HYDAC FILTER SYSTEMS TCU Series Operating And Maintenance Instructions Manual Download

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TransformerCare Unit

Installing the TCU

Installing the TCU

DANGER

Electric shock

Danger of fatal injury

►

Any work involving electrical equipment may only

be done by a properly trained, certified electrician.

Install the TCU in a cool location, away from direct sunlight where possible.

Secure the TCU to a vertical wall or on a bracket ~ 1.1 m horizontally above the
ground. This makes access for maintenance work easier and provides positive inlet
pressure at the TCU's suction connection.

The installation height for small transformers must be lower, see chapter Connecting
the suction line on Page 24.

For installation in concrete walls, we recommend - Ø 8 mm expanding screws.

Install the TCU or make changes to the connections to the transformer only when
the transformer has been shut down and grounded.

Work such as maintenance and sampling on the TCU can be performed while the
transformer is operational.

Proceed as follows to install the TCU:

Dismantle the cover by removing one of the two nuts and pulling out the
thread bar.

The drilling template for mounting is on Page 21.

Mark and drill the holes for the expanding screws.

Install the expanding screws.

Mount the TCU on the wall and fasten the nuts of the expanding screws.

Install the external electrical box beside the TCU.

Use the open switch box to mark the drilling points on the mounting wall.

Drill the holes for the switch box.

Use suitable screws, sealing rings or washers with neoprene seals, for
example, to secure the switch box.

The IP protection rating of the switch box is only guaranteed if the
mounting method guarantees that the mounting holes are sealed.

HYDAC FILTER SYSTEMS GMBH

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BeWa TCU 3472805b en 2011-07-05.doc

2011-07-05

Summary of Contents for TCU Series

Page 1: ...TCU TransfomerCare Unit Operating and maintenance instructions English translation of original instructions Document no 3472805b ...

Page 2: ...liability for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors The content of the manual is checked regularly Any corrections required will be incorporated in future editions We welcome any suggestions for improvements All details are subject to technical modifications Technical specifications are subject to change without notice HYDAC FILTE...

Page 3: ...CU 11 Storing the TCU 12 Storage conditions 12 Decoding the model code label 12 Checking the scope of delivery 13 To be provided on site 13 Items supplied 13 TCU Features 14 TCU components 15 Hydraulic functions 17 Electric functions 20 TCU Dimensions Drilling Template 21 Installing the TCU 22 Notes on piping hosing 23 Connecting the suction line 24 Connecting the return line 24 Collecting the lub...

Page 4: ...l 40 Checking the gas and water content in the oil 41 Oil samples for gas analysis DGA 41 Specifying the gas formation rate of the transformer 43 Checking the TCU Servicing 47 Periodical check up monthly 48 Maintenance annual 48 Checking the degasification and dewatering unit for function 49 Cleaning the check valve of the degasification and dewatering unit 50 Changing the Filter Element 52 Checki...

Page 5: ...rmation on the unit s engineering contained in the documentation was that available at the time of publication There may be deviations in technical details figures and dimensions as a result If you discover errors while reading the documentation or have additional comments or suggestions contact us at HYDAC FILTER SYSTEMS GMBH Technische Dokumentation Postfach 12 51 66273 Sulzbach Saar Germany The...

Page 6: ... the product e g purchasing additional options etc may mean that the information in the operating instructions is no longer applicable or adequate After modification or repair work that affects the safety of the product has been carried out on components the product may not be returned to operation until it has been checked and released by a HYDAC technician Please notify us immediately of any mod...

Page 7: ...here can I find the information I m looking for The documentation has a table of contents at the beginning There I select the chapter I m looking for and the corresponding page number HYDAC FILTER SYSTEMS GMBH en Page 7 64 BeWa TCU 3472805b en 2011 07 05 doc 2011 07 05 Chapter description Page number Edition date Document language Documentation no with index file name The documentation number with...

Page 8: ...tate of the art and in compliance with the technical safety regulations Nevertheless hazards may be posed to the life and limb of the individual using the product or to third parties Risk of damage may be posed to the product or other equipment and property The Unit is to be used only solely for its designated use only when in a safe perfect condition Immediately remedy any malfunctions that might...

Page 9: ...ead to property damage if safety precautions are not observed Proper Designated Use The TransformerCare Unit was designed for stationary continual degassing and dewatering of transformer oil Any other use shall be deemed to be improper and not in keeping with the product s designated use Proper or designated use of the product extends to the following Permanent degassing and dewatering of transfor...

Page 10: ... connections damaged cables and hoses with original spare parts WARNING Hydraulic systems are under pressure Danger of bodily injury The hydraulic system must be depressurized before performing any work on the hydraulic system Electrical Hazards DANGER Electric shock Danger of fatal injury Any work involving electrical equipment may only be done by a properly trained certified electrician Only ins...

Page 11: ...nless supervised by an experienced staff member Individuals Persons undergoing training Individuals with technical training engineering background Electrician Supervisor with the appropriate authority Activity Packing Transportation X X X Commissioning X X X Operation X X X X Troubleshooting locating the source of malfunction X X X Troubleshooting mechanical problem X X Troubleshooting electrical ...

Page 12: ...ll the unit Storage conditions Storage temperature 20 C 40 C Relative humidity max 80 non condensing Decoding the model code label For identification details of the TransformerCare Unit see the type label This is located on the top of the unit and contains the exact product description and the serial number HYDAC FILTER SYSTEMS GMBH en Page 12 64 BeWa TCU 3472805b en 2011 07 05 doc 2011 07 05 ...

Page 13: ... site Please have the following items at hand for installing and starting up the TCU Qty Designation 1 Bucket at least 10 liter capacity to catch the insulating oil when filling and bleeding the TCU and hoses 1 Canister at least 25 liter capacity for transporting the oil quantity gathered 1 Funnel for pouring the oil 1 Suction hose 1 Return hose 1 1 bar check valve for connecting the return line t...

Page 14: ...ent in the oil The pressure switch is connected to two separate floating monitoring circuits Connection to a central alarm means that a warning signal is sent whenever anything occurs in the transformer which requires a more thorough investigation Precise status control After a period of continuous degasification a stable condition occurs in which the gas content of the oil is stabilized at a cons...

Page 15: ...a common wall bracket with a bottom trough It is protected against weathering by a cover made of ABS plastic The electrical switching unit is to be mounted outside the cover depending on model The components are as follows HYDAC FILTER SYSTEMS GMBH en Page 15 64 BeWa TCU 3472805b en 2011 07 05 doc 2011 07 05 ...

Page 16: ...nsulating oil 7 Pressure control valve to build up the required pressure for the degasification and dewatering unit 20 bar 8 Bleed screw for dewatering and degasification unit 9 Automatic shut off valve 10 Measurement point upstream of the fluid filter for taking oil samples e g for DGA 14 Safety switch reports leaks and full safety drip tray reports problems and deactivates the TCU 17 Filter unit...

Page 17: ...flow in one direction The oil flows through the ball valve 5 and the automatic shut off valve 9 If there is a malfunction or if the pressure in the dewatering and degasification unit 8 rises above 600 mbar absolute the shut off valve 9 closes automatically The oil passes through to the suction side of the pump 2 via the fluid filter 4 The oil flow rate of the pump is 7 2 l min 50Hz 8 7 l min 60Hz ...

Page 18: ...onent of the monitoring function of the TCU as it allows the total gas content in the insulating oil to be monitored Two monitoring pressures are preset in the pressure sensor The Alarm pressure SP2 is used to monitor a possible increase in the overall gas content in the insulating oil As the total gas content decreases continuously during the first months after installation the alarm pressure mus...

Page 19: ...el 110 230 2 The alarm pressure SP2 should be 20 above the pressure currently shown upper pressure At least 20 mbar higher than the actual pressure 270 3 Stopping pressure SP1 600 mbar After expiry of a preset delay K1 the TCU deactivates automatically 600 4 Atmospheric pressure 1013 5 The signal lamp illuminates 6 Absolute pressure 7 Absolute vacuum 0 HYDAC FILTER SYSTEMS GMBH en Page 19 64 BeWa ...

Page 20: ...ch in the collecting canister optional is not switched the gate K3 switches the electric motor of the pump on permanently Make sure the alarm functions for example the stopping pressure SP1 or the safety switch 14 in the safety drip tray are deactivated for the duration of the delay time Similarly after power failure or resumption of the power supply and a restart of the delay time the alarm funct...

Page 21: ...the fuse F1 in the control circuit was probably tripped and needs to be reset The signal lamps H1 on the switch box light up if the alarm pressure SP2 is exceeded When the alarm pressure SP2 is reached relay K2 switches The motor circuit breaker Q2 protects the motor against electric overload if the pump fails or short circuits TCU Dimensions Drilling Template The following diagram shows the TCT w...

Page 22: ...sformer has been shut down and grounded Work such as maintenance and sampling on the TCU can be performed while the transformer is operational Proceed as follows to install the TCU 1 Dismantle the cover by removing one of the two nuts and pulling out the thread bar 2 The drilling template for mounting is on Page 21 3 Mark and drill the holes for the expanding screws 4 Install the expanding screws ...

Page 23: ...ure at the connection 5 of the TCU depends on the height difference between the connection 5 and the fluid surface in the expansion vessel P height and the line losses P line As the TCU suction connection is below the fluid surface in the expansion vessel the pressure can be estimated as follows P 1 bar P height P line You can calculate the P height as follows P height bar h meters 10 meters bar h...

Page 24: ...e transformer 20 2 Fit the manual ball valve included to the free end of the suction line and close it Do not connect the suction hose to the TCU yet Connecting the return line Proceed as follows to connect the return line 1 Fit a check valve with 1 bar opening pressure to the lower connection shut off fitting of the transformer The check valve prevents the transformer draining via this connection...

Page 25: ... be up to 6 liters year If regular checks of the TCU are guaranteed we recommend Allow the ejected oil to drain into the safety drip tray The drip tray fills up until the safety switch deactivates the TCU Drain the oil from the drip tray cyclically via the drain connection in the drip tray If no regular checks of the TCU are guaranteed we recommend Install a separate collecting canister capacity a...

Page 26: ...y Designation 1 1 Collecting canister capacity 25 liters 2 1 Connection hose of gas withdrawal connection to the collecting canister 3 1 Float switch For monitoring the level in the collecting canister It is electrically connected in series to the safety switch of the drip tray see chapter 4 1 Strap to secure or fasten the collecting canister HYDAC FILTER SYSTEMS GMBH en Page 26 64 BeWa TCU 347280...

Page 27: ...ower supply Observe the voltage specifications on the type label of the TCU the electric motor Depending on the design the TCU is supplied with or without a power plug See the enclosed circuit diagram for the electrical connections In 3 phase operation Using jog mode quick switching on and off check the rotation direction of the electric motor An arrow on the housing shows the correct direction of...

Page 28: ...ing pressure in parallel See also Setting the alarm pressure and stopping pressure in chapter Setting EDS switchpoints for the alarm and stopping pressure Connections with potential Terminal X2 Description 4 Stopping pressure SP1 The terminal is a PNP transistor output High 24 VDC or low 0 VDC Maximum load 0 5 A During normal operation pressure 600mbar the voltage level is high Switches when the p...

Page 29: ... 4 20mA corresponds to saturation of 0 100 16 Temperature of the AquaSensor AS1000 The terminal is a current output with 4 20 mA for the external display of the AquaSensor AS 1000 4 20mA corresponds to 25 100 C Connecting the collecting canister float switch optional Connect the float switch of the collecting canister see page 25 in series with the safety switch of the drip tray Both switches are ...

Page 30: ... upper transformer connection 20 fully 3 Hold the suction hose 15 with a ball valve 5 in a container at least 10 liters 4 Open the manual ball valve 5 on the suction hose As soon as a constant flow rate of non aerated oil comes from the suction hose 15 close the ball valve 5 5 Perform further bleeding measures at the connection depending on the type or requirements e g careful opening of the faste...

Page 31: ...nch 6 Activate the automatic shut of valve 9 by pressing the button on the right of the filter housing to fill the degasification and dewatering unit 8 with oil 7 Release the valve 9 as soon as the unit is filled until about 1 cm of air remains 8 Install the air bleed screw Bleeding the return connection on the transformer Proceed as follows to bleed the return connection 1 When the return valve h...

Page 32: ...s sucked from the degasification and dewatering unit The level drops Stop the TCU switch off after approx 5 10 seconds and wait until the oil level starts to rise again and has reached a constant level Air bubbles become visible and rise to the surface of the oil 4 Restart the TCU Oil is pumped from the TCU into the return hose 4 Stop the TCU switch off as soon as a constant flow rate of deaerated...

Page 33: ...rted with a new delay time If the system stops after restarting this indicates a fault in the system See also Setting the time relay K1 on Page 35 and the Electronic pressure switch EDS 6 on Page 35 4 When the signal lamp goes out and the TCU is operational check the function of the safety switch 14 in the drip tray and of the optional float switch in the collecting canister To do so lift the swit...

Page 34: ...ple stopping pressure SP1 or the safety switch 14 in the safety drip tray are deactivated Monitor the system until the indicator lamp goes out 5 minutes Settings Setting the time relay K1 To adjust the time relay proceed as follows 1 Switch off the TCU at the main switch 17 and disconnect the TCU from the power supply 2 Open the electrical switch box 3 Use a suitable screwdriver to turn the adjust...

Page 35: ...display can be changed as follows Display of the maximum value TOP The highest pressure measured in the system since the unit was last switched on or reset is displayed permanently Display of the set switchpoint SP1 SP2 Depending on the variant switchpoint 1 or switchpoint 2 can be displayed permanently Display dark OFF The display is switched off Depending on the setting after the activation mess...

Page 36: ... short of The switch back point is always determined by the set hysteresis switch back point switchpoint minus hysteresis SP1 SP2 Switchpoint 1 or 2 HY1 HY2 Hysteresis 1 or 2 Alarm pressure SP2 Stop pressure SP1 We recommend the following for setting the alarm pressure and the stop pressure Alarm pressure SP2 The alarm pressure should be 20 above the currently displayed pressure upper pressure At ...

Page 37: ...n and the settings are saved 1 Actuate the mode button until the desired parameter is reached 2 Display SP1 Switchpoint 1 3 After 2 seconds the display switches to the current value of SP1 Switchpoint 1 Set the required value with the or button If the or is held down the value will automatically count on 4 If you do not actuate any button for 3 seconds the display will return to the indication of ...

Page 38: ...causes include strong electromagnetic interference or a defective component Check all of the settings programming enable switchpoints switch back points and basic settings and correct these if necessary Contact HYDAC if the error occurs repeatedly E 12 An error has been detected in the saved calibration data Possible causes include strong electromagnetic interference or a defective component Disco...

Page 39: ...ent with unchanged temperature or a change in the operating temperature The upper pressure shown is proportional to the overall gas content in the oil The overall gas content can be calculated approximately 0 3 using the following rule of thumb Overall gas content in OIL in Measured upper pressure mbar abs x 2 100 Example Pressure bar abs Days 110 mbar abs x 2 100 2 2 50 mbar abs x 2 100 1 HYDAC F...

Page 40: ...in the range of 0 100 as 4 20mA signal For this 0 would mean water free oil and 100 would mean oil that is completely saturated with water The AquaSensor absorbs water molecules from the fluid which leads to a change in the capacity of the sensor element The measured value received presents the saturation of the fluid as a percentage A thermocouple integrated on the AquaSensor measures the tempera...

Page 41: ... to the flask with the adapter 6 The flask and the hoses must be held vertically to prevent the ambient air mixing with the oil sample and the air flowing out upwards Hold the end of the hose into a collecting vessel 7 Turn the adapter a few times and allow the oil to flow into the flask 8 Let the oil bleed until the oil in the flask contains no bubbles To do so knock the hoses and flask repeatedl...

Page 42: ... lower pressure of the degasification and dewatering unit 6 Cycle time of the degasification and dewatering unit average of 5 cycles 12 7 Other transformer specific details 13 Send the sample to the following laboratory as quickly as possible with all information required 14 Västerås PetroleumKemi AB VPdiagnose Försegelvägen 2 723 48 Västerås SWEDEN Phone 46 21 17 22 30 Please note that cooling th...

Page 43: ...ity of dissolved gases can be assumed to be constant over time This status is never fully reached as the conditions such as the load and temperature change constantly The gas content has reached relatively low values so that the majority of the gases are removed by the TCU and accordingly only a negligible quantity escapes through the expansion vessel The time required to reach these balanced cond...

Page 44: ...uration Days Measured gas pressure mbar Gas withdrawal l 24 h Cycle time s The measured pressure upper pressure in the degasification and dewatering unit is proportional to the overall gas content in the oil and decreases correspondingly quickly As does the overall gas quantity removed Experience values for the withdrawn overall gas quantity l 24hours after the balanced status is reached for the a...

Page 45: ...tch at the same time Fill the gas sampling bag to approx 2 3 300ml The required filling time depends on the gas quantity withdrawn The following periods can serve as guideline values depending on the upper pressure in the vacuum colony Display of upper pressure Required filling time 50 mbar abs 12 h 100 mbar abs 40 min 130 mbar abs 30 min 200 mbar abs 25 min 5 200 mbar abs 20 min These are only gu...

Page 46: ...ntity of the respective gas in ml day and to determine the gas formation rate The values as ml day can be converted to ppm year via the oil quantity in the transformer and the number of days in a year If the DGA performed simultaneously reveals an increase in the gas it can be added to the gas formation rate determined The details can then be compared with typical gas formation rates e g to EN6059...

Page 47: ...s can be shown Gas formation rates as of the typical values guideline values per EN60599 Example of display of gas formation rates as of the typical values guideline values per EN60599 Checking the TCU Servicing Regular system checks and service consists of the following actions Periodical check up monthly Maintenance annual General overhaul HYDAC FILTER SYSTEMS GMBH en Page 47 64 BeWa TCU 3472805...

Page 48: ...ion and dewatering unit 3 Cycle time of the degasification and dewatering unit average of 5 cycles Maintenance annual Precautionary maintenance and checking of the unit should be done at least once a year and to the following extent 1 Check the degasification and dewatering unit for function see Page 49 2 Clean the check valve of the degasification and dewatering unit see Page 50 3 Replace the fil...

Page 49: ...ition Note the air movement when the rod moves down fully and then up again X The function is correct when the air only escapes from the hose The air flow is visible at an interval of 1 1 5 minutes depending on the pressure and temperature There is a malfunction if the air flows in both directions The reason for this is a leak in the check valve Clean the check valve as described in the instructio...

Page 50: ...ng point with the hose adapter in the lower section of the degasification and dewatering unit 1 Insert one A M3 x 50 mm screw included into the valve element A 2 Release the spring retainer 3 Push the spring retainer to one side 4 Remove the spring HYDAC FILTER SYSTEMS GMBH en Page 50 64 BeWa TCU 3472805b en 2011 07 05 doc 2011 07 05 ...

Page 51: ...surface of the valve element using a clean lint free cloth 7 Clean the valve seating in the lower section with a lint free cloth 8 Check that the O ring at the valve holder is securely held in place 9 Reverse the process to install the valve HYDAC FILTER SYSTEMS GMBH en Page 51 64 BeWa TCU 3472805b en 2011 07 05 doc 2011 07 05 ...

Page 52: ...lay moves from the green to the red zone at 0 4 bar A check up should be performed when filling the degasification and dewatering unit Designation HYDAC item no Replacement filter element 3 µm 6083022 To change the filter element proceed as follows 1 When the oil level in the degasification and dewatering unit reaches fill level close the ball valve 5 at the inlet of the TCU 2 Switch the TCU off a...

Page 53: ...to the filter element Fit the filter cover 8 Insert the four screws for the filter cover manually and tighten them to a torque of 7 Nm 9 Open the bleed screw slightly 10 Open the ball valve 5 at the inlet of the TCU 11 Activate the automatic shut off valve 9 until oil escapes via the bleed screw The system has now been bled 12 Tighten the bleed screw 13 The filter element change is now complete HY...

Page 54: ...ave expired after starting the TCU the system must deactivate automatically 3 Do not switch off the system by lifting the safety switch 14 check the settings on the time relay K1 See chapter Setting the time relay K1 4 Restart the TCU To do so switch the main switch on and off General overhaul The TCU is developed for continuous operation for years We recommend a general overhaul as preventive mai...

Page 55: ... is probable that gas formation in the transformer has increased significantly or for example the membrane in the expansion vessel leaks in a sealed transformer If the alarm level is reached after a longer TCU downtime this is due to a natural increase in the gas content To stop the alarm change the setting for the alarm pressure SP2 in the EDS as described in Page 36 Note down the set alarm press...

Page 56: ...ollecting container see Page 25 note the date of draining and the oil quantity in the notebook If more than 6 liters of oil is used per year please contact HYDAC to discuss possible measures 2 After the system restarts check the actual pressure at the higher oil level in the degasification and dewatering unit upper pressure After 5 minutes of operation the pressure must be lower than the stop pres...

Page 57: ...auge suitable for the pressure range from 0 30 bar to the test port 3 Check the pressure behind the differential pressure relief valve 7 The differential pressure relief valve is factory set to 18 bar If the pressure gauge shows 18 bar the test is positive Remove the pressure gauge and screw the dust cap back onto the test port If the pressure gauge shows 18 bar you must set the differential press...

Page 58: ... black lid on the differential pressure relief valve 2 Undo the counternut B with a size 19 screw wrench 3 Set the required pressure of 18 bar on the setscrew A using a screwdriver 4 Tighten the counternut B holding the setscrew A in the correct position 5 Replace the black lid onto the differential pressure relief valve HYDAC FILTER SYSTEMS GMBH en Page 58 64 BeWa TCU 3472805b en 2011 07 05 doc 2...

Page 59: ...easuring hose at the front on the block of the degasification and dewatering unit 5 Hold a suitable vessel with a capacity of at least 2 liters under the connection and remove the measuring hose 6 The degasification and dewatering unit is still under vacuum pressure which is why only a little oil drips from the connection nozzle in the block 7 Open the bleed nozzle in the head of the degasificatio...

Page 60: ...Disposing of the TCU On decommissioning and or disposal of the TCU observe all local directives and requirements for occupational health and safety and protection of the environment This applies in particular to the oil contained in the unit to components coated in oil and to electronic components After disassembling the unit and separating the various materials reuse them or dispose of them prope...

Page 61: ...r element 3 µm see Page 52 1 6083022 Spring for filter element see Page 52 only if the spring for the system goes missing 1 600 9 14 3 Collecting canister 25 liters for TCU see Page 25 1 3534977 Glass flask for DGA sampling see Page 41 1 3561424 Gas sampling bag for TCU to determine the gas formation rate see Page 43 1 3568340 Adapter hose to attach the gas sampling bag see Page 43 1 3572270 ...

Page 62: ... Flow rate 50Hz For continuous operation 15 m per week Filtration rating 3 µm absolute Permitted pressure at the TCU suction connection 0 1 0 5bar Storage temperature range 20 40 C Ambient temperature range 35 50 C Fluid temperature 90 C maximum Viscosity range 5 300 mm s IP class IP55 Sealing material NBR Customer Service For repair work please use the follow shipping address HYDAC Service GmbH R...

Page 63: ...Notes ...

Page 64: ...iet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 0 6897 509 01 Central Fax 49 0 6897 509 846 Technical Department Fax 49 0 6897 509 577 Sales Department Internet www hydac com E Mail filtersystems hydac com ...

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