type recommended. Do not disassemble batteries or attempt to recharge them outside the system. Dispose of batteries properly in accordance with the manufacturer's instructions and local regulations. To replace the EZHub controller�s battery: 1. Disconnect the input power from the bottom of the EZHub controller and remove all other connections from the device prior to starting battery replacement.
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2. Remove yellow band from the EZHub controller by removing the 4 screws and 4 washers using a small Phillips head screwdriver. Save these screws and washers.
Removed screws and washers
3. Using a medium Phillips head screwdriver, remove one screw on the front side, one screw on the top, and two screws on the back side of the EZHub controller (as shown below). Save the (4) screws.
Removed screw (front side)
Removed screw (top)
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Removed screws (back side)
4. Remove the left (LTC) side cover from the EZHub controller. 5. Locate the battery on the main board (clipped in).
6. Remove the battery by bending the clip up slightly with a small Flat head screwdriver and sliding the battery up and out. Note: Try not to over-bend the clip. If you bend it too far up, you may need to bend it back down slightly before inserting the new battery.
Caution: Use rubber gloves or other protection when handling the new battery, as finger prints can reduce the battery’s life span.
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7. Insert the new battery into the clip with the positive side facing up.
8. Reinstall the left (LTC) side cover and reattach the yellow band. 9. Reconnect the EZHub controller. TM
7.2.2 Replacing the LumaSMART i Core Battery Ensure you have the following parts and tools on hand prior to starting installation: PROVIDED BY CUSTOMER Qty Description 1 New Replacement Battery 1 Medium Phillips Head Screwdriver 1 Small Flat Head Screwdriver (optional) The battery life span will be approximately 8 years. After this period, the battery needs to be replaced. The LumaSMART i Core uses a standard non-rechargeable CR2032 coin-type lithium battery. The battery holder is accessed from the bottom of the i Core. Caution: Battery replacement should only be performed by authorized personnel. There is danger of explosion if the battery is mishandled or incorrectly replaced. Replace the battery only with one of the same manufacturer and type or equivalent type recommended. Do not disassemble batteries or attempt to recharge them outside the system. Dispose of batteries properly in accordance with the manufacturer's instructions and local regulations. To replace the LumaSMART iCore unit�s battery: 1. Disconnect all electrical connections. 2. On the bottom of the i Core unit, remove the small access panel in the middle using a medium Phillips head screwdriver. Save the (2) screws.
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3. Removed the bottom �U-shaped� panel using a medium Phillips head screwdriver. Save the (5) screws.
Note: You may need to use a small Flat head screwdriver in order to remove this panel if it is tight. 4. Locate the battery directly above the 5-pin �SERIAL� connector.
5. Remove the old battery by pushing down on the retention tab and then sliding the battery straight out. Caution: Use rubber gloves or other protection when handling the new battery, as finger prints can reduce the battery’s life span. 6. Insert the new battery into the holder with the positive side facing down (toward the �SERIAL� connector). 7. Reattach the �U-shaped� and small access panels. 8. Reconnect the iCore unit and bring the system back online. 9. Using the touchscreen, navigate to the Battery Life software screen and press the Reset button.
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7.3
Sensor Replacement Note: Each H2 and O2 sensor has its own calibration file that needs to be loaded after sensor replacement; please contact LumaSense for further details prior to performing sensor replacement.
To gain access to the gas manifold: 1. After powering down the EZHub, remove the the power/communications cable with multipin connector from the bottom dome of the SmartDGA instrument.
Multi-pin connector 2. Remove the twelve screws using a 9/64� hex driver and carefully lift up the top dome to remove it from the central housing. The gas manifold will be the aluminum block attached to the top of the 8� printed circuit board (PCB).
Oxygen sensor
Hydrogen sensor holding nut
Gas Manifold
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Hydrogen sensor plug
Oxygen sensor plug
Sensor plugs are located under the fan.
7.3.1 Replacing the H2 Sensor To replace the H 2 sensor: 1. Remove the hydrogen sensor plug from the PCB socket labeled J36.
Hydrogen sensor plug Oxygen sensor plug
Hydrogen Sensor Plug and PCB Socket J36
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2. Unscrew and remove the hydrogen sensor �Holding Nut’ from the gas manifold.
Hydrogen Holding Nut
3. Screw the replacement hydrogen sensor assembly into the gas manifold, hand tighten. 4. Insert the hydrogen sensor plug into the PCB socket labeled J36. 5. Reattach the top dome.
7.3.2 Replacing the O2 Sensor 1. Remove the oxygen sensor plug from the PCB socket labeled J24.
Oxygen Sensor Plug and PCB Socket J24
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2. Unscrew the oxygen sensor from the gas manifold.
Oxygen Sensor Removal 3. Remove the replacement oxygen sensor from its packaging and attach the included O-ring.
O-Ring 4. 5. 6. 7.
Screw the replacement oxygen sensor into the gas manifold, hand tight. Insert the oxygen sensor plug into the PCB socket labeled J24. Reattach the top dome. Load calibration file using DGA Viewer (See O 2 Sensor Field Replacement instructions). Note:
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8 Troubleshooting 8.1 Visual Light Indicators ®
8.1.1 SmartDGA Instrument The indicator light on the front of the SmartDGA instrument is on for 5 seconds and off for 15 seconds, then repeats the cycle. This means that during a one minute period you have three indication cycles on the SmartDGA instrument. The LED indication light on the EZHub will be the same as on the instrument, except it will not flash and will be a solid indication. The color indications are noted below: Note: A caution, warning, or alarm state can be caused by ppm level, rate of change, or ratio limit being exceeded.
Instrument Light(s)
Action
Meaning
Green
Flashing 5 seconds every 15 seconds
Indicates normal operation
Yellow
Flashing 5 seconds every 15 seconds
Indicates caution
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Blue
Flashing 5 seconds every 15 seconds
Indicates warning
Red
Flashing 5 seconds every 15 seconds
Indicates alarm
Red & Blue
Flashing, 5 seconds blue followed by 5 seconds red (repeated
Indicates Status and Error Condition
until condition clears or is reset)
A Status and Error condition indicates that one of the several monitored variables (temperature, pressure, sensor operations, etc.) has exceeded the set point for that condition. On the EZHub, the LED indication will be a solid red and blue and remain solid until the condition clears or is reset.
Yellow & Green
Flashing, 5 seconds green followed by 5 seconds yellow (repeated until condition clears or is reset)
Indicates Loss of Communication
On the EZHub, the LED indication will be a solid green and yellow and remain solid until the condition clears or is reset.
Note: SmartDGA Status and Error Codes will require you to contact the factory for further guidance on corrective actions and diagnosis. Most Error Codes will require unit maintenance which may require the unit to be returned to the factory for repair.
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TM
8.1.2 SmartDGA EZHub Controller The LED indication light on the SmartDGA EZHub controller will be the same as on the instrument, except it will not flash and will be a solid indication. The color indications are noted below.
EZHub Light(s)
Action
Meaning
Green
Solid
Indicates normal operation
Green & Yellow
Solid
No communication with instrument
Red & Blue
Solid
Status and Error indication - Lights only activated when �Error� setting is exceeded
Yellow
Solid
Caution indicating exceeding caution level limits set for the gas level, rate of change, or ratio
Blue
Solid
Warning indicating exceeding warning level limits set for the gas level, rate of change, or ratio
Red
Solid
Alarm indicating exceeding alarm level limits set for the gas level, rate of change, or ratio
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9 Diagrams & Drawings 9.1 Multiple SmartDGA EZHubTM Setup with Ethernet Hub or Switch
Note: The preferred implementation is a switch, especially if the LumaSMART i Core is connected to a high traffic network.
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9.2 LumaSMART i CoreTM RS485 Connections
Note: The LumaSMART i Core is optional and is not required for the SmartDGA system.
Note: An Ethernet switch at the LumaSmart i Core is required to connect to both the EZHub and SCADA system using Ethernet. Use of RS485 with IEC61850 protocol will not be supported due to bandwidth restrictions.
Note: The RS485 port on the LumaSmart i Core is always COM 2. Other addresses may appear in the pull down menu choice, but they are not functional RS485 ports.
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9.3 LumaSMART i CoreTM Ethernet Connections
Note: The LumaSMART i Core is optional and is not required for the SmartDGA system.
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9.4 Unistrut Stand Note: Example of typical installation. Customer is responsible for verifying design meets local facility requirements and safety requirements.
Note: The NEMA4 enclosure will heat up significantly when exposed to direct sunlight. The installation location should be chosen to minimize sunlight. If this is not possible, a sunshade over the top of the enclosure is recommended.
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9.5 SmartDGA NEMA 4 Enclosure
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9.6 Inline Mounting Plate
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9.7 Wiring Connection
SmartDGA Connector Pin
Wire Color EZHub RS 485 pin (1-4 from left to right)
A C E G J M N P R S
Brown Yellow Black Green White Purple (Violet) Grey Red Blue Orange
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EZHub Power Pin (1-6 from left to right) 6 5 2
3 4 4 3 1 1 2
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9.8 Assy, Wall Mount, SmartDGA EZHubTM
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9.9 Assy, Panel Mount, SmartDGA EZHubTM
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9.10 Assy, Wall Mount, LumaSMART i CoreTM
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9.11 Assy, Panel Mount, LumaSMART i CoreTM
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9.12 SmartDGA Instrument Sun Shade
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9.13
SmartDGA Instrument Dimensions 10.765� 273.43
12.152� 308.66 mm
20.918� 531.32
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Index
A
G
Access Panel 84
Gauge 12, 57 Grounding terminal 57
B
Guard 12, 57
Battery Replacement 81, 84
C
Guide 12, 57
I
Commissioning 67 Commissioning Software See DGA Commissioning Tool
i Core 14, 21, 59, 84, 96, 97
D
Battery 84 Communications Output 63 Ethernet Connection 63 Panel Mount 61 Serial (RS485) Connection 64 Wall Mount 60 Inline 19, 40
DGA Commissioning Tool 67
Installing 67
Communications Cable 54 Connector Pin 56
DGA Viewer 12 Disposal 9
M
Dual Valve 35
Maintenance 81, 84 Measurement cycle 11, 16
E
Mounting plate 42
Ethernet 23
Mounting Ring 49
Ethernet Connection 63 EZHub 13, 20, 50, 55, 93, 102, 104, 108 Communications Cable 54 Panel Mount 53 Power Pin 56 Power Wiring 58, 65 Relay Outputs 58 RS485 pin 56 Wall Mount 52
N NDIR 14 NEMA 4 99 Non-Dispersive Infrared 14
O Oil-Gas Separating Membrane 16
F
O-rings 31, 38, 43
Field Replaceable Unit 81
P
Filter Systems 40
Panel Mount 53 iCore 61
SmartDGA® Manual
Index
113
