QUALITROL STB-100 Series

QUALITROL STB-100-1 

QUALITROL STB-100-2 

Smart Transformer Breather

Operating Instructions
Document ID: IST-110-1 Rev-30919
Legal

Information in this document is subject to change without notice. This document is provided to purchasers of Qualitrol
products for use in the installation, operation and servicing of such products. No other use, nor any reproduction, distribution
or the making of any derivatives of this document is authorized, without the express prior written permission of Qualitrol.
Qualitrol endeavors to ensure the accuracy and quality of its published materials; however, no warranty, expressed or
implied, is provided. Qualitrol disclaims any responsibility or liability for any direct or indirect damages resulting from the use
of the information in this manual or products described in it. Mention of any product or brand does not constitute an
endorsement by Qualitrol of that product or brand.
This document was originally composed in English and was subsequently translated into other languages. The fidelity of
subsequent translations cannot be guaranteed. In case of conflict between the English version and another language version,
the English version takes precedence.

©2008 QUALITROL Company LLC, an ISO 9001 system certified company. All rights reserved. Information subject to change without notice.
®

All trademarks are properties of their respective companies, as noted herein. IST-099-1.

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About Qualitrol®
QUALITROL® manufactures substation and transformer monitoring and protection
devices used by electric utilities and OEM manufacturing companies. It is the global leader
in sales and installations of transformer asset protection equipment, fault recorders, and
fault locators. Established in 1945, QUALITROL® produces different types of products on
demand, customized to meet unique requirements.

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Table of Contents
List of Abbreviations/Acronyms .............................................................................................. 7 
Chapters in the manual .......................................................................................................... 8 
Introduction ............................................................................................................................ 9 
QUALITROL® STB .............................................................................................................. 9 
Operation ............................................................................................................................ 9 
Specifications ....................................................................................................................... 10 
Safety ................................................................................................................................... 11 
Installation ............................................................................................................................ 12 
Mounting the STB.............................................................................................................. 12 
Electrical Connection......................................................................................................... 14 
AC Power connections .................................................................................................. 14 
MODBUS Connections .................................................................................................. 14 
4-20 mA current loop ..................................................................................................... 15 
Regeneration status relay .............................................................................................. 15 
DIP Switch Setting for Frequency Generation ................................................................... 16 
Startup............................................................................................................................... 17 
Establishing Communication with STB Control Unit .......................................................... 18 
USB Communication ..................................................................................................... 18 
MODBUS Communication ............................................................................................. 26 
Troubleshooting ................................................................................................................... 29 
Alarms ............................................................................................................................... 29 
Priority of Alarms ........................................................................................................... 29 
Troubleshooting the USB Communication Link ................................................................. 31 
USB Communication ..................................................................................................... 31 
MODBUS Communication ............................................................................................. 31 
Annual Inspection .............................................................................................................. 32 
Servicing .............................................................................................................................. 33
Notes………………………………………………………………………………………………….35

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List of Figures
Figure 1.  Parts of STB .......................................................................................................... 9 
Figure 2.  Mounting Plate Dimensions ................................................................................. 12 
Figure 3.  Hose Barb ............................................................................................................ 13 
Figure 4.  AC Power Connections ........................................................................................ 14 
Figure 5.  MODBUS Connections ........................................................................................ 14 
Figure 6.  Current Loop ........................................................................................................ 15 
Figure 7.  Regenaration Status Relay .................................................................................. 15 
Figure 8.  Loosening the screw ............................................................................................ 16 
Figure 9.  Printed Circuit Board ............................................................................................ 16 
Figure 10. Cleaning the Filter ................................................................................................ 32 
Figure 11. Removing the Screw ............................................................................................ 33 
Figure 12. Removing the RH Sensor Cap ............................................................................. 33 
Figure 13. Blowing dry air ..................................................................................................... 34 
Figure 14. Inserting the RH Sensor Cap ............................................................................... 34 
Figure 15. Tightening the Screw ........................................................................................... 34 

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List of Tables
Table 1.  Parts of STB .......................................................................................................... 9 
Table 2.  Specifications ....................................................................................................... 10 
Table 3.  DIP Switch Setting ............................................................................................... 17 
Table 4.  Parameters .......................................................................................................... 20 
Table 5.  MODBUS Parameters.......................................................................................... 28 
Table 6.  Error Description .................................................................................................. 29 
Table 7.  Control Actions .................................................................................................... 30 
 

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List of Abbreviations/Acronyms

List of Abbreviations/Acronyms
Abbreviations/Acronyms Expansion

AC Alternating Current

DIP Dual In-line package

LED Light Emitting Diode

NEC National Electric Code

PCB Printed Circuit Board

RH Relative Humidity

STB Smart Transformer Breather

USB Universal Serial Bus

VAC Volts Alternating Current

VDC Volts Direct Current

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Chapters in the manual

Chapters in the manual

Chapters Description

Introduction Provides a product overview

Specifications Details product features

Safety Safety symbols and instructions

Installation Product installation instructions

Troubleshooting Alarm and error code information

Maintenance Provides inspection procedures

Servicing Provides instructions for routine maintenance

Notes Blank page for User Notes

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Introduction

Introduction
QUALITROL® Smart Transformer Breather
The QUALITROL® STB (Smart Transformer Breather) is a transformer accessory which removes moisture
from air entering oil-filled transformer or LTC conservators. Silica gel is the desiccant used to absorb
moisture. The system is automated to regenerate the desiccant at a user selectable interval of 5, 10, 20 or
40 days or when a relative humidity level is exceeded.
The device is available in two models:
1. Small air breather – for up to 8,000 gallons of tank oil
2. Large air breather – for up to 18,000 gallons of tank oil

Operation
Atmospheric air enters the STB and is routed through the silica gel desiccant to the top port, where a relative
humidity (RH) sensor continuously monitors the humidity level of the air exiting the breather to the
transformer. Based on the RH sensor input the microcontroller determines whether regeneration of the
desiccant is necessary. A heater placed at the center of the desiccant container regenerates the silica gel
based on either the RH level or the user selectable regeneration frequency, whichever occurs first. The
moisture from the desiccant then condenses on the outer polycarbonate tube and drains out of bottom port
of the STB. The regeneration occurs only during the exhale phase of the conservator. The built-in
intelligence system monitors the system’s status and automatically selects an appropriate time window for
desiccant regeneration. System status is communicated via a local USB port, local LED indication, MODBUS
protocol, 4-20 mA output, and a regeneration status relay.

Figure 1. Parts of STB

1 Sensor Block 4 Light Emitting Diode (LED)

2 Mounting Plate 5 Control Box

3 Polycarbonate Tube 6 Hose Barb Fitting

Table 1. Parts of STB

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Specifications

Specifications
Electrical
Voltage / frequency 100 – 240 VAC, 50 / 60 Hz

Inrush control Staged heating at 10 seconds (dual heater unit only)

Conducted/Radiated Emissions EN55011

EN61000-4-2, EN61000-4-3, EN61000-4-4, EN61000-
Immunity Tests
4-5, EN61000-4-6, EN61000-4-8, EN61000-4-11
Harmonics and Flicker tests EN61000-3-2 AND EN61000-3-3

Dielectric Isolation 1500 VAC for 60 seconds to ground

Functions
Regeneration frequency setting 5, 10, 20, 40 days

Solenoid valve 12 VDC

Humidity range RH 2% TO 100%

Pressure sensing Normally open, approximately 0.5 inch H2O to close

Status indication LEDs – green, amber, red

Regeneration frequency control 2 position DIP switch

Relative humidity trigger level User configurable: 50% default value

Regeneration cycle 3 hours full power, 1 hour cool-down

Regeneration status monitoring Relay – 4A, 30 VDC, normally closed

Failure detection RH sensor, pressure switch, heater, solenoid

Analog output signal 4 - 20 mA @ maximum 500 Ohms for RH

Communication MODBUS (remote) and USB (local)

Operating Conditions

Temperature -40 °C to 80 °C*

Relative humidity > 90 %

Enclosure protection IP55

Vibration 50/60 Hz @ .004” displacement

Table 2. Specifications
*Note that at temperatures less than 0°C, condensation in the tube may frost over – this does not affect the proper operation of the STB.

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Safety

Safety
The following symbols appear throughout the manual and indicate important safety
instructions:
WX Warning
Indicates information is important for personal safety. Failure to follow may result in
personal injury or death.
WCaution
Indicates information is important for the proper operation of the equipment. Failure to
follow may result in damage to the equipment.

WX Warning
 Switch off the power supply before performing installation, maintenance and/or
troubleshooting.
 Do not touch the STB when in operation (when the amber light is ON) as the
heater and polycarbonate tube can become hot.

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Installation

Installation
WCaution
Mounting the STB
1. Mount the STB in the vertical position shown. Do not mount on its back or side.

Figure 2. Mounting Plate Dimensions

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Installation
2. Connect the hose barb fitting to the sensor block and tighten it.

Figure 3. Hose Barb

Note: Seal the hose barb fitting using thread sealant to provide an air and water tight
seal.
3. Connect the hose between the hose barb fitting of the STB and the transformer.
WCaution
 Do not mount the STB in an enclosed cabinet, as that may block ventilation to the
unit.
 Do not block access to the inlet or outlet of the STB, as this can damage the unit.
 Make sure that the hose connecting the STB and the transformer does not contain
oil or debris.
 Make sure to connect the hose to the STB in such a way that oil cannot enter the
STB.
 Make sure to install the STB away from any heat source.

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Installation

Electrical Connection
WX Warning
Make sure to ground the STB according to local regulations.
Communications and relay connections must be made with shielded cabling.
AC Power connections
 AC power is applied to connector J15 as shown in Figure 4.
 Grounding has to be provided as a part of installation and it must be in accordance
with requirements of National Electric Code (NEC) or any international code that is in
effect locally.

Figure 4. AC Power Connections

MODBUS Connections
 RS-485 connector (J12) is located on the control board.
 For four-wire RS-485 connections, make the connections as shown in Figure 5.
 For two-wire RS-485 connections, short TX+ with RX+ to make T/R+ and short
TX- with RX- to make T/R-.

Figure 5. MODBUS Connections

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4-20 mA current loop

 The 4-20 mA curent loop output is located on control board (J9).
 Connect current sensing device to connector J9 with polarity as shown in Figure
6.

Figure 6. Current Loop

Regeneration status relay

Regeneration status relay connector (J3) is located on control board. Make the relay
connections as shown in Figure 7.

Figure 7. Regeneration Status Relay

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Installation

DIP Switch Setting for Frequency Generation

A DIP switch is provided to set the regeneration frequency at regular intervals regardless
of the humidity reading. This feature assures the STB will regenerate desiccant even
when the RH sensor shows an error. The DIP switch can be configured according to the
particular geographical conditions of the installation site at 5, 10, 20 or 40 days.
To set the frequency in DIP switch:
WX Warning
Make sure that the unit is de-energized from the power source before setting the DIP
switch.
1. Loosen the four screws on the control box and remove the cover, being careful not to
overextend the LED leads.

Figure 8. Loosening the screws

2. The DIP switch is located on Printed Circuit Board (PCB).

Figure 9. Printed Circuit Board

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Installation
3. Set the DIP switch position according to table 3.
DIP Switch Position Regeneration
Frequency
Position 1 Position 2

ON ON 5 Days

ON OFF 10 Days

OFF ON 20 Days

OFF OFF 40 Days

Table 3. DIP Switch Setting

4. Replace the control box cover and tighten the four screws.
Startup
To start the STB:
1. Verify that the STB is mounted in an upright position.
2. Verify that all electrical connections are properly made.
WCaution
3. Verify that the control box enclosure screws have been properly fastened: use
approximately 24 in-lbs torque to assure cover is fully seated and sealed. Tighten
power and communications cable glands so that they tightly grip cables, providing
sealing and strain relief to cables. Any unused cable gland entries should be plugged.
4. Energize the STB.
5. Verify that the green LED is lit.
Note: Make sure that the amber and red LEDs are OFF. The red LED will light
momentarily. If the green LED does not turn ON, refer to “Troubleshooting”.

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Installation

Establishing Communication with STB Control Unit

USB Communication
Using HyperTerminal or similar terminal emulator a user can utilize USB communication
for reading/writing certain parameters from/to the STB. The STB firmware supports a
menu based communication interface. The USB driver can be downloaded from

http://www.ftdichip.com/Drivers/VCP.htm

Follow the steps below to establish USB communication between a PC/laptop and the
STB:
1. Switch OFF the STB.
2. Connect the STB and a PC/laptop with a USB cable. Switch ON the STB unit.
3. Open HyperTerminal (or equivalent) on laptop/PC
4. Enter the session name and click OK.

5. Select the COM port assigned to the STB connection and click OK.

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Installation

6. Configure the communication properties and click OK.

 Bits per second: 19200
 Data bits: 8
 Parity: None
 Stop bits: 1
 Flow control: Hardware/None

A successful communication link is established when:

 User clicks on “Call” tab provided in HyperTerminal.
 A welcome string “Qualitrol’s Auto Regenerating Air Breather” appears on
HyperTerminal screen as shown below:

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Installation

User can read/write below parameters from/to breather unit:

Parameter R/W Description

Breather state R Normal mode/Regeneration mode

Regeneration status R ON/OFF

Run time DIP switch settings R Run time status of DIP switch

System up time R Time in days from last device restart

Humidity sensor value R Current relative humidity in percent

System error status R STB error status

DIP switch timer reading R Current DIP switch timer status in days

Humidity threshold R/W Current RH threshold for activating heater

Firmware mode W Firmware mode selection between release mode and

production test mode

Table 4. Parameters

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Installation

a) To read Breather State:

1. Press ‘x’ or ‘X’ to display the main menu.
2. Press ‘a’ or ‘A’ to select the read operation.
3. Press ‘1’ to read the breather state.

b) To read Regeneration Status:

1. Press ‘x’ or ‘X’ to display the main menu.
2. Press ‘a’ or ‘A’ to select the read operation.
3. Press ‘2’ to read the regeneration status.

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Installation
c) To read Run-Time DIP Switch Settings:
1. Press ‘x’ or ‘X’ to display the main menu.
2. Press ‘a’ or ‘A’ to select the read operation.
3. Press ‘3’ to read the run time DIP switch setting.

d) To read System Up Time In Days:

1. Press ‘x’ or ‘X’ to display the main menu.
2. Press ‘a’ or ‘A’ to select the read operation.
3. Press ‘4’ to read the system up time in days from last power ON.

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Installation

e) To read Humidity Sensor Value:

1. Press ‘x’ or ‘X’ to display the main menu.
2. Press ‘a’ or ‘A’ to select the read operation.
3. Press ‘5’ to read the current humidity sensor reading.

f) To read System Error Status:

1. Press ‘x’ or ‘X’ to display the main menu.
2. Press ‘a’ or ‘A’ to select the read operation.
3. Press ‘6’ to read the current system error status.

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Installation
g) To read DIP Switch Timer Reading:
1. Press ‘x’ or ‘X’ to display the main menu.
2. Press ‘a’ or ‘A’ to select the read operation.
3. Press ‘7’ to read the DIP switch timer reading in days.

h) To read Humidity Threshold:

1. Press ‘x’ or ‘X’ to display the main menu.
2. Press ‘a’ or ‘A’ to select the read operation.
3. Press ‘8’ to read the current humidity threshold setting.

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Installation

i) To write Humidity Threshold:

1. Press ‘x’ or ‘X’ to display the main menu.
2. Press ‘b’ or ‘B’ to select the write operation.
3. Press ‘a’ or ‘A’ to change the humidity threshold value.
4. Enter the threshold value from the available list.

Note: the Firmware mode option can only be factory set and requires a password. It can,
however, be read:
j) To read Firmware Mode:
1. Press ‘x’ or ‘X’ to display the main menu.
2. Press ‘a’ or ‘A’ to select the read operation.
3. Press ‘b’ or ‘B’ to toggle the firmware mode.
4. Firmware mode should read “Release Mode”.

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Installation

MODBUS Communication
MODBUS communication is supported with RS-485 2-wire and 4-wire mode to enable
remote monitoring and control of STB parameters.
In MODBUS communication, the STB acts as a SLAVE and 509ITM device acts as the
MASTER. Note: Check with factory to confirm availability of STB MODBUS on the 509ITM.
Follow the below steps to establish RS-485 communication between MODBUS Master
and STB:
1. Switch OFF the STB.
2. Connect the STB and MODBUS Master with suitable cable (for more details, refer
MODBUS Connections).
3. In MODBUS Master, open the GUI.
4. Select the correct COM port used for MODBUS communication.
5. Configure the rest of the communication parameters as shown below:
 Baud rate: 9600
 Data bits: 8
 Stop bits: 1
 Parity: Even
 Error Checking: CRC16
 Slave address: 1
6. Click on ‘Connect’ tab provided in Master GUI.
7. User can use function code 0x03 to read data from and 0x06 to write data to the STB.

Listed below is the MODBUS register map:

Parameter REG # Attributes Description

Breather State 0x0001 Read 0 = NORMAL

1 = REGENERATION

DIP trigger status 0x0002 Read 1 = ENABLED

0 = DISABLED

RH trigger status 0x0003 Read 1 = ENABLED

0 = DISABLED

DIP based regeneration status 0x0004 Read 1 = DIP BASED REGNERATION ACTIVE
0 = DIP BASED REGNERATION NOT
ACTIVE

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Installation

RH based regeneration status 0x0005 Read 1 = RH BASED REGNERATION ACTIV

0 = RH BASED REGNERATION NOT
ACTIVE

Regeneration frequency 0x0006 Read REGENERATION FREQUENCY SET BY

USER

Run-Time DIP switch setting 0x0007 Read RUN TIME DIP SWITCH SETTING

DIP based regeneration count 0x0008 Read TOTAL NUMBER OF DIP BASED
REGENERATIONS

RH based regeneration count 0x0009 Read TOTAL NUMBER OF RH BASED

REGENERATION

System up time in days 0x000A Read SYSTEM UP TIME FROM LAST BOOTUP IN
DAYS

Solenoid status 0x000B Read 0 = SOLENOID ACTIVATED

1 = SOLENOID DEACTIVATED

Pressure switch status 0x000C Read 0 = PRESSURE NOT DETECTED

1 = PRESSURE DETECTED

Humidity sensor reading 0x000D Read HUMIDITY SENSOR READING

Temperature sensor reading 0x000E Read TEMPERATURE SENSOR READING

Heater 1 status 0x000F Read 1 = HEATER 1 ENABLED

0 = HEATER 1 DISABLED

Heater 2 status 0x0010 Read 1 = HEATER 2 ENABLED

0 = HEATER 2 DISABLED

System error status 0x0011 Read SYSTEM ERROR STATUS WORD

Bit 0 = 1: DIP SWITCH ERROR
Bit 1 = 1: RH SENSOR ERROR
Bit 2 = 1: PRESSURE SENSOR ERROR
Bit 3 = 1: HEATER 1 ERROR
Bit 4 = 1: HEATER 2 ERROR
Bit 5-15: Unused, read as zero

Regeneration timer reading in hours 0x0012 Read REGENERATION TIMER READING

DIP timer reading in days 0x0013 Read DIP TIMER READING

System local display unit status 0x0014 Read SYSTEM LOCAL DISPLAY STATUS
Bit 0 = 1: NORMAL MODE
Bit 1 = 1: REGENERATION MODE

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 Bit 2 = 1: RH SENSOR ERROR
Bit 3-7: Unused, read as zero
Bit 8: HEATER ERROR
Bit 9: PRESSURE SENSOR ERROR
Bit 10-15: Unused, read as zero

Summary of system alarms 0x0015 Read ALL SYSTEM FLAGS PACKED IN A WORD
Bit 0 = 1: BRETAHER STATE
Bit 1 = 1: DIP SWITCH TRIGGER ENABLED
Bit 2 = 1: RH SENSOR TRIGGER ENABLED
Bit 3 = 1: DIP BASED REGNERATION
ENABLED
Bit 4 = 1: RH BASED REGNERATION
ENABLED
Bit 5 = 1: HEATER 1 ENABLED
Bit 6 = 1: HEATER 2 ENABLED
Bit 7-15: Unused read as '0'

Current humidity threshold setting 0x0016 Read/Write HUMIDITY THRESHOLD VALUE

25 / 30 / 35 / 40 / 45 / 50

Regeneration slot timings 0x0017 Read Bit 15-8: START TIME

Bit 7-0: END TIME

Firmware mode 0X0018 Read/Write 0x555: PRODUCTION TEST MODE

0xAAA: RELEASE MODE

Device learning status 0X0019 Read 0: LEARNING PROCESS NOT STARTED

1: LEARNING PROCESS STARTED

Table 5. MODBUS Parameters

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Troubleshooting

Troubleshooting
Alarms
Priority of Alarms
High: The STB will stop working and the defective part must be replaced.
Low: The STB will continue to work. The defective part has to be serviced or replaced as
per the requirement.
The following table lists the LED status and the corresponding errors:

Green Amber Red Error Description

ON OFF OFF Normal mode

OFF ON OFF Regeneration mode

ON OFF ON RH sensor error

OFF Blinking OFF Pressure sensor error

OFF OFF Blinking Heater error

Blinking Blinking Blinking Multiple errors

Table 6. Error Description

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Troubleshooting

The following table lists the alarm, priority and recommended control actions.

Alarm Priority Control Actions

Run time DIP Low Alarm is shown locally and transmitted to the remote monitoring
switch error device.
STB will continue operation with initial DIP switch settings.
STB control logic will continuously look for recovery.
RH sensor failure Low Alarm is shown locally and transmitted to the remote monitoring
device.
STB will continue working in auto-mode.
Regeneration frequency is reduced to default 5 days. Only DIP
switch trigger will be considered for regeneration.
STB control logic will continuously look for recovery.
Pressure switch High Alarm is shown locally and transmitted to the remote monitoring
failure device.
STB will stop working in auto-mode and starts operating in
conventional mode.
Manual servicing and device restart is required.
Heater failure High Alarm is shown locally and transmitted to the remote monitoring
device.
STB will stop working in auto-mode and starts operating in
conventional mode.
Manual servicing and device restart is required.

Table 7. Control Actions

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Troubleshooting

Troubleshooting Communications
USB Communication
If a problem occurs in establishing a USB communication link between the PC/laptop
and the STB:
 Check that the STB control unit is energized.
 Check that the cable connected to the COM port is assigned to the present USB
communication link.
 Check that the port parameter configurations like baud rate, data bits, parity, stop
bits, and flow control are correct.

MODBUS Communication
If a problem occurs in establishing a MODBUS communication link between the 509ITM
and the STB:
 Check that the STB unit is energized.
 Check that the RS-485 connection is made as per the guidelines in MODBUS
Connections.
 Check that communications parameters such as slave address, baud rate, data bits,
parity, stop bits, and CRC are correct.
 Check that the function code and address/data range are valid.

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Troubleshooting

Maintenance
The STB is equipped with a real time monitoring system that signals whenever there is a
malfunction.
Note: Check the STB regularly for proper operation.
Annual Inspection
For annual inspection of the STB:
1. Remove the two pan head screws at the bottom of the STB.
2. Take the filter out and inspect for contamination. If any contaminants are present
clean the filter with a soft brush before re-assembling.

Figure 10. Cleaning the Filter

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Servicing

Servicing
RH Sensor
To service the RH sensor:
1. Turn OFF the main power supply.
2. Remove the four pan-head screws and washers that hold the RH sensor cap to the
sensor block using the screwdriver.

Figure 11. Removing the Screw

3. Remove the RH sensor cap.

Figure 12. Removing the RH Sensor Cap

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Servicing

4. Gently blow moisture away from the RH sensor and RH sensor ports using a dry air
can.

Figure 13. Blowing dry air

5. Insert the RH sensor cap.

Figure 14. Inserting the RH Sensor Cap

6. Tighten the four washers and pan-head screws using the screwdriver.

Figure 15. Tightening the Screw

7. Connect the power to the unit.

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Notes

Notes

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