EDO-MNL-COE-COR-INT-XXX-016-622-801-Rev-A-ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER

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A 01.06.2014 ISSUED FOR INFORMATION A.G A.G E.

D
Rev. Date Description Prepared Checked Approved --------------
No. Published by
ORIGINATOR

DESIGNED BY
EDOPEC ENERJİ PETROL MÜHENDİSLİK SANAYİİ VE TİCARET
LİMİTED ŞİRKETİ
www.ioncpteam.com
PRODUEC BY Document Title
ION-2430-OFC OIL COOLED
AUTOMATIC TRANSFORMER / RECTIFIER
www.edopec.com
UNIT
Head Office :
Palmiye Mah. 1219 Sk. Gürarslan Document No.
Apt. (Kapı No:15) Kat:2 D:6 PK-
33110 Yenısehır –Mersın –Turkey
P:+90 324 3260595 Rev Scale
EDO MNL COE COR INT XXX 016 622 801
F:+90 324 3260596
www.edopec.com
A
info@edopec.com Co. Org. Doc Type Disc. Unit Code Prj. Prj. Prıj. Proj. DCC
Cod Code Type NO Year Seq.No Seq.No Page 26
ION-2430-OFC

OIL COOLED AUTOMATIC


TRANSFORMER/RECTIFIER UNIT

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
 
INDEX 
FEATURES ................................................................................................................................ 4 
OPERATING MODES................................................................................................................. 4 
GENERAL SPECIFICATIONS ....................................................................................................... 5 
STANDARDS ............................................................................................................................ 6 
TECHNICAL INFORMATION ...................................................................................................... 7 
T/R UNIT CONTROL PANEL ...................................................................................................... 8 
T/R UNIT CONTROL PANEL DETAILS ......................................................................................... 9 
T/R UNIT ELECTRICLAL BACK PANEL DETAILS ......................................................................... 11 
T/R UNIT STAR‐UP INSTRUCTIONS ......................................................................................... 11 
SETUP AUTOMATIC MODE ............................................................................................................. 12 
SETUP MANUAL MODE .................................................................................................................. 14 
SETUP INDEPENDENT MODE .......................................................................................................... 15 
STANDBY / OFF .............................................................................................................................. 16 
TRANSFORMER ...................................................................................................................... 17 
RECTIFIER .............................................................................................................................. 17 
RECTIFIER BLOCK DETAILS ..................................................................................................... 18 
ELECTRONIC CONTROL CARD DETAILS ................................................................................... 19 
SCADA COMMUNICATION (OPTIONAL) .................................................................................. 21 
TROUBLESHOOTING .............................................................................................................. 23 
PART LIST .............................................................................................................................. 26 
 
 

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
FEATURES

1) Fully Micro-processor based,


2) Remote Monitoring / Controlling on MODBUS-RTU (RS-485)
3) Automatic, Manual and Independent Operation (Constant
Current, Constant System Potential and constant PWM
4) Precision control with 15-bit PWM by DSP
5) LC Filtered DC output for minimum ripple
6) Surge Protection on both AC and DC side
7) Oil Cooled Type
8) Fully Solid-State Design
9) Automatic Error Correction
10) EEprom Memory Against Electricity Failure
11) Automatic Over-Load Protection
12) Automatic Over-Heat Protection

OPERATING MODES

- Automatic (Constant System Potential)


- Manual (Constant Output Current)
- Independent (PWM Control)

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
GENERAL SPECIFICATIONS

A DC Power equipment such as Transformer Rectifier supplies current


that is applied for Cathodic Protection of buried or immersed metal
structure. The Transformer Rectifiers (TR) are normally used on
impressed cathodic protection designs.

ION-2430-OFC Cathodic Protection TR Units (Oil-Cooled) are specially


designed for safe and long-term operation in environments such as desert
and tropical locations.

The Transformer Rectifier is housed inside an oil tank and control box
with the control and indication mounted on an internal hinged door.

The power transformer, choke, capacitor, current sense shunt, diodes and
IGBT assembly are mounted inside the oil tank.

Primary MCB, AC fuses, DC fuses, and DC surge arrestors are mounted


back side of the IP65 control panel.

The followings are mounted on the internal door of the control panel:
digital voltmeter, digital ammeter, digital ref. cell meter, digital set
display, AC ‘Phase’ lamp, power switch, power / mode indicator, 8
Alarm indicator, 4 adjustment buttons, set button, ref. cell tracker switch.

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
STANDARDS

ION-2430-OFC series of rectifiers are under manufacturing and testing meeting recognized standards and

regulations of cathodic protection, electrical and electronic system and devices.

 ANSI C34.2 SemiconductorPowerRectifiers, PracticesandRequirements


 ANSI C57.12.13 Liquid FilledTransformersused in UnitInstallationsincludingUnitSubstations,
ConformanceStandard
 ANSI C57, 12.70 Terminal markingsandconnectionsfor Distribution andPowerTransformers
 ANSI C57.92 LoadingGuidelines
 ASQ Q9000 Quality Management andQualityAssurance
 ASTM A 123 SpecificationforZinc (hot dip galvanized) Coatings on Ironand Steel Products
 ASTM B 209 SpecificationforAluminumandAluminumAlloySheetandPlate
 IEEE C57.98 ImpulseTests, Guide forTransformers
 NEMA 250 EnclosuresforElectricalEquipment (1000 voltsmaximum)
 NFPA-70 NationalElectricalCode
 NEMA-ICS6 Industrial Control andSystemsEnclosures
 BS 171 PowerTransformers
 BS 6493 SemiconductorDevices
 BS 7361 Cathodic Protection
 NACE-MS-TP-03 Materialstandardsfor Cathodic Protection
 IEC 60051 RecommendationforIndicatingElectricalMeasuring Instruments andTheir Accessories
 IEC 60076 PowerTransformers
 BS 2914 SurgeDiverters
 IEC 60144 DegreeofProtection of EnclosuresforLowVoltageSwitchgearand Control Gear
 IEC 60146 SemiconductorConverters
 IEC 60269 LowVoltageFuses
 IEC 60296 Unused Mineral InsulatingOilforTransformersandSwitchgear
 IEC 60391 Marking of InsulatedConductors
 IEC 60445 IdentificationifApparatus Terminal Marking Using an AlphanumericNotation
 IEC 60464 SpecificationforInsulatingVarnishesContainingSolvent
 IEC 60529 Classification of degrees of protectionprovidedbyEnclosures
 IEC 60117 & 617 RecommendedGraphicalSymbols

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
TECHNICAL INFORMATION
ION‐2430‐OFC (ONAN)
24V 300A OIL COOLED AUTOMATIC TRANSFORMER RECTIFIER UNIT 
INPUT:
Input Voltage:  400 VAC ±%5, 3 Phase, 50 Hz
Input Current:  16 A (Fully Load for each Phase)
Input Protection:  Surge Arrester  Neutral + 3 Phase (Siemens 5SD7464-0 40 KA) 
Working Temperature:  ‐20°C, +50°C 
OUTPUT:
Output DC Voltage:  0 ‐ 24 VDC (15‐Bit, 32767 Steps)
Output DC Current:  0 ‐ 300 ADC (15‐Bit, 32767 Steps)
Rectifier Type:  Microprocessor Controlled PWM (IGBT Driving with Pulse Width Modulation)
Output Filter:  LC Type 
Output Ripple:  < %2 at max. load
Output Protection:  Surge Arrester (Siemens 5SD7464-0 40 KA), Anode + Cathode 
Efficiency:  > %90 
REFERENCE CELL:
Cell Type:  Ag/AgCl or Cu/CuSO4
Cell Quantity:  6  (with 1 common reference cathode)
Input Voltage:  0 ‐ 2500 mVDC 
Input Impedance:  > 1 MOhm 
Input Protection:  Varistor (12 V,1 A)
Input Isolation:  DC‐DC Converter (3 KV)
OPERATINGS MODES:
Automatic Mode:  Keeps the reference cell set potential constant.
Manuel Mode:  Keeps the current set value constant.
Independent Mode:  Keeps the PWM constant.
Interrupted Mode:  ON/OFF with SCADA Synchronization. (with Tact Signal)
DISPLAYS:
Display Type:  3½ Digit, Semi‐powered intelligent LED Display.
DC Voltmeter:  Shows the output DC voltage.
DC Amperemeter:  Shows the output DC current.
Referans Display:  Shows the selected reference cell voltage.
SET Display:  Shows the Set value and operating mode.
INDICATORS:
Power‐Mode Indicator  Indicates the operating mode with different collors.
ADC 1 Failure:  Indicates the failure of DC output voltage and current reading ADC. 
ADC 2 Failure:  Indicates the failure of 6 Reference cell reading ADC.
Reference Cell Out of Range:  Indicates one or more reference cell reading out of range.
Reference Cell Failure  Indicates one or more reference cell is out of order.
High Temperature:  Indicates high temperature of cooling oil
Anode / Cathode Failure:  Indicates open circuit on Anode / Cathode connection.
Limit Reached:  Indicates the current limit reached on Automatic Mode if it is set.  
Rectifier Failure:  Indicates the failure of rectifier section.
SCADA:
Communication Metode:  RS‐485 
Communication Protocol:  MODBUS RTU 
Communication Speed:  2400‐19200 bps
Access:  Read / Write (Full Control)

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
T/R UNIT CONTROL PANEL

3 2 1

18 5 6
19 20 22
7 8
9 10
11 12
21 4

14 16
13
15 17

1. Power Led 12. Rectifying Stack Failure Led


2. Power Switch 13. Set Button
3. Power indicator 14. Coarse Up Button
4. Reference Cell Tracker Switch 15. Coarse Down Button
5. ADC1 Failure Led 16. Fine Up Button
6. ADC2 Failure Led 17. Fine Down Button
7. Reference Cell Failure Led 18. DC Ammeter Display
8. Reference Cell Out of Range 19. DC Voltmeter Display
Led 20. DC Reference Cell Potential
9. High Temperature Led Display
10. Anode/Cathode Failure 21. Set Display
11. Limit Reached Led 22. Reference Cell Indicator Led

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
T/R UNIT CONTROL PANEL DETAILS

1. Power Led: It Lights Green on Idle, blue on Automatic Mode, on Manual Mode,
purple on Independent mode and red on fatal error.
2. Power Switch: It turns on and off the T/R unit.
3. Power Indicator: They indicates the main power Phases.
4. Reference Cell Tracker Switch: It is possible to watch all 6 reference cell
potentials and errors connected to T/R unit.
5. ADC1 Failure Led: It lights red when any error occurs on first analog to digital
converter of main control card reading DC current and DC output potential.
6. ADC2 Failure Led: It lights red when any error occurs on second analog to digital
converter of main control card reading 6 reference cell potentials.
7. Reference Cell Failure Led: It lights red when TR unit is off and reference cell
reads more positive than -450 mvDC and if it reads more positive or negative
potential of 150 mvDC than average reference cell potential.
8. Reference Cell Out of Range: It lights red when any reference cell value positive
than -800 mvDC of negative than -1200 mvDC
9. High Temperature Led: It lights red when Oil or Panel Temperature reaches the
critical limit of 85 Degrees Celsius.
10. Anode/Cathode Failure Led: It lights red when T/R microprocessor detects any
connection failures on Anode or Cathode Cables.
11. Limit Reached: It lights red when hi or low current limits on automatic mode
reaches set values.
12. Rectifying Stack Failure: It lights red when T/R microprocessor detect any failure
on rectifying elements. (PWM card, Fuses, etc)
13. Set Button: It is used to set the T/R working parameters. When pressed single for 3
seconds, enters TR Unit main setup menu.
14. Coarse Up Button: It increases any value at set menu. When pressed with set
button about 3 seconds, enters automatic mode set menu. When pressed single
about 3 seconds, sets TR unit working mode to automatic.
15. Coarse Down Button: It decreases any value at set menu. When pressed with set
button about 3 seconds, enters independent mode set menu. When pressed single
about 3 seconds, sets TR unit working mode to independent.
Project: Proj. Identification:
ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
16. Fine Up Button: It increases any value slowly at set menu. When pressed with set
button about 3 seconds, enters manual mode set menu. When pressed single about 3
seconds, sets TR unit working mode to manual.
17. Fine Down Button: It decreases any value slowly at set menu. When pressed single
about 3 seconds, puts TR unit to Stanby (off).
18. Cathodic Protection Current Display: It shows DC output current applied to the
cathodic protection system connected to TR Unit.
19. DC Output Voltage Display: It displays DC voltage applied to the cathodic
protection system connected to TR Unit
20. Reference Cell Potential Display: It shows DC potential of selected reference cell
by Reference Cell Tracker Switch.
21. Set Display: It shows TR Unit working mode and set parameters.
22. Reference Cell Indicator Led: It lights green when selected reference cell value is
normal by the Reference Cell Tracker Switch, lights orange if selected reference
cell is the picked one for automatic working mode, lights red when selected
reference cell is failed and lights nothing if channel is disabled from TR Unit main
set menu.

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
T/R UNIT ELECTRICLAL BACK PANEL DETAILS

30 29 28 27 26 25 24 23 31 32 33

34

23. Main Circuit Breaker 30. 230 VAC Socket


24. Transformer Circuit Breaker 31. 40 KA Surge Arresters
25. Main Card Circuit Breaker (R,S,T,N)
26. AC Socket Circuit Breaker 32. 40 KA Anode Surge Arrester
27. Internal Lamp Circuit Breaker 33. 40 KA Cathode Surge Arrester
28. Modbus Converter Circuit 34. Phase Indicators
Breaker
29. Spare Circuit Breaker



T/R UNIT STAR‐UP INSTRUCTIONS

1. Check phase indicator. (3)


2. Check all circuit breakers from inside of the panel.(23-24-25-26-28)
3. Turn on Power Switch (2)
4. Wait for Power Led (1) to become Green.
5. Setup Working Mode Parameters.
6. Put TR Unit to Working Mode.

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
SETUP AUTOMATIC MODE

 To Enter Automatic Mode Setup Menu; Press Set Button (13) and Coarse
Up Button (14) Together for 3 Seconds.

 Adjust the Reference SET Value by Using Adjustment Buttons


(14,15,16,17) and Press Set Button (13) to Continue Setup.

rEF SEt

-0.90

 Select one of six Reference Cells (r1 to r6) or Reference Avarage (rA) that
the TR Unit Keeps Constant by Using Adjustment Buttons. (14,15,16,17)
Then Press Set Button (13) to Continue Setup.

rEF SEL

r1

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
 Adjust Low Current Limit Value that TR Unit Does Not Go under This
Current Value Whatever System Potential is by Using Adjustment Buttons.
(14,15,16,17) To Disable this Feature; Set Current Limit Value to 0. Then
Press Set Button (13) to Continue Setup

l Lo

005

 Adjust High Current Value that TR Unit Does Not Go over This Current
Value Whatever System Potential is By Using Adjustment Buttons.
(14,15,16,17) To Disable this Feature; Set Current Limit Value to
Maximum. Then Press Set Button (13) to Finish Automatic Mode Setup.

ı Hi

050

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
 To Set TR Unit Works on Automatic Mode; Press Coarse Up Button (14) for
3 Seconds until Power/Mode Indicator LED (1) becomes Blue.

009 02.7 -0.90

Aut

SETUP MANUAL MODE

 To Enter Manual Mode Setup Menu; Press Set Button (13) and Fine Up
Button (16) Together for 3 Seconds.

 Adjust Current Value by Using Adjustment Buttons (14,15,16,17) and Press


Set Button (13) to Finish Setup.
 

ı SEt

025
 
 
 
 

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
 
 To Set TR Unit Works on Manual Mode; Press Fine Up Button (16) for 3
Seconds until Power/Mode Indicator LED (1) becomes Orange.

025 05.9 -1.05

Con

SETUP INDEPENDENT MODE

 To Enter Independent Mode Setup Menu; Press Set Button (13) and Coarse
Down Button (15) Together for 3 Seconds.

 Adjust Firing Angle Percent Value by Using Adjustment Buttons


(14,15,16,17) and Press Set Button (13) to Finish Setup.

SEt PEr

45.5
 
 
 
 
 
 

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
 
 To Set TR Unit Works on Independent Mode; Press Coarse Down Button
(15) for 3 Seconds until Power/Mode Indicator LED (1) becomes Magenta.

025 05.9 -1.05

lnd

STANDBY / OFF

 To Put TR Unit Standby / Off Position; Press Fine Down Button (17) for 3
Seconds until Power / Mode Indicator LED Becomes (1) Green.

000 01.3 -0.81

off

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
TRANSFORMER

Step-down Transformer have been rated for Magnetic wire and


insulation materials to comply to minimum of Class F insulation within
minimum of 95% of efficiency to provide Lowered AC voltage to the
rectification form the incoming AC leads of the transformer. Copper
earth shield have been provided between primary and secondary winding
to provide appropriate earthing requirements. The Transformer unit
complies to IEC 60076 Power Transformers recommendations.

RECTIFIER

Rectification have been performed by a 3 phase full bridge connection of


silicon diodes which reverse tension are above 1200 V and conforms to
IEC 60146 Semiconductor Converters.

Power rectifying diodes have been mounted on anodized aluminum heat


sinks and sized for temperature of 85 C degree oil and rated load. The
Diodes have been selected to comply to the minimum of 150% greater
than the full rated rectifier output.

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
RECTIFIER BLOCK DETAILS

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
ELECTRONIC CONTROL CARD DETAILS

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
Project: Proj. Identification:
ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
SCADA COMMUNICATION (OPTIONAL)

ION-2430-OFC’ MODBUS hardware gives all system parameters about T/R


Unit variables like operating mode, set value, current system potential, dc
output voltage, CP current, error codes, temperatures and etc.

MODBUS addresses and details can be found on following table.

Register
Data: Range: Length: Access:
Address:
40001 DC Output Voltage (x10) 0-1000 2 Bytes R
40002 CP Current (x10) 0-100 2 Bytes R
40003 Selected Ref. Cell Value -2500-0 2 Bytes R
40004 Reference Cell #1 -2500-0 2 Bytes R
40005 Reference Cell #2 -2500-0 2 Bytes R
40006 Reference Cell #3 -2500-0 2 Bytes R
40007 Reference Cell #4 -2500-0 2 Bytes R
40008 Reference Cell #5 -2500-0 2 Bytes R
40009 Reference Cell #6 -2500-0 2 Bytes R
40010 Reference Cell Avrerage -2500-0 2 Bytes R
40011 Error Code 0 - 255 2 Bytes R
40012 Oil / Transformer Temp. (ºC) 0 - 255 2 Bytes R
40013 Air Temperature (ºC) (Optional) 0 - 255 2 Bytes R
40014 Panel Temperature (ºC) 0 - 255 2 Bytes R
40015 Current Firing Angle Percentage 0 - 100 2 Bytes R
40016 Working Mode (Off,Auto,Man,Ind.) (0,1,2,3) 2 Bytes RW
40017 Reference Cell Set Value for Auto. Mode -2500-0 2 Bytes RW
40018 Current Set Value for Man. Mode 0 - 300 2 Bytes RW
40019 Ref. Cell #1 Position (On,Selected,Error) (1,2,3) 2 Bytes RW
40020 Ref. Cell #2 Pos. (Ch Off,On,Selected,Error) (0,1,2,3) 2 Bytes RW
40021 Ref. Cell #3 Pos. (Ch Off,On,Selected,Error) (0,1,2,3) 2 Bytes RW
40022 Ref. Cell #4 Pos. (Ch Off,On,Selected,Error) (0,1,2,3) 2 Bytes RW
40023 Ref. Cell #5 Pos. (Ch Off,On,Selected,Error) (0,1,2,3) 2 Bytes RW
40024 Ref. Cell #6 Pos. (Ch Off,On,Selected,Error) (0,1,2,3) 2 Bytes RW
40025 Ref. Cell Avr. Pos. (Ch Off,On,Selected,Error) (0,1,2,3) 2 Bytes RW
40026 High Current Limit for Auto. Mode 1 - 301 2 Bytes RW
40027 Low Current Limit for Auto. Mode 0 - 299 2 Bytes RW
40028 Firing Angle % Set Value for Ind. Mode 0-100 2 Bytes RW
40029 MODEBUS RTU Adress 10-250 2 Bytes RW

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
ION-2430-OFC MODBUS interface supports “03” Read single or multiple
register and “06” write single register commands. Its default MODBUS
communication speed is 4800 bps.

Sample MODBUS cycle can be found on following tables;

## 03 ## ## 00 01 ## ##
Insturument Read High Byte Low Byte High Byte Low Byte Low Byte High Byte
Adress Command Starting Starting Number of Number of CRC CRC
Register Register Registers Registers
Address Address

TR unit answer the question as follows;

## 03 02 00 01 ## ##
Insturument Read Number of High Byte Low Byte Low Byte High Byte
Adress Command Bytes Register Register CRC CRC
Data Data

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
TROUBLESHOOTING

1. When Power Switch turned on, Power Led not blinks or lights.
a. Check all phases are OK
b. Check all circuit breakers from T/R distribution panel at backside.
c. Check main card’s fuse.
d. Check main card’s transformer.

2. ADC1 Led indicator is active: TR Unit gives this error when cannot get data from
first Analog to Digital Converter module that reads DC Output Potential, DC
Output Current and 3 Temperatures.
a. Connectors of card might be loosened or oxidized. Check and clean
connectors first. (X3, X5)
b. ADC module might be failed, replace the Main Card.

3. ADC2 Led indicator is active: TR Unit gives this error when cannot get data from
second Analog to Digital Converter Module that reads 6 reference cell value.
a. Connectors of card might be loosened or oxidized. Check and clean
connectors first. (X11)
b. ADC card might be failed, replace the Maincard.

4. Reference Cell Failure led indicator is active: TR unit generates this error when;
1 - Value of any reference cell is positive than -450 mV when TR unit is Off
position.
2 - Value of any reference cell has more than 150 mV of positive potential
difference from reference average value.
Note: In this case if T/R unit was working on automatic mode and failed reference
cell is selected one when failure occurred, TR Unit sets itself to manual mode to
keep protecting the structure.)
a. Check relevant reference cell value from connectors with a calibrated TRUE
RMS Multimeter.
b. Check cable connections. (X11)

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
5. Reference Cell Out of Range led indicator is active: If any reference cell value
connected to TR Unit is positive then -800 mV or negative then -1200 mV, Tr Unit
generates this Error.
a. Check Reference Cell Values with a calibrated TRUE RMS Multimeter.
b. Check TR Unit Working Mode Parameters.
c. Check Reference Cell Connections.
6. High Temperature led indicator is active and T/R unit has no output.
a. Temperature of Panel environment or oil might be exceeded the maximum
working limit of 85 ºC and T/R unit shut itself down to prevent damaging.
b. Thermistor’s connectors might be loosened or oxidized. Check and clean the
connector.
c. Panel or oil thermistor might be damaged. Replace the thermistors.

7. Anode / Cathode Failure led indicator is active.


a. Anode or cathode connection terminals might be loosened or oxidized.
Check and clean terminals both inside the T/R unit and distribution boxes.
b. Anode or cathode cables from T/R unit to distribution boxes might be
damaged. Check cable continuities with multimeter.

8. Limit Reached led indicator is active: When TR Unit working on Automatic Mode,
if output current reaches minimum or maximum set value, CPU generates this error.
a. Check Automatic Mode parameters and correct the error if it is necessary.

9. Rectifying Stack Failure led indicator is active.


a. Rectifying elements on the rectifying block inside the oil tank might be
damaged. Replace the rectifying block.
b. SCR Firing Board might be damaged. Replace Firing card.
c. Main card might be damaged. Replace the main card.

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
10. T/R unit has no output.
a. Rectifying elements on the rectifying block inside the oil tank might be
damaged. Replace the rectifying block.
b. SCR Firing Board might be damaged. Replace card.
c. Transformer circuit breaker might be switch off. Switch on circuit breaker.
d. Transformer power connections might be loosened or oxidized. Check and
clean connections.
e. Main card might be damaged. Replace main card.
f. Over heating might be occurred. Check High Temperature indicator.

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016
PART LIST

No: Part Name: Part Description:


1 Power Indicator 10 mm RGB LED
2 Power Switch Siemens 3SB 1400-0A
3 Phase Indicators Siemens 3SB 1400-2A (Red)
4 Reference Cell Selector Switch Lorlin-12R
5 ADC1 Failure Indicator 10 mm Red LED
6 ADC2 Failure Indicator 10 mm Red LED
7 Reference Cell Failure Indicator 10 mm Red LED
8 Reference Cell Out of Range Indicator 10 mm Red LED
9 High Temperature Indicator 10 mm Red LED
10 Anode / Cathode Failure Indicator 10 mm Red LED
11 Limit Reached Indicator 10 mm Red LED
12 Rectifying Stack Failure Indicator 10 mm Red LED
13 Set Switch Siemens 3SB1 202-0AE01
14 Coarse Up Button Emas KB14
15 Coarse Down Button Emas KB14
16 Fine Up Button Emas KB14
17 Fine Down Button Emas KB14
18 Cathodic Protection Current Display ION-IDisp-1
19 DC Output Display ION-IDisp-2
20 System Potential Display ION-IDisp-3
21 Set Display ION-IDisp-4
22 Reference Cell Indicator 10 mm RG LED
23 Main Circuit Breaker Siemens 5SQ2670-2YA32
24 Transformer Circuit Breaker Siemens 5SQ2370-2YA16
25 Main Card Circuit Breaker Siemens 5SQ2170-2YA06
26 240 VAC Socket Circuit Breaker Siemens 5SQ2170-2YA06
27 Spare Circuit Breaker Siemens 5SQ2170-2YA06
28 240 VAC Socket SCHNEIDER A9A15310
29 40 KV Surge Arrester Siemens 5SD7464-0
30 Cathode Fuse Siemens 3NA3803
31 Main Card Transformer Gunduz 240-2x2x12 25W
32 Main Card IONMainIGBT
33 Hybrid IGBT Driver Card IONVLA500
34 PWM Generator Card IONDSP15
35 Cable Terminals AVK Type Size 6 - 50

Project: Proj. Identification:


ION-2430-OFC OIL COOLED AUTOMATIC TRANSFORMER / RECTIFIER EDO-MNL-COE-COR-INT-XXX-016-622-801-REV-A-ION-2430-
Document Title: Document No.:
UNIT OFC OIL COOLED AUTOMATIC TRANSFORMER
Revision: A Date: 28.01.2016

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