2013 BPL Global

ON-LINE TRANSFORMER
MONITOR INSTALLATION GUIDE
MODEL TM1
810-1902-01 REV A
JULY 12, 2013


On-Line Transformer Monitor Installation Guide 2013 BPL Global i
Model TM1 810-1902-01 Rev A
For more information, contact your nearest BPL Global Representative




BPL Global, Ltd.
20325 NW Von Neumann Drive, Suite 120
Beaverton, OR 97006 USA
Office: +1 (800) 880-2552
Fax: (503) 924-3290
[email protected]
Technical Support: +1 (866) 273-7763, E-mail: [email protected]
http://www.bplglobal.net/






Copyright 2013 BPL Global, Ltd.
All rights reserved
The following is a non-exclusive list of registered trademarks, registered service marks, or trademarks or
service marks of BPL Global, Ltd. or its subsidiaries and affiliates, in the United States and/or other
countries or jurisdictions: BPL Global, CLN Power Plant, CNRG, CNTRYwcc, Connected Energy, Demand
Dispatch, DER Buildout, EasyGreen, enerVIEW, Foundation, iDD, iDER, Islands of Intelligence, LoadGuide,
MasterBox, Power Is Information, Power SG, Serveron, Smart Integration, TM8,TM3, TM1, TM View, and
TrueGas.
All other trademarks, registered trademarks, service marks, and trade names are the property of their
respective owners.


On-Line Transformer Monitor Installation Guide 2013 BPL Global ii
Model TM1 810-1902-01 Rev A
Table of Contents
PRODUCT OVERVIEW ........................................................................................... 1
PRODUCT SYMBOLS ............................................................................................. 2
ENVIRONMENTAL CONDITIONS ............................................................................... 3
WARRANTY ....................................................................................................... 3
INTRODUCTION ................................................................................................... 4
SYSTEM DESCRIPTION .......................................................................................... 5
ITEMS SHIPPED ................................................................................................... 6
TOOLS/MATERIALS REQUIRED ................................................................................ 7
MONITOR INSTALLATION ....................................................................................... 8
SITE PREPARATION ...................................................................................................................... 8
MOUNTING THE MONITOR ........................................................................................................... 8
WIRING TERMINATIONS ...................................................................................... 14
POWER ................................................................................................................................... 14
I/O CONNECTIONS .................................................................................................................... 16
RELAYS ................................................................................................................................... 17
BLEEDING AIR FROM THE MONITOR ....................................................................... 18
MONITOR CONFIGURATION ................................................................................. 19
PRODUCT AND SHIPPING DIMENSIONS ................................................................... 19




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PRODUCT OVERVIEW
The TM1 is a remotely-deployed transformer monitor which can be safely installed onto an energized or
non-energized transformer to detect and measure dissolved hydrogen found in an electrical power
transformers insulating oil. The monitor is designed and constructed to resist environmental conditions
in Power Plants, Switchyards or Substations.
The TM1 is directly mounted to an existing valve on the transformer and circulates transformer oil within
it to provide a continuous reading of hydrogen in ppm. Data can be viewed with the supplied TM View
software or via a customers SCADA system (RS 485 or RS 232) and will allow the end user to track the
hydrogen ppm levels over time and compare against user-defined caution and alarm settings.
The TM1 monitor includes two 4-20mA inputs for use with an optional moisture sensor. In addition to
the inputs, there are three 4-20mA outputs. Also included are three user-programmable relays, as well
as relays for service-related conditions and loss-of-power.



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PRODUCT SYMBOLS
The following symbols are used throughout the Transformer Monitor or accessories. They are defined by
the International Electrotechnical Commission, IEC 878 and IEC 417A. It is important for safety reasons to
have an understanding of their representation.

Voltage Output

Voltage Input

Fuse

High Voltage

Caution: Refer to On-Line Transformer Monitor
Installation Guide and accompanying documentation.

Protective Earth (ground)
L1 Connect to mains live conductor (brown)
L2 Connect to mains neutral conductor (blue)
__I__
O
The I position indicates the power switch is ON
The O position indicates the power switch is OFF

This device has been tested and certified by UL to
comply with applicable U.S. and Canadian safety
standards.
Table 1: Product Symbols
WARNING statements in this manual identify conditions or practices that could result in
personal injury.
CAUTION statements in this manual identify conditions or practices that could result in
damage to the equipment or other property.
NOTE statements provide additional important information.



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ENVIRONMENTAL CONDITIONS
The TM1 is designed to operate within the following outdoor conditions:
Altitude Range -2000 to 15,000 ft. (-610 to 4,572 m)
Humidity Range 5% to 95%
Temperature Range -50C to +55C
Oil Inlet Pressure 0 to 100psi
Oil Inlet Temperature -20C to +105C
Installation Category 1
Pollution Degree 1
Please note that the altitude, humidity, and temperature ranges indicated are considered extended
environmental conditions from the minimum ranges required by ICE/UL/CAN 61010-1, Clause 1.4.1.
WARRANTY
BPL Global warrants its Goods to be free from latent defects in materials or workmanship for 24 months
from the date of shipment. BPL Global will repair or replace, at BPL Globals discretion and without cost
to Buyer, any Goods furnished hereunder that are found to contain defects in materials or workmanship
during that period. BPL Global uses new and reconditioned parts in performing warranty repairs and
building replacements. BPL Global owns all Goods it has replaced and all parts removed from repaired
Goods. It is Buyers responsibility to return the Goods to BPL Global for warranty coverage. This
warranty does not cover items damaged in shipment or damages resulting from misuse, neglect, abuse,
acts of war or acts of God. BPL Global recommends using the provided shipping material and packing
inserts for transportation. The TM1 is designed to be mounted and used in normal transformer
operation. It is not designed to be mounted or affixed to the transformer or any other device during
transportation; doing so is subject to void all and any warranties. Prior to returning any item (whether
during the warranty period or out of warranty), Buyer must obtain a Return Material Authorization
(RMA) number from BPL Global by calling (800) 880-2552 Monday through Friday, 8 am to 5 pm, Pacific
Time, or by sending a fax request to (503) 924-3290. BPL Global makes no warranties, expressed or
implied, other than the warranties expressly stated in this paragraph. All other warranties, expressed or
implied, arising by law or otherwise, including, but not limited to, the implied warranties of title,
merchantability, noninfringement and fitness for a particular purpose, are expressly disclaimed.


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BPL Globals product operations manuals and product installation guides describe approved accessories,
options, operating materials and installation methods. Use of accessories, options, operating materials
and installation methods not as described, will void the warranty.
INTRODUCTION
Transformer importance is independent of size. Medium and small distribution transformers are often
associated with service to critical infrastructure. The TM1 Online Transformer Monitor is a single-gas
DGA condition warning device designed specifically to serve these small, but important assets.
The TM1 measures hydrogen (H
2
) without cross-interference from other gases. Hydrogen is formed
under all known thermal fault conditions in the transformer and is one of the first gases to be generated,
making it an excellent early indicator of a broad range of fault types. The TM1 uses a patented solid-
state H
2
sensor that eliminates the use of membranes. Both ppm H
2
levels and H
2
rate-of-change (ROC)
are measured and reported. Moisture can also be measured with an optional oil moisture sensor.
The TM1 has no membrane, requires no scheduled maintenance or sensor replacement and does not
utilize consumables. The design incorporates numerous patent-pending technologies designed to
provide long-term reliability for monitoring smaller transformers in the distribution network. Other
applications include wind farms, vault transformers, pad-mount transformers and larger power
transformers in the transmission network.
Note: The TM1 is designed for use on mineral-oil insulated transformers; FR3 is not
supported at this time.
The TM1 is designed to be installed and configured by the end-user. The monitor requires a continuous
supply of oil and installs directly on a drain valve or other valve locations. Configuration of the monitors
alarms, settings and options is accomplished using a PC-based TM1 Configuration Tool described later in
this manual. TM1 data can be viewed in the configuration tool, in TM View Software supplied with the
monitor, or in Microsoft

Excel or similar programs that accept .csv files.

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SYSTEM DESCRIPTION
The TM1 measures hydrogen using a patented solid-state sensor made of Palladium. The sensor is in
direct contact with the transformer oil; neither gas extraction nor membranes are utilized. An electric
potential is applied to the palladium sensor. When hydrogen from the oil contacts the sensor, the
electrical properties of the palladium sensor change, resulting in a change in the electrical output of the
sensor. This electrical change is proportional to the concentration of hydrogen in contact with the sensor
and is reported as ppm H
2
. Using the ppm results, ROC is calculated and reported in units of ppm/day.
The TM1 circulates transformer oil through the monitor and across the sensor. The temperature of the
measurement environment is precisely controlled in order to ensure stable readings. The TM1 will make
one measurement approximately every 30 minutes. The exact time between measurements is a
function of the temperature of the incoming oil. Therefore, the time between measurement results may
vary slightly.
TM1 data is stored onboard in non-volatile RAM. At least two years worth of most recent data is stored.
Once the available memory is full, data is overwritten in a first-in, first-out manner. Numerous
communication options allow for the transfer of data in near real-time, or discrete batch download of
data is available via the USB port.
The major components of the TM1 include:
H
2
Sensor Palladium sensor selective for H
2
gas
Oil Circulation System utilizes a patent-pending design that eliminates the need for a
reciprocating or positive-displacement pump. More robust in design, the auger-style TM1 pump
is used to provide a representative oil sample at the sensor.
Heater provides thermal control of measurement environment
Electronics power supply, analog inputs and outputs, alarm relays, system board and
communications ports
Enclosure IP66 /NEMA 4X rated enclosure with integrated sunshield
Transformer connections 1 NPT Valve (can be adapted to other sizes), power and
communication wiring glands, bleed port.



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ITEMS SHIPPED
Upon receipt of your TM1 Transformer Monitor, it is important to verify the contents of the shipping
carton with the packing list. After inspection of the contents, please notify BPL Global directly if there
are any signs of damage that may have occurred in transit. If possible, please retain the original shipping
container and packing materials in the event that it becomes necessary to return the monitor.
Part Number Description
782-0042-00 TM1 Transformer Monitor
140-0342-00 Uni-tee, 1 NPT Stainless Steel
253-0216-00 Set Screw, -20 3/8L
250-0258-00 Plug, NPT
250-0259-00 Plug, NPT
642-0020-00 Quick Clamp
252-0038-00 Lock Nut
254-0117-00 Washer
259-0045-00 Gasket
420-0118-01 Oil Inlet assembly
160-1514-01 USB Flash Drive (4GB contains all User documentation)
291-0060-00 Disposable Syringe, 20ml
648-0107-00 Tygon Tubing (6 inches)
250-0249-00 Luer Fitting, Male
250-0250-00 Luer Fitting, Female
900-0135-00 Oil Moisture / Temperature Kit (optional)
Table 2: Items Shipped




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TOOLS/MATERIALS REQUIRED
The following tools are required for installation of the TM1 monitor:
7/16, and 1 wrenches (or an adjustable wrench)
1/8, 3/16and 3/32 Allen keys (3/16 Allen key used for optional Moisture Kit only)
Small flat-blade screw driver
Large flat-blade or Phillips screwdriver
Teflon tape and pipe-thread sealant
Wire strippers/cutters
Container to collect oil during installation
Pipe wrench



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Model TM1 810-1902-01 Rev A

MONITOR INSTALLATION
CAUTION: Do not attempt to install your TM1 On-Line Transformer Monitor until you
have read and fully understand the procedures outlined in this document.
Installation of the TM1 consists of the following:
Site preparation
Mounting the monitor
Wiring the monitor
Bleeding air from the monitor
Configuration
SITE PREPARATION
Ensure the following prior to mounting the monitor:
An adequate valve location for mounting the TM1 monitor has been identified
Note: BPL Global recommends a minimum size of 1for the oil supply valve.
Power is present and available at the installation site for the monitor
Transformer is oil-filled
All shipped items have been located
MOUNTING THE MONITOR
Note: If the desired valve is not 1 NPT, then the appropriate hardware must be
installed.
Note: Whenever installing or un-installing the monitor, the cover must be installed and
secured. The cover only needs to be removed when wiring the monitor or connecting to
it with the USB flash drive or cable.
1. Ensure the transformer valve is closed and remove any existing plug on the valve.
Position a container to collect any oil after removing the plug. Remove any debris from
the threads.


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2. Wrap the threads of the supplied stainless-
steel uni-tee with Teflon tape and apply a thin
layer of pipe-thread sealant. Insert the tee
into the transformer valve and tighten,
ensuring the NPT plug is oriented vertically
as shown in (Fig 1).


Figure 1: Tee Orientation
3. Remove the NPT plug from the tee and
apply Teflon tape and pipe-thread sealant to
the threads, then re-install in the tee (Fig 2). If
the optional Moisture Kit will not be installed,
remove the NPT plug and apply Teflon tape
and pipe-thread sealant to it as well. Then re-
install in the tee. If the Moisture Kit will be
installed, remove the NPT plug from the
tee entirely.
Figure 2: 1/2 and NPT plug
4. Remove the yellow protective shipping cap
and absorbent pad from the end of the TM1.
It is normal to see a small amount of oil after
removing the cap. Install the Oil Inlet
assembly into the threaded hole on the back
of the TM1 (Fig 3) and tighten, but do not
over-tighten.


Figure 3: Oil Inlet Assembly



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5. Install the black gasket onto the uni-tee,
ensuring that it is seated in the groove, as shown
in Fig 4.




Figure 4: Mounting the Monitor
6. While properly supporting the TM1, position it on the open end of the uni-tee, carefully
inserting the tube of the oil inlet assembly into the tee. Make sure the gasket is properly
seated between the tee and the TM1. Install the clamp, capturing the uni-tee and the
TM1 flanges as shown (Figs 5 & 6). Make sure the flat washer is directly under the nut as
shown and tighten the nut on the clamp, ensuring that the TM1 is oriented vertically.






Figure 5: Clamping Flange






Figure 6: Quick Clamp



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Model TM1 810-1902-01 Rev A

7. If installing the optional Moisture Kit, wrap the
threads of the supplied NPT stainless steel
fitting with Teflon tape and apply a thin layer of
pipe-thread sealant. Insert the fitting into the
uni-tee and tighten as shown (Fig 7). Do not
tighten the compression nut at this time.


Figure 7: Moisture Fitting
8. Insert the moisture probe into the fitting, leaving
approximately 1/8 of the probe body exposed
from the fitting (Fig 8). Tighten the compression
nut on the fitting.
9. Place a container under the uni-tee. Partially
open the transformer valve. Using a 1/8 Allen
key, slowly loosen the set-screw until oil exits the
bleed hole (Fig 9), then tighten the set screw and
close the transformer valve.
Figure 8: Moisture Probe Alignment







Figure 9: Set Screw and Bleed Hole

Compression
Nut
Leave 1/8 of
the probe
exposed
Bleed hole
Set Screw


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10. The cable coming from the probe is permanently attached to
the transmitter box. Remove the two screws securing the
mounting plate from the transmitter box, using the Allen key
supplied with the kit as shown (Fig 10).



Figure 10: Moisture Transmitter
11. Locate the coupling nut and the left-center
threaded stud (as viewed from the rear) on the
back plate of the TM1 body. Install the coupling
nut onto the stud and tighten as shown (Fig 11).




Figure 11: Coupling Nut
12. Locate the white rain shield supplied with the Moisture kit. Secure both the rain shield
and mounting plate to the coupling nut as shown (Fig 12) with the supplied hex
screw. Secure the lower part of the mounting plate to the rain shield with the supplied
3/8 screw and nut. Re-install the transmitter box to the mounting plate through the
hole in the rain shield with the screws removed previously as shown in (Fig 13).






Figure 12: Rain Shield Mounting
Loosen Screws (2X) to
separate plate from
transmitter
Coupling Nut
Hex Screw


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Figure 13 : Transmitter Mounting
13. Locate the moisture probe wire harness with the orange connector. Insert the connector
into the socket on the bottom of the transmitter box (it will only fit when it is properly
aligned) and tighten the collar as shown in the figure below. After determining the
proper length of cable to pass through the gland fitting on the back panel of the TM1
and reach the wiring terminal on J22, cut the excess cable and discard. Continue to the
next section for wiring instructions







Figure 14: Transmitter Cable



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WIRING TERMINATIONS
POWER
Input: 100 to 240VAC, 50/60Hz
Power: 120VAC - Max 0.5A, nominal 0.1A @ 25C
240VAC Max 0.25A, nominal 0.05A @ 25C
Note: A switch or circuit breaker should be installed in close proximity to the equipment,
easily accessible by an operator and be clearly marked as identifying its use.
The equipment is to be installed in accordance with local and national electrical codes
and installed by a licensed electrical installer. Remove the 4 thumb-screws securing the
cover of the TM1.
1. Determine the power source for the TM1 (e.g. 120VAC, 240VAC.). Make sure the power
is locked out at the source.
2. Insert the power cable through the small center gland fitting and connect as follows:
Note: Recommended minimum torque for the power connector terminal is 5 in-lbs.
Terminal Conmnections 120VAc 240VAC
Earth GND GRN/YLW GRN/YLW
L1 BRN or BLK - Line BLK
L2 BLUE or WHT - Neutral RED
Table 3: Power Terminations



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3. Tighten the gland fitting to provide a secure
weather-tight seal.
4. Source power should remain off until all
wiring service has been completed.





Figure 15: Cable Locations










Figure 16: Power Terminals

AUX2
AUX1
Power
GND, L2, L1


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I/O CONNECTIONS
1. Refer to the figure below to identify the various wiring connectors.
Note: IO cable must be shielded and grounded
2. The wiring connections specific to the cable coming from the optional Oil
Moisture/Temperature probe are shown below.
3. Terminate any additional wiring (alarm/service relays, 4-20mA inputs/outputs) per the
diagram below, which is also located on the inside of the TM1 cover.
CommGND
CTS/RXB
RX/RXA
RTS/TXB
TX/TXA
OutGND
(2) -
(2) +
(1) -
(1) +
(0) -
(0) +
DCD
DTR
FrameGND
J21
1
15
4-20
Outputs
FrameGND
IN GND
(1) RTN
(1) IN
(1) PWR
(0) RTN
(0) IN
(0) PWR
J22
1
8
4-20
Inputs
J4
1 7
SRV PWR
J3
1 10
PRGM
F1
F2
1A, 250VAC, 3AG(T)
Earth GND
L2
L1 1
3
Input Voltage
100-240 VAC 50/60Hz
Jumper Settings
3-4 232
2-3 485-Full
1-2 485-Half
J6
1
4
PRGM
Interface
Comms
Interface
Serial Configuration
Input Voltage
Terminal Connection not
located on this board

Figure 17: Connection Details
Oil Moisture/Temperature
GND (GRY) Pin 7
CH2 (YLW) Pin 5
CH1 (GRN) Pin 2
+24V (Pink) Pin 1


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Model TM1 810-1902-01 Rev A

RELAYS
There are five dry-contact relays which can be wired for normally-open (NO) or normally-closed (NC)
configuration. The relays are defined as follows:
PRGM-0 H2 ppm alarm
PRGM-1 H2 ROC alarm
PRGM-2 Moisture ppm alarm
SVC Service Events
PWR Loss of Power
Note: The relay contact ratings for resistive loads are:
Max switched Power 100W or 600VA
Max switched Current 3A
Max switched Voltage 150VDC or 300VAC



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Model TM1 810-1902-01 Rev A

BLEEDING AIR FROM THE MONITOR
1. Open the transformer valve fully and inspect for any
oil leaks. Power the TM1 ON with the black toggle
switch. Using a 3/32 Allen key, remove the two cap
screws located on the top of the bleed selector on
either side of the screw in the center as shown (Fig
18).

Figure 18: Bleed Selector Screws
2. Rotate the bleed selector clockwise to position 2,
exposing the Luer fitting. Unscrew the white cap
from Luer fitting (Fig 19). Connect the supplied
Tygon tube to the supplied syringe. Secure the other
connector on the end of the tube onto the Luer
fitting (Fig 20). Return the bleed selector to position
1.

Figure 19: Luer Fitting Cap
3. Draw the syringe plunger back to remove air and
draw bubble-free oil into it. Rotate the bleed selector
clockwise and repeat for the other two positions,
pulling air and then oil out of each port. Remove the
syringe from the Luer fitting, replace the Luer cap
and rotate the bleed selector counter-clockwise to
the Run position (Fig 18).

Figure 20: Syringe Attachment
4. Reinstall the two cap screws that were removed previously. Make sure that the screws
are securely tightened and that the center screw is tight.
5. Replace the monitor cover and secure the four thumb-screws.
6. The TM1 installation is now complete. Please refer to the TM1 Operation & Maintenance
Guide (810-1298-00 Rev B) for further instruction on these topics.
Remove Screws (2X)
Luer Cap in position 2


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MONITOR CONFIGURATION
The TM1 can be configured with the TM Configuration Utility Tool preloaded on the USB flash drive
included with the monitors accessories. To get started, refer to the Users guide, can be found under the
Help tab.
PRODUCT AND SHIPPING DIMENSIONS
TM1 Monitor and Accessories:
Shipping Weight: 15lbs (6.8 kgs)
Shipping Dimensions: 15 in L x 15 in W x 12 in H (38.1 cm L x 38.1 cm W x 30.5 cm H)
TM1 Monitor and Accessories w/ Moisture Option
Shipping Weight: 20lbs (9.1 kgs)
Shipping Dimensions: 18 in L x 15 in W x 16 in H (45.7 cm L x 38.1 cm W x 40.6 cm H)



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Figure 21: TM1 Dimensions