GE Intellix BMT 330 Installation Manual
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GE Intellix BMT 330 Installation Manual

Bushing monitoring and partial discharge detection for transformers
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GE
Grid Solutions
Intellix™ BMT 330
Installation Manual
Bushing Monitoring and Partial Discharge
Detection for Transformers
GEDE-GA_M-DLIS-TE.MA-017
Rev 3.3
4-Mar-22

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  • Page 1 Grid Solutions Intellix™ BMT 330 Installation Manual Bushing Monitoring and Partial Discharge Detection for Transformers GEDE-GA_M-DLIS-TE.MA-017 Rev 3.3 4-Mar-22...

  • Page 2: Table Of Contents

    Decommissioning ........................35 Mounting Stand & Sun Hood ........... 37 Parts and Tools List ..............41 B.1 GE-supplied items (shipped with the product) ................ 41 B.2 GE Field Service Engineer (FSE)-supplied items ............... 42 B.3 Customer-supplied Items ......................42 Connecting Coaxial Cables ............44 C.1 Routing the Coaxial Cables .......................
  • Page 3 Front Panel Lights............... 67 Troubleshooting ..............68 Contact & Copyright Details ............... 69 List of Figures and Tables Item Page Table 1-1: Installation materials ....................... 6 Table 3-1: Measurements ......................... 8 Table 3-2: Environmental .......................... 8 Table 3-3: Power............................8 Table 3-4: Type Tests ..........................
  • Page 4 Figure A-3: Sun hood ..........................39 Figure A-4: Intellix™ BMT 330 with stand and sun hood attached ............40 Table B-1: GE-supplied items ......................... 41 Table B-2: GE FSE-supplied items ......................42 Table B-3: Customer-supplied items ...................... 42 Table C-1: Required materials ........................ 44 Table C-2: Required tools ........................
  • Page 5 Related Documents Ref# Title CG-051 BMT 330 Pre-Installation Requirements MA-018 BMT 330 User Manual MA-019 BMT 330 Service Manual WI-048 BMT 330 Commissioning Instructions CG-058 BMT 330 Modbus Registers List CG-049 BMT 330 DNP3 Objects & I/O Points Index CG-050 BMT 330 IEC 61850 Objects &...

  • Page 6: Introduction

    INTRODUCTION Product Overview Intellix™ BMT 330 (the product) is a monitoring system that continuously: ▪ measures the condition of transformer bushings (through changes in Capacitance and Power Factor) for one or two sets of three bushings in a single three-phase transformer, or three single-phase transformers.

  • Page 7: Safety

    SAFETY Symbols The meaning of symbols used on the Intellix™ BMT 330: Caution. Refer to the Installation Manual / User Manual to prevent death, bodily injury, equipment damage or loss of data. Electrical Hazard. Risk of electric shock. Primary Protective Earth connection. The meaning of safety symbols used in this manual: Caution: A procedure, practice, or condition could cause death, bodily injury, equipment damage or loss of data.

  • Page 8: Technical Specifications

    TECHNICAL SPECIFICATIONS Measurements Table 3-1: Measurements Feature Value Input current measuring range 2 mA – 200 mA rms, 1% of reading Relative phase angle accuracy 0.01 deg of angle Maximum number of PD measured 200 pulses per cycle (50 to 60 Hz) Measurement category for signal inputs CAT III.

  • Page 9: Type Tests

    Type Tests Table 3-4: Type Tests Category Standard Class/Level Test Radiated & Conducted CISPR 11 Emissions Emissions FCC part 15 Radiated & Conducted Emissions IEC 61000-3-2 Harmonic Current Emissions Limits EMC Immunity IEC 61000-4-2 Electrostatic Discharge IEC 61000-4-3 Electro Magnetic Field Immunity IEC 61000-4-4 Electrical Fast Transients...

  • Page 10: Pre-Installation

    ▪ mounted on the transport stand (see Appendix A for dimensioned drawings). It is not recommended that the product be mounted directly on the transformer. If this method of installation is being considered, contact GE Technical Support. Requirements Observe the following requirements to install the product: ▪...

  • Page 11: Base & Access

    If the GE manufactured mounting stand has not been purchased, a stand should be constructed as outlined in Appendix A. Communications & Power Cable Runs If possible, communications and power cable runs from the intended product location to their sources should be pre-installed.
  • Page 12 If working at heights is required during the product installation, it is the responsibility of the installer as a minimum to: ▪ ensure that planned work complies with national and site regulatory requirements. ▪ ensure that any third-party equipment to be used is suitable and safe before commencing work.

  • Page 13: Installation

    INSTALLATION Figure 5-1 illustrates the general installation layout of an Intellix™ BMT 330 with the required connections for a single transformer. Figure 5-1: General installation layout - single transformer Figure 5-2 illustrates the general installation layout of an Intellix™ BMT 330 with the required connections for a bank of three single phase transformers.
  • Page 14 Figure 5-3 shows the rear side of the product door. LED control board Figure 5-3: Rear side of the product door Figure 5-4 shows the key parts inside the product cabinet. System PCBs Power supply protection shield Optional communications module USB cable Mains input Bushing &...

  • Page 15: Mounting

    Contact GE Technical Support before mounting the product directly on the transformer. The GE stand is shipped with the top portion of the stand inverted. Remove the hardware holding the stand together, then remove the top section which is inverted within the larger stand base, and assemble in an upright position reusing the original hardware.
  • Page 16 ▪ A Bushing Adaptor circuit integrity test is performed. ▪ The cabling is attached through the top cover and O-ring. ▪ The top cover of the Busing Adaptor is re-attached as illustrated in Figure 5-6. Figure 5-5: Bushing Adaptor - without top cover Figure 5-6: Bushing Adaptor - with top cover The rubber O-rings must not be contaminated with grease during the assembly process.
  • Page 17 If it is a good fit, continue with the Bushing Adaptor installation. If the original test tap cap does not fit the plastic-threaded cap, halt the installation and contact GE Technical Support. Install a Bushing Adaptor...
  • Page 18 Figure 5-8: Bushing Adaptor with initial threads covered in grease As the bushing adaptor is installed into the tapping point of the bushing, the grease will work its way down ensuring an even coating across all threads as shown in Figure 5-9. Figure 5-9: Bushing Adaptor with all threads covered in grease Screw the complete Bushing Adaptor into the tapping point of the bushing.
  • Page 19 Figure 5-10: Liquid-tight fitting thread Thread the end of the metal liquid tight conduit as well as the coaxial cable into the fitting. Terminate the conduit into the fitting carefully to form a liquid-tight assembly. Place the O-ring in its seat for the cover (see Figure 5-5). Connect the coaxial cable as outlined in Appendix C.4.

  • Page 20: High Frequency Current Transformer (Hfct) Connection

    Figure 5-12: Tightening order WARNING: Ensure that the Bushing Adaptor has been assembled carefully with the liquid tight fitting and conduit to form a liquid tight connection. Water ingress inside the bushing may result in catastrophic failure. Route all the Bushing Adaptor cables through conduit to the product cabinet. If the cabling is being routed as part of the pre-installation work, then ensure that the phase is properly marked on each coaxial cable.
  • Page 21 Figure 5-13: HFCT cannot be installed if a switch is on cable from the Neutral Bushing to ground To minimise noise, the HFCT should be installed as close to the High Voltage Neutral bushing as possible provided there is no switch on the path to ground as per the warning above.

  • Page 22: Magnetically-Mounted Temperature Sensors

    Figure 5-16: HFCT installed after the switch on cable from the Neutral Bushing to ground The HFCT (if to be fitted) is specific to the transformer connection point (as provided in the pre-installation information). Fit the HFCT clamp to the neutral ground connection as shown in Figure 5-14.
  • Page 23 To install the MMTS on a transformer: ▪ Apply a liberal amount of thermal compound (Wakefield Engineering Thermal Joint Compound 120 series, GE P/N: CONS01026) on the metal probe located in the centre as shown in Figure 5-18. Note: A lack of thermal compound degrades sensor performance.
  • Page 24 5 4 3 2 1 5 4 3 2 1 Terminal Key (SHD) Shield 12 V DC (red) CANH (green) CANL (white) Ground (black) Figure 5-22: MMTS #2/3 without jumper Figure 5-21: MMTS #1 with jumper MA-017 – BMT 330 Installation Manual – Rev 3.3 4-Mar-22 Page 24 of 69...

  • Page 25: Communications Connections

    Communications Connections The chosen communication line must be routed to the product cabinet. The RS-485 Modbus must be connected directly to the DIN rail. Alternatively, if fibre optic or armoured Ethernet cable is used, it must be connected to the optional communications module as shown in Figure 5-23.
  • Page 26 The product cabinet has a primary protective earth bonding lug as shown in Figure 5-25 (bottom left-hand side corner when viewed from the front). This bonding lug and the mounting stand must be connected to earth in accordance with local practices and safety codes.
  • Page 27 WARNING: The mains supply should be connected so that the protective earth wire should be the last wire to take the strain and break free in the event of the cord being pulled out of the cabinet. Tighten the cable gland to secure the cable.
  • Page 28 WARNING: The rated maximum working voltage that may be present on each phase is 5 V AC rms and the rated maximum current that may be present is 200 mA. The measurement category is CAT III for circuits that can be connected to any coaxial cable connection.
  • Page 29 Magnetically-Mounted Temperature Sensors The MMTS is connected to the CANbus connectors on the DIN rail. See Figure 5-4 for an overview to the key parts of the product and Figure 5-30 below for a more detailed look at the connection points. CAN High (HI) CAN 12 V RS-485 B...
  • Page 30 Communications RS-485 Modbus (standard) The standard RS-485 connection is routed to the DIN rail from the main PCB as shown in Figure 5-30. Copper Ethernet (optional) Copper Ethernet supports the Modbus protocol with DNP 3.0 or IEC 61850. With this equipment, only shielded cable should be used to meet the required EMC standards.
  • Page 31 Fibre Optic Ethernet Fibre optic Ethernet supports the Modbus protocol with DNP 3.0 or IEC 61850. If an optional communication channel has been specified, then there will be an extra module on the Intellix™ BMT 330 motherboard as shown in Figure 5-32. This module supports MultiMaster communications.
  • Page 32 Connect host Rx Fibre Connect host Tx Fibre Figure 5-33: Fibre optic connections GPS Antenna The Intellix™ BMT 330 has a built-in GPS chip, which is used to provide a date/time stamp to the event monitoring. The supplied GPS antenna has a magnetic mounting. Place the GPS antenna in a position where it has a clear view of the sky.
  • Page 33 ▪ If the product cabinet is installed at a location with a clear view of the sky, the antenna can be installed on the exterior of the cabinet. A ferromagnetic plate is welded towards the top-right interior corner of the cabinet to allow the GPS antenna to be magnetically mounted externally at this position as shown in Figure 5-35.
  • Page 34 – internal top-right - ferromagnetic side plate Figure 5-35: Cabinet - external top right - GPS antenna If no suitable place is found (and no GPS antenna has been installed) or the GPS signal is lost during operation, the product will use an internal clock to time stamp events and data.

  • Page 35: Configuration And Commissioning

    The maximum drive capacity of each relay is: 2 A @ 240 V AC, resistive load, or 2 A @ 30 V DC. If connecting external alarms to these relays, route the cables though one of the available cable glands. WARNING: Only use cables rated at 75 °C minimum for the installation.
  • Page 36 The SD card should only be retrieved by an approved engineer — under no circumstances should it be inserted into a PC as that would risk accidental reformatting and subsequently data loss. Perform the following steps to decommission the product: 1.

  • Page 37: Mounting Stand & Sun Hood

    Mounting Stand & Sun Hood Figure A-1 to Figure A-4 below show the dimensioned drawings of the Intellix™ BMT 330 stand and sun hood. These are for illustration purposes only. If pre-installation work depends upon the stand dimensions, request the current issue of these drawings before commencing any work.
  • Page 38 Figure A-2: Lower stand Note: Each foot on the base stand has three available mounting holes (of which only one hole is required). MA-017 – BMT 330 Installation Manual – Rev 3.3 4-Mar-22 Page 38 of 69...
  • Page 39 Figure A-3: Sun hood MA-017 – BMT 330 Installation Manual – Rev 3.3 4-Mar-22 Page 39 of 69...
  • Page 40 Figure A-4: Intellix™ BMT 330 with stand and sun hood attached MA-017 – BMT 330 Installation Manual – Rev 3.3 4-Mar-22 Page 40 of 69...

  • Page 41: Parts And Tools List

    The parts, supplies and tools for a product installation are listed in tables Table B-1 to Table B-3 and are needed on site at the time of the installation. Note: Confirm with GE Technical Support as lubricants and quantities are subject to change without prior notice. GE-supplied items (shipped with the product)

  • Page 42: Ge Field Service Engineer (Fse)-Supplied Items

    > One spare O-ring for each bushing adaptor is supplied GE Field Service Engineer (FSE)-supplied items If GE performs the installation, the GE FSE will bring the following items: Table B-2: GE FSE-supplied items Description Handheld multimeter 4½ digit with: ▪...
  • Page 43 Description > Liquid-tight flexible metal conduit (½ in. and/or ¾ in.) to provide protection for the Bushing Adaptors’ cables and Neutral CT cable (working temperature range: −55 °C to 105 °C recommended). Recommended models from Thomas & Betts: ▪ Metal conduit ½ in. liquid-tight, Model ATLA050-30 (30 m) ▪...

  • Page 44: Connecting Coaxial Cables

    Connecting Coaxial Cables Follow these steps to connect the coaxial cables: Routing the Coaxial Cables 1. Route the coaxial cables through the metal conduits from each Bushing Adaptor to the product cabinet as required. 2. On the cabinet side, the coaxial cables must be routed though the connector fittings at the bottom of the cabinet.

  • Page 45: Coaxial Cables Preparation

    Coaxial Cables Preparation Note: Each coaxial cable must be prepared on both ends (Bushing Adaptor and cabinet) as follows. Table C-3: Coaxial cables preparation Steps Visual 1. Cut the in. heat shrink tubing. into pieces approximately 30 mm (1 ¼ in.) long.

  • Page 46: Connecting To The Grounding Switch

    Table C-4: Connecting to the Bushing Adaptor Steps Visual 1. Select two red pin terminals and the corresponding hand crimp tool. 2. Insert the central conductor of the coaxial cable into one pin terminal and crimp that terminal. 3. Insert the braid shield into the second pin terminal and crimp that terminal.

  • Page 47: Connecting To The Neutral Ct

    Table C-5: Connecting to the grounding switch Steps Visual 1. The central white wire must be connected to the core connector. 2. The braid shield must be connected to the shield connector. 3. Repeat these steps for all input phases for the Bushing Adaptors and the Neutral CT(s).
  • Page 48 4. Insert the tubing through the metallic braid and heat shrink the tubing. 5. Strip away about 7 mm (¼ in.) of insulation from the central conductor. Twist the strands together. 6. Remove the connector fitting from the 7. Insert the dome nut, fitting body and seal ring through the coaxial cable as shown.

  • Page 49: Bushing Adaptor Circuit Integrity Test Record

    Bushing Adaptor Circuit Integrity Test Record The Bushing Adaptor Circuit Integrity Test is to be performed upon installation, after periodic transformer maintenance or any bushing repair activities. Required Material ▪ Antenna Analyser, RigExpert (model: AA-170) ▪ UHF to BNC adaptor ▪...
  • Page 50 The grounding switches for the coaxial cables in the product cabinet are to be set to ‘not grounded’ (operational position). Disconnect ALL the coaxial cables as shown in Figure D-3. Figure D-3: Disconnection of coaxial cables Follow these steps to calibrate the AA-170. Note: The calibration considers the waveguide between the measuring circuit and the load i.e.
  • Page 51 Set the COM port assigned to the AA-170 as shown in Figure D-4. Note: To verify that this COM port is the one assigned to AA-170, check the vendor id (VID=0403) and product id (PID=6001). Figure D-4: AA-170 - USB serial port Select the AA-170 as the antenna analyser model in the AntScope software (select Configure and then AA-170).
  • Page 52 10. Use this measurement for calibration. Select Configure > Save calibration > as “open” as shown in Figure D-6. Figure D-6: Save calibration as “open” 11. Select File > Save As and type the filename calibOpen as shown in Figure D-7 to save the data in the folder created in Step 1 for this Bushing Adaptor.
  • Page 53 Figure D-10: Load Figure D-8: Open calibration Figure D-9: Short calibration calibration 14. Select the Configure menu item and ensure that Use calibration data is checked as shown in Figure D-11. Note: If the calibration is used, a message stating “Using OSL calibration” is shown on the top left of the graph.
  • Page 54 17. Run another measurement (press F8 or click the button). Select File > Save as and type the filename adaptorOnly. 18. Connect the Bushing Adaptor as outlined in Section 5.2 Bushing Adaptor Connections. 19. Redo the measurement (press F8 or click the button).
  • Page 55 25. For each Bushing Adaptor, test the continuity between the coaxial cable shield and ground at the cabinet as shown in Figure D-14. It should be less than 5 Ω. Record this measurement in the Results table. Figure D-14: Resistance between cable shield and ground 26.
  • Page 56 27. For each Bushing Adaptor input, measure the resistance across the pins of the terminals as show in Figure D-16. Record this measurement as [R2] in the Results table. It should be less than 2000 Ω and within 5 % of the input channel impedance in Calibration > PCB > Phase Voltage >...
  • Page 57 Table D-1: Results Date: ____________ STEP 23: Bushing Adaptor ID STEP 23: MMTS # STEP 21: Bushing Adaptor Internal Pin Correctly Installed STEP 22: Manufacturer Nameplate Power Factor % [PF%] STEP 22: Manufacturer Nameplate Capacitance [C1] STEP 22: Manufacturer Nameplate Capacitance [C2] STEP 22: Temperature at which...

  • Page 58: Communications Module Setup

    Communications Module Setup This appendix details the steps to update the communications settings for the optional Kalkitech module (if required at the time of installation). Figure E-1 illustrates the connectivity provided by the Kalkitech module. Figure E-1: Communication options between the BMT 330 and a customer network Network Settings For a computer to access the optional communications module, the computer must be set up to communicate on the same network.

  • Page 59: Easyconnect Software Installation

    EasyConnect software installation Should it be necessary to alter the communications module IP settings from the factory default, EasyConnect software will need to be installed as described in the steps below. EasyConnect can be found on the CD shipped with the Intellix™ BMT 330. 1.
  • Page 60 3. Open the EasyConnect 4.10.0 folder and double-click the Setup.exe file to install the software application as shown in Figure E-5. Figure E-5: EasyConnect Setup.exe file 4. The ‘EasyConnect - InstallShield Wizard’ opens on the ‘License Agreement’ window as shown in Figure E-6. Select I accept the terms… and click Next to continue. Figure E-6: License Agreement MA-017 –...
  • Page 61 5. The ‘Choose Destination Location’ window displays as shown in Figure E-7. Click Next to accept the default installation folder. Figure E-7: Choose Destination Location 6. The ‘Ready to Install the Program’ window displays as shown in Figure E-8. Click Install to start the installation.

  • Page 62: Communications Module Configuration

    7. The ‘Setup Status’ window shows the progress of the installation as shown in Figure E-9. Figure E-9: Setup Status 8. The ‘InstallShield Wizard Complete’ window displays as shown in Figure E-10. Click Finish to exit the Wizard. Figure E-10: InstallShield Wizard Complete Communications module configuration The EasyConnect software can be used to interrogate the communications module settings.
  • Page 63 1. Start the EasyConnect software application (navigate to the ‘Kalkitech\EasyConnect’ folder and double-click the EasyConnect.exe file or use the EasyConnnect shortcut as shown in Figure E-11. Figure E-11: EasyConnect Installation folder & shortcut 2. The EasyConnect application opens as shown in Figure E-12. Click the Upload button to change the IP address.
  • Page 64 3. In the Upload dialog box, type the IP address (the default is 192.168.0.121), uncheck the LAN settings box and click the Upload button as shown in Figure E-13. Figure E-13: Upload Kalkitech module settings 4. In the left-hand tree view, select Protocol Configuration. When the new settings are received from the communications module, the configuration tree updates as shown in Figure E-14.
  • Page 65 5. To change the IP address from the default value, select Settings > IP Configuration as shown in Figure E-15. Figure E-15: IP Configuration 6. The Lan Settings dialog box displays the Device name and current IP Address as shown in Figure E-16. Type the new IP address below (for example, 192.168.0.122), but leave the Subnet and Gateway on the default values and click OK.
  • Page 66 7. The Lan Settings confirmation message prompts for a device restart. Click Yes to continue. Figure E-17: Restart confirmation 8. The progress bar and subsequent Lan Settings confirmation message as shown in Figure E-18 indicates a successful change of IP address. Click OK. Figure E-18: IP address confirmation The communications module will restart and communications will be available using the new IP address.
  • Page 67 Front Panel Lights Table F-1: Front panel lights Light Light Meaning Colour Symbol AC power applied Green Blue Service Required. Triggered by one of: • Low Bushing current warning • Power system frequency warning • No signal warning • Bushing Adaptor Resistance failure warning Yellow A measured parameter has exceeded a user-programmed ‘Hi’...
  • Page 68 The blue Service light Maintenance action is required. indicator is flashing. Contact GE Technical Support. WARNING: The product may have more than one source of power supply, e.g. the alarm relays may be from an independent AC supply. Disconnect all supplies at their source before servicing.
  • Page 69 Other company or product names mentioned in this document may be trademarks or registered trademarks of their respective companies. GE reserves the right to make changes to specifications of products described at any time without notice and without obligation to notify any person of such changes.

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