INTELLIXTM BMT 300

INSTALLATION MANUAL

GE Energy, Lissue Industrial Estate East,

Lissue Road, Lisburn, BT28 2RE, United Kingdom
Tel: +44 (0) 28 9262 2915,
Fax: +44 (0) 28 9262 2202
40-0170-0F, July 12 E-mail: [email protected], Web: www.gedigitalenergy.com/md.htm
 Intellix™ BMT 300 Installation Manual

Table of Contents

INTRODUCTION ................................................................................................................................. 4
Product Overview ......................................................................................................................... 4
Scope ................................................................................................................................................ 4
Abbreviations & Definitions ...................................................................................................... 5
Warnings & Cautions .................................................................................................................. 5
Conventions ................................................................................................................................... 6
Technical Specifications ............................................................................................................ 7
Measurements ......................................................................................................................... 7
Environmental .......................................................................................................................... 7
Power........................................................................................................................................... 7
Key Pre-Installation Requirements ........................................................................................ 8
Transformer Criteria .............................................................................................................. 8
Intellix™ BMT 300 Location ................................................................................................. 8
Pre-Installation Information Sheet ................................................................................... 9
Key Installation Requirements ................................................................................................ 9
PRE-INSTALLATION .......................................................................................................................... 9
Base &Access................................................................................................................................. 9
Sensor Cable Runs ..................................................................................................................... 10
Communications and Power Cable Runs.......................................................................... 10
INSTALLATION .................................................................................................................................. 11
Mounting Intellix™ BMT 300 on Stand ............................................................................... 15
Transformer – Bushing Adapter Connections ................................................................. 15
Transformer – Neutral Sensor Connection....................................................................... 19
Transformer – Temperature Sensors.................................................................................. 20
Ambient Sensor........................................................................................................................... 21
Communications – External connections ......................................................................... 22
Intellix™ BMT 300 Cabinet Connections ............................................................................ 23
Earth .......................................................................................................................................... 23
Mains AC................................................................................................................................... 23

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Intellix™ BMT 300 Installation Manual

Bushing & Neutral Sensors................................................................................................ 25

Bushing Adapter Circuit Integrity Tests........................................................................ 26
Temperature Sensors .......................................................................................................... 28
Communications – Internal Connections .................................................................... 29
Serial Fibre-Optic (Optional) .............................................................................................. 29
Multi Master (Optional) ........................................................................................................ 30
GPS Antenna ........................................................................................................................... 31
Alarm Relays ........................................................................................................................... 32
Set Up ............................................................................................................................................. 34
Decommissioning ...................................................................................................................... 34
APPENDIX 1 - MOUNTING STAND DIMENSIONS .................................................................. 35
APPENDIX 2 – PARTS AND TOOLS LIST.................................................................................... 37
APPENDIX 3 – FRONT PANEL LIGHTS....................................................................................... 39
APPENDIX 4 – TROUBLESHOOTING .......................................................................................... 40
APPENDIX 5 – BUSHING ADAPTER CIRCUIT INTEGRITY TEST RECORD ........................ 41

Copyright 2012, General Electric Company.

Intellix is a registered trademark of General Electric Company.
This release of this document is accurate at the time of this writing. General Electric
Company reserves the right to change the Intellix BMT 300 and this document without
notice.

General Electric Company, Lissue Industrial Estate East

Lissue Road, Lisburn, BT28 2RE, United Kingdom
Tel: +44 28 9262 2915
Fax: +44 28 9262 2202
e-mail: [email protected]
Web: www.gedigitalenergy.com/md.htm

Related Documents

# Document Number Document Title

1 36-0051 BMT 300 Required Installation Information

2 40-0171 Intellix™ BMT 300 User Manual

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 Intellix™ BMT 300 Installation Manual

INTRODUCTION

Product Overview

The Intellix™ BMT 300 is a monitoring system that continuously:

Measures the condition of transformer bushings.
Detects any Partial Discharges (PD) activity in the bushings and the
transformer main tank; (measured as high frequency pulses).
Monitors the ambient temperature and humidity.
Monitors the transformer top and bottom oil temperatures.
Discriminates between those partial discharges that occur externally and
those that occur internally within the transformer, if a neutral CT is used.
All measurements and alarms can be reported to a remote monitoring centre via
either the standard RS485 connection, one of the other communications options, or
manually downloaded by a visiting service engineer. The Intellix™ BMT 300 is
supplied with PC Monitor software that is used to setup the device.
The sensors that have to be fitted are:
A bushing adapter, connected to the bushing tapping point. This adapter
brings the PD signals to the Intellix™ BMT 300. A bushing adapter is
attached to each of the transformer 3-phase bushings.
A Current Transformer (CT) sensor at the transformer neutral, if available.
Two magnetic temperature sensors on the transformer outer casing, to
measure the transformer oil temperature.
A combined atmospheric temperature and humidity sensor, mounted
close to the Intellix™ BMT 300 enclosure.

Scope

This installation manual covers the pre-installation and installation tasks

associated with the stand alone Intellix™ BMT 300 device.

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 Intellix™ BMT 300 Installation Manual

Abbreviations & Definitions

Abbreviation Meaning

BMT Bushing Monitor for Transformers

CT Current Transformer

PD Partial Discharge

Warnings & Cautions

The meaning of safety symbols used on the Intellix™ BMT 300 device:

Refer to the Instruction Manual to prevent injury

or damage to equipment

Hazardous voltages may be present

Protective earth connection

All procedures in this manual must be strictly adhered to. Any deviation from
these could cause irreversible damages to the transformer being monitored and/or
the Intellix BMT 300, and could lead to property damage, personal injury and/or
death.

The meaning of safety messages used in this Instruction Manual:

A procedure, practice, or condition could cause

CAUTION
equipment damage or permanent loss of data

A procedure, practice, or condition could cause bodily

WARNING
injury or death

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 Intellix™ BMT 300 Installation Manual

Conventions

Menu items or options displayed on the display screen are represented in the text
in bold, for example Alarm Setup.
Choosing several options sequentially is represented by using “>” between the
options, for example Alarm Setup > Top Oil Alarms.

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 Intellix™ BMT 300 Installation Manual

Technical Specifications
Measurements

Feature Value

Maximum Bushing Temperature at 90 deg C (194 deg F)

sensor

Relative Phase Angle accuracy 0.01 deg of angle

Maximum number of PD measured 400 PD per cycle (50 to 60Hz)

Maximum PD measurable CAT III. 5Vrms, 200mA; on each phase

Environmental

Feature Value

Operating Temperature Range -30 to +55 deg C (-22 to +131 deg F)

When equipped with multi-master -20 to +55 deg C (-4 to +131 deg F)
comms option

Operating Humidity Range 5 to 95% RH, non-condensing

Maximum Operating Altitude 2000m (6500 ft) above sea level

Storage Temperature Range -40 to +85 deg C (-40 to +185 deg F)

Minimum Ambient Temperature for -20 deg C (-4 deg F)

Installation and Service Activities

Cabinet Protection Level IP55

BMT 300 Weight 20 kg (44lb)

Power

Feature Value

AC power supply requirement 100 to 240Vac, 50 to 60Hz, 1.24 to 0.41A

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 Intellix™ BMT 300 Installation Manual

Feature Value

Control Relays (quantity 3) Single Phase Change Over (SPCO), Maximum

RATED: 2A @240VAC resistive load, 2A @
30VDC

Fuse (1 each on Live & Neutral) 10 x 38 mm time delay 500V, 3A

Key Pre-Installation Requirements

Transformer Criteria

The transformer should meet the following criteria:

The transformer must have bushing tapping points that are available and
accessible.
Intellix™ BMT 300 Location

The Intellix™ BMT 300 requires an installation location that:

Is close enough to the transformer so that the cable runs from the
Intellix™ BMT 300 to the bushings are likely to be less than 25m.
Has an electrical supply of 230VAc (1A) or 110VAC (2A). This may be taken
from a nearby GE Energy Transfix device, if convenient. The electrical
supply(ies) is to have an independent means of disconnection.
Has suitable site access to carry the Intellix™ BMT 300 to its destination,
noting that the dry weight of the Intellix™ BMT 300 is approx 20 kg.
A base that can take the 30kg distributed load and accommodate the
Intellix™ BMT 300 dimensions of: 500mm H x 300mm W x 200mm D.
There should be at least 750mm clear space in front to allow access to the
Intellix™ BMT 300 cabinet.
The Intellix™ BMT 300 should be mounted in a location that does not
interfere with the transformer cooling system, with regular maintenance
activities or with the operation of the electrical supply disconnection
device.
Is within the maximum line length of the chosen communications method.
Note that the Intellix™ BMT 300 can be linked to a nearby Transfix to
utilize its communications for measurement reporting.
It is not recommended that the Intellix™ BMT 300 enclosure is mounted
directly onto the transformer; contact GE Energy Technical Support if you
are considering this.
It is recommended that the Intellix™ BMT 300 is mounted on the transport stand;
see Appendix 1 on page 35 for dimensioned drawings.

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Pre-Installation Information Sheet

The pre-installation information sheet (document #36-0051) must be returned to

GE-Energy at least 12weeks before the intended installation date, and the Purchase
Order cannot be acknowledged until this information is provided.

Key Installation Requirements

The transformer will have to be turned off and earthed for the duration of
the installation process.
Cable runs are required from the Intellix™ BMT 300 location to the
bushings.

All sensor cables from the Bushing adapters to the

CAUTION
Intellix™ BMT 300 cabinet MUST be run inside an
electrically grounded protective metal conduit.

If the equipment is installed or used in a manner not

WARNING
specified by the manufacturer, the protection provided
by the equipment may be impaired.

PRE-INSTALLATION

It is crucial that the pre-installation information form (Document # 36-0051) is

returned to GE Energy well in advance (at least 12 weeks) of the intended installation
date. (Note: the customer Purchase Order cannot be acknowledged until this
information is provided. This information is used to:
Adjust the on-board shut resistors.
Manufacture the bushing adapters.
Estimate the cable lengths.

Base &Access

The base should be level and firm enough to accept the stand being bolted down.
See Appendix 1 on page 35 for the required dimensions. Factors to consider:
The site should be readily accessible as the Intellix™ BMT 300 weighs
approximately 20 kg (44 lbs.
There should be 2m headroom.
If a new concrete pad is required, it is recommended that it be at least
61cm (24”) wide by 122 cm (48”) long and 9cm (3 1/2”) thick with #3

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(10mm) steel reinforcing bar around the perimeter. (Grounded and

bonded in accordance with local practice and code.)
The Intellix™ BMT 300 should never be mounted directly to the
transformer without first consulting GE Energy Technical support.
The intended AC supply is to be provided with a switch or circuit breaker
so that it can be independently de-energised. The location of the switch
or circuit breaker should be in close proximity to the intended location of
the Intellix™ BMT 300 cabinet, and within easy reach of the operator.
If the GE Energy-manufactured mounting stand has not been purchased, a stand
must be constructed as outlined in Appendix 1.

Sensor Cable Runs

If possible, sensor cable runs from the intended Intellix™ BMT 300 location to the
transformer bushings should be pre-installed. See the general layout at Figure 1 on
page 11.

All sensor cables from the Bushing adapters to the Intellix™ BMT 300
CAUTION
cabinet MUST be run inside an electrically grounded protective metal
conduit or flexible armoured cable.

All installation activity should take place in ambient temperatures

CAUTION
greater than -20 deg C (-4 deg F) to prevent damage to connectors and
cabling as they may become brittle at extreme low temperatures.

Details of recommended conduit and fittings are at Appendix 2 on page 37.

Communications and Power Cable Runs

If possible, communications and power cable runs from the intended Intellix™
BMT 300 location to their sources should be pre-installed. See the general layout at
Figure 1 on the next page. Note that both can be linked to a nearby Transfix device,
if convenient.

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 Intellix™ BMT 300 Installation Manual

INSTALLATION

Figure 1: General Installation Layout

Figure 1shows the general layout of the sensor connections required for the
Intellix™ BMT 300. Figure 2 overleaf shows the key parts of the Intellix™ BMT 300
cabinet.

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 Intellix™ BMT 300 Installation Manual

Figure 2: Key Parts of the Intellix™ BMT 300 Cabinet

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Intellix™ BMT 300 Installation Manual

CAN cable to
humidity sensor
and external
CAN connector
on cabinet door

All comms
cables
routed up
left side
Alarm
relay
PCB

Functional
Earth
alarm cables
Routing for

Earth Bond

Figure 3: Typical Cable Routing – Cabinet

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 Intellix™ BMT 300 Installation Manual

Earth for AC
supply

CANBUS:
1 – Ground
2 – CANH
3 – CANL
4 – 12Vdc
5 - Shield

Figure 4: Cable Routing - Inner Door

Perspex
cover

Plastic
cover

Figure 5: AC Protection Shields

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 Intellix™ BMT 300 Installation Manual

Mounting Intellix™ BMT 300 on Stand

Do not attempt to install the Intellix™ BMT 300 unless

WARNING the transformer is turned off.

Ensure HV & LV are grounded before installation of

WARNING Intellix™ BMT 300.

Once installed, this unit may have more than one

WARNING source of supply. Disconnect all supplies, at their
source, before accessing the cabinet for servicing.
The Intellix™ BMT 300 should not be mounted where it
CAUTION
may interfere with the transformer cooling system or
maintenance activities.

There should be at least 75cm clear in front of the

CAUTION
Intellix™ BMT 300 to allow access to the cabinet.

Contact GE Energy Technical support before mounting

CAUTION
the Intellix™ BMT 300 cabinet directly on the
transformer.

The GE Energy stand is shipped with the top portion of the stand inverted.
Remove the hardware holding the stand together, then remove the top section
which is inverted within the larger stand base, and assemble in an upright position
re-using the original hardware.
Use the diagram of the mounting stand footprint or the mounting stand
itself (recommended) to mark at least one hole in each mounting tab from
the mounting stand.
Use the supplied (or other suitable) concrete anchors to anchor the
mounting stand to the mounting surface.
Ensure that the stand is on a reasonably level surface.

Transformer – Bushing Adapter Connections

A full parts and tools list for the Intellix™ BMT 300 installation is at Appendix 2, on
page 37.
The Bushing Adapter is supplied assembled, but with both “O” rings separately
packed. In overview, the installation has 4 distinct parts:
The whole sensor body is screwed into the bushing tapping point.
The top cover of the sensor is removed, leaving the body in place.

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 Intellix™ BMT 300 Installation Manual

The cabling is attached through the top cover and “O” ring.
The top cover is re-attached.

The rubber “O” rings must not be contaminated with

CAUTION
grease during the assembly process.
The length, in meters, of each the Bushing Adapter and
CAUTION
neutral sensor cables is required for the software set
up. It is suggested that all of the cables start the same,
known length. Then when they are cut to suit during
the connection to the Intellix™ BMT 300 cabinet, the
removed lengths can be measured and thus the actual
installed length calculated with accuracy.
It is advised that the bare ends of the sensor co-ax
CAUTION
cable are tinned or crimped, to ensure that there are no
stray strands of conductor when connected to the
terminal blocks.
All sensor cables from the Bushing adapters to the
CAUTION
Intellix™ BMT 300 cabinet MUST be run inside an
electrically grounded protective metal conduit. (see
Appendix 2 on page 37 for recommendations)

Figure 6: Bushing Adapter, with and without Top Cover

To install a Bushing Adapter:

Remove the bushing tap covers. Retain the tap covers in a safe place in
case the Intellix™ BMT 300 has to be decommissioned in the future.
With clean hands, put the smaller “O” ring in its seat, as shown in the left
hand illustration of Figure 6. Note: There are 2 spare “O” rings per bushing
adapter in the installation kit.

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Intellix™ BMT 300 Installation Manual

Put a smear of high temperature anti-seize grease on the thread at the

base of the sensor body. Run your finger around the thread to remove the
excess grease, so that it is just a thin film. See Table 1 on the next page
for recommended greases.
Screw the complete sensor body into the tapping point of the bushing.
First just hand-tighten and check that the resistance between the Bushing
Adapter body and the bushing well is less than 20 Ohms. Note: you may
have to scrape a little paint off the bushing well to get a good conductive
path.
Then, tighten the Bushing Adapter to 20 Nm (15 lbft), then to 40Nm (30 lbft)
and finally to 60 Nm (44 lbft). Doing it in these steps prevents the
possibility of metal-to-metal welding occurring. Finally, re-check that the
resistance between the Bushing Adapter body and the bushing well is still
less than 20 Ohms.
Remove the 5 Allen key screws from the ring around the sensor body and
lift off the top casing.

Choice
Base Mounting Thread Qty 5 Allen Key Screws
#

1 Graphite - 50 C5-A Copper anti-seize

2 C5-A Copper anti-seize C5-A Copper anti-seize

3 Heavy duty anti-seize Heavy duty anti-seize

Table 1: High Temperature Grease Recommendations

Thread the end of the coax sensor cable through the following, in this
order:
o The top cable sealing grommet.
o The top casing.
o The larger “O” ring. Do not allow grease to contaminate the “O”
ring.
Using a small screwdriver, open the clamps in the terminal connector and
connect the co-ax cable. The terminal is shown in Figure 7 below. The
co-ax core is to be connected to inner, Signal, terminal connection. The
co-ax shield is to be connected to the outer, Shield, terminal connection.
The correct connection orientation is shown in Figure 7.

Figure 7:
Bushing
Adapter
Terminal Block

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 Intellix™ BMT 300 Installation Manual

Place the “O” ring in its seat (the grey ring in the right hand illustration of
Figure 6 on page 16 above).
With the top cover above the top of all of the inner components, tighten
the cable grommet into the top of the centre of the top cover, ensuring
that there is a small loop of coax cable. This will ensure that in a future
top cover removal, the coax is not pulled out of the terminal block as the
top cover is lifted off.

Ensure that cable grommet is tightened onto the cable

CAUTION
and that there is a loop of cable inside the bushing
adapter as this provides strain relief to the sensor
cable.

Push the top cover down on its seat and re-assemble using the 5 screws.

Note: Use anti-seize lubricant, as recommended in Table 1 on the page

above, with these screws.

Tighten the 5 screws progressively; working across the circle, as shown in

Figure 8 below, rather than around the circle of screws, in order to
compress the sealing “O” ring evenly. Tighten the screws to 1.24Nm.

Figure 8: Tightening Order

Record the Bushing capacitance from the maker’s plate. This value will be
required during the cable testing at the Intellix™ BMT 300 cabinet.
Route all of the Bushing Adapter cables through armoured conduit to the
Intellix™ BMT 300 cabinet. It is desirable that the sensor cables are all left at the
same length until they are to be connected to the terminals inside the Intellix™ BMT
300 cabinet. When trimming the cables to suit, measure the removed lengths so

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 Intellix™ BMT 300 Installation Manual

that the actual cable lengths can be calculated. The cable lengths are entered into
the software, as the difference in the time of the pulse transmission through the
phase cables and the neutral is used to discriminate between internal and external
Partial Discharges. If the cabling is being routed as part of a pre-installation activity,
then ensure that the phase and cable length is marked on each sensor cable.

Transformer – Neutral Sensor Connection

The Neutral CT sensor, if it is to be fitted, will be particular to the transformer

connection point available (one of the pre-installation questions). Fit the CT clamp to
the neutral ground connection, an example is shown in Figure 9 below. Note that the
sensor arrow must point towards earth.

Figure 9: A Typical Neutral CT

As with the Bushing Adapter cables, the Neutral Sensor cable should be routed
through armoured conduit. It is desirable that the Neutral Sensor cable is left at its
original length until just before connection to the Intellix™ BMT 300 cabinet.
Measure the removed cable length so that the actual length of the Neutral Sensor
cable can be calculated and entered into the set up software. If the cable routing is
carried out as part of a pre-installation activity, mark the cable end to identify it as
the Neutral connection and its installed length.

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 Intellix™ BMT 300 Installation Manual

Transformer – Temperature Sensors

To install the sensors on transformer:

Apply a liberal amount of thermal compound on the metal probe located
in the center (Refer to picture below, arrow A).
Note: A lack of thermal compound degrades sensor performance.
Apply RTV silicon sealant around the edge of the magnetic temperature
sensor. This helps keep out moisture and aids in the adhesion.
The sensors should be attached at the top and bottom of the transformer, so
that the temperature differential can be measured. Note that the top (hot)
sensor has only a single cable gland; the bottom (cold) sensor has 2 cable glands.

Figure 10: Magnetic Temperature Sensors. Bottom left, Top right

The Bottom sensor is supplied with Four-core Ethernet cable already attached.
Route the longer cable to the Intellix™ BMT 300 cabinet and the shorter cable to the
single gland Top sensor. Figure 11 on the next page illustrates the terminal
connection inside the Top magnetic temperature sensor.

Notes:
The shield is to be connected at each terminal block in the sensor cable.
It is advisable that the cables are run inside conduit to provide protection
against mechanical damage. The conduit does not need to mate with
cable glands, nor provide EMC shielding.

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 Intellix™ BMT 300 Installation Manual

Bottom oil Top oil

sensor sensor

1 5
1 5

5 1

Terminal Key:
1 – 12 Vdc (red)
2 – CANH (green)
3 – CANL (white)
4 – Ground (black)
To BMT 300 5 – Shield
cabinet

Figure 11: Magnetic Temperature Sensor - Terminal Connections

Ambient Sensor

The ambient temperature and humidity sensor should be mounted by screwing

directly into the 25mm aperture located at the front left hand side of the gland plate
in the base of the Intellix™ BMT 300 cabinet.

Figure 12: Ambient Temperature & Humidity Sensor

The cable allocation is:

Black – Ground White – CANH
Red – 12 Vdc Green – CANL

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Communications – External connections

The RS485 cable from the local Transfix or dedicated modem is to be routed to
the Intellix™ BMT 300 cabinet. Or, if you have specified the Multi Master Fibre Optic
comms module, then route the fibre optic cable from your host to the Intellix™ BMT
300 cabinet. See the section entitled Communications – Internal Connections on
page 29 for the comms connection to be made inside the Intellix™ BMT 300 cabinet.
If using a local Transfix as the communications method, then follow the steps
below at the Transfix end of the communications cable.

The Transfix must have an internal RS485 connector. ie

CAUTION
the board must be 12-0253-03, or newer and the
Transfix must be running firmware that is revision
12.2.7, or later.
Turn off and isolate the Transfix before making this
WARNING modification.

Identify connector P28, as shown in the red rectangle in Figure 13 below.

Cut track between

LK3 pins

Figure 13: Transfix RS485 Terminal, P28.

Score between the pins of Link LK3 (circled in blue in Figure 13 above) to
cut the track.
Connect a 3 core cable to P28 and mark the Intellix™ BMT 300 end
according to the pin-out in Table 2 below.
Pin # of P28 P28 Intellix™ BMT
description 300 MODBUS pin
(see Figure 20)
1 (top) RS485 + MODA (pin 2)
2 (middle) RS485 - MODB (pin 3)
3 (bottom) GND Common (pin1)
Table 2: Transfix RS485 Pin Out

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 Intellix™ BMT 300 Installation Manual

Figure 14: RS485 Cable Connection at Transfix

The internal bus in the Transfix is to be enabled, using the Transfix software.

Intellix™ BMT 300 Cabinet Connections

ALL leads coming into the enclosure should have at least

WARNING 6 inches (150mm) of free length.
Do not open the cabinet during rain or snow storms
WARNING during the installation process.
Remove the 2 AC shields, shown in Figure 5 on page 14.
Earth

First connect the protective earth conductor to the primary earth protective
conductor terminal, which is adjacent to the fuse holder inside the cabinet. The
Intellix™ BMT 300 cabinet has a bonding lug located at the bottom of the left hand
side as you look at it; this is the secondary protective earth. This bonding lug, and
the mounting stand, MUST be connected to earth, in accordance with local practices
and safety codes.

Mains AC

Only use cables rated at 75 deg C, minimum, for the

WARNING installation.
An external circuit breaker must be installed on the AC
WARNING source, at a close proximity to the unit. It should be
labelled as the disconnecting device for the Intellix™ BMT
300. The circuit breaker should be in close proximity to
the Intellix™ BMT 300 and within easy reach of the
operator.
Fuses and/or an external circuit breaker must be installed in
WARNING accordance with the IEC 60947-1 and IEC 60947-3 standards,
the local and/or national wiring requirements.
The outer sheath of the mains supply cable should
WARNING continue into the equipment as far as possible so that
reinforced insulation is maintained between the operator
and mains supply.
The mains supply should be connected so that the
WARNING protective earth wire should be the last wire to take the

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 Intellix™ BMT 300 Installation Manual

strain and break free in the event of the cord being pulled
out of the cabinet. Tighten the cable gland to secure the
cable.

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 Intellix™ BMT 300 Installation Manual

Ensure that the Mains AC supply is de-

energised. Connect the Mains AC supply cable, Ground
through the left most cable gland of the cabinet for AC
to the Intellix™ BMT 300 Fuse Holder, which is supply
located on the inside of the cabinet door.
Ensure that there is enough slack in the cable to
allow for the cabinet door to open to its fullest
extent.
Note: For power supply wiring gauge and
length, refer to local/national wiring
requirements.
Bushing & Neutral Sensors Figure 15: AC Fuse Holder

Before connecting the bushing sensor cables to the

CAUTION
Intellix™ BMT 300 cabinet, test that the ground
connections have been made correctly: Confirm that
there is continuity from the shield of each of the
bushing adapter cable to the Intellix™ BMT 300 cabinet
ground terminal.

Do not pull the Bushing Adapter sensor cables tight; to

CAUTION
ensure that no strain is put on the Bushing Adapter end.

An overview of the Bushing Adapter connections is at Figure 16 below.

PCB input
terminals

Inter-
connecting
coax cables

Isolation/
grounding
block

Sensor cable
connections
Figure 16: Bushing Adapter Connections

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 Intellix™ BMT 300 Installation Manual

The RATED maximum WORKING voltage that may be

WARNING present on each phase is 5Vrms and the RATED maximum
current that may be present is 200mA. The measurement
category is CAT III, for circuits which can be connected to
any sensor cable connection.

The interconnecting coax cables should have been installed at manufacture. The
order of the PCB inputs is, from left to right:
Three secondary windings: phases A, B & C.
Three primary windings: phases A, B & C.
Neutral.
Two spare for high frequency inputs
As illustrated in Figure 17 below.
Note: At each terminal block, the coax centre is connected to the left and the
shield to the right.

Figure 17: PCB Phase Inputs

After connecting the sensor cables, it is crucial that the

WARNING Bushing Adapter circuit integrity tests below are carried
out.

Bushing Adapter Circuit Integrity Tests

After connecting the sensor cables, it is crucial that the following continuity
testing is carried out:
Ensure that the Transformer is switched off.
The safety switches for the sensor cables in the cabinet are to be set to
“operational”.
Disconnect ALL of the coaxial cables at the plugs shown in Figure 18 (left)
overleaf.
For each phase connection, in turn:

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Intellix™ BMT 300 Installation Manual

o Test the continuity between the sensor cable shield and ground at
the cabinet as shown in Figure 18 (centre) below. It should be less

than 5 Ohm.
Figure 18: Continuity Tests

o Test the resistance between the sensor cable core and the shield,
as shown in Figure 18 (right) above. It should equal the load
resistance on the Bushing Adapter; this is normally 100 Ohm, but
may have been varied to suit the particular Bushing, so confirm the
target load resistance with the Bushing Adapter specification
sheet. Note this as [R1]
o Test the capacitance between the cable core and shield. This
should be the similar, but slightly greater than the Bushing
capacitance, see the Bushing maker’s plate.
o Measure the resistance across the screws of the terminals (ie the
input resistance of the PCB circuits, as in Figure 19 below. Note
this as [R2].

Figure 19: Testing Motherboard Input Resistance

o Reconnect the coax plug of the phase.

o Re-test the resistance across the 2 screws. The resulting
resistance should be the parallel sum [R3] of the 2 resistances
measured above.

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 Intellix™ BMT 300 Installation Manual

[R3] = [R1]x[R2]/([R1]+[R2])
Note all of the above test values in a copy of the sheet at APPENDIX 5 –
BUSHING ADAPTER CIRCUIT INTEGRITY TEST RECORD.
Repeat for the remaining phases.

Store a completed copy of this record with the transformer maintenance

documents.
After periodic Transformer maintenance, or any Bushing repair activities,
these Bushing Adapter circuit integrity tests should be repeated.

Temperature Sensors

The oil temperature sensors are connected to the CANBUS connection block that
is on the inner side of the door, see Figure 4 on page 14. Note the pin outs of the
temperature sensors described at Figure 11 above, on page 21. Ensure that the
CANBUS connections are connected so that the CANH of the magnetic temperature
sensors is connected to the CANH input of the Intellix™ BMT 300 PCB, and likewise
for the CANL, 12V dc and ground terminals.
REPLACE THE AC PROTECTOR SHIELD ON THE INNER DOOR

The ambient temperature/humidity sensor is connected in parallel to the Relay PCB

input connector; see Figure 3 on page 13.
Ensure that the CANBUS connections are connected so that the CANH of the
combined temperature/humidity sensor is connected to the CANH input of the
Intellix™ BMT 300 PCB, and likewise for the CANL, 12V dc and ground terminals.

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 Intellix™ BMT 300 Installation Manual

Communications – Internal Connections

The MODBUS connector for the communications is the lower of the 3 inputs on
the right hand side of the PCB, circled in Figure 20 below. Note that pin 4, 12VDC is
not used when connecting to a Transfix device.

CANBUS pin out, from top to

bottom:
1: Ground [black]
2: Low [white]
3: High [green]
4: 12V [red]
5: nc
6: shield
MODBUS Pin Out, from top to
bottom
1: nc
2: nc
3: Common
4: MODA
5: MODB
6: nc

Figure 20: MODBUS Location & Pin Out

Serial Fibre-Optic (Optional)

If the serial multimode fibre optics comms option has been specified, then there
will be an extra module on the Intellix™ BMT 300 motherboard at the location
outlined in red on Figure 20 above.
The fibre optic module should be connected to a converter of the customer’s
choice if needed. If no converter is used, this procedure can still be followed for
proper connection. To connect to the Intellix™ BMT 300 serial fibre optic module:
The fibre optic cable coming from the host fibre optic Tx connector,
should go to the Rx connector of the Intellix™ BMT 300 serial fibre optic
module.
After this connection is done, then connect the fibre optic wire coming
from the Rx connector of the host fibre optic module to the Tx connector
of the Intellix™ BMT 300 serial fibre optic module.

See Figure 21 on the next page.

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 Intellix™ BMT 300 Installation Manual

LED transmitters for fibre optics are

WARNING
classified as IEC 60825-1 Accessible
Emission Limit (AEL) Class 1. Class 1
devices are considered to be eye-safe to
the unaided eye. Do not view directly with
optical instruments

Figure 21: Fibre Optic Connections on the Intellix™ BMT 300 Motherboard

Multi Master (Optional)

If the Multi Master communications option has been specified, there will be a
Multinet module on the inside of the cabinet door, see Figure 22 below.

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 Intellix™ BMT 300 Installation Manual

Figure 22: MultiNet Module in BMT 300

The MultiNet module will have been pre-wired so that all of the internal
communications are taken to the MultiNet. At site installation, connect the
consumer comms feed, be it Ethernet or optical, to the relevant connections on the
MultiNet module. Ensure that the comms cables are routed and tied correctly as
they cross the cabinet door hinge line.

LED transmitters for fibre optics are

WARNING
classified as IEC 60825-1 Accessible
Emission Limit (AEL) Class 1. Class 1
devices are considered to be eye-safe to
the unaided eye. Do not view directly with
optical instruments

GPS Antenna

The Intellix™ BMT 300 has a built-in GPS chip, which is used to provide a
date/time stamp to the event monitoring. The supplied GPS antenna has a magnetic
mounting. Place the GPS antenna in a position where it has a clear view of the sky.
Route the antenna cable into the Intellix™ BMT 300 cabinet, through one of the cable
gland entries. The antenna cable should be connected to the dedicated point at the
top right hand corner of the PCB, indicated in Figure 23 overleaf.

Figure 23: GPS Antenna Connection Point

The GPS antenna installation place must be carefully selected:

The antenna must have a clear line-of-sight of a significant portion of the
sky, so that GPS satellites’ signals can be received.
The antenna is magnetically mounted so a suitable ferromagnetic surface
must be found. This ferromagnetic surface must be grounded.

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 Intellix™ BMT 300 Installation Manual

As a fall-back, the installation kit is supplied with a 1” (2.5cm) length of DIN

rail 1” (2.5cm) square of double-sided adhesive tape. The DIN rail can be
stuck to the inside of the BMT 300 cabinet and the GPS antenna
magnetically mounted to the outside of the BMT 300 cabinet over the DIN
rail. If using this option, then ensure that the GPS antenna will have a
clear view of the sky when mounted on the exterior of the BMT 300
cabinet.
Although the antenna does not increase the likelihood of lightning strikel,
the surface itself must not be part of a structure that might potentially
become a lightning conductor.
The GPS antenna is supplied with a 7m cable, the maximum advisable cable
length is 100m; the cable can be extended by a customer supplied in-line extension
cable.
Note: If no suitable place is found (and no GPS antenna has been installed) or
GPS signal is lost during operation, the Intellix™ BMT 300 will use an internal clock to
time stamp events and data. This clock is continuously synchronised with the GPS
time when available. If no GPS is available at power up, Intellix™ BMT 300 will use
the time stamp of the most recent event or data to use as the current time. As soon
as GPS is available it will synchronise back to the GPS time. If communication is
established with Intellix™ BMT 300 and no GPS synchronisation has occurred, the
user will be asked to either synchronise Intellix™ BMT 300 to the PC’s time or to
manually set the time.
Alarm Relays

Three alarm relays are provided on a small PCB to the right of the main PCB,
shown schematically in Figure 24 overleaf. These relays can be used to drive a
hardware alarm, eg control room light, klaxon etc. The precise alarm conditions that
will active each of the relays is set up in the Intellix™ BMT 300 Monitor Software.
The maximum drive capacity of the relays is:
2A @ 240VAC, resistive load, or
2A @ 30VDC.
If connecting external alarms to these relays, route the cable up the right hand side
of the isolation bar, see Figure 3 on page 13.

If you connect external alarm devices, cable tie the

CAUTION
cables together as close to the relay PCB as possible.
Thus, if a conductor comes out of the terminal block, it
will be prevented from falling on to another electrical
component and causing a short circuit.

Only use cables rated at 75 deg C, minimum, for the

WARNING
installation

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 Intellix™ BMT 300 Installation Manual

Figure 24: Schematic of Relay PCB

The pin out, from top to bottom, is at Table 3 below:

Pin # Relay # Purpose Pin # Relay # Purpose

1 Relay #1 Normally Open 7 Relay #2 Common

2 Normally Closed 8 Ground

3 Common 9 Relay #3 Normally Open

4 Ground 10 Normally Closed

5 Relay #2 Normally Open 11 Common

6 Normally Closed 12 Ground

Table 3: Relay Connection Pin Outs

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 Intellix™ BMT 300 Installation Manual

Set Up

If you are not going to immediately set up the Intellix™ BMT 300, replace the
Perspex AC shield in the compartment.
After all of the connections have been made, the Intellix™ BMT 300 has to be set
up using the companion Intellix™ BMT 300 Monitor software. Please refer to the
Intellix™ BMT 300 User Manual for the software installation (on a laptop) and the
Intellix™ BMT 300 set up procedure. (Document number 40-0171)
Decommissioning
Before decommissioning make sure that original bushing tap covers are
available and in good condition.

Follow the steps below in the precise order, ensure that

WARNING
the Transformer and all AC supplies to the Intellix™ BMT
300 cabinet are de-energised before commencing the
de-commissioning.

Do not open the BMT 300 cabinet during rain or snow

WARNING
storms.

Before decommissioning download latest data if required (data can also be

retrieved later since it is internally stored in a SD card).
Carry out the following steps to decommission the Intellix™ BMT 300:
De-energise the Transformer.
Remove power from the AC supply to the Intellix™ BMT 300.
Remove power from the relay supplies that are controlled by the Intellix™
BMT 300.
Open the Intellix™ BMT 300 cabinet.
Remove the protective cover on the inside of the door. Remove the AC
supply cable from the fuse holder (see Figure 4 and Figure 15 respectively).
Remove the protective cover from the main body of the cabinet (see
Figure 5 ) and remove the relay control cables from the relay PCB (see
Figure 3).
Remove the SD card data storage from the motherboard. Copy the data
files to your laptop for a security copy.
Replace the Intellix™ BMT 300’s bushing adapters by the original tap
covers.
Remove cabling and external sensors (top and bottom temperature, GPS
antenna and neutral CT).
Remove cabinet and stand.
Re-energise the Transformer.

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 Intellix™ BMT 300 Installation Manual

APPENDIX 1 - MOUNTING STAND DIMENSIONS

Excerpts from the dimensioned drawings of stand that is used for Intellix™ BMT
300; these are the purposes of illustration only. If pre-installation work depends
upon the stand dimensions, please request the current issue of these drawings
before commencing any work.

Figure 25: Intellix™ BMT 300 Upper Stand Section

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 Intellix™ BMT 300 Installation Manual

Figure 26: Intellix™ BMT 300 Stand Base Section

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 Intellix™ BMT 300 Installation Manual

APPENDIX 2 – PARTS AND TOOLS LIST

Intellix™ BMT 300

o 1 x Intellix™ BMT 300 (Partial Discharge and Bushing Monitor) cabinet.
o 3 x Bushing adaptors (3 for basic installation, 6 for full installation),
each with 3 “O” rings.
o 1 x Neutral CT.
o 2 x Magnetic mounted temperature sensors.
o 1 x Ambient temperature and humidity sensor.
o 1 x Stand, or customer manufacture.
o GPS antenna.
o SD card (2Gb – 8Gb recommended)
Cables
o RG400 50Ω co-axial to connect bushing adaptors and neutral CT to
Intellix™ BMT 300 (235-5453 from RS). Length determined from pre-
installation.
o 4 core Ethernet cable to connect the magnetic mounted temperature
sensors the Intellix™ BMT 300, and to link Intellix™ BMT 300 to TransFix
if required (623-5921 from RS).
o Armoured mains cable (522-632 from RS) to power Intellix™ BMT 300.
o Grounding cable between Intellix™ BMT 300’s earth terminal and
ground.
o Metal conduit in sufficient length to provide protection to bushing
sensor cables and Neutral CT cable. Recommended type ½” conduit
from Thomas & Betts, (has a wide working temperature range and can
be buried or used in poured concrete).
Conduit ½” liquid-tight type ATLA050-30).
Liquid-tight fittings type 3322
o Plastic conduit in sufficient length to provide protection to the
temperature-sensor cables.
o Cable trays and cable ties to run the cables.
o Insulated crimps:
M5 ring type for the coaxial inputs (267-3616 from RS).
1.8mm 8mm long bootlace ferrule type for comms (458-702
from RS)
Tools
o Multimeter, capable of measuring capacitance
o Ratchet crimp tool.
o USB to 485 converter.
o 2.5mm Hex Torque Wrench bit.

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 Intellix™ BMT 300 Installation Manual

o 27mm spanner to fit Torque Wrench.

o Torque wrench, covering 60Nm (44 lbft) within its range.
o 1.25 Nm torque screwdriver.
o 3mm ball hex blade for Torque screwdriver.
o General tools (drill, drill bits, screwdrivers, cutter, spanners).
High Temperature Anti-Seize Grease

Choice
Base Mounting Thread Qty 5 Allen Key Screws
#

1 Graphite - 50 C5-A Copper anti-seize

2 C5-A Copper anti-seize C5-A Copper anti-seize

3 Heavy duty anti-seize Heavy duty anti-seize

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 Intellix™ BMT 300 Installation Manual

APPENDIX 3 – FRONT PANEL LIGHTS

Light Light Symbol Meaning

Colour

GREEN AC power applied

BLUE Service Required. Triggered by one of:

Low Bushing current warning
Power system frequency warning
No signal warning
Bushing R failure warning

YELLOW A measured parameter has exceeded a user-

programmed “Hi” alarm threshold.

RED A measured parameter has exceeded a user-

programmed “Hi-Hi” alarm threshold.

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 Intellix™ BMT 300 Installation Manual

APPENDIX 4 – TROUBLESHOOTING

The troubleshooting actions outlined in Table 4 below can be performed on-site

out by a qualified General Electric technician, or by authorised personnel.

Icon(s) Problem Action(s)

The green Power light Verify the AC power supply.

indicator does not turn Verify the protective circuit
on. breaker is set.
Verify the 3A fuses in the Live
and Neutral, see Figure 15 on
page 25

The red Alarm or Reset the alarm.

amber Caution light Check the Alarm or Caution
indicator is flashing. level setting.

The blue Service light Maintenance action is required,

indicator is flashing. contact GE customer service.

Table 4: Problems and Actions

During service access: Note that this unit may have

WARNING
more than one source of supply. Eg the alarm relays
may be from an independent AC supply. Disconnect all
supplies at their source before servicing.

The Intellix™ BMT 300 has no periodic maintenance

WARNING
required. If modifications must be made inside the unit,
turn off the external circuit breaker and ensure that the
green LED power indicator has turned off. Once inside
the unit, disconnect the seven (7) safety switches by
pulling each one of them down.

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 Intellix™ BMT 300 Installation Manual

APPENDIX 5 – BUSHING ADAPTER CIRCUIT INTEGRITY

TEST RECORD
The Bushing Adapter Circuit Integrity Test is to be carried out upon installation,
and any time that the Bushings or Bushing Adapters are disturbed. The test
procedure is:
Ensure that the Transformer is switched off.
The safety switches for the sensor cables in the cabinet are to be set to
“operational”.
Disconnect ALL of the coaxial cables at the plugs shown in Figure 27 (left)
below.

Figure 27: Testing Continuity

For each phase connection, in turn:

o Test the continuity between the sensor cable shield and ground at
the cabinet, as shown in Figure 27 (centre) above. It should be less
than 5 Ohm.
o Test the resistance between the sensor cable core and the shield,
as shown in Figure 27 (right) above. It should equal the load
resistance on the Bushing Adapter; this is normally 100 Ohm, but
may have been varied to suit the particular Bushing, so confirm the
target load resistance with the Bushing Adapter specification
sheet. Note this as [R1]
o Test the capacitance between the cable core and shield. This
should be the similar, but slightly greater than the Bushing
capacitance, see the Bushing maker’s plate.
o Measure the resistance across the screws of the terminals (ie the
input resistance of the PCB circuits, as shown in Figure 28 overleaf.
Note this as [R2].

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 Intellix™ BMT 300 Installation Manual

Figure 28: Measuring Motherboard Input Resistance

o Reconnect the coax plug of the phase.

o Re-test the resistance across the 2 screws. The resulting
resistance should be the parallel sum [R3] of the 2 resistances
measured above.
[R3] = [R1]x[R2]/([R1]+[R2])
Note all of the above test values in a copy of this sheet.
Repeat for the remaining phases.

Store a completed copy of this record with the transformer maintenance

documents.

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 Intellix™ BMT 300 Installation Manual

Results Table

Date:

Secondary C
Secondary A

Secondary B
Primary C
Primary A

Primary B
____________
N

Shield to ground
resistance

Cable core to
shield resistance
[R1]

Capacitance
between cable
core & shield

PCB input
resistance [R2}

Combined
resistance after
reconnection

Calculated value
[R3]

Page 43