Transformer Health Monitor

Our Transformer Health Monitor uses patented Solid State Electrochemical Sensor Technology to directly measure Hydrogen levels, making it specific, selective, and intelligent to Hydrogen alone. Plus, our sensors have no cross-sensitivity to other combustible and reducing gases present in the transformer oil with a wide detection range from 0% to 10% Hydrogen v/v.

With strategic placement, our sensor analyzes the concentration and rate of Hydrogen outgassing from transformer oil, indicating the occurrence of any incipient fault. With over 92% of Hydrogen not soluble in oil, our Transformer Health Monitor is strategically placed to provide a simple and affordable first line of defense against violent transformer explosions and early diagnosis of faults for remedial action.

Our Transformer Health Monitor is designed as per intrinsic safety methods of protection, making it incapable of causing a spark that can trigger an explosion in hazardous areas. It weighs less than 350 grams and is 4-5X lighter and smaller than commercially available sensors for hazardous area installations.

Enable our sensor’s world-leading sensing capabilities in extreme temperatures – Coming Soon!

Product / Solution Features:
  • Low Cost: Low-cost alternative to online DGA systems
  • Real Time Monitoring: Enables real-time gas phase Hydrogen measurement for analysis
  • Fleet-wide monitoring with classification of transformers based on health criticality
  • Simple Design: Designed for ease of deployment with low downtime with no manual sampling or complex gas extraction systems required
  • Flexible design: Adaptable to different transformer types and constructions
  • Deployment Options: Can be deployed using adapters at various points including Buchholz Relay, Conservator Tank, and Breather Vent
  • Communication Options:
    • Wired communication through RS 485 protocol for interface with existing SCADA, PLC or data gathering systems
    • Wireless communication options available for cloud platform interfacing including GSM, LoRa, Wi-Fi and RF
  • Powerful analytics platform: Rule-based condition monitoring, information visualization, data historian, email alerts, and report generation capabilities
  • Intelligent learning engine: AI/ML and rule based engine that recognize anomalous behavior and pattern-based fault prediction.
  • Modular capability: extensible for additional sensing requirements.
Configuration Options / Technical Specification:
Hydrogen Concentration Terminology Conversion Table for Ease of Reference 250% H2 LEL = 10% H2 v/v in Air = 100,000 ppm H2 v/v
Performance Parameters Specifications
Selectable Range Range values are defined as H2 v/v in Background Gas
Start 0%
Span 10%
Resolution 0.005%
MDL 0.01%
Accuracy (MV=Measured Value) ± (50 ppm + 2% of MV)
Selectable Output Signal
Analogue Outputs Digital Output
4mA to 20mA (2-wire loop) ≤1,000 meters RS485 Modbus (4-wire) ≤1,000 meters
Standard Calibration Interface RS485 Modbus based digital calibration, via computer or Portable Calibrator
Purpose To classify the health condition of transformer, on the basis of measured Hydrogen concentration in gas phase, into following categories:

  • Healthy
  • Early Signs of Fault
  • Recurring Faults
  • Needs Immediate Action
  • Very Critical
Start-Up Time 2 seconds. Calibration mode interrupt allowed upon start-up within 2 second window
Response Time T20 to T90 in 1 second to 5 seconds
Cross Sensitivity No cross sensitivity to other combustible and reducing gases
Input Power Supply 24V DC (± 5%) | Maximum current consumption ≤ 30 mA.
Operating Temperature -20℃ to +65℃
Storage Temperature -20℃ to +65℃
Extreme Temperature Application The sensors have industry-leading performance parameters and can be used in extreme temperature conditions beyond their operating range. This is achieved by housing the sensor in a temperature-controlled chamber and using an aspirated system to condition (heat or cool) and draw multi-point sample gas to the sensor. This cost-effective solution maximizes the sensors’ performance while ensuring accurate measurements in extreme temperature conditions.
Operating Pressure 1 Bar to 1.5 Bar
Humidity 99% RH at 40℃ (Non-condensing)
Enclosure Rugged and sleek enclosure for tough outdoor as well as indoor applications.
Dimensions 98mm x 64mm x 34mm.
Material of Construction Powder Coated Die Cast Aluminium.
Weight < 350 grams
Sensing Surface Position Flush against gas exposure hole with detachable sampling cup, or threaded protruding sensor face for interface with adapter.
Ingress Protection IP 68 as per IS/IEC 60529:2001
Gas Exposure Method Diffusion. Gas exposure aperture ID 5 mm.
Mounting Flanges Stainless steel straight flanges for structural support (optional)
Compatible User Interfaces User’s SCADA, PLC, DCS, or other data acquisition and control systems which can accept a digital RS485 Modbus output or analogue signals like 4mA to 20mA.
MNST’s Modular Compatible Devices for Wireless Transmission to Cloud Platform
Calibration Periodicity Recommended cycle: Once in every 6 months for high accuracy applications.

Mandatory cycle: Once in every 12 months.

Calibration Procedure The sensor can be calibrated within 5 minutes using MNST’s Gas Calibration Setup, which consists of a calibration gas holder (for interfacing with sensor), a flexible PU pipe, rotameter, pre-certified calibration gas cannister and calibration controller (or Sensor to Computer Interface) which uses the RS485 Modbus line for calibration commands. Detailed procedure for calibration and a quote for the Gas Calibration Setup can be requested on our website.
Compatible Devices for Safe Area
  • Locally powered display unit
  • Multiple relay contacts
  • Wireless transmission hubs
  • Multi-sensor cluster hubs
  • Multi-channel control and display units with NO/NC relay contacts
Intrinsically Safe Internationally Certified Version Coming Soon!

The product is under certification process for IECEx, ATEX, UL, CSA, and PESO as per region specific standards equivalent to IEC 60079-0, IEC 60079-11, IEC 60079-29-1 and IEC 61010. The sensor must be powered through a certified Zener Barrier with matching parameters. The certified product shall be suitable for installation in Zone 0 and Class I Division I hazardous areas for Gas Group IIC, with “ia” method of protection, which provides for safe operation even with 2 countable faults.

Use Cases:

Oil cooled Generation Transformers, Transmission Transformers, and Distribution  Transformers.

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