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ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL
Document No.
EDO
Co. Org. Cod

MAN
Doc Type

COE
Disc. Code

COR
Unit Code

INT
Prj. Type

XXX
Prj. NO

13
Prj. Year

112
Proj. Seq.No

139
DCC Seq.No

Rev

Scale

Page

48

Page 2

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ION-501-OTC

OIL COOLED AUTOMATIC TRANSFORMER/RECTIFIER UNIT


Project: Document Title: Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 3 INDEX

of 28

FEATURES ......................................................................................................................... 4 OPERATING MODES .......................................................................................................... 4 GENERAL SPECIFICATIONS ................................................................................................. 5 STANDARDS ...................................................................................................................... 6 TECHNICAL INFORMATION ................................................................................................ 7 T/R UNIT CONTROL PANEL DETAILS ................................................................................... 9 T/R UNIT ELECTRICLAL PANEL DETAILS ............................................................................ 11 T/R UNIT STARTING UP INSTRUCTIONS ........................................................................... 12
SETUP AUTOMATIC MODE ...................................................................................................... 12 SETUP MANUAL MODE ........................................................................................................... 15 SETUP INDEPENDENT MODE ................................................................................................... 16 STANDBY / OFF ...................................................................................................................... 17

TRANSFORMER ............................................................................................................... 18 RECTIFIER ....................................................................................................................... 18 ELECTRONIC CONTROL CARD DETAILS ................................Hata! Yer iareti tanmlanmam. CABLE TERMINAL DETAILS ............................................................................................... 21 SCADA COMMUNICATION ............................................................................................... 22 TROUBLESHOOTING ........................................................................................................ 24 PART LIST........................................................................................................................ 27

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 4 FEATURES

of 28

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12)

Fully Micro-processor based, Remote Monitoring / Controlling on MODBUS-RTU (RS485) Automatic, Manual and Independent Operation (Constant Current, Constant System Potential and SCR Firing Angle %) Precision control with 13-bit independent firing CPUs LC Filtered DC output for minimum ripple Surge Protection on both AC and DC side Oil Cooled Type Fully Solid-State Design Automatic Error Correction EEprom Memory Against Electricity Failure Automatic Over-Load Protection Automatic Over-Heat Protection
OPERATING MODES

- Automatic (Constant System Potential) - Manual (Constant Output Current) - Independent (SCR Firing Angle Control)

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 5 GENERAL SPECIFICATIONS

of 28

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-501-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, shunt and thyristor assembly are mounted inside the oil tank.

Primary MCB, AC fuses, DC fuses, and DC surge arrestors are mounted inside the IP65 control box.

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

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 6 STANDARDS

of 28

ION-XXX-OFC series of rectifiers are under manufacturing and testing meeting recognized standards and regulations of cathodic protection, electrical and electronic system and devices.
SemiconductorPowerRectifiers, PracticesandRequirements 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 ANSI C34.2 ANSI C57.12.13

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 7
ION-501-OTC (ONAN) 50V 10A OIL COOLED AUTOMATIC TRANSFORMER RECTIFIER UNIT INPUT: Input Voltage: 400 VAC %5, 3 Phase, 50 Hz Input Current: 0.5 A (Fully Load) Input Protection: Surge Arrester Notral + 3 Phase (Siemens 5SD7464-0 40 KA) Working Temperature: -20C, +55C OUTPUT: Output DC Voltage: 0 - 50 VDC (13-Bit, 8192 Steps) Output DC Current: 0 - 10 ADC (13-Bit, 8192 Steps) Rectifier Type: Microprocessor Controlled SCR (Silicone Controlled Rectifier) Output Filter: LC Type Output Ripple: < %2 at max. load Output Protection: Ceramic Parafudr (600 V, 10 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 SCR firing angle constant. Interrupted Mode: ON/OFF with SCADA Synchronization. (with Tact Signal) DISPLAYS: Display Type: 3 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. Indicates one or more reference cell reading out of range. Reference Cell 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: 4800 bps Access: Read / Write (Full Control)

of 28

TECHNICAL INFORMATION

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 8 T/R UNIT CONTROL PANEL

of 28

1. 2. 3. 4. 5. 6. 7. 8.

Power Led Power Switch Phase indicators Reference Cell Tracker Switch ADC1 Failure Led ADC2 Failure Led Reference Cell Failure Led Reference Cell Out of Range Led 9. High Temperature Led 10. Anode/Cathode Failure 11. Limit Reached Led

12. 13. 14. 15. 16. 17. 18. 19. 20.

Rectifying Stack Failure Led Set Button Coarse Up Button Coarse Down Button Fine Up Button Fine Down Button DC Ammeter Display DC Voltmeter Display DC Reference Cell Potential Display 21. Set Display 22. Reference Cell Indicator Led

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 9 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. Phase Indicators: 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. (SCR Firing card, Fuses, etc) 13. Set Button: It is used to set the T/R working parameters. When pressed single for 3 secends, 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.

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Page 10 of 28 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.

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: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 11 of 28 T/R UNIT ELECTRICLAL PANEL DETAILS

23. Main Circuit Breaker 24. Transformer Circuit Breaker 25. Main Card Circuit Breaker 26. AC Socket Circuit Breaker 27. Spare Circuit Breaker 28. 240 VAC Socket 29. Input Surge Arresters

30. Cathode Fuse 31. Main Card Transformer 32. SCR Firing Board 33. Main Control Card 34. RS-232 RS-485 Converter 35. Cable Terminals

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 12 of 28 T/R UNIT STARTING UP INSTRUCTIONS

1. Check all phases from indicators.(3) 2. Check all circuit breakers from inside of the panel.(23-24-25-26) 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. To Enter Automatic Mode Setup Menu; Press Set Button (13) and Coarse Up Button (14) Together for 3 Seconds. Adjust Reference Value by Using Adjustment Buttons (14,15,16,17) and Press Set Button (13) to Continue Setup.
SETUP AUTOMATIC MODE

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 13 of 28

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

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

Project: Document Title: Prj. Identification:


ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 14 of 28

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.

To Set TR Unit Works on Automatic Mode; Press Coarse Up Button (14) for 3 Seconds until Power/Mode Indicator LED (1) becomes Blue.

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

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Date: 15.12.2013

Page 15 of 28 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.

To Set TR Unit Works on Manual Mode; Press Fine Up Button (16) for 3 Seconds until Power/Mode Indicator LED (1) becomes Orange.

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

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Date: 15.12.2013

Page 16 of 28

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.

SETUP INDEPENDENT MODE

To Set TR Unit Works on Independent Mode; Press Coarse Down Button (15) for 3 Seconds until Power/Mode Indicator LED (1) becomes Magenta.

Project: Document Title: Prj. Identification:


ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 17 of 28 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.

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 18 of 28 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 thyristors which reverse tension are above 1200 V and conforms to IEC 60146 Semiconductor Converters. Power rectifying thyristors have been mounted on anodized aluminum heat sinks and sized for temperature of 85 C degree oil and rated load. The Thyristors have been selected to comply to the minimum of 150% greater than the full rated rectifier output.

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 19 of 28

ELECTRONIC CONTROL CARD DETAILS

Page 20 of 28

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Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

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Date: 15.12.2013

Page 21 of 28

CABLE TERMINAL DETAILS

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Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

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Date: 15.12.2013

Page 22 of 28

SCADA COMMUNICATION ION-501-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 Address: 40001 40002 40003 40004 40005 40006 40007 40008 40009 40010 40011 40012 40013 40014 40015 40016 40017 40018 40019 40020 40021 40022 40023 40024 40025 40026 40027 40028 40029 Data: DC Output Voltage (x10) CP Current (x10) Selected Ref. Cell Value Reference Cell #1 Reference Cell #2 Reference Cell #3 Reference Cell #4 Reference Cell #5 Reference Cell #6 Reference Cell Avrerage Error Code Oil / Transformer Temp. (C) Panel Temperature (C) Outside / Air Temperature (C) Current Firing Angle Percentage (x10) Working Mode (Off,Auto,Man,Ind.) Reference Cell Set Value for Auto. Mode Current Set Value (x10) for Man. Mode Ref. Cell #1 Position (On,Selected,Error) Ref. Cell #2 Pos. (Ch Off,On,Selected,Error) Ref. Cell #3 Pos. (Ch Off,On,Selected,Error) Ref. Cell #4 Pos. (Ch Off,On,Selected,Error) Ref. Cell #5 Pos. (Ch Off,On,Selected,Error) Ref. Cell #6 Pos. (Ch Off,On,Selected,Error) Ref. Cell Avr. Pos. (Ch Off,On,Selected,Error) High Current Limit for Auto. Mode (x10) Low Current Limit for Auto. Mode (x10) Firing Angle % Set Value for Ind. Mode (x10) MODEBUS RTU Adress Range: 0-1000 0-100 -2500-0 -2500-0 -2500-0 -2500-0 -2500-0 -2500-0 -2500-0 -2500-0 0 - 255 0 - 255 0 - 255 0 - 255 0 - 1000 (0,1,2,3) -2500-0 0 - 100 (1,2,3) (0,1,2,3) (0,1,2,3) (0,1,2,3) (0,1,2,3) (0,1,2,3) (0,1,2,3) 1 - 101 0 - 99 0-1000 10-250 Length: 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes 2 Bytes Access: R R R R R R R R R R R R R R R RW RW RW RW RW RW RW RW RW RW RW RW RW RW

Page 23 of 28

ION-501-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; ##
Insturument Adress

03
Read Command

##
High Byte Starting Register Address

##
Low Byte Starting Register Address

00
High Byte Number of Registers

01
Low Byte Number of Registers

##
Low Byte CRC

##
High Byte CRC

TR unit answer the question as follows; ##


Insturument Adress

03
Read Command

02
Number of Bytes

00
High Byte Register Data

01
Low Byte Register Data

##
Low Byte CRC

##
High Byte CRC

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 24 of 28

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 cards fuse. d. Check main cards 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.)
Project: Document Title: Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 25 of 28 a. Check relevant reference cell value from connectors with a calibrated TRUE RMS Multimeter. b. Check cable connections. (X11)

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 C and T/R unit shut itself down to prevent damaging. b. Thermistors 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.
Project: Document Title: Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 26 of 28

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. Main card might be damaged. Replace the main card. 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: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 27 of 28

PART LIST
No: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Part Name: Power Indicator Power Switch Phase Indicators Reference Cell Selector Switch ADC1 Failure Indicator ADC2 Failure Indicator Reference Cell Failure Indicator Reference Cell Out of Range Indicator High Temperature Indicator Anode / Cathode Failure Indicator Limit Reached Indicator Rectifying Stack Failure Indicator Set Switch Coarse Up Button Coarse Down Button Fine Up Button Fine Down Button Cathodic Protection Current Display DC Output Display System Potential Display Set Display Reference Cell Indicator Main Circuit Breaker Transformer Circuit Breaker Main Card Circuit Breaker 240 VAC Socket Circuit Breaker Spare Circuit Breaker 240 VAC Socket 20 KV Surge Arrester Cathode Fuse Main Card Transformer 3PH SCR Firing Board Main Card Isolated RS-232 to RS485 Converter Cable Terminals Part Description: 10 mm RGB LED Siemens 3SB 1400-0A Siemens 3SB 1400-2A (Red) Lorlin-6R 10 mm Red LED 10 mm Red LED 10 mm Red LED 10 mm Red LED 10 mm Red LED 10 mm Red LED 10 mm Red LED 10 mm Red LED Siemens 3SB1 202-0AE01 Emas KB14 Emas KB14 Emas KB14 Emas KB14 ION-IDisp-1 ION-IDisp-2 ION-IDisp-3 ION-IDisp-4 10 mm RG LED Siemens 5SQ2670-2YA16 Siemens 5SQ2370-2YA10 Siemens 5SQ2170-2YA06 Siemens 5SQ2170-2YA06 Siemens 5SQ2170-2YA06 SCHNEIDER A9A15310 Siemens 5SD7464-0 Siemens 3NA3803 Gunduz 240-2x2x12 AC ION-B.2001-05-Dual876A-6 ION- B.2001-05-IONMain3PH-10A ADAM 4520 AVK Type Size 6 - 25

Project: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

Page 28 of 28 2. 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: Document Title:

Prj. Identification:
ION-501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER RECTIFIER UNIT OPERATORS MANUAL

Document No.:

EDO-MAN-COE-COR-INT-XXX-013-112-139-REV-A-ION501-OTC OIL COOLED SMALL AUTOMATIC TRANSFORMER - RECTIFIER UNIT OPERATORS MANUAL

Revision:

Date: 15.12.2013

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