Hydrocal 1009

DGA Sensor 9 Outputs

Online gas-in-oil measurement sensor Hydrocal 1009, a system with 9 outputs for measuring:

  • H2 Hydrogen
  • CO Carbon Monoxide 
  • CO2 Carbon Dioxide
  • CH4 Methane
  • C2H2 Acetylene
  • C2H4 Ethylene
  • C2H6 Ethane
  • OOxygen
  • H2O  Moisture

Hydrocal 1009

The HYDROCAL 1009 is a permanently installed multi-gas-in-oil analysis system with transformer monitoring functions.

It individually measures the key gases dissolved in transformer oil, such as:

  • Hydrogen (H2)
  • Carbon Monoxide (CO)
  • Carbon Dioxide (CO2)
  • Methane (CH4)
  • Acetylene (C2H2)
  • Ethylene (C2H4
  • Ethane (C2H4)
  • Oxygen (O2)

It additionally measures Moisture in Oil (H2O).

As Hydrogen (H2) is involved in nearly every fault of the insulation system of power transformers and Carbon Monoxide (CO) is a sign of involvement of the cellulosic / paper insulation, the presence and increase of Acetylene (C2H2) and Ethylene (C2H4) further classifies the nature of a fault as overheating, partial discharge or high energy arcing. Oxygen (O2) can be a sign of excessive ageing or leakages within the sealing of hermetic transformers.

The device can serve as a compact transformer monitoring system by the integration/connection of other sensors present on a transformer via its optional analog inputs:

  • 4 Analog inputs 0/4 ... 20mADC
  • 6 Analog inputs 0/4 ... 20mAAC +20% or 0 ... 80 VAC +20% (configurable by jumpers)

It also has digital outputs for transmitting alerts or performing control functions (e.g. controlling a transformer cooling system):

  • 10 digital relay outputs
  • 6 digital optocoupler outputs (Option)

Key Advantages
  • Individual measurement of Hydrogen (H2), Carbon Monoxide (CO), Carbon Dioxide (CO2), Methane (CH4), Acetylene (C2H2), Ethylene (C2H4), Ethane (C2H6) and Oxygen (O2)
  • Moisture in Oil (H2O) measurement
  • 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 10/100 Mbit/s (copper-wired / RJ 45 or fibre-optical / SC Duplex) and RS 485 to support MODBUS®RTU/ASCII, MODBUSÒTCP, 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
  • Optional HV and LV bushing sensors for HV and LV bushing monitoring applications via communication interface

Transformer monitoring functions

The Hydrocal 1009 can be used as a complete monitoring system for the condition of the transformer. The main monitoring options are listed below:

Voltages and Currents
  • via voltage and current transformers/transducer
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 (acc. IEC 60076)
  • Loss-of-Life
  • Ageing Rate
HV and LV Bushing monitoring functions (option)

The Bushing Monitoring System simultaneously monitor’s the bushing leakage current of 2, three-phase groups of bushings. The Bushing Monitoring system incorporates three different measurement modes on each tested component to provide accurate Power Factor and Capacitance values to evaluate the condition of bushing insulation. The measurement modes are:

Phase comparison: Compares the power factor of the tested component with another tested component energised with the same phase voltage

Sum of three current tests: Measures the imbalance current from the summation of A, B and C phase currents from three tested components such as the three HV or LV bushings on the transformer

Adjacent phase reference test: Compares the power factor of the tested components with other phase components on the same equipment

The bushing sensors/adapters are connected to the capacitor taps designed for all types of bushings to allow measurement of the leakage current up to 140 mA. The adapters are designed for bushings with grounded and undergrounded capacitor taps. The adapter is designed to prevent voltage from developing on the equipment should the sensor become disconnected from Bushing Monitoring System.

Monitoring of high- and low voltage side

Different bushing sensor configurations are possible:

  • Monitoring of high voltage side
  • Monitoring of high- and low voltage side
  • Reference HV bushing from other transformers
  • Reference CCVT / CCPT

Configuration with 3, 6, 9 or 12  bushing sensors possible.

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)
  • Online functions (online sensors, extraction status and process flow)
  • Diagnostic functions (Duval triangle and Rogers 3D graphic)
  • 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
  • 10 Relay outputs
  • 10 analog outputs 4-20 mA
  • Communication: RJ45 interface or multimodal fibre optic with SC-Duplex interface with ETHERNET or MODBUS®TCP protocol
Operation principle
  • Miniaturised gas-sample production based on headspace principle (no membrane, negative pressure proofed)
  • Patent-pending oil sampling system (EP 1 950 560 A1)
  • Near-infrared gas sensor unit for CO, C2H2 and C2H4
  • Near-infrared gas sensor unit for CO2, CH4 and C2H6
  • Micro-electronic gas sensor for H2 and O2
  • Thin-film capacitive moisture sensor H2O
  • Temperature sensors (for oil and gas temperature)
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. 600 VA
DimensionsW 263 x H 263 x D 327.5 mm
Weightapprox. 15 kg 
Operation temperature (ambient)-55°C ... +55°C (below -10°C display function locked)
Oil temperature (inside transformer)-20°C ... +90°C
Storage temperature (ambient)-20°C ... +65°C
Oil pressureup to 800 kPa (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
Analogic outputs
TypeRangeDefault concentration (Free assignment)
1 Current DC0/4 ... 20 mA DCHydrogen H2
1 Current DC 0/4 ... 20 mA DCCarbon Monoxide CO
1 Current DC 0/4 ... 20 mA DCCarbon Dioxide CO2
1 Current DC 0/4 ... 20 mA DCMethane CH4
1 Current DC0/4 ... 20 mA DCAcetylene C2H2
1 Current DC0/4 ... 20 mA DCEthylene C2H4
1 Current DC0/4 ... 20 mA DCEthane C2H6
1 Current DC0/4 ... 20 mA DCOxygen O2
1 Current DC0/4 ... 20 mA DCMoisture H20
1 Current DC0/4 ... 20 mA DCFreely programmable
Digital output
TypeControl VoltageMax. Switching capacity (Free assignment)
10 Relay12 V DC220 V DC / V AC / 2A / 60 W
RS 485 (proprietary or MODBUS® RTU/ASCII protocol)

ETHERNET 10/100 Mbit/s copper-wired / RJ 45 or fibre-optical / SC Duplex (proprietary or MODBUS® TCP protocol)

2G/3G modem with external adhesive antenna (optional) (proprietary protocol)
DNP3 serial modem (Option)
IEC 61850 modem (Option)

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