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GE TOP-FREEZER 16, Installation Manual

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GE TOP-FREEZER 16 Installation Manual Download Page 32

 

MA-001 – TRANSFIX-family Installation Manual – Rev 3.0 

18-Jan-16 

Page 32 of 55 

11

 

COMMUNICATIONS 

Various communication options are available for the product. These include: 

 

A  USB  slave  connection  —  allows  serial  communications  with  an  external 
computer. This connection is available on the panel inside the product. 

 

An  Ethernet  connection  (using  the  MODBUS/TCP  protocol).  This  connection  is 
available on the circuit board inside the inner door. 

 

Up to two further communications channels. However, if a DNP3 module is fitted 
(one maximum) this limits the available communication channels to one. 

The  product  supports  simultaneous  communication  on  several  channels  –  up  to  three 
masters over Ethernet, and one master on each of the serial connections (including the 
USB connection) as listed in Table 11—1. 

Table 11—1: Product communications channels 

Channel 

Carrier 

Protocol 

MODBUS/ 
RTU 

MODBUS/ 
TCP 

MODBUS/ 
ASCII 

DNP3.0 

IEC61850 

USB 

USB 

- 

- 

 

- 

- 

Chan

ne

l A*

 

RS-232 Isolated 

 

- 

 

 

 

RS-485 2-wire 

 

- 

 

 

 

RS-485 4-wire 

 

- 

 

 

 

PSTN 

- 

- 

 

- 

- 

GSM/GPRS 

- 

- 

 

- 

- 

CDMA 

- 

- 

 

- 

- 

Chan

ne

l B

 

RS-232 Isolated 

 

- 

 

 

 

RS-485 2-wire 

 

- 

 

 

 

RS-485 4-wire 

 

- 

 

 

 

PSTN 

- 

- 

 

- 

- 

GSM/GPRS 

- 

- 

 

- 

- 

CDMA 

- 

- 

 

- 

- 

Ethernet 

Ethernet 

- 

 

- 

- 

- 

DNP3 

Ethernet 

- 

- 

- 

 

- 

*Note: Channel A is disabled when DNP3 over Ethernet is selected. 

The options listed above are available at the time of printing – other options may become 
available. (Contact the GE Customer Service Centre for further information.) 

Summary of Contents for TOP-FREEZER 16

Page 1: ...GEDE GA_M DLIS TE MA 001 Rev 3 0 18 Jan 16 GE Grid Solutions Kelman TRANSFIX family Installation Manual Transformer Oil Dissolved Gas and Moisture Monitor ...

Page 2: ... Plumbing 15 8 1 Transformer Valves 16 8 1 1 Fill Valve 16 8 1 2 Drain Valve 16 8 1 3 Ancillary Valves 16 8 1 4 Cooling Loop Valves 17 8 2 Supply Return Valves 17 8 2 1 Oil Supply 17 8 2 2 Oil Return 18 8 3 Tubing 18 8 3 1 Fitting Requirements 20 8 3 2 Fitting Instructions 22 8 3 3 Connection to Oil Supply Valve 22 8 3 4 Connection to Oil Return Valve 23 9 Power 26 9 1 Connections 26 9 2 Cold Star...

Page 3: ...les of possible line configurations three of many 15 Figure 8 3 Transformer Valve locations 16 Figure 8 4 TRANSFIX 1 6 connections bottom view 20 Figure 8 5 MULTITRANS connections bottom view 21 Figure 8 6 TAPTRANS connections bottom view 21 Figure 8 7 Fitting body and tubing 22 Figure 8 8 Nut at 6 o clock position 22 Figure 8 9 Nut at 9 o clock position 22 Figure 8 10 Bleed assembly on flange typ...

Page 4: ... Figure G 2 TAPTRANS mounting stand dimensions top front side 49 Figure H 1 TRANSFIX 1 6 MULTITRANS footprint dimensions 50 Figure H 2 TAPTRANS footprint dimensions 50 Figure I 1 System board 51 Figure I 2 RS 232 RS 485 connections 53 List of Tables Table 4 1 Technical specification 10 Table 5 1 Type tests 11 Table 11 1 Product communications channels 32 Table I 1 List of terminals 52 ...

Page 5: ... on load tap changer OLTC including both the separate diverter tank and selector tank where one exists The key features and characteristics are summarised as follows Utilises dynamic headspace sampling to extract target gases from the oil sample No consumables such as carrier gases are required Accurate results are available as often as once per hour Minimal maintenance Uses highly accurate and st...

Page 6: ...lumbing power electronics and communications including tools supplies and items to purchase Differences between the products are always qualified by the use of the respective product name and operational details can be found in the respective product user guides This manual must be read in its entirety prior to installation so as to prepare the site and obtain the necessary equipment Refer to the ...

Page 7: ...eived appropriate training for working at height prior to work commencing This includes but is not limited to Working at height training If working at a height greater than 4 feet or at a height greater than that stipulated by national or site regulatory requirements it is the responsibility of the installer to ensure that planned work complies with those requirements The installer shall also ensu...

Page 8: ...ersonnel may commission GE products Commissioning tasks include making any connections and or performing any work within the enclosure or performing tasks such as purging the oil circuit between the transformer and the product and or all first start up procedures relating to equipment or firmware software ...

Page 9: ...tain additional information such as drawings forms and checklists that need to be reviewed and completed prior to the installation This relates to materials and facilities that need to be ordered acquired and in place well in advance of the scheduled installation date Confirmation of this needs to reach GE as soon as possible at a minimum four weeks prior to the installation date unless prior arra...

Page 10: ... C to 120 C 2 Altitude Up to 2000 m Atmospheric pressure Up to 1050 mbar Operating humidity 10 95 RH non condensing Enclosure IP55 Weight 72 kg 159 lb TRANSFIX 1 6 88 kg 194 lb TAPTRANS 76 5 kg 169 lb MULTITRANS POWER REQUIREMENTS 110 230 V AC 3 factory set 50 60 Hz 8 A Max Single phase Alarm Relays NO and NC provided 3 A 250 V AC 150 mA 300 V DC 4 200 mA 125 V DC 3 A 30 V DC Fuses 5 10 A 500 V Co...

Page 11: ...II Surge Immunity EN 61000 4 6 III Conducted RF Immunity EN 61000 4 8 IV V Magnetic Field Immunity IEC 61000 4 9 X Pulsed Magnetic Field Immunity IEC 61000 4 10 X Damped Oscillatory Magnetic Field Immunity EN 61000 4 11 III Voltage Dips Interruptions IEC 61000 4 12 X 2 5 kV 1kV Oscillatory Wave IEC 61000 4 18 X Damped Oscillatory Wave EN 61000 3 3 Pst 10 min Plt 120 min Voltage fluctuations flicke...

Page 12: ...e product The valve size should measure at least 15 mm in in diameter The ambient temperature in the area where the product resides should not fall below 40 C nor exceed 55 C If the transformer is nitrogen blanketed check the pressure vacuum gauge If the pressure is positive then the product can be installed If the pressure is negative a vacuum exists within the transformer Air will be drawn into ...

Page 13: ...astened to a flat mounting surface Additional reinforcement and or dampening may be necessary if local conditions environmental or otherwise could expose the product to potential external forces or vibration The product must be mounted on a flat surface within 5 degrees of plumb and level on both axes which is capable of supporting the combined weight of the product and its mounting stand See Appe...

Page 14: ...ansformer GE strongly advises against mounting the product to the body of a transformer Furthermore should damage occur to the product that is attributable to the mounting arrangement and or excessive transformer vibration such damage will not be covered under warranty Care should be taken at all times to ensure that damage does not occur to the transformer or the product during installation The c...

Page 15: ...of the gases see Figure 8 1 and Figure 8 2 Figure 8 1 Schematic representation of an installation The oil is removed from one valve of the transformer the supply valve and returned via another the return valve The location of the supply valve should produce an oil sample that is a well mixed representation of the transformer oil The following pages contain points to consider when choosing where to...

Page 16: ... be oil at this position However it is acceptable to return oil through this valve 8 1 2 Drain Valve The drain valve may be used as an oil supply or oil return valve However it is particularly useful to return the oil to the transformer through this valve because it is near ground level providing an easily accessible point to bleed the air from the oil lines during the installation 8 1 3 Ancillary...

Page 17: ...product When choosing how to prepare the oil supply and return valves consider these points 8 2 1 Oil Supply Oil is typically taken from a valve midway up on the transformer or from an active cooling loop Note If oil has to be taken from an oil forced cooling loop the oil supply valve must be located on the high pressure side of the oil pump It is necessary to ensure that the oil is taken from a l...

Page 18: ...y accessible and visible location This valve can be used to conveniently shut off the oil return if required It is important to ensure that the configuration of the Return Assembly eliminates any pre existing air pockets This is achieved by the use of a Tee on the return valve with the bleed port facing upwards To reduce the possibility of air pockets behind the flange the position of the in NPT h...

Page 19: ...ither tubing path exceeds 6 m 20 ft in stainless steel compression unions will need to be provided along with the additional tubing The required amount of tubing in accordance with the specification in Appendix D must be on site on the day of the installation Bending the rigid tubing is a complicated procedure and if there is a change to the proposed route during the installation it could require ...

Page 20: ...n line is connected to the OIL OUT port this is the bulkhead fitting at the bottom of the product that is located closest to the left hand side when viewed from the front This line will route to the Return Assembly on the transformer valve All stainless steel tubing is clean and de burred before attaching the tube fittings All tubing is properly secured to the transformer or other suitable non vib...

Page 21: ... sampling port E Ambient temperature sensor B Oil out ports circuits 1 2 3 F Communications cables gland C Oil in ports circuits 1 2 3 with filters G M8 earth connection point D Power cable gland A Out C selector F In A main B Out A main I M8 earth connection point C Manual DGA A C J Ambient temperature sensor D In C selector K Out B diverter E Manual DGA B L In B diverter ...

Page 22: ...the transformer or the stainless steel tubing This is performed by GE trained and certified personnel during the commissioning phase to prevent air bubbles from entering the transformer 8 3 3 Connection to Oil Supply Valve Oil is typically taken from a valve midway up on the transformer or from an active cooling loop see Section 8 1 for information on valve selection Oil must be taken from a locat...

Page 23: ...he transformer drain valve Note The distance from the oil supply valve should be at least 30 cm 12 in Do not return the oil into a high pressure area on the transformer such as a cooling loop The following points must be observed when connecting to the oil return valve see Section 8 1 for information on valve selection The return line to the transformer must be via the Return Assembly see Figure 8...

Page 24: ... Return Assembly kit All pipe fittings should be tight and all threaded pipe fittings tightly wrapped with PTFE tape with a light coating of PTFE paste or other quality pipe thread sealant applied over the taped male threads to prevent leaks Both of these items are included in the product installation kit Note GE recommends two wraps of PTFE tape or three wraps for large pipe fittings Bolt holes I...

Page 25: ...MA 001 TRANSFIX family Installation Manual Rev 3 0 18 Jan 16 Page 25 of 55 Figure 8 13 depicts the proper arrangement of the Return Assembly Figure 8 13 Bleed assembly on threaded type oil return valve ...

Page 26: ...ply line near the product The switch or breaker shall be rated at 10 A minimum 250 V AC minimum The switch or breaker shall be approved to IEC60947 1 or IEC60947 3 and installed in accordance with local wiring regulations The switch or breaker shall be identified as the disconnect device for the product and should be located where it is visible from the product and easily accessible Before commenc...

Page 27: ...clockwise Route the mains supply cable through the 25 mm cable gland on the bottom of the product The outer sheath of the mains supply cable shall continue into the equipment as far as possible so that reinforced insulation is maintained between the operator and the mains supply The mains supply shall be connected so that the protective earth wire is the last wire to take the strain and break free...

Page 28: ... on to increase the internal temperature to within the PGA operational temperature range The system does not fully power up until the working temperature in zone 1 reaches 10 C after which the system becomes operational Lights for the system power supplies are situated on the circuit board at the rear See the relevant product user guide for more details Note Once the DC power supply resumes the in...

Page 29: ...ure 9 5 3 Slide the battery out of its housing 4 Replace with a new Panasonic CR2450 3 V 620 mAh coin cell 5 Close the inner door There is a danger of a new battery exploding if installed incorrectly Dispose of the used battery in accordance with local regulations not in a fire or with household waste Contact your local waste disposal agency for the address of the nearest battery deposit site Perc...

Page 30: ...d alarm relays and four front panel LEDs Relay outputs are located along the terminal strip on the System board see Appendix I Three connections are provided to each relay NO Normally Open NC Normally Closed and COM Common Each alarm relay can handle a maximum of 3 A at 250 V AC 150 mA at 300 V DC 200 mA at 125 V DC or 3 A at 30 V DC see Appendix I Service relay notifies the user of an error condi...

Page 31: ... is a split core current sensor that can be installed unobtrusively around a CT line receiving a feed from the main bushing secondary wiring usually located within the marshalling control cabinet of the transformer It should be possible to locate a suitable current transformer with a 0 A 5 A secondary circuit on which to mount the sensor The sensor is supplied with 2 5 m 100 in of cable and may be...

Page 32: ...cation channels to one The product supports simultaneous communication on several channels up to three masters over Ethernet and one master on each of the serial connections including the USB connection as listed in Table 11 1 Table 11 1 Product communications channels Channel Carrier Protocol MODBUS RTU MODBUS TCP MODBUS ASCII DNP3 0 IEC61850 USB USB Channel A RS 232 Isolated RS 485 2 wire RS 485...

Page 33: ...nsure continued EMC compliance a Wurth 74271221S ferrite as shown in Figure 11 1 supplied as part of the COMMS kit must be fitted to make connection with an RS 232 and or RS 485 module using connector P1 The communications cable must be looped twice through the ferrite as shown in Figure 11 1 Figure 11 1 Ferrite placement on RS 485 ...

Page 34: ...m 12 in Nylon UV resistant cable ties 1 bag in tubing P clamps 1 Laptop computer for commissioning the product and running the TRANSCOM software for downloading and interpreting the results of the gas analysis Minimum specification Windows 2000 or Windows XP operating system PII 400 MHz processor 128 MB of RAM and 1 2 GB hard drive space 28 8 Kbps modem or faster and USB 1 1 or faster A 2 Customer...

Page 35: ... valve if required see Section 8 3 in stainless steel compression unions if the length of either tubing path exceeds 6 m 20 ft see Section 8 3 Communications option tested and located at the installation site see Section 11 Circuit capable of 110 V AC 100 121 V AC or 230 V AC 207 253 V AC 50 60 Hz with suitable overcurrent protection as per local regulations see Section 9 If heat trace cable is us...

Page 36: ...ion Site Name Site Address City State Postcode Zip Country Primary Corporate Contact Name Title Address City State and Postcode Zip Country Phone Mobile Email address Secondary Contact Name Mobile Primary Site Contact Name Title Address City State and Postcode Zip Country Phone Mobile Email address Secondary Contact Name Mobile Site Map Please attach a detailed map or GPS coordinates on how to loc...

Page 37: ...s ___________ ppm sum of all measured gases Please describe or attach separately details of any major maintenance actions such as a rebuild vacuum degassing or filtering etc C 2 1 Transformer Oil Oil Capacity in gallons in litres Manufacturer Type Certified PCB free Yes No Temperature range at oil supply valve High C Low C Temperature range at oil return valve High C Low C C 2 2 Transformer Nitrog...

Page 38: ...n Alternative Return valve location Secondary Shut Off valve location if needed Oil supply return routing the in stainless steel tubing C 3 2 Proposed Product location Overview from front Overview from left side Overview from back Overview from right side C 3 3 Proposed Cable routing and connection locations Communication cable routing include terminations Power cable routing include terminations ...

Page 39: ...18 Jan 16 Page 39 of 55 C 3 5 Additional Photographs Any additional devices used in conjunction with the installation such as junction boxes telephone line sharing devices alternative communication devices etc Overall site photos Any other useful photos ...

Page 40: ...our local Swagelok representative Flexible Hose Flexible hose can be ordered from Swagelok but must be ordered in custom lengths well in advance of the installation For example a custom 8 meter FL series hose would have part number SS FL4TA4TA4 800 specified in centimetres see the Swagelok website www swagelok com or your local Swagelok representative Do not use copper tubing See Section D 6 D 3 T...

Page 41: ...or this are outlined below D 6 1 Flow Rate The solid seamless stainless steel tubing that GE specifies is 316 Stainless Steel 1 4 in OD with a 0 035 in thick wall Most 1 4 in copper tubing has a greater wall thickness which reduces the flow rate rendering it too fragile to place in the field Bends in standard soft copper tubing crush and deform more easily which can reduce the flow rate than would...

Page 42: ... reasons our equipment or installations cannot create these compounds The reaction changes the chemical makeup of the oil before it reaches the sensor in the product This causes the product to measure acetylene and possibly other gasses inaccurately Although a transformer already contains copper GE diagnostic and monitoring equipment is designed to accurately measure the gasses in the oil of the t...

Page 43: ...e than one transformer such as the MULTITRANS must have suitable dielectric fittings placed in line with the tubing and installed close to the product Dielectric fittings provide electrical isolation and prevent circulating currents from flowing in the tubing circuits Both Swagelok and Ham Let offer dielectric fittings Details of the Swagelok dielectric fittings ...

Page 44: ...MA 001 TRANSFIX family Installation Manual Rev 3 0 18 Jan 16 Page 44 of 55 Details of the Ham Let dielectric fittings ...

Page 45: ... 3 0 18 Jan 16 Page 45 of 55 Appendix F Product Dimensions Figure F 1 shows the TRANSFIX 1 6 dimensions The TRANSFIX 1 6 weighs 72 kg 159 lb All dimensions are in millimetres mm Tolerance is 5 mm Figure F 1 TRANSFIX 1 6 dimensions 1 metre clearance ...

Page 46: ...stallation Manual Rev 3 0 18 Jan 16 Page 46 of 55 Figure F 2 shows the TAPTRANS dimensions The TAPTRANS weighs 88 kg 194 lb All dimensions are in millimetres mm Tolerance is 5 mm Figure F 2 TAPTRANS dimensions 1 metre clearance ...

Page 47: ...lation Manual Rev 3 0 18 Jan 16 Page 47 of 55 Figure F 3 shows the MULTITRANS dimensions The MULTITRANS weighs 76 5 kg 169 lb All dimensions are in millimetres mm Tolerance is 5 mm Figure F 3 MULTITRANS dimensions 1 metre clearance ...

Page 48: ...nting Stand Dimensions Figure G 1 shows the TRANSFIX 1 6 and MULTITRANS mounting stand dimensions with the product mounted The mounting stand weighs 20 kg 45 lb All dimensions are in millimetres mm Tolerance is 5 mm Figure G 1 TRANSFIX 1 6 MULTITRANS mounting stand dimensions top front side ...

Page 49: ...Jan 16 Page 49 of 55 Figure G 2 shows the TAPTRANS mounting stand dimensions with the product mounted The mounting stand weighs 16 kg 36 lb All dimensions are in millimetres mm Tolerance is 5 mm Figure G 2 TAPTRANS mounting stand dimensions top front side ...

Page 50: ...1 shows the TRANSFIX 1 6 and MULTITRANS footprint dimensions All dimensions are in millimetres mm Tolerance is 5 mm Figure H 1 TRANSFIX 1 6 MULTITRANS footprint dimensions Figure H 2 shows the TAPTRANS footprint dimensions All dimensions are in millimetres mm Tolerance is 5 mm Figure H 2 TAPTRANS footprint dimensions ...

Page 51: ...dix I System Board Figure I 1 shows the product System board A description of each terminal is provided in Table I 1 Figure I 1 System board Hinged side Terminal 1 Terminal 3 Terminal 9 Terminal 15 Terminal 27 Ethernet MODBUS TCP IP Ethernet DNP3 Optional Module 1 Optional Module 2 ...

Page 52: ...NO Relay 6 22 COM 23 NC Spacer 24 NO Relay 7 25 COM 26 NC Spacer Digital Inputs Note Digital inputs have a maximum voltage level of 12 V The switching voltage input level is approximately 2 5 V The three digital channels are separate from each other Digital inputs are not available through PERCEPTION software but can be read through the Modbus protocol 27 DIG IN 1 Digital Input channel 1 positive ...

Page 53: ...ily Installation Manual Rev 3 0 18 Jan 16 Page 53 of 55 I 1 Optional communications modules Figure I 2 illustrates the connections for the RS 232 and RS 485 connections including DNP3 Figure I 2 RS 232 RS 485 connections ...

Page 54: ...trace cable must be done by a qualified electrician familiar with local wiring regulations The heat trace cable selected shall have all necessary safety approvals required by local wiring regulations The heat trace cable rating shall be suitable for the voltage of the power source the temperature rating required and the size of tubing it is to be installed on Heat trace cable must be installed in ...

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