509-300 Load Tap Changer Monitor

Don’t wait
for a
surprise! 509-300 Load Tap
Changer Monitor

Continuous
monitoring
The Load Tap Changer (LTC) and control cabinet. It comes standard
of Load Tap its drive mechanism are the most
vulnerable components of your
with universal power supply and
user-friendly computer-aided setup
liquid filled transformer— software, and can be supplied with
non-intrusive, easy to retrofit
Changer undetected problems can lead to
catastrophic failure. The Qualitrol
509-300 Load Tap Changer Monitor
sensors.

provides the most thorough LTC

performance diagnostics at the lowest cost on
the market today. It enables
condition-based maintenance, thus
eliminating calendar-based
maintenance and preventing costly, The 509-300 Series Load Tap
Changer Monitor:
h e r e
unexpected repairs.
Provides early warning to prevent
An Intelligent Electronic Device catastrophic failure
(IED), the 509-300 LTC Monitor’s
accurate equipment assessment Is TWO monitoring systems in one
l g o

improves the reliability of

w i l easy

Is a diagnostics tool for condition-based

transformers equipped with load maintenance
tap changers. The monitor can
a g l i n e made

determine tap position; create a Is easy to install and use

tap position history; detect contact Is a single device
wear or coking; monitor the LTC Is accurate and durable in harsh substation
TAutomation

drive motor and mechanism; and conditions

detect proper tap movement, Offers stand-alone or networked capability
alerting you to potential problems
and extending the life of your
transformer.
The device is easy to install and
use. It is designed to be mounted
outdoors or in the transformer
Provides early warning to prevent
catastrophic failure
Prevent catastrophic failures!
LTC’s utilize a variety of mechanical
components; motors, drive shafts,
linkages, bearings, cams, springs, gears,
and others to change the tap position.
The switch contacts themselves are
subject to heavy load currents, high
transient currents, wear and coking.
The LTC is subject to high wear and
accounts for a large percentage of
maintenance costs.
TWO monitoring systems in one
Present monitoring solutions require
separate monitoring devices for
Transformer Temperature Monitoring and
for Load Tap Changer Monitoring. The
509-300 combines both.
Diagnostic tool for condition-
based maintenance
Take maintenance action only when the
Tap Changer deteriorates in health. Avoid
the excessive cost of calendar-based
maintenance.
Easy installation and use
Accuracy and durability in harsh
substation conditions
Offers stand-alone or networked
capacity
The 509-300 monitors a number of Load Tap Changer characteristics:
-Differential temperature between LTC and transformer tanks to
provide warning of potential contact wear/coking.
-Number of tap changes. Stores history.
-Make and break load currents for each tap position.
-Motor steady state and inrush currents.
Our product immediately alerts you to potential problems:
-Contact loading (instantaneous and cumulative).
-Excessive tap counts over a time period.
-False tap movements.
-False or no motor movement.
-Motor and mechanism problems such as overloading, breakage
or binding.
-Worn tap contacts or coking.
-Two-stage alert—deteriorating vs. critical condition.
-Customer adjustable setpoints for possible alarm conditions.
The 509-300 is two monitors in one. First, it provides all of the advanced
thermal monitoring and temperature control of our 509-100 series, and in
addition it provides extensive Load Tap Changer monitoring. All in one
instrument.
Maintenance is only required when problems are detected.
The 509-300 intelligent logic gives two stages of warning. The first stage
indicates that conditions are deteriorating and need to be investigated,
but the situation is not critical. This allows you to schedule maintenance
as resources allow. The second says that conditions have exceeded alarm
thresholds. Tap Changer operation should be halted and maintenance
must take place immediately.
Two mounting options are available. The control panel configuration
mounts conveniently inside existing control cabinets. The self-contained
corrosion and weatherproof enclosure version mounts directly on the
outside of the transformer.
Crucial measurement information is displayed without pushing any buttons.
Front panel controls can be operated easily—even while wearing gloves.
For retrofit applications, universal RTD sensors offer unparalleled convenience.
Magnetic sensors are available for Load Tap Changer monitoring where a
thermal well is inconvenient.
The 509-300 incorporates a totally universal power supply. It connects to
any substation power, with a voltage range from 90-264 VAC or 40-290 VDC.
This minimizes inventory, simplifies control wiring design and helps eliminate
damage due to incorrect wiring or voltages.
Computer-aided programming simplifies the setup of operating parameters
for the 509-300.
Measurement accuracy is held across the complete range of environmental
and power-supply extremes.
The 509-300 withstands the hostile electromagnetic environment of the
substation. Protection from electrical surges and radio frequency
interference is designed into the device. It meets the stringent
performance requirements of the IEEE and CE for European norms.
Self-diagnostic functions continuously test the internal circuitry processor
system, external sensors and applied power. An independent “watchdog”
circuit monitors the processor system itself. In the event of a problem,
“fail-safe” relays activate cooling and alarm.
Utilize as a stand-alone monitor or integrate into SCADA or digital
substation communications systems.
Functional Specifications

Power Supply Universal, 90 to 264 VAC, 47 to 63 Hz or 40 to 290 VDC;

(<10 watts)
Display: One, easy to read two-line, 16 character alphanumeric Liquid
Crystal Display (LCD). Character size: 0.38” (9.66mm) high x
0.19” (4.84 mm) wide per line.
Front Panel and
Status Indicators: Eight, Light Emitting Diodes (LEDs)
Interference
Controls: Eight, large keys for programmable settings and user interaction

Front Panel Membrane: UV stabilized polyester

Accuracy: ± 0.5% full-scale input range
Temperature: 100 ohm platinum (Pt100) or 10 ohm copper (Cu10).
RTD sensors: -40 to 120°C (for liquid) or -40 to 200°C (for
winding) ranges
Current: Clamp-on CT 0 to 5A, 0 to 10A, 0 to 20A and others available
Current Loop: 0 to 1 or 4 to 20 mA DC
Input Parameters
Voltage: 0 to 100 mV or 0 to 10 VDC
Switch Contact Closure: Open/Closed
(isolated dry)
Switch Contact Closure: >80 volts AC/DC open, 0 volts closed; optically isolated
(powered)
Tap Position: 0 - 1, 0 to 5, 0 to 10, -5 to +5, -10 to +10, 0 - 125 VCD or non-
powered; Resistor bridges of 40.2 to 2500Ω (1% accuracy, 100 ppm)

Control/Alarm Contacts: Eight form C (changeover) relay contacts for cooling control, alarms,
trip, etc.
Outputs Diagnostics Alarm: One relay for sensors, power and internal instrument circuitry diagnostics
Heater Control One relay
Contact Rating: 10A @ 115/230 VAC, 10A @ 30 VDC
Remote (SCADA) Output: 0 to 1 mA, 4 to 20 mA (other options available), max. allowable load
resistance: 10,000 ohms for 0 to 1 mA, 450 ohms for 4 to 20 mA
Data Communications: RS-232, RS-485, (optically isolated), optional fiber optic interface
uses ST connector; 820 nm wavelength; max. distance 1500 meters

Dielectric Isolation (hi pot): 2500 VAC, 60 seconds to ground

Surge Withstand Capability: IEEE C37.90.1

509-300 Load Tap Changer Monitor

Immunity
Conducted/Radiated Emissions: IEC 61000-6-1
Conducted/Radiated Radio: IEC 61000-6-2
Frequency Immunity

Safety: IEC 61010-1

Temperature Range: -40° to +72°C

Storage Temperature: -50° to +85°C

Environment
Humidity: 90% non-condensing
Vibration: 60/120 Hz @ .004 inch displacement

Shock: 10 G’s half-sine, in three orthogonal planes

 Configurations

Weather-Proof Enclosure

.41” (10 mm) 12.55” (319 mm) .50” (13 mm) 8.5” (216 mm)
10.00” (254 mm)

19.50” (496 mm)

Max.
Vent

15.99” (406 mm)

14.95”
(380 mm)

Quick-Release
Hinge (2 places)

Panel Mount 10.88” (276 mm)

.44” (11 mm) .44” (11 mm)

.44”
(11 mm)

12.82” (326 mm)

2.86” (73 mm)

.44” (11 mm)

Rack Mount 1.38”

(34.9 mm)
19.02” (483 mm) 10.42” (264.7 mm)
Instrument
TRANSFORMER MONITOR
handle
TEST RESET

MENU
5.22”
(132.5 mm)

RS-232
Mounting
slots (4)
11.55” (293.4 mm) .296” (7.5mm)
X .409” (10.4mm)

4.95”
(125.7 mm)

REAR VIEW

Qualitrol Corporation Phone: 716-586-1515 E-mail: info@qualitrolcorp.com

1385 Fairport Road Fax Orders: 716-377-0220 www.qualitrolcorp.com
Fairport, New York 14450 Fax Quotes: 716-377-9613
USA

AB Qualitrol AKM Phone: +46 8 447 54 50 E-mail: info@akmsweden.com

Flygfältsgatan 6C Fax: +46 8 604 68 10 www.akmsweden.com
SE - 128 30 Skarpnäck
Sweden

© Qualitrol 2004 Qualitrol Corporation is an ISO-9001 certified company.

QSB 509-300, 4/04. Information subject to change without notice.