Operating Instructions OI/CoreSense-EN Rev A CoreSense hydrogen and moisture sensor The sensor that enables Transformer Intelligence Online hydrogen and moisture sensor for incipient fault detection Introduction Transformers are critical elements of the electrical grid. To increase their reliability, performance and service life you need to know the unknown. Monitoring and detection of early faults before they become apparent. CoreSense continuously monitors hydrogen levels in transformer oil to provide an early warning for most incipient transformer faults. In addition to hydrogen, CoreSense can also continuously monitor moisture levels. Moisture can compromise the insulating properties of oil and accelerate the aging of transformers.
TABLE OF CONTENTS 1.0 About This Manual... 3 1.1 Purpose of Document... 3 1.2 Definition of Symbols... 3 2.0 Safety... 4 2.1 Warnings, Cautions and Notices... 4 2.2 Handling... 4 2.3 Power Connections... 5 7.0 Post installation check list... 27 8.0 Maintenance... 28 8.1 Replacing the fuse... 28 8.2 Taking an oil sample... 28 8.3 Cleaning... 28 9.0 Frequently asked questions and Troubleshooting... 29 3.0 Description of the CoreSense hydrogen and moisture sensor... 6 4.0 Installation Preparation... 7 4.1 Tools for the installation... 7 4.2 Unpacking... 7 4.3 Handling... 7 4.4 Place of installation on the transformer... 9 4.5 Planning your cabling... 10 4.6 Planning your communications... 10 4.6.1 Default RS-485 configuration...10 4.7 Password protection... 11 5.0 Physical Installation... 12 5.1 Installation on transformer valve (part 1)... 12 5.1 Installation on transformer valve (part 2)... 13 5.2 Remove cover... 14 5.3 Cabling... 14 5.3.1 AC power line terminal block...16 5.3.2 Wiring the RS-485 interface to SCADA...16 5.3.3 Wiring the Ethernet interface to SCADA...16 5.3.4 Wiring the optional optical Ethernet interface to SCADA...16 5.3.5 Wiring the alarm relays (dry-contact)...17 5.3.6 Wiring the analog 4-20 ma outputs...17 5.3.7 Wiring the optional 4-20 ma inputs...17 5.4 Re-install cover... 18 Appendix A - Technical Specifications... 31 A.1 Description... 31 A.2 Measurement specifications... 31 Appendix B - Modbus Table... 33 B.1 Default RS-485 configuration... 33 B.2 Default TCP configuration port... 33 B.3 Modbus parameters... 33 Appendix C - DNP3... 35 C.1 Default RS-485 configuration... 35 C.2 Default TCP configuration port... 35 Appendix D - Sensor software update... 36 Appendix E - List of CoreSense factory default values... 37 Appendix F - List of system events... 38 Appendix G - Definition of exported values... 39 G.1 Hydrogen.csv... 39 G.2 Moisture.csv... 39 G.3 Events.csv... 39 Appendix H - Third Party Legal Notices... 40 6.0 Configuration... 19 6.1 Connecting a Laptop for the first time... 19 6.1 Configuring the sensor... 19 6.2 Tabs of the web interface... 20 6.2.1 Hydrogen settings dialog box...22 6.2.2 Moisture settings dialog box...22 6.2.3 Administration settings dialog box...23 6.2.4 Communication settings dialog box...23 6.2.5 About dialog box...24 6.3 Configuring alarm levels... 25 6.3.1 ROC trigger level...25 6.3.2 Latched alarms...25 6.4 Visual Indication, system status, hydrogen and moisture alarms... 25 6.4.1. How to interpret the hydrogen or moisture visual indicators...25 6.4.2 What to do if there is a WARNING or an ALARM?..26 2 OI/CoreSense-EN Rev A Operating Instructions
1.0 About This Manual 1.1 Purpose of Document This document is intended for personnel installing and operating the CoreSense hydrogen and moisture sensor. It contains product specifications as well as instructions for installation, operation and troubleshooting. To ensure personal safety and optimal performance, make sure you thoroughly read and understand the contents of this manual before installing or using the Sensor. NOTICE Property damage There are no field serviceable or user adjustable parts in the sensor except for the fuse. Any maintenance or repair work on the sensor must be carried out at the factory. NOTICE Property damage This symbol indicates a potentially damaging situation. Failure to observe this safety information may result in damage to or destruction of the product and / or other system components. IMPORTANT (NOTE) This symbol indicates operator tips, particularly useful information, or important information about the product or its further uses. The signal word IMPORTANT (NOTE) does not indicate a dangerous or harmful situation. The ESD symbol indicates the presence of equipment sensitive to electrostatic discharge. The Ground symbols is used to identify protective earth conductor terminals. 1.2 Definition of Symbols This publication uses pictographic symbols to attract attention to key technical or safety related information. The symbols should be interpreted as follows: DANGER Serious damage to health / risk to life The electrical warning symbol indicates the presence of a potential hazard which could result in electrical shock. WARNING Bodily injury The electrical warning symbol indicates the presence of a potential hazard which could result in electrical shock. DANGER Serious damage to health / risk to life The ISO General Warning symbol indicates safety information that must be followed by the user. The information concerns the presence of a potential hazard which could or may result in personal injury or even death. WARNING Bodily injury The ISO General Warning symbol indicates safety information that must be followed by the user. The information concerns the presence of a potential hazard which could or may result in personal injury or even death. DANGER Hot Surface Potential burn hazard. DANGER Sharp surface The sharp surface warning symbol indicates the presence of a sharp surface of object that could result in personal injury if touched. Operating Instructions OI/CoreSense-EN Rev A 3
2.0 Safety 2.1 Warnings, Cautions and Notices User must comply with all warnings, cautions and notices indicated in this manual. DANGER Serious damage to health / risk to life Failing to comply with any of the instructions, precautions or warnings contained in this manual is in direct violation of the standards of design, manufacture, and intended use of the equipment. ABB assumes no liability for the user s failure to comply with any of these safety requirements which may result in personal injuries and/or equipment damages. DANGER Serious damage to health / risk to life Do not, under any circumstances, remove the warning and caution labels. Information must be available at all times for the security of the user. Read this manual thoroughly before using this equipment. If you do not fully understand the information contained in this manual or if the equipment shows any sign of damage, please contact ABB. Refer to the back cover of this manual for contact information. If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. Equipment intended for field installation by qualified service personnel according to manufacturer s installation instructions and local/national wiring requirements. DANGER Serious damage to health / risk to life - High Voltage Disconnect power at circuit breaker of the distribution panel before opening the sensor. Ensure that the equipment and any devices or power cords connected to the Sensor are properly grounded. Make sure the sensor ground is at the same potential as the transformer ground. Protective earthing connection (grounding) must be active at all times. The absence of grounding can lead to a potential shock hazard that could result in serious personnel injury. If an interruption of the protective earthing is suspected cut the power to the sensor at the plant s distribution panel and have the electrical circuit tested. NOTICE Property damage In accordance with IEC61010-1 edition 3.0, to prevent contamination of the electronics by outside elements the sensor cover shall be removed only under controlled environmental conditions defined as: Temperature shall be 5 C to 40 C Maximum relative humidity 80 % for temperatures up to 31 C decreasing linearly to 50 % relative humidity at 40 C. Do not expose the interior of the sensor to rain or snow. DANGER Serious damage to health / risk to life An external circuit breaker with a 15 amps rating or less must be installed on the AC source and labelled accordingly in compliance with your country s National Electrical Code. DANGER Serious damage to health / risk to life The CoreSense is an overvoltage category II instrument. DANGER Serious damage to health / risk to life Use only fuse(s) specified as appropriate for this equipment, refer to Appendix A - Technical Specifications on page 31. NOTICE Property damage The sensor can be powered when it does not contain any oil for configuration purposes. But the thermal pump must be turned OFF, this can be done in the web interface (in Settings/ administration settings). The CoreSense is delivered with the thermal pump turned OFF to avoid accidents. When the installation is complete and the sensor is in contact with oil, make sure the thermal pump is enabled in the web interface. Operating the heater in air will result in failure of the thermal pump. 2.2 Handling The CoreSense hydrogen and moisture sensor weighs approximately 8 kg. Make sure to use proper body mechanics (bend your knees) when lifting the sensor to avoid personal injuries. WARNING Bodily injury Do not grab the sensor by the threaded NPT interface. The threaded edges are sharp and there is a risk of personal injury. 4 OI/CoreSense-EN Rev A Operating Instructions
DANGER Hot Surface The sensor contains an internal heater and thus some parts of the sensor may be hot when powered, i.e. all parts that contain the hot oil. Always manipulate the sensor with caution. 2.3 Power Connections In accordance with international safety standards, the sensor uses a three wire power cord typically connected to an electrical panel that provides grounding for the chassis of the sensor. Installation of the equipment is to be performed by qualified personnel only. Operating Instructions OI/CoreSense-EN Rev A 5
3.0 Description of the CoreSense hydrogen and moisture sensor The CoreSense continuously monitors hydrogen and moisture levels in oil and alerts the user when either one starts increasing beyond a predefined threshold. Realtime monitoring complements periodic off-line dissolved gas analysis by alerting the user much sooner to evolving conditions. Hydrogen was chosen as the main fault indicator for the CoreSense because it is almost always the first gas present when an incipient fault begins to manifest itself. Increased moisture together with temperature and oxygen can lead to accelerated insulation aging. Thus monitoring both parameters allows users to react quickly, investigate and fix developing issues with their transformers. The CoreSense can be mounted at multiple locations on the transformer including on the drain valve because it uses a heating element to induce forced convection and ensure that fresh representative oil is always reaching the solid state sensing elements. The goal of the CoreSense is to reduce transformer maintenance and increase reliability. These benefits should not be compromised by sensor maintenance requirements. Therefore, we designed the CoreSense for maximum reliability. The result is a design that is entirely solid state and does not make use of any oil-gas separation system whatsoever, neither membrane or headspace. Instead two solid state sensing elements are directly in contact with the oil. The hydrogen sensing element is a small palladium element deposited on an electronic chip. This element was subjected to long term tests showing no deterioration over a 20 year period. The moisture sensing capacitor does not deteriorate over time. The rest of the CoreSense consists of the thermal pump that induces forced convection so that fresh oil is always in contact with the sensing elements and the electronics to drive the readings and communications. The effective lifetime of the CoreSense is therefore expected to be at least 15 years. The CoreSense user interface is designed as a series of simple web pages that can be accessed through most web browsers. The web interface allows viewing the current status of the CoreSense and setting configurable parameters. Oil sampling access panel Cabling ports (1/2 NPT) 1.5 NPT port Interface to transformer valve Ground lug connection Moisture LED System LED Hydrogen LED 6 OI/CoreSense-EN Rev A Operating Instructions
4.0 Installation Preparation 4.1 Tools for the installation Wire cutter Supplied tools 4 mm Allen Key Flat screwdriver 5 mm Allen Key Optical termination equipment if installing the optional optical Ethernet port Spare parts (one of each included with the sensor) O-ring No. 1 (Sensor enclosure) Buna-N O-ring no: AS568A DASH NUMBER 269 O-ring No. 2 (Sensor brass fitting) Metric Buna-N O-ring 3 mm width, already installed on sensor 50 mm inside diameter Additional recommended tools (not provided by ABB) Torque wrench Transformer valve adapter (when applicable). Laptop with Internet Explorer 9 or above (for sensor commissioning) Personal protection equipment necessary for installation Safety shoes Straight Ethernet cable (for sensor commissioning) 2 in wrench or adjustable wrench (50.8 mm) Gloves 8 mm wrench or adjustable wrench (0.31 in) Protective glasses Roll of PTFE tape Bleeding hose (ID. 1/8 ) Bucket and rags 4.2 Unpacking The sensor is supplied in a cardboard box with internal shock absorbing packaging. Always transport the sensor in the packaging supplied to minimize the risk of damage. Wire stripper 4.3 Handling The product is designed to withstand many industrial environmental conditions. However, a few handling precautions will ensure reliable operation of the unit for many years to come: DO NOT DROP the sensor. It is not recommended to open the CoreSense if it is raining or snowing Operating Instructions OI/CoreSense-EN Rev A 7
Always turn off power at the electrical panel before doing any installation or adjustment. Do not expose the internal electronics of the sensor to any liquids or dirt. Ensure that the cable glands are tight after connection and that all 4 cable glands contain a cable. Make sure the cover is well secured with the supplied O-ring once connections inside the sensor have been completed, refer to 5.2 Remove cover on page 14. IMPORTANT (NOTE) While the initial (cold start) accuracy of the sensor is likely to be within specification, a settling period of approximately 12 hours is strongly recommended to allow the electronic components to fully warm up and the internal temperature to stabilize. 8 OI/CoreSense-EN Rev A Operating Instructions
4.4 Place of installation on the transformer On the transformer, several mounting locations may be available for installing the sensor. Care should be taken to select a mounting location where the sensor will be exposed to maximal oil flow and minimal oil temperature. The following table can be used to help select the best location: Locations Benefits Issues A- Radiator Return Good oil flow Connection flange rarely present Low operating temperature Easily accessible B- Drain valve Low operating temperature Low oil flow may increase reaction time Easily accessible Sludge could accumulate here Always available C- Top tank (fill valve) Good oil flow from thermal convection Temperature may exceed 100 C Difficult to access Installation requires working at height Power down of transformer during installation mandatory D- Top of radiator Good oil flow Temperature may exceed 100 C Difficult to access Installation requires working at height Connection flange rarely present Power down of transformer during installation mandatory C Acceptable Installation location Acceptable Installation location D B Good installation location Figure 4-1 Recommended installation locations A Best Installation location Operating Instructions OI/CoreSense-EN Rev A 9
4.5 Planning your cabling Select cabling according to your communication needs. Refer to table below for recommended cable gauge or cable type. Always comply with national codes and electrical standards. Cable Gauge/type Maximum length Power 12 AWG 15 m (50 ft) 14 AWG 10 m (33 ft) Ground 10 or 6 AWG 15 m (50 ft) RS-485 24 AWG 1220 m (4003 ft) Alarm relays 16 or 14 AWG N/A 4-20 ma 18 AWG N/A Ethernet (SCADA) Category 5 cable 100 m (328 ft) Optical Ethernet ST-ST Plenum Duplex 2000 m (6562 ft) 62.5/125 Multi-mode Fiber Ethernet (service port) Category 5 cable 3 m (10 ft) USB (service port) USB key only N/A Warning All cables must have a diameter of 10 to 14 mm when used with the supplied cable glands in order to maintain the IP67 rating of the sensor. All 4 cable glands must contain a cable. If necessary tape can be used to adjust for the minimum required diameter. Failure to comply may result in water infiltration and create an electrical shock hazard. 4.6 Planning your communications The digital protocols supported by the sensor are Modbus and DNP3. Both protocols are available on the RS-485 serial interface, the Ethernet SCADA port or the Optical Ethernet port. Table 1 below shows the default RS-485 serial configuration. These defaults can be modified at any time using the built-in web interface. 4.6.1 Default RS-485 configuration Baud rate 9600 Data bit 8 Stop bits 1 Parity None Flow control None The RS-485 default settings can be modified using the Web interface. When using Modbus, the default slave ID=1 and when using the DNP3 the default outstation ID=4. Table 1: Summary of communications Port Default communication setup Setting options from web page (refer to 6.2.4 Communication settings dialog box on page 23). RS485 serial Baud rate 9600 Baud rate 110; 300; 600; 1200; 2400; 4800; 9600; 19200; 38400; 57600; 115200; 230400; 576000; 921600; 11520000 Data bits 8 Data bits 7; 8 Stop bits 1 Stop bits 1; 2 Parity None Parity None; Even; ODD Flow control None Flow control None SCADA Ethernet DHCP client Static IP; DHCP client Admin settings on SCADA port can be enabled or disabled using the web interface. Fiber optic DHCP client Static IP; DHCP client SCADA Admin settings on SCADA port can be enabled or disabled using the web interface. When the fiber optic port is in use the ETHERNET SCADA port must not be used. Service Ethernet DHCP server Static IP; DHCP server. Default IP address range 172.16.100.x for PC ABB remote access can be enabled or Default IP address for CoreSense disabled using the web interface. 172.16.100.1 Protocols Modbus (point to point only): default slave ID = 1 Default DNP3 outstation ID = 4 Web http port 80 Modbus TCP port 502 DNP3 port 20.000 Web http port 80 Modbus TCP port 502 DNP3 port 20.000 10 OI/CoreSense-EN Rev A Operating Instructions
IMPORTANT (NOTE) For best results it is recommended to configure the Modbus or DNP3 master with a timeout of 10000 ms and 5 retries. Minimum delay between polls shall be at least 100 ms. User role Default password Acknowledge Ack Administrator Admin Default passwords can be modified using the Web interface. NOTICE Cyber security This product is designed to be connected to and to communicate information and data via a network interface. It is the User s sole responsibility to provide and continuously ensure a secure connection between the product and the User s network or any other network (as the case may be). User shall establish and maintain any appropriate measures (such as but not limited to the installation of fire walls, application of authentication measures, encryption of data, installation of antivirus programs, etc) to protect the product, the network, its system and the interface against any kind of security breaches, unauthorized access, interference, intrusion, leakage and/or theft of data or information. ABB Ltd and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information. If you are planning on connecting to the Ethernet port or the optional optical Ethernet port, contact your network administrator to confirm the network settings and check that the service ports described in the table below are accessible. The SCADA Ethernet port and the optional optical Ethernet port are configured at the factory as DHCP clients. Ethernet ports may also be configured with static IP settings. The SERVICE Ethernet port is configured as a DHCP server and will automatically assign an IP address to your laptop\pc in the 172.16.100.x range. The default server address on the SERVICE port is 172.16.100.1 Application TCP ports table Application Port Web Interface 80 Modbus TCP 502 DNP3 20.000 ABB diagnostic port 22 The ABB TCP diagnostic port can be enabled or disabled using the Web interface. 4.7 Password protection The sensor is secured by a password for the acknowledger role and a password for the administrator role. The default passwords should be changed during the installation process. Passwords should comply with your company s policies and meet minimal complexity requirements to avoid security breaches. Operating Instructions OI/CoreSense-EN Rev A 11
5.0 Physical Installation 5.1 Installation on transformer valve (part 1) NOTICE Property damage In accordance with IEC61010-1 edition 3.0, to prevent contamination of the electronics by outside elements the sensor cover shall be removed only under controlled environmental conditions defined as: Temperature shall be 5 C to 40 C. Maximum relative humidity 80 % for temperatures up to 31 C decreasing linearly to 50 % relative humidity at 40 C. Do not expose the interior of the sensor to rain or snow. The sensor is designed to be installed on a 1.5 NPT transformer valve. Detailed steps shown below. 1. Loosen the rotating flange screws (8) with the 5 mm Allen Key. 5. Once fully tightened, make sure the sensor is in horizontal position with the sampling access panel pointing upwards, rotate the CoreSense as required to achieve this. NOTICE Application warning Always install the CoreSense horizontally. Failure to position the CoreSense Horizontally with the access panel pointing upwards will cause the thermal pump to malfunction and may result in erroneous readings. NOTICE Property damage The rotating flange nuts must be tightened to the proper torque of 8.1 N-m (6.0 lb-ft) in order to prevent oil leakage from the rotating flange. Do not overtighten. 2. Wrap the sensor male fitting thread with PTFE tape. 6. Tighten the rotating flange nuts to a torque of 8.1 N-m (6.0 lb-ft) according to the following tightening pattern with the 5 mm Allen key. Start all the bolts or nuts a few threads and then run them hand-tight. Tighten mildly by hand, then according to the torque specification. 3. Install sensor on transformer valve. An optional adaptor can be used if the valve fitting is not 1.5, for example most North American ones are 2 1 8 5 4 3 6 4. Tighten with a 2 (50.8 mm )wrench or use an adjustable wrench set for 2 (50.8 mm) diameter. 7 2 12 OI/CoreSense-EN Rev A Operating Instructions
5.1 Installation on transformer valve (part 2) 1. Remove the external sampling port cover located on top of the sensor with the 4 mm Allen key. 5. To ensure that all air is purged wait until oil comes out of the sensor. 6. Tighten the bleed screw. 2. Connect the sampling adaptor to your bucket (for oil collection) with a bleeding hose (ID. 1/8 ). 3. Loosen the bleed screw with the 4 mm Allen key. 7. Wipe excess oil with a clean cloth. Re-install the external sampling port cover and secure with the 4 mm Allen key. 4. Slowly open the transformer valve. Operating Instructions OI/CoreSense-EN Rev A 13
NOTICE Property damage The sensor can be powered when it does not contain any oil for configuration purposes. But the thermal pump must be turned OFF, this can be done in the web interface (in Settings/administration settings). The CoreSense is delivered with the thermal pump turned OFF to avoid accidents. When the installation is complete and the sensor is in contact with oil, make sure the thermal pump is enabled in the web interface. Operating the heater in air will result in failure of the thermal pump. 5.2 Remove cover DANGER Serious damage to health / risk to life The sensor is equipped with 4 ports for cabling. Make sure the power cables (line voltage) and all other cables are routed separately in a dedicated cable port throughout a proper cable gland. I.e. there must never be more than 1 multi strand cable through any of the cable glands. Putting two cables through a cable gland can invalidate the IP67 protection, cause a water ingress and electrical hazard 1. Make sure to ground the CoreSense either by means of the 3-wire cables on the internal ground wire of the power cable or with a separate cable to the external ground lug 2. Install on the sensor the required watertight cabling. DANGER Serious damage to health / risk to life Prior to removing cover, power must be disconnected at the electrical distribution panel. 1. Unscrew the retaining screws for the enclosure cover with the 5 mm Allen Key. Figure 5-1 Unscrew the 4 retaining screws 2. Remove the enclosure cover. 3. Discard used O-ring, if applicable. 5.3 Cabling DANGER Serious damage to health / risk to life Make sure to comply with the national electrical standards. DANGER Serious damage to health / risk to life Prior to performing any adjustment (connections) on the sensor, power must be disconnected at the electrical distribution panel. 14 OI/CoreSense-EN Rev A Operating Instructions
AC Line 100-240 VAC 1 Line L 2 Neutral N 3 Ground G Relay 1 SYSTEM 1 NC 2 COM 3 NO Relay 2 WARNING 4 NC 5 COM 6 NO Optical Ethernet port SCADA Ethernet port RESET button USB port SERVICE Ethernet port RS-485 6 Tx+ 5 GND 4 Tx- 3 Rx- 2 GND 1 Rx+ Relay 3 ALARM 7 NC 8 COM 9 NO 4-20 ma In1 1 +24 V 2 IN+ 3 IN- 4-20 ma In2 1 +24 V 2 IN+ 3 IN- 4-20 ma In3 1 +24 V 2 IN+ 3 IN- 4-20 ma Out1 HYDROGEN 1 Out+ 2 Out- Figure 5-2 Port and relay connections of the CoreSense 4-20 ma Out2 MOISTURE 3 Out+ 4 Out- Operating Instructions OI/CoreSense-EN Rev A 15
5.3.1 AC power line terminal block DANGER Serious damage to health / risk to life The CoreSense is an overvoltage category II instrument. DANGER Serious damage to health / risk to life An external circuit breaker with a 15 amps rating must be installed on the AC source and labelled accordingly in accordance with your country s National Electrical Code. DANGER Serious damage to health / risk to life The cable glands must be torqued to 3.6 N m to assure safe installation. NOTICE Property damage The sensor can be powered when it does not contain any oil for configuration purposes. But the thermal pump must be turned OFF, this can be done in the web interface (in Settings/administration settings). The CoreSense is delivered with the thermal pump turned OFF to avoid accidents. When the installation is complete and the sensor is in contact with oil, make sure the thermal pump is enabled in the web interface. Operating the heater in air will result in failure of the thermal pump. NOTICE Property damage Use only shielded cable for wiring the RS-485 interface. RS-485 6 Tx+ 5 GND 4 Tx- 3 Rx- 2 GND 1 Rx+ Shield Terminal Description 1 Earth GND 2 Earth GND Figure 5-3 Wiring details of RS-485 in half duplex mode NOTICE Property damage Make sure the power cord is properly secured. The AC voltage must be between 100 V and 240 V and have a minimum capacity of 1 A. The frequency must be between 50 Hz and 60 Hz. The AC Power must be supplied through a 12 AWG cable of at most 10 m (33 ft) or 14 AWG cable of at most 15 m (50 ft.) with an overcurrent protection, refer to 4.5 Planning your cabling on page 10. Figure 5-4 Wiring details of RS-485 in full duplex mode The RS-485 interface is intended to be used in point to point mode. There is no need to add a termination of 120 Ohm on receiver (Rx), the resistor is present on board. The transmitter (Tx) must be terminated at the other end. Other RS-485 topologies are not supported. 5.3.3 Wiring the Ethernet interface to SCADA ABB recommend the CAT-5 Ethernet Cable. Its maximum length must not exceed 100 m. 5.3.2 Wiring the RS-485 interface to SCADA The RS-485 can be used in half or full duplex, refer to figures 5-3 and 5-4. All the signals on RS-485 (J18) are isolated. 5.3.4 Wiring the optional optical Ethernet interface to SCADA IMPORTANT (NOTE) Since ST connectors do not fit through the cable glands, the optical fiber must be terminated once pulled through the cable gland. 16 OI/CoreSense-EN Rev A Operating Instructions
IMPORTANT (NOTE) When using the Optical Ethernet port the copper-based SCADA Ethernet port must not be used. Use 62.5/125 μm or 50/125 μm multimode optical fiber to connect to the 100Base-FX optical Ethernet interface on the sensor. Prior to connecting the optical transceiver, consult appendix A of this manual for the optical characteristics. Make sure optical power levels and wavelength are within the specified range. 4-20 ma Output Terminal (J2) Description 1 Hydrogen output 1 2 Hydrogen output 1 3 Moisture output 2 4 Moisture output 2 Shield Terminal (J3) Description 1 Earth GND 2 Earth GND 5.3.5 Wiring the alarm relays (dry-contact) DANGER Serious damage to health / risk to life To avoid shock hazard, all relays shall be connected to the same power source. NOTICE Property damage The current on the relay should not exceed 3 A. NOTICE Property damage Inductive load must be protected with voltage suppressor. A derating on current must be applied to keep contact endurance. The relay contacts can be used in normally closed or normally open mode by using the appropriate pins on the connector. Use NC and C for normally closed operation and use NO and C for normally open operation. 5.3.6 Wiring the analog 4-20 ma outputs DANGER Serious damage to health / risk to life Use only shielded cable for wiring the 4-20 ma outputs interface. The 4-20 ma output range can be configured using the web interface. A value higher than 21 ma is used to indicate an error of the detector. Figure 5-5 Wiring the analog 4-20 ma outputs 5.3.7 Wiring the optional 4-20 ma inputs DANGER Serious damage to health / risk to life Shielded cable must be used for connecting to the 4-20 ma outputs. Terminal (J4, 5, 6) Description 1 Power (24 ma max.) 2 Input 3 return Shield Terminal (J3) Description 1 Earth GND 2 Earth GND Figure 5-6 Wiring of self-powered, analog inputs Operating Instructions OI/CoreSense-EN Rev A 17
ensure IP67 rating. 3. Make sure the fasteners are secured in an alternate pattern, see image below. Start all the bolts a few threads and then run them hand-tight. Tighten mildly by hand, then to a torque of 8.1 N-m (6.0 lb-ft). 1 4 3 2 Figure 5-7 Wiring of two-wire, loop-powered, analog inputs Figure 5-10 Close-up showing the O-ring and the closed covers Figure 5-8 Wiring of three-wire, loop-powered, analog inputs Re-install the enclosure cover and secure with the 5 mm Allen keys. 5.4 Re-install cover 1. Install enclosure cover O-ring (Buna-N O-ring no: AS568A DASH NUMBER 269) that is supplied in an identified plastic bag with the sensor. Make sure it is well fitted in the groove of the front cover. The enclosure cover O-ring can be compressed one time only. Each time the cover is removed, a new O-ring must be used. Figure 5-9 O-ring fitted on the front enclosure cover 2. When the O-ring is properly placed, re-close the cover and make sure pressure is evenly applied on the O-ring to 18 OI/CoreSense-EN Rev A Operating Instructions
6.0 Configuration 6.1 Connecting a Laptop for the first time 1. Power up your laptop. 2. Connect the laptop to the SERVICE Ethernet port using a straight Ethernet cable. For the location of the Ethernet port, refer to Figure 5-2 Port and relay connections of the CoreSense on page 15. 3. The sensor SERVICE Ethernet port is configured as a DHCP server and will assign a valid IP address automatically to your laptop. 4. Start up your web browser (recommended: Internet Explorer 9 or above). 5. Direct your web browser to http://172.16.100.1 to connect to the web interface. 6. Click on the <administration tab> to configure the communication settings. Refer to 6.2.3 Administration settings dialog box on page 23. 7. Set the system ID to label each specific CoreSense. 8. Set the system date. 9. Modify your password. 10. Configure communication settings, i.e. RS-485 configuration, TCP configuration, 4-20 Output configuration. Refer to 6.2.4 Communication settings dialog box on page 23. 11. Enable the thermal pump. NOTICE Property damage When enabling the thermal pump, the CoreSense must be properly connected and contain oil. Make sure there are no oil leaks. 6.1 Configuring the sensor Operating Instructions OI/CoreSense-EN Rev A 19
6.2 Tabs of the web interface The web interface allows easy visualization of the hydrogen and moisture levels. Clicking of the various tabs gives access to more options. Dashboard: Use the dashboard to quickly assess the state of the system and the hydrogen and moisture measurements (see figure above). Hydrogen: Use the hydrogen tab to gain access to charts with historical data or export the historical data in csv format. To export data, simply select a time range and click export. A dialog box prompts asking where the save the.csv file. For more details on the Hydrogen tab, refer to G.1 Hydrogen.csv on page 39. Moisture: Use the moisture tab to gain access to charts with historical data or export the historical data in csv format. To export data, simply select a time range and click export. A dialog box prompts asking where the save the.csv file. For more detail on the Moisture tab, refer to G.2 Moisture.csv on page 39. 20 OI/CoreSense-EN Rev A Operating Instructions