Hydrocal 1003

DGA Sensor 3 Outputs

Online gas-in-oil measurement sensor Hydrocal 1003, a system with 3 outputs for measuring:

  • H2 Hydrogen
  • CO Carbon monoxide 
  • H2O  Moisture

Hydrocal 1003

Transformer Online Monitoring System with Gas-in-Oil and Moisture in Insulation Oil Measurement.

The analysis of the gases dissolved in power transformer oil (DGA, DissolvedGas Analysis) is recognized as the most useful tool for detecting and diagnosing incipient faults in transformers.

In addition, water contamination deteriorates the performance of the oil as high moisture content increases the risk of corrosion and overheating. This is particularly when the water content reaches the saturation point of the oil and free water is formed.

Besides regular gas chromatographic analysis and off-line moisture analysis of the isolation oil of power transformers, online monitoring systems are becoming more important worldwide.

By online monitoring of the key fault gases, Hydrogen (H2) and Carbon Monoxide (CO) and Moisture in Oil (H2O), an additional potential of cost reductions and safety improvements can be achieved.

Key Advantages
  • Individual analysis of the dissolved gas contents for Hydrogen (H2) and Carbon Monoxide (CO)
  • Analysis of moisture (H2O) dissolved in transformer oil (both relative humidity [%] and absolute humidity [ppm])
  • Easy to mount on a transformer valve (G 1½" DIN ISO 228-1 or 1½" NPT ANSI B 1.20.1)
  • Installation on the operational transformer without any operational interruption
  • Advanced software (on the unit and via PC)
  • Maintenance-free system
  • Communication interfaces ETHERNET (Option) 10/100 Mbit/s (copper-wired / RJ45 or fiber-optical / SC duplex), RS 232 and RS 485 to support MODBUS®RTU/ASCII, DNP3 proprietary communication and IEC 61850 protocols
  • Optional 2G/3G modem with external adhesive antenna
  • Optional DNP3 serial modem for SCADA connection
  • Optional IEC 61850 Modem for SCADA Connection

Transformer Monitoring Functions

The Hydrocal 1003 can be used as a complete monitoring system for the condition of the transformer. The main monitoring options are listed below:

Voltages & Currents
  • via voltage and current transformers / transduce
Temperature Monitoring
  • Bottom and top oil temperature, ambient temperature
    (via additional temperature sensors)
Cooling Stage / Tap Changer Position
  • e.g. via a current transducer
Free Configuration
  • Analog inputs can be free allocated to any additional sensor
Further Calculations
  • Hot-Spot
  • Loss-of-Life
  • Ageing Rate 
RS 232 (Standard)
  • RS 232 interface (connection on backplate - without removing protection cover)
  • On-site, e.g. with notebook via a proprietary protocol
RS 485 (Standard)
  • Bus-Operation or point-to-point operation
  • MODBUS® RTU/ASCII or proprietary protocol
  • Bus length up to 1000 m
  • Communication with up to 31 HYDROCAL units
  • Configuration via internal firmware or PC software HYDROSOFT
GSM modem (Option)
  • Internal 2G/3G modem with external adhesive antenna and cable
  • Proprietary protocol
Analog modem (Option)
  • Integrated on-board analog modem with connection cable 15 m
  • Proprietary protocol
Ethernet modem (Option)
  • Internal ETHERNET 10/100 Mbit/s communication modem (copper-wired / RJ45 or fibre-optical / SC duplex)
  • IEC 61850 (prepared) or proprietary protocol
DNP3 modem (Option)
  • Internal DNP3 serial modem with RS 485 interface
  • DNP3 protocol
Unit Mounting
Transformer without cooling system

Mounting of the HYDROCAL 1003 unit on a valve on the transformer tank.

Natural oil convection inside of the transformer is ensuring the exchange of the oil at the membrane.

Transformer with cooling system and forced oil flow

The HYDROCAL 1003 unit is mounted on a T-fitting valve on the return flow of the cooling system.

The forced oil convection is ensuring the exchange of the oil at the membrane.

HydroSoft PC-Software
Program key features
  • Configuration and administration of each HYDROCAL unit
  • Data and configuration readout of HYDROCAL units
  • Processing and presentation of data readout (Trend or table)
  • Further processing of the processed data (Excel, CSV, clipboard and printing)
  • Storage of the processed data and unit configuration
  • Automatic data readout and alerting by e-mail

Key Features
  • 230V AC or 110V DC supply
  • Connection to valve: NPT 1” ½ or DIN-ISO 1” ½
  • Degree of protection: IP55
  • 4 digital relay outputs (220 VDC/VAC / 2 A / 60 W)
  • 8 optocoupler (UCE: 24 V - ICE: 40 mA max.)
  • 8 analog DC outputs
  • 4 current DC 4-20 mA
  • Communication: RS 232 serial interface and MODBUS® RTU
Operation Principle
  • Diffusion principle with gas-permeable TEFLON membrane
  • Micro-electronic gas sensors for H2 measurement
  • Electro-chemical measurement cell for CO measurement
  • Thin-film capacitive moisture sensor for H2O measurement (relative [%] and absolute [ppm])
  • Temperature sensors (oil temperature, gas temperature, backplate temperature)
General Technical Data

Optional nominal voltages of auxiliary supply

120 V -20% +15% AC 50/60 Hz
230 V -20% +15% AC 50/60 Hz
120 V -20% +15% DC
230 V -20% +15% DC

Power consumptionMax. 250 VA
DimensionsW 224 x H 224 x D 307.5 mm
Weightapprox.7.5 kg
Operation temperature (ambient)From -55 °C to +55 °C (below -10°C display function locked)
Oil temperature (inside transformer)From -20 °C to +90 °C
Storage temperature (ambient)From -20 °C to +65 °C
Oil Pressureup to 800 kPa (no negative pressure allowed)
Connection to valveG 1½" DIN ISO 228-1
1½” NPT ANSI B 1.20.1
SafetyCE certified
Insulation protectionIEC 61010-1:2002
Degree of protectionIP-55
Analog outputs
TypeRangeDefault concentration (Free assignment)
1 Current DC0/4 ... 20 mA DCHydrogen H2
1 Current DC0/4 ... 20 mA DCMoisture H20
1 Current DC0/4 ... 20 mA DC
1 Current DC0/4 ... 20 mA DCCarbon monoxide CO
Digital Outputs
TypeControl voltageMax. Switching capacity (Free assignment)
4 relay12 V DC220 V DC / V AC / 2A / 60 W
8 optocoupler5 V DCUCE: 24 V rated / 35 V max.
UEC: 7 V max.
ICE: 40 mA max.
Analog inputs



4 Current DC

4 Voltage DC

0/4 ... 20 mA DC + 20%

0 ... 10 V + 20%

≤ 1.0 % Configurable by jumpers (default configuration: Current)

4 Current DC 

0/4 ... 20 mA 

≤ 0.5 %
RS 232 - Serial interface with external connector (Proprietary or MODBUS® RTU/ASCII protocol)

RS 485 (proprietary or MODBUS® RTU/ASCII protocol)

ETHERNET 10/100 Mbit/s modem (Option) Copper-wired / RJ45 or fibre-optical / SC duplex connector (Proprietary protocol)

2G/3G modem with external adhesive antenna (Option) (proprietary protocol)
Analog modem (Option) (Proprietary protocol)
DNP3 serial modem (Option) with RS 485 connection (DNP3 protocol)
IEC 61850 modem for SCADA connection (Option)


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