Fiber Optic Probe Guide

for Liquid-Filled
Transformers

CAB-699-X

Installation Manual
IST-096-1
 CAB-699-X
Inside Power Transformers
Version 1.2

Qualitrol Company LLC Neoptix, Inc.

1385 Fairport Road 1415, rue Frank-Carrel, Suite 220
Fairport, NY, 14450 Québec, QC, G1N 4N7
USA Canada
Tel: 585-586-1515 Tel: 418-687-2500
Fax: 585-377-0220 Fax: 418-687-2524
support@qualitrolcorp.com support@neoptix.com

Proprietary notice:

Details of design and engineering are the exclusive property of Neoptix, Inc. and are strictly confidential. The
information given herein is subject to change, at any time and without notice.

All rights are reserved. The information in this document may not be reproduced or passed on in any manner
without prior written consent of Neoptix, Inc.

Neoptix, Inc. shall not be liable for technical or editorial errors or omissions contained herein; nor for
incidental or consequential damages resulting from the furnishing, performance, or use of this material.

All trademarks are the property of their respective owners.

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 TABLE OF CONTENTS

1 INTRODUCTION ..................................................................................................................................................................4
1.1 DISCLAIMER...........................................................................................................................................................................4
2 PROBE INSTALLATION (INSIDE TRANSFORMER) .............................................................................................5
2.1 HANDLING FIBER OPTIC PROBES..........................................................................................................................................5
2.2 PROBE DESCRIPTION .............................................................................................................................................................5
2.3 POSITIONING AND ROUTING THE PROBES............................................................................................................................6
2.3.1 When to install the probe............................................................................................................................................6
2.3.2 Installation during the normal winding process ......................................................................................................6
2.3.3 Installation using spacers...........................................................................................................................................7
2.3.4 Dielectric connector....................................................................................................................................................9
2.3.5 Feedthrough installation.............................................................................................................................................9
2.4 KEEPING YOUR EQUIPMENT AND FIBER CLEAN ............................................................................................................... 10
2.5 PROBE TESTING................................................................................................................................................................... 10
2.5.1 Testing probes, when?.............................................................................................................................................. 10
2.5.2 Probe testing procedure........................................................................................................................................... 11
3 USING THE TEMPERATURE PROBES .................................................................................................................... 12
3.1 CAUTION ............................................................................................................................................................................. 12
3.2 DESCRIPTION ...................................................................................................................................................................... 12
3.3 W ARNING............................................................................................................................................................................ 13
3.4 W ORKING WITH LONG PROBES.......................................................................................................................................... 13

Warning

Permanent damage may be done to the thermometer if the power supply connections are not done correctly.
In particular, do not connect the power input (18-24VDC or 110-240VAC) to any of the analog output
connectors. Note that the 20 mA analog output options are self-powered interfaces (by opposition to loop-
powered interfaces), and thus do not require any external supply.

Fiber optic probes are fragile, and will break if the bending radius becomes less
than 1cm, even temporarily. Furthermore, as the tips of the T2 probes are fragile,
exercise care to:
• Make sure the last ~1 cm of probes is free standing, and not pressurized by
any glue, or by the spacers
• Avoid bending the last 1cm of probes.
Furthermore, due to the unique construction of the Neoptix T2 type probes, it is
important that you avoid applying glue to the last 1 cm of the probes during their
installation in transformer windings.

Probe breakages are not covered under standard Qualitrol warranty.

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 1 INTRODUCTION
This guide has been put together in order to help the transformer manufacturer achieve maximum success
when installing Neoptix probes inside power transformers.

1.1 Disclaimer
This manual should be used in conjunction with other Qualitrol & Neoptix Guides for products for power
transformers.

Warning: Neoptix does not pretend to be an expert in probe installation; however, Neoptix has some
experience in this field and wants to share it with transformer manufacturers. The ultimate
responsibility for probe installation remains with the transformer manufacturer.

Neoptix & Qualitrol decline any responsibility in regard to the misuse of this guide.

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 2 PROBE INSTALLATION (INSIDE TRANSFORMER)
Transformer manufacturers should use the following information as a guide to safely install the probes inside
windings of a power transformer. Make sure you instruct all of your employees that fiber optics, contrary to
conventional copper wires, are very fragile. Generally speaking, fiber optics, contrary to copper wires, cannot
1
be repaired very easily once broken!

2.1 Handling fiber optic probes

The following lists some of the important points to keep in mind in order to prevent damage to the probes
throughout the installation:

1. Avoid applying glue over the last 1cm of the probe. It is better to leave the last 1cm completely
free and not attached to anything (make sure last 1 cm of the probe is free and not subject to any
sort of pressure
2. Avoid pulling the probe over sharp bends (corners), as this can snap the probe
3. Avoid applying undue external pressure at the tip end of the probe
4. Avoid bending the last 1cm of the probe
5. Avoid straining and over-twisting the fiber
6. Avoid dropping heavy objects on the probes or dragging heavy objects over them, as this can crush
the fiber
7. To secure the probe, do not use nylon cord, as this could overstrain the fiber. It is preferable to use
cloth or cotton strapping and to tie it only as firmly as necessary
8. Avoid placing the fiber in areas where it could be damaged by internal movements of the transformer
while in operation
9. Secure the fiber safely on the conductor in a way that it cannot be crushed by the sudden contraction
of adjacent coils or when there is a sudden change in current
10. If possible, protect the probe from mechanical stress by running it through rigid insulation tubing
11. Do not use flexible tubing that bends at sharp angles
12. Another alternative is to tie the probes to any supporting structures while respecting the previous
points.

Refer to Chapter 3 for additional information concerning the maintenance of probes and fiber-optic cables.

2.2 Probe description

To maximize success when installing probes, it is important to understand the different parts of it. This
Section gives a brief description of a typical Neoptix transformer T2 probe. This drawing shows a T2 probe.

1
Neoptix offers a dielectric connector that can be installed inside a transformer. It is made of material that is
completely dielectric. Neoptix sells probes that can have this connector pre-installed. It might also be possible
for users that have fiber optic handling experience to install them on site; however, it is very important to
emphasis that they will have to polish and glue connectors on site (telecom expertise may be very useful for
this!).

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Some details about this probe:
• The far left of the drawing shows the sensor end of the probe; be careful not to crush it!
• The Teflon spiral wrap is only provided for mechanical protection; the orange color is used to
maximize viewing inside the transformer.
• A dust cap is shown, to the right. This is provided to protect the ST connector when handling the
probe, while the winding is being made, and so forth, until the connector is finally and permanently
connected to the feedthrough.

2.3 Positioning and routing the probes

Warning: The next few Sections present some ideas and suggestions on how the probes should be installed.
Neoptix wants to stress the fact that these are suggestions only and cannot be considered as strict directives
given by Neoptix. The ultimate responsibility for the probe installation and performance remains with
the transformer manufacturer.

We recommend installation of the probes using radial spacers as described in the following illustrations.

If it is necessary, for any reason, to attach the probe directly to the conductor, then tape the probe side-on
against the conductor. The thermal contact between the probe and the winding is better with side-on
attachment than end-on. In this case, insert the probe tip inside a “U-shape” protector (see figure below) and
use crepe paper to hold this probe-spacer assembly against the conductor; this “U-shape” protector is
important as it avoids excessive pressure to be applied to the tip of the probes.

U-Shape spacer:

The sensing tip is located at the extremity of the probe. To monitor the temperature of the windings, the probe
tip should be secured adjacent to the winding’s hottest spot.

The winding’s hottest spot is determined by the transformer manufacturer’s calculations.

The tip should be safely secured onto the conductor in a way that the winding couldn’t crush the sensor when
there is a sudden change in current or an abrupt contraction of adjacent coils.

Warning: Exercise care to avoid bending the last 1cm at the end of the probe.

2.3.1 When to install the probe

In general, two options are available to the installer:

• In general, it is preferable to install probes as far along the manufacturing process as possible in
order to minimize handling. Wedges are used and winding is separated after it is completed in order
to install probes before compression.

• However, some manufacturers do not want to do this manipulation. They install modified spacers
with probes during the normal winding process.

2.3.2 Installation during the normal winding process

The following figure illustrates this process.

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2.3.3 Installation using spacers
Waning: This procedure shows only one of the methods that can be used to install probes using isolation
spacers. Its purpose is to illustrate one of the many ways the Neoptix probes can be installed.

2.3.3.1 Preparing the spacer

Warning: In all cases, case must be exercised to assure that the tip of the probe is NEVER pressurized by
excessive glue, by spacers that might be too thin, and so forth. Any undue stress applied to the tip of the
probe may be destroyed it irreversibly.
2
Drill cut a notch in a spacer , as shown in the figure below.

Cut the tabs off the spacer where on one side so that the axial strip will not interfere with insertion.

2.3.3.2 Fixing the probe into the spacer

Use transformer approved adhesive (milky glue) and/or crepe paper to hold the probe in place as illustrated
in the above figures.

The probe should be snug against the spacer and the probe tip should remain exposed.

2
A 3mm think spacer works best.

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Warning: Avoid any sharp bending of the probe, as this may permanently break it, or lower its performance.
Do not apply pressure, or glue, to the last 1 cm of the probe.

Some manufacturers have successfully used some Gore-Tex sheeting material (see website
http://www.gore.com/en_xx/products/sealants/gaskets/gore-tex_gr_sheet_gasketing.html) 1/16 inch thick to
help holding the probe in place in the spacer; if using this material, a much larger slot needs to be cut in the
spacer. This PTFE-based material is completely compatible with power transformer environments. When
using Gore-Tex, make sure the Gore-Tex is not exercising a pressure to the last 1 cm of the probe.

2.3.3.3 Do you need a gap spacer?

If the probe must be channeled into a duct that is not adjacent to the spacer, you probably need a gap
spacer.

Probes should not pass between an axial strip and the pressboard cylinder as it may be crushed.

2.3.3.4 Preparation of a gap spacer

This can be done using two thinner spacers. See figure below.

Alternatively, you can use two pieces of a radial spacer and crepe paper.

2.3.3.5 Inserting the probes into the windings

If the winding is already done, use wedges into the windings to create the required space and then pull out
the spacers and replace them by the good ones.
If you install the probes during the winding process, use modified spacers directly.

Fix the spacers with the probe in place with transformer-approved adhesive.

2.3.3.6 Routing the probes out of the windings

When installing the probe, it is advisable to coil the unused part in loops no smaller than 30 cm (in general,
the larger the better!).

It is also preferable not to have the connector swinging freely during dry out and assembly.

The coil and the connector can be attached with cotton strapping or string. A cotton bag can also be useful.

Important Note

The dust cap should be left on the connector during all the process.

This keeps the dust away from the fiber tip.

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2.3.3.7 Routing the probes up to the feedthroughs
Assuming the probe exits the winding beside the winding leads, probes can all be run along the tops of the
windings to one wall of the tank. Note that this routing should be done only after the winding and core
assembly has been installed in the tank, the idea again being to leave any probe installation steps until as
many of the other fabrication steps have been done as possible.

Probes can be run through Bakelite tubing or any other rigid tubing or secured using cotton strapping (do not
over tie) to any supporting structure. Tubing that is flexible but stiff is dangerous because when it bends it
makes sharp edges which can damage the probe if it is jerked; avoid using tubing or jacketing of this
description.

2.3.4 Dielectric connector

As mentioned above, Neoptix offers T2 -type probes that can pre-fitted with dielectric connectors that are
compatible with transformer environments. Generally speaking, the use of such connector is not
recommended, as it is generally acceptable for most applications to insert probes using modified radial
spacers after the winding construction.

This type of connectors requires special attention, as they are relatively fragile. Here are some
recommendations and hints that might be useful while installing and using them:

1. Neoptix recommends that mineral oil (or equivalent transformer compatible oil) be used to
lubricate the ferrules before snapping the connector together.

2. While holding the connector in your hands, avoid applying undue pressure on the orange Teflon
cable that emerges from the connector, as otherwise this may break the fiber inside this orange
cable.

3. As always, make sure the ferrules are clean prior to use. It is recommended to clean the ferrule
and then to dip it in oil, as suggested in step # 1 above.

2.3.5 Feedthrough installation

Qualitrol offers transformer tank wall feedthroughs that have been specially designed and manufactured for
this application. In addition, Qualitrol offers convenient tank wall plate that can accommodate up to 12
feedthroughs; these wall plates can be either welded to the transformer wall (the plates are made of carbon
standard carbon steel), or bolted.

Handling the feedthroughs requires special attention. Here are some points to pay attention to:

• The feedthroughs are made to be installed from the outside of the transformer.

• Before installing the feedthroughs, the threads should be sealed with some sealing material, such as
Teflon PTFE tape
o Plumber grade tape is not recommended. Instead, Swagelok™ tape (part # MS-STR-8) and
sealant (part # MS-PTS-6) should be considered. Also recommended, as an alternative:
Loctite 567™, which is designed for locking and sealing of metal tapered threads and
fittings.

• Warning: Do not over tight. In addition, make sure you tight only the hex nut, not on the side “hand-
nut”; doing so, may damage permanently the feedthrough. See this figure:

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 Inside Outside
transformer transformer

Use this nut

to tighten
feedthrough

• After installation, each feedthrough should be tested for proper operation, in the same way as a
probe would be tested (e.g., make sure a good probe is connected inside the transformer and a
patch cord is installed outside, and refer to Section 2.5.2).

• The connector ends must be cleaned prior to final connection to remove debris that may have
collected during installation. Debris can block the passage of light down the fiber. For this purpose,
follow this procedure:

• Use optic-grade wipes and optic grade 99% isopropyl alcohol OR Optic Prep pads.
• Gently wipe the ferrule (and especially the end) in a circular motion.
• With a dry KimWipes™ tissue (or equivalent), wipe out any excess alcohol. Allow 10 seconds for
the alcohol to evaporate.

• It very important also to clean the insides of the two ferrules composing each feedthrough, to remove
contaminants and debris that may have made their way into the ferrules during installation. 2.5mm
mini foam swabs (Fiber Instruments Sales part # F1-0005) work best for this application.

• Connect the probe on the inside side of the feedthrough and the patch cord on the outside side of the
feedthrough. Align the “key” on the connector with the slot on the mating sleeve, slide connector into
sleeve and gently rotate the connector body while pushing towards the mating sleeve until the “keys”
on the mating sleeve slide into place. This is similar to a bayonet or BNC type connector. Due to
variations in the manufacturing process, some feedthroughs may be more difficult to connect than
others; Neoptix has tested ALL feedthroughs prior to shipment, and they meet our stringent
specifications. So, when they are a bit more difficult to install, exercise care that no damage is done
during the installation.

2.4 Keeping your equipment and fiber clean

Fiber optic carries the light in a conduit as small as a piece of thread. So, cleanliness of interconnections is
essential for the light to circulate. On this scale, a dust badly placed can significantly deteriorate the signal.

Refer to other sections of this manual for detailed instructions on how to clean and to connect correctly any of
the probes and the patch cords, as applicable. In general, the following procedure gives good results:

• Use optic-grade wipes and optic grade 99% isopropyl alcohol OR Optic Prep pads.
• Gently wipe the ferrule (and especially the end) in a circular motion.
• Allow 10 seconds for the alcohol to evaporate.
• Or simply use the connector cleaner provided.

2.5 Probe testing

2.5.1 Testing probes, when?

It is recommended the probes be tested at least 5 times, as follows:

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 1. After winding is completed and compressed
2. After the outer winding has been installed over the inner winding
3. After drying process
4. Before and after connecting to feedthrough
5. Before and during all Heat-Runs.

2.5.2 Probe testing procedure

To test your probes for the first time, follow this simple procedure:

1. Plug the AC power supply

2. Turn on the instrument
3. Plug the probes in the probe connectors.

The temperatures can be read on the user panel.

A portable monitor (KIT-057-1) is available to read T2 type probes. The Qualitrol Portable Fiber Optic
Thermometer is battery operated and offers excellent flexibility to test probes at various stages of the
transformer fabrication. Contact Qualitrol for more information.

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 3 USING THE TEMPERATURE PROBES
3.1 Caution
Each time you connect a temperature probe to the unit, the probe optical connector should be cleaned
beforehand. Otherwise, particles of grease or dirt may obstruct the devi ce internal connector and affect the
measurements by completely blocking the signal or by generating too much attenuation when using a long
fiber length.

Never use a cloth other than the type recommended for fiber optic cleaning. Dampening the cloth with pure
isopropyl alcohol ensures good cleaning.

Occasionally, clean the inside of the bulkhead connector (attached to the thermometer) with a wipe or cotton
swab dipped in alcohol (2.5 mm mini foam swabs work best).

Locking nut

Ferrule key

Ferrule

For very dirty connectors, acetone can also be used, but should be used very carefully, as it is a very strong
solvent. Care should be exercised so you do not apply any on plastic materials, etc.

3.2 Description
The optical connector used is a standard ST type connector.

Device connector
Insert the Ferrule key here

Pins BNC type

To install the connector,

Slide the ferrule key gently into the above key.
Then, turning, insert the two BNC pins into
The appropriate slots on the ST connector.

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3.3 Warning
Probes are quite fragile and must be handled carefully. Please note that any probe damages are not covered
by the standard warranty.

T2 transformer probes use exclusively epoxy glue; no silicone rubber is used in the manufacturing of these
probes. This ensures that the probes are completely resistant to transformer oil and to transformer cleaning
fluids, such as kerosene and other white spirits.

Contact your Qualitrol for additional chemical compatibility information.

Do not expose your probes to temperatures that are higher than 200°C. Permanent damage can be caused
to probes that have been exposed to temperatures that are higher than their limits.

3.4 Working with long probes

This note is important when using probes or extensions that have a combined length of 100 meters or more.
Working with long probes or extensions presents special problems. To limit the amount of back reflection
caused by the fiber optic connector located on the thermometer unit, you may have to use a matching gel
optical couplant in the connector. This gel is a grease-like compound with high clarity, good resolution
properties and a refractive index close to quartz. Apply the gel onto connector end faces.

Avoid disconnecting the connectors for which gel has been used. In other words, it is recommended to use
the gel only for permanent installations. If the connectors are disconnected many times, you may have to
clean thoroughly the connector assemblies that have had the gel; this may require opening the instrument
enclosure to remove the excess gel.

Note that it is not required to use this gel with connectors that are far away from the thermometer electronic
unit.

The Hot Spot Module includes some special features that help sometime to enhance the response from weak
or marginal probes. In the particular, the “gskip” and “wtune” setup commands can be very useful; refer to the
Hot Spot Module manual for more information on how to apply those commands.

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Qualitrol Company LLC
1385 Fairport Road
Fairport, NY, 14450
USA

Tel: 585-586-1515
Fax: 585-377-0220
www.qualitrolcorp.com
support@qualitrolcorp.com

Neoptix, Inc.
1415, rue Frank-Carrel, Suite 220
Québec City, QC
CANADA G1N 4N7

Tel: 418-687-2500
Fax: 418-687-2524
www.neoptix.com
support@neoptix.com

Printed in U.S.A.

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