Vaisala Optimus OPT100 Installation Manual Download Page 1

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M211857EN-R

Installation Guide

Vaisala Optimus™ DGA Monitor for

power transformers

OPT100

Summary of Contents for Optimus OPT100

Page 1: ...M211857EN R Installation Guide Vaisala Optimus DGA Monitor for power transformers OPT100...

Page 2: ...en time and hereby disclaims any and all responsibilities related thereto This document does not create any legally binding obligations for Vaisala towards customers or end users All legally binding o...

Page 3: ...compliance statement 19 3 Mechanical installation 20 3 1 Unpacking DGA monitor 20 3 2 Mounting with Ground Mounting Set 20 3 2 1 Parts with Ground Mounting Set 23 3 2 2 Dimensions with Ground Mountin...

Page 4: ...ing DGA monitor 72 5 9 Configuring autocalibration 75 5 10 Configuring Modbus protocol 76 5 11 Configuring DNP3 protocol 77 5 12 Configuring IEC 61850 protocol 78 5 13 Using protocol test mode 79 5 14...

Page 5: ...46 Figure 18 Terminal block Y2 wiring 47 Figure 19 Terminal block X4 wiring 48 Figure 20 Terminal block Y1 wiring example 50 Figure 21 Location of the RS 485 repeater inside the DGA monitor cabinet 5...

Page 6: ...Y2 wiring 47 Table 6 Terminal block X4 wiring 48 Table 7 Terminal block Y1 wiring 50 Table 8 DIP switch configuration of RS 485 output 52 Table 9 Terminal block X3 wiring 56 Table 10 Terminal block X1...

Page 7: ...11857EN P June 2022 Applicable from software version 1 16 0 onwards Added sections Installing oil lines with flexible hoses page 35 Updated sections Required materials page 12 OPTPSU cable glands and...

Page 8: ...of injury or even death WARNING Caution warns you of a potential hazard If you do not read and follow instructions carefully at this point the product could be damaged or important data could be lost...

Page 9: ...lla Foundation Microsoft and Edge are either registered trademarks or trademarks of Microsoft Corporation in the United States and or other countries All other product or company names that may be men...

Page 10: ...ate legislation and regulations WARNING Make sure that you prepare and connect only de energized wires WARNING Keep away from live circuits Operating personnel must observe safety regulations at all t...

Page 11: ...hases Planning Mechanical installation Electrical installation Commissioning Installation reporting These phases correspond to chapters of the Installation Guide Post installation checklist is include...

Page 12: ...ust have either Wall Mounting Set or Ground Mounting Set Wall Mounting Set Vaisala item OPTMSET1 Installation beam 2 pcs Cradle for Power Supply Unit Screws and washers Ground Mounting Set Vaisala ite...

Page 13: ...0 157 in the maximum length is 5 m 16 ft Recommended oil pipe material stainless steel tubing with 10 mm 0 39 in outer diameter and 1 1 5 mm 0 039 0 059 in wall thickness Enough to connect the oil in...

Page 14: ...DGA monitor If you want to relocate an already installed DGA monitor you must prepare it for transport and reinstallation by following the uninstallation procedure See OPT100 User Guide M211858EN for...

Page 15: ...t directly conducted to the DGA monitor 2 8 2 Installation weather If the installation site is outdoors and not protected from the effects of weather make sure you can keep the equipment clean and dry...

Page 16: ...r circulates its oil by forced convection Oil flow inside the transformer makes the sampled oil more representative of the overall oil volume It is also useful if you have to use two valves that are c...

Page 17: ...of the oil tank Not recommended due to risk of sludge and free water Measurement from the bottom of the tank is also not representative for moisture measurement Operate the selected valves and make su...

Page 18: ...rt 1 General requirements 2 9 1 FCC Part 15 compliance statement This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to part 15 of the FCC Rules Th...

Page 19: ...ICES 003 compliance statement This Class A digital apparatus complies with Canadian ICES 003 Cet appareil numerique de la classe A est conforme a la norme NMB 003 du Canada Chapter 2 Planning the ins...

Page 20: ...ight of the unit on the cable glands and oil connections may damage them Keep the oil connections clean to ensure tight connections and to prevent dirt from getting into the oil circulation CAUTION 3...

Page 21: ...the parts of the mounting stand together 3 Holes on the bottom three on each side are for anchoring the mounting stand to the ground 4 Attach the power supply unit to the middle part using these four...

Page 22: ...51 140 5 51 Figure 3 Anchoring holes on the mounting stand 3 Drill holes for the anchors using an impact drill and an 8 mm 315 in drill bit The holes must be 60 mm 2 36 in deep 4 Install the anchors i...

Page 23: ...1 2 3 4 5 6 7 Figure 4 OPT100 front parts with Ground Mounting Set 1 Status LEDs 2 OPT100 DGA Monitor 3 Door lock 3 pcs 4 Power supply unit OPTPSU 5 Door lock 6 Mounting stand 7 Wedge anchors 6 pcs C...

Page 24: ...2 3 Figure 5 OPT100 rear parts with Ground Mounting Set 1 Weather shield 2 Cable glands and oil connections for DGA Monitor 3 Cable glands for power supply unit OPT100 Installation Guide M211857EN R 2...

Page 25: ...mm in 1552 61 10 1630 64 17 675 26 57 550 21 65 700 27 56 280 11 02 580 22 83 400 15 75 350 13 78 453 17 83 35 1 38 140 5 51 20 0 79 510 20 08 140 5 51 Figure 6 OPT100 dimensions with Ground Mounting...

Page 26: ...of the OPT100 cabinet to be Make sure it is securely attached from at least two points and can bear the full weight of the DGA monitor 2 Attach the second installation beam at the height of the secon...

Page 27: ...ed screws and tighten them The cabinet is now secured to the installation beams by a total of eight screws 1 2 1 Installation beam mounting screws 2 Leave second set of mounting holes free for weather...

Page 28: ...with Wall Mounting Set 1 2 3 4 5 Figure 7 OPT100 front parts with Wall Mounting Set 1 Status LEDs 2 OPT100 DGA Monitor 3 Door lock 3 pcs 4 Power supply unit 5 Door lock OPT100 Installation Guide M211...

Page 29: ...parts with Wall Mounting Set 1 Installation beam upper 2 Weather shield 3 Installation beam lower 4 Cable glands for DGA Monitor 5 Cradle for power supply unit 6 Cable glands for power supply unit Cha...

Page 30: ...ons with Wall Mounting Set 1390 54 72 675 26 57 1307 51 46 550 21 65 467 14 45 461 18 15 Minimum 100 18 15 mm in 400 15 75 Figure 9 OPT100 dimensions with Wall Mounting Set OPT100 Installation Guide M...

Page 31: ...33 274 10 79 Installation beam symmetry lines 8 50 holes for M8 anchors or bolts 30 1 18 50 1 97 0 25 0 98 75 2 95 125 4 92 175 6 89 225 8 86 Figure 10 Mounting dimensions of installation beams Chapt...

Page 32: ...pes hoses and connection adapters must be dry without any free water residue inside Water inside the oil lines can cause issues with the OPT100 measurement and water may be carried with the oil to the...

Page 33: ...e transformer to match them to the size of the oil pipe material 3 Measure the distance from the oil valves to the DGA monitor and plan the length and shape of the oil pipe sections Minimize the amoun...

Page 34: ...ing with a second wrench to keep it from turning when tightening f Tighten the nut 1 1 4 turns with a wrench If you are not using the recommended oil pipe size install adapters into the oil connection...

Page 35: ...xible hoses The flex hose kit and adapters are not delivered with the standard DGA monitor delivery When working with oil pipes hoses fittings and adapters Keep parts and tools clean and off the groun...

Page 36: ...ves into the waste oil container Verify that the oil is clean and there is no sludge coming out with the oil If there is sludge do not use that valve to connect the DGA monitor 2 Install the adapters...

Page 37: ...r leaks during commissioning when the DGA monitor is pumping oil Ideally check the connections again after the DGA monitor has been running for some time for example the next day More information Reco...

Page 38: ...he left side panel Note that the panels have an assigned side they are not identical b Attach the right side panel c Verify that all screws holding the side panels of the weather shield are tight d At...

Page 39: ...mm2 12 5 AWG conductor 13 mm 4 RS 485 RS 485 connection 5 10 mm 0 20 0 39 in 20 mm 5 Relay control out Relay control to OPTPSU Use Vaisala cable CBL210539 7 12 mm 0 28 0 47 in 24 mm 6 DC in DC input f...

Page 40: ...OPTPSU1 Mains power input 100 240 V AC 50 60 Hz 10 A 9 16 mm 0 35 0 63 in 0 5 10mm2 24 6 AWG conductor 30 mm DC in OPTPSU2 Mains power input 110 220 V DC 6 3 2 5 A 9 16 mm 0 35 0 63 in 0 5 10mm2 24 6...

Page 41: ...3 Oil block 4 Valve 2 5 Valve 3 6 Valve 1 7 In oil measurement of hydrogen and moisture 8 Oil out 9 Oil in 10 Terminal blocks for RS 485 output Y1 and relay control Y2 11 Circuit breakers main breake...

Page 42: ...X4 9 Relay output terminal block X3 10 Mains power in terminal block X1 4 4 Grounding DGA monitor Grounding cable with 4 16 mm2 12 5 AWG conductor Enough to reach from the DGA monitor and the power s...

Page 43: ...DGA monitor Instrument power cable Vaisala cable CBL210544 Screwdriver with 3 mm wide 0 12 in slotted head Adjustable wrench If the Vaisala supplied instrument power cable is not available use a shiel...

Page 44: ...ound 24 V DC BLK RED BLK GRN YEL Figure 16 Terminal block Y3 wiring 6 Open the cable gland marked DC out on the power supply unit Remove the plug and store it for later use 7 Insert the instrument pow...

Page 45: ...seal insert so that it will make contact with metal when the cable gland is tightened 9 Push the outer nut and the seal insert against the contact socket of the gland and tighten the outer nut Chapte...

Page 46: ...elay control to power supply unit Relay control cable marked RELAY Vaisala cable CBL210539 Screwdriver with 3 mm wide 0 12 in slotted head Adjustable wrench 1 Open the cable gland marked Relay control...

Page 47: ...rol White 1 Relay 1 control Brown 2 Relay 2 control Green 3 Relay 2 control Yellow 4 Relay 3 control Grey 5 Relay 3 control Pink 6 Relay 1 Relay 2 Relay 3 1 3 5 2 4 6 BRN WHT YEL GRN PNK GRY Figure 18...

Page 48: ...de the power supply unit connect the wires to terminal block X4 Table 6 Terminal block X4 wiring Signal Wire color Vaisala cable CBL210539 Terminal Relay 1 control White 2 Relay 1 control Brown 3 Rela...

Page 49: ...cable braid from the part of the cable that will be left inside the DGA monitor c Strip the ends of the individual wires to expose the conductors for 1 cm 0 4 in d Remove some more of the outer sheath...

Page 50: ...the wiring colors of your cable before making any connections Table 7 Terminal block Y1 wiring Signal Terminal RS 485 1 RS 485 3 Common 5 RS 485 RS 485 Common 1 3 5 2 4 6 BLU WHT BLU BRN Figure 20 Ter...

Page 51: ...inside the DGA monitor cabinet There are two banks of DIP switches on the underside of the RS 485 repeater Switches for configuring the RS 485 output are at the front of the repeater next to the grou...

Page 52: ...2 k transmit bias resistor default Switch 7 Receive bias resistor ON Use external or no bias resistor default OFF Use built in 1 2 k receive bias resistor Switch 8 is not used DGA monitor is wired fo...

Page 53: ...e protection shell over the RJ45 connector on your Ethernet cable Assemble according to Code A see instructions on top of the bag that contains the parts You must use the protection shell to maintain...

Page 54: ...nsure ingress protection through cable glands Figure 24 Alternative Ethernet connection 4 9 Connecting relays Relay cable with 0 14 4 mm2 26 12 AWG conductors and 7 12 mm 0 28 0 47 in external diamete...

Page 55: ...asure how much cable you need to reach from the cable gland to terminal block X3 b Remove the outer sheath and cable braid from the part of the cable that will be left inside the power supply unit c S...

Page 56: ...able before making any connections Table 9 Terminal block X3 wiring Signal Terminal Relay 1 NC 1 Relay 1 common 2 Relay 1 NO 3 Relay 2 NC 4 Relay 2 common 5 Relay 2 NO 6 Relay 3 NC 7 Relay 3 common 8...

Page 57: ...ty devices Liability for customer installed devices is not covered by Vaisala Only devices with 24 V DC input voltage and maximum class B electromagnetic interference EMI are allowed to be installed i...

Page 58: ...inal blocks Y5 3 Circuit breaker F3 Y4 Make sure the auxiliary device is not touching the existing components to avoid surges and thermal disturbances 2 Make sure the auxiliary device is firmly in pla...

Page 59: ...nds Use the provided cable glands to maintain the ingress protection rating of the cabinet CAUTION 6 Turn power on from circuit breaker F3 7 Check the correct operation of the system 8 Tie the auxilia...

Page 60: ...relief WARNING 1 Install needed external disconnection and overcurrent protection devices for example circuit breakers for the mains power connection Note the following The external disconnection and...

Page 61: ...for connection to the power supply unit a Strip 14 cm 5 51 in of the cable to expose the wires b Cut off 2 cm 0 79 in of the line and neutral wires brown and blue Leave the green and yellow grounding...

Page 62: ...nd CAUTION Table 10 Terminal block X1 wiring Signal Wire color Terminal Line Brown L Neutral Blue N Ground Green yellow Line Neutral Earth BRN BLU GNR YEL L N Figure 27 Terminal block X1 wiring for OP...

Page 63: ...re the gland holds the cable tight 4 12 Verifying tightness of cable glands Adjustable wrench To maintain cabinet tightness and provide strain relief to the cables all cable glands on the DGA monitor...

Page 64: ...2 Check that every unused cable gland is plugged and tightened OPT100 Installation Guide M211857EN R 64...

Page 65: ...k the DC OK LED on the power supply If the LED is lit solid green OPTPSU power to the DGA monitor is successfully turned on If the LED keeps blinking it is likely that the 24 V DC connection to DGA mo...

Page 66: ...ting with a new device The user interface of the DGA monitor is secured with a self signed certificate by default Continue despite the warning HTTPS traffic is always encrypted even if the certificate...

Page 67: ...The new password must be at least 8 characters long 4 Select Save 5 4 Configuring network connection Figure 30 IP address settings page Configure the network settings of the external Ethernet connect...

Page 68: ...xternal network connection ETH0 since they are reserved for the service port ETH1 5 Select Apply to save your changes 5 5 Configuring user interface security Figure 31 Network security settings page C...

Page 69: ...rface select Settings Network Security 2 Select HTTP to use unencrypted user interface connections or HTTPS default to secure the interface using encryption 3 To use your own certificate with HTTPS co...

Page 70: ...ce select Settings General 2 Enter a name for the device into Name Maximum length is 64 characters You can use alphanumerical characters space hyphen and underscore _ 3 Select Apply to save the name 5...

Page 71: ...ime zone of the connecting web browser 1 In the user interface select Settings General 2 To set date and time manually a Select Set time manually b Select or enter the current date into Date The forma...

Page 72: ...tered d Wait for the message Time successfully synchronized to appear 4 To set up time synchronization using DNP3 protocol a Enable and configure the DN3 protocol b Select Use DNP3 c Select Apply to s...

Page 73: ...elect Start to start the initialization sequence 4 Turn the gray knob on the side of the bleed valve 90 counterclockwise to open the manual override lock The knob pops outward when the lock is open Se...

Page 74: ...sed in the beginning of the filling and assisted using the oil pump of the DGA monitor in the later stage Typical duration of this step is 30 60 minutes depending on oil pressure viscosity temperature...

Page 75: ...on page Even if the automatically started autocalibration is disabled the initial autocalibration will still run after the DGA monitor has been initialized Autocalibration can also be manually started...

Page 76: ...be enabled Select TCP Ethernet RTU serial line or both 3 If you enabled Modbus RTU configure the serial connection a Select Baud rate for the connection Available options are 4800 9600 19200 38400 576...

Page 77: ...nterface select Settings Network DNP3 2 Select if the DNP3 protocol should be Enabled or Disabled 3 If you enabled the DNP3 protocol configure the following settings Connection type Interface where DN...

Page 78: ...the classes used for the Gas alarm Gas caution and Device status events 6 Select Apply to save your changes Select Download to download the DGA monitor device profile in XML format It is needed to co...

Page 79: ...Protocol Implementation Conformance Statement PICS Model Implementation Conformance Statement MICS 5 13 Using protocol test mode Figure 38 Protocol test mode enabled 1 In the user interface select Set...

Page 80: ...enable the desired caution and warning level alerts c Select Update at the bottom of the page to take the new test data into use 5 The test mode will end automatically after one hour You can select a...

Page 81: ...an the caution limit except when configuring a minimum limit alert for total gas pressure TGP d If the alert is for the total gas pressure TGP value select if you want the limit value to be a maximum...

Page 82: ...elect Settings Units 2 Select the preferred unit to use for total gas pressure hPa or psi This selection only affects the viewing of the user interface and the downloading of data from the Latest valu...

Page 83: ...ct the Test mode You can also use it to test that wiring has been connected correctly b Select relay Trigger Gas Caution activates the relay if any gas level alert of caution severity is active Gas Al...

Page 84: ...90 minutes Verify that there are no oil leaks in the oil pipes or inside DGA monitor 5 18 Finalizing installation 1 If you have connected DGA monitor to a host system using Ethernet or RS 485 connect...

Page 85: ...6 Installation report 6 1 Site and device information Site information Company Contact information Substation name and address Date s of visit Transformer ID Chapter 6 Installation report 85...

Page 86: ...Site information Scope of work Device information DGA monitor model DGA monitor serial number Mounting type Oil line type and size OPT100 Installation Guide M211857EN R 86...

Page 87: ...monitor configuration report Table 12 Wiring Item Yes No Comment Instrument power cable installed between DGA monitor and power supply unit Relay control cable installed between DGA monitor and power...

Page 88: ...te and time set Admin password changed Device name configured Ethernet connection configured User interface security configured Autocalibration configured IEC 61850 protocol configured and enabled DNP...

Page 89: ...l installation steps Table 14 Post installation checklist Item Yes No Comment Mechanical installation stable and secure DGA monitor is installed vertically and not tilted more than 5 degrees Mains pow...

Page 90: ...by No errors active in user interface Status LED on DGA monitor door is green Bleed plug in place on the bleed valve Connection to DGA monitor verified from SCADA system DGA monitor cabinet closed and...

Page 91: ...32 personnel 11 phases 11 required materials 12 site 14 tools 13 Installation oil lines 35 installation report 85 M maintenance measurement starting 83 Modbus protocol 76 mounting Ground Mounting Set...

Page 92: ...T total gas pressure 82 transporting 14 U units 82 unpacking 20 user interface general page 70 network page 67 W weather 15 OPT100 Installation Guide M211857EN R 92...

Page 93: ...helpdesk vaisala com Provide at least the following supporting information as applicable Product name model and serial number Software Firmware version Name and location of the installation site Name...

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