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Operation Manual HYDROCAL BPD English - R02 (07.2022) (001-078)
Operation Manual HYDROCAL BPD English - R02 (07.2022) (001-078)
Operation Manual HYDROCAL BPD English - R02 (07.2022) (001-078)
Note!
To prevent the loss of data, it is recommended to save the measurement
data with the Windows-based optional software HydroSOFT Hybrid App.
Important: MTE and EMH accept no liability for any kind of data loss.
A HYDROCAL BPD can be combined with other HYDROCAL models, preferably HYDROCAL genX,
to set up a comprehensive monitoring system.
According to CIGRÉ Working Group A2.37, bushings or the line output represent the second largest
group of transformer failures (about 25%) after windings (43%) and before tap changers (23%).
Therefore, bushing monitoring can help reduce these errors, while UHF partial discharge analysis of
the active part of a power transformer is an ideal combination with online DGA from the HYDROCAL
product family.
The modular concept of the HYDROCAL BPD allows the user to select the combination of bushing
monitoring and partial discharge functions that best suits his monitoring requirements and technological
beliefs. While measuring voltage and phase angle at the test tap of high-voltage bushings allows tanδ
/ PF to be compared with factory test results, partial discharge analysis can help detect electrical
failures of these bushings more quickly. A UHF (ultra-high frequency) partial discharge analysis of the
active part of large power transformers can be a good method to determine windings or other electrical
faults without disturbances, e.g. from corona discharges.
The voltage and phase angle measurement covers a measuring range up to 28 V in the frequency
range of 40...70 Hz with an accuracy of 0.1%. Measurements can be synchronized with the 3-phase
system voltage via a reference channel up to 300 V. Partial discharges can be electrically between 100
pC...10 nC and 0.1..0.4 MHz according to IEC 60270. The UHF partial discharge measurement covers
a range between -60...0 dBm and 0.2...3 GHz.
1.3 Operation
HYDROCAL BPD features an intuitive operating concept via a large capacitive 7-inch TFT colour touch
screen and an integrated WiFi interface. The integrated genX-Webserver enables operation of the
devices from any smartphone, tablet or notebook PC equipped with an internet browser. The product
integrates various communication interfaces: USB, ETHERNET 10/100 Mbit / s (electrical / RJ45 or
fibre optic / SC Duplex) and RS485 to support MODBUS (RTU / ASCII and TCP), DNP3 and IEC 61850
protocols.
Attention!
Read and follow th§e operating instructions and safety instructions before
using the HYDROCAL BPD.
Attention!
Incorrect or improper handling will invalidate all warranty claims.
Attention!
In the installation of the mains voltage supply, there must be an
over-current protection device 10 A in place
Attention!
When performing high-voltage type tests on the transformer or the bushings,
the output voltages from connected bushing sensors may exceed the
measuring ranges of the HYDROCAL BDP measuring device. In this case,
correct measurements cannot be performed. Under certain circumstances, the
voltage level can exceed the limits of the protective circuitry of the sensors. In
principle, this does not cause any damage, but it can unnecessarily age the
sensors. In principle, the sensors are dimensioned in such a way that this
should not happen (however, if the data required for dimensioning has not been
sent to the manufacturer correctly, it could happen). If in doubt, contact our
after-sales service team before carrying out high-voltage tests.
Attention!
The device must be protected from environmental influences such as sun and
moisture.
Attention!
Hazardous voltage. The device may only be opened by the Service department.
When the user replaces the device’s fuse, the mains input voltage must be
disconnected.
Attention!
Unauthorized opening of the device or damage to seals etc. jeopardizes the
warranty claim.
Note: The connections for sensors, voltages, digital outputs and RS485 are made at the terminal block
below the cable duct on the mounting plate [4.3.3].
Fuse
GSM
Antenna
connection
On/Off
Switch WiFi
Antenna
connection
SD card
Ethernet
USB A
RS485*
USB B
Digital
outputs*
* RS485 and digital outputs are connected via the terminal strip on the mounting plate [4.3.3]
For details on connecting the relay outputs, see mounting plate [4.3.3].
3.1.2.3.6 Ethernet
Note: Before inserting a memory card into the device, it must be FAT32 formatted. The SD card
supplied with the device is already formatted.
3.1.3.1.2 Implementation monitoring - Capacitance I tanδ(PF) H1, H2, H3, X1, X2, X3
Depending on the configuration of the HYDROCAL BPD, the bushing or/and bushing
PD sensors are connected here. Channel H1-H3 is for the primary voltages and
channel X1-X3 for the secondary voltages.
....
Note: Connection lines to the sensor terminals are connected to the terminal blocks of the mounting
plate, see [4.3.3].
When using the reference voltage on the HYDROCAL BPD, the value for
capacitance/C and the dissipation factor/tanδ of the bushing(s) are displayed as
absolute values.
Without reference voltage, the values of the bushing capacitance are displayed on
the HYDROCAL BPD as a percentage deviation of the capacitance/∆C. The loss
factors/∆tanδ are determined using the "adjacent phase method"
For settings and selection of the reference voltage, see [4.4.1] and [5.3.3.1.3].
Note: Connection lines to the reference voltage terminals are connected to the terminal blocks of the
mounting plate, see [4.3.3].
The HYDROCAL BPD is equipped with a mains input with wide range input. This
allows worldwide use with the connection of the power supply in the range
85...264VAC (45...65Hz) or 90-350VDC.
Note: Connection lines to the power supply terminals are connected to the terminal blocks of the
mounting plate, see [4.3.3].
Note: There must be a 10 A over-current protection device in the mains power supply installation. This
protective device must be freely accessible. Furthermore, it must be clearly marked as a protective
device for the HYDROCAL BPD.
4.3 Installation
The HYDROCAL BPD with mounting plate must be installed in a switch cabinet. This is the only way
to ensure that the device is protected from weather influences such as rain, moisture and solar
radiation. Existing control cabinets are a good choice here. The dimensions of the mounting plate can
be found in the section [9.2].
Optionally, the HYDROCAL BPD can be installed in a control cabinet specially made for the
HYDROCAL BPD. For details on the optional control cabinets, see [7.2.2] and [9.3].
Before the mounting plate with the HYDROCAL BPD is installed in the switch cabinet, it must be
attached to a bracket that is not included in the scope of delivery.
Connector sensor
• After the sensors have been mounted on the test connections, the sensor cables are connected.
• Only the supplied cables and connectors may be used.
• If no pre-assembled cables are used, the cable must be assembled according to the following
instructions:
4.3.3 Mounting the basic device/mounting plate with connections on the customer side
The mounting plate is provided with the HYDROCAL BPD basic device, as well as with connection
terminals. Depending on the BPD configuration [1.2], different terminals are available.
Note: The customer connection of power supply, reference voltage, relay outputs, RS485 as well as
sensors only takes place at the terminals of the terminal block below the cable duct on the mounting
plate. Changing the wiring between the BPD basic device and the terminal block can lead to
malfunctions, incorrect measured values and damage to the device.
4.3.3.1 Earthing
4.3.3.1.1 General points
An earthing is provided to which all metallic frame and housing parts connect. Earthing cables are
provided to ensure such equipotential bonding, where all metallic parts are connected to earth. The
base plate, as well as the optional control cabinet, must be connected to it with low impedance.
4.3.3.1.4 Earthing sensor cable and RS485 when used with optional control cabinet
If a HYDROCAL BPD control cabinet from [7.2.2] is used, the earth connections are preferably made
via the cable bushings on the underside of the control cabinet. In this way, the best shielding effect is
achieved. It is also possible to route the shielding of the connecting cables to the grounding terminal
block.
Note: After mounting the device and commissioning [4.4], the correct installation must be checked.
4.3.3.2.1 Connection technology of the terminal blocks sensor inputs X1, (X2) and mains input
X4 on the mounting plate
The terminal blocks X1, X2* and X4 are designed with push-in connection technology. This makes it
easy to contact conductors, directly and without tools. The special contact spring allows easy plugging
and scores top marks with its high contact quality. Rigid conductors and flexible conductors with
ferrules are contacted by direct insertion. Flexible conductors without ferrules (is not recommended)
are connected with the actuating pusher (X1 and X2*) or by inserting a screwdriver (X4).
X1,
X2
X4
4.3.3.2.2 Connection technology of the terminal blocks X3, X5, X6 and X7 of the mounting plate
The tension clamp connection of terminal X3, X5, X6 and X7 is very convenient due to its front
connection, the mounting cables are as follows:
• Open the clamping point with a standard screwdriver.
• Insert the conductor into the clamping space and remove the screwdriver. The conductor
contacts automatically.
X3,
X5,
X6,
X7
Note: The cross-sections of the connection lines must be observed, see [4.3.3.2]. For settings of the
sensor inputs, see [4.4.1] and [5.3.3].
HYDROCAL BPD Installation and Operation Manual_R02 Page 19/123
4.3.5 Connection of terminals X3-X7
4.3.5.1 Connection of reference voltage to X3
The reference voltage from the HYDROCAL BPD is connected to terminal X3.
Note: The cross-sections of the connection lines must be observed, see [4.3.3.2]. For settings for the
reference voltage, see [4.4.1] and [5.3.3.1.3].
Note: The cross-sections of the connection lines must be observed, see [4.3.3.2].
Attention: The parameters from [3.1.2.2] must be complied with.
For details on testing the relay outputs, see [5.3.3.1.7].
For settings for the relay outputs for alerts, see [5.3.2.5.1.1].
RS485 Terminal X6 an X7
Note: The cross-sections of the connection lines must be observed, see [4.3.3.2].
For more information on the settings of the RS485 interfaces, see [5.3.4.1.3].
After the HYDROCAL BPD and the sensors have been installed according to [4.3], the device can be
switched on via the mains switch. To do this, set the mains switch to position 1 [3.1.2]. The device then
starts up and is ready for operation after booting. The start screen appears, see also [5.2].
Select the “Operation” menu, and you will reach the operation overview.
Note: The data displayed in the “BPD” menu are factory-set parameters and
cannot be changed by the operator.
For details on the settings, see also the “Bushing settings” menu [5.3.3]. Once all settings have been
made, the input measurement signals are checked for plausibility. Under [5.3.3.1.6.] the instantaneous
values of voltages, phase and frequency can be displayed. All bushings, as well as the reference
voltage (if selected and connected), can thus be checked for correct connection. Furthermore, when
using the reference voltage, the currently measured capacitance C1 can be displayed in pF. Without
the use of reference voltages, the relative capacity is measured and displayed in %.
In case of missing or implausible measuring signals, check the complete wiring. Subsequently, the
input measuring signals are to be checked again according to [5.3.3.1.6.].
If all settings are done and the above input signals are as expected, the measurement can be started.
HYDROCAL BPD Installation and Operation Manual_R02 Page 25/123
4.4.2 Start / stop measurement
After successful configuration of the HYDROCAL BPD, the measurement can be started, see also
[5.3.3.1.1].
Now, the measurement starts. If the device is started for the first time or if the bushing reference
measurement has been reset [4.4.2.1], the reference measurement of the bushings is carried out
during the start-up time. Only then are the measurement data of the bushings recorded.
This is followed by initialization (“Start = 10s”, this corresponds to the start-up time, see [4.4.1] and
[5.3.3.1.5]) and a progress bar with the time that has already elapsed.
After that, the set recording time appears (here: Rec = 1Min this corresponds to the recording time,
see [4.4.1] and [5.3.3.1.5]) of the bushing measurement and an elapsed time bar.
Analysis [5.3.1]
Alert [5.3.2]
Operation [5.3.3]
Setup [5.3.4]
Bushing [5.3]
Manual [5.5.2]
Help [5.7]
Exit
Device type Model code Software version and date Serial number
*SD storage
*SSD storage and Process flow
Currently selected menu item and help texts, see below and Memory Time and Date
Memory use And time lapse
use
*Tip: The screens in this manual were made on different systems or with different software versions.
Therefore, the memory sizes shown may vary from image to image.
When a field is pressed, a help text appears in the left-hand area; the length of the display can be set
individually, see [5.3.4.3].
In the illustration above, a blue line can be seen between the control fields on the left. This gives an
indication of other menu items.
… …
Depending on the setting in the following, the sensor selection fields are colored differently. There are
also fields with a small triangle in the lower right corner, which can also be colored differently. For
details on the colors of the selection fields, see [5.3.1.1.1].
The elapse of time (1 second) is indicated by a small clock symbol in the upper right corner of
a sensor selection field.
Note: If a sensor selection field is pressed only briefly (less than 1 second), the result field is displayed.
If pressed for a longer time (at least 1 second), a change can be made to the selection parameters.
The following examples of measured variables refer to the sensor bushing H1 transformer primary
side phase 1. The selection fields shown refer to a BPD 600 configuration with reference voltage!
C1 H1 [pF] Capacity C1 in pF
This is selected by operating a control field for measured variables. Pressing the same field again
deactivates the selection. See also [5.3.1.1.2].
In the picture, a selection of the measurement results to be displayed was made after [5.3.1.1]
(C1 H1 [pF], ∆ C1 H1 [%] and tan δ H1 [%])
If more measured variables are selected than can be displayed on the screen, this is indicated by the
grey scroll bar at the bottom edge.
By moving sideways in the result field, the areas that are not visible can be displayed.
If there are more measured variables over time than can be displayed on the screen, this is indicated
by the grey scroll bar at the bottom edge.
By moving sideways in the result field, the areas that are not visible can be displayed.
By pressing the control field “Cursor Left”, this jumps to the values of a previous
measurement.
By pressing the control field “Cursor Right”, this jumps to the next values of a
measurement.
By pressing the control field “Larger”, the time range (X-axis) of the displayed values is
enlarged.
By pressing the control field “Smaller”, the time range (X-axis) of the displayed values is
reduced.
If there are more measured variables than can be displayed on the screen, this can be recognized by
the grey scroll bar at the bottom and/or right edge (only on the right in the example image). By
moving vertically or horizontally in the result field, the areas that are not visible can be displayed.
Day and time of the measured value Measured variables (secondary or primary side and
transformer phase)
Devices of the measured variables
The “H∑U” control field is used to select the primary-side measured value history of
the transformer’s total voltages for display.
The “X∑U” control field is used to select the secondary-side measured value history
of the transformer’s total voltages for display.
After selecting sum voltages, the respective control fields appear with an orange
background.
The following fields can be used to display or select different time ranges or data records.
Display of the selected time period (start and end date as well as time range
in YYMMDDHH)
Data sets
If a grey bar appears on the right in the data manager, more files are available than are visible on the
screen.
You can make them visible by swiping up and down in the list with your finger.
While a measured variable is selected, it is displayed with a yellow background. By setting or deleting
green ticks, the respective desired measured variables are selected or deselected.
In addition, the control fields on the left side of the screen can be used to navigate in the list of measured
variables.
The following can be seen in the report for the respective sensor (here: bushing H1):
• Day: Date [yy-MM-dd] and
• Time Time [hh-mm-ss] of the last action (setting up the alert, triggering
etc.)
• Measurement name: Measured value name
• Status: Status of the alert.
• Measured value: Measured value at the sensor during triggering
• Alert threshold: The thresholds configured in the alert setup [5.3.2.5]
The two lower fields (in the case of a Hi-Hi alert) reflect the respective alert configurations, in the case
of a Hi alert there is only one field here:
High alert: High-High alert:
• Threshold • Threshold
• Threshold value • Threshold value
• Delay • Delay
• Action • Action
• Output • Output
For settings see [5.3.2.5].
Similar to the analysis menu, the selection of the alert protocol to be displayed is highlighted in
colour. In the case of an alert, the various symbols (bells) for the respective alert status are added.
A spanner in the selection field indicates that the alert has not yet been configured, a
configuration is done via the setup [5.3.2.5].
A green bell in the selection field indicates that the alert configuration of the respective
sensor has been made, but an alert threshold has not yet been reached at the moment.
A red bell in the selection field indicates that a Hi-Hi alert has been triggered.
This already happens when only one value of the alert configuration is exceeded.
Hi-Hi alert was triggered (triggering threshold has already been undershot again and the
alert was not acknowledged)
A yellow bell in the selection field indicates that a Hi alert has been triggered.
This already happens when only one value of the alert configuration is exceeded.
Hi alert was triggered (triggering threshold has already been undershot again and alert
was not acknowledged)
Note: If a blue bar is visible to the left of the sensor fields, this indicates that there are more sensor
fields than shown. These can be displayed by scrolling down.
After pressing the “Confirm” button, you will be asked to enter your password. To do this, first type in
the middle grey field
The alert is then acknowledged. When an alert has been acknowledged, this is shown by the
following symbol .
Note: Every alert must be acknowledged individually!
In the following example, no alerts are configured yet. This can be recognized by the
spanner in the fields of the sensors. And for the selected sensor (in this case bushing
H1), the message “Alert not yet set!”
The copied alert configuration parameters can be assigned to another measured variable
by pressing the “Paste” field.
Then press the control field “Save”. This saves the entire alert configuration.
After that, the sensor field is displayed marked with a circle double arrow. This mark
remains until the alert configuration has been saved.
Threshold: The signal threshold for the sensor is entered here, i.e. the sensor value
at which the alert is to be triggered. The submenu is called up either by actuating the
“Threshold” field
or by touching the field containing the value (here “20”). Then the value is entered in
the opening setting menu via the keyboard and confirmed with the input field (green
field).
Delay: The time delay between the signal threshold being reached and the alert being
activated is set here. The value can be entered in seconds [s], minutes [m] or hours
[h]. The submenu is accessed either by pressing the “Delay” field or by pressing the
field in which the value is written (here “55”).
Action: This is used to set the action to be carried out when the alert is activated.
The following settings are possible:
• “Entry (in log file) outputs are disabled in this case.
• “Output” (set a relay output)
• “-” (no action)
Output: Here the relay output [4.3.5.3] is assigned, which is assigned after previous setting when the
alert is activated.
The following is an overview of the bushing alert parameters for a HYDROCAL BPD with reference
voltage.
After that, the sensor field is displayed marked with a circle double arrow. This mark
remains until the alert configuration has been saved.
In the following example, the configuration is copied from bushing H1 to bushing H2:
The configuration of an alert is only completed after the “Save” field has been pressed
and the respective alert is only activated then
Selection of the Actuation of an alert After that, the Actuation Save Alert
configuration to field configuration field configuration is
be deleted is overwritten deleted
After configuring or changing an alert, the sensor field is displayed marked with a
circle double arrow. This mark remains until the alert configuration has been saved.
The configuration of an alert is only completed after the “Save” field has been pressed
and the respective alert is only activated then
Status [5.3.3.1.1]
BPD [5.3.3.1.2]
Bushing [5.3.3.1.3]
PD [5.3.3.1.4]
Measurement [5.3.3.1.6]
• The Start/Stop menu field that is not released is shown in grey tones.
In addition, the following symbol indicates the menu item that has not been released
£
In addition, the following symbol indicates an approved setup
• After that, the release is locked and no changes can be made in the selection menus.
In the menu shown above it is possible to start, currently the measurement is stopped. This is
indicated by the entry in the status bar.
Note: Before starting the measurement, some basic settings must be made, see [4.4.1]
To lock the release again, press the After that, the release is locked
lock symbol. and no change is possible.
In this way, the measurement can only be stopped after the release has been made according to
[5.3.3.1].
Note: The data displayed in the BPD menu are factory-set parameters and cannot be
changed by the operator.
Bushing manufacturer.
Bushing type.
The respective input mask (in the following example, the bushing capacity C1) can be
accessed by tapping on the respective control field or directly on the value
The input mask of the following values can be reached by tapping on the respective control field or
directly on the value. The value is then entered in the following via the number fields and the menu is
exited via the green input field.
Note: The reference voltage is selected either for 3 phases or for no phase.
To be able to make settings in this menu, the release must be set to [5.3.3.1]. The release has
already been carried out in the example.
After pressing one of the following control fields, an input mask opens in which the calibration data of
the respective sensors are entered. See the following page.
The basic setting can be seen via menu Bushing operating menu - BPD
Note: Before using PD measurement, the available sensor inputs must be calibrated. The data
supplied by the sensor manufacturer for each sensor is used for this purpose.
The input mask of the following values can be reached by tapping on the respective
control field or directly on the value. The value is then entered in the following via the
number fields and the menu is exited via the green input field. Use the ESC field to
exit the menu without accepting the entered values.
The operation of the following control fields results from the previously entered values
Cal.Km This control field is released for selection after entering C0and Km.
Afterwards, the calibration of the input is completed and a note of the successful
calibration with the calibration date is stored in the respective information fields.
After pressing the button, the overview appears again; here, too, a note of the
calibration that has been carried out (green tick) with the calibration date is stored in
the respective information fields
The input mask of the following values can be reached by tapping on the respective
control field or directly on the value. The value is then entered in the following via the
number fields and the menu is exited via the green input field. Use the ESC field to
exit the menu without accepting the entered values.
Cal.Km This control field is released for selection after entering Ks, U0 and Km
After pressing the button, the overview appears again; here, too, a note of the
calibration that has been carried out (green tick) with the calibration date is stored in
the respective information fields
Start-up time / duration of the mean value period for determining the reference value
of the bushing's measurement
The fact that one or more time fields cannot be set (i.e. are greyed out) can have various reasons:
• The release of the settings menu has not been activated, see also [5.3.3.1].
• The start-up time can only be set during commissioning, see also [4.4].
• The HYDROCAL BPD is not configured for this measurement.
Then the input mask opens in which the time is entered via the number field. The time device
(second/minute/hour) is selected using the up or down arrow. After the configuration has been
completed, confirm the entry and exit the input mask via the green input field.
Pressing the “Vector” control field displays the view of the current measured values in a
measured value diagram.
If installed correctly, the correct phase position must be displayed. Usually U1-U2-U3, as shown.
Pressing the “Interval” control field opens the configuration of the update time of the
measured value display.