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Summary of Contents for GE Digital Energy Kelman MINITRANS
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Digital Energy Kelman MINITRANS ™ Installation Manual Transformer Oil Dissolved Gas and Moisture Monitor GEDE-GA_M-DLIS-SE.MA-005 Rev 3.1 29-Sep-15...
1 INTRODUCTION 1.1 Product Overview The MINITRANS™ (herein referred to as the product) is an on-line DGA (Dissolved Gas Analysis) system for transformer diagnostics. The product measures the following key fault gases in transformer oil: hydrogen, carbon monoxide and acetylene as well as moisture in the oil and the transformer load current.
2 SAFETY 2.1 Symbols General Warning or Caution. Refer to the Installation Manual / User Guide to prevent injury or damage to equipment. Electrical Hazard. Risk of electric shock. Primary Protective Earth connection. Hot surfaces may be present. 2.2 Warnings The minimum ambient temperature for installation and service activities is −10 °C.
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Only GE-trained and certified personnel may commission GE products. Commissioning tasks include making any connections and/or performing any work within the enclosure, or performing tasks such as purging the oil circuit between the transformer and the product, and/or all first start-up procedures relating to equipment or firmware/software.
3 REQUIREMENTS 3.1 Pre-installation The product can be safely connected to an energised or non-energised transformer. However, if installation personnel are required to work in an energised environment they must be made aware of this prior to work commencing and must observe all health and safety practices, especially when working with conductive materials such as stainless steel installation tubing.
5 DESIGN CRITERIA The product meets the following type tests as listed in Table 5—1: Table 5—1: Type tests Category Standard Class/Level Test EMC Emissions – CISPR 11 Radiated & Conducted Emissions EN 61326-1:2006 FCC Part 15 Radiated & Conducted Emissions IEC 61000-3-2 Harmonic Current Emissions Limits...
6 TRANSFORMER CRITERIA The transformer shall meet the following criteria: The transformer contains mineral type oils (paraffinic or naphthenic) that meet the requirements of IEC 60296, BS EN 60296, VDE 0370 or ASTM D 3487. The transformer oil must be certified PCB free. ...
7 MOUNTING Depending on requirements and the installation environment, the product can be mounted on a separate standalone mounting stand (see Section 7.1) or direct mounted to the body of a transformer using the GE direct mount cradle (see Section 7.2). When considering where and how to mount the product, observe the following points to ensure an appropriate mounting configuration: The location for the product shall allow easy access to the transformer oil...
The chosen location should take account of the potential requirement for testing an onsite water deluge system (if applicable), such that the product is not located in the direct line of water jets. While the product provides IP55-level water spray protection, a water deluge system could exceed IP55 thresholds depending on the location, pressure and direction of the water jets.
7.1.1 Mounting the Product to the Stand The product must be installed on an appropriate mounting structure, such as the optional but recommended mounting stand as shown in Figure 7—1. Note: The product weighs up to 30.5 kg (68 lb) so it is important to take precautions prior to lifting.
Alternatively, for new products (not previously commissioned) it is acceptable to carefully lay the bottom mounting stand on its back and join the product to it while on the ground. Then securely attach both ends of the mounting stand (in the same manner as above), and carefully lift the whole assembly upright.
7.3 Sun Canopy An optional sun canopy provides effective solar shade for the product in environments with prolonged sun exposure. The canopy is fitted to the mounting arrangement onsite as one of the final installation steps. Two types of canopy are available to order separately.
8 PLUMBING The product removes oil from the transformer, extracts the gases, analyses the gases and then returns the oil to the transformer. The locations from which the oil is removed and to which it is returned are important for the accurate analysis of the gases (see Figure 8—1 and Figure 8—2).
8.1 Transformer Valves Figure 8—3 shows the location of the following valves: Figure 8—3: Possible valve locations of a transformer 8.1.1 Fill Valve If the transformer is nitrogen blanketed, the fill valve or any other valve at the top of the transformer should not be used as an oil supply valve because there is no guarantee that there will always be oil at this position.
Ensure that the valve chosen to return oil is not internally piped to another location within the transformer, such as the headspace or the internal windings. 8.1.4 Cooling Loop Valves The product should only be supplied with oil from a cooling loop valve if there are no other valves available.
8.2.2 Oil Return Oil is typically returned to a valve lower on the transformer, such as the transformer drain valve. Do not return the oil to a location that leads directly to a critical location within the transformer, such as a cooling loop designed for directed cooling. ...
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Consider these points when choosing where to route the tubing and estimating how much tubing is required: The route must not interfere with the regular maintenance of the transformer. The tubing shall not be routed so that it could be stepped on, tripped over or damaged by activities near the transformer.
8.3.1 Fitting Requirements Figure 8—4 shows the bottom plate connection points. The stainless steel tubing should be fitted between the transformer and the product as follows, ensuring that The supply line is connected to the OIL IN port (this is the bulkhead fitting at the bottom of the product that is located closest to the right-hand-side when viewed from the front).
8.3.2 Fitting Instructions 1. Insert one end of the tubing into the Swagelok or Ham-Let fitting body as shown in Figure 8—5. Figure 8—5: Fitting body and tubing 2. Ensure that the tubing rests firmly on the shoulder of the fitting body and that the nut is finger-tight.
These points must be observed when connecting to the oil supply valve: Locate the valve on the transformer chosen for the oil supply line. Identify the items needed to adapt the oil supply valve to a ¼ in. female NPT fitting. Select fittings and adaptors made from stainless steel, brass or black iron.
If a flange-type valve is to be used to return the oil and the flange is drilled and tapped to a ¼ in. female NPT fitting, then the drilled hole should be offset to the top of the internal valve diameter to prevent an air pocket from being trapped behind the flange (see Figure 8—9).
9 POWER This section outlines the power requirements, electrical connections and related aspects that must be observed. The power source must be rated 90 V AC to 264 V AC, 47 Hz to 63 Hz. A 10 A to 15 A circuit meeting these requirements must be available at the time of installation.
Figure 9—1 shows the location of the various cable glands and connection points on the base of the product. Power-in (gland) Cable grommet (blank) M8 earth Cable Ambient temperature sensor Condensation Figure 9—1: Bottom plate connections The mains fuse holders with modular fuses for the product are shown in Figure 9—2. Figure 9—3 shows the location of the power supply terminals for the mains supply.
The outer sheath of the mains supply cable shall continue into the equipment as far as possible, so that reinforced insulation is maintained between the operator and mains supply. The mains supply shall be connected so that the protective earth wire is the last wire to take the strain and break free in the event of the cord being pulled.
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The following steps describe how to change the battery: 1. Back up the product data – contact your GE representative. 2. Open the inner door to locate the battery on the system board (see Figure 9—5). 3. Slide the battery out of its housing. 4.
10 ELECTRONICS 10.1 Input Board The product has an input board and a marshalling board for connections. The input board is located on the internal bottom tier of the product and has screw terminals to provide connections to the alarms, PSTN, serial communications and transformer load sensor (see Appendix I).
10.3 Accessory Power There are additional power points to connect +12 V DC or +24 V DC at 0.5 A accessories, such as wireless modems or protocol converters. These are available on the Input board at the front of the product as shown in Figure 10—1). Figure 10—1: Accessory power points for 12 V and 24 V 10.4 External Sensors A transformer load sensor is provided in the product installation kit to measure and...
11 COMMUNICATIONS The product has various communication options available: A USB slave connection allows serial communications with an external computer. This connection is located on the left-hand side of the Input board (see Appendix I). An Ethernet connection using the MODBUS/TCP protocol. This connection is located on the bottom left-hand side of the input board (see Appendix I).
Appendix A Installation Tools and Supplies The tools and supplies for a product installation are listed below. If GE performs the installation, the GE installation engineer will provide these items: GE-supplied Items Description in. Combination wrench (must be imperial in.) 30 cm (12 in.) Adjustable wrench 35 –...
Appendix B Customer Checklist The following checklist details items that the customer must acquire prior to the installation: Prepared, flat mounting surface (unless direct mounted using the cradle)—see Section 7). Parts needed to fabricate a mounting stand (if the product mounting stand or cradle has not been purchased)—see Section 7.
Appendix C Installation Record Customer Contact and Site Details Company: Address: City, State and Postcode (Zip): Country: Phone: Installation Site Name: Site Address: City, State: Postcode (Zip): Country: Primary Corporate Contact: Name: Title: Address: City, State and Postcode (Zip): Country: Phone: Mobile: Email address:...
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Transformer Details Make: Year: Years in Service: Type: Conservator Nitrogen Blanketed Other: MVA Rating: CT ratio: Condition of Desiccant: Attach several photos showing the transformer and surrounding area Attach all available DGA data Total Dissolved Gas: ___________ ppm (sum of all measured gases) Please describe (or attach separately) details of any major maintenance actions, such as a rebuild, vacuum degassing or filtering etc.
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Pre-Installation Photographs It is recommended that photographs of the installation site be taken in advance of the installation in order to properly assess the site, aid in planning the installation and contribute to the Short Duration Safety Plan. The following areas should be photographed: C.3.1 Valves / Plumbing: ...
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C.3.5 Additional Photographs: Any additional devices used in conjunction with the installation, such as junction boxes, telephone line sharing devices, alternative communication devices etc. Overall site photos Any other useful photos MA-005 - MINITRANS Installation Manual - Rev 3.1 29-Sep-15 Page 40 of 85...
Appendix D Tubing Specification and Ordering Details Specifications Rigid Tubing ¼ in. OD X 0.035 in. wall T316 seamless stainless steel tubing (6.35 mm OD X 0.889 mm wall) (ASTM A269 / A213). Flexible hose ¼ in. ID low pressure, 316 stainless steel braid over stainless steel metal flexible hose with welded ¼...
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Do not use 6 mm tubing without the above adaptors. To do so would void the warranty. Tubing Material Stainless steel is the only material that should be used. The use of any other tubing material will cause reliability issues or inaccurate results and void the warranty of the product.
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The reaction changes the chemical makeup of the oil before it reaches the sensor in the product. This causes the product to measure acetylene and possibly other gasses inaccurately. Although a transformer already contains copper, GE Energy’s diagnostic and monitoring equipment is designed to accurately measure the gasses in the oil of the transformer without affecting that oil.
Appendix E Product Dimensions Figure E—1: Front and side dimensions Figure E—2: Base dimensions Note: The product weighs 30.5 kg (68 lb). All dimensions in millimetres (mm). Tolerance is ±5 mm. MA-005 - MINITRANS Installation Manual - Rev 3.1 29-Sep-15 Page 44 of 85...
Appendix F Mounting Stand Dimensions Figure F—1: Front and side dimensions with stand Note: Mounting stand weight is 20 kg (45 lb). All dimensions in millimetres (mm). Tolerance is ± 5 mm. MA-005 - MINITRANS Installation Manual - Rev 3.1 29-Sep-15 Page 45 of 85...
Appendix H Sun Canopy Dimensions Figure H—1 to Figure H—4 show the two canopies and dimensions with the product mounted. All dimensions are in millimetres (mm). Tolerance is ±1 mm. Figure H—1: Mounting-stand canopy front dimensions Figure H—2: Mounting-stand canopy side dimensions MA-005 - MINITRANS Installation Manual - Rev 3.1 29-Sep-15 Page 47 of 85...
Appendix I Input Board Figure I—1 shows the product input board labelled with each terminal and corresponding signal. A description of each terminal is provided in Table I—1. Figure I—1: Input board MA-005 - MINITRANS Installation Manual - Rev 3.1 29-Sep-15 Page 49 of 85...
Appendix J Heat Trace Cable It is recommended that heat trace cable be used on the tubing, if the oil temperature in the tubing can reach temperatures below −10 °C. The customer is responsible for supplying the heat trace cable, which must be installed by a qualified electrician.
Appendix K Direct Mount Cradle Vibration Levels Introduction K.1.1 Purpose and scope The purpose of this appendix is to give guidance as to when the ‘GE Direct Mount Cradle’ should be used to directly mount the product to a transformer. This guidance is based on the study of the: ...
Appendix L Direct Mount Cradle Installation Purpose and Scope The purpose of this appendix is to provide a detailed description of how to install the product onto a transformer using the ‘GE Direct mount cradle’ (Figure L—1) in the following scenarios: ...
Important Considerations The primary earth must be installed. Since the silicone isolators provide a degree of electrical isolation from Ground, the importance of installing the primary earth increases (see Section 9.1). [In a retrofit scenario only.] If welded threaded studs are being used instead of M6 bolts to mount the product to the transformer through the product’s lugs, and those studs are larger than M6 x 40 mm, then the studs must be removed and replaced with the supplied A2 stainless steel M6 bolts torqued to 12 Nm.
Standard Kit The standard GE Direct Mount Cradle kit is outlined in Table L—1: Table L—1: MINI DM-Cradle retrofit kit — KITT00071 Item No. Description 21-1318 MINITRANS - Direct mount support bracket 21-1317 MINITRANS - Direct mount right frame 21-1316 MINITRANS - Direct mount left frame 21-1345 MINITRANS Foam skid...
Installation Procedure L.5.1 Position the product on the foam skid Place the foam skid (21-1345) on the ground with the drawn lines facing upwards as shown in Figure L—3. Figure L—3: Foam skid Remove the product from the transformer ensuring that [Note: In a retrofit scenario only.] the product is kept vertical at all times.
L.5.2 Attach the right and left brackets to the product The following tools and fittings as listed in Table L—2 and as shown in Figure L—5 are required in order to attach the brackets to the product. Table L—2: Bracket tools and fittings Item No.
Push the right bracket up vertically as far as possible before tightening the fittings. Use the nut spinner and Allen key as listed in Table L—2 to tighten the fittings as shown in Figure L—7 (recommended torque is 12 Nm). ...
Place the support bracket (21-1318) at the mounting position on the transformer and bolt in position with the fittings as per the images shown in Figure L—9 (recommended torque is 12 Nm). M6 bolt (20, 40 or 60 mm as M6 nut, M6 spring &...
L.5.4 Suspend the product on the support bracket and attach the bottom isolators The following tools and fittings as listed in Table L—4 and as shown in Figure L—12 are required in order to suspend the product to the support bracket and attach the bottom isolators.
On the remaining two isolators, place an O ring (MECH00249) over the thread of each isolator (one O ring per isolator) as shown in Figure L—14. Position the isolators between the bottom lugs of the support bracket and the bottom holes on the right and left brackets.
Large flat washers M6 nut, spring and flat washers M6 nut, spring and flat washers Figure L—15: Attach fittings to isolators L.5.5 Fit the failsafe mechanism The following tools and fittings as listed in Table L—5 and as shown in Figure L—16 are required in order to fit the failsafe mechanism to the support bracket.
Attach the parts for the failsafe mechanism to the remaining threaded inserts in the support bracket as shown in the images of Figure L—17 and tighten with the Allen key. Note: If necessary, use the spanner to tighten the nut (recommended torque is 5 Nm). M6 nut, washer and spring washer Figure L—17: Fitting the failsafe mechanism...
Checks and Measurements Isolator Alignment: Inspect all six isolators to ensure proper alignment. If required, unscrew the nuts and adjust the isolators so that the opposing threaded portions of each isolator are aligned. Measure skew distance: Report any skew which is greater than 4 mm (measured from bolt centre to bolt centre) as shown in Figure L—18.
Appendix M Direct Mount Cradle Locking Mechanism Introduction M.1.1 Purpose and scope This appendix details how to use the Locking Mechanism on a Direct Mount Cradle- installed MINITRANS so as to prepare a transformer for transit. Typically this occurs in the following scenarios: ...
M.1.3 Visual inspection Inspect all six isolators at the following times: In situ before and after preparation for transit. In situ before and after relocation / installation at each new site. Each inspection shall look for the following signs: ...
Compression check: Measure the distance of compression on all six isolators and ensure that it is less than 21 mm as shown in Figure M—3. If it is greater than this value, the isolator will be in tension and will likely fail. Contact the Customer Service Centre.
Preparation for Transit If the transformer and monitoring product (mounted to the transformer using the GE Direct Mount Cradle) are to be transported in situ, then the following steps must be taken: Power down the product as outlined in the MINITRANS User Guide or as outlined in Section M.2.1.
Place the top locking piece (21-1341) over the isolator threads and into the cutout of the top arm as shown in Figure M—7. Locking Piece Top 21-1341 Figure M—7: Locking Piece Top Replace the fittings, failsafe configuration and fasten as per the images shown in Figure M—8.
M.2.2.2 Bottom isolators Partially unscrew the fittings from the front of the bottom two isolators. Pull the large flat washer forward to allow room to install the bottom locks. [pull forward] Figure M—9: Bottom isolators with partially unscrewed fittings ...
Attach the two bottom locks (21-1339) over the two bottom isolators by sliding them over the isolator threads as shown in Figure M—11. Note: Fitting the locks may require a little pressure in order to compress the isolators. This is achieved by pushing the bottom of the product towards the transformer.
M.2.3 Attach the interior PGA locks The following tools and fittings as listed in Table M—2 and as shown in Figure L—12 are required in order to attach the PGA locks to the product. Table M—2: Tools & fittings Item No. Description 4 mm Allen key 21-0598...
Take one of the PGA locks (21-0598) and attach it to the right hand side of the PGA between the top and bottom PGA brackets as per the images shown in Figure M—15. Use two M5 × 30 mm bolts and two rib lock washers to fasten the PGA lock and tighten with a 4 mm Allen key.
Reconnect the LCD cable to the inner panel’s LCD display board as shown in Figure M—16. Figure M—16: Reconnect LCD display board cable Replace the inner panel and secure in place with the previously removed screws as shown in Figure M—17. Figure M—17: Inner panel ...
Preparation for Installation If the transformer and monitoring product (mounted to the transformer using the GE Direct Mount Cradle) are to be reengaged after transportation in situ, then the following steps must be taken: M.3.1 Remove the exterior isolator locks The exterior isolator locks must be removed after transit and before the product is powered on.
M.3.1.2 Top isolators Unscrew both failsafe bolts and remove the failsafe configuration shown in Figure M—21 using a 5 mm Allen key or a 10 mm spanner. Then unscrew the M6 nut from the isolator and remove the fittings from all four top isolators as shown in Figure M—21 and Figure M—22.
Remove the top locking pieces, then replace the failsafe configuration securely and invert the top locking pieces over the threads of the isolators as shown in Figure M—23. Use the front isolator threads to store the bottom locking pieces. ...
M.3.2 Remove the interior PGA locks The interior PGA locks must be removed after transit and before the product is powered Ensure that the product is isolated from the mains electrical supply. Open the door of the product. Loosen screws and remove panel Figure M—26: Inner panel Remove the black inner panel by removing the screws as shown in Figure M—...
Disconnect the cable shown in Figure M—27 from the rear of the LCD display. Disconnect this cable from the LCD board Figure M—27: Rear view of LCD display board with cable attached Locate the PGA locks and unscrew the M5 × 30 screws that hold the PGA locks in place using a 4 mm Allen key.
Store the locks and fittings in a secure location. If preferred, the PGA locks and fittings can be secured to the right hand side of the bottom PGA bracket using the threaded inserts as per the images shown in Figure M—29 to Figure M—31. Figure M—30: Stored PGA locks Figure M—29: Threaded inserts Figure M—31: PGA locks secured using Allen key...
Reconnect the LCD cable to the inner panel’s LCD display board as shown in Figure M—32. Figure M—32: Reconnect LCD board cable Replace the inner panel and secure in place with the previously removed screws as shown in Figure M—33. Close the door of the product. Figure M—33: Inner panel...
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