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SmartDGA

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

Global and Regional Centers


Our Headquarters Americas, Australia, & Other Asia Europe, Middle East, Africa
LumaSense Technologies, Inc. LumaSense Technologies, Inc. LumaSense Technologies GmbH
3301 Leonard Court 3301 Leonard Court F Kleyerstrasse 90
Santa Clara, CA, 95054 Santa Clara, CA, 95054 60326 Frankfurt, Germany
Ph: +1 800 631 0176 Ph: +1 800 631 0176 Ph: +49 (0) 69 97373 0
Fax: +1 408 727 1677 Fax: +1 408 727 1677 Fax: +49 (0) 69 97373 167

Brazil India China


LumaSense, Vendas Brasil LumaSense Technologies, India LumaSense Technologies, China
Rua Ataliba Camargo Andrade, 514, A Wing, Sagar Tech Plaza, Rm 1004,
172/sl 112 Sakinaka Junction, No. 1607 South Pudong Rd
Campinas, SP 13025-290 Andheri Kurla Road Pudong New Area
Brasil Andheri East, Mumbai 400072 Shanghai, 200122
Ph: +55 19 3367 6533 India China
Fax: +55 19 3367 6533 Ph: + 91 22 67419203 Ph: +86 133 1182 7766
Fax: + 91 22 67419201 Ph: +86 21 5877 2383

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

2 System Overview ......................................................................................................... 11


2.1 System Components............................................................................................ 12
2.1.1 SmartDGA Instruments .................................................................................... 12
2.1.2 SmartDGA EZHubTM Unit.................................................................................... 13
2.1.3 LumaSMART iCoreTM Controller (Optional) ....................................................... 14
2.2 Theory of Operation ............................................................................................ 14
2.2.1 Non-Dispersive Infrared (NDIR) Theory ............................................................. 14
2.2.2 Other Gas Measurements .................................................................................. 15
2.2.3 Sampling Sequence ........................................................................................... 15
2.2.4 Oil-Gas Separating Membrane .......................................................................... 16

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

4 Valve Installation ........................................................................................................ 25


4.1 Single Valve (VA-1) .............................................................................................. 26
4.1.1 VA-1 Parts and Tools ......................................................................................... 26

SmartDGA Manual Contents iii


4.1.2 VA-1 Installation ................................................................................................ 27
4.2 Dual Valve (VA-2) ................................................................................................ 35
4.2.1 VA-2 Parts and Tools ......................................................................................... 35
4.2.2 VA-2 Installation ................................................................................................ 36
4.3 Inline (Off-Transformer) Mounting (VA-0) ......................................................... 40
4.3.1 VA-0 Parts and Tools ......................................................................................... 41
4.3.2 VA-0 Installation ................................................................................................ 42

5 SmartDGA System Installation ................................................................................... 49


5.1 SmartDGA Instrument ......................................................................................... 49
5.1.1 Parts and Tools for the SmartDGA Instrument ................................................. 49
5.1.2 Mounting the SmartDGA Instrument................................................................ 49
5.2 EZHub ................................................................................................................... 50
5.2.1 Parts and Tools for the EZHub........................................................................... 50
5.2.2 Mounting the EZHub......................................................................................... 52
5.2.3 Connecting the EZHub ...................................................................................... 54
5.3 iCore or External Computer ................................................................................ 59
5.3.1 Parts and Tools for the iCore............................................................................. 59
5.3.2 Mounting the iCore ........................................................................................... 60
5.3.3 Connecting the iCore ........................................................................................ 63

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

SmartDGA Manual Contents iv


8 Troubleshooting .......................................................................................................... 91
8.1 Visual Light Indicators ........................................................................................ 91
8.1.1 SmartDGA Instrument...................................................................................... 91
8.1.2 SmartDGA EZHubTM Controller .......................................................................... 93

9 Diagrams & Drawings.................................................................................................. 95


9.1 Multiple SmartDGA EZHubTM Setup with Ethernet Hub or Switch .................... 95
9.2 LumaSMART iCoreTM RS485 Connections ............................................................ 96
9.3 LumaSMART iCoreTM Ethernet Connections ........................................................ 97
9.4 Unistrut Stand ..................................................................................................... 98
9.5 SmartDGA NEMA 4 Enclosure ............................................................................. 99
9.6 Inline Mounting Plate ....................................................................................... 100
9.7 Wiring Connection............................................................................................. 101
9.8 Assy, Wall Mount, SmartDGA EZHubTM ............................................................. 102
9.9 Assy, Panel Mount, SmartDGA EZHubTM............................................................ 104
9.10 Assy, Wall Mount, LumaSMART iCoreTM ............................................................ 106
9.11 Assy, Panel Mount, LumaSMART iCoreTM .......................................................... 108
9.12 SmartDGA Instrument Sun Shade .................................................................... 110
9.13 SmartDGA Instrument Dimensions .................................................................. 112

Index ................................................................................................................................ 113

SmartDGA Manual Contents v


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SmartDGA Manual Contents vi


1 General

1.1 Information about this Manual



Congratulations on choosing this high quality and highly efficient SmartDGA system.
This manual provides important information about the system and can be used as a work of
reference for installing, operating, and maintaining the SmartDGA system. It is important that you
carefully read the information contained in this manual and follow all safety procedures before
installing or operating the instrument.
This manual assumes you have a working knowledge of the Windows Operating System and its
conventions; including how to use a mouse, standard menus and commands, and how to open,
save, and close files. For help with any of these functions, refer to the documentation that came
with your computer.

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.

Caution: Denotes information critical to avoiding instrument damage or a severe


impact to processing. When this symbol is found on the instrument it indicates a
potential hazard. Consult the documentation before proceeding with any
actions.

Warning: Denotes information critical to avoiding personal injury, such as when an


electrical hazard is present. When this symbol is found on the instrument it
indicates a potential hazard. Consult the documentation before proceeding
with any actions.

1.3 System Requirements


TM
To operate the SmartDGA instruments you will need to use the DGA Viewer software, which
TM
requires either a PC or an iCore controller installed and connected through Ethernet or RS485 to
the EZHub device. If using a PC to operate the DGA Viewer software, ensure it is a Windows-based
computer with the following (minimum) components:
Processor: 1 GhZ, 32-bit or 64-bit
Operating System: Windows XP Embedded, Windows Server 2003, Windows 7, Windows 8,
and Windows Server 2008
Hard Disk Memory: 100 MB for installation files, 10 MB for normal use
System Memory: 512 MB or more
Microsoft .NET Framework

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.

1.5 Malfunction or Service Request


Contact LumaSense Technologies Technical Support in case of a malfunction or service request.
Provide clearly stated details of the problem as well as the instrument model number and serial
number. Upon receipt of this information, Technical Support will attempt to locate the fault and, if
possible, solve the problem over the telephone.
If Technical Support concludes that the instrument must be returned to LumaSense Technologies for
repair, they will issue a Return Material Authorization (RMA) number.
Return the instrument upon receipt of the RMA number, transportation prepaid. Clearly indicate
the assigned RMA number on the shipping package exterior. Refer to Section 1.6, Shipments to
LumaSense for Repair, for shipping instructions.
Technical Support can be contacted by telephone or email:

Santa Clara, California Frankfurt, Germany


Telephone: +1 408 727 1600 Telephone: +49 69 97373 0
+1 800 631 0176
Email: support@LumaSenseInc.com Email: eusupport@LumaSenseInc.com

1.6 Shipments to LumaSense for Repair


All RMA shipments of LumaSense Technologies instruments are to be prepaid and insured by way of
preferred carrier. For overseas customers, ship units air-freight, priority one.
The instrument must be shipped in the original packing container or its equivalent. LumaSense
Technologies is not responsible for freight damage to instruments that are improperly packed.
Clearly indicate the assigned RMA number on the shipping package exterior. If no RMA is indicated,
shipment will not be accepted.

SmartDGA Manual General 8


Send RMA Shipments to your nearest technical service center:

Santa Clara, California Frankfurt, Germany


LumaSense Technologies, Inc. LumaSense Technologies GmbH
3301 Leonard Court Kleyerstr. 90
Santa Clara, CA 95054 USA 60326 Frankfurt, Germany
Telephone: +1 408 727 1600 Telephone: +49 69 97373 0
+1 800 631 0176
Email: support@LumaSenseInc.com Email: eusupport@LumaSenseInc.com

1.7 Disposal and Decommissioning


Inoperable instruments must be disposed of in compliance with local regulations for
electronic materials. Sensors must be disposed of in compliance with local regulations.

General 9

SmartDGA Manual
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SmartDGA Manual General 10


2 System Overview

The LumaSense SmartDGA system was designed
with the environmental conditions of a
transformer substation in mind and utilizes a
specially constructed Non-Dispersive Infrared
Sensor (NDIR) detection system to measure fault
gases. LumaSense offers three SmartDGA
Instrument models: Gauge, Guard, and Guide.
A SmartDGA system includes the instrument
itself (Gauge, Guard, or Guide), necessary
mounting hardware for a transformer single or
dual valve mounting or an inline adapter
mounting which can be applied to a transformer
or a LTC filtering system, power and/ or + I/O
connection cable to an EZHub device, and an
optional LumaSMART iCore which contains the
SmartDGA Viewer software. Installations can be
accomplished within hours (less than 4 hours in
most cases) and requires no carrier gases,
consumables, or scheduled calibration.
The SmartDGA EZHub has a battery backed-up
Real-Time-Clock-Calendar (RTC). The RTC allows the EZHub to be programmed to report
measurements at a selectable rate. The first measurement cycle can be programmed to start at a
specific time of day. The rates that can be programmed are: 3 hours, 6 hours, 9 hours, 12 hours, 24
hours, 48 hours, and weekly.
When a measurement cycle starts, the LumaSense SmartDGA instrument flushes the old oil within
it and returns it to the transformer and/or LTC. The instrument then pulls a fresh oil sample to run
the measurement cycle and uses a membrane gas separator to extract a sample of the dissolved
gases from the transformer oil. The instrument measures the dissolved gases using an NDIR gas
sensor. After the NDIR measurement, the gas sample is sent past the oxygen and hydrogen sensors
to determine those gas concentrations. Oxygen and hydrogen cannot be measured by (non-
dispersive) infrared spectroscopy, but instead are measured using sensors which consume oxygen
and hydrogen, which is why it is done as a single step at the end. The instrument also performs a
background gas measurement which serves as a reference measurement. The SmartDGA system
collects the results of each gas analysis cycle and stores the data in memory within the SmartDGA
EZHub controller.
At the end of each measurement cycle, the EZHub stores the results on the internal memory and
sends them to the DGA Viewer software. The EZHub can also be configured to give an indication of
the fault condition in the oil by comparing the gas results to programmable thresholds for the gases
in level, rate, and ratio. The indications and conditions are:

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.

2.1 System Components


A SmartDGA system typically consists of:
SmartDGA instrument(s) with valve mounting kit(s) (VA-0, VA-1, or VA-2)
EZHub(s) with connection cable(s)
iCore (optional) or PC with DGA Commissioning Tool and DGA Viewer software
2.1.1 SmartDGA Instruments
The SmartDGA family of instruments is the industrys most cost effective
Dissolved Gas Analysis (DGA) solution, designed to be the most flexible and to
provide the best user experience available. Each model has been designed using
Non-Dispersive Infrared (NDIR) technology, which LumaSense Technologies
incorporated in over 400,000 instruments spanning the last 45 years.
The SmartDGA suite of products is designed to continuously monitor the
condition of electrical transformers and Load Tap Changers (LTC). The
SmartDGA instrument provides DGA values in order to develop a comprehensive
analysis of potential fault conditions through specific key gases being
monitored.
Installations are accomplished within hours (less than 4 hours in most cases) and require no carrier
gases, consumables, or scheduled calibration. The resulting online DGA information is made
available with user friendly software that allows convenient viewing of all measured and recorded
information. The ability to trigger corrective actions is provided by user programmable alarms for
individual gases plus real time indicators that are sunlight visible.
The SmartDGA Gauge is the industry's first dedicated online Load Tap Changer (LTC)
condition monitor. The Gauge measures and records acetylene, methane, and ethylene plus
moisture to assess LTC health.
The SmartDGA Guard measures and reports four (4) critical gases that results in a cost
effective reliable early warning online monitoring system to prevent transformer failures.
The Guard measures and records hydrogen, acetylene, carbon dioxide, and carbon
monoxide plus moisture to provide an early warning diagnostic tool. Each gas indicates that
a specific potential failure type could be pending, hydrogen indicates that a potential fault
is pending, acetylene indicates that there has been arcing or sparking within the
transformer, and a carbon dioxide/monoxide ratio is an indicator that there is a potential
failure or fault associated with the insulation within the transformer.
The SmartDGA Guide measures and reports nine (9) DGA gases plus moisture and vastly
reduces total cost of ownership due to its differentiated design and installation scheme. The
Guide provides comprehensive online DGA results that enable diagnostic techniques that
are essential in protecting critical assets and helping to prevent unplanned outages. The
DGA values and diagnostics are available via user friendly software that allows complete
access to all measured and recorded values.

System Overview 12

SmartDGA Manual
2.1.2 SmartDGA EZHubTM Unit
Light
Light
Indicators Indicators

Relay
Connections
Relay
Connections

LTC RS485 RS485 RS485 Transformer


Power LTC OUT Ethernet Transformer Power
USB

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).

Front View Bottom View

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.

2.2 Theory of Operation


With traditional technologies, widespread condition monitoring of transformers has been
unattainable, mostly due to high costs and excessive installation times. LumaSense is the industry
leader in the use of Non-Dispersive Infrared (NDIR) technologies and has redefined the way gases
are measured. The following sections provide a brief overview of the technology behind our
products that makes widespread condition monitoring of transformers possible.
2.2.1 Non-Dispersive Infrared (NDIR) Theory
The SmartDGA instrument utilizes Non-Dispersive
Infrared (NDIR) absorption to measure the partial
Absorbance (a.u.)

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.

2.2.2 Other Gas Measurements


The SmartDGA utilizes various independent sensors and calculations to measure Oxygen (O 2),
Hydrogen (H2), Moisture, and Nitrogen (N2). Hydrogen is measured using a metal oxide sensor,
Oxygen is measured with a galvanic cell type sensor, and Moisture is measured in-oil using a
thermoset polymer capacitive sensing element. All sensors are individually calibrated by LumaSense
Technologies for optimal performance and accuracy. Nitrogen gas values are calculated as a residual
based on temperatures, gas pressures, and other gas measurements
2.2.3 Sampling Sequence
1. All of the oil valves are defaulted to their normally closed state between measurement
cycles.
2. A pressure equalization routine runs continuously between measurement cycles. If the
pressure inside the instrument gets too far away from the oil tank pressure (due to
temperature changes), the routine will open the oil valves and equalize the pressure.
3. When the Real-Time-Clock-Calendar of the EZHub unit reaches the time of the next
measurement cycle, it sets the instruments state to Go.
4. As a safeguard against the transformer/LTC being degassed when a cycle starts, if the
measured inlet oil pressure is not 0.1 psi above the measured ambient pressure, the cycle
will abort.
5. The instrument flushes the oil within its oil loops with fresh oil from the transformer/LTC.
This takes approximately 3 minutes.
6. At the end of the flush, the instrument will circulate the fresh oil sample through its inner
oil loop. The oil loop contains approximately 35 mL of oil.
7. As the sample of oil circulates past the membrane gas separator, the gas migrates across the
membrane to establish partial pressure equilibrium with the gas collection volume.
8. While the oil is circulating past the gas separator on the oil side, the gas collection volume is
circulating past the gas separator on the gas side.
9. Gas is allowed to equilibrate for a predetermined period of time.

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.

2.2.4 Oil-Gas Separating Membrane


Gases dissolved in the Transformer/LTC insulating oil are
sampled by the SmartDGA instrument via an amorphous
polymer membrane. The non-porous membrane absorbs
gases dissolved in the oil and transfers them to a closed gas
sample space while preventing large oil molecules from
passing. A porous metal frit support prevents distortion of
the membrane into the gas sample space allowing it to
withstand high oil pressures.
To protect the membrane against the application of
negative pressure, the oil pressure is continuously monitored and the oil valves can isolate the
membrane from the oil tank. There is a metal plate with a grid of holes on the side of the
membrane to add further support.
At the beginning of each SmartDGA measurement cycle, a flow-controlled pump refreshes an
internal reservoir with oil from the transformer/LTC system. During gas collection, the same pump is
used to continuously replenish oil at the surface of the oil-gas separation membrane to expedite gas
transfer. Measurements of gas in the sample space as well as oil temperatures and pressures are
used to conduct the dissolved gas analysis of the oil.

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.

3.1 Unpacking and Verifying Contents


When unpacking and inspecting your system components:
1. Check all materials in the container against the enclosed packing list.
2. Carefully unpack and inspect all components for visible damage.
3. Save all packing materials, including the carriers identification codes, until you have
inspected all components and find that there is no obvious or hidden damage.

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.

3.2 Confirming Installation Locations


Confirm that the mounting locations for the SmartDGA instrument and associated mounting
requirements are complete and the site is ready for installation. Power supply should already be
ready for connections and communication systems should be set up for installation.

3.2.1 Confirm Mounting for SmartDGA Instrument


Confirm that the dimensions of the instrument work for the selected installation location and that
the valve kit included is suitable for installation.

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.

Caution: The SmartDGA Instrument must be installed in a location that is shaded


throughout the day. Rapid sunlight induced heating will negatively affect SmartDGA
measurements. See the LumaSense offered sun shade in Section 9.12 and contact us for
more information.

Caution: The SmartDGA instrument is designed to withstand typical vibration levels


found on transformers. Certain combinations of drain valve pipe diameter and length,
combined with line frequency, may result in a mechanical harmonic which amplifies
the inherent line frequency of the transformer. This can occur in the range of 180-
240 Hz. The SmartDGA instrument continues to function but it will experience
increased noise and is subject to accelerated wear due to high g forces. If this
behavior is observed, the installation must be modified. Changes in the pipe extension
length and/or diameter or additional mechanical support can be used to shift the
harmonic frequency higher. Alternatively, the SmartDGA instrument can be mounted
off transformer.

3.2.2 Confirm Valve Kit


Review your site setup and the items you received from LumaSense alongside the charts below. You
may need additional reducers to connect the equipment, so please review closely.

VA-1 (Single Valve)


Description Thread Type Clearance (Distance)
Use this kit when separate Confirm that the thread type
To Left of the Valve > 18 (45.7 cm)
points for oil sampling and for the valve is female 1 NPT.
return are not available on If it is not a 1 NPT thread type,
the transformer. This should you will need an NPT reducer. To Right of the Valve > 18 (45.7 cm)
only be used when VA-2 and Verify that you have a reducer
VA-0 options are not on hand. Bottom to Ground > 12 (30 cm)
available. This valve kit is
compatible with ball, gate, Top to Obstruction > 17 (43.2 cm)
and plug valves.
Clearance gives the installation team easier
Not compatible with Globe access to the valves for workmanship. If there
or Butterfly valves. is not enough free space and obstructions
cannot be moved, a new location may need
to be chosen.

SmartDGA Manual Pre-Installation Verification 18


VA-2 (Dual Valve)
Description Thread Type Clearance (Distance)

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.

Return (Top) Valve Vertical distance 3 to 20


from the drain valve (0.91 m to 6.1 m)
Confirm that return valve
to the return valve
accepts 3/8 tubing. If it is not,
you may need an NPT reducer
and adapter to decrease the Piping distance from < 32.8 (10.0 m)
present transformer return the drain valve to
valve size to accept 3/8 tubing. the return valve
You can also purchase a
Swagelok adapter (PN SS-600-1- Number of right < 5 turns
16) that will thread into the angles to the return
female 1 reducer and accept valve for piping
3/8 tubing.

VA-0 (Inline or Off-Transformer)


Description Clearance (Distance)

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

SmartDGA Manual Pre-Installation Verification 19


Warning: Do not cross the top of the tank when routing piping.

3.2.3 Confirm Mounting/Location for EZHub


The EZHub unit provides power and communications for the SmartDGA system. The EZHub can be
mounted in a substation control building, a transformer control cabinet, or a NEMA4X enclosure
mounted on a wall or on a Unistrut stand.

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 55 C.
Examples of EZHub mounting:

EZHub mounted in NEMA 4X EZHub mounted in NEMA 4X enclosure on


enclosure on a wall a Unistrut Stand

Confirm EZHub Type & Location


1. Confirm that the EZHub shipped for your system is correct by verifying that it has LTC,
Transformer, or both sets of connections.

LTC Transformer LTC & Transformer


2. Confirm distance from the EZHub installation location to the SmartDGA instrument
installation location is less than 30 m (98 ft).

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.

EZHub Location EZHub Mounting Type Notes


Transformer Control Wall or Panel
Cabinet
Substation Control Panel
Building
NEMA 4X Enclosure Wall Ensure the enclosure is properly
mounted to wall or Unistrut
stand.

Caution: Direct sunlight will cause heating of the enclosure and may cause
overheating beyond the temperature rating of the EZHub.

3.2.5 Confirm Mounting Location/Type for External Computer or


LumaSMART iCore (Optional)
In order to configure and operate your SmartDGA system with the software, you will need an
external computer or an iCore.

Confirm Mounting Location


1. Confirm distance from the external computer or iCore installation location to the EZHub
location to ensure the cable (Ethernet or RS485) is long enough.

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.

Confirm Mounting Type


External Computer: If using an external computer, verify that it uses a supported Windows
operating system. Mounting is configuration dependent.
LumaSMART iCore:
1. Verify that the enclosure is rated IP55 and provides enough space for the iCore (per
dimensions shown in section 9.10 or 9.11, depending on mounting style.) Check for USB stick
clearance where the iCore will be installed.

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).

iCore Location iCore Notes


Mounting Type
Transformer Control Cabinet Wall or Panel
Substation Control Building Panel
NEMA 4X Enclosure Wall Ensure the enclosure is properly
mounted to wall or Unistrut stand.

Caution: Direct sunlight will cause heating of the enclosure and may cause
overheating beyond the temperature rating of the iCore.

Examples of LumaSMART iCore mounting:

Wall or Panel Mount NEMA 4X Enclosure Substation Panel

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.

Ensure input power is available for the EZHub by identifying a VAC/VDC


source and installing any necessary power cables using an appropriate
conduit. The EZHub requires 90 to 264 Volts AC, 127 VDC to 370 VDC,
47-63 Hz, 2.5 A max. Use size 14 AWG wire for the included crimps and
EZHub connectors to bring power to the EZHub. Each EZHub must have a 10 A
circuit breaker for system isolation and protection (customer-provided).
In addition, both the EZHub and SmartDGA Instrument must have a low-
impedance path to a trusted grounding source. Ensure a grounding
source is available for the EZHub at the mounting location.

External Computer Verify computer has power supply (battery or otherwise).


Ensure input power is available for the iCore by identifying a VAC/VDC
source and installing any necessary power cables using an appropriate
conduit. The iCore requires 90 to 264 Volts AC, 127 VDC to 370 VDC, 47-
LumaSMART iCore 63 Hz, 2.5 A max. Use size 18 AWG wire for the included crimps and
Controller connectors to bring power to the iCore. Each iCore must have a 10 A
circuit breaker for system isolation and protection (separate from any
other iCore or EZHub units).

3.3.2 Verify Communications


Verify Ethernet or RS485 equipment available:
o If Ethernet, verify that a switch is available if installed on a corporate network or that a
hub is available if installed on a standalone network.
o If RS485 to USB, locate included converter.

SmartDGA Manual Pre-Installation Verification 23


To ensure consistent document formatting, this page was intentionally left blank.

SmartDGA Manual Pre-Installation Verification 24


4 Valve Installation

Once complete with Pre-Installation Verification, proceed with installation of the SmartDGA
system. Recommended installation order is installing the valve kits, then the instruments, followed
by the EZHub and computer/iCore. There are three types of valve installations. Follow instruction for
the valve kit and configuration you are using:
For Single Valve (VA-1) installation instructions, see section 4.1.
For Dual Valve (VA-2) installation instructions, see section 4.2.
For Off-Transformer/Inline (VA-0) installation instructions, see section 4.3.

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.

4.1 Single Valve (VA-1)


The single valve (part number VA-1) is intended for installation on the bottom/drain of the
transformer. Oil is drawn out of the bottom drain valve and returned to the same region. This
option is intended for use in situations where separate points for oil sampling and return are not
available.

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.

4.1.1 VA-1 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 Single Valve (VA-1) Kit 815-0029-02
1 Adapter, 1 Valve-Tube, DGA (Drain Valve Side Adapter) 115-0120-02
1 Assy, Adapter, Tube, Single Valve, DGA (Instrument Side Adapter) 915-0027-03
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, 1/8 MNPT (1/8 Bleed Valve) 90-2395

PROVIDED BY CUSTOMER (or ordered separately) Part #


QTY Description
1 NPT Reducer to 1 ID (optional, from LumaSense): 2 to 1 NPT Reducer 90-2382
1.5 to 1 NPT Reducer 90-2381
1 Soft polymer tubing for bleed valve (3/16 ID, 10 cm L, clear)
1 Tee (stainless steel) and an extra valve (optional, for drain valve)
1 Pipe cutter 1/4 to 1/2
1 Hacksaw (optional alternative if no pipe cutter is available)
1 Pipe bender 1/4 to 1/2
1 Set of Allen (hex) keys (9/64 & 3/16) (ball end or stubby recommended)
1 Wrench, pipe (adjustable 1 to 3)
1 2-4 Channel lock pliers (optional alternative if no pipe wrench is available)
1 Teflon (PTFE) pipe thread sealant tape, 0.0032 inch or greater thickness,
density 1.2 g/cc
1 PTFE containing pipe thread sealant such as:
Leak Lock, Part #HS10001 by Highside Chemicals or
Harveys, TFE paste, Part # 023015 or
TM
Rectorseal, Tru-Blu Vibration resistant or similar
1 Screw driver, Phillips (#3, 3/16)
1 Deburring tool
1 Oil cleaner and wiping rag (to clean any potential spills)
1 Compressed air

SmartDGA Manual Valve Installation 26


PROVIDED BY CUSTOMER (or ordered separately) Part #
3-4 Cotton swabs (to clean grooves for O-rings)
1 Container (at least 3 Liters for waste oil)

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.

Remove protective caps

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).

Drain Valve Side


Adapter
PN 115-0120-02

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.

Drain Valve Side


Drain Valve
Adapter
115-0120-02

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.

X + transformer wall thickness

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.

22. Fully open the drain valve.

SmartDGA Manual Valve Installation 33


23. With the drain valve fully open, carefully slide the SSP extension tube further into the drain
valve until the Instrument Side Adapter meets the Drain Valve Side Adapter. Ensure that all
the holes correctly line up and that the Bleed Valve is pointing down.

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

PROVIDED BY CUSTOMER (or ordered separately) Part #


QTY Description
1 NPT Reducer to 1 ID (optional, from LumaSense):
2 to 1 NPT Reducer 90-2382
1.5 to 1 NPT Reducer 90-2381
1 NPT Reducer to female 3/8 ID (if needed) Available from Swagelok SS-600-1-16
Tubing, SS, 3/8 ID (length will vary)
2 Soft polymer tubing for bleed valves (3/16 ID, 10 cm L, clear)
1 Tee (stainless steel) and an extra valve (optional, for drain valve)
1 Pipe cutter 1/4 to 1/2
1 Hacksaw (optional alternative if no pipe cutter is available)
1 Pipe bender 1/4 to 1/2
1 Wrench, pipe (adjustable 1 to 3)
1 2-4 Channel lock pliers (optional alternative if no pipe wrench is available)
1 Teflon (PTFE) pipe thread sealant tape, 0.0032 inch or greater thickness,
density 1.2 g/cc
1 PTFE containing pipe thread sealant such as:
Leak Lock, Part #HS10001 by Highside Chemicals or
Harveys, TFE paste, Part # 023015 or
TM
Rectorseal, Tru-Blu Vibration resistant or similar
1 Screw driver, Phillips (#3, 3/16)
1 Oil cleaner and wiping rag (to clean any potential spills)
3-4 Cotton swabs (to clean grooves for O-rings)
1 Container (at least 3 Liters for waste oil)

SmartDGA Manual Valve Installation 35


Top/ Fill Valve

3/8 Male Connector

3/8 Stainless Steel


Tubing

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

Dual Valve Adapter


1/8 PN 115-0043-03
Bleed Valve
PN 90-2395
4.2.2 VA-2 Installation

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.

11. If needed, attach a SS tee to the top/fill valve.


12. If needed, attach 3/8 reducer to the top/fill valve.
13. Install a 3/8 Connector to the top/fill valve or reducer.
14. Attach 3/8 stainless steel tubing from the end of the outlet port to up near the top/fill
valve. Attach the 3/8 Female Branch Tee to the stainless steel tubing.

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.

4.3 Inline (Off-Transformer) Mounting (VA-0)


In this installation, the adapter and SmartDGA instrument are connected to a plate adapter and
mounted on a wall, Unistrut, or other appropriate flat surface. Oil is brought from the transformer
or LTC to the SmartDGA unit and then returned back using 3/8 stainless steel tubing.

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.

Connection to LTC Filter Systems


The interface between the SmartDGA and LTC filter system is based on sampling a separate side
stream of the filtered oil. While this approach is used with all LTC filter systems, the details of the oil
lines and connections vary by manufacturer and model. LumaSense can provide further technical
details and provide the most relevant examples of interfaces with specific models of the Filmax and
Velcon filtration systems upon request with relevant technical information. Please contact your local
LumaSense representative for further details.

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

PROVIDED BY CUSTOMER (or ordered separately)


QTY Description
1 NPT Reducer to 1 ID (optional, from LumaSense):
2 to 1 NPT Reducer 90-2382
1.5 to 1 NPT Reducer 90-2381
4 Reducers/adapters as required to convert to 3/8 tubing
Tubing, SS, 3/8 ID (length will vary)
1 NEMA Unistrut Stand (optional, to secure the mounting plate)
2 Soft polymer tubing for bleed valves (3/16 ID, 10 cm L, clear)
1 Tee (stainless steel) and an extra valve (optional, for drain valve)
1 Pipe cutter 1/4 to 1/2
1 Hacksaw (optional alternative if no pipe cutter is available)
1 Pipe bender 1/4 to 1/2
1 Wrench, pipe (adjustable 1 to 3)
1 Wrench, hex 3/16
1 2-4 Channel lock pliers (optional alternative if no pipe wrench is available)
1 Teflon (PTFE) pipe thread sealant tape, 0.0032 inch or greater thickness,
density 1.2 g/cc
1 PTFE containing pipe thread sealant such as:
Leak Lock, Part #HS10001 by Highside Chemicals or
Harveys, TFE paste, Part # 023015 or
TM
Rectorseal, Tru-Blu Vibration resistant or similar
1 Screw driver, Phillips (#3, 3/16)
1 Oil cleaner and wiping rag (to clean any potential spills)
3-4 Cotton swabs (to clean grooves for O-rings)
1 Container (at least 3 Liters for waste oil)

SmartDGA Manual Valve Installation 41


Oil Return Port

1/4 Female 3/8 Connectors


Branch Tee
PN 99-10086
1/8 Bleed Valve
PN 90-2395
Inline Valve Adapter
PN 115-0146-03 3/8 Connector
3/8 Stainless Steel Tubing

Mounting Plate
Mounting Ring
PN 115-0047-01
PN 115-0044-01

1/8 Bleed Valve


PN 90-2395

Oil Inlet Port

4.3.2 VA-0 Installation


The VA-0 Adapter is designed with 1 male NPT thread to mount to the provided mounting plate.
The Inline Adapter provides three ports (one OUT port and two IN/BLEED ports). Plugs are used to
control flow through these ports.

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.

1. If needed, mark drilling holes for mounting plate.


2.50 2.50
(63.50 mm) (63.50 mm)

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.

Valve Installation 43

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.

7. Install the inlet port using the following steps:

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.

Valve Installation 44

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.

Valve Installation 45

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.

8. Install outlet port using the following steps.


a. Install a 1/4"Male Connector (PN 99-10088) into the OUT port (tape, grease, and
tighten).

b. Slide 1/4"Elbow Tubing Connector (PN 115-0191-01) into the other end of the
1/4" Male Connector. Tighten with wrench.

Valve Installation 46

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.

Valve Installation 47

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.

Valve Installation 48

SmartDGA Manual
5 SmartDGA System Installation

5.1 SmartDGA Instrument


5.1.1 Parts and Tools for the SmartDGA Instrument
Ensure you have the following items on hand prior to starting installation.
PROVIDED BY LUMASENSE
Qty Description Part #
1 SmartDGA Instrument (Guard) or 015-0004-04
SmartDGA Instrument (Guide) or 015-0003-04
SmartDGA Instrument (Gauge) 015-0005-04
1 DGA Custom Flash Drive with S/W and Manuals 815-0191-01
1 Ring, Mounting, Adapter (Mounting Ring) 115-0044-01

PROVIDED BY CUSTOMER (or ordered separately)


Qty Description Part #
1 3 3/4" face spanner wrench (Available from LumaSense) SPN-01

5.1.2 Mounting the SmartDGA Instrument


Now that the valve installation is complete, you are ready to install the SmartDGA instrument.
1. Remove the protective cap and two plugs (do not remove serial tag). Save for future use.

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.

SmartDGA Manual SmartDGA System Installation 49


4. After hand-tightening, use a 3-3/4 face spanner wrench to tighten the mounting ring until
it cannot move any further.
Use these holes for
the spanner wrench

5. Proceed to installing additional SmartDGA instruments or the EZHub (section 5.2).

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)

SmartDGA Manual SmartDGA System Installation 50


PROVIDED BY LUMASENSE Two Instruments (TRF & LTC)
Qty Description Part #
1 EZHub, LTC and XFMR (EZ0010) 015-0010-01
1 Kit, EZHub, LTC and XFMR 915-0031-01
2 Power and Communications Cable DGA-EZHub, STD, 10m 815-0236-01
1 Kit, Conn, 1 Relay, Facility, EZHub 815-0043-01
8 Connector, Relay MC 15/3 47-1407
1 Connector, System RS485 Out 47-1408
2 Connector, Unit RS485 47-1409
2 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
2 Lug Ring, Red (shield ground for cable to instrument) 90-2249
50 Ferrule, AL 0.75-8 GY (Crimp Pins) (You will have extra) 99-10043
3 Ferrule, (Large Crimp Pins for EZHub Power Connector) 99-10352
1 Kit, EZHub Mounting Hardware 815-044-01
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)

PROVIDED BY CUSTOMER (or ordered separately)


Qty Description Part #
1 Screw driver, Phillips (#3, 3/16)
1 Screw driver, Phillips (#1, 1/16)
1 Screw driver, Flat Head (small)
4 Sets of hardware for attaching EZHub brackets to wall, panel, etc.
1 Drill to fasten the EZHub brackets to the main vertical support
1 Power cable (AC IN)
1 Conduit to insulate the shield drain wire
Gland seal for cable at conduit
Crimper and Stripper (for terminating cables)

SmartDGA Manual SmartDGA System Installation 51


5.2.2 Mounting the EZHub
The EZHub is mounted either on a flat surface (wall mount) or in a hole/slot (panel mount). Both
types of brackets and hardware are sent with each order.

Example of wall mount in NEMA enclosure

EZHub Wall Mount


1. Remove 4 screws on the back of the EZHub with a Phillips screw driver. Save the screws.

2. Line up the provided EZHub wall mount brackets (PN 115-0074-01) with the holes on the
back of the EZHub.

3. Fasten the brackets with the 4 provided screws/washer/split-washer.

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SmartDGA Manual
4. Determine the location of the 4 mounting holes to be drilled into the vertical mounting
surface.

11.37 (288.80 mm)

5.00
(127 mm)

12.07 (307.58 mm)


5. Drill the four holes and attach the EZHub to the wall with customer-provided hardware (#10
or M5 screws).

EZHub Panel Mount


1. Remove 8 screws (4 on the back and 2 on each side). Save the screws.

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SmartDGA Manual
2. Line up the provided EZHub panel mount brackets (PN Left - 115-0087-01 and
Right 115-0097-01) with the holes on the back of the EZHub.

3. Fasten with the 8 screws/washer/split-washer provided.

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)

12.33 (313.18 mm)

5. Install customer-provided fasteners (#10 or M5 screws) to secure the SmartDGA EZHub to


the front panel.

5.2.3 Connecting the EZHub


Communications Cable

The SmartDGA system requires a power/communications
cable with multi-pin connector to be connected from the
TM
SmartDGA device to the SmartDGA EZHub controller.
The standard connection cable length is 10 meters and
longer cables (up to 30 meters (98 ft)) are also available.
The standard connection cable is outdoor weather rated
for -20 C to 150 C. If extreme weather conditions exist,
an extended weather rated cable is available (rated for -50 C to 125 C.)

SmartDGA System Installation 54



SmartDGA Manual
Warning: The communications cable completes the sealing mechanism of the housing. The
SmartDGA Instrument (Gauge, Guard, Guide) housing is not water tight when the
communications cable is not attached and locked in place. Failure to properly connect this
cable will invalidate the IP55 rating.

The power/communications cable is provided unterminated


on the SmartDGA EZHub controller end so that it can be cut
to length and then terminated with provided two Phoenix
connectors. The communications cable connects to the
RS485 Transformer (or LTC) connector and the Transformer
Power (or LTC Power) connector. The communications
between the instrument and the SmartDGA EZHub
controller are proprietary ASCII binary communications.

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.

To install the communications cable:

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.

1. Connect the power/communications cable multi-pin connector to the mating receptacle on


the SmartDGA instrument. Since this is a key connection, gently turn the plug until key slots
line up and then push the plug into the receptacle until you hear a click. Then tighten the
thread until it locks into place.

SmartDGA System Installation 55



SmartDGA Manual
2. Route the power/communications connection cable to the SmartDGA EZHub location.
3. Once the cable has been routed, cut the cable to the appropriate length and terminate per
the following table/diagram. We recommend cutting at least 0.5 m (1.6) longer than
needed to ensure there is enough cable when completing the connection. Trim as needed.

SmartDGA
Connector Wire Color
Pin

EZHub RS485 pin EZHub Power Pin


(1-4 from left to right) (1-6 from left to right)
A Brown 6
C Yellow 5
E Black 2
G Green 3
J White 4
M Purple (Violet) 4
N Grey 3
P Red 1
R Blue 1
S Orange 2

SmartDGA System Installation 56



SmartDGA Manual
4. Insert the connectors into the appropriate slots:

Left LTC Side Right Transformer Side


SmartDGA Gauge Instrument SmartDGA Guide or Guard Instrument
To connect an LTC (Gauge) Instrument (Left Side of EZHub):
a. Connect the 6-pin into the LTC Power slot located on the bottom left of the EZHub.
Tighten the 2 connector screws with a small Flathead screwdriver.
b. Connect the 4-pin Phoenix connector into the RS485 LTC slot located next to the
Transformer Instrument Power slot on the bottom left of the EZHub. Tighten the 2
connector screws with a small Flathead screwdriver.
To connect a transformer - SmartDGA Guard/Guide instrument (Right Side of EZHub):
a. Connect the 6-pin Phoenix connector into the Transformer Power slot located on
the bottom right of the EZHub. Tighten the 2 connector screws with a small
Flathead screwdriver.
b. Connect the 4-pin Phoenix connector into the RS485 Transformer Power slot
located next to the Transformer Instrument Power slot on the bottom right of the
EZHub. Tighten the 2 connector screws with a small Flathead screwdriver.
5. The shield drain wire should be insulated and terminated with the supplied ring lug. Fasten
the ring lug to the SmartDGA EZHub controllers ground terminal.

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

Power Supply Wiring


No input power cable is provided with the SmartDGA EZHub controller. However, the connector
and pins are provided.

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SmartDGA Manual
Note: The EZHub requires 90 to 264 Volts AC, 127 VDC to 370 VDC, 47-63 Hz,
2.5 A max. Use size 14 AWG wire for the included crimps and connectors to bring
power to the EZHub. We recommend a power cable with the following characteristics:
AWG 14, CU type TFFN or MTW or gasoline and oil resistant II.

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.

1. Route the EZHub power cable to the SmartDGA EZHub location.


2. Once the cable has been routed, cut the cable to the appropriate length and connect. The
AC/DC pin connections are as follows:
Pin Use DC Polarity
N Return line used by AC or DC - negative
Middle Not used (prior to SN XYZ) or earth ground
L Input line voltage (AC) or DC voltage + positive
3. Wire the ground to the systems grounding terminal on the bottom of the unit using the
Blue Lug Ring (PN 95-1970).

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.

SmartDGA System Installation 58



SmartDGA Manual
Status Caution

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

5.3 iCore or External Computer


5.3.1 Parts and Tools for the iCore
Ensure you have the following items on hand prior to starting installation.
PROVIDED BY LUMASENSE
Qty Description Part #
1 iCore Assembly (IC-0012) 015-0002-01
1 Kit, Wall Mount, LumaSMART 01-15046-01
2 Bracket, Wall Mount 02-15-226-01
4 Screw, 10-32 X 1/2,Phillips, Pan Head 99-11061-308
4 Washer, #10, Flat 99-31020-300
4 Washer, #10, Split 99-31040-300
1 Kit, Panel Mount, iCore 815-0040-01
1 Bracket, Panel Mount, L, iCore 115-0151-01
1 Bracket, Panel Mount, R, iCore 115-0152-01
1 Kit, Ship iCore 815-0214-01
8 Ferrule (Small Crimp Pins for iCore Power Connector) 99-10043
1 Connector, AC IN (Power) 47-1302
1 Connector, RS485 47-1303
1 Lug Ring, Red 90-2249

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SmartDGA Manual
PROVIDED BY CUSTOMER (or ordered separately)
Qty Description Part #
1 Screw driver, Phillips (#3, 3/16)
1 Screw driver, Phillips (#1, 1/16)
4 Sets of hardware for attaching iCore brackets to wall, panel, etc.
1 Drill to fasten the iCore brackets to the main vertical support
PROVIDED BY CUSTOMER (or ordered separately)
1 Power cable (AC IN)
Conduit to insulate the shield drain wire
1 Ethernet Cable (optional, for iCore or PC)
1 Serial Cable (RS485) (optional, for iCore)

5.3.2 Mounting the iCore


The iCore is mounted either on a flat surface (wall mount) or in a hole/slot (panel mount). When
ordering, an iCore configuration is provided (wall or panel) and the appropriate brackets are sent
with the system.

Wall Mount NEMA 4 Enclosure Substation Panel Rack Mount

iCore Wall Mount


1. Line up the provided brackets (PN 01-15046-01) with the 4 holes on the back of the iCore.

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SmartDGA Manual
2. Fasten the brackets with the 4 screws, washers and split-washers provided.

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).

iCore Panel Mount


1. Remove the sides of the iCore. Save the screws (8 total).

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SmartDGA Manual
2. Rest the provided brackets on the back of the iCore so that the brackets are flush with the
sides and back of the iCore.

3. Use the 8 screws saved from Step 1 and the 4 screws provided to fasten the brackets.

4. Determine location for and drill 4 holes into panel.

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.

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SmartDGA Manual
5.3.3 Connecting the iCore
The following are directions to electrically wire the LumaSMART iCore unit power, outputs, and
communication. The following sections outline the provided connections on the rear of the
LumaSMART iCore.

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:

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Note: DGA Viewer supports Modbus protocol on a PC. DNP3 and IEC require an iCore
to run DGA Viewer software.

Serial (RS485) Connection


If using RS485 with an iCore, use the Phoenix 3-pin (EZHub PN 47-1408) and Phoenix 5-pin (iCore
PN 47-1303) connectors.
Phoenix 3-pin connector (for EZHub connector)
Pin 1 is TXD+ for RS485 iCore connector

Pin 2 is TXD- for RS485


Pin 3 is ground EZHub connector

Phoenix 5-pin connector (for iCore connector)


Pin 1 is RS485 TXD-
Pin 2 is RS485 TXD+
Pin 5 is ground
To connect RS485 to the iCore:
1. Locate the 3-pin connector (PN 47-1408) shipped with the EZHub and the 5-pin connector
(PN 47-1303) shipped with the iCore.
2. Use a customer-provided connection cable and the included crimp pins to terminate the
ends of the cable for the EZHub and iCore.
3. Insert the 3-pin connector into the EZHub RS485 OUT port and the 5-pin connector into the
iCore SERIAL (RS485) port.

EZHub RS485 OUT port & 3-pin connector iCore SERIAL port & 5-pin connector

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To connect RS485 to the PC:
If using RS485 with a PC, you will need to connect the RS485-USB converter:

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.

Note: Power for the connector is drawn from the computer.

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.

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3. Connect a cable appropriate for the provided connector (PN 47-1302) with the provided
crimp pins (PN 99-10043). The AC/DC pin connections are as follows:
Pin Use DC Polarity
N Return line used by AC or DC - negative
Middle Not used
L Input line voltage (AC) or DC voltage + positive
*Ground wire goes to grounding terminal on the side.

Note: Color convention for line power wiring varies by country.

4. Wire the ground to the systems grounding terminal using the Red Lug Ring (PN 99-2249).

Power Wiring Diagram

Caution: To protect the instrument, do not operate the LumaSMART iCore unit above
the factory default voltage levels.

System Status Relay


Unused connection.

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6 SmartDGA Commissioning

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.

6.1 Installing the DGA Commissioning Tool


Check to see if the DGA Commissioning Tool is installed. If not, proceed with the following
instructions to install the DGA Commissioning Tool onto the iCore or personal computer (PC).

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.

To install the DGA Commissioning Tool:

Note: We recommend using a personal computer to install the DGA Commissioning


Tool software. To install the software on the iCore, you will need to use remote
desktop or a keyboard.

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.

SmartDGA Manual SmartDGA Commissioning 67


3. Double-click DGA Commissioning Tool to run the installer.

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.

SmartDGA Manual SmartDGA Commissioning 70


Example Topology

6.3 Using the Commissioning Tool


Once the software is successfully installed, a DGA Commissioning Tool icon should appear on your
desktop. Double click the icon to start the software.

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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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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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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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.

Single Dual Inline

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2. Prepare a container (at least 3 quarts) for bleeding the valves.

Single Dual Inline

Note: Ensure the soft polymer bleed tubes are clear enough so that you can see the
oil/bubbles in a later step.

3. Open bleed valves and valve/ plugs.

Single Dual Inline

Note: For dual and inline installations, the bleed valves are on the tees.

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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.

6.3.5 Final Test


1. Close bleed valve and plugs/valves and click Next > to continue.

Single Dual Inline

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SmartDGA Manual
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.

4. Remove containers. Leave tubing on bleed valves.


Once you complete commissioning of all SmartDGA instruments, your SmartDGA system will be
ready for use. Refer to the SmartDGA Software manual for more information on obtaining gas
information.

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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SmartDGA Manual SmartDGA Commissioning 80


7 Maintenance

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.

7.1 Field Replaceable Unit (FRU) List


Battery - EZHub A standard non-rechargeable CR1632 coin-type lithium battery purchased
directly from most electronic outlets

Battery - iCore A standard non-rechargeable CR2032 coin-type lithium battery purchased


directly from most electronic outlets

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

7.2 Battery Replacement


7.2.1 Replacing the EZHub Battery
Ensure you have the following parts and tools on hand prior to starting installation:
PROVIDED BY CUSTOMER
Qty Description
1 New Replacement Battery
1 Small Phillips Head Screwdriver
1 Medium Phillips Head Screwdriver
1 Small Flat Head Screwdriver
The battery life span will be approximately 8 years. After this period, the battery needs to be
replaced. The SmartDGA EZHub controller uses a standard non-rechargeable CR1632 coin-type
lithium battery. The battery is located on the left side of the SmartDGA EZHub controller (LTC Side)
and is clipped in directly on the main board.

Caution: Battery replacement should only be performed by authorized personnel.


There is danger of explosion if the battery is mishandled or incorrectly replaced.
Replace the battery only with one of the same manufacturer and type or equivalent
type recommended.
Do not disassemble batteries or attempt to recharge them outside the system. Dispose
of batteries properly in accordance with the manufacturer's instructions and local
regulations.

To replace the EZHub controllers battery:


1. Disconnect the input power from the bottom of the EZHub controller and remove all other
connections from the device prior to starting battery replacement.

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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.

Removed 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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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.

7.2.2 Replacing the LumaSMART iCoreTM Battery


Ensure you have the following parts and tools on hand prior to starting installation:
PROVIDED BY CUSTOMER
Qty Description
1 New Replacement Battery
1 Medium Phillips Head Screwdriver
1 Small Flat Head Screwdriver (optional)
The battery life span will be approximately 8 years. After this period, the battery needs to be
replaced. The LumaSMART iCore uses a standard non-rechargeable CR2032 coin-type lithium
battery. The battery holder is accessed from the bottom of the iCore.

Caution: Battery replacement should only be performed by authorized personnel.


There is danger of explosion if the battery is mishandled or incorrectly replaced.
Replace the battery only with one of the same manufacturer and type or equivalent
type recommended.
Do not disassemble batteries or attempt to recharge them outside the system. Dispose
of batteries properly in accordance with the manufacturer's instructions and local
regulations.

To replace the LumaSMART iCore units battery:


1. Disconnect all electrical connections.
2. On the bottom of the iCore unit, remove the small access panel in the middle using a
medium Phillips head screwdriver. Save the (2) screws.

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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.

4. Locate the battery directly above the 5-pin SERIAL connector.

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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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.

To gain access to the gas manifold:


1. After powering down the EZHub, remove the the power/communications cable with multi-
pin connector from the bottom dome of the SmartDGA instrument.

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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SmartDGA Manual
Hydrogen
Oxygen sensor sensor plug
plug

Sensor plugs are located under the fan.

7.3.1 Replacing the H2 Sensor


To replace the H2 sensor:
1. Remove the hydrogen sensor plug from the PCB socket labeled J36.

Hydrogen
sensor plug

Oxygen
sensor plug

Hydrogen Sensor Plug and PCB Socket J36

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2. Unscrew and remove the hydrogen sensor Holding Nut from the gas manifold.

Hydrogen Holding Nut

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.

7.3.2 Replacing the O2 Sensor


1. Remove the oxygen sensor plug from the PCB socket labeled J24.

Oxygen Sensor Plug and PCB Socket J24

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2. Unscrew the oxygen sensor from the gas manifold.

Oxygen Sensor Removal


3. Remove the replacement oxygen sensor from its packaging and attach the included O-ring.

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).

Note: Sensors must be disposed of in compliance with local regulations.

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SmartDGA Manual Maintenance 90


8 Troubleshooting

8.1 Visual Light Indicators


8.1.1 SmartDGA Instrument
The indicator light on the front of the SmartDGA instrument is on for 5 seconds and off for
15 seconds, then repeats the cycle. This means that during a one minute period you have three
indication cycles on the SmartDGA instrument. The LED indication light on the EZHub 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:

Note: A caution, warning, or alarm state can be caused by ppm level, rate of change,
or ratio limit being exceeded.

Instrument Light(s) Action Meaning


Green Flashing 5 seconds Indicates normal operation
every 15 seconds

Yellow Flashing 5 seconds Indicates caution


every 15 seconds

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Blue Flashing 5 seconds Indicates warning
every 15 seconds

Red Flashing 5 seconds Indicates alarm


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.

Yellow & Green Flashing, 5 seconds Indicates Loss of Communication


green followed by 5 On the EZHub, the LED indication will be a solid
seconds yellow green and yellow and remain solid until the
(repeated until condition
clears or is reset)
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.

EZHub Light(s) Action Meaning


Green Solid Indicates normal operation
Green & Yellow Solid No communication with instrument
Red & Blue Solid Status and Error indication - Lights only activated
when Error setting is exceeded
Yellow Solid Caution indicating exceeding caution level limits set
for the gas level, rate of change, or ratio
Blue Solid Warning indicating exceeding warning level limits
set for the gas level, rate of change, or ratio
Red Solid Alarm indicating exceeding alarm level limits set for
the gas level, rate of change, or ratio

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SmartDGA Manual Troubleshooting 94


9 Diagrams & Drawings

9.1 Multiple SmartDGA EZHub TM Setup with Ethernet Hub or


Switch

Note: The preferred implementation is a switch, especially if the LumaSMART iCore is


connected to a high traffic network.

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SmartDGA Manual
9.2 LumaSMART iCore
TM
RS485 Connections

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.

Diagrams & Drawings 96



SmartDGA Manual
9.3 LumaSMART iCore
TM
Ethernet Connections

Note: The LumaSMART iCore is optional and is not required for the SmartDGA system.

Diagrams & Drawings 97



SmartDGA Manual
9.4 Unistrut Stand
Note: Example of typical installation. Customer is responsible for verifying design
meets local facility requirements and safety requirements.

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.

Diagrams & Drawings 98



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9.5 SmartDGA NEMA 4 Enclosure

Diagrams & Drawings 99



SmartDGA Manual
9.6 Inline Mounting Plate

Diagrams & Drawings 100



SmartDGA Manual
9.7 Wiring Connection

SmartDGA
Wire Color
Connector Pin

EZHub RS 485 pin EZHub Power Pin


(1-4 from left to right) (1-6 from left to right)
A Brown 6
C Yellow 5
E Black 2
G Green 3
J White 4
M Purple (Violet) 4
N Grey 3
P Red 1
R Blue 1
S Orange 2

Diagrams & Drawings 101



SmartDGA Manual
TM
9.8 Assy, Wall Mount, SmartDGA EZHub

Diagrams & Drawings 102



SmartDGA Manual
Diagrams & Drawings 103

SmartDGA Manual
TM
9.9 Assy, Panel Mount, SmartDGA EZHub

Diagrams & Drawings 104



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Diagrams & Drawings 105

SmartDGA Manual
9.10 Assy, Wall Mount, LumaSMART iCore
TM

Diagrams & Drawings 106



SmartDGA Manual
Diagrams & Drawings 107

SmartDGA Manual
9.11 Assy, Panel Mount, LumaSMART iCore
TM

Diagrams & Drawings 108



SmartDGA Manual
Diagrams & Drawings 109

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9.12 SmartDGA Instrument Sun Shade

Diagrams & Drawings 110



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Diagrams & Drawings 111

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9.13 SmartDGA Instrument Dimensions

10.765
273.43
mm

12.152
308.66 mm

20.918
531.32
mm

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SmartDGA Manual
Index

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

Dual Valve 35 Maintenance 81, 84


Measurement cycle 11, 16
E Mounting plate 42
Ethernet 23 Mounting Ring 49
Ethernet Connection 63
EZHub 13, 20, 50, 55, 93, 102, 104, 108 N

Communications Cable 54 NDIR 14


Panel Mount 53 NEMA 4 99
Power Pin 56
Power Wiring 58, 65 Non-Dispersive Infrared 14
Relay Outputs 58
RS485 pin 56 O
Wall Mount 52
Oil-Gas Separating Membrane 16

F O-rings 31, 38, 43

Field Replaceable Unit 81


P
Filter Systems 40
Panel Mount 53
iCore 61

SmartDGA Manual Index 113


Parts 26, 35, 41, 59 Serial (RS485) Connection 64
Phoenix connectors 55 Service 8
Power 66 Single Valve 26
Power Connections 66 SmartDGA Instrument 49, 91, 93
Power Supply 57, 65, 66 Dimensions 112
Sun Shade 110
EZHub 23
Power Wiring Support 8
EZHub 58, 65 System Overview 11
iCore 66, 101
System Requirements 7
Pre-Installation Verification 17
System Status Relay 66
R
T
Real-Time-Clock-Calendar 11
Theory of Operation 14
Relay Outputs 58
Repair 8 V
RS485 23, 64 VA-0 See Inline
EZHub pin 56 Valve Installation 25
iCore 64
RS485 converter 23 Visual Light Indicators 91
RS485 to USB 23, 65
W
S Wall Mount
Sampling Sequence 15 EZHub 52
iCore 60
Sensor Replacement 86 Warranty 8

SmartDGA Manual Index 114