HYDROCAL1005 Gas-in-Oil Analysis System with Transformer Monitoring Functions Manual for installation and operation

Transcription

1 HYDROCAL1005 Gas-in-Oil Analysis System with Transformer Monitoring Functions Manual for installation and operation HYDROCAL 1005 Manual for Installation and Operation Edition

2 Copyright MTE Meter Test Equipment 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 HYDROCAL 1005 Manual for Installation and Operation Page 2/111

3 Summary 1. General Mounting of HYDROCAL1005 unit Locations for installation of HYDROCAL Security precautions for installation Preparation for installation Power supply for the unit Requested tools: Installation of the HYDROCAL1005 unit Electrical Installation of HYDROCAL1005 unit Completion of Installation Hardware components of HYDROCAL Front view of HYDROCAL Rear side of HYDROCAL1005 unit Connections on the measuring and controller card Measurement and extraction Components Software on HYDROCAL unit General information Description of Gas measurement Process Operation Cycles Zero measurement Safety function and error observation for Zero measurement cycle Depression Safety function and error observation for depression cycle Leak detection Safety function and error observation for leak detection cycle Filling to level Safety function and error observation for filling to level 1 cycle Degassing Safety function and error observation for degassing cycle Filling to level Safety function and error observation for filling to level 2 cycle Measurement Safety function and error observation for measurement cycle Flushing Safety function and error observation for flushing cycle Draining Safety function and error observation for draining cycle Wait Safety function and error observation for wait cycle Operation of HYDROCAL1005 by its keyboard Contrast Set-up Main menu Extraction Menu Display of stored Gas-in-oil measuring values Graphic display Table presentation HYDROCAL 1005 Manual for Installation and Operation Page 1/111

4 4.8 Status of alarms Acknowledgment of alarms Device set up Menu Transformer data setup DGA Adjustment: Input of correction factor Hot Spot calculation Ageing Rate / Loss of Life Configuration of analogue outputs Configuration of analogue inputs (external sensors) Configuration of alarms and digital outputs Unit Setup Digital Output Test Device options Configuration of user settings Date. Time & Clock Settings Configuration of the communication Ethernet setup Alert SMS setup Internal modem setup RS 232 / RS 485 setup MODBUS Windows Software HydroSoft Purpose of the program Remarks for use of this operation handbook Requirements to the PC Installation Microsoft.NET.NET Framework 1.1 Redistributable Microsoft Data Access Components Adaptation of installation Functions of HydroSoft program Start of program Preparation / rename of a new customer list Opening a new transformer station Opening a file for a new transformer Modem settings RS232 interface settings Settings of HYDROCAL1005 unit Alert Setup External sensors (see also chapter 4.7.3) HYDROCAL 1005 Manual for Installation and Operation Page 2/111

5 Alert SMS Setup Input of DGA Level Adjustment Analog Output Setup Digital Output Setup Device Setup (Clock settings) Ethernet Modbus-TCP MODBUS Data transmission from / to the HYDROCAL1005 unit View of results Sensor selection Time range selection Result window Print and export of results View of alarm status Alarm selection Time range selection Alarm window Status of alarms Print and export of results Online Sensors RS 485 Wiring HYDROSOFT Scheduler General Scheduler Configuring a Transformer for automatic History Data Update Connection Scheduler Dialog Scheduler Status Visualization Status Icons Transformer Station Customer Example HydroSoft and the Windows Task Scheduler Command Line Options for Windows Task Scheduler IdleClose Minimized Internal Operation Data Directory Lock Technical data HYDROCAL Dimensional drawings HYDROCAL HYDROCAL 1005 Manual for Installation and Operation Page 3/111

6 1. General The HYDROCAL 1005 is a permanently-installed multi-gas-in-oil analysis system with transformer monitoring functions. It allows for the individual measurement of moisture and the key gases hydrogen (H 2 ), carbon monoxide (CO), acetylene (C 2 H 2 ) and ethylene (C 2 H 4 ) dissolved in transformer oil. As hydrogen (H 2 ) is involved in nearly every fault of the isolation system of power transformers and carbon monoxide (CO) is a sign of an involvement of the cellulosic / paper isolation the presence and increase of acetylene (C 2 H 2 ) and ethylene (C 2 H 4 ) further classifies the nature of a fault as overheating, partial discharge or high energy arcing. The device can serve as a compact transformer monitoring system by the integration / connection of other sensors present on a transformer via its analog inputs: 5 analog outputs 0/4-20mADC 4 analog inputs 0/4-20 madc (Option) 6 analog inputs 0/4-20 madc +20% / 0-80 VAC +20% (option) configurable by jumpers It is 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 (H 2 ), Carbon monoxide (CO), acetylene (C 2 H 2 ) and ethylene (C 2 H 4 ) measurement Moisture-in-oil measurement Communication interfaces ETHERNET 10/100 Mbit/s (copper-wired or fibre-optical) and RS 485 to support proprietary communication protocols and to be open / prepared for substation communication protocols IEC 61850, MODBUS, DNP 3 etc. Optional on-board GSM and analog modems for remote communication 6 analog AC current inputs for the connection of capacitive HV bushing sensors for HV bushing monitoring applications The present operating instructions are divided in the following sections: Instructions for mounting the HYDROCAL 1005 unit (chapter 2) Hardware components of HYDROCAL 1005 (chapter 3) Description of software of the HYDROCAL 1005 unit (chapter 4) Description of Windows software HydroSoft (chapter 5) RS 485 Wiring (chapter 6) New HydroSoft Scheduler functions (chapter 7) Technical Data of HYDROCAL 1005 (chapter 8) HYDROCAL 1005 dimensional drawings (chapter 9) HYDROCAL 1005 Manual for Installation and Operation Page 4/111

7 2. Mounting of HYDROCAL1005 unit 2.1 Locations for installation of HYDROCAL1005 To ensure the correct function of the HYDROCAL1005 the location of mounting is very important. For a typical transformer, four places are possible: Pos. 1 Pos. 2 Pos. 3 Pos. 4 On return side of cooling circuit: Please install the unit on a straight piece of tube on the cooler output between the cooler and the main oil tank. In order to avoid negative pressure, the unit must absolutely be mounted on the downstream side (after the bend) of the oil circulation pump. Remark: Choose this place only in case of continuous oil flux through the cooler. 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. 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 mounting position. This position is not recommended, because the filling process is influenced by the hydrostatic pressure of the oil and it may be difficult to operate and read the data of the unit. Never install the HYDROCAL1005 unit on top of the cooler or on the suction face of the pump. In this case, filling oil step cannot be carried out in the right way. HYDROCAL 1005 Manual for Installation and Operation Page 5/111

8 2.2 Security precautions for installation The following security precautions must be strictly observed during the installation. Otherwise no warranty claims will be accepted. Never remove the protection cap from the sensor before you are ready to mount the unit on the valve of the transformer. The protection cap protects the sensor against dust and other foreign bodies. Additionally it protects the thread of the measuring head and/or adapters. Note: Use the protection cap also after dismounting of the unit. Never close the aeration holes for oxygenation. They are situated in bottom side of the protection cover and at the back plate of the device Never use or stock chemicals with hydrocarbon contents near the measuring 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 can also close the valve of the transformer Never install the HYDROCAL unit on a valve that is closed for a long period of time. Remove the unit if this cannot be avoided. Please refer to De-installation instructions Never install the HYDROCAL1005 on the suction side of the cooling pump! The HYDROCAL 1005 should be installed on positions located 100 cm below of the oil level inside the transformer Never install the HYDROCAL1005 unit on an elbow or curve of a tube. The unit cannot operate by negative pressure produced by turbulences in curves. HYDROCAL 1005 Manual for Installation and Operation Page 6/111

9 Never install or remove the HYDROCAL1005 without opening first the aeration screw. Never use galvanized fittings or valves to mount the HYDROCAL1005 unit. Galvanized fittings or valves can react with oil; this will produce incorrect measuring 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 ½. Attention!!! Faulty or inappropriate handling of the sensor head like malfunction by negative pressure, paint or solvent liquids make the warranty invalid. HYDROCAL 1005 Manual for Installation and Operation Page 7/111

10 2.3 Preparation for installation Before installation, a visual inspection of the unit must be carried out. Remove the protection cover and check visually the components. All cables and tubes must be connected Power supply for the unit The HYDROCAL1005 unit requires an auxiliary power supply of 110 / 230V close to the unit. The power needed is max. 350 VA Requested tools: Long Allen key, size 4 for aeration screw Bucket, oil absorber, cleaning rag Teflon-band Drill / screw driver Digital multimeter Tin spanner M55 or adjustable tin spanner of 1 ½ for valve and fittings To seal the thread of the measuring head, either Teflon band (minimum 4 to 5 layers must be applied) 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 1½ (DIN ISO 228: G 1½). The HYDROCAL unit has a 1½ thread (Dimensional drawings, see. chapter 8). As an option a valve with NPT 1½ standard can also be used. A good oil flux should exist on the mounting location. If necessary, use a reduction piece (adapter). It is recommended to mount the HYDROCAL 1005 unit to valve with a union- or sleeve nut. In this case the device has not to be turned to fix during the installation. An O-ring should be used as sealing. In case there exist strong vibrations on the mounting valve, the valve should be relieved by a support. Then mount the unit according to the following steps: HYDROCAL 1005 Manual for Installation and Operation Page 8/111

11 Only remove the protection cap (slowly while turning) when you are ready to mount the measuring head! Clean the internal side of the installation valve. In case you don t use a union or sleeve nut as connection 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 Hydrocal 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 fixed mechanically. Turn the unit in order to get 12 o clock position. HYDROCAL 1005 Manual for Installation and Operation Page 9/111

12 Attention!!! The following steps must be done according to the company procedures. Work carefully in order to prevent air entering into the transformer. 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 cleaning! HYDROCAL 1005 Manual for Installation and Operation Page 10/111

13 2.5 Electrical Installation of HYDROCAL1005 unit Use steel protected cables for power supply, alarm-cables and communication cables and connect them to the appropriate connectors. Recommendations for main supply cable: Mains supply cable (3-wire) (1) Phase 230VAC 20% (2) Neutral (3) Protection Earth Wire : 1,5mm 2 If optional GSM Modem is used, GSM antenna must be connected to Hydrocal as above drawing: 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 specified conditions confirming that the HYDROCAL1005 is functioning correctly. o Brown (L) o Blue (N) o Green - yellow (PE) HYDROCAL 1005 Manual for Installation and Operation Page 11/111

14 2.6 Completion of Installation START-SCREEN At first, date and time must be setup, refer to chapter The HYDROCAL1005 has a sub menu allowing configuration of time, 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. (Controlled draining and stopping) HYDROCAL 1005 Manual for Installation and Operation Page 12/111

15 Then, if everything is working correctly put the housing in correct position and secure it with the knurled thumbscrews. The measuring 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 ) or with HydroSoft (chapter ). HYDROCAL 1005 Manual for Installation and Operation Page 13/111

16 3. Hardware components of HYDROCAL Front view of HYDROCAL1005 On the front side 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 HYDROCAL 1005 Manual for Installation and Operation Page 14/111

17 3.2 Rear side of HYDROCAL1005 unit [1] Measuring sensor with an internal thread of 1½ (DIN ISO 228: G 1½) or optionally (NPT 1½) HYDROCAL 1005 Manual for Installation and Operation Page 15/111

18 [2] Entrance for power supply 88 VAC min 276 VAC max Optional: 88 VDC min 390 VDC max 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 HYDROCAL 1005 Manual for Installation and Operation Page 16/111

19 3.3 Connections on the measuring and controller card [1] Connector ST13: 4 x Valve Control Connection for valve control HYDROCAL 1005 Manual for Installation and Operation Page 17/111

20 [2] Connector ST14: Pumps Oil Air Connection for pumps oil air control [3] Connector ST11: Oil Level / Oil-Flow Connection for oil level / oil flow 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 VAC min 276 VAC max 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 HYDROCAL 1005 Manual for Installation and Operation Page 18/111

21 [6] Connector ST12: Heating Connection of the heating resistors, depending from the supply voltage [7] Connector KL302: Interface RS485 and Modem X7:1 (OUT B ) RS485 X7:2 (OUT A ) RS485 X7:3 GNDIO Signal ground not shield X7:4 Phone B X7:5 Phone A [8] Connector KL301: Analogue Outputs 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 ) X9:5 (Relay output 3 ) X9:6 (Relay output 3 ) X9:7 (Relay output 4 ) X9:8 (Relay output 4 ) X9:9 (Relay output 5 ) X9:10 (Relay output 5 ) HYDROCAL 1005 Manual for Installation and Operation Page 19/111

22 [10] Connector KL102: Analogue AC Inputs (in Option) 6 x V +20% 6 x 0/4 20mA +20% X10:1 (Analogue AC input 1 ) X10:2 (Analogue AC input 1 ) X10:3 (Analogue AC input 2 ) X10:4 (Analogue AC input 2 ) X10:5 (Analogue AC input 3 ) X10:6 (Analogue AC input 3 ) X10:7 (Analogue AC input 4 ) X10:8 (Analogue AC input 4 ) X10:9 (Analogue AC input 5 ) X10:10 (Analogue AC input 5 ) X10:11 (Analogue AC input 5 ) X10:12 (Analogue AC input 5 ) [11] Connector 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 / U CE : 4 V / U EC : 7 V / U CE : 40 ma [13] GSM/GPRS-module / GSM antenna Connector Mini-BNC X12:1 (Opto coupler output 1 ) X12:2 (Opto coupler output 1 ) X12:3 (Opto coupler output 2 ) X12:4 (Opto coupler output 2 ) X12:5 (Opto coupler output 3 ) X12:6 (Opto coupler output 3 ) X12:7 (Opto coupler output 4 ) X12:8 (Opto coupler output 4 ) X12:9 (Opto coupler output 5 ) X12:10 (Opto coupler output 5 ) HYDROCAL 1005 Manual for Installation and Operation Page 20/111

23 [14] ETHERNET connector Copper-wired or Fibre-optical These sockets are connected with the back plane. It means that normally only connection on back plane is needed [15] Measuring cell connector HYDROCAL 1005 Manual for Installation and Operation Page 21/111

24 3.4 Measurement and extraction Components [1] Capacitive Sensor F0 (ZERO) [2] Capacitive 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 HYDROCAL 1005 Manual for Installation and Operation Page 22/111

25 HYDROCAL 1005 Manual for Installation and Operation Page 23/111

26 4. Software on HYDROCAL unit 4.1 General information The gas-in-oil analyzer HYDROCAL1005 is based on a microprocessor controlled measuring system. A 32 Bit Coldfire processor with a clock frequency of 240 MHz (bus clock 80 MHz) is used. The software has been developed with the language C. The system has a flash memory of 16 / 32 / 64 Mbyte for measuring data. This offers approximately 2 / 4 / 8 years time storage capacity for the measuring data. After this period, the oldest data will be overwritten by the latest values. When using additional external 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): Memorydept h days Byte / day 288 Byte / day Sensorstorages n 1 Std n With one additional sensor with a time interval of 5 minutes the following calculation results: Byte Byte / day 3456 Byte / day Byte Memorydepth days 2500 days Byte / day Also an additional reduction of the storage time takes place by the definition of alarms. Each change of alarm status requires 12 Bytes. Byte Attention: To avoid any loss of data, it is proposed to read out regularly the measuring data by the Windows based software HydroSoft. 4.2 Description of Gas measurement Process HYDROCAL 1005 Manual for Installation and Operation Page 24/111

27 4.3. Operation Cycles This chapter describes each process steps and provides information in regards to the safety functions as well as how to reset errors. The consequence of all errors is that the cycle will be interrupted immediately and all valves will be closed. For all observed errors, you can acknowledged them by pressing button.. If nothing changes, check status of all components according to actual cycle. Check that all tubes go straight into the FESTO quick screws 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 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 K1 not active [9] Valve V4 closed [10] Valve V2 closed [11] Pump P1 active [12] Valve V5 open Safety function and error observation for Zero measurement cycle Observed Components Filling Sensor 0, 1, 2 Detectable Errors Operating in normal parameters Measurement chamber Pressure Sensor Measurement chamber offline Pressure stability HYDROCAL 1005 Manual for Installation and Operation Page 25/111

28 4.3.2 Depression For pressure compensation of the measurement chamber 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 open [8] Compressor K1 active [9] Valve V4 closed [10] Valve V2 closed [11] Pump P1 not active [12] Valve V5 open Safety function and error observation for depression cycle Observed Components Filling Sensor 0, 1, 2 Measurement chamber Pressure Sensor Detectable Errors Operating in normal parameters Measurement chamber offline Pressure does not decrease HYDROCAL 1005 Manual for Installation and Operation Page 26/111

29 Leak detection During the leak detection cycle the pressure stability of the complete system is checked 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 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 Safety function and error observation for leak detection cycle Observed Components Filling Sensor 0, 1, 2 Measurement chamber Pressure Sensor Flow meter Detectable Errors Operating in normal parameters Measurement chamber offline Leakage V6 closed HYDROCAL 1005 Manual for Installation and Operation Page 27/111

30 Filling to level 1 Step No. Status of the components [1] Capacitive Sensor F0 active [2] Capacitive Sensor FI active [3] Capacitive Sensor FII not active [4] Valve V6 open [5] Flow meter 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 Safety function and error observation for filling to level 1 cycle Observed Components Filling Sensor 0, 1, 2 Filling Sensor 0, 1 Flow meter Timer Measurement chamber Detectable Errors Operating in normal parameters - Filling level 1 lost - Filling stopped? - Filling timeout Measurement chamber offline Pressure Sensor - leakage - flow stuck Filling Sensor 0, 1, 2 Measurement chamber offline HYDROCAL 1005 Manual for Installation and Operation Page 28/111

31 Degassing Step No. Status of the components [1] Capacitive Sensor F0 active [2] Capacitive Sensor FI active [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 closed [11] Pump P1 active [12] Valve V5 closed Safety function and error observation for degassing cycle Observed Components Filling Sensor 0, 1, 2 Filling Sensor 0, 1 Flow meter Measurement chamber Detectable Errors Operating in normal parameters - Filling level 1 lost - Filling stopped Measurement chamber offline Pressure Sensor - depression lost, leakage - V4 closed Flow meter V6 closed HYDROCAL 1005 Manual for Installation and Operation Page 29/111

32 Filling to level 2 Step No. Status of the components [1] Capacitive Sensor F0 active [2] Capacitive Sensor FI active [3] Capacitive Sensor FII active [4] Valve V6 open [5] Flow meter 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 Safety function and error observation for filling to level 2 cycle Observed Components Detectable Errors Filling Sensor 0, 1, 2 Filling Sensor 0, 1, 2 Flow meter Timer Measurement chamber Operating in normal parameters - Flow Stuck - Flow leak - Level Timeout - Avoid flooding meas. chamber Measurement chamber offline Pressure Sensor - No pressure rise HYDROCAL 1005 Manual for Installation and Operation Page 30/111

33 Measurement Step No. Status of the components [1] Capacitive Sensor F0 active [2] Capacitive Sensor FI active [3] Capacitive Sensor FII 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 Safety function and error observation for measurement cycle Observed Components Filling Sensor 0, 1, 2 Measurement chamber Detectable Errors Operating in normal parameters Measurement chamber offline HYDROCAL 1005 Manual for Installation and Operation Page 31/111

34 Flushing Step No. Status of the components [1] Capacitive Sensor F0 active [2] Capacitive Sensor FI active [3] Capacitive Sensor FII 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 open [10] Valve V2 closed [11] Pump P1 not active [12] Valve V5 open Safety function and error observation for flushing cycle Observed Components Filling Sensor 0, 1, 2 Measurement Chamber Pressure Sensor Detectable Errors Operating in normal parameters Measurement Chamber offline No depression HYDROCAL 1005 Manual for Installation and Operation Page 32/111

35 Draining Step No. Status of the components [1] Capacitive Sensor F0 active [2] Capacitive Sensor FI active [3] Capacitive Sensor FII active [4] Valve V6 open [5] Flow meter active [6] Valve V1 draining / 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 Safety function and error observation for draining cycle Observed Components Filling Sensor 0, 1, 2 Filling Sensor 0, 1, 2 Flowmeter Timer Measurement chamber Pressure Sensor Detectable Errors Operating with normal parameters - Flow Stuck - Flow leak - Level Timeout - Avoid transformer aeration Measurement chamber offline No depression HYDROCAL 1005 Manual for Installation and Operation Page 33/111

36 Wait 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 K1 not active [9] Valve V4 closed [10] Valve V2 closed [11] Pump P1 active [12] Valve V5 open Safety function and error observation for wait cycle Observed Components Filling Sensor 0, 1, 2 Measurement chamber Detectable Errors Operating in normal parameters Measurement chamber offline HYDROCAL 1005 Manual for Installation and Operation Page 34/111

37 4.4 Operation of HYDROCAL1005 by its keyboard The HYDROCAL1005 unit when in use can be operated by its built-in keyboard. For this its external housing must be removed. Loosen the knurled thumb screws on the front side 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 Contrast Set-up Contrast of HYDROCAL1005 display can be setup while pushing on up and down arrow keys from the main display. HYDROCAL 1005 Manual for Installation and Operation Page 35/111

38 4.5 Main menu After connection of the HYDROCAL1005 unit to the power supply, the main menu appears on the display. The actual measuring values of concentration for hydrogen, carbon monoxide, acetylene, ethylene and moisture in the oil are displayed. If other sensors are connected or an unacknowledged alarm exists, then the display will change 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 Remark: External sensor menu From the main display under Customer, Station, Transformer and Comment data, you find Serial Number of the unit (For example: #11111) and Firmware version implemented on the unit (For example: V ). To display immediately external sensor screen, you can push on 2. To display immediately alert status screen, you can push on 3 HYDROCAL 1005 Manual for Installation and Operation Page 36/111

39 4.6 Extraction Menu Please refer chapter 2.6. Installation completion 4.7 Display of stored Gas-in-oil measuring values In the menu Gas-in-oil an overview in the form of a bar chart with the composition of measured gases in the oil are shown. The values for H 2, C 2 H 2, C 2 H 4, CO and H 2 O indicate their actual measurement values of the total gas content. I.e. as shown below: 30ppm is H 2, 131ppm is C 2 H 2, 46ppm is C 2 H 4, 308ppm is CO and 0.0ppm is H 2 O. The following values are available: Hydrogen acetylene ethylene Carbon monoxide Moisture Temperatures: - 1 Temperature in sensor area (measure cell) - 2 Temperature of oil Graphic display After selection of the measuring quantity, a graph displaying the trend over the time is shown HYDROCAL 1005 Manual for Installation and Operation Page 37/111

40 Following functions are available: Scroll graph to the right Scroll graph to the left Zoom-out with minimum resolution of 3 days / page Zoom-in with maximum resolution of 8 hours / page Go to table presentation Exit Table presentation After selection of presentation in form of a table, the measured values are shown with time and current 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 Go to graphic display Exit HYDROCAL 1005 Manual for Installation and Operation Page 38/111

41 4.8 Status of alarms In the menu status of all programmed alarms are presented in a table. All alarms defined are shown together with their status. In the column Date / Time the last change of status is shown. The followings alarm statuses are available: OK, Symbol : No active alarm for this measuring value exists. o If a date exists: For this measuring value an acknowledged alarm existed in the past. o If no date exists: For this measuring value no alarm existed in the past. High - Alarm active: : The defined Level 1 for a High - Alarm has been exceeded at the date/time indi- o Symbol cated. o Symbol : The defined 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 exceeded at the time indicated. : The defined level for a High - High - Alarm has been High - High - Alarm inactive, Symbol : The defined Level 2 for a High - High - Alarm has been exceeded in the past. The value has fallen below Level 1 at the time indicated. In history of alarms, the following functions are available: Acknowledge alarm selected Scroll up one line Scroll down one line Show details of alarm selected. Exit Acknowledgment of alarms For confirmation of an alarm, a password is required (Default password is 999). HYDROCAL 1005 Manual for Installation and Operation Page 39/111

42 4.9 Device set up First of all, you can define the application language while selecting it by the keyboard. You can choice between: English, German, French, Russian, Polish and Turkish. Before any amendment of settings can be made, the system asks for the password (Default password is 999). After input of password by the alphanumeric keyboard and confirmation with enter device setup menu is opened: button, the The following configurations can be modified: Transformer data, e.g.: allocation of sensors to algorithms for calculation of life expectancy and input of correction factors Configuration of Analogue outputs Configuration of Analogue inputs (extern sensors) Configuration of alarms Configuration of the unit HYDROCAL 1005 Manual for Installation and Operation Page 40/111

43 4.9.1 Menu Transformer data setup This data is not necessarily required for operation of the unit. In the menu Transformer Setup, input of correction factor, Hot-Spot Calculation as well as Ageing Rate / Loss-of-Life Calculation are possible. Parameters can be set only on the device not in HydroSoft DGA Adjustment: Input of correction 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 calculated and presented. After the results of laboratory analysis have been introduced in the fields Laboratory Value for H 2, C2H2, C 2 H 4, and CO, the button is activated and new correction factors are calculated. HYDROCAL 1005 Manual for Installation and Operation Page 41/111

44 These values can be used. The new values are stored and activated by the button exit. For the following measured values the new correction factor will then be used. Store and 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. HYDROCAL 1005 Manual for Installation and Operation Page 42/111

45 External Sensors After selection of the external sensor submenu, following screen will be displayed: By operation of the arrow keys ( all, you must define each field with required information. ) the different fields can be chosen. First of For Load Current, you can select between Load Current and None. Remark: A Load Current external sensor must exist. See chapter For Top Oil Temperature, you can select between Top oil Temperature, Ambient temperature, Hot-Spot temperature, 1 (Temperature of oil on the sensor), 2 (Temperature in sensor area (ambient temp)) and None. Remark: A Top Oil Temperature external sensor must exist. An Ambient Temperature external sensor must exist A Virtual Hot-Spot Temperature sensor must exist See chapter 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 If necessary, you have to define previously external sensor references as analogue input while pushing button (See chapter for setup). Then, you must define calculation interval. Calculation interval in the field "Calculation interval" is edited by arrow keys and confirmed by the alphanumeric keyboard. The sample interval is made in seconds or by a button in days hours min - seconds. For a double point the After confirmation by the - seconds. button is used. button, the value will be converted and displayed in days hours min At the end, the new references and calculation interval are stored and activated by the button Store and exit. HYDROCAL 1005 Manual for Installation and Operation Page 43/111

46 Cooling stage #1 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: Cooling stage #1 condition o Sensor reading less / equal: in ma Hot-Spot Calculation parameters o Rated Current: Ir in Amp o Winding Exponent: y o Gradient at rated Current: gr o Hot-Spot-Factor: H o Winding Time Constant: Tw in second Usually, all data can be known through transformer manufacture technical specifications. At the end, conditions and parameters are stored and activated by the button Store and exit. For Cooling Stage #2 and Cooling Stage #3, please apply exactly the same procedure in order to setup required information 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 Insulation (Paper): you can select between Normal and Thermally Updated Hot-Spot Temperature Sensor: you can select between None, 1 (Temperature of oil on the sensor), 2 (Temperature in sensor area (ambient temp)), Top Oil temperature, Ambient temperature and Hot-Spot temperature Transformer Loss-of-Live: in hour Transformer Time into Service: in hour into Service since: YYYY-MM-DD If necessary, you have to define previously Hot-Spot Temperature Sensor as analogue input while pushing button (See chapter for setup). HYDROCAL 1005 Manual for Installation and Operation Page 44/111

47 At the end, setup is stored and activated by the button Store and exit Configuration of analogue outputs The HYDROCAL1005 has 5 analog outputs for measured gas-in-oil concentration as well as for external sensors values. The output signal is 0-20 ma or 4-20 ma. The screen also allows to apply test currents to the outputs to verify the functionality. The test current overlays the real signal. Leaving the screen will apply the real signals to all outputs again. First a quantity / variable must be selected. The following functions are available: Scroll up / down marking Enter button: selection of active menus or submenus Store configuration of outputs and exit Exit The following measuring quantities are available in "Sensor" field: H 2 - C 2 H 2 - C 2 H 4 - CO - H 2 O concentration H 2 - C 2 H 2 - C 2 H 4 - CO - H 2 O Daily trend H 2 - C 2 H 2 - C 2 H 4 - CO - H 2 O 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 defined in the field "Sensor : 0, 1, 3, 4, 5, 10, 15, 19 and 20 ma Configuration of analogue inputs (external sensors) The HYDROCAL1005 has a total of 14 analogue inputs. The first six inputs are for bushing sensors and allow an AC signal of either ma or V (configurable by jumper). The next four inputs are for external sensors and a DC signal of 0/ ma can be applied. In addition to the analogue inputs there are so called virtual sensors. These virtual sensors are configured in the same way as the analogue inputs and are explained in this chapter as well. HYDROCAL 1005 Manual for Installation and Operation Page 45/111

48 External sensors with standard output signals (0(4)...20mA) can be connected to the HYDRO- CAL1005 analogue inputs. Note: No power supply is available for external sensors. First an input number must be selected. The first 10 input numbers are assigned to the analogue inputs (1.. 6 bushing, external sensors and 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 are available:, the following functions Scroll up / down Enter button: selection of active menus or submenus Cancel input Scroll up Scroll down HYDROCAL 1005 Manual for Installation and Operation Page 46/111

49 Selection of different input possibilities for the input mode [Mode], and the unit [Unit] - See below. Store alarm configuration and exit Exit without storage The following inputs signal can be selected by pressing the button: The first 6 can be set-up in 0..80VAC, 0..20mA AC, ma or ma The last 4 can be set-up in ma or ma The following unit s can be selected by pressing button: (No unit) ppm ppm/day ppm/week ºC % ma A KA V KV The external sensors names in the field "External sensor #" are edited by arrow keys and confirmed by and the alphanumeric keyboard. The sample interval in the field "Sample interval" is edited by arrow keys and confirmed by and the 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 under the input signals 10V or 20mA. In addition, the display range can be limited by inputting introduction of Minimum Display and Maximum Display. Remark: on following display, you could see 4 additional inputs named: #11: H.-Spot for Hot-Spot Temperature #12: Ag.Rate for Ageing Rate #13: L.o.life for loss of Life #14: All of them are virtual sensors and any cases have to be considered as real analog inputs. However these values are displayed on the main display as external sensors (See Chapter 3.3: Main Menu External sensor setup ). HYDROCAL 1005 Manual for Installation and Operation Page 47/111

50 4.9.4 Configuration of alarms and digital outputs The HYDROCAL1005 unit has 10 digital outputs for alarms. The first 5 (Out1...5) are relay outputs. The on status is closed and the off status is open (output #1 can be configured for reverse operation by a jumper on the circuit board). The next 5 outputs (Out 6..10) are optional opto-couplers, with status contact closed for on and contact open for off. You can have up to 16 possibilities 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 alarm Select setting for configuration of alarm Exit The following measuring quantities are available: H 2 - C 2 H 2 - C 2 H 4 - CO - H 2 O concentration H 2 - C 2 H 2 - C 2 H 4 - CO - H 2 O Daily trend H 2 - C 2 H 2 - C 2 H 4 - CO - H 2 O Weekly trend Temperature 1 Temperature 2 All quantities / variables defined under external sensors HYDROCAL 1005 Manual for Installation and Operation Page 48/111

51 After a measuring variable has been selected and opened with functions are available: for configuration, the following Selection of different input possibilities for the alarm mode (mode), Action (action1..2) and choice of the output (clamp1..2) Activation of input over alphanumeric keyboard for the values: Alarm limit (Level1..2), Delay (Delay1..2) Scroll up Scroll down Scroll up / down Cancel alarm Store configuration of alarm and exit Exit without storage Following alarm settings can be chosen by pressing the button : High: An alarm is triggered when Level 1 is exceeded. High-High: An alarm in 2 steps is triggered. The first alarm is triggered when Level 1 is exceeded; the second 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 2 steps is triggered. Step 1 is alarm is triggered when the measured value falls below the limit defined in Level 1, the second 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 below 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 are edited by arrow keys and confirmed by the button and the alphanumeric keyboard. The quantity is defined by the unit. This is ppm for gas concentration and C for temperatures and for external sensors the unit defined for the respective sensor (e.g. Volt, Ampere...). The alarm limits must be within the corresponding measuring ranges. This is ppm for gases, C for temperatures and for external sensors the limit is defined for the respective sensor. Delays (Delay1...2) can be programmed to suppress alarms if the limits are exceeded only for a short time. 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 button are used. After confirmation by the button, the value will be converted and displayed in days hours min - seconds. HYDROCAL 1005 Manual for Installation and Operation Page 49/111

52 For example: if CO Alarm is setup as follow (delay 1: 10min and delay 2: 20min) In the event of alarms, CO alarms will be activated as follow: Note: CO measurement interval is 20 min. The following actions can be selected by pressing the button: Log entry: An entry in the history of alarms is made; this has to be confirmed (see history of alarms). Output: 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 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 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 alarms is made; this has to be confirmed (see history of alarms) and an entry in the history of alarms is made, this has to be confirmed (see history of alarms) and an SMS is sent to the number indicated. Output & SMS: 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 status on described above is activated. If the measured value falls under the limit, the output is switched off again. In addition, an SMS is sent to the number indicated. HYDROCAL 1005 Manual for Installation and Operation Page 50/111

53 Out, hold & SMS: 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 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 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 Unit Setup The following setup can be modified: Digital Output Test Device Options setup (Backlight display) Date. Time & Clock Settings Communication settings Exit HYDROCAL 1005 Manual for Installation and Operation Page 51/111

54 Digital Output Test This is for Test of the 10 Digital Outputs. For testing the 5 alarms relay outputs, please check Fields KL 402 #. For testing the 5 alarms opto-coupler outputs, please check Fields KL 103 # Device options The configuration of the Backlight display as well as User 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 used. After confirmation by the button, the value will be converted and displayed in days hours min - seconds. Note: 0 means that the screen will be always enlightened. HYDROCAL 1005 Manual for Installation and Operation Page 52/111

55 Input of new User Name and Password are made by operation of the arrow keys ( ) the different fields are selected. Selection is confirmed by the enter button. The customer data can be modified by the alphanumeric keyboard and the arrow keys. Remark: User Name is used for Modem login. The default User Name is EMH String Password is used also for Modem Login. The default String Password is KWA Numeric Password is used for Device Setup menu, Customer Data Setup as well as for communication from HydroSoft Software to the unit (The default password is 999). Toggling of the main Display is made by operation of the arrow keys ( ) the different fields are selected. Selection is confirmed by the enter button. You have followings possibilities: 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 Configuration of user settings By operation of the arrow keys ( ) the different fields are selected. Selection is confirmed by the enter button. The customer data can be modified by the alphanumeric keyboard and the arrow keys. These amendments are stored by selection of button or are rejected by selection of the. In the main menu (standard display) up to 26 characters can be entered. Only the first 10 characters will be displayed. Reset The activation of the reset button will perform a software reset of the device Date. Time & Clock Settings The HYDROCAL1005 has a sub menu allowing configuration of time, date as well as clock HYDROCAL 1005 Manual for Installation and Operation Page 53/111

56 The following functions are available: Scroll 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 is used. button HYDROCAL 1005 Manual for Installation and Operation Page 54/111

57 The HYDROCAL1005 has a universal GMT clock in order to modify the time zone. The time zone setup in the field "Clock offset" is made by button. The time zone values are between -6 and +6 hours. Variable Custom" allows manual setup in the field on the right side. Input of time is made in - hours - minutes -. For a double point, used the button. Note: "None means that GMT clock is not activated. 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 Configuration of the communication The configuration of the communication is made in the following menu: The following functions are available: Ethernet / Network setup Alert SMS setup Internal modem setup RS 232 / 485 setup, MODBUS setup HYDROCAL 1005 Manual for Installation and Operation Page 55/111

58 Status information activation Scroll up / down marking Enter button: selection of active menus or submenus Exit Note: on the main display, you have the currently communication status Ethernet setup The device is equipped with an Ethernet interface to allow the integration into a TCP/IP local area network. How the device has to be incorporated into the network (on site) has to be defined by the network administrator. Hydrocal supports static and dynamic integration. Dynamic 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 corresponding fields in the Hydrocal network screen: IP address Network mask Default gateway TCP Port Number The TCP Port Number may also be defined by the network administrator. Depending on the requirements of other software or devices installed, the port number must be assigned obeying specific rules. If non of these limitations apply, the port number should be assigned in a range (possible range is , but some numbers are reserved e.g. by HTTP or FTP). HYDROCAL 1005 Manual for Installation and Operation Page 56/111

59 Remark: For test purposes a DHCP server can be activated on the device. This feature is only implemented to allow the connection of a laptop / portable computer with Windows standard network configuration. Only for the time of the test the DHCP server would be activated, allowing service staff to communicate with the device via Ethernet. The device is not designed to serve as a real DHCP server in a real network environment Alert SMS setup The configuration of the alert SMS transmission is made in the following menu if HYDROCAL1005 is equipped within an on-board GSM. This function allows sending SMS in correlation with beforehand definite alarms for gas-in-oil concentrations, temperatures as well as for external sensors values. The telephone number of the SMS - Service Center" can be entered into this field. Normally this number is stored on the SIM card and it is not necessary to enter the number. It is required only, if the number is not stored on the SIM card. The system has the possibilities to send 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 entered 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 receive a SMS with serial number of the unit {1}- Custom Line 1: means that in the event of alarms, you will receive a SMS with customer 1 st line displayed on the main HYDROCAL1005 Menu {2}- Custom Line 2: means that in the event of alarms, you will receive a SMS with customer 2 nd line displayed on the main HYDROCAL1005 Menu {3}- Custom Line 3: means that in the event of alarms, you will receive a SMS with customer 3 rd line displayed on the main HYDROCAL1005 Menu {4}- Custom Line 4: means that in the event of alarms, you will receive a SMS with customer 4 th line displayed on the main HYDROCAL1005 Menu {T}- Long Time: Means that in the event of alarms, you will receive a SMS with Time of alarm which has been exceeded with following format: hh:mm:ss {t}- Short Time: Means that in the event of alarms, you will receive a SMS with Time of alarm which has been exceeded with following format: hh:mm HYDROCAL 1005 Manual for Installation and Operation Page 57/111

60 {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 the event of alarms, you will receive a SMS with the alarm Name {a}- Alert Number: means that in the event of alarms, you will receive a SMS with Alert Number {l}- Alert Level: means that in the event of alarms, you will receive a SMS with Alert Level ( 1 for a High alarm or Level 1 and 2 for a High-High alarm or Level 2) Note: The SMS mode (in Alarm set-up) must be selected to use this function. Moreover, GSM modem must be also installed on HYDROCAL1005. These amendments are stored by selection of Internal modem setup button or are rejected by selection of the 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 available: Scroll up / down marking Enter button: selection of active menus or submenus Store the configuration and exit Exit Input of Modem type in the field "modem Type" is made by button: NONE means that the function is not activated Analog (Internal) means that an analog modem is installed on the unit and you want to use it GSM (Internal) means that a GSM modem is installed on the unit and you want to use it Analog Modem If you select an Analog Modem, following screen will e displayed: HYDROCAL 1005 Manual for Installation and Operation Page 58/111

61 Input of Number of Ring 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 - seconds. For a double point, used the button GSM Modem If you select a GSM Modem, following screen will e displayed: Input of Number of Ring 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 - seconds. 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 alphanumeric keyboard and the arrow keys. If no PIN code is necessary to use the SIM card, the input field can be left empty. These amendments are stored by selection of button or are rejected by selection of the RS 232 / RS 485 setup The serial interfaces configuration is made in the following menu. HYDROCAL 1005 Manual for Installation and Operation Page 59/111

62 This section illustrates different ways to communicate with HYDROCAL devices. There are the following main connection / communication scenarios: Host (PC) with one HYDROCAL device via RS232, RS485 or via Modem Point-to-Point Host (PC) with many HYDROCAL devices via RS485 bus RS485-Bus Host (PC) with many 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 software. After a short description screen shots of HYDROCAL and HydroSoft illustrate the setup. Some descriptive comments and hints may follow the screen shots. The setup of the HYDROCAL has to be carried out manually on the device. HYDROCAL 1005 Manual for Installation and Operation Page 60/111

63 A. Point to Point A point-to-point connection / communication is the simplest setup. The host (PC) is connected directly to one HYDROCAL device. The connection can use the RS232, the RS485 or the modem. The default configuration for a HYDROCAL device assumes a point-to-point connection. The same applies to HydroSoft. I. RS485 The RS485 can be used for long connection distances (up to 1000 m). It is implemented as a twowire interface with half-duplex and a soft-handshake. HydroCal HydroSoft Assure that the baud rate is matching and that 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 in special way. For this setup to work, the RS485 bus lines must be biased correctly. The default setup for this property is: ART disabled (i.e. checkbox inactive). PC RS485 Adapters Connecting a PC to the RS485 of a HYDROCAL device usually requires an adapter (interface converter). Depending on the properties of the adapter in use, the RS485 related check boxes in Hydro- Soft must be set accordingly. HYDROCAL 1005 Manual for Installation and Operation Page 61/111

64 For communication with a HYDROCAL device only the two-wire half-duplex mode is of interest. This mode requires a kind of send/receive-control which is either ART (Automatic Receive Transmit control) or a manual control (e.g. via the RTS signal). Further the adapter may echo the send out data. The two checkboxes in the HydroSoft Connection dialog must mirror the properties of the adapter: Ignore Echo Must be checked, if the adapter echo the send out data RTS Send Control Must be checked, if the adapter requires a manual send/receive-control via the RTS signal Answer Delay If an RS485 adapter with RTS send control is used it may be necessary 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 communication point of view the connection via modem is very similar to the point-to-point connection via RS232. The connection supports full duplex, but may be limited in speed. HydroCal HydroSoft The HYDROCAL modem configuration should have been carried out as the device left the production. For HydroSoft select "Connect via:" - "Modem" and fill in the modem connection fields as described in the user manual, i.e. enter user name, password and phone number and select the modem to use for the communication. HYDROCAL 1005 Manual for Installation and Operation Page 62/111

65 B. RS485-Bus Using the RS485 interface it is possible to connect more the one HYDROCAL to a host. Nonetheless it is only possible to communicate with one device at a time. The illustration below shows the schematic topology. Remark: The host (PC) must only be present once (the 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 HYDROCAL can be made right now with up to 32 units Setup "Answer Delay" as required by the RS485 adapter in use (see also chapter: PC RS485 Adapters and Answer delay ) MODBUS must be off Configure RS485 baudrate HYDROCAL 1005 Manual for Installation and Operation Page 63/111

66 In the HydroSoft connection dialog: Use "Connect via:" "Com-Port" Select RS485 baudrate chosen for the devices Check RS485 Set RS485 related checkboxes are required by the adapter (see also: Answer delay ) Enter correct bus address C. Bridge The (RS485-Bus-) bridge is an extension 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 exception. The HYDROCAL that shall serve as the communication gateway must be configured as a (bus-) bridge. I. Bridge Setup HydroCal HydroSoft HYDROCAL 1005 Manual for Installation and Operation Page 64/111

67 On HYDROCAL device: Configure the device as Bus Bridge Set an unique address (1..254). Note: Communication with HYDROCAL1005 can be made right now with up to 32 units Setup Answer Delay as required by the RS485 adapter in use MODBUS must be off Configure RS232 baud rate In the HydroSoft connection dialog: Use Connect via: Com-Port Select RS232 baud rate chosen for the bridge devices Enter correct bus address Bridge via Modem The bridge functionality can also be activated, if the primary connection uses the modem. The corresponding 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 can be made right now with up to 32 units Setup Answer Delay as required by the RS485 adapter in use MODBUS must be off Configure RS485 baud rate In the HydroSoft connection dialog: Use Connect via: Bridge Select the transformer that is equipped with the bridge HYDROCAL in the Device combo box. Enter correct bus address HYDROCAL 1005 Manual for Installation and Operation Page 65/111

68 MODBUS MODBUS via serial interfaces If one or more HYDROCAL devices shall be integrated into a SCADA System for online monitoring, the MODBUS communication setup might be applicable. MODBUS is currently not supported by HydroSoft, but the setup is shown here for completeness As a reference example, the setup of an ADAM port Modbus to Ethernet Data Gateway by Advantech ( is shown below. HydroCal HydroSoft HYDROCAL 1005 Manual for Installation and Operation Page 66/111

69 On HYDROCAL device: Activate MODBUS using the RS485 and the desired mode (RTU/ASCII) Set an unique MODBUS address for each device (1..247). Note: Communication with HYDRO- CAL1005 can be made right now with up to 32 units Set "Baudrate", "Data Bits", "Parity" and "Stop bits" Setup "Answer Delay" if required (i.e. if communication problems occur) Remark: If the MODBUS protocol on the RS 232 interface is active: * If the data flow control (RTS / CTS) is not available * If the internal modem is not available The following parameters in the configuration menu can be entered Mode: This is a toggle button to select the transmission mode (RTU / ASCII) and the serial interface to use for MODBUS. Available entries are: - Off (i.e. the proprietary HYDROCAL protocol is used) - MODBUS RTU via RS485 - MODBUS ASCII via RS485 - MODBUS RTU via RS232 - MODBUS ASCII via RS232 only available for service purposes Address: This is an edit field to enter the device address. For MODBUS, values in the range from 1 to 247 are allowed. For the proprietary HYDROCAL protocol the addresses can be configured from 1 to 254. Note: Communication 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 configured manually. o The proprietary HYDROCAL protocol allows only configuration of the baud rate. The settings of the Data Bits, Parity and Stop Bits toggle buttons are ignored and the configuration is fixed to 8-N-1. Answer delay Test / Debug Options at the HYDROCAL Device In the lower left corner of the configuration screen there is a small MODBUS statistics line with the following information: <==> 0 ; count of all MODBUS messages -> 0 ; count of MODBUS messages for this device <- 0 ; count of all MODBUS answers from this device #! 0 ; count of parity and framing errors in the interface MODBUS via network The MODBUS communication is also possible via the network interface. MODBUS/TCP is implemented on the device and using the default port number 502. It is available regardless of the serial configuration. The functions, registers and address mapping are identical to the serial port implementation. Two MODBUS/TCP connections are possible at the same time. HYDROCAL 1005 Manual for Installation and Operation Page 67/111

70 I. Function, Register and Address Mapping The following MODBUS functions, register- and address ranges are used: Modbus- Function Code 0x02 Read Discrete Inputs 0x04 Read Input Registers 0x04 Read Input Registers Modbus- Address Dec. / Hex 1000 / 3E / 3F / 3E / / 7D / 7D / 7D / 80B Register Address 1) (5 Digit Dec.) HydroCal Alert status Alert #1.. Alert #16 Only the information whether an alert condition is pending is returned. The level of the alert (e.g. Hi or Hi-Hi) is not transmitted. Sensor value Sensor #1.. Sensor #30 The sensor assignment is given below the mapping tables. The sensor value is transmitted as a signed integer. Prior to transmission the real reading is multiplied 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 (0x8000). Sensor value Sensor #1 Sensor #2 Sensor #3.. Sensor #30 The sensor assignment is given above this table. The sensor value is transmitted as a floating point value (32 bit, big endian). An open sensor input is returned as a non signalling NAN (0x7FFFFFFF). HYDROCAL 1005 Manual for Installation and Operation Page 68/111

71 Modbus- Function Code 0x04 Read Input Registers 0x04 Read Input Registers 0x06 Write Single Register 0x06 Write Single Register 0x06 Write Single Register 0x03 Read Holding Registers Modbus- Address Dec. / Hex Register Address 1) (5 Digit Dec.) HydroCal Alert status Alert #1.. Alert #16 The full alert status information is returned. 0 no alert 1 level 1 alert (not active) 2 level 2 alert (not active) 3 active level 1 alert 4 active level 2 alert Query ageing rate Loss-of-Life in seconds Time-into-Service in seconds A value is returned within 2 MODBUS register as a 32-bit unsigned integer in big endian format. Holding Register Test register #1, #2 To test the write functionality there are 2 registers that may be modified freely. (The reset initialization values of the registers are 0xA5A5 and 0x5A5A.) Confirmation / Reset of alerts Alert status #16.. #1 The alerts are coded as a bit field and are presented 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 be reset. Writing '0000' resets all alerts. Switch MODBUS protocol off MODBUS off It is now possible to switch the MODBUS protocol off via MODBUS. This is done by writing 0x00FF (like OFF). Holding Registers 16-Bit test register #1, # ) Modicon PLC addressing scheme Alert status bit pattern #16.. #1 MODBUS protocol status Remark: The reading is always 0x0000. If the MODBUS status is OFF it is not possible to read this status via MODBUS. HYDROCAL 1005 Manual for Installation and Operation Page 69/111

72 Currently the following assignment of sensor numbers applies: 1 gas sensor H 2 2 gas sensor C 2 H 2 3 gas sensor C 2 H 4 4 gas sensor CO 5 temperature sensor (measurement chamber) 6 temperature sensor (oil) 7 humidity/moisture 8 - reserved - 9 daily trend gas sensor H 2 10 daily trend gas sensor C 2 H 2 11 daily trend gas sensor C 2 H 4 12 daily trend gas sensor CO 13 weekly trend gas sensor H 2 14 weekly trend gas sensor C 2 H 2 15 weekly trend gas sensor C 2 H 4 16 weekly trend gas sensor CO external analogue sensors 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 application are free for download. The hardware is not the only hardware that is working with HYDROCAL. The devices are just an example. Applications (for Microsoft Windows): QuickMod Modbus scanning tool (Windows based) AzeoTech, Inc. ( Modpoll Modbus Polling Tool (Command Line Tool) FOCUS Software Engineering ( Hardware: Roline RS232C / RS485 Converter Roline, IC-485S ( ), IC-485SI ( ), ( ADAM port Modbus to Ethernet Data Gateway Advantech ( HYDROCAL 1005 Manual for Installation and Operation Page 70/111

73 I. MODBUS/RTU via RS232 (using QuickMod) RS232 only available for service purposes This test of HYDROCALMODBUS/RTU via RS232 was executed using the QuickMod application. Connection, setup and results are shown below. Physical 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 1016 to query the HYDROCAL external sensors 1..8 (address= , register= ). HYDROCAL 1005 Manual for Installation and Operation Page 71/111

74 QuickMod Monitor II. MODBUS/ASCII via RS232 (using Modpoll) RS232 only available for service purposes This test of HYDROCALMODBUS/ASCII via RS232 (RS232 only available 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= , register= ). HYDROCAL 1005 Manual for Installation and Operation Page 72/111

75 III. MODBUS/RTU via RS485 (using QuickMod) This test of HYDROCALMODBUS/RTU via RS485 was executed using the QuickMod application and the Roline RS2327RS485 adapter ( ). Connection, setup and results are shown below. Physical Connection The RS232-to-RS485 adapter is configured for 2-wire (referred to as MultiDrop Half Duplex in the adapter manual). The terminals pairs T+, R+ and T-, R- are short connected (terminal block connectors 1+4, 2+3). The RS232-to-RS485 adapter is configured to use RTS send / receive control (SW2 in middle position 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 the RS232-to-RS485 adapter from send to receive. In the QuickMod configuration dialog, setting RTS Control to Toggle will operate the RS232-to- RS485 adapter in the desired way. HYDROCAL and QuickMod Data Screens Dumps HYDROCAL 1005 Manual for Installation and Operation Page 73/111

76 QuickMod Monitor IV. MODBUS/RTU on RS485-Bus (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 HYDROCAL 1005 Manual for Installation and Operation Page 74/111

77 HYDROCAL(only device #90) and ADAM-4572 Setup: HYDROCAL is 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) HYDROCAL 1005 Manual for Installation and Operation Page 75/111

78 5. Windows Software HydroSoft 5.1 Purpose of the program HydroSoft is a program compatible with MS Windows for use with HYDROCAL1005 to provide a comprehensive transformer monitoring system. HydroSoft not only reads and processes the data of HYDROCAL1005 but can also used in the configuration of the HYDROCAL1005 unit. The program is compatible for use with operating systems MS XP with Service Pack 3 / Vista /Windows 7. HydroSoft offers the following functions: Reading data from HYDROCAL1005 unit Data processing Export of data to other standard windows programs Storage on data mediums, read from data medium, archiving of measuring data Configuration of analogue inputs of HYDROCAL1005 unit Configuration of alarms and respective alarm outputs of HYDROCAL 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 Export and storage of data 5.3 Requirements to the PC The PC must fulfil the following requirements: Pentium Processor c lock 300MHz Free disc space for installation on hard disk 20 MB, additional memory space for data storage RAM memory 256MB Operating system: XP with Service Pack 3 / Vista /Windows 7 CD-ROM drive Interface RS232C / Ethernet Signals used are RxD, TxD, GND Serial interface cable 1:1.NET Framework 1.1 redistributable must be supported Microsoft Data Access Components 2.6 (MDAC) or new version must be supported HYDROCAL 1005 Manual for Installation and Operation Page 76/111

79 5.4 Installation All components for installation of HydroSoft software package are available on the CD. All components of the software should be installed by the installation program. Put the CD into the drive and start by Setup.exe. Now the installation program guides you through the different steps of the installation. After installation the program HydroSoft can be started. Should the installation program not be executed and ended, not all components will be installed. The missing components will have to be installed manually (chapter 4.41 and 4.42). Please act as described following. First install the.net Framework Microsoft.NET.NET Framework 1.1 Redistributable Install Microsoft.NET Framework 1.1 Redistributable by: dotnetfx.exe and follow the instructions Microsoft Data Access Components Install if necessary Microsoft Data Access Components by execution of: mdac_typ.exe and follow the instructions. HYDROCAL 1005 Manual for Installation and Operation Page 77/111

80 5.4.3 Adaptation of installation If required, you can place the HydroSoft data ("C:\Documents and settings\all Users\HydroSoft\data") into another root, e.g.: "D:\HydroSoft\data" Important: The file "root.xml" (contained in the installation data) must exist in the correspondent new root. The data will be stored in the file Hydrosoft.xml. In case this file does not exist, the system tries to find a file Data in the installation list. In case this file exists, it will be used as a data list. If this file does not exist, the correspondent file in the menu File under Set Data Location... must be selected. 5.5 Functions of HydroSoft program The program HydroSoft works together 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 printed directly. Configuration of HYDROCAL1005 units. 5.6 Start of program In case you have introduced a link to the start menu, press Start in the task bar. Open HydroSoft in the submenu Programs. It is also possible to start the program by HydroSoft.exe If pre-settings are used; the program is to be found under "C:\Programme\MTE\HydroSoft\. First of all, you must to select appropriate application language, by Extra->Language Followings languages can be selected: English, German, French, Spanish, Russian, Chinese, Polish and Turkish. HYDROCAL 1005 Manual for Installation and Operation Page 78/111

81 5.7 Preparation / rename of a new customer list Information is presented in a tree format with the customer 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 possibilities: Either by the menu shown when pressing the right mouse button Or by File->Customer->Rename HYDROCAL 1005 Manual for Installation and Operation Page 79/111

82 5.8 Opening a new transformer station After the customer list has been renamed, a file for a new transformer station can be opened as indicated under chapter 4.7 File->Customer->New Station after selection of the customer list. The number of stations is not limited. After opening a file for a new transformer station, the address of the station can be entered. By double 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 using (HYDROCAL 1002, 1003, 1005 or 1008). The number of transformers for a transformer station is not limited. Then additional details/technical data can be introduced. HYDROCAL 1005 Manual for Installation and Operation Page 80/111

83 In addition to the existing fields Name Manufacturer Type Year Primary voltage Secondary voltage Prim. current Sec. current Additional lines can be added by a right mouse click or by the menu Edit->New. The settings can be put back by Revert. Amendments are stored by Save or by selection of another element in the tree diagram. A transformer has the following sub-information: History: Measured data is presented in form of trend 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 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 5.10) After opening a transformer file and entering its data, connection/communication settings should be entered. It must first be defined, whether the connection shall be via modem (option), by an interface RS232 (Com-Port) or by Network (IP Address). Select the Radio Selection field concerned. HYDROCAL 1005 Manual for Installation and Operation Page 81/111

84 5.9.1 Modem settings During establishment of a modem connection, the Login Name and the password is requested. The name EMH and the password KWA are always used as defaults. In the box Device a modem installed on the PC can be selected for communication. Finally the phone number of the telephone line connected to the HYDROCAL unit must be introduced. Attention: When using a GSM-Modem with HYDROCAL1005, it must be confirmed that a connection to an analogue modem is possible. The network operator should be able to confirm this. Otherwise a GSM modem (e.g. a cell phone) must be used on the PC side too. When connection is via a GSM Modem it is possible that communication during data reading is interrupted due to a communication faults on the GSM network. Under these circumstances 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 RS232 interface settings For local communication over an RS232 interface, the interface number of the PC must be selected. Transmitting speed is Baud; this must be entered into the field Baud rate Settings of HYDROCAL1005 unit Settings for alarms and external sensors can be programmed by HydroSoft. The file HYDROCAL contains the following information, these are read out during a connection: Serial number of HYDROCAL1005 unit Firmware version of HYDROCAL1005 unit Contains the list where data are stored on the PC Date of last read data Customer 1 st line Customer 2 nd line Customer 3 rd line Customer 4 th line Numerical password to modify settings (Default password is 999). String Password to modify Modem Login (Default String Password is KWA). User Name to modify settings (Default User name is EMH). HYDROCAL 1005 Manual for Installation and Operation Page 82/111

85 Alert Setup In the menu settings to alarms can be programmed by HydroSoft. Alarms can be triggered by internal sensors (H 2, H 2 C 2, H 2 C 4, CO, H 2 O, Oil temperature, temperature of sensor) or by external sensors (see chapter 5.11). The recommended temperatures for fault free operation of HYDROCAL1005. Temperature for sensors and oil below 30 C and over 60 C are generally not to expected and indicate a problem in the heating circuit. If temperatures are outside this range, then external (air) temperature and oil temperature must be considered. 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 alarms use the same output line, the status of alarms will be connected by an OR - statement, resulting to activate the corresponding output if an alarm is triggered. In the overview of alarms, (Alert Setup Overview) the following displays forms can be selected: Either List / View in form of a list Or Details view (listing details of alarm settings) Or Symbol view (presenting alarm settings as symbols) HYDROCAL 1005 Manual for Installation and Operation Page 83/111

86 Selection is made by the menu and with right mouse click or by View->View As->... In the views List and Symbol, the following dialogue can be opened by double clicking on one of the alarms (in view Details it is not possible to open this dialogue): First the mode of alarms must be selected under Alert 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 exceeded; 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 the measured value falls below the limit defined in Level 1; the second alarm is triggered when the measured value falls below the limit defined in level 2. HYDROCAL 1005 Manual for Installation and Operation Page 84/111

87 Low-high: An alarm in two steps is triggered. Step 1 is triggered when the measured value falls below 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 outside the limits defined in Level 1 and Level 2. Once the alarm mode is set then, a sensor must be chosen. All above mentioned internal sensors are available. If external sensors are connected and configured, these can also be used (see chapter 4.11). The following measuring values are available: H 2 - C 2 H 2 - C 2 H 4 - CO - H 2 O concentration H 2 - C 2 H 2 - C 2 H 4 - CO - H 2 O Daily trend H 2 - C 2 H 2 - C 2 H 4 - CO - H 2 O Weekly trend Temperature 1 Temperature 2 All values defined under external sensors For a clear distinction of an alarm, under Name a name can be inputted. The alarm levels are entered in the fields Level 1 and if necessary in Level 2. The units defined for concentration of gases ppm, for temperatures C and for external sensors the unit defined for the respective sensor (e.g. Volt, Ampere...) will be used. The alarm limits must be within the respective measuring ranges. This is ppm for gas concentration, C for temperatures and for external sensors the maximum and minimum values of the sensor used. Delays1..2 can be introduced to suppress alarms during short-time exceeding of limits. Since the measuring cycle for gas sensors is 20 min, the delay time should not be less than 20 minutes. The input of delay time is made in seconds or directly in the form [days]-[hours]:[min]:[sec]. The value introduced will be converted after confirmation in [days]-[hours]:[min]:[sec]. Following actions can be selected: Log entry: An entry in the history of alarms is made; this has to be confirmed (see history of alarms). Output: 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 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 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 4.11 or 3.6). Log & SMS: An entry in the history of alarms is made; this has to be confirmed (see history of alarms) and an entry in the history of alarms is made, this has to be confirmed (see history of alarms) and an SMS is sent to the number indicated. Output & SMS: 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 status on described above is activated. If the measured value falls under the limit, the output is switched off again. In addition, an SMS is sent to the number indicated. Out, hold & SMS: 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 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). In addition, an SMS is sent to the number indicated. Data in the tree are changed after modification of alarm settings. The star indicates that modifications have been made; this 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). HYDROCAL 1005 Manual for Installation and Operation Page 85/111

88 External sensors (see also chapter 4.7.3) In the menu, the settings of external sensors are modified. The form of presentation can be chosen as under alarms as List Symbol Details The menu Sensor properties is opened by double clicking on a value or a symbol. The settings of internal sensors cannot be modified and are therefore greyed out. In the box Input Signal, the unit of the input signal can be selected. For the first six inputs (Free analog #1 to Free analog #6), according to options purchased, the following must be chosen: With option Bushing input: mA AC Bush. In. or V AC Bush. In. With option Current input (External Sensors): mA anal In or mA 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 Sensors): mA anal In or mA anal. In For the next four inputs (Free virtual #11 to Free virtual #14), these four inputs are virtual sensors and in any case have to be consider as external sensors or bushing sensors. It is used for calculation of Hot Spot Temperature, Aging Rate and Loss of Life HYDROCAL 1005 Manual for Installation and Operation Page 86/111

89 After selection of the input unit, the unit of the sensor has to be chosen from this list: - no unit C: for temperature-sensors e.g. oil temperature, ambient temperature... ppm: for oil humidity-sensors or other sensors of chemicals %: for oil humidity sensors or other sensors of chemicals V: for voltmeters KV: for voltmeters ma: for ampere meters A: for ampere meters ka: for ampere meters ppm/d: for ppm per day ppm/w: for ppm per week #: A name can be given to each sensor for ease of use. 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 under the input signals 100V or 20mA. In addition, the display range can be limited by inputting introduction of Minimum Display and Maximum Display. Smooth calculation can be used, you can activate this function. Data in the tree are changed after modification of sensor settings. The star indicates 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) Alert SMS Setup In the menu, the configuration of the alert SMS transmission is made if HYDRO- CAL1005 is equipped within an on-board GSM modem. This function allows sending SMS in correlation with beforehand definite alarms for gas-in-oil concentrations, temperatures as well as for external sensors values The telephone number of the SMS - Service Center" can be entered into this field. Normally this number is stored on the SIM card and it is not necessary to enter the number. It is required only, if the number is not stored on the SIM card. The system has the possibility to send 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 entered by alphanumeric keyboard. HYDROCAL 1005 Manual for Installation and Operation Page 87/111

90 A message in the field "Message" can be pre-write in order to be sent to the recipient in the event of alarms while using pre-send message. For this, In the field message click on right mouse button and click on Insert to visualize followings pre-send messages: To add pre-send message, you have to click on them. The following possibilities are available: {#}- Serial Number: means that in the event of alarms, you will receive a SMS with serial number of the unit {1}- Custom Line 1: means that in the event of alarms, you will receive a SMS with customer 1 st line displayed on the main HYDROCAL1005 Menu {2}- Custom Line 2: means that in the event of alarms, you will receive a SMS with customer 2 nd line displayed on the main HYDROCAL1005 Menu {3}- Custom Line 3: means that in the event of alarms, you will receive a SMS with customer 3 rd line displayed on the main HYDROCAL1005 Menu {4}- Custom Line 4: means that in the event of alarms, you will receive a SMS with customer 4 th line displayed on the main HYDROCAL1005 Menu {T}- Long Time: Means that in the event of alarms, you will receive a SMS with Time of alarm which has been exceeded with following format: hh:mm:ss {t}- Short Time: Means that in the event of alarms, you will receive 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 the event of alarms, you will receive a SMS with the alarm Name {a}- Alert Number: means that in the event of alarms, you will receive a SMS with Alert Number {l}- Alert Level: means that in the event of alarms, you will receive a SMS with Alert Level ( 1 for a High alarm or Level 1 and 2 for a High-High alarm or Level 2) Note: You can combine the variable between them in order to have requested Alarm SMS information (e.g. {#}{1}{T}{D}{A}{l}) A message in the field "Message" can also be free pre-write in order to be sent to the recipient in the event of alarms. Note: The SMS mode (in Alarm setup) must be selected to use this function. A GSM / Analogue modem must be also installed in HYDROCAL1005. 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, 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). HYDROCAL 1005 Manual for Installation and Operation Page 88/111

91 Input of DGA Level Adjustment Results of laboratory analysis can be introduced in the menu. These can be used for calculation of correction factors for definition of the gas content. After opening of transformer menu page, the correction factors are shown in the fields Cur. Offset. 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 calculated and presented. After the results of laboratory analysis have been introduced in the fields Laboratory Value for H 2, C 2 H 2, C 2 H 4, CO, CO 2, C 2 H 6 and CH 4, the button is activated and the new correction factor are calculated 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 of sensor settings. The star indicates that modifications have been made; these must be transferred to the HYDROCAL 1008 unit for activation. This means, the settings indicated are not identical to those of HYDROCAL With next connection, it is requested whether the settings on HYDROCAL 1008 unit shall be updated (see chapter 5.11). HYDROCAL 1005 Manual for Installation and Operation Page 89/111

92 Analog Output Setup In the menu, The HYDROCAL1005 has 5 analog outputs for measured gas-in-oil concentration, temperatures as well as for external sensors values. The output signal is 0-20 ma or 4-20 ma. First a quantity / variable must be selected in the field "Sensor", the following variable are available: H 2 - C 2 H 2 - C 2 H 4 - CO - H 2 O concentration H 2 - C 2 H 2 - C 2 H 4 - CO - H 2 O Daily trend H 2 - C 2 H 2 - C 2 H 4 - CO - H 2 O 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 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). HYDROCAL 1005 Manual for Installation and Operation Page 90/111

93 Digital Output Setup Not supported in Hydrocal Device Setup (Clock settings) In the menu, you can modify the date and the time on each HYDROCAL1005. The field "Daylight Saving Time Mode" allows to configure the following time mode : 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 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 HYDROCAL1005 with PC clock while confirming by a click on the field "Synchronize with PC clock" in the following communication box: HYDROCAL 1005 Manual for Installation and Operation Page 91/111

94 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, 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) Ethernet If HYDROCAL1005 communication must be carried out through Ethernet, you must define settings in above menu 2 possibilities: Static IP: Enter the following values o IP address o Port number o Mask (generally 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 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, 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 Error! Reference source not found.). HYDROCAL 1005 Manual for Installation and Operation Page 92/111

95 Modbus-TCP Modbus-TCP is always active on TCP Port 502. Point-to-Point or Bus communication is not possible with Ethernet connection. Ethernet can be used only with Modbus communication MODBUS If one or more HYDROCAL1005 devices shall be integrated into a SCADA System for online monitoring, the MODBUS communication setup might be applicable. MODBUS is currently not supported by HydroSoft, but the setup is shown here for completeness Activate MODBUS using the RS 485 and the desired mode (RTU/ASCII) Set a unique MODBUS address for each device (1 247). Note: Communication 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, 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 Error! Reference source not found.) Data transmission from / to the HYDROCAL1005 unit For transmission of data, the respective transformer menu must be selected in the root. In the lower part of the window, there are three selection buttons available for communication. HYDROCAL 1005 Manual for Installation and Operation Page 93/111

96 Pressing button the connection is initiated and the following selection box is opened: In the dialogue, the following actions can be selected: Read Configurations : Read configurations from HYDROCAL1005 unit. This means that the modifications of alarms and sensor settings made in HydroSoft (indicated by a star) are overwritten by the settings active in the HYDROCAL unit. Read History and Alerts : All measured and stored values, not downloaded previously, are read and stored in the database of HydroSoft. Update Configuration : 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 action (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 disconnect when done : Disconnects automatically the line after data transmission. It is recommended that this field is always selected when using modem connections in order to save on transmission costs. Synchronize with PC clock : synchronize automatically the date and time on the unit with internal PC clock. Input of a numerical password is necessary for this action (Default password is 999). HYDROCAL 1005 Manual for Installation and Operation Page 94/111

97 The standard timeout is 5 seconds, for Modem connections a timeout of 20 seconds is recommended. After confirmation by the Start button, the status of communication will be presented in the window. By pressing the button connection is interrupted. This must be avoided during Login. After interruption, the log-data must be closed by button case of communication problems.. The log-data is used for error tracing in HYDROCAL 1005 Manual for Installation and Operation Page 95/111

98 5.12 View of results To view measured results read out, you must select the History field of the respective transformer. Three operation elements are available (see below picture) Sensor selection This window shows the different sensors available on the HYDROCAL unit. Besides the sensor name, the last measuring value is displayed; this means after having read-out data this is the last measured value. On the left of the sensor name is an activation mark (e.g. : H2 sensor is activated for data presentation). By double clicking on a sensor name, the sensor is activated / deactivated 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 Time range selection The time range for presentation is selected in two steps. Selection of the time range the field Time Span. Available are: 1 hour, 2 hours, 3 hours, 6 hours, 12 hours, 1 day, 2 days, 3 days, 1 week, 2 weeks, 3 weeks, 1 month, 2 months, 3 months, 6 months, 1 year, 2 years and all data. Selection of date of start by mouse click on a date. Using arrow buttons in the calendar dialogue, the following or the next month is presented. HYDROCAL 1005 Manual for Installation and Operation Page 96/111

99 Result window The result window shows all sensor results activated for presentation. The results are presented in form of time trend or graph tables. When on the result window, click the right mouse button to open the menu and select the form desired. There is also 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 selection 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 or by File->Export->Excel. Export into a text file is possible only by File->Export->CSV. Data can be printed directly from the trend view. HYDROCAL 1005 Manual for Installation and Operation Page 97/111

100 5.13 View of alarm status To view alarms, you must select the list Alert under the corresponding transformer. The operation elements are same as indicated under View of results. Under Alarm selection the different alarms defined and selected on the HYDROCAL unit can be activated in form of time trend and table views. In the time range selection, the time to be viewed is defined and results are presented in the alarm window Alarm selection The alarm selection window presents the different alarms available on the HYDROCAL unit. On the right side of the alarm name, the last alarm 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 displayed (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 right mouse button Time range selection The time range for presentation is selected in two steps. Selection of the time range the field Time Span. Available are: 1 hour, 2 hours, 3 hours, 6 hours, 12 hours, 1 day, 2 days, 3 days, 1 week, 2 weeks, 3 weeks, 1 month, 2 months, 3 months, 6 months, 1 year, 2 years and all data. Selection of start date by mouse click on a date. Using arrow buttons in the calendar dialogue, the following or the next month is presented. HYDROCAL 1005 Manual for Installation and Operation Page 98/111

101 Alarm window The alarm window shows all alarm status activated for presentation. The results are presented in form of a time trend chart or a table. When on the alarm window, click right mouse button to open the menu and select the form desired. There is also the possibility to activate the print-function (only from time trend chart) or export function (only from table view) and to fade out the sensor and time range selection Status of alarms Five different alarm status are presented in both View as table and in View as graph. The meaning of the different status is described as follows: 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 limit defined for a High - Alarm is currently exceeded. Status 4: The defined level for a High - High - Alarm is currently exceeded 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 or by File->Export->Excel. Export into a text file is possible only by File->Export->CSV. HYDROCAL 1005 Manual for Installation and Operation Page 99/111

102 5.14 Online Sensors To view a direct/online visualisation, you must select the list Online Sensors under the corresponding transformer. The operation elements are same as indicated under View of results. Under visible sensors the different measuring values (H 2 - C 2 H 2 - C 2 H 4 - CO and H 2 O) 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 Graph Width in second (s) Recording Time Span Recording time in hour (h) HYDROCAL 1005 Manual for Installation and Operation Page 100/111

103 6. RS 485 Wiring This chapter contains information for the wiring of the RS485 connection. RS485 The RS485 interface is implemented as a three-wire interface. The three 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 (see the section Tech Notes). HYDROCAL 1005 Manual for Installation and Operation Page 101/111

104 7. HYDROSOFT Scheduler 7.1 General Up to version the transfer of the history data from the HYDROCAL device into the HydroSoft application could only be started manually. With version an automatic read-out of the history data is possible. This is managed by the new scheduler integrated into HydroSoft. In conjunction with the task scheduler provided by the Windows operating systems, the history data can be held up to date automatically. 7.2 Scheduler The scheduler is active in the background. It periodically checks 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 Configuring a Transformer for automatic History Data Update To configure the automatic history data read-out for a transformer, the connection scheduler dialog is used. To launch the dialog, the transformer main page must be activated by selecting the corresponding transformer in the tree view. The dialog is accessible via the main menu (Transformer -> Scheduler...) or by clicking the rightmost button in the control area of the transformer window. HYDROCAL 1005 Manual for Installation and Operation Page 102/111

105 Connection Scheduler Dialog The connection scheduler dialog allow to configure the automatic history data read-out. (For further details on the setting see 7.2.4, Internal Operation.) The checkbox Scheduled Data Read-Out en- or disables the automatic history data update. The combo box Connect Interval allows the selection of the time span between read-out actions. After a successful history data update the next connection time is calculated by adding the selected interval time span to the current time. If the Connect Interval is at least one day, a connection time can be set in the text box Connect Time. The format for the time is hh:mm:00 (seconds must be zero). When a connect time is set, the time-of-day for the next connection will be set to the specified value. If no special time-of day is required, a dash must be entered ('-'). The Data Read Timeout has the same 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 communication. 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, a double-click on the text box will change the date and time so that the communication will be scheduled in the near future (dialog must be closed with OK to accept the change). The text box Connect Fail Count shows the number of connection failures. Remark: A double-click on this text box can be used to reset the failure counter to zero (dialog must be closed with OK to accept the change) Scheduler Status Visualization The status of the scheduler is visualized in the tree view by changing the icons of the customer, the stations and the transformers Status Icons The status of transformers, stations and the customer is reflected by special icons. The following description explains the meaning of the different icons. HYDROCAL 1005 Manual for Installation and Operation Page 103/111

106 Transformer The standard icon is used for transformers that are not activated for scheduled history data update. The read-out status is good. (The number of connection failures is less than 3.), The read-out status is bad. A connection has been tried several times but was not successful. The icon will be yellow (red) if the number of connection failures is greater then 2 (5). A read-out is pending. The transformer has been marked for a communication and the history data update will be started in the near future. - This status overrules the good/bad-status. The transformer is currently busy in scheduler communication. The history data update is in progress. The transformer is currently busy in a non-scheduler communication (manual connection or online sensor graph running). - This status overrules the good/bad/pending-status Station The station icon is derived from the status of the transformers that are 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 update, 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 transformer of the station. - This status overrules both the good/bad-status. A transformer in this station is currently busy in a scheduler communication Customer The customer icon is derived from the status of all transformers activated for scheduled history data update. The scheduler is active and idle. No communication is pending or active. The scheduler is active and waiting for the next pending communication to be started. A transformer is currently busy in a scheduler communication Example The following screen shots illustrate the scheduler operation. The scheduler is active (clock icon) and has scanned the transformers. The pending communications (Station1 and Transformer4 icon with clock) are marked. Station2 does not contain any scheduled transformers. HYDROCAL 1005 Manual for Installation and Operation Page 104/111

107 The scheduler has started the communication for Transformer1 in Station1 (all related icons indicate the active scheduler communication). The communication buttons in the transformer window control area are disabled. The control area is shown with an alternate background colour to indicate the busy status. The communication with Transformer1 in Station1 has failed more than 5 times. The transformer as well as the station are marked with failure indication icons (red station, red transformer) HydroSoft and the Windows Task Scheduler 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 scheduled history data update in HydroSoft. If for example a daily update is configured in HydroSoft the Windows task must also invoke HydroSoft every day. After the entry has been created with the help of the wizard, the new command line options may be applied to tune the HydroSoft task. Remark: Prior to setting up a HydroSoft task it should be checked that the communication setup for the transformers is correct and it should be proved that the communication is working. HYDROCAL 1005 Manual for Installation and Operation Page 105/111

108 Command Line Options for Windows Task Scheduler HydroSoft comes with two new command line options for use in conjunction with the scheduled history data update. Example: <path>\hydrosoft -IdleClose 0:15:00 -Minimized IdleClose The IdleClose command line option can be given to let the application terminate after all history data updates have be carried out. Following the command line option, a time span argument must be supplied, that defines the idle close time. The syntax for the close time is [hh:[mm:]]ss. When the HydroSoft scheduler scans the transformers for pending history data updates, it determines the shortest time span, when the next communication has to be started. If this time span is greater than the idle close time, the application exits. When a daily update is configured a reasonable default for the idle close time is 15 minutes. This would allow for repeated communication tries (in case of failure), but exit, when the communication fails too often Minimized The Minimized command line option can be given to let the application start minimized. Remark: This option will also suppress the warning message, if the HydroSoft data directory is in use by a manually started HydroSoft application. A Windows task scheduler started instance of Hydro- Soft can immediately exit, if a manually started HydroSoft application is already running Internal Operation This is a more detailed description of the internal operation of the scheduler (the terms in italics are related to the data configured in the connection scheduler dialog). The scheduler runs as a separate thread in the background of HydroSoft. Approximately every 15 seconds all transformers are checked if scheduled data read-out is active. Once a transformer is active, a further check 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 set to zero and the next connect at time is updated (current time plus connect interval - optionally aligned to the connect time). In case of an error the connect fail count is incremented and the next connect at time is set based on the current connect fail count. If the count is less than 3, a connection retry with 5 minutes delay is set, for a count less than 5 the retry is scheduled in 10 minutes. If the count exceeds 5, the next retry is scheduled to the current time plus the connect interval (- optionally aligned to the connect time, i.e. the same time as if the connection had succeeded). When the scheduler detects, that a time span of 3 times the connect interval has expired since the last start of the application, the connect fail count is reset to 4. This will lead to a double communication try for a transformer with a bad status when the application has not been used for a longer time period. Because of the internal operation the following notes apply: Changes applied through the connection scheduler dialog take some time until they are reflected in the tree view. Even if the read-out status of a transformer is bad, there will always be a try to update the data with the configured connect interval. A manual update of the history data does not update the next connect at time of the scheduler. Even if an update occurs immediately before the next connect at time, the scheduled data readout will still be executed. A log file 'Scheduler.log' is created in the root if the HydroSoft data directory. If a problem arises with the scheduler a look into this file may help finding the cause. The log file entries are always written in English. HYDROCAL 1005 Manual for Installation and Operation Page 106/111

109 7.2.5 Data Directory Lock HydroSoft now protects the data directory by a lock. Once an instance of HydroSoft 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 background 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. HYDROCAL 1005 Manual for Installation and Operation Page 107/111

110 8. Technical data HYDROCAL1005 General Auxiliary supply: Power consumption: Housing: Dimensions: Weight: Operation temperature: (ambient) Oil temperature: (inside transformer) Oil Pressure: Connection to valve: 88 VAC min 276 VAC max Optional: 88 VDC min 350 VDC max max. 350 VA Aluminium W 263 x H 263 x D 257 mm Approx kg -55 C C -20 C C Safety CE certified Isolation protection: IEC :2002 Degree of protection: IP-55 Measurements Gas/Humidity-in-Oil Measurement up to 800 kpa (negative pressure permitted) DIN ISO 228: G 1½ Optional: NPT 1½ Measuring Quantity Range Accuracy Hydrogen H ppm ± 15 %± 25 ppm Carbon Monoxide CO ppm ± 20 %± 25 ppm Acetylene C 2 H ppm ± 20 %± 5 ppm Ethylene C 2 H ppm ± 20 %± 10 ppm Moisture ppm ± 3 %± 3 ppm Operation Principle Miniaturized gas sample production based on headspace principle (no membrane, negative pressure-proof) Patent-pending oil sampling system (EP A1) Infrared NIR gas sensor unit for CO, C 2 H 2 and C 2 H 4 Micro-electronic gas sensor for H 2 Thin-film capacitive moisture sensor Analogue and Digital Outputs (Standard) Analogue DC Outputs Default Alternative functions functions Type Range Current DC 0/ madc H 2 Con. Free configurable Current DC 0/ madc CO Con. Free configurable Current DC 0/ madc C 2 H 2 Con. Free configurable Current DC 0/ madc C 2 H 4 Con. Free configurable Current DC 0/ madc Moisture Con. Free configurable Digital Outputs Type Control Voltage Max. Switching Capacity Relay 5 x 12 VDC 220 VDC/VAC / 2 A / 60 W HYDROCAL 1005 Manual for Installation and Operation Page 108/111

111 Analogue Inputs and Digital Outputs (optional) Analogue DC Inputs (External sensors) Accuracy Remarks Type Range of the measuring value Current DC 4 x 0/ madc 0.5 % Analogue AC Inputs (Cap. HV Bushing) Accuracy Remarks Type Range of the measuring value Voltage or Current 6 x 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 U CE : 4 V (rated) / 35 V (max.) U EC : 7 V (max.) U CE : 40 ma (max.) Communication ETHERNET 10/100 Mbit/s (copper-wired or fibre-optical) RS 485 (proprietary or MODBUS protocol) On-board GSM or analog modem (optional) HYDROCAL 1005 Manual for Installation and Operation Page 109/111

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

113 HYDROCAL 1005 Manual for Installation and Operation Page 111/111