INSTRUCTION MANUAL T-935 FO DIGITAL TECSYSTEM S.r.l. Via Cristoforo Colombo, 5/C 20094 Corsico (MI) tel. +39-02 - 48601011 / 4581861 Fax: +39-02 48600783 http://www.tecsystem.it R.3 15/10/01 T-935-FO-DIGITAL protection relays
1) SERIAL TRANSMISSION RS485 (DIGITAL OUTPUT) Due to the introduction of more and more sophisticated long-range control devices of the variables such as the working temperature of Medium Voltage transformers and to their more elaborate protection system, it was necessary to develop ou new monitoring unit, Mod. T-935 FO/DIG. All the variable data and signals coming from the various signal transductors are sent to a PC which works out digital information data and monitors the whole system. In addition to the temperature monitoring of the transformer, through the alarms lightening beyond the set thresholds temperatures, our Mod. T935 FO/DIG also sends to the central PC all digital information about the transformer such as the coils temperature and protection relays condition (ALL1-TRIP-FAULT-FAN1-FAN2). Serial RS485 transmission allows the insertion on the same transmission line of various monitoring units which can also be of a different kind. The PC not only allows to monitor the single Units, but also to change the protection configuration. The transmission protocol used is ModBus RTD which is nowadays one of the most used in the field. The wide and fully detailed instructions that follow will help to understand the application of the digital transmission device. 2 T-935-FO-DIGITAL protection relays
2) TECHNICAL SPECIFICATIONS AUXILIARY POWER SUPPLY Rated voltage 24-240 Vac-dc Maximum ratings 20-270 Vac-dc Vdc with reversible polarities INPUTS COMMUNICATION Serial output Rs232/485 Modbus RTU OUTPUTS 3 inputs RTD Pt100 sensors-3 wires 4 additional input for Pt100 removable rear terminals input channels protected against electromagnetic noises and spikes sensors length cables compensation up to 500 m (1 mm²) opt. Analog inputs 4-20 ma (range 0-200 C) TESTS AND PERFORMANCES Assembling in accordance with CE rules Protection against electrical and magnetic noises CEI-EN50081-250082-2 Dielectric strength: 2500 Vac for 1 minute from relays to sensors,relays to power supply, power supply to sensors Accuracy: ± 1% full scale, ± 1 digit Ambient operating temperature 20 C to +60 C Humidity 90% no-condensing ABS self-extinguishing housing-noryl 94VO Frontal polycarbonate-ip65 Burden 3VA Data storage 10 years minimum Digital linearity of sensors signal Self-diagnostic circuit Opt. Frontal plastic protection Opt. Protection treatment of electronic part DIMENSIONS 96X96MM-DIN43700-prof. 140mm (with rear terminals) panel cutout 92x92mm 2 alarm relays (ALARM-TRIP) 2 alarm relays for fan control (FAN1- FAN2) 1 alarm relay for sensor fault or working anomaly (FAULT) output contacts capacity: 5A-250Vac res. Arranged for output relays test DISPLAYNG AND DATA MANAGEMENT 1 dispaly 13mm high with 3 digits for displaying temperatures led for displaying reference channel led indicating alarm or trip channel led indicating fault temperature monitoring from 0 C to 200 C 2 alarm thresholds opt. 2 alarm ON-OFF thresholds for fan control sensors diagnostic (Fcc-Foc- Fcd) entering the programming by frontal push button automatic output from programming cycle after 1 minute of no-operation wrong programming automatic display programmed data call out possibility of set automatic channel scanning, hottest channel, manual scanning maximum temperatures and alarm reached storage frontal alarm RESET push button possibility of set HOLD function for output relays T-935-FO-DIGITAL protection relays 3
2) MOUNTING Make a hole with the dimensions of 92x92 mm in the panel plate. Fasten firmly the unit by the fixing blocks you are equipped with. 3) POWER SUPPLY The T-935-FO-DIGITAL unit has a Universal Power Supply: it can be supplied indifferently from 24 to 240 Vac-dc without any respect to the polarities. This feature is obtained by the application of a tried power supplier which provides the installer free from the worries concerning the correct Vac or Vdc power supply. The ground cable must be fixed to the clamp 41. When the unit is supplied directly from the secondary of the transformers to protect, it can be fulminated by high intensity overvoltage. This happens when the locking of the master switch is connected without charge. This is much more evident when the 220 Vac voltage is obtained directly from the bars of the secondary of the transformers and there is a fixed phase adjustment condenser of the same transformer. In order to protect the electronic apparatus, we recommend the application of the electronic discharges of the serie PT-73 - mono or double phase - which have been studied by Tecsystem Srl for this specific purpose. Alternatively, we recommend the application of a power supply by 24 Vac or better 24 Vdc. 4) ALARMS AND FAN CONTROL ELECTRICAL CONNECTIONS Carry out the electrical connections on the extractable terminal board after having taken them off from the apparatus (follow the Fig.1). ALARM and TRIP relays energize only when the prefixed temperature limits are reached. The FAULT relay energizes when the apparatus is supplied and it de-energizes when the Pt100 are damaged or when there is no power supply voltage. FAN 1 and FAN 2 relays can be used for cooling-fan control or else they can be fit into the conditioning circuit of the transformer box. 5) THERMOMETRIC SENSORS CONNECTION Each Pt100 sensor has three conductors : one white and two red (CEI 75.8) The Fig.1 shows the disposition in the terminal board of the connection cables to the unit. The CH2 channel must be always refired to the central column of the transfomer. The CH4 channel must be always refired to the core of the transformer or else to the ambient Pt100 sensor, if you want to keep the box of the transformer under thermic control by the T- 935-FO-DIGITAL unit. 4 T-935-FO-DIGITAL protection relays
6) MEASURE SIGNALS TRANSPORT All the transport cables of the Pt100 measure signals must absolutely: be divided from the power ones be realized with shielded cable with twisted conductors have a section of min 0,5 mm² be twisted if you have no shield be firmly fixed in the terminal board have tinned or silvered conductors All the T series units have the sensors linearization with a max error of 1% v.f.s.. TECSYSTEM srl has realised a special cable for the measure signal transport with all the protection requirements according to CEI Norms: mod. CT-ES 7) THERMOMETRIC SENSORS DIAGNOSTIC In case of damage of one of the thermometric sensors which are installed on the machine to protect, the FAULT relays energizes immediately, the ALARM and TRIP LED of the damaged channel (Chn) lighten and the FAULT LED is lightening. The kind of sensor damage will automatically appear on the display. It can be: Fcc if the sensor is in short circuit Foc if the sensor is disconnected 8) SENSOR TEST DEVICE Fcd (damaged sensor) During the normal working of the unit, if you programmed Fcd/YES the display will signal by Fcd that a sensor is damaged and the LED which corresponds to the respective channel will lighten (Chn). The FAULT relay energizes giving a signal to the operator. After the replacement of the damaged sensor, you can RESET the alarm pushing RESET until RST appears on the display. 9) TEMPERATURES DIAGNOSTIC When one of the thermometric sensors surveys a temperature which is superior to 1 C of the alarm limit, after 4 seconds the ALARM relay will energize and the ALARM LED of the respective channel (Chn) will switch on.. We have the same situation when the TRIP temperature limit is surveyed: we have the energizing of the TRIP relay and the lighting of the LED TRIP of the respective channel (CHn). Then the surveyed temperature falls of 1 C in comparison with the prefixed limit for the ALARM and TRIP switching, the relays deenergize and the respective LEDS switch off. T-935-FO-DIGITAL protection relays 5
10) COOLING-FAN CONTROL The T-935-FO-DIGITAL unit, if suitably programmed, can control the ON/OFF condition of the transformer fans according to the two different levels of set temperatures. The transformer side-fans or the air-drifting fans can be controlled in two different ways: using the temperatures surveyed by the sensors on the three columns CHF 1.2.3 - CH4 excluded ALARM and TRIP LED CH1.2.3 switched on (ex. F1: ON at 80 C - OFF at 70 C) (ex. F2: ON at 90 C - OFF at 79 C) by an additonal sensor (CH4/YES) for the ambient temperature in the box of the transformer. CHF 4 ALARM e TRIP LED Ch4 switched on (ex. F1: ON at 40 C - OFF at 30 C) (ex. F2: ON at 45 C - OFF at 35 C) You can select it by UP and DOWN push-buttons. 11) FAN TEST By programming (hxx) you can establish to have the fans set for 5 minutes every xx hours, independently on columns or ambient temperature values. This function has the purpose to verify periodically the fans working, when they are not utilized. Establishing h00 this functions is excluded. 12) HOLD FUNCTION If you set up by programming HLD-YES, ALARM and TRIP relays will be energized until the manual reset when the temperatur falls down below the set alarm thresholds. If you do not want this function you have to establish HLD no by up and dowm push-buttons. 13) DISPLAY MODE Pressing on DISPLAY MODE you establish the visualization ways of the display: HOT: the unit visualizes automatically the hottest channel MAN : manual reading of the channels temperature by UP and DOWN push-buttons T.MAX :the unit visualizes the max. temperature reached by the sensors and the possible alarms starting from last reset. To check the channels press AUM and DIM. SCAN : channels are ciclely every 2 seconds 14) WORKING PROGRAM CONROL In order to control the programmed temperature values, you have to push shortly on PRG. By pushing PRG repeatedly the values previously established appear on the display in sequence. In order to end the visualization you have to push ENT. 6 T-935-FO-DIGITAL protection relays
15) LAMP TEST It is advisable to carry out regularly the LED test of the unit. For this operation you have to push TEST. If one of the LEDS does not work, please send us the unit in order to be repaired. 16) ALARM RELAYS TEST This function allows to test the relays working without any additional instrument. To carry out the test you have to push TEST for 5 seconds: all the LED will switch on and tst lightening will appear on the display. Release it when the RELAY TEST LED will be alight. The first relay to test will be indicated by the display and the respective LED will be alight. The relays to test will be indicated on the display by: Fan 1 : Fan 2 : Flt : Alr : trp : 1st cooling relay 2nd cooling relay Pt100 fault relay alarm relay trip relay Select the relay to test by UP and DOWN push-buttons. Energize it by pushing SET and deenergize it by pushing RESET. In order to stop this procedure, you have to push again TEST and all the relays will be restored to the starting configuration. After 5 minutes of inactivity of the keyboard, the TEST RELAY procedure will be automatically interrupted. 17) ALARM RELAY EXCLUSION If you want to exclude the alarm signal, you have to push RESET: the relay de-energizes and the respective LED, which was alight, starts to lighten. If the transformer temperature is still rising, the ALARM relay will energize again until the temperature value falls down to 5 C below TRIP threshold. In this moment the user can exclude the ALARM again, but in this case, it will not appear any other indication as regards to ALARM relay. The exclusion system will be automatically disconnected when the temperature falls down the ALARM threshold. 18) IMPORTANT NOTICE Before making the insulation test on the electrical panel on which the unit is installed, you must take it off from the power supply in order to keep it out of damage. T-935-FO-DIGITAL protection relays 7
19 PROGRAMMING N PUSH BUT- TONS EFFECT NOTES 1 PRG/SET Keep the push button pressed for 7 until Set appears and PRG starts to lighten. When PRG stops lightening the set DEFAULT ALARM temperature will appear on the display Led program allight 2 set up the established limit 3 PRG/SET TRIP set T appears 4 set up the established limit 5 PRG/SET FAN appears 6 set up FAN YES or NO 7 PRG/SET on the display appears OFF 8 PRG/SET the OFF T appears YES:FAN connected NO: FAN disconnected 9 set up the temperature only if at the step 6 you established YES 10 PRG/SET on the display appears ON 11 PRG/SET the ON T appears 12 set up the temperature only if at the step 6 you established YES 13 PRG/SET on display appears CH4 14 set up CH4 YES or NO 15 PRG/SET way of FAN control on the display appears CHF YES: CH4 connected NO: CH4 disconnected 16 set up CH 1,2,3 or CH4 respective LED alight 17 PRG/SET way of FAN control TEST on the display appears h00 18 set up the number of hours 19 PRG/SET on display appears HLd 20 set up HLd YES or no 21 PRG/SET on display appears Fcd 22 set up Fcd YES or no only if at the step 6 you established YES h00=function disconnected with HLd YES function HOLD established Fcd YES= control of damaged Pt100 connected 23 PRG/SET RS232/RS485 24 set up the Baud rate Baud rate: 1200-2400 - 9600-19.2K, 8 bit, Parity=Even, Stop=1 25 PRG/SET ONLY IF OPZ. RS485 26 set up address for opt. RS485 from 0 to 31 max 27 PRG/SET Prg appears on display 28 set up Prg YES or NO Prg NO= the programming is blocked 29 ENT out of the programming lamp test 30 PRG/SET return to step 1 to set up FAN2 repeat the same procedure as FAN1 8 T-935-FO-DIGITAL protection relays
20) PROGRAMMING REHABILITATION IN CASE OF BLOCK (Prg! no) If the programming has been blocked (step 28), in order to enter again the programming of the unit, it is necessary to carry out the following unblocking procedure : enter the program vision way pushing PRG keep TEST pushed until PRG stops to lighten. ( LED PROGRAM alight ) During the blocking, pushing PRG for more than two seconds, on the display it appears nop to indicate the impossibility to program the data. 21) WARRANTY The T series units are under warranty for 12 months from the delivery date marked on the unit. The warranty is recognised when the unit breaks down due to some production faults or insufficient calibration. The warranty is not valid when the unit is tampered with or when it has been damaged for a wrong sensors connection or wrong power supply, out of the max working limits (20 270 Vac-dc). The warranty is not valid when the unit has been fulminated by eccessive transitory voltages. In this case TECSYSTEM Srl does not answer for damages caused by faulted or defective units. All the delivery expenses (there and back) of the unit must be payed by the Customer.(ANIMA prices, Col. C.). In case of dispute, the qualified FORUM is the one in Milan. The warranty is always EXW our Company in Corsico. 22) PT100 EXTENSION CABLE: TECHNICAL SPECIFICATIONS Cable 20xAWG 20/19 cu/stg Section 0,55 mm² Antiflame Insulation PVC105 In accordance with CEI 20.35 IEC 332.1 Max. working temperature: 105 C Conformation : 4 terns of the numbered conductors (1-1-1...4-4-4) RRW twisted and coloured conductors Shield cu/stg PVC Antiflame protecting covering External diameter 9,0 mm Skeins of 100 m T-935-FO-DIGITAL protection relays 9
FAULT DIAGNOSTIC The unit doesn t switch on even if there is voltage to the terminals The CH4 is in FAULT FOC (Only three Pt100 sensors are connected) One of the 3/4 channels is in FAULT for FOC/FCC During the main switch manoeuvre ON- OFF, the ALARM and TRIP relays energize All the Pt100 sensors are in FCC. The temperature indicated by 1 or more channels is wrong. CAUSES AND REMEDIES Connector not well fit in its place. Connection wires not well closed in the clamp Burnt power supplier. Take away and give voltage again. Wrong programming of the unit. Repete the programming. Check the sensors Pt100 connection. Probable damaged sensor. Subsitute the damaged sensor Strong electrical noises on the power supply line. Plug in the PT-73. Check if the shield of the signal transport cable is connected to the ground on the side of the panel. If you have no shielded cable, you have to put it. (Mod. CT-ES). If it is not available, twist the three connecting wires of the sensors. Wrong connection of the sensors. Upsidedown terminal board. Check the connections and the terminal board Contact Technical Dept. of TECSYSTEM S. r.l. Sudden release of the main switch with a normanl temperature level. A single channel caused the unhooking. Pt100 sensor defective (Fcd). Substitute the sensor.check the measure signal terminal board. Set Fcd function (see page 5). Should the Fcd Fault signal appear on the display again, change the indicated sensor. 10 T-935-FO-DIGITAL protection relays
INSTRUCTION MANUAL T935 MODBUS RTU PROTOCOL Software re. V2.3 T-935-FO-DIGITAL protection relays 11
1) INTRODUCTION : The T935 FO/DIGITAL implements a sub-whole of the standard serial communication protocol Modicon Modbus RTU. The modbus T935 FO/DIGITAL employs a RS485 connection with 2 twisted-pair wire hardware; with this mode it is allowed to connect up to 32 monitoring units on the same wiring. The T935 FO/DIGITAL is always in slave mode. 2) ELECTRICAL CONNECTION The twisted-pair wiring that connects all the units with RS485 needs 120ohm therminal resistors. They are already installed inside the T 935 FO-DIGITAL, therefore it is enough to set the Dip-switch 1 to the ON (rear side), but only on the last unit of the series. The switch is on the rear side of the unit below the plastic cover that can be easily removed with a screw-driver. Important Note : the twisted-pair wires must be connected according to the polarity; then, all the (+) with the (+) and all the (-) with the (-). 3) DATA FRAME The asynchronous transmission frame is made of 1 bit of START, 8 bit Data, 1 bit of parity Even and 1 bit of Stop. The allowed Baud rate are: 1200, 2400, 9600 and 19.2K; the addresses are from 0 to 32 (0 for non-connected). The DATA are 16bit lenght where no specified. 4) DATA PACKET A complete question/answer sequence is as follows : Question from the master : SLAVE ADDRESS FUNCTION CODE DATA CRC - 1byte - 1byte - variable, depends on the function code - 2 bytes Answer from slave : SLAVE ADDRESS FUNCTION CODE DATA CRC - 1byte - 1byte - variable, depends on the function code - 2 bytes 12 T-935-FO-DIGITAL protection relays
5) FUNCTION CODE READING DATA A Bit : CODE 1 (10) Question : Slave addr, 1 (10),Starting address Hi, Starting address Lo, Number of points Hi, Number of points Lo CRC-Hi, CRC-Lo Answer Slave addr, 3 (10), Byte count, Data.., CRC-Hi, CRC-Lo READING DATA OF SET POINT AND TEMPERATURE REGISTERS: CODE 3 (10) Question : Slave addr, 3 (10),Starting address Hi, Starting address Lo, Number of points Hi, Number of points Lo CRC-Hi, CRC-Lo Answer: Slave addr, 3 (10), Byte count, Data Hi, Data Lo..., CRC-Hi, CRC-Lo T-935-FO-DIGITAL protection relays 13
WRITING DATA : CODE 16 (10) Writing questions: Slave addr, 16 (10),Starting address Hi, Starting address Lo, Number of registers Hi, Number of registers Lo, Byte count, Data Hi, Data Lo,..., CRC Hi, CRC Lo Writing answer Slave addr, 16 (10),Starting address Hi, Starting address Lo, Number of registers Hi, Number of registers Lo, CRC-Hi, CRC-Lo EXCEPTION CODE: Exception responses In case of wrong question, the T935 FO/DIGIT answers with modified codes and codified errors according to the following: Packet of error answer : Slave address, Function code (+bit 7 a 1), Exception code, CRC-Hi, CRC-Lo 1 - Function code not present 2 - Wrong data address 3 - Wrong data (ex. length) 6 - The T935 FO/DIG is in programming mode and it cannot answer 6) Holding register e input register addresses (in decimals): Addr. (10) Hi-Lo DataHi DataLo 00-00 00 ALARM SET POINT >Absolute data from 0-199 (10) =0-199 C 00-01 00 TRIP SET POINT > 00-02 00 FAN ON SET POINT > 00-03 00 FAN OFF SET POINT > 00-04 00 FAN2 ON SET POINT > 00-05 00 FAN2 OFF SET POINT > 14 T-935-FO-DIGITAL protection relays
00-06 00 TEMP CH1 > Temp. with offset 25 (10) (range 0-200) 26=1 C, 25=0 C, 24=-1 C,etc. 00-07 00 TEMP CH2 > 00-08 00 TEMP CH3 > Temp. with offset 10 (10) (range 0-240) > 11=1 C, 10=0 C, 9=-1 C,etc. Special values for error Pt100: 00-09 00 TEMP CH4 > (see the instruction T935) 00-10 00 TEMP. MAX CH1 > 0 (10) = Fcc 00-11 00 TEMP. MAX CH2 > 1 (10) = Foc 00-12 00 TEMP. MAX CH3 > 2 (10) = Fcd 00-13 00 TEMP. MAX CH4 > 00-14 00 H.FAN (max cycling interval for test fan operation) 00-15 00 RL-STATUS : relays (1=ON): bit 0 -> Alarm, 1 -> Trip, 2 -> Fault, 3 -> Fan1, 4 -> Fan2 00-16 00 Status prog. : bit 0-> Fan Y/n, bit 1-> Fan2 Y/n, bit 2-> Ch4 Y/n, bit 3-> Fan CH4, bit 4-> Hold Y/n, bit 5-> Fcd Y/n, bit 6->Prg Lock Y/n 00-17 00 Alarm memory : bit 7 6 5 4 3 2 1 0 Ch4 Ch3 Ch2 Ch1 Ch4 Ch3 Ch2 Ch1 --TRIP -ALARM 00-18 Sn.0 Sn.1 00-19 Sn.2 Sn.3 00-20 Sn.4 Sn.5 00-21 Sn.6 Sn.7 00-22 Sn.8 Sn.9 00-23 Sn.10 Sn.11 7) Bit data address (to read with code 1: read coil status): Addr. (10) Hi-Lo DataHi DataLo 00-00 00 RL-STATUS : relays (1 = ON) : bit 0 -> Alarm, 1 ->Trip, 2 -> Fault, 3 -> Fan1, 4 -> Fan2 00-01 00 Status prog. : bit 0 -> Fan Y/n, bit 1 -> Fan2 Y/n, bit 2 -> Ch4 Y/n, bit 3 -> Fan CH4,bit 4 -> Hold Y/n, bit 5 -> Fcd Y/n, bit 6 -> Prg Lock Y/n 00-02 00 Alarm memory : bit 7 6 5 4 3 2 1 0 Ch4 Ch3 Ch2 Ch1 Ch4 Ch3 Ch2 Ch1 --TRIP -ALARM Attention! 1 - The bit sent to the original position, also if the start address needs one bit in the intermediate position 2 - The bit not asked are not masked. T-935-FO-DIGITAL protection relays 15
8) CRC calculation This protocol includes 2 byte CRC-16 in all the transmission. The typical polinomium (11000000000000101B) is used for the calculation and the result is hanged up at the end of the packet. The polinomium is used in reverse order with the more sigificant bit eliminated because useless for the calculation. 9) Parameters description : A - 16bit register AL - A lower part AH - A upper part i,j, - COUNTERS (+) - EXCLUSIVE OR Di - frame datum (thousandth) of the packet N - byte number of the packet, excluded the 2 of CRC G - Polinomium : 1010-0000-0000-0001 shr - shift to the right 10) Algorithm : 1) 0xFFFF -> A 2) 0 -> i 3) 0 -> j 4) Di (+) AL -> AL 5) j +1 -> j 6) shr A 7) if carry then G (+) A -> A 8) if NOT j=8 then go to 5 9) i +1 -> i 10) if NOT i = N then go to 3 11) A -> in CRC (the result is in the L,H) 16 T-935-FO-DIGITAL protection relays
11) CUSTOMER S PROGRAM SETTING NOTES DESCRIPTION SET DATE OF INSTALLATION TRANSFORMER NO. ALARM TEMPERATURE TRIP TEMPERATURE COOLING RELAY YES NO COOLING RELAY 1 T OFF T ON COOLING RELAY 2 T OFF T ON COOLING RELAY CHANNEL 1,2,3 4 CHANNEL 4 YES NO COOLING RELAY TEST h HOLD FUNCTION YES NO SENSOR TEST DEVICE YES NO BAUD RATE bps ADDRESS N. PROGRAM YES NO NOTES T-935-FO-DIGITAL protection relays 17
BT MT 220VAC-24VAC PT-73 FIG.2 T-935 T-935 Possible configuration of Alarm and Fault relays parallel connection 1 2 3 4 5 6 7 8 9 10 11 Fig.3 18 T-935-FO-DIGITAL protection relays
FIG.1 ELECTRICAL CONNECTIONS Pt100 SENSOR CONNECTION CH 1 CH 2 CH 3 CH 4 13 14 15 16 17 18 19 20 21 22 23 24 ALARM AND FAN RELAYS CONNEC- 1 2 3 4 5 6 7 8 9 ALARM TRIP FAULT 10 11 FAN 1 50 51 FAN 2 Pt100 42 41 40 POWER SUPPLY 24-240 VCA-VCC WHITE RED RED 60 61 62 RS 232 GND TX RX RS 485 GND - + TERMINALS FOR DIGITAL OUT- PUT RS232/RS485 MODBUS T-935-FO-DIGITAL protection relays 19
T-935-FO-DIGITAL TEST DESCRIPTION The unit was submitted to the following tests during production: N Description 1 PC board test 2 Input test 3 Test of relay contacts and outputs 4 Key test 5 Lamp test 6 Calibration at 100 and 200 C (for temperature monitoring units) 7 Software test 8 Burn-in minimum 24h Date of shipment: 20 T-935-FO-DIGITAL protection relays