Beruflich Dokumente
Kultur Dokumente
MANUAL
Confidential Information
The material contained herein consists of information that is the property of LumaSense
Technologies, Inc. and intended solely for use by the purchaser of the equipment described in this
manual. All specifications are subject to change without notice. Changes are made periodically to
the information in this publication, and these changes will be incorporated in new editions.
LumaSense Technologies, Inc. prohibits the duplication of any portion of this manual or the use
thereof for any purpose other than the operation or maintenance of the equipment described in
this manual, without the express written permission of LumaSense Technologies.
Copyright
LumaSense Technologies 2017. All rights reserved.
Trademarks
SmartDGA, SmartDGA Guide, SmartDGA Gauge, SmartDGA Guard, SmartDGA EZHub, LumaSMART
iCore, DGA Viewer, and LumaSMART are trademarks of LumaSense Technologies, Inc. All other
trademarks are trademarks, registered trademarks, and/or service marks of their respective holders.
Service Centers
LumaSense Technologies, Inc. LumaSense Technologies GmbH
North America Other Than North America
3301 Leonard Court Kleyerstrasse 90
Santa Clara, CA, 95054 60326 Frankfurt, Germany
Ph: +1 800 631 0176 Ph: +49 (0) 69 97373 0
Ph: +1 408 727 1600 Fax: +49 (0) 69 97373 167
Fax: +1 408 727 1677
E-mail info@LumaSenseInc.com
support@LumaSenseInc.com
eusupport@LumaSenseInc.com
Website http://www.LumaSenseInc.com
Part No 515-0009-01 EN
Revision H
March 2017
Contents
1 General........................................................................................................................... 7
1.1 Information about this Manual ............................................................................ 7
1.2 Conventions ........................................................................................................... 7
1.3 System Requirements ........................................................................................... 7
1.4 Limit of Liability and Warranty ............................................................................ 8
1.5 Malfunction or Service Request............................................................................ 8
1.6 Shipments to LumaSense for Repair .................................................................... 8
1.7 Disposal and Decommissioning ............................................................................ 9
3 Pre-Installation Verification........................................................................................ 17
3.1 Unpacking and Verifying Contents..................................................................... 17
3.2 Confirming Installation Locations ...................................................................... 17
3.2.1 Confirm Mounting for SmartDGA Instrument .................................................. 17
3.2.2 Confirm Valve Kit .............................................................................................. 18
3.2.3 Confirm Mounting/Location for EZHub ............................................................ 20
3.2.4 Confirm EZHub Mounting ................................................................................. 21
3.2.5 Confirm Mounting Location/Type for External Computer or LumaSMART iCore
(Optional) ....................................................................................................................... 21
3.3 Verify Power and Communications .................................................................... 23
3.3.1 Verify Power Supply .......................................................................................... 23
3.3.2 Verify Communications ..................................................................................... 23
6 SmartDGA Commissioning.......................................................................................... 67
6.1 Installing the DGA Commissioning Tool ............................................................ 67
6.2 Connecting the SmartDGA System..................................................................... 70
6.3 Using the Commissioning Tool ........................................................................... 71
6.3.1 Setup.................................................................................................................. 71
6.3.2 Preparation ........................................................................................................ 75
6.3.3 Pump Setup ....................................................................................................... 77
6.3.4 Priming .............................................................................................................. 78
6.3.5 Final Test............................................................................................................ 78
7 Maintenance ................................................................................................................ 81
7.1 Field Replaceable Unit (FRU) List ........................................................................ 81
7.2 Battery Replacement ........................................................................................... 81
7.2.1 Replacing the EZHub Battery ............................................................................ 81
7.2.2 Replacing the LumaSMART iCoreTM Battery ...................................................... 84
7.3 Sensor Replacement ............................................................................................ 86
7.3.1 Replacing the H2 Sensor..................................................................................... 87
7.3.2 Replacing the O2 Sensor .................................................................................... 88
1.2 Conventions
Section headings appear in large Frutiger type.
Instruction sets appear with Bold headings.
Menu, display, and keyboard options appear in Bold Title Case. (i.e., File, Open, etc.)
Note: Indicates tips and useful information in this manual. All notes should be read to
effectively operate the instrument.
General 7
SmartDGA Manual
1.4 Limit of Liability and Warranty
All general information and notes for handling, maintaining, and cleaning of the instruments are
offered according to the best of our knowledge and experience.
LumaSense Technologies is not liable for any damages that arise from the use of any examples or
processes mentioned in this manual or in case the content of this document should be incomplete
or incorrect. LumaSense Technologies reserves the right to revise this document and to make
changes from time to time in the content hereof without obligation to notify any person or persons
of such revisions or changes.
All SmartDGA systems from LumaSense Technologies have a regionally effective warranty period.
Please check our website at http://info.LumaSenseinc.com/warranty for up-to-date warranty
information. This warranty covers manufacturing defects and faults which arise during operation,
only if they are the result of defects caused by LumaSense Technologies.
A SmartDGA system has only three user-serviceable components: the battery, hydrogen (H2) sensor,
and oxygen (O2) sensor. The warranty is VOID if the instrument is otherwise disassembled, tampered
with, altered, or otherwise damaged without prior written consent from LumaSense Technologies;
or, if considered by LumaSense Technologies, to be abused or used in abnormal conditions.
General 9
SmartDGA Manual
To ensure consistent document formatting, this page was intentionally left blank.
GREEN Normal
YELLOW Caution
BLUE Warning
RED Alarm
System Overview 11
SmartDGA Manual
The SmartDGA Viewer software enables the user to configure the SmartDGA instrument and
EZHub. The software can be installed on a Windows based PC or on the optional LumaSmart iCore
device. The software also displays results and other data from the EZHub and SmartDGA instrument.
This allows the user to track the dissolved gas as parts per million (ppm) levels over time and
monitor gas levels against user defined warning, caution, and alarm settings. As an option, a
LumaSMART iCore device is available to allow local display of DGA values and provide data to
external SCADA systems via DNP3, Modbus, and IEC61850 protocols.
System Overview 12
SmartDGA Manual
2.1.2 SmartDGA EZHubTM Unit
Light
Light
Indicators Indicators
Relay
Connections
Relay
Connections
Note: The EZHub pictured above is configured for both an LTC (Gauge) and
Transformer (Guide/Guard). Your EZHub may only be configured with an LTC or a
transformer side, depending on your setup.
The SmartDGA EZHub unit is the central node for the SmartDGA system. A fully configured EZHub is
capable of handling the power and communication needs of a pair of SmartDGA instruments, either
one Guard or one Guide in combination with an individual LTC (Gauge) simultaneously. All
interface functions and interconnects are provided in the EZHub unit as well as internal memory
and four (4) relays and bright LED indicators for Caution, Warning, and Alarm conditions. The
fourth relay is a system status relay to notify of a SmartDGA system failure or abnormality as
measured by several components internal to the instrument and EZHub. The SmartDGA instrument
collects DGA gas level data and stores it in the EZHub. The data can be transferred (via RS485 or
Ethernet connections) from the EZHub and displayed on the DGA Viewer software running on a
computer or on an iCore controller. In addition, each EZHub provides a USB interface for fast data
downloading or firmware uploading.
System Overview 13
SmartDGA Manual
2.1.3 LumaSMART iCoreTM Controller (Optional)
The LumaSMART iCore controller provides a local interactive touch screen display of DGA data
collected from the SmartDGA system and EZHub using the SmartDGA Viewer software. This
software allows you to set-up your system, create alarm conditions and notifications, and view data
collected by the SmartDGA instrument(s). The controller has its own battery backed-up Real-Time-
Clock-Calendar. The iCore stores up to 40+ years of date and time stamped memory storage when
connected to external power.
Additionally, the iCore controller provides advanced communications to external systems using
standard communications connections. Each iCore controller enables connectivity to multiple EZHub
units (up to a maximum of 4).
5.7-inch
Interactive
Touch Screen
Unused Ethernet AC In
Power Indicator USB Unused
Connection Serial Connection
RS 485
Note: The LumaSMART iCoreTM is not required to operate the SmartDGA system.
CO2
pressure of the gases: Acetylene (C2H2), Ethylene (C2H4),
Methane (CH4), Ethane (C2H6), Carbon Monoxide (CO)
CO
and Carbon Dioxide (CO2). The NDIR measurement is
based on Infrared (IR) Absorption. The light from a
black body emitter is directed at a gas sample. The 4 4.2 4.4 4.6 4.8 5
light that passes through the gas sample is then Wavelength (m)
incident on a narrow band IR filter and detector. There
is an IR filter/detector pair for each gas to be measured. The detectors in the SmartDGA instrument
are thermopiles. The filters are each designed to be band pass filters with the band being at a
System Overview 14
SmartDGA Manual
wavelength the gas of interest absorbs. The amount of that wavelength absorbed is proportional to
the concentration of the gas of interest. By quantifying the amount of light transmitted to the
detectors with and without the gas of interest, the concentration of gas can be determined.
System Overview 15
SmartDGA Manual
10. Once the gas has equilibrated, its absorption levels are collected for about 10 minutes for
data processing.
11. Ambient air is passed across the Hydrogen and Oxygen sensors, conditioning them for
reading gas levels.
12. The Zero level for the Hydrogen and Oxygen is read for about 1 minute.
13. Ambient air is used to push the gas collection volume past the Hydrogen and Oxygen
sensors. The sensors read their gases for 1 minute.
14. As ambient air continues to be pushed through the instrument, the NDIR absorption levels
for ambient air is collected for about 10 minutes.
15. The data is processed.
16. The cycle is completed and the oil valves are closed.
17. The EZHub unit reads the results from the SmartDGA instrument.
18. The pressure equalization routine starts.
System Overview 16
SmartDGA Manual
3 Pre-Installation Verification
This chapter involves verifying that you have all system components, confirming the installation
locations are ready, and verifying power supply and communications setup. Also, please ensure all
valves are properly shut with limited to no oil leakage.
Note: LumaSense Technologies cannot be responsible for shortages against the packing
list unless a claim is immediately filed with the carrier. If you note any damage or suspect
damage, immediately contact the carrier and LumaSense Technologies, Inc. Final claim
and negotiations with the carrier must be completed by the customer.
Instrument Dimensions
Verify that the installation location is suitable for the dimensions of the SmartDGA instrument:
10.765
273.43 mm
12.152
308.66 mm
20.918
531.32 mm
Pre-Installation Verification 17
SmartDGA Manual
Note: The SmartDGA Instrument is designed for vertical installation. Horizontal
installation is not recommended.
Use this kit when there is a Mount (Bottom) Valve To Left of the Valve > 18 (45.7 cm)
bottom drain valve and a
Confirm that the thread type
return valve available on the To Right of the Valve > 18 (45.7 cm)
for the valve is female 1 NPT.
transformer. This valve kit is
If it is not a 1 NPT thread type,
compatible with ball, gate, Bottom to Ground > 12 (30 cm)
you will need an NPT reducer.
plug, globe, and butterfly
Verify that you have a reducer Top to Obstruction > 17 (43.2 cm)
valves
on hand.
Use this kit any time the SmartDGA Left of the mounting plate > 18 (45.7 cm)
instrument cannot be mounted directly on
the transformer valve or when connecting Right of the mounting plate > 18 (45.7 cm)
the SmartDGA Gauge instrument to a LTC
tank. Mounting plate to the ground > 12 (30 cm)
Mounting Plate
The support for the mounting plate must be Mounting plate to the top obstruction > 17 (43.2 cm)
capable of holding at least 50 pounds (22
kg) and mounted near the transformer or Vertical distance from the 3 to 20
LTC filter. The typical support will either be instrument to the oil ports (0.91 m 6.1 m)
the transformer wall or a Unistrut post
supported by concrete. Piping distance from the instrument < 32.8
to the outlet/return port (10.0 m)
The location chosen must be appropriate for
the support and allow for oil lines to and
from the transformer or LTC filter. If Number of right angles to the
< 5 turns
installing in a cold climate where the oil will outlet/return port for piping
reach a temperature of
-10 C or less in the lines, the lines must be Piping distance from the instrument < 32.8
heated, otherwise the oil will be too viscous to the inlet/feed port (10.0 m)
to be pumped by the SmartDGA instrument.
Number of right angles to the
< 5 turns
inlet/feed port for piping
Note: A standard 10 m (32 ft) outdoor weather (-20 C to 150 C) cable is provided with
the SmartDGA system. The EZHub may be located up to 30 m (98 ft) away from the
SmartDGA instrument. Additional lengths (20 m and 30 m) as well as cold weather (rated
-50 C to 125 C) cables of 10 m, 20 m, and 30 m are available to order from LumaSense.
3. Ensure the conduit for the connection cable between the EZHub and SmartDGA instrument
is present.
Pre-Installation Verification 20
SmartDGA Manual
3.2.4 Confirm EZHub Mounting
1. Verify that the enclosure is rated IP55 and provides enough space for the EZHub (per
dimensions shown in section 9.8 or 9.9, depending on mounting style). Check for USB stick
clearance where the EZHub will be installed.
2. Locate the mounting brackets match the type of mounting (panel or wall) planned.
Caution: Direct sunlight will cause heating of the enclosure and may cause
overheating beyond the temperature rating of the EZHub.
Note: If using Ethernet with copper wire, this distance should be less than 100 m (328 ft). If
longer distances are required, a fiber optic connection should be used.
Note: If using the included RS485 to USB converter, the distance between the EZHub and
the external computer cannot be longer than 50 m (164 ft). Use a shielded 18 AWG cable.
2. Ensure the conduit for the connection cable between the EZHub and SmartDGA instrument
is present.
Caution: The mounting position and location chosen for the iCore should ensure that the
vents on the top of the iCore box will not be blocked during normal operation. Blocked
vents could cause the iCore to overheat.
Pre-Installation Verification 21
SmartDGA Manual
Note: If mounting in a NEMA4X enclosure, keep environmental conditions in mind. Direct
sunlight can cause temperatures to reach above the maximum rated ambient temperature
of 70 C. Direct sunlight will greatly reduce the apparent contrast of the iCore LCD display
and make it difficult to operate. A shaded installation location is recommended.
2. Locate the mounting brackets for the type of mounting (panel or wall) planned (both are
included with your shipment).
Caution: Direct sunlight will cause heating of the enclosure and may cause
overheating beyond the temperature rating of the iCore.
Pre-Installation Verification 22
SmartDGA Manual
3.3 Verify Power and Communications
3.3.1 Verify Power Supply
Note: LumaSense supplies the connector but does not supply a power cable for the
EZHub or iCore. Ensure the cables you are using are the right length for the planned
installation locations.
Note: To avoid leaks, tape, grease, and tighten. Use tape and grease on all NPT
threads throughout the installation process. Starting from the bottom, wrap the tape
in the opposite direction as the threads so that when connecting, the tape is not torn
off. Once taped, apply enough grease to cover the threads. Then connect and tighten.
Tightening Swagelok Fittings
Many of the provided connectors are Swagelok fittings. Follow these steps to ensure a
proper fit:
1. Insert the tube into the fitting as far as it will go and rotate the nut until it is
hand tight.
2. Mark the nut at the 6 oclock position. Hold the fitting body steady with a
second wrench and tighten the marked nut 1.25 turns to the 9 oclock position.
As you assemble and attach the valve kits, tighten as you go, but be careful not to
overtighten. Overtightening can cause the part to distort and not properly seal when
retightened.
Visit Swageloks website for more information on tightening fittings (page 62):
http://www.swagelok.com/downloads/WebCatalogs/en/MS-01-140.PDF
Warning: All oil wetted metal components of the SmartDGA system are made of 316
stainless steel to avoid corrosion and interaction with dissolved gases. SmartDGA
performance and reliability are only guaranteed when all oil wetted connections use
316 stainless steel, including any customer supplied tubing or adapter components for
the following reasons:
Components other than stainless steel will likely experience accelerated corrosion.
Different metals in direct contact with each other will undergo galvanic corrosion
even under mild ambient conditions.
Copper and copper containing alloys react with dissolved gases such as acetylene
to form unstable potentially explosive compounds and reduce the apparent
concentration of analyte gases.
Galvanized components can release hydrogen and cause false readings.
Copper tubing is soft and does not form a reliable long term seal.
Polymer based flexible hoses are gas permeable and allow ambient oxygen into
the oil and dissolved gases to escape. Use stainless steel lined flexible hoses such
as Swagelok FL hoses. Tubing should have an appropriate inner diameter for flow
while maintain enough wall thickness for strength for 1/4" OD tubing the wall
thickness should be 0.035.
Valve Installation 25
SmartDGA Manual
Note: Before beginning the installation process, ensure that there are no leaks and
that all the valves are turned off on the transformer and/or LTC.
Note: Examples and pictures in this manual use a test set-up to display configurations
and installation. Actual installation will vary on location and setup of valves.
Note: This mounting approach has inherent limitations and risks and should only be used
when the VA-0 and VA-2 options are not viable.
Bottom/Drain Adapter
Valve (Instrument Side)
915-0027-03
Mounting Ring
Small Bleed 115-0044-01
Valve (O-rings are part of
3/8 Stainless 90-2395 VA-1 kit)
Steel Pipe (SSP)
NPT Reducer
Adapter
(Drain Valve Side) Machine Screws
115-0120-02 (QTY = 6)
99-10064
4.1.2 VA-1 Installation
1. Ensure that the drain valve is completely shut and that there is no oil leakage.
2. If you need to preserve the ability to use this drain valve to sample oil directly from the
transformer, install a stainless steel tee and another valve with plug onto the drain valve.
Extra
valve
Tee
Plug
Valve Installation 27
SmartDGA Manual
3. If necessary, attach an appropriate NPT reducer to the drain valve or tee. Be sure to tape,
grease, and tighten.
NPT Reducer
2 to 1
4. Remove the 3 protective caps from the single valve adapter. Save them for future use.
5. Remove the 6 machine screws from the Drain Valve Side Adapter (PN 115-0120-02) with an
Allen wrench. Save them (you will need them in a later step).
Remove
machine
screws
Valve Installation 28
SmartDGA Manual
6. Slide the Drain Valve Side Adapter off of the stainless steel pipe (SSP).
Note: This may take some effort due to the friction from the already installed O-rings
on the Drain Valve Side Adapter.
7. Remove one Plate Cover screw over the OUT port on the Drain Valve Side Adapter using the
Phillips screwdriver. Save the screw; you will reattach it during the commissioning process.
Note: Instead of removing both screws, you may instead remove one screw and leave the
plate cover hanging by the other screw to reduce the likelihood of lost hardware.
8. Check to ensure that the plug is closed. If not, tighten the isolation plug on the Drain Valve
Side Adapter with an Allen wrench until it is fully closed.
Closed Plug
Valve Installation 29
SmartDGA Manual
9. Tape and grease the threads on the Drain Valve Side Adapter. Thread and secure it into the
drain valve or previously installed NPT reducer. Tighten with the wrench.
Note: To prevent leaks, use tape and grease on all NPT threads. Starting from the bottom,
wrap the tape in the opposite direction as the threads so that when attaching, the tape is
not torn off. Once taped, apply enough grease to cover the threads.
NPT Reducer
10. Place absorbent towels under or around the drain valve assembly as there may be a minor
amount of leakage from the drain valve in later steps.
11. Determine the proper length of the stainless steel pipe (SSP) needed using a measuring
tape. The SSP has to reach from the inside wall of the transformer tank to the outside of the
Drain Valve Side Adapter to make sure that the SmartDGA instrument gets fresh oil at all
times. Total required length is the transformer wall thickness + X as marked below.
Drain Valve
Side Adapter
Transformer Wall
X Distance Transformer
Wall Thickness
Warning: DO NOT extend the SSP beyond the transformer wall. If the SSP extends too
far into the transformer it may come into contact with internal electrical components
and short the internal components to the transformer housing causing severe damage
to the transformer and endangering any personnel working in the area. Always consult
"as built" transformer drawings and verify dimensions whenever possible.
Valve Installation 30
SmartDGA Manual
12. Cut the SSP to the length (X + transformer wall thickness) as determined in the previous
step.
13. Completely deburr and smooth the cut end of the SSP. Use compressed air to remove any
shavings that may have fallen into the adapter.
Caution: Any sharp edges or shavings left on the SSP will damage sealing O-rings
when the SSP is used in later steps. This will cause oil to leak from the transformer!
14. Clean the grooves for the three O-rings using cotton swabs.
15. Install the three O-rings to the Instrument Side Adapter (PN 915-0027-03).
Large O-Ring
PN 99-10559
Medium O-Ring
PN 90-2378
Small O-Ring
PN 99-10558
Valve Installation 31
SmartDGA Manual
16. Place the mounting ring (PN 115-0044-01) over the stainless steel pipe and the Instrument
Side Adapter as shown below.
Note: The mounting ring is shipped with the SmartDGA instrument packaging.
17. Remove the plate cover over the IN port on the instrument side adapter by removing the
two screws with a Phillips screwdriver. Save the plate cover and the two screws for use
during the commissioning process.
Note: Instead of removing both screws, you may instead remove one screw and leave the
plate cover hanging by the other screw to reduce the likelihood of lost hardware.
18. Check to ensure that the plug is closed. If not, tighten the isolation plug on the Instrument
Side Adapter with an Allen wrench until it is fully closed.
Closed Plug
Valve Installation 32
SmartDGA Manual
19. Locate the 1/8 Bleed Valve (PN 90-2395) and remove the protective cap and save it for
future use. Tape, grease, and tighten.
Remove
protective cap
20. Attach the 1/8 Bleed Valve to the port on the Instrument Side Adapter. Use an adjustable
wrench to fully tighten. Verify that the Bleed Valve is closed and pointing away from the
mounting ring.
21. Carefully insert the SSP pipe with attached Instrument Side Adapter into the open port on
the Drain Valve Side Adapter and gently slide it through until the SSP reaches the gate.
24. Reattach 2 machine screws diagonally from one another first. Use an Allen wrench to
tighten and ensure a flat surface/tight fit of the adapters. Install the remaining 4 screws.
Secure with 2
diagonal screws
first. Then tighten
remaining 4 screws
Note: Due to the tight space, a Ball End Allen Wrench or Stubby Allen Wrench is
recommended, but a standard Allen Wrench will also work.
25. Check for leaks. If you encounter leaks, remove the 6 machine screws from the previous step
to pull out the SSP just past the gate and close the valve. Fix any leaks and reinstall.
26. Chain and lock the drain valve open. Install a tag on the drain valve warning individuals that
there is an extension going through the valve and to not close the valve without removing
the extension.
Caution: Failure to remove the extension before closing the valve could potentially
damage the valve.
27. Install a tag on the bleed valve warning individuals to keep the bleed valve fully closed
unless sampling oil.
28. Proceed to Chapter 5 to install the SmartDGA instrument.
Valve Installation 34
SmartDGA Manual
4.2 Dual Valve (VA-2)
In this installation, the adapter and SmartDGA instrument are mounted on the bottom drain valve
of the transformer. Oil is drawn out of the bottom drain valve and returned to the top/fill valve
using 3/8 stainless steel tubing.
4.2.1 VA-2 Parts and Tools
Ensure you have the following parts and tools on hand prior to starting installation:
PROVIDED BY LUMASENSE
Qty Description Part #
1 Mounting Ring (included as part of SmartDGA instrument) 115-0044-01
1 Dual Valve (VA-2) Kit 815-0027-01
1 Adapter, Two-valve, DGA (Dual Valve Adapter) 115-0043-03
1 O-ring, Viton , 3 1/8 ID (Large O-ring) 99-10559
1 O-ring, Viton, 1 3/16 ID (Medium O-ring) 90-2378
1 O-ring, Viton, 5/16 ID (Small O-ring) 99-10558
1 Valve, Bleed, SS 1/8 MNPT (1/8 Bleed Valve) 90-2395
1 Valve, Bleed, SS 1/4 MNPT (1/4 Bleed Valve) 99-10160
1 Female branch tee, 3/8 TUBE OD X 3/8 TUBE OD X FEMALE NPT 99-10158
(3/8 Female Branch Tee)
1 Conn, Male 3/8 Tube 1/8 Male NPT (3/8 Male Connector) 99-10159
Adapter for
3/8 tubing
3/8 Female
Branch Tee
PN 99-10158 1/4
Bleed Valve
Bottom/Drain PN 99-10160
Valve
3/8 Connector
PN 99-10159
Mounting Ring
PN 115-0044-01
NPT Reducer
2 to 1 Valve
Note: To prevent leaks, use tape and grease on all NPT threads. Starting from the
bottom, wrap the tape in the opposite direction as the threads so that when attaching,
the tape is not torn off. Once taped, apply enough grease to cover the threads.
1. Ensure that the drain valve and top/fill valve are properly shut and that there is not
excessive oil leakage or obstructions to prevent installation.
2. If you need to preserve the ability to use this drain valve to sample oil directly from the
transformer, install a stainless steel tee and another valve with plug onto the drain valve.
Extra
valve
Tee Plug
Valve Installation 36
SmartDGA Manual
3. If necessary, attach an appropriate NPT reducer to the drain valve or tee. Be sure to tape,
grease, and tighten.
NPT Reducer
2 to 1
4. Remove the 2 protective caps from the dual valve adapter. Save them for future use.
Remove
protective caps
5. Clean the grooves for the three O-rings using cotton swabs.
Valve Installation 37
SmartDGA Manual
6. Install the three O-rings onto the Dual Valve Adapter (PN 115-0043-03).
Large O-Ring
PN 99-10559
Medium O-Ring
PN 90-2378
Small O-Ring
PN 99-10558
7. Place the mounting ring (PN 115-0044-01) over the Dual Valve Adapter as shown below.
Note: The mounting ring is shipped with the SmartDGA instrument packaging.
8. Install a 3/8 Male Connector (PN 99-10159) to outlet port. Be sure to tape, grease, and
tighten.
Valve Installation 38
SmartDGA Manual
9. Remove the protective cap from the 1/8 Bleed Valve (PN 90-2395) and save for future use.
Attach the bleed valve to the open BLEED port on the adapter. Be sure to tape, grease, and
tighten.
10. Thread and secure the completed dual valve assembly into the drain valve or previously
installed NPT reducer. Be sure to tape, grease, and tighten with wrench.
Caution: When the oil level is above the top/fill valve, install the 3/8 Female Branch
Tee and 1/4"Bleed Valve as close as possible to the top/fill valve where the oil is
returned to. Whenever the oil level is above this return valve point it is possible for air
to enter the transformer which creates the risk of transformer damage. Placing the
bleed valve as close as possible to the return point and purging the line before opening
the top/fill valve will minimize the potential amount of air. Observe safety procedures
when accessing valves within proximity of live electrical lines.
15. Remove the protective cap from the 1/4" bleed valve (PN 99-10160) and save for future use.
Be sure to tape and grease. Attach the bleed valve to the tee.
Remove
protective cap
Valve Installation 39
SmartDGA Manual
16. Attach the rest of the tubing from the 3/8 connector on the top/fill valve to the top of the
tee to complete the connection. Tighten with wrench.
17. Install a tag on the bleed valves warning individuals to keep the bleed valve fully closed
unless sampling oil.
18. Proceed to Chapter 5 to install the SmartDGA instrument.
Caution: The installation of the SmartDGA Gauge instrument for Load Tap Changers
(LTCs) requires the use of an oil filtration system before oil enters the instrument. If no
filter is used, metal particulates which are generated during normal LTC operation will
enter the instrument and cause component failure. Use of the unit with unfiltered LTC
oil will void the warranty of the SmartDGA instrument.
Note: The LTC filter system must be running at the time the SmartDGA is extracting an
oil sample. LumaSense recommends leaving the filtration system on at all times.
Alternatively, the time when the filtration system is on must be synchronized with the
SmartDGA sampling time (a 20 minute window every 3 hours with starting time as
defined by user/installer in DGA Viewer/Commissioning Tool software). The clock
between the filtration system timer and iCore or EZHub must be synchronized
occasionally to prevent drift of respective starting times. The SmartDGA pump is not
capable of generating enough suction to pull oil through the filtration system on its
own. If drawing oil through a large pressure drop filter/closed valve or pushing oil
against a closed valve, the internal safeguards on the SmartDGA will automatically
stop the measurement cycle.
Warning: LTC filters have significantly higher flow rates than the SmartDGA
instrument allows. The filter oil sent to the instrument should be sampled using a side
stream off of the main line.
Contact your local LumaSense representative for information on installation.
Valve Installation 40
SmartDGA Manual
4.3.1 VA-0 Parts and Tools
Ensure you have the following parts and tools on hand prior to starting installation.
Qty Description Part #
1 Mounting Ring (included as part of SmartDGA instrument) 115-0044-01
1 Inline (VA-0) Kit 815-0028-01
1 Adapter, Inline DGA (Inline Adapter) 115-0146-03
1 Plate LTC Adapter (Mounting Plate) 115-0047-01
6 Nut, with Spring (for Mounting Plate) 99-10341
6 Screw, 1/4-20 x 1.25 (for Mounting Plate) 99-10342
6 Washer (for Mounting Plate) 99-10343
1 Tubing 0.25 OD 90 D Elbow (1/4 Elbow Tubing Connector) 115-0191-01
2 Tubing 0.25 OD 1.30L,Straight (1/4 Straight Tubing Connector) 115-0192-01
(Typically only one required)
1 O-ring, Viton, 3 1/8 ID (Large O-ring) 99-10559
1 O-ring, Viton, 1 3/16 ID (Medium O-ring) 90-2378
1 O-ring, Viton, 5/16 ID (Small O-ring) 99-10558
2 Valve, Bleed, SS 1/8 MNPT (1/8 Bleed Valve) 90-2395
1 Female branch tee 1/4 tube (1/4 Female Branch Tee) 99-10086
2 Conn, Male, 1/4"Tube 1/8 M (1/4 Male Connector) 99-10088
2 Tube Fitting Plug Valve 1/4 (1/4 Shut-Off Plug Valve) 99-10219
2 Tube Fitting Reducer 3/8 x 1/4 (3/8 Tube Reducer) 99-10220
Mounting Plate
Mounting Ring
PN 115-0047-01
PN 115-0044-01
Note: The support for the mounting plate must be capable of holding at least 50
pounds (22 kg) and mounted near the transformer or LTC filter. The typical support will
either be the transformer wall or a Unistrut post supported by concrete. The location
chosen must be appropriate for the support and allow for oil lines to and from the
transformer or LTC filter. If installing in a cold climate where the oil will reach a
temperature of -10 C or less in the lines, the lines must be heated, otherwise the oil
will be too viscous to be pumped by the SmartDGA instrument.
8x 0.2810.002
THRU ALL
2.50
(63.50 mm)
2.50
(63.50 mm)
Valve Installation 42
SmartDGA Manual
2. Drill holes in chosen vertical structure/surface for mounting plate and secure the plate using
the included screws and the 3/16 hex wrench.
Note: The mounting plate has 8 holes for installation flexibility. Use at least 4 of the
screws for installation.
3. Remove the two protective caps and save for future use.
Remove
4. Clean the grooves for the three O-rings using cotton swabs.
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SmartDGA Manual
5. Attach the three O-rings to the Inline Valve Adapter.
Large O-Ring
PN 99-10559
Medium O-Ring
PN 90-2378
Small O-Ring
PN 99-10558
6. Place the mounting ring (PN 115-0044-01) over the Inline Valve Adapter as shown below.
Note: The mounting ring is shipped with the SmartDGA instrument packaging.
Caution: Do not overtighten Swaglok 3/8 connectors as this can cause part distortion.
Note: To prevent leaks, use tape and grease on all NPT threads. Starting from the
bottom, wrap the tape in the opposite direction as the threads so that when attaching,
the tape is not torn off. Once taped, apply enough grease to cover the threads.
a. Install a 1/4" Male Connector (PN 99-10088) into the IN/BLEED port (tape, grease,
and tighten).
Note: When selecting an IN/BLEED port, choose a position that allows for a clean
final installation alignment. We recommend the IN port at 12 oclock, OUT at 3 oclock,
and SAMPLE at 6 oclock.
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SmartDGA Manual
b. Slide one 1/4" Straight Tubing Connector (PN 99-1092-01) to the other end of the
1/4"Male Connector. Tighten with wrench.
c. Attach 1/4" Shut-Off Plug Valve (PN 99-10219) to the 1/4 Straight Tubing
Connector. Tighten with wrench.
Note: Make sure this is attached facing the correct direction. The arrow should be
pointing in toward the adapter and in the same direction as the oil flow.
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SmartDGA Manual
d. Attach the 3/8 Tube Reducer (PN 99-10220) to the other end of the 1/4 Shut-Off
Plug Valve. Tighten with wrench.
b. Slide 1/4"Elbow Tubing Connector (PN 115-0191-01) into the other end of the
1/4" Male Connector. Tighten with wrench.
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SmartDGA Manual
c. Attach 1/4" Shut-Off Plug Valve (PN 99-10219) to the 1/4" Straight Tubing
Connector. Tighten with wrench.
Note: Make sure Shut-Off Plug Valve is facing the correct direction. The arrow should
be pointing away from the adapter and in the direction of the oil flow.
d. Slide the 3/8 Tube Reducer (PN 99-10220) into the open end of the Shut-Off Plug
Valve. Tighten with wrench.
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SmartDGA Manual
9. Install the 1/8 Bleed Valve (PN 90-2395) into the other IN/BLEED port on the adapter. This
valve will serve as the sample valve.
Sample
Valve
Oil Inlet
Oil Outlet
10. Attach the completed assembly, with all fittings, to the installed mounting plate.
11. If needed, attach a 3/8 reducer to the feed port on the transformer or side stream of LTC.
12. Attach 3/8 stainless steel tubing from the inlet port on the adapter to the feed port or
reducer on the transformer or stream side of the LTC.
13. If needed, attach a 3/8 reducer to return port on the transformer or side stream of LTC.
14. Remove the protective cap and attach a 1/8 Bleed Valve (PN 90-2395) to the middle section
of the 1/4"Female Branch Tee (tape, grease, and tighten).
15. Install customer-provided 3/8 to 1/4"reducer/connectors to the open ends of the tee.
16. Attach stainless steel tubing from the oil return port on the transformer or side stream of
the LTC to the female tee. Tighten with wrench.
Caution: When the oil level is above the return point, install the 1/4 Female Branch
Tee and 1/8"Bleed Valve as close as possible to the where the oil is returned to.
Whenever the oil level is above this return valve point it is possible for air to enter the
transformer which creates the risk of transformer damage. Placing the bleed valve as
close as possible to the return point and purging the line before opening the top/fill
valve will minimize the potential amount of air. Observe safety procedures when
accessing valves within proximity of live electrical lines
Note: If safety regulations prohibit installing the air bleed valve at the oil return point,
please contact LumaSense for installation alternatives.
17. To complete the connection, attach 3/8 stainless steel tubing from the tee to the oil outlet
on the adapter. Tighten with wrench.
18. Install tags on the bleed valves warning individuals to keep the sample valve fully closed
unless sampling oil.
19. Proceed to Chapter 5 to install the SmartDGA instrument.
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5 SmartDGA System Installation
Remove Plugs
2. Position the SmartDGA instrument vertically so that the mounting ring can align and fasten
onto the SmartDGA instrument.
Note: Although not required, an additional person is helpful for this step. One person
can hold the SmartDGA instrument into position while the other fastens the mounting
ring onto the SmartDGA instrument.
3. Fasten the mounting ring onto the SmartDGA instrument until hand-tight.
5.2 EZHub
5.2.1 Parts and Tools for the EZHub
Ensure you have the following items on hand prior to starting installation.
PROVIDED BY LUMASENSE Single Instrument
Qty Description Part #
1 EZHub, LTC (EZ0003) or 015-0009-01
EZHub, XFMR (EZ0004) 015-0007-01
1 Kit, EZHub, LTC or XFMR 915-0030-01
1 Power and Communications Cable DGA-EZHub, STD, 10m 815-0236-01
1 Kit, Conn, 1 Relay, Facility, EZHub 815-0042-01
4 Connector, Relay MC 15/3 47-1407
1 Connector, System RS485 Out 47-1408
1 Connector, Unit RS485 47-1409
1 Connector, Unit Power 47-1410
1 Connector, EZHub Power 47-1411
1 Adapter-Male Micro B to Female A 57-0045
1 Lug Ring, Blue (for power to the EZHub) 95-1970
1 Lug Ring, Red (shield ground for cable to instrument) 90-2249
28 Ferrule (Small Crimp Pins) (You will have extra) 99-10043
3 Ferrule (Large Crimp Pins for EZHub Power Connector) 99-10352
1 Kit, EZHub Mounting Hardware 815-0044-01
8 Screw, Pan Head 6-32X.50 02615-08SS1
(4 for wall mount or 8 for panel mount)
8 Washer, #6, Flat (4 for wall mount or 8 for panel mount) 99-10000
8 Washer, #6, Split (4 for wall mount or 8 for panel mount) 99-39908-100
1 Kit, Bracket, Wall Mount, EZHub 815-0045-01
2 Bracket, Wall Mount 115-0074-01
1 Kit, Bracket, Panel Mount, EZHub 815-0046-01
1 Bracket, EZHub Panel Mount L-Side 115-0087-01
1 Bracket, EZHub Panel Mount R-Side 115-0097-01
1 Kit, Fuse, EZHub (this is a spare) 815-0209-01
1 Kit, USB-ISO-485 / Cable Assembly (RS485 to USB Converter) (used for 815-0052-01
connection with a PC)
2. Line up the provided EZHub wall mount brackets (PN 115-0074-01) with the holes on the
back of the EZHub.
5.00
(127 mm)
Note: The screw heads on the yellow band will cause some spacing between the brackets
and the EZHub enclosure. Use your judgement to align the brackets properly.
4. Determine location for the 4 panel holes and drill.
11.58
(294.13 mm)
5.00
(127 mm)
Note: In order to better protect the SmartDGA power/communications cable, you can run
the cable through a 1 flexible conduit from the SmartDGA Instrument to the EZHub
location. Be sure to seal the point of entry on the cable into the conduit with a gland seal
or similar part.
Note: Ensure that the Phoenix connectors are not installed on the cable until after the
routing is completed. It is easier to route the cable through cable trays and conduit without
the Phoenix connectors installed. Also, note that the exterior cable should be adequately
protected from extreme conditions in the outside environment.
SmartDGA
Connector Wire Color
Pin
Note: The ring lug should be between the star washer and securing nut (pictured on
the right). Tighten fully so the star washer cuts through the paint to make a good
electrical contact with the EZHub housing. The cable is not grounded at the DGA unit
side and must be grounded at the EZHub side.
Securing nut
Ring lug
Star washer
Note: Each EZHub must have a 10 A circuit breaker for system isolation and protection
(customer-provided).
Warning: Exercise proper electrical procedures when wiring the electrical input power
connectors to ensure complete insulation of electrical conductors.
Grounding
AC/DC Power terminal
Connector
Relay Outputs
There are four optional relay outputs for status, caution, warning, or alarm. Use of these is optional
and they may be used to connect to things such as SCADA systems, alarms, etc. Configuration of the
settings and thresholds for using these relays is done with the DGA Viewer software. Refer to the
SmartDGA Software Manual.
Note: Relays are intended for enunciation use, not for control purposes.
The connectors and pins are provided, but wires are not.
Warning Alarm
When alert is
Relay # Name Meaning When normal
triggered
1 Status SmartDGA system status Com-NO Com-NC
Gas Level/Rate/Ratio exceeds user
2 Caution Com-NC Com-NO
defined normal threshold
Gas Level/Rate/Ratio exceeds user
3 Warning Com-NC Com-NO
defined caution threshold
Gas Level/Rate/Ratio exceeds user
4 Alarm Com-NC Com-NO
defined warning threshold
3. Determine the location of the four mounting holes to be drilled into the vertical mounting
surface. Mark the holes for drilling.
9.43
(239.52 mm)
6.58
(167.13 mm)
5.58
141.73 mm
10.07
(255.78 mm)
4. Drill the four holes and attach the iCore to the wall with customer-provided hardware (#10
or M5).
3. Use the 8 screws saved from Step 1 and the 4 screws provided to fasten the brackets.
8.76
(222.50 mm)
5.74
(145.80 mm)
5.25
(133.35 mm)
9.4
(238.76 mm)
5. Install customer-provided fasteners (#10 or M4) to secure the iCore to the front panel.
Communications Output
The SmartDGA system requires a communication connection from the EZHub to either an iCore or
PC. This can be done via Ethernet or RS485 connection.
USB
Ethernet AC In RS485
Unused Unused
Serial Out Ethernet
Connection Connection
(RS485)
Ethernet Connection
The Ethernet connector is the normal RJ45 (CAT5) standard cable. A shielded Ethernet cable must
be used. This cable is not provided as the required length will vary. The IP address for the Ethernet
connection can be supplied statically or by a DHCP server.
Note: For an EZHub using a static IP, you could change the IP address using the
Commissioning Tool via RS485 or Ethernet. The new EZHub IP address will take affect
only after you power cycle the EZHub. It is recommended to power cycle the EZHub
immediately after you change the IP address.
Note: The USB connection is only for uploading and downloading functions (such as
downloading data or uploading a new version of firmware).
When using Ethernet to communicate between the SCADA and the iCore, as well as between the
iCore and EZHub(s), the use of an Ethernet switch (not provided) is required. An example of the
network topology in such a case is shown in the following figure:
EZHub RS485 OUT port & 3-pin connector iCore SERIAL port & 5-pin connector
1. Plug in 3-pin connector from the converter cable into the EZHub RS485 Out port.
2. Plug in the 6-pin connector from the converter cable into the Converter Serial Comm Port.
3. Plug the square USB side into the converter box and the standard USB side into your
computer USB port.
4. Once powered, your computer may take a few minutes to identify and may install some
driver software. If your computer does not automatically install the software, use the
enclosed CD to install the software.
Power Supply Wiring
No power cord is supplied with the LumaSMART iCore unit. However, the connector and pins are
provided.
Note: The iCore requires 90 to 264 Volts AC, 127 VDC to 370 VDC, 47-63 Hz,
2.5 A max. Use size 18 AWG wire for the included crimps and connectors to bring
power to the EZHub. We recommend a power cable with the following characteristics:
18 AWG and UL 1061 (300V, 80C) approved.
Note: Each iCore unit requires that there be a 10A circuit breaker (separate from any
other iCore or EZHub units) on the power line that feeds it as a secondary line. This
circuit breaker is used to power the unit ON and OFF. The LumaSMART iCore unit does
not include any external switches or circuit breakers. Consult local building codes for
the appropriate switch or circuit breaker to install. Externally fuse for 200W.
Warning: Exercise proper electrical procedures when wiring the electrical input power
connectors to ensure complete insulation of electrical conductors.
1. Route the iCore power cable from the circuit breaker to the iCore location.
2. Once the cable has been routed, cut the cable to the appropriate length. The connection for
the AC/DC input is located at the bottom of the LumaSMART iCore unit.
4. Wire the ground to the systems grounding terminal using the Red Lug Ring (PN 99-2249).
Caution: To protect the instrument, do not operate the LumaSMART iCore unit above
the factory default voltage levels.
After everything is installed, you need to check the SmartDGA system to ensure everything is
connected and working properly. Use the DGA Commissioning Tool on the PC or iCore.
Caution: The on-board protection mechanisms will prevent the SmartDGA system from
running a measurement cycle if the pressure exceeds the following pressure limits:
minimum oil inlet pressure 2 psig (0.14 bar gauge)
maximum oil outlet pressure 45 psig (3.1 bar gauge)
The height of the oil level in an operational transformer provides sufficient
pressure for SmartDGA operation (approximately 0.4 psi per vertical foot or 0.09
bar per vertical meter).
If the SmartDGA is connected to a laboratory simulated transformer, the minimum
pressure threshold may not be reached. In this case, a different mounting location or
use of a pressure generating booster pump may be required.
If the SmartDGA is connected to the outlet of LTC filter which exceeds the maximum
pressure threshold, then use of a pressure reducing stage such as a needle valve or
orifice is required.
The SmartDGA is capable of generating up to 45 psig (3.1 bar gauge) of pressure on
the oil outlet to return the oil to the transformer or LTC.
Caution: Do not turn off power to the SmartDGA instrument unless it has been
prepared for storage. The instrument requires power to protect the gas separation
membrane from pressure changes induced by outside environmental changes even if
no measurements are being made. If you need to turn off power to the SmartDGA
instrument, please contact LumaSense for instructions on how to properly prepare the
instrument for safe storage.
Note: If you previously installed the DGA Commissioning Tool on a personal computer
and would like to install an updated version, please uninstall it using the Control Panel
before proceeding with installation.
1. Close all programs. If using the USB stick, insert it into the USB drive.
2. Locate the DGA Commissioning Tool Installer package on the USB or download the file from
Box.com.
4. Acknowledge the warning and click Next > to continue with installation.
5. If desired, click Browse to change the folder for software installation. Click Next >.
Note: If you would like everyone on your computer to use the DGA Commissioning
Tool, be sure to select Everyone below the folder selection.
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6. Click Next > .
7. Once installed, the installer will display a success message. Click Close.
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6.2 Connecting the SmartDGA System
In order for the DGA Commissioning Tool to communicate with the SmartDGA EZHubTM, you must
set up your SmartDGA EZHub to connect via Ethernet/IP or by RS485 COM. Check to ensure all
necessary cables and/or adapters are properly connected.
If using a PC, you will also need to verify that the firewall is turned off and that it is set to a static IP
address that is slightly different than the connected EZHub. For example, you might have your
computer IP address set to 192.168.0.10 and the EZHub IP address set to 192.168.0.8. Use the
information below for reference (blue indicates default value) and consult your IT support team for
assistance.
Parameter EZHub 1 EZHub 2 EZHub 3 EZHub 4 ** iCore/PC
Board ID 48 49 50 51 Use per EZHub
IP Address 192.168.0.8 192.168.0.9 192.168.0.10 192.168.0.11 192.168.0.7
Subnet Mask 255.255.255.0 Same for all Same for all Same for all Same for all
Gateway
192.168.0.1 Same for all Same for all Same for all Same for all
Address*
N.A. for DGA Viewer
ID LTC (Gauge) 64 66 68 70
software
ID TRF (Guard N.A. for DGA Viewer
65 67 69 71
or Guide) software
Com Port (for N.A. N.A. N.A. COM2 for iCore, per
N.A.
RS-485) PC
Enter Board ID(s) and
Notes Use Commissioning Tool to set values Device ID(s) used into
DGA Viewer Software
Firewall=disabled
DHCP=disabled
Network Use hub/switch
between the iCore/PC
and EZHubs***
* Leave Gateway Address blank if unsure. Incorrect address will cause the unit not to function.
** A maximum of 3 EZHubs are supported for protocols (DNP3, Modbus, and IEC61850).
*** A network switch is preferred. A hub is acceptable if installed on a standalone network. If connected to a
corporate network without a switch (to route appropriately), the network traffic will overwhelm.
Notes:
Duplicate IP addresses are not allowed on the same network.
Duplicate EZHub Board IDs are not allowed on the same iCore/PC
Duplicate SmartDGA Instrument IDs are not allowed on the same iCore/PC
(If the instrument on the LTC or TRF side is not present in the current
configuration, the checkbox for this instrument should be unchecked in the
DGA Commissioning Tool. Default addresses may be kept for the not present
instrument. If the instrument will be added to configuration later, modify the
address at that time).
If using Ethernet for communication between the EZHub(s) and iCore/PC, a
dedicated private network is recommended.
Note: We recommend using the DGA Commissioning Tool on a laptop due to the
limited memory of the iCore (you can use the iCore, but it takes longer to run.)
6.3.1 Setup
1. Click the START button to begin.
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2. Select the connection type you are using for your system and click Next >.
If using RS485, select the correct COM port (when using the iCore, this is always COM2)
from the drop down. If you are using a PC and do not know the COM port associated with
the RS485 converter, start with COM1 and use trial and error until you find the correct COM.
If using Ethernet, select the appropriate IP address for the EZHub. The default EZHub IP
Address is 192.168.0.8 and EZHub ID is 48.
Note: If using Ethernet and a personal computer in a docking station, connect the
Ethernet cable in the docking stations Ethernet port.
Note: If you wish to turn off the animations used throughout the
DGA Commissioning Tool, uncheck the Use Animations checkbox.
3. The software will attempt to locate the SmartDGA EZHub unit. If it is unsuccessful, check
your connections and retry. If still unsuccessful, please check your connections and try again.
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SmartDGA Manual
If successful, you will see a screen similar to the following:
4. If needed, edit any of the device settings. Click Save Settings. Any changes you made will
then be saved to the EZHub. If you change the IP Address, you then need to reboot the
EZHub. Make sure the lights are off before supplying power back to the EZHub.
Note: If installing multiple EZHub controllers, the EZHub ID should be changed to the
next value (i.e. start at 48, then use 49, 50, 51, ).
The Transformer ID or LTC ID should be unique for each unit connected.
5. The software will then search for SmartDGA instruments located connected to the EZHub
and save the information to the instrument(s). If one is not found, or you are still unable to
connect to the instrument, please check your connections and try again.
6. After you save your settings, click Next > to continue. The information will be loaded onto
the EZHub(s) and SmartDGA instrument(s).
Note: The information is not carried over into the DGA Viewer software. Make note of
the IP Address and ID.
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SmartDGA Manual
7. The software will identify the connected SmartDGA instrument(s). Select the first instrument
type (Gauge, Guide, or Guard) you would like to commission and click Next > to continue.
Note: Outlined instruments (such as Gauge and Guard in the above example) are not
selectable for commissioning since only a Guide instrument is connected to the EZHub.
Indicate your selection by clicking on the grayscale icon (Guide).
Note: You can only commission one SmartDGA instrument at a time and must repeat
the process for each additional instrument.
8. Verify the communications by clicking on each of the color boxes. The selected light will
flash for 5 seconds every 15 seconds on the SmartDGA instrument. After testing, select
Green again and click Next > to continue.
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SmartDGA Manual
9. Select the type of valve installation used for your SmartDGA instrument (Single, Dual, or
Inline (Off-Transformer)) and click Next > to continue.
10. Acknowledge the information about the icons and click OK to continue.
6.3.2 Preparation
1. Confirm that you have completed the actions by clicking the gray checkmark next to each
item to turn it green. Click Next > to continue.
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SmartDGA Manual
2. Prepare a container (at least 3 quarts) for bleeding the valves.
Note: Ensure the soft polymer bleed tubes are clear enough so that you can see the
oil/bubbles in a later step.
Note: For dual and inline installations, the bleed valves are on the tees.
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SmartDGA Manual
6.3.3 Pump Setup
1. The default flow rate is 190. DO NOT change the flow rate. Click Next > to continue.
If for some reason you feel the flow rate needs to be adjusted, contact LumaSense.
2. When ready, click Next > to continue. The oil pump will turn on and begin streaming oil.
3. Stream oil until no bubbles are visible and click Next > to continue and begin priming.
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6.3.4 Priming
The system/instrument will automatically prime the SmartDGA instrument. When finished, click
Next > to continue.
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2. Select No when given the option to run a test cycle, as this will be done later using the
Viewer Software.
3. SmartDGA Commissioning is complete. Click Next > to return to the beginning of the DGA
Commissioning Tool to commission additional SmartDGA instruments or close the program
and refer to the Software Manual to configure the DGA Viewer software.
Caution: Do not turn off power to the DGA instrument unless it has been prepared for
storage. The instrument requires power to protect the gas separation membrane from
pressure changes induced by outside environmental changes even if no measurements
are being made. If you need to turn off power to the DGA instrument, please contact
LumaSense for instructions on how to properly prepare the instrument for safe
storage.
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To ensure consistent document formatting, this page was intentionally left blank.
To ensure the highest level of performance of DGA Instrument, the following procedures and list of
Field Replaceable Units (FRU) have been generated so that periodic maintenance can successfully be
performed.
O2 Sensor Part number O2-DGA that can be purchased by contacting LumaSense customer
care at support@lumasenseinc.com
H2 Sensor Part number H2-DGA that can be purchased by contacting LumaSense customer
care at support@lumasenseinc.com
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SmartDGA Manual
2. Remove yellow band from the EZHub controller by removing the 4 screws and 4 washers
using a small Phillips head screwdriver. Save these screws and washers.
3. Using a medium Phillips head screwdriver, remove one screw on the front side, one screw on
the top, and two screws on the back side of the EZHub controller (as shown below).
Save the (4) screws.
Removed screw
(front side)
Removed screw
(top)
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SmartDGA Manual
Removed screws
(back side)
4. Remove the left (LTC) side cover from the EZHub controller.
5. Locate the battery on the main board (clipped in).
6. Remove the battery by bending the clip up slightly with a small Flat head screwdriver and
sliding the battery up and out.
Note: Try not to over-bend the clip. If you bend it too far up, you may need to bend it
back down slightly before inserting the new battery.
Caution: Use rubber gloves or other protection when handling the new battery, as
finger prints can reduce the batterys life span.
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7. Insert the new battery into the clip with the positive side facing up.
8. Reinstall the left (LTC) side cover and reattach the yellow band.
9. Reconnect the EZHub controller.
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3. Removed the bottom U-shaped panel using a medium Phillips head screwdriver.
Save the (5) screws.
Note: You may need to use a small Flat head screwdriver in order to remove this panel
if it is tight.
5. Remove the old battery by pushing down on the retention tab and then sliding the battery
straight out.
Caution: Use rubber gloves or other protection when handling the new battery, as
finger prints can reduce the batterys life span.
6. Insert the new battery into the holder with the positive side facing
down (toward the SERIAL connector).
7. Reattach the U-shaped and small access panels.
8. Reconnect the iCore unit and bring the system back online.
9. Using the touchscreen, navigate to the Battery Life software screen and press the Reset
button.
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SmartDGA Manual
7.3 Sensor Replacement
Note: Each H2 and O2 sensor has its own calibration file that needs to be loaded after
sensor replacement; please contact LumaSense for further details prior to performing
sensor replacement.
Multi-pin connector
2. Remove the twelve screws using a 9/64 hex driver and carefully lift up the top dome to
remove it from the central housing.
The gas manifold will be the aluminum block attached to the top of the 8 printed circuit
board (PCB).
Oxygen sensor
Hydrogen sensor
holding nut
Gas Manifold
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Hydrogen
Oxygen sensor sensor plug
plug
Hydrogen
sensor plug
Oxygen
sensor plug
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SmartDGA Manual
2. Unscrew and remove the hydrogen sensor Holding Nut from the gas manifold.
3. Screw the replacement hydrogen sensor assembly into the gas manifold, hand tighten.
4. Insert the hydrogen sensor plug into the PCB socket labeled J36.
5. Reattach the top dome.
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2. Unscrew the oxygen sensor from the gas manifold.
O-Ring
4. Screw the replacement oxygen sensor into the gas manifold, hand tight.
5. Insert the oxygen sensor plug into the PCB socket labeled J24.
6. Reattach the top dome.
7. Load calibration file using DGA Viewer (See O 2 Sensor Field Replacement instructions).
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Note: A caution, warning, or alarm state can be caused by ppm level, rate of change,
or ratio limit being exceeded.
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Blue Flashing 5 seconds Indicates warning
every 15 seconds
Red & Blue Flashing, 5 seconds Indicates Status and Error Condition
blue followed by 5 A Status and Error condition indicates that one
seconds red (repeated of the several monitored variables
until condition clears or is
reset)
(temperature, pressure, sensor operations, etc.)
has exceeded the set point for that condition.
On the EZHub, the LED indication will be a solid
red and blue and remain solid until the
condition clears or is reset.
Note: SmartDGA Status and Error Codes will require you to contact the factory for
further guidance on corrective actions and diagnosis. Most Error Codes will require unit
maintenance which may require the unit to be returned to the factory for repair.
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8.1.2 SmartDGA EZHubTM Controller
The LED indication light on the SmartDGA EZHub controller will be the same as on the instrument,
except it will not flash and will be a solid indication. The color indications are noted below.
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Note: The LumaSMART iCore is optional and is not required for the SmartDGA system.
Note: An Ethernet switch at the LumaSmart iCore is required to connect to both the
EZHub and SCADA system using Ethernet. Use of RS485 with IEC61850 protocol will not
be supported due to bandwidth restrictions.
Note: The RS485 port on the LumaSmart iCore is always COM 2. Other addresses may
appear in the pull down menu choice, but they are not functional RS485 ports.
Note: The LumaSMART iCore is optional and is not required for the SmartDGA system.
Note: The NEMA4 enclosure will heat up significantly when exposed to direct sunlight.
The installation location should be chosen to minimize sunlight. If this is not possible, a
sunshade over the top of the enclosure is recommended.
SmartDGA
Wire Color
Connector Pin
10.765
273.43
mm
12.152
308.66 mm
20.918
531.32
mm
A G
Access Panel 84 Gauge 12, 57
Grounding terminal 57
B
Guard 12, 57
Battery Replacement 81, 84
Guide 12, 57
C
I
Commissioning 67
iCore 14, 21, 59, 84, 96, 97
Commissioning Software See DGA
Commissioning Tool Battery 84
Communications Output 63
Communications Cable 54 Ethernet Connection 63
Connector Pin 56 Panel Mount 61
Serial (RS485) Connection 64
Wall Mount 60
D Inline 19, 40
DGA Commissioning Tool 67 Installing 67
DGA Viewer 12
Disposal 9 M