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HYDROCAL 1005 Manual for Installation and Operation

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These values can be used. The new values are stored and activated by the button

„Store and

exit“. For the following measured values the new correction factor will then be used.

4.9.1.1

Hot Spot calculation

HYDROCAL1005 can calculate the Hot-Spot temperature. For this calculation, it is important to know
that system needs external sensor references. These references are: minimum one of Load Current,
Top oil Temperature as well as Cooling Stage (this last reference is not necessary required but can
improve the calculation). The references have to be set up as external sensors.

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Summary of Contents for HYDROCAL1005

Page 1: ...HYDROCAL 1005 Manual for Installation and Operation Edition 01 2011 HYDROCAL1005 Gas in Oil Analysis System with Transformer Monitoring Functions Manual for installation and operation ...

Page 2: ...pment AG All rights reserved The contents of this manual are subject to change without notice All efforts have been made to ensure the accuracy of this publication but MTE Meter Test Equipment AG can assume no responsibility for any errors Customs tariff number or their consequences 9027 1010 ...

Page 3: ...ment cycle 25 4 3 2 Depression 26 4 3 2 1 Safety function and error observation for depression cycle 26 4 3 3 Leak detection 27 4 3 3 1 Safety function and error observation for leak detection cycle 27 4 3 4 Filling to level 1 28 4 3 4 1 Safety function and error observation for filling to level 1 cycle 28 4 3 5 Degassing 29 4 3 5 1 Safety function and error observation for degassing cycle 29 4 3 ...

Page 4: ...guration of the communication 55 4 9 5 5 Ethernet setup 56 4 9 5 6 Alert SMS setup 57 4 9 5 7 Internal modem setup 58 4 9 5 8 RS 232 RS 485 setup 59 4 9 5 9 MODBUS 66 5 Windows Software HydroSoft 76 5 1 Purpose of the program 76 5 2 Remarks for use of this operation handbook 76 5 3 Requirements to the PC 76 5 4 Installation 77 5 4 1 Microsoft NET NET Framework 1 1 Redistributable 77 5 4 2 Microsof...

Page 5: ...range selection 98 5 13 3 Alarm window 99 5 13 4 Status of alarms 99 5 13 5 Print and export of results 99 5 14 Online Sensors 100 6 RS 485 Wiring 101 7 HYDROSOFT Scheduler 102 7 1 General 102 7 2 Scheduler 102 7 2 1 Configuring a Transformer for automatic History Data Update 102 7 2 1 1 Connection Scheduler Dialog 103 7 2 2 Scheduler Status Visualization 103 7 2 2 1 Status Icons 103 7 2 2 2 Trans...

Page 6: ...s further equipped with digital outputs for the transmission of alarms or the execution of control functions e g control of a cooling system of a transformer 5 digital relay outputs 5 digital opto coupler outputs Option Key Advantages Hydrogen H2 Carbon monoxide CO acetylene C2H2 and ethylene C2H4 measurement Moisture in oil measurement Communication interfaces ETHERNET 10 100 Mbit s copper wired ...

Page 7: ...rculation pump Remark Choose this place only in case of continuous oil flux through the cooler Pos 2 Flange below on the transformer tank The flange must be at minimum height of 40 cm in order to allow installation and mounting of HYDROCAL1005 unit Pos 3 Upper filling valve It is possible to mount the Hydrocal 1005 unit on this position if the filling level of the oil is min 100 cm higher than the...

Page 8: ... hydrocarbon contents near the meas uring sensor Never clean the measuring head with solvents because its gases will strongly impair the measuring accuracy and the sensitivity of the sensors Never apply a negative pressure to the measuring head Negative pressure can cause problem during filling process Remove the HYDROCAL1005 unit from the valve every time you degas or refill the transformer You c...

Page 9: ...ng values Never clean the HYDROCAL1005 unit with high pressure cleaning equipment High pressure cleaning equipment used to clean transformers can seriously damage the HYDROCAL1005 unit Never use a chaining key tool for mounting Use of such tools can damage the surface of the measuring head and the threads Please use an adjustable thin spanner for 1 Attention Faulty or inappropriate handling of the...

Page 10: ...yers must be ap plied or an O Ring must be used 2 4 Installation of the HYDROCAL1005 unit Attention Mount the unit horizontally on the valve The aeration screw must be in the 12 o clock position Please mount the HYDROCAL1005 unit on a valve with full opening full bore valve or a ball valve with an internal thread of 1 DIN ISO 228 G 1 The HYDROCAL unit has a 1 thread Di mensional drawings see chapt...

Page 11: ...on point with o ring wind 4 to 5 layers of Teflon band on the Hydrocal 1005 connection thread and mount it either directly into the valve or into an additional adapter If you use an adapter it should be mounted to the valve before the Hy drocal 1005 will be mounted to the adapter Wind 4 to 5 layers of Teflon band on the thread of the adapter and mount it into the valve Make sure that everything is...

Page 12: ...ransformer Use a bucket to catch oil coming out as described on following drawing Unscrew the aeration screw 3 4 turns with Allen key No 4 Aeration is active Open the valve slowly until oil comes of the sample tube As soon as no air bubbles sort on the sample tube close the aeration screw Then fully open the valve Remove the oil from the measuring head externally Do not use any solvents for cleani...

Page 13: ... Phase 230VAC 20 2 Neutral 3 Protection Earth Wire 1 5mm2 If optional GSM Modem is used GSM antenna must be connected to Hydrocal as above draw ing Recommendations for alarm and external sensor cables Cable Specification or equivalent Type e g Ölflex FD855CP Cable 13 3mm of external cable Wire 0 5mm 2 of 16 intern wires Connect the power supply to the HYDROCAL1005 unit The display shows the specif...

Page 14: ...e date as well as clock MOUNT BUTTON The Hydrocal is currently not installed After the mount button is activated the Detect Cycle will start DETECT SCREEN The Hydrocal filled up to level 1 A circulation is made to remove air from the system Finally system is drained to level 0 UNMOUNT BUTTON The Hydrocal is installed in normal operation Currently Sync Wait The selected Button is the unmount button...

Page 15: ...ng cycle of the HYDROCAL1005 unit is synchronized on the hour mark this means the first measuring value is available approx 2 22 or 42 min after the hour mark and can be read on the display After first start up in all cases date and time have to be checked on the HYDROCAL1005 display and eventually have to be adjusted manually in clock settings chapter 3 7 5 2 or with HydroSoft chapter 4 10 7 ...

Page 16: ... of the HYDROCAL1005 unit the following operating elements are available 1 LCD display with 240 x 320 pixels 2 Screw mounting to mount the cover 3 Alphanumeric keyboard to enter numbers and text 4 Arrow buttons to move in the menus for data input and contrast set up from the main display Up an Down 5 Enter button to confirm and stop functions and data ...

Page 17: ...HYDROCAL 1005 Manual for Installation and Operation Page 15 111 3 2 Rear side of HYDROCAL1005 unit 1 Measuring sensor with an internal thread of 1 DIN ISO 228 G 1 or optionally NPT 1 ...

Page 18: ...VACmax Optional 88 VDCmin 390 VDCmax max 350 VA 50 60 Hz Then power supply must be connected as follow o Brown L o Blue N o Green yellow PE 3 System outlet for digital and analogue inputs and outputs Communication outlet for communication via analogue or GSM GPRS modem 4 ETHERNET connector 5 Gas Air Outlet ...

Page 19: ...HYDROCAL 1005 Manual for Installation and Operation Page 17 111 3 3 Connections on the measuring and controller card 1 Connector ST13 4 x Valve Control Connection for valve control ...

Page 20: ...ow control 4 Connector ST3 Humidity Temperature Connection for humidity temperature control 5 Connector KL1 Power supply Note The connection 5 is connected to a filter module from where the connection to the power supply 88 VACmin 276 VACmax and PE is made As showed on picture on the left side usually you just need to connect cables to the main power supply connector Brown L Blue N Green yellow PE...

Page 21: ...Analogue Outputs 4 20 mADC X8 1 Analogue output 1 X8 2 Analogue output 1 X8 3 Analogue output 2 X8 4 Analogue output 2 X8 5 Analogue output 3 X8 6 Analogue output 3 X8 7 Analogue output 4 X8 8 Analogue output 4 X8 9 Analogue output 5 X8 10 Analogue output 5 9 Connector KL402 Relay Outputs 12 VDC 220 VDC VAC 2 A 60 W X9 1 Relay output 1 X9 2 Relay output 1 X9 3 Relay output 2 X9 4 Relay output 2 X9...

Page 22: ...or KL101 Analogue DC Inputs in Option 0 4 20 mA X11 1 Analogue DC input 1 X11 2 Analogue DC input 1 X11 3 Analogue DC input 2 X11 4 Analogue DC input 2 X11 5 Analogue DC input 3 X11 6 Analogue DC input 3 X11 7 Analogue DC input 4 X11 8 Analogue DC input 4 12 Connector KL301 Opto coupler output in Option 5 VDC UCE 4 V UEC 7 V UCE 40 mA X12 1 Opto coupler output 1 X12 2 Opto coupler output 1 X12 3 O...

Page 23: ...stallation and Operation Page 21 111 14 ETHERNET connector Copper wired or Fibre optical These sockets are connected with the back plane It means that normally only con nection on back plane is needed 15 Measuring cell connector ...

Page 24: ...citive Sensor FI Level 1 3 Capacitive Sensor FII Level 2 4 Valve V6 Safety 5 Flow meter Flow IN OUT 6 Valve V1 Filling Circulation Draining 7 Valve V3 Vacuum Generation Ventilation 8 Compressor K1 9 Valve V4 Pressure Ventilation 10 Valve V2 Oil chamber Connection Gas Chamber Measuring Cell 11 Pump P1 12 Bypass Valve Pump V5 13 Oil separator ...

Page 25: ...HYDROCAL 1005 Manual for Installation and Operation Page 23 111 ...

Page 26: ...r nal sensors the storage capacity depends on the number of sensors and the time interval selected for storage The following formula can be used to determine the storage capacity in the example 64 Mbyte is used 12 1 20 1 288 23000 2 64 n n Std ages Sensorstor day Byte day Byte Byte days h Memorydept With one additional sensor with a time interval of 5 minutes the following calculation results days...

Page 27: ...ews and any oil air leakages have appeared Check that cables and all pins of the plug go straight into their socket pushing the plug in carefully 4 3 1 Zero measurement Step No Status of the components 1 Capacitive Sensor F0 not active 2 Capacitive Sensor FI not active 3 Capacitive Sensor FII not active 4 Valve V6 closed 5 Flow meter not active 6 Valve V1 circulating 7 Valve V3 closed 8 Compressor...

Page 28: ...Sensor FII not active 4 Valve V6 closed 5 Flow meter not active 6 Valve V1 circulating 7 Valve V3 open 8 Compressor K1 active 9 Valve V4 closed 10 Valve V2 closed 11 Pump P1 not active 12 Valve V5 open 4 3 2 1 Safety function and error observation for depression cycle Observed Components Detectable Errors Filling Sensor 0 1 2 Operating in normal parameters Measurement chamber Measurement chamber o...

Page 29: ...3 Capacitive Sensor FII not active 4 Valve V6 closed 5 Flow meter not active 6 Valve V1 draining filling 7 Valve V3 closed 8 Compressor K1 not active 9 Valve V4 closed 10 Valve V2 open 11 Pump P1 not active 12 Valve V5 open 4 3 3 1 Safety function and error observation for leak detection cycle Observed Components Detectable Errors Filling Sensor 0 1 2 Operating in normal parameters Measurement cha...

Page 30: ...closed 8 Compressor K1 not active 9 Valve V4 closed 10 Valve V2 open 11 Pump P1 not active 12 Valve V5 open 4 3 4 1 Safety function and error observation for filling to level 1 cycle Observed Components Detectable Errors Filling Sensor 0 1 2 Operating in normal parameters Filling Sensor 0 1 Flow meter Timer Filling level 1 lost Filling stopped Filling timeout Measurement chamber Measurement chambe...

Page 31: ...g filling 7 Valve V3 closed 8 Compressor K1 not active 9 Valve V4 closed 10 Valve V2 closed 11 Pump P1 active 12 Valve V5 closed 4 3 5 1 Safety function and error observation for degassing cycle Observed Components Detectable Errors Filling Sensor 0 1 2 Operating in normal parameters Filling Sensor 0 1 Flow meter Filling level 1 lost Filling stopped Measurement chamber Measurement chamber offline ...

Page 32: ...illing 7 Valve V3 closed 8 Compressor K1 not active 9 Valve V4 closed 10 Valve V2 open 11 Pump P1 not active 12 Valve V5 open 4 3 6 1 Safety function and error observation for filling to level 2 cycle Observed Components Detectable Errors Filling Sensor 0 1 2 Operating in normal parameters Filling Sensor 0 1 2 Flow meter Timer Flow Stuck Flow leak Level Timeout Avoid flooding meas chamber Measurem...

Page 33: ... active 4 Valve V6 closed 5 Flow meter not active 6 Valve V1 circulating 7 Valve V3 closed 8 Compressor K1 not active 9 Valve V4 closed 10 Valve V2 closed 11 Pump P1 not active 12 Valve V5 open 4 3 7 1 Safety function and error observation for measurement cycle Observed Components Detectable Errors Filling Sensor 0 1 2 Operating in normal parameters Measurement chamber Measurement chamber offline ...

Page 34: ...alve V6 closed 5 Flow meter not active 6 Valve V1 circulating 7 Valve V3 open 8 Compressor K1 active 9 Valve V4 open 10 Valve V2 closed 11 Pump P1 not active 12 Valve V5 open 4 3 8 1 Safety function and error observation for flushing cycle Observed Components Detectable Errors Filling Sensor 0 1 2 Operating in normal parameters Measurement Chamber Measurement Chamber offline Pressure Sensor No dep...

Page 35: ...ning filling 7 Valve V3 open 8 Compressor K1 active 9 Valve V4 open 10 Valve V2 open 11 Pump P1 active 12 Valve V5 closed 4 3 9 1 Safety function and error observation for draining cycle Observed Components Detectable Errors Filling Sensor 0 1 2 Operating with normal parameters Filling Sensor 0 1 2 Flowmeter Timer Flow Stuck Flow leak Level Timeout Avoid transformer aeration Measurement chamber Me...

Page 36: ... FII not active 4 Valve V6 closed 5 Flow meter not active 6 Valve V1 circulating 7 Valve V3 closed 8 Compressor K1 not active 9 Valve V4 closed 10 Valve V2 closed 11 Pump P1 active 12 Valve V5 open 4 3 10 1 Safety function and error observation for wait cycle Observed Components Detectable Errors Filling Sensor 0 1 2 Operating in normal parameters Measurement chamber Measurement chamber offline ...

Page 37: ...e and remove carefully the housing The unit can then be operated by the keyboard as shown below Following the description of functions of the keyboard Moves the cursor horizontally Enter button Selection of active menus or submenus Moves the cursor in the tables and contrast set up from the main display Alphanumerical input of customer specific data 4 4 1 Contrast Set up Contrast of HYDROCAL1005 d...

Page 38: ...every 5 seconds can be also changed in setup menu to these measuring values In the main menu the following sub menus can be activated Extraction status menu Gas in oil menu Alarm menu history of alarms Configuration menu Transformer menu not yet available External sensor menu Remark From the main display under Customer Station Transformer and Comment data you find Serial Number of the unit For exa...

Page 39: ... oil are shown The values for H2 C2H2 C2H4 CO and H2O indicate their actual meas urement values of the total gas content I e as shown below 30ppm is H2 131ppm is C2H2 46ppm is C2H4 308ppm is CO and 0 0ppm is H2O The following values are available Hydrogen acetylene ethylene Carbon monoxide Moisture Temperatures 1 Temperature in sensor area measure cell 2 Temperature of oil 4 7 1 Graphic display Af...

Page 40: ...ion of 8 hours page Go to table presentation Exit 4 7 2 Table presentation After selection of presentation in form of a table the measured values are shown with time and cur rent record number The most recent measured value is on top of the table The following functions for tables are available Scroll up one line Scroll up one page Scroll down one page Scroll down one line Scroll one page up down ...

Page 41: ...fined Level 2 for a High High Alarm has been exceeded in past The value has fallen below the limit at the time indicated however it is still over the limit of Level 1 High Alarm inactive Symbol The defined level for a High Alarm has been exceeded in the past The value has fallen below the limit at the time indicated High High Alarm active Symbol The defined level for a High High Alarm has been exc...

Page 42: ...made the system asks for the password Default pass word is 999 After input of password by the alphanumeric keyboard and confirmation with enter button the device setup menu is opened The following configurations can be modified Transformer data e g allocation of sensors to algorithms for calculation of life ex pectancy and input of correction factors Configuration of Analogue outputs Configuration...

Page 43: ...ion factor Results of laboratory analysis can be introduced in this menu These can be used for calculation of correction factors for definition of the gas content By operation of the arrow keys the different fields can be chosen For the input of results of laboratory analysis first the date of analysis should be entered in the field Sample Date Then the average value of gas concentration is calcul...

Page 44: ...or will then be used 4 9 1 1 Hot Spot calculation HYDROCAL1005 can calculate the Hot Spot temperature For this calculation it is important to know that system needs external sensor references These references are minimum one of Load Current Top oil Temperature as well as Cooling Stage this last reference is not necessary required but can improve the calculation The references have to be set up as ...

Page 45: ...A Virtual Hot Spot Temperature sensor must exist See chapter 4 9 3 For Cooling Stage you can select between Cooling Stage Ageing rate Loss of Life and None Remark A Cooling Stage external sensor must exist A Virtual Ageing rate sensor must exist A Virtual Loss of Life sensor must exist See chapter 4 9 3 If necessary you have to define previously external sensor references as analogue input while p...

Page 46: ...g Stage 3 please apply exactly the same procedure in order to setup required information 4 9 1 2 Ageing Rate Loss of Life After selection of the Ageing Rate Loss of Life submenu following screen will be displayed By operation of the arrow keys the different fields can be chosen First of all you must define each field with required information Followings information must be entered Kind of Insulati...

Page 47: ...tities are available in Sensor field H2 C2H2 C2H4 CO H2O concentration H2 C2H2 C2H4 CO H2O Daily trend H2 C2H2 C2H4 CO H2O Weekly trend Temperature 1 Temperature 2 All quantities variables defined under external sensors The following analog outputs signals are available in the field Mode OFF 0 20 mA 4 20 mA TEST Allow simulating an output signal between 0 and 20 mA The following values can be de f...

Page 48: ... 10 input numbers are assigned to the analogue in puts 1 6 bushing 7 10 external sensors and 11 14 virtual sensors The following functions are available Scroll up marking Scroll down marking Scroll up down marking Enter button selection of active menus or submenus Exit As soon as an input is selected and made available for configuration the following functions are available Scroll up down Enter bu...

Page 49: ...e alphanumeric keyboard The sample interval is made in seconds or by a button in days hours min seconds For minus the button and for a double point the button are used After confirmation by the button the value will be converted and displayed in days hours min seconds For conversion of input units the inputs Minimum Value are made under the input signals 0V 0 mA or 4 mA and Maximum Value are made ...

Page 50: ...ilities to setup Alarms Alarms can be triggered either by internal gas or temperature sensors or by external sensors Configuration of alarms is shown on the following pictures First a quantity variable must be selected For this choice the following functions are available Configuration of SMS transmitting functionality Scroll up marking Scroll down marking Scroll up down marking Select setting for...

Page 51: ... alarm is triggered below Level 2 when the measured value falls below the limit defined in Level 2 Low high An alarm in 2 steps is triggered Step 1 is triggered when the measured value falls be low the limit defined in Level 1 the second alarm is triggered after exceeding Level 2 Range An alarm is triggered when the measured value is between the limits defined in Levels 1 and 2 The alarm limits ar...

Page 52: ... be confirmed see history of alarms and an output is switched on If the measured value exceeded the limits in the field Level 1 2 The status on described above is activated If the measured value for this output falls under the limit the output remains switched on Only a manual deleting of alarm allows that the output is switched off again see chapter 5 11 or 4 6 Log SMS An entry in the history of ...

Page 53: ...If the measured value for this output falls under the limit the output remains switched on Only a manual deleting of alarm allows that the output is switched off again see chapter 4 11 or 3 6 In addition an SMS is sent to the number indicated If it is possible to use the same output for different alarms and therefore collection alarms can be defined 4 9 5 Unit Setup The following setup can be modi...

Page 54: ...Name and Password String and Numeric Password are made in the following menu The following functions are available for Display Backlight Timeout Scroll up down marking Enter button selection of active menus or submenus Store the configuration and exit Exit Input of delay time is made in seconds or by a button in days hours min seconds For minus the button and for a double point the buttons are use...

Page 55: ...ou have followings possibili ties Standard means that your Main Display will switched every 5 seconds Slow means that your Main Display will switch every 15 seconds Very Slow means that your Main display will switch every 25 seconds These amendments are stored by selection of button or are rejected by selection of the 4 9 5 2 1 Configuration of user settings By operation of the arrow keys the diff...

Page 56: ...l up down marking Enter button selection of active menus or submenus Store the configuration and exit Exit Input of time in the field System Time is made in hours minutes seconds For a double point used the button Input of date in the field System Date is made in year month days For minus the button is used ...

Page 57: ...ted The setting None is recommended Input of time mode in the field Daylight Saving Time Mode is made by button MET Middle European Time adjusts the official local time forward one hour from its official standard time for the duration of the spring and summer months NONE means that the function is not activated These amendments are stored by selection of button or are rejected by selection of the ...

Page 58: ...amic integration via DHCP The network administrator will have given the information that the devices in the network will be automatically configured by DHCP Static setup The network administrator has to deliver the following information that will be entered into the corre sponding fields in the Hydrocal network screen IP address Network mask Default gateway TCP Port Number The TCP Port Number may ...

Page 59: ...nd the alarm SMS in to five different recipients The different telephone numbers can be entered into the fields Recipient 1 5 The telephone number can be en tered by alphanumeric keyboard A message in the field Message can also be pre write in order to be sent to the recipient in the event of alarms The Following abbreviations can be used Serial Number means that in the event of alarms you will re...

Page 60: ... Note The SMS mode in Alarm set up must be selected to use this function Moreover GSM mo dem must be also installed on HYDROCAL1005 These amendments are stored by selection of button or are rejected by selection of the 4 9 5 7 Internal modem setup The modem configuration is made in the following menu if HYDROCAL1005 is equipped within an on board GSM or Analogue modem The following functions are a...

Page 61: ...g before answer in the field No of RINGs be fore Answer is made by button Input of Timeout in the field Idle Hang Up Timeout s is made in hours minutes sec onds For a double point used the button Input of Pin code in the field PIN is made by button Pin code can be modified by the alphanu meric keyboard and the arrow keys If no PIN code is necessary to use the SIM card the input field can be left e...

Page 62: ...HYDROCAL devices via RS485 bus using a HYDROCAL bridge Bridge SCADA System with online monitoring of one or more HYDROCAL devices MODBUS General The RS232 interface is only available for Service puposes and a special cable adapter is necessary The following sections describe how to configure the HYDROCAL devices and the HydroSoft soft ware After a short description screen shots of HYDROCAL and Hyd...

Page 63: ...hat the correct COM port is chosen in HydroSoft Also check the RS485 checkbox to indicate the half duplex connection A RS485 adapter might require some special setup of the other checkboxes ART The Hydrocal 1005 hardware is able to support a special kind of automatic receive transmit control ART When the corresponding checkbox in the RS232 485 setup screen is active the RS485 lines are activated i...

Page 64: ...cessary to set up some answer delay in the HYDROCAL device If everything is configured right and still the communication does not work this may be due to problems with the send receive control If the adapter does not release the transmitter quick enough the answer of the HYDROCAL may be damaged and thus unrecognized II Modem The modem allows a remote connection using the phone network From a commu...

Page 65: ... host connected via the TCP IP adapter is only present to show an alternate way to connect to the RS485 bus as it is offered by third party network to serial bridges HydroCal HydroSoft On HYDROCAL device Configure the device as Bus Node Set an unique address for each device on the RS485 bus 1 254 Note Communication with HYDROCAL1002 1003 can be made right now with up to 32 units Setup Answer Delay...

Page 66: ...to access a range of HYDROCAL devices on a RS485 bus In this setup the host PC is not directly connected to the RS485 bus but is using one of the HY DROCAL devices as communication gateway The bridge functionality can be used for an RS232 or Modem primary connection as indicated by the illustration below The setup of all HYDROCAL devices must be according to a standard RS485 bus setup with one exc...

Page 67: ... be activated if the primary connection uses the modem The corre sponding setup for the HYDROCAL and HydroSoft must be carried out as already described in the point to point section and is not repeated here see 0 II RS485 Bus Setup HydroCal HydroSoft On HYDROCAL device Configure the device as Bus Node Set an unique address for each device on the RS485 bus 1 254 Note Communication with HYDROCAL1005...

Page 68: ... integrated into a SCADA System for online monitoring the MODBUS communication setup might be applicable MODBUS is currently not supported by Hy droSoft but the setup is shown here for completeness As a reference example the setup of an ADAM 4572 1 port Modbus to Ethernet Data Gateway by Advantech www advantech com is shown below HydroCal HydroSoft ...

Page 69: ...with HYDROCAL1005 can be made right now with up to 32 units Baud rate Data Bits Parity and Stop Bits These toggle buttons allow adjusting the coding format of the serial interface for MODBUS protocol Remarks o Change of the transmission mode does not set the coding format parameters to the default values for the selected mode RTU 19200 8 E 1 ASCII 19200 7 E 1 The right configuration has to be conf...

Page 70: ...3E8 1029 405 31001 31030 Sensor value Sensor 1 Sensor 30 The sensor assignment is given below the map ping tables The sensor value is transmitted as a signed inte ger Prior to transmission the real reading is mul tiplied by 10 to have a 1 digit precision So to get the real measurement the returned value must be divided by 10 An open sensor input is returned as 32768 0x8000 0x04 Read Input Register...

Page 71: ...ty there are 2 registers that may be modified freely The reset initializa tion values of the registers are 0xA5A5 and 0x5A5A 0x06 Write Single Register 1000 41001 Confirmation Reset of alerts Alert status 16 1 The alerts are coded as a bit field and are pre sented as a single MODBUS register alert 16 0x8000 alert 1 0x0001 By writing a 0 Bit at the corresponding position a probably active alert can...

Page 72: ... 30 virtual sensors hot spot ageing rate etc MODBUS Serial Communication Examples This chapter describes working test setups for MODBUS communication The following hardware and applications were used to test the MODBUS communication with HYDROCAL Both test applica tion are free for download The hardware is not the only hardware that is working with HYDROCAL The devices are just an example Applicat...

Page 73: ...cal Connection HYDROCAL and QuickMod Connection Setup HYDROCAL can be set up without any answer delay due to full duplex on RS232 RS232 only available for service purposes The timeout for Quickmod can be short The answer of HYDROCAL is received within less than 50 ms see QuickMod Monitor screen shot below HYDROCAL and QuickMod Data Screens The QuickMod Tag field must be filled with the address 101...

Page 74: ... for service purposes was executed using the Modpoll application Connection setup and results are shown below Physical Connection HYDROCAL Setup and Data Screen Dump HYDROCAL can be set up without any answer delay due to full duplex on RS232 Modpoll Result Screen Dump The Modpoll utility expects the start reference to be set to the register 1017 to query the HY DROCAL external sensors 1 8 address ...

Page 75: ...l The terminals pairs T R and T R are short connected terminal block con nectors 1 4 2 3 The RS232 to RS485 adapter is configured to use RTS send receive control SW2 in middle po sition to TxRTS RxRTS with the underlined text indicating that the signal in not active HYDROCAL and QuickMod Connection Setup HYDROCAL is set up with an answer delay of 100 ms to give enough time for QuickMod to toggle t...

Page 76: ... using Modpoll This test of HYDROCALMODBUS RTU on RS485 bus was executed using the Modpoll application and the ADAM 4572 Ethernet Data Gateway It demonstrates the ability to connect multiple HY DROCAL devices to an RS485 bus Connection setup and results are shown below Physical Connection RS485 Bus Topology ...

Page 77: ...s set up without an answer delay Each HYDROCAL on the bus has its own unique address 90 93 0 reserved for the bus master The timeout for ADAM 4572 can be short The answer of HYDROCAL is received within less than 100 ms and the ADAM 4572 uses ART that does not require additional delay Modpoll Result Screen Dump partial ...

Page 78: ...logue inputs of HYDROCAL1005 unit Configuration of alarms and respective alarm outputs of HYDROCAL1005 5 2 Remarks for use of this operation handbook The following operation handbook explains in details the installation and operation of HydroSoft on your PC It contains the following sections Program Installation and Start up Program functions General rules for use as transformer monitoring system ...

Page 79: ...stallation the program HydroSoft can be started Should the installation program not be executed and ended not all components will be installed The miss ing components will have to be installed manually chapter 4 41 and 4 42 Please act as described following First install the NET Framework 1 1 5 4 1 Microsoft NET NET Framework 1 1 Redistributable Install Microsoft NET Framework 1 1 Redistributable ...

Page 80: ...with the HYDROCAL1005 unit The main functions of the program are Reading of data from HYDROCAL1005 The data can be read out through the interface RS 485 Ethernet or from a modem integrated in the HYDROCAL1005 unit option Processing and presentation of measuring data data can be presented in form of trend graphics or tables history see chapter 4 12 Tables can be exported to MS Excel Graphs can be p...

Page 81: ...ustomer being at the top Within a customer transformer stations are defined and within a transformer stations transformers followed by HY DROCAL1005 s are defined See below A customer list is opened automatically by the program It can be renamed there are two possibili ties Either by the menu shown when pressing the right mouse button Or by File Customer Rename ...

Page 82: ... transformer station the address of the station can be entered By dou ble clicking on one of the four Property fields address data can be inputted 5 9 Opening a file for a new transformer To open a new transformer file an existing transformer station must be selected Then similarly as a transformer station a new transformer element can be opened and please select which HYDROCAL version you are usi...

Page 83: ...end charts or tables see chapter 5 12 Alarms Status of alarms are presented in form of trend charts and tables Alarms can also be acknowledged see chapter 4 12 Connection Communication Settings can be defined see chapter 4 9 1 and 5 9 2 Online Sensors A direct online visualisation of the measuring data can be made HYDROCAL1005 settings plus alarms and external sensors can be configured see chapter...

Page 84: ...nder these circum stances a waiting time of 5 minutes is recommended before re sending of data This time is required to restart the modem in the HYDROCAL1005 and to make a new connection to the GSM network 5 9 2 RS232 interface settings For local communication over an RS232 interface the interface number of the PC must be selected Transmitting speed is 19200 Baud this must be entered into the fiel...

Page 85: ...sidered Lower sensor temperatures are possible during severe frosts or when transformers are switched off Under certain circumstances temperatures higher than 60 C can exist with very hot oil in the transformer without being a problem of the heating circuit In such a case the measuring result can have additional error deviations A total 16 alarms can be defined on the HYDROCAL1005 unit If several ...

Page 86: ...lert Mode Following modes are available High An alarm is triggered when Level 1 is exceeded High High An alarm in two steps is triggered The 1 st alarm is triggered when Level 1 is ex ceeded the 2nd alarm is triggered after exceeding Level 2 Low An alarm is triggered when a value falls below the limit defined in Level 1 Low Low An alarm in two steps is triggered Step 1 is alarm is triggered when t...

Page 87: ...easured value exceeded the configured limits in the field Level 1 2 The status on described above is activated If the measured value falls under the limit the output is switched off again Out hold An entry in the history of alarms is made this has to be confirmed see history of alarms and an output is switched on If the measured value exceeded the configured limits in the field Level 1 2 The statu...

Page 88: ...t six inputs Free analog 1 to Free analog 6 according to options purchased the following must be chosen With option Bushing input 0 20mA AC Bush In or 0 100V AC Bush In With option Current input External Sensors 0 20mA anal In or 4 20mA anal In For the next four inputs Free analog 7 to Free analog 10 according to options purchased the following must be chosen With option Current input External Sen...

Page 89: ... modification of sensor settings The star indi cates that modifications have been made these must be transferred to the HYDROCAL1005 unit for activation This means the settings indicated are not identical to those of HYDROCAL1005 With next connection it is requested whether the settings on HYDROCAL1005 unit shall be updated see chapter 5 11 5 10 3 Alert SMS Setup In the menu the configuration of t...

Page 90: ...eive a SMS with Time of alarm which has been exceeded with following format hh mm D Long Date Means that in the event of alarms you will receive a SMS with Date of alarm which has been exceeded with following format YYYY MM DD d Short Date Means that in the event of alarms you will receive a SMS with Date of alarm which has been exceeded with following format YY MM DD A Alert Name means that in th...

Page 91: ...presented After the results of laboratory analysis have been introduced in the fields Laboratory Value for H2 C2H2 C2H4 CO CO2 C2H6 and CH4 the button is activated and the new correction factor are calcu lated and displayed in the field New Offset These values can be used or can be manually adjusted The new values are stored and activated by button Data in the tree are changed after modification o...

Page 92: ...CO H2O Daily trend H2 C2H2 C2H4 CO H2O Weekly trend Temperature 1 Temperature 2 All quantities variables defined under external sensors The following analog outputs signals are available in the field Mode OFF 0 20 mA 4 20 mA Data in the tree are changed after modification of sensor settings and validation with The star indicates that modifications have been made these must be transferred to the HY...

Page 93: ...European Time adjusts the official local time forward one hour from its official standard time for the duration of the spring and summer months NONE means that the function is not activated The field Clock offset allows modifying time zone The time zone values are between 6 and 6 hours Note None means that the function is not activated Moreover you can synchronize the date and time on each HYDROCA...

Page 94: ...ssibilities Static IP Enter the following values o IP address o Port number o Mask generally 255 255 255 0 should be used o The Gateway field is not significant the automatically assigned setting can be kept DHCP Client The device will receive it IP address from a DHCP server that must be available in the network environment Only the TCP port number can be entered Data in the tree are changed afte...

Page 95: ...munication with HYDRO CAL1005 can be made right now with up to 32 units Setup Answer Delay if required i e if communication problems occur Set Baudrate Data Bits Parity and Stop bits Data in the tree are changed after modification of sensor settings and validation with The star indicates that modifications have been made these must be transferred to the HYDROCAL1005 unit for activation This means ...

Page 96: ...n All sensor and alarm modifications made in HydroSoft are transferred to the HYDROCAL unit and activated there Input of a numerical password is necessary for this ac tion Default password is 999 Reset Alert This command resets all alarms on the HYDROCAL unit which have not previously been acknowledged Input of a numerical password is necessary for this action Default password is 999 Auto disconne...

Page 97: ... seconds is recom mended After confirmation by the Start button the status of communication will be presented in the win dow By pressing the button connection is interrupted This must be avoided during Login After interruption the log data must be closed by button The log data is used for error tracing in case of communication problems ...

Page 98: ...i vated for data presentation By double clicking on a sensor name the sensor is activated deacti vated for presentation In this case the left vertical scale is used Open by a right mouse button click on a sensor name the menu for allocation to different Y axis or deactivation as well as to change the color 5 12 2 Time range selection The time range for presentation is selected in two steps Selecti...

Page 99: ... the possibility to activate the print function only from trend or export function only from graph table and to fade out the sensor and time selec tion 5 12 4 Print and export of results There exist two possibilities to process measuring data for the purpose of documentation From the table view data can be exported to MS Excel or as a text file Export to Excel can be activated either from the menu...

Page 100: ...arm status is shown this is the current status at the time of data retrieval On the right side of the alarm name is to be found a status and activation mark is dis played e g alarm status 0 is activated for presentation alarm status 0 is deactivated for presentation alarm status 3 is activated The alarm name can be activated deactivated for presentation by a double click The menu is opened with ri...

Page 101: ...ollows Status 0 No alarm active the limits for the alarm have not be exceeded in the past or an alarm existing has been acknowledged Status 1 The limit defined for a High Alarm was exceeded in the past but value has fallen below the limit Status 2 The defined Level 2 for a High High alarm has been exceeded in past The value has fallen below the Level 2 but is still higher than Level 1 Status 3 The...

Page 102: ...ults Under visible sensors the different measuring values H2 C2H2 C2H4 CO and H2O and external sensors defined in Sensor setup and selected on the HYDROCAL unit can be activated in form of graphical view To activate Online visualisation you must first of all select the right connection settings See chapter 4 9 and then click on Start button You can define followings settings Visible Time Span Grap...

Page 103: ...signal wires must be clamped onto connector 7 pin 1 pin 2 and pin 3 inside of the HYDROCAL Care must be taken for the right polarity Termination Biasing Grounding and Protection of an RS485 Bus Termination biasing grounding and protection of an RS485 Bus is a complex thing and far beyond the scope of this document A very good source of information related to these issues can be found at www bb ele...

Page 104: ...ecks all transformers for pending history data transfers If an update is awaiting a connection to the HYDROCAL is established and the history data read out is executed Remark It is not possible to update the configuration to reset alerts or to synchronize the real timer clock by the scheduler these actions still must be carried out manually 7 2 1 Configuring a Transformer for automatic History Dat...

Page 105: ...ame meaning as in the manual communication and defines a time when the connection has to be regarded as broken leading to an error abort of the commu nication For direct connections 5 seconds should be used for a modem connection at least 15 seconds are reasonable The text box Next Connect at shows the date and time of the next connection Remark If a test of the scheduler communication is desired ...

Page 106: ...e members of the station and activated for scheduled history data update If a station does not contain any transformer that is activated for scheduled history data up date it is shown with the standard icon The read out status of all scheduled transformers of the station is good The read out status of at least one scheduled transformer of the station is bad A read out is pending for at least one t...

Page 107: ...To fully automate the history data update HydroSoft can be regularly invoked via the task scheduler available in the Windows operating system Windows provides a wizard to set up a task Follow the instructions to create an entry for HydroSoft The timing setup for the Windows task depends on the personal needs and the setup of the sched uled history data update in HydroSoft If for example a daily up...

Page 108: ...k is made whether the current time is greater than the next connect at time This way a list of pending connections is generated If the list of pending connections is non empty it is processed step by step i e the list is traversed and all pending connection requests are executed before a new list is build For each transformer a try to update the data is done On success the connect fail count is se...

Page 109: ...oSoft is working on a data directory no second instance of HydroSoft can operate on the same data This locking is introduced to keep data integrity in case a user is running HydroSoft and a back ground instance of HydroSoft started via the Windows task scheduler also tries to work on the data HydroSoft will exit with a return code of 2 if the data directory is locked ...

Page 110: ...ide CO 0 5 000 ppm 20 25 ppm Acetylene C2H2 0 2 000 ppm 20 5 ppm Ethylene C2H4 0 2 000 ppm 20 10 ppm Moisture 0 100 ppm 3 3 ppm Operation Principle Miniaturized gas sample production based on headspace principle no membrane negative pres sure proof Patent pending oil sampling system EP 1 950 560 A1 Infrared NIR gas sensor unit for CO C2H2 and C2H4 Micro electronic gas sensor for H2 Thin film capac...

Page 111: ...ogue AC Inputs Cap HV Bushing Accuracy Remarks Type Range of the measuring value Voltage or Current 6 x 0 80 V 20 6 x 0 4 20 mA 20 0 5 Configurable via jumper Digital Outputs Type Control Voltage Max Switching Capacity Opto coupler 5 x 5 VDC UCE 4 V rated 35 V max UEC 7 V max UCE 40 mA max Communication ETHERNET 10 100 Mbit s copper wired or fibre optical RS 485 proprietary or MODBUS protocol On b...

Page 112: ...HYDROCAL 1005 Manual for Installation and Operation Page 110 111 9 Dimensional drawings HYDROCAL1005 ...

Page 113: ...HYDROCAL 1005 Manual for Installation and Operation Page 111 111 ...

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