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TABLE OF CONTENTS

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TABLE OF CONTENTS

List of Figures II

Summary III

1. 0 INTRODUCTION 11.1 Using This Manual 11.2 Documentation Scope and Updates 11.3 Instrument Warranty 21.4 Calisto/Calisto 2 Overview 31.5 Instrument Main Components 51.6 Standard Package Content 81.7 Options 9

2.0 INSTALLATION 112.1 Introduction 112.2 Mounting of Monitor’s Enclosure 12

2.2.1. General Considerations 122.2.2. Factory Installed 132.2.3. Field Retrofit 13

2.3 Wiring Connections 142.3.1. Monitor Interface Board 142.3.2. Connecting the Mains Power 162.3.3. Connecting the Alarm Relays 172.3.4. Connecting the Analog Outputs 192.3.5. Connecting the Analog Input 202.3.6. Connecting the RS-485 Communication 212.3.7. Connecting the RS-232 Communication 232.3.8. Connecting the Ethernet Communication 242.3.9. Connecting the USB Communication 26

2.4 Installing the Oil Lines 272.4.1. General Considerations 272.4.2. Factory Installation 272.4.3. Field Retrofit 282.4.4. Preparing the Transformer Valves 292.4.5. Attaching the Oil Lines 302.4.6. Purging the Oil Lines 32

2.5 Installation Summary 37

3.0 POWER UP 393.1 Important Checks before Power Up 393.2 Instrument Power Up 403.3 Display Interface 41

4.0 INSTRUMENT SETUP AND OPERATION 43

4.1 Connecting Locally Over USB 434.2 Calisto Access Software 44

4.2.1. Installing Calisto Access Software 444.2.2. Connecting to the monitor 444.2.3. Calisto/Calisto 2 Status 464.2.4. Entering Transformer Information 504.2.5. Communication Settings 514.2.6. Setting Alarm Limits 544.2.7. Relay Output Configuration 564.2.8. Fail-Safe Configurations 594.2.9. Selecting the Water Measurement Mode 604.2.10. Selecting the Oil Type 604.2.11. External Input Sensor Configuration 624.2.12. Downloading Data 634.2.13. Graphic Display of Data Bank 65

5.0 COLLECTING AN OIL SAMPLE 67

6.0 MAINTENANCE AND SUPPORT 69

APPENDIX I - Technical Specifications 71Standard Calisto/Calisto 2 On-line Monitor 71Precision Oil Temperature Probe –

Standard Edition 76Stainless Steel Braided Flex Lines 78Ethernet Outdoor Connectivity Kit 79

LIST OF FIGURES

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LIST OF FIGURES Figure 1: Front View (Calisto 2 model shown) ................................................................................................................................... 6Figure 2: Calisto/Calisto 2 - Bottom View .......................................................................................................................................... 6Figure 3: Calisto/Calisto 2 - Main Internal Components ................................................................................................................. 7Figure 4 : Calisto/Calisto 2 - Mounting Diagram ............................................................................................................................. 12Figure 5: Calisto/Calisto 2 - Interface Board Components ............................................................................................................ 15Figure 6: Calisto/Calisto 2 - Power Connections ............................................................................................................................. 16Figure 7: Calisto/Calisto 2 - Alarm Relays and Connections ......................................................................................................... 17Figure 8: Calisto/Calisto 2 - Analog Outputs Connector ............................................................................................................... 19Figure 9: Calisto/Calisto 2 - 4-20 mA Analog Input Connector ................................................................................................... 21Figure 10: Calisto/Calisto 2 - RS-485 Connection ........................................................................................................................... 22Figure 11: Calisto/Calisto 2 - RS-232 Connection ........................................................................................................................... 24Figure 12: Calisto/Calisto 2 - RJ45 Ethernet port ........................................................................................................................... 25Figure 13: Ethernet Outdoor Connectivity Kit Patchcord ............................................................................................................. 25Figure 14: Tee Fitting Assembly for the Precision Oil Temperature Probe Option ................................................................. 29Figure 15: Transformer Valve Elbow Fitting .................................................................................................................................... 29Figure 16: Adapting the Transformer Valve ...................................................................................................................................... 29Figure 17: Attaching the Copper Tubing to the INLET Port ....................................................................................................... 30Figure 18: Attaching the Copper Tubing to the OUTLET Port ................................................................................................... 31Figure 19: Monitor with Both Valves Closed .................................................................................................................................... 32Figure 20: Quick Connect Oil Sampling Tube .................................................................................................................................. 33Figure 21: Connecting the Quick Connect Oil Sampling Tube to the monitor ......................................................................... 33Figure 22: Flushing the Oil RETURN Tube ..................................................................................................................................... 34Figure 23: Flushing the Oil SUPPLY Tube ....................................................................................................................................... 35Figure 24: Disconnecting the Quick Connect Oil Sampling Tube from the Monitor ............................................................... 35Figure 25: Monitor with both Valves Open ...................................................................................................................................... 36Figure 26: Calisto/Calisto 2 Display Interface Structure ................................................................................................................ 42Figure 27: 6-Feet Long A/B Type USB Cable .................................................................................................................................. 43Figure 28: Calisto Access Status Tab with an Error Code .............................................................................................................. 47Figure 29: Error Code Interpretation Chart ...................................................................................................................................... 48Figure 30: Calisto Access Settings Tab ............................................................................................................................................... 51Figure 31: DNP3/RS485 ...................................................................................................................................................................... 53Figure 32: DNP3/TCP ......................................................................................................................................................................... 53Figure 33: Calisto/Calisto 2 Access Default Set-Up ........................................................................................................................ 56Figure 34: Oil Types Selection ............................................................................................................................................................. 61Figure 35: Calisto Access External Input Settings ............................................................................................................................ 62Figure 36: Calisto Access Graphic Plotting Panel– H2 ................................................................................................................... 66Figure 37: Calisto Access Graphic Plotting Panel – CO for Calisto 2 only ................................................................................. 66Figure 38: Calisto Access Graphic Plotting Panel – H2O .............................................................................................................. 66Figure 39: Quick Connect Oil Sampling Tube Connected to a 30cc Syringe ............................................................................. 67Figure 40: 30cc Syringe Connected to the Monitor SAMPLING Port ........................................................................................ 67

SUMMARY

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SUMMARY The Calisto/Calisto 2 monitor is designed to be permanently installed on critical transformers for continuous measurement of dissolved fault gases in dielectric insulating fluids. Calisto and Calisto 2 monitor hydrogen and moisture. Hydrogen is a reliable indicator of a recent or existing fault, as all fault types produce it to a greater or lesser extent. Calisto 2 additionally monitors carbon monoxide. Carbon monoxide and moisture levels may highlight undesirable deterioration of the paper/oil system, and conditions suitable for such deterioration. Calisto 2 provides the key measurements required to monitor the health of the insulation system, in order that informed service decisions may be taken, and major transformer problems may be avoided.

DISCLAIMER Calisto/Calisto 2 IED (Intelligent Electronic Device) has been carefully designed and engineered to provide maximum accuracy while continuously monitoring the concentration of dissolved gases in transformer oil. It is assumed by Morgan Schaffer that users will read the present Installation & Operation Manual and will understand the operation of the instrument prior to installation of the IED. All results obtained using Calisto/Calisto 2 monitor are based upon material and equipment under the responsibility of the client. Morgan Schaffer assumes no responsibility and makes no warranty or representation, expressed or implied, as to the condition, productivity or proper operation of any equipment or other property for which Calisto/Calisto 2 monitor may be used or relied upon for any reason whatsoever.

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1. 0 INTRODUCTION

1.1 Using This Manual An electronic version of this manual is available on the Calisto/Calisto 2 CD supplied with your monitor and at Morgan Schaffer’s web site www.morganschaffer.com. To access this manual on the website, click Instruments under Products. Then click either Calisto or Calisto 2 and then Downloads under the Menu (on the right). In order to use the electronic manual efficiently, proceed as follows after opening Acrobat Reader®:

1. Click Window, Show Bookmarks. 2. Click View, Fit Width. 3. Click View, Continuous.

When necessary, use the Zoom command to view drawing or picture details.

1.2 Documentation Scope and Updates This Installation & Operation Manual provides the required information for installing and setting up a Calisto monitor version C76-00000 or a Calisto 2 monitor version C85-00000 for operation. All types of signals, alarm relays and communications are also covered. Users should visit Morgan Schaffer’s website regularly at www.morganschaffer.com or contact us directly for documentation, firmware and software updates.

NOTICE

This manual applies for both Calisto and Calisto 2 monitors. Always consider if you are working with one or the other. Some sections of this manual apply for Calisto 2 only and are expressly marked “for Calisto 2 only”. If not stated, the section applies to both Calisto and Calisto 2 monitors.

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1.3 Instrument Warranty A 3-year warranty covers each new Calisto/Calisto 2 IED. In order to activate this warranty, the user must fill the Warranty Registration Form located in the documentation included with each instrument and fax it to Morgan Schaffer at 001.514.739.0434. An electronic version of this form is also available on the Calisto/Calisto 2 CD and can be e-mailed to [email protected] once it has been filled. Upon receiving the registration form, Morgan Schaffer will confirm the validity period of the warranty. End users may also visit our website and electronically register their monitor. In the main menu, under Products, click Instruments and then Calisto or Calisto 2. On the right side of the menu, click Registration. The warranty can be activated at any time within the 6-month period following the ship date from Morgan Schaffer. Additional information must be provided by the end-user if registration of the warranty is performed after the activation period. Extended warranties are available from Morgan Schaffer. Extended warranty confirmations will be provided at the time of their purchase or when the standard Warranty Registration Form is received.

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1.4 Calisto/Calisto 2 Overview Precise, accurate and continuous hydrogen readings allow detection of transformer incipient faults at their earliest stage. Hydrogen is a reliable indicator of a recent or existing fault as all fault types produce it to a greater or lesser extent. Hydrogen’s low solubility in oil and high diffusibility facilitate its early detection at low concentrations thus providing the earliest warning of the presence of a fault. Precise, accurate and continuous moisture readings allow correlations to be established between moisture in oil and transformer load. They also provide key information on long term trends of the insulation condition. In combination with polar products and acids, dissolved water can significantly affect the dielectric properties of insulating fluids and materials. Monitoring dissolved water over an extended period of time and undertaking proper action following sudden or abnormal increases in dissolved water content extends the life expectancy, performance and serviceability of oil-filled equipment. Additional continuous measurement of dissolved carbon monoxide in oil differentiates the Calisto 2 from the Calisto monitor. Carbon monoxide readings can help transformer specialists assess the remaining life of transformers. Carbon monoxide is often generated in large quantities when transformer cellulose overheats. Built-in oil circulation and flow monitoring assure reliability of the readings. Effective on-line monitoring of dissolved fault gases requires that sensors be in continuous contact with representative oil from the transformer, in order to react quickly to variations in gas concentrations. To guarantee accuracy and fast response to developing faults, Calisto/Calisto 2 features an oil circulation system based on an anti-cavitation reciprocating pump with an outstanding reliability record. In addition, an integrated oil flow monitor, also designed for maintenance-free operation and long-term reliability, provides a low-flow warning if the flow drops below a pre-set threshold, as may occur if a valve is inadvertently closed. Continuous enclosure and oil conditioning is essential for accurate readings. The most important source of interference on dissolved gas sensors comes from environmental temperature variations. Varying ambient and oil temperatures significantly affect the solubility and diffusion rates of dissolved fault gases, leading to baseline drift and signal variation. This often limits the ability of IEDs to monitor low levels of fault gases. Calisto/Calisto 2 features passive and thermo-electric temperature conditioning modules which continuously maintain both enclosure and oil temperatures constant to pre-set levels. This results in unequalled sensitivity, repeatability and long-term stability, independent of the environment where the instrument is installed. Reliable gas extraction and detection technologies are both crucial to produce reliable readings. As the oil within the Calisto/Calisto 2 is conditioned to a precisely regulated temperature, it is pumped past a bundle of PTFE capillary tubes which together form the gas probe. Dissolved gases permeate through the walls of the tubing to form a representative gas sample within the probe. Gases then diffuse along the capillary tubes to form a gas sample inside the detection cell. Any change in gases concentration in the oil will modify the equilibrium within the probe and the cell. The Calisto/Calisto 2 detection cell uses an enhanced version of Morgan Schaffer’s proprietary high-accuracy thermal conductivity detection (TCD) technology, to provide accurate gas

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measurements, without any field calibration, for the lifetime of the instrument. The Calisto and Calisto 2 detection cells take validated measurements for hydrogen and carbon monoxide (Calisto 2 only) every three hours. Validated measurements are continuously zeroed to guarantee long-term stability and low level detection accuracy. A continuous measurement of the hydrogen concentration is also performed for both monitors, to indicate any variation of hydrogen concentration which may occur between validated readings. Vacuum tolerance is made possible because of the intrinsic properties of the capillary tubing used to form the gas sample and because the oil circulating and conditioning systems inside the Calisto/Calisto 2 can both sustain vacuum. As a result, no action is required to protect the monitor if the transformer is put under vacuum for degassing purposes. Precise moisture measurement is achieved using a capacitive thin-film sensor immersed directly in circulating oil to continuously measure dissolved moisture. Moisture content can be reported in parts per million (ppm), %RS at 25 oC or %RS at a specific transformer temperature using the Expert Series Calisto Precision Oil Temperature Probe.

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1.5 Instrument Main Components The complete technical specifications of the two instruments are included in Appendix I of this manual. Prior to installing or commissioning the IED, users should understand the basic principles of operation of the instrument and identify the main components of the built-in systems. Both Calisto and Calisto 2 monitors feature substantially the same internal components and user interface hardware. The detection cells are calibrated differently and are specific to each monitor type. The instrument is usually installed permanently on a transformer or a pedestal-style mounting stand. The system requires that oil from the transformer be brought to the IED and then returned to the transformer. To accomplish this, Calisto/Calisto 2 features separate oil inlet and outlet ports. Oil circulation is achieved with the use of a small reciprocating pump (nominal flow of 60 ml/min. or 0.95 US gal/hr) located inside the instrument. Figure 1 on the following page shows the general front view of a Calisto/Calisto 2 which features a vacuum fluorescent display (ultra bright at day and night) and the three-button display interface. Figure 2 illustrates the main features visible on the bottom view of a Calisto/Calisto 2, including the oil inlet/outlet ports and the quick-connect oil sampling port. Figure 3 illustrates the main components inside a Calisto/Calisto 2. Calisto/Calisto 2 IED controls the oil temperature and the air temperature inside the enclosure using heat exchangers and thermo-electric elements. A waterproof long-life cooling fan, located at the bottom of the enclosure, provides the primary heat removal from the system. A small fan, located inside the enclosure provides temperature stability to the electronics and the gas measurement cell. When the system is in operation, date and time stamped measurements are stored in the instrument’s memory at a factory set storage frequency of one reading every 3 hours. This data can be retrieved and viewed graphically using Morgan Schaffer’s Calisto Access software. Data can also be viewed at any time on the door display, which provides the most recent validated hydrogen and carbon monoxide (Calisto 2 only) measurements, in addition to the real-time dissolved moisture measurements. Other instrument operation and manufacturing parameters can be viewed on the display. Section 3.3 describes the operation of the display buttons in detail.

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Figure 1: Front View (Calisto 2 model shown)

Figure 2: Calisto/Calisto 2 - Bottom View

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Figure 3: Calisto/Calisto 2 - Main Internal Components

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1.6 Standard Package Content

QTY. DESCRIPTION 1 Standard Calisto/Calisto 2 monitor 1 6-foot male A/B USB 2.0 cable for local connection 1 Calisto Access interface software CD-ROM 1 Quick Connect Oil Sampling Tube 4 Stainless steel vibration mount assembly 2 Copper tubing – 3/8 O.D. × 25 ft (7.6 m) 1 Thermal cut-off fuse (spare) 2 Brass elbow – ½ NPT (M) – 3/8" Tube 4 Brass nut – 3/8 Tube 4 One-lokTM brass ferrule – 3/8 Tube 1 Shipping box 1 Installation & Operation Manual (softcopy, also available on our website) 1 Factory Test Certificate 1 Declaration of Conformity

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1.7 Options Calisto Mounting Stand

For a fast and easy installation, Morgan Schaffer has designed a pedestal-style mounting stand for Calisto/Calisto 2. This stand is highly corrosion resistant and includes all required hardware to perform the installation in less than one hour.

Precision Oil Temperature Probe – Standard Edition

The Precision Oil Temperature Probe was specifically developed to meet client demands to report the %RS in oil at a specific transformer temperature in a truly accurate and reliable way. The 24 in. (610 mm) temperature probe is customized at the moment of the installation of the monitor and does not require any specifications from the client at the moment of the order. Refer to Appendix I for the complete technical specifications.

Stainless Steel Braided Flex Lines

The Stainless Steel Braided Flex Lines are a popular customizable option to the Calisto/Calisto 2 configuration that has the advantage of being highly resistant to corrosion and easy to install. Refer to Appendix I for the complete technical specifications.

Ethernet Outdoor Connectivity Kit

Calisto/Calisto 2 features an Ethernet port isolated to 1500 V. The Ethernet Outdoor Connectivity Kit includes all the necessary parts to bring a communication cable from the monitor to a control box switch/hub in an easy and reliable way. Refer to Appendix I for the complete technical specifications.

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Other available options: Insulation kit (for -50 to 55°C operation) IEC 61850 Ethernet communication kit 900 MHz radio modem over RS-485 2.4 GHz radio modem over RS-485 Quick-connect dust plug Calisto MultiTrack software Extended warranty up to 5 years On-site commissioning assistance

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2.0 INSTALLATION

2.1 Introduction

The following steps must be undertaken to properly install a Calisto/Calisto 2 IED on a transformer: Mounting of the monitor on a transformer or structure Electrical connections: power, alarms, signals and communication Attachment of oil circulation lines between transformer valves and IED Flushing of the oil lines with oil to remove air

The following tools are usually required for a standard installation: Pipe cutter (for copper oil lines only) Pipe wrench, 5/8 and 11/16 keys (or adjustable wrenches) Knife Small screwdriver (flat) Large screwdriver (flat) Installation kit for Calisto/Calisto 2

WARNING

IED’s should only be installed by qualified personnel familiar with their operation and associated hazards. Improper electrical or hydraulic circuitry may result in personal injury and/or instrument damage and may void warranty. Two persons are recommended for lifting the equipment.

NOTICE

Calisto/Calisto 2 is designed for industrial use and shall not be connected to the public low-voltage distribution system. Section 2.0 Installation applies for both Calisto and Calisto 2 monitors.

CAUTION

All IEDs are filled with new transformer mineral oil when shipped. DO NOT OPEN INLET AND OUTLET VALVES PRIOR TO INSTALLATION.

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2.2 Mounting of Monitor This section will provide guidelines on where to install the monitor on the transformer. Two different scenarios will be discussed. One will be based on the Calisto/Calisto 2 being shipped directly from a new transformer manufacturer or transformer rewinder (Factory Installed) and the other is based on a field retrofit.

2.2.1. General Considerations Calisto/Calisto 2 must be solidly bolted to a suitable support approximately 4 ft (1.2 m) above ground level to allow easy access to the internal oil sampling valves. A minimum of 24 in. (61 cm) is required for air circulation under the unit. The mounting structure should be located to protect the monitor from extreme vibrations. A typical location would be the side of the transformer control box. Vibration mounts (4) are provided with each monitor and should be used to provide the instrument with additional protection against possible vibrations. If the monitor is field installed, the use of a post bolted to the concrete base of the transformer is an ideal configuration. The Calisto/Calisto 2 mounting holes locations are shown in Figure 4. Standard dimensions are in inches and dimensions in brackets are in millimetres.

Figure 4 : Calisto/Calisto 2 - Mounting Diagram

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Electronic mounting and installation drawings are included in the provided CD.

2.2.2. Factory Installed In most cases the factory will install the monitor on Unistrut® brackets that are welded to the main transformer tank. Calisto/Calisto 2 is generally installed at eye level and two additional ½ inch valves are welded directly to the main tank near the monitor for the oil supply and return.

2.2.3. Field Retrofit In most cases the top oil fill valve and the main drain valve are located on the same side of the main tank. It is best to install the monitor near the bottom drain valve. Of course this location will vary as needed based on the oil lines requirements discussed later in this section. Typically Unistrut® brackets are used to make a base to mount the Calisto/Calisto 2. The mounting structure can be designed to clamp on to various members of the transformer tank, on the main control cabinet, on a post installed in the ground or concrete base. A Morgan Schaffer Calisto Mounting Stand is available as an optional accessory. Contact Morgan Schaffer for more information. A complete Installation Manual is included with the Morgan Schaffer Calisto Mounting Stand accessories. Refer to this manual when mounting a Calisto/Calisto 2 on it.

NOTICE The IED is designed to be installed vertically (as shown in this manual). The unit MUST NOT BE MOUNTED IN ANY OTHER ORIENTATION.

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2.3 Wiring Connections

The following section explains in detail the monitor interface board and how to connect the mains power, safety ground, alarm relays, analog signals, and communication cables to a Calisto/Calisto 2 monitor. Calisto/Calisto 2 monitor features a 4-hub detachable electrical entry plate made of stainless steel. All entry holes are 7/8 in. (22 mm) in diameter and can accept most ½ in. entry hub fittings. Four waterproof rubber entry hole plugs are provided with the instrument to cover unused holes.

2.3.1. Monitor Interface Board Opening Calisto/Calisto 2 enclosure door will provide access to the monitor interface board. Figure 5 shows the Calisto/Calisto 2 interface board main components. All connections to the monitor are made using this board. Items 1, 12 and 11 are respectively the mains power connectors, the thermal cut-off fuse and the over-current fuse. Items 10 and 2 are the programmable NO/NC dry-contact relays with their respective connectors. Items 4, 5, 6 and 7 are respectively the RS-485, RS-232, 4-20 mA analog input and 4-20 mA analog output connectors.

WARNING Electrical shock hazard. Only persons with electrical safety training and certification should install the equipment or open the enclosure once the equipment has been installed.

NOTICE It is recommended to select a shielded cable suitable for outdoor use for all communication and signal wiring. For any configuration, the installer must follow these guidelines:

Minimize the length of cable from the hub to the interface board (avoid loops); Protect against mechanical stress on wires and connectors attached to the interface

board;

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Items 8, 9 and 3 are respectively the USB type B port, the Ethernet port and the Ethernet shield earth jumper. The USB port is for local connection only, used during servicing or maintenance of the instrument.

Figure 5: Calisto/Calisto 2 - Interface Board Components

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2.3.2. Connecting the Mains Power

Protective earth connection is essential to guarantee client safety. To install the protective earth conductor to the earth ground terminal, secure the protective earth conductor tightly using the two screw terminals provided. It is the client’s responsibility to ensure the integrity of the ground cable and client-side ground connection. The Calisto/Calisto 2 monitor is designed to accept any supply voltage from 100 to 240 VAC with frequencies in the range 50 to 60 Hz. Mains power connections are made to connector 1 (neutral) and connector 2 (line) using either solid or stranded conductors (See Figure 6). Connections must be made in accordance with the connector ratings provided in the table below.

Figure 6: Calisto/Calisto 2 - Power Connections

RATING NOMINAL VALUE/RANGE Connection range 3.00 – 4.00 mm2 solid Connection range (UL/CSA) 14 – 12 AWG Wire strip length 9 mm (~3/8 in.)

Wire insulation ratings 300V, 90ºC (194ºF) or better

Flammability VW-1 or better Screw type M2.5

To connect the mains power, loosen completely each screw terminal, insert the conductor to the bottom of the terminal slot, and then tighten the screw.

WARNING

Install the protective earth conductor to the earth ground terminal before making any other connections. When uninstalling the unit, remove all other connections before removing the protective earth connection.

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The Calisto/Calisto 2 nominal power is 320W. The main supply switch may be used to turn the unit ON or OFF. A circuit breaker must also be dedicated to the unit for this purpose. Although the Calisto/Calisto 2 is equipped with an internal over-current fuse, it is strongly recommended that a suitable fuse or breaker be installed in the mains supply external to the unit, with rating appropriate to the supply voltage and nominal power.

2.3.3. Connecting the Alarm Relays

Calisto/Calisto 2 features 5 programmable dry-contact relays. Each relay can be connected in a normally open (NO) or normally closed (NC) configuration. All 5 relays are located on the monitor interface board as shown on Figure 7.

Figure 7: Calisto/Calisto 2 - Alarm Relays and Connections

WARNING

Electrical shock hazard. Alarm relays may be connected to hazardous live voltage even if the mains power is OFF or disconnected.

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The table below describes the alarm relays connections pinout assignment:

CONNECTOR NO. MARKING CONNECTION TYPE 1 RLY1_NC Relay 1 normally closed (NC) 2 RLY1_COM Relay 1 common 3 RLY1_NO Relay 1 normally open (NO) 4 RLY2_NC Relay 2 normally closed (NC) 5 RLY2_COM Relay 2 common 6 RLY2_NO Relay 2 normally open (NO) 7 RLY3_NC Relay 3 normally closed (NC) 8 RLY3_COM Relay 3 common 9 RLY3_NO Relay 3 normally open (NO) 10 RLY4_NC Relay 4 normally closed (NC) 11 RLY4_COM Relay 4 common 12 RLY4_NO Relay 4 normally open (NO) 13 RLY5_NC Relay 5 normally closed (NC) 14 RLY5_COM Relay 5 common 15 RLY5_NO Relay 5 normally open (NO) 16 SHIELD Shield to earth ground 17 SHIELD Shield to earth ground 18 SHIELD Shield to earth ground

Connectors 2, 5, 8, 11 and 14 are all commons and can be looped together into one single common if all signals must route to the same location. Connectors 16, 17 and 18 can be used to terminate an alarm cable shield to the earth ground. The relay connections must be made in accordance with the following connector ratings:

RATING NOMINAL VALUE/RANGE Connection range 0.5 – 2.5 mm2 stranded Connection range (UL/CSA) 22 – 141 AWG stranded Wire strip length 9 mm (~3/8 in.)

Wire insulation ratings 300V, 90ºC (194ºF) or better


To connect the relay connections, loosen completely each screw terminal, insert the conductor in the terminal slot until the bottom is reached, and then tighten the screw.

1 Using gauge 14 conductors to wire the relays may force the use of a larger diameter protective conduit thus enlarging one of the electrical entry holes. Two entry holes can also be dedicated to the alarm relays wiring as an alternative.

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Recommended use of the alarm relays:

AC CONNECTIONS Characteristic Nominal value/range Min./Max. switching voltage 5V/400VAC Rated resistive load 16A/250VAC Min switching current 5mA Coil-contact dielectric strength 5000VAC

DC CONNECTIONS

Characteristic Nominal value/range Min./Max. switching voltage 5V/300VDC

Rated resistive load

16A/24VDC 1A/48VDC 0.4A/100VDC 0.3A/(150-300)VDC

Min switching current 5mA Coil-contact dielectric strength 5000VAC

For more information on how to configure the alarm relays, refer to Section 4.2.6 Setting Alarm Limits and Section 4.2.7 Relay Output Configuration of this manual. The factory default alarm relays configuration can also be found at Section 4.2.7.

2.3.4. Connecting the Analog Outputs Calisto monitor features two 4-20 mA analog outputs, one for dissolved hydrogen and one for moisture. Calisto 2 features one additional 4-20 mA analog output dedicated for carbon monoxide. All analog outputs are isolated to 1500 V. The analog outputs screw-terminal plug-in connector is located on the monitor interface board (Refer to Figure 8). Although pin 8 and 9 are present in a Calisto monitor, no signal from this output can be used as Calisto does not report carbon monoxide.

Figure 8: Calisto/Calisto 2 - Analog Outputs Connector

It is recommended to un-plug the connector to simplify wiring the connections, and to screw the connector in place after the connections are made.

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The analog outputs connector pinout has the following configuration:

PIN NO. OUTPUT DESCRIPTION 1 N/A Shield to earth ground 2 N/A Shield to earth ground 3 N/A Unused 4 Moisture (H2O) Positive (+) 5 Moisture (H2O) Negative (-) 6 Hydrogen (H2) Positive (+) 7 Hydrogen (H2) Negative (-) 8 Carbon monoxide (CO) Positive (+) (Calisto 2 only) 9 Carbon monoxide (CO) Negative (-) (Calisto 2 only)

The analog outputs connections must be made in accordance with the following connector ratings:

RATING NOMINAL VALUE/RANGE Connection range 0.5 – 1.5 mm2 solid/stranded Connection range (UL/CSA) 22 – 16 AWG Wire strip length 6.5 mm (~1/4 in.)

Wire insulation ratings 150V (300V preferred2

90ºC (194ºF) or better ),


The load resistance can be anywhere from 0 Ohm to a maximum of 500 Ohms including resistance of the wires. Maximum length of the wires depends on the overall resistance of the load and acceptable noise level. The setup of the analog outputs is done using the Calisto Access software. Refer to Figure 33: Calisto/Calisto 2 Access Default Set-Up for more information.

2.3.5. Connecting the Analog Input Calisto/Calisto 2 features one 4-20 mA analog input that can be used to provide a reading of the transformer oil temperature to the unit. The 4-20 mA analog input is loop-powered to +13.5 VDC and isolated to 1500 V. The analog input screw-terminal plug-in connector (Refer to Figure 9) is located on the monitor interface board.

2 To preserve 1500V functional I/O isolation 300V rated voltage is preferred.

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Figure 9: Calisto/Calisto 2 - 4-20 mA Analog Input Connector

It is recommended to un-plug the connector to simplify wiring the connections, and to screw the connector in place after the connections are made. The 4-20 mA analog input connector pinout has the following configuration:

PIN NO. MARKING DESCRIPTION 1 SHLD Shield to earth ground 2 Unused 3 - 4-20 mA negative (-) 4 + 4-20 mA positive (+)

The 4-20 mA analog input connections must be made in accordance with the following connector ratings:





If the option Precision Oil Temperature Probe for Calisto/Calisto 2 was purchased with your instrument, refer to the Precision Oil Temperature Probe Manual. An electronic version of this manual can be found on our website www.morganschaffer.com. The configuration of the analog input temperature range is done via the Calisto Access software.

2.3.6. Connecting the RS-485 Communication Calisto/Calisto 2 features one RS-485 communication port isolated to 1500 V. The RS-485 uses a differential balanced line over twisted pair and can thus span relatively large distances, up to 4000 ft (1200 m). It is highly recommended to select an industrial grade shielded twisted pair cable of minimum 22 AWG to set up a communication via RS-485. The RS-485 screw-terminal plug-in connector is located on the monitor interface board (See Figure 10).



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Figure 10: Calisto/Calisto 2 - RS-485 Connection

It is recommended to un-plug the connector to simplify wiring the connections, and to screw the connector in place after the connections are made. The RS-485 connector pinout has the following configuration:

PIN NO. MARKING DESCRIPTION 1 SHLD Shield to earth ground 2 Unused 3 COMM Common signal ground 4 A Line A 5 B Line B

The RS-485 connections must be made in accordance with the following connector ratings:





The RS-485 common signal ground (pin 3, marked “COMM”) should always be wired properly to insure a reliable connection. The signal ground of an RS-485 cable must not be connected to the chassis ground or “SHLD” when optical or galvanic isolation is used at both ends. Since Calisto/Calisto 2 provides 1500 V isolation, it is recommended to use RS-485 devices that also offer good isolation. The signal ground conductor should be connected to pin 3 (COMM) and should be connected at all ends.


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The monitor interface board provides a 120 Ohm terminating resistor which may be used to terminate the RS-485 cable shield. The value of the terminating resistor is designed to match the characteristic impedance of the cable, and may be useful in cases where the monitor is on the end of an RS-485 network. Termination resistors are generally not required when communicating with a Calisto/Calisto 2 monitor at the standard speed of 9600bps. To connect the terminating resistor, install the jumper provided across J6 on the monitor interface board, just below the RS-485 connector. However, to determine whether or not termination resistors should be used, the cable length and data rate must be taken into account. If the propagation delay of the data line is less than one bit width, termination should not be required. Reflections would dampen out in several trips up and down the data line. Since the receiving device will sample the data in the middle of the bit, it is important to have a good signal level at that point. The propagation delay can be calculated by multiplying the cable length by the propagation velocity of the cable (usually specified by the cable manufacturer, typically between 66% and 75% of the speed of light). For example, in a system with 2000 feet of wire a round trip would cover 4000 feet. Using a propagation velocity of 66% of the speed of light, a round trip would be completed in about 6.2µs. If we assume the reflections damp out in three round trips, the signal would stabilize 18.6µs after the leading edge of a bit. At 9600bps one bit is 104µs wide: the reflections would be dampened out before the center of the bit, and therefore termination resistors would not be required. Calisto/Calisto 2 supports several protocols over RS-485:

MSSP (Morgan Schaffer Systems Protocol); DNP3 (widely used protocol specific to the electric utility industry); ModBus (widely used protocol in general automation industry);

Refer to Section 4.2.5 Communication Settings of this manual for more information on the above protocols.

2.3.7. Connecting the RS-232 Communication Calisto/Calisto 2 features one RS-232 communication port isolated to 1500 V. The maximum recommended range for RS-232 communication is 50 feet (15m). The RS-232 screw-terminal plug-in connector is located on the monitor interface board (See Figure 11).

CAUTION

Morgan Schaffer cannot be held responsible for a monitor communication malfunction if the RS-485 cable shield is not properly attached to pin 1 (SHLD). For RS-485 communication, the common signal ground is not a shielding/earthing ground.

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24 Version 1.10

Figure 11: Calisto/Calisto 2 - RS-232 Connection

It is highly recommended to select an industrial grade shielded twisted pair cable of minimum 22 AWG to set up a communication via RS-232. The RS-232 connector pinout has the following configuration:

PIN NO. MARKING DESCRIPTION 1 SHLD Shield to earth ground 2 Unused 3 GND Signal ground 4 RX Received data 5 TX Transmitted data

The RS-232 connections must be made in accordance with the following connector ratings:





The RS-232 signal ground (pin 3, marked “GND”) should always be wired properly to insure a reliable connection.

Calisto/Calisto 2 RS-232 communication port does not support other protocol than our proprietary MSSP.

2.3.8. Connecting the Ethernet Communication Calisto/Calisto 2 features one Ethernet port which allows the unit to be connected to a computer or a corporate LAN or WAN. The port is isolated to 1500 V. The port connector is located on the monitor interface board. Figure 12 illustrates the onboard RJ45 receptacle that can be shielded using jumper J7 (Ethernet shield to earth ground).


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Figure 12: Calisto/Calisto 2 - RJ45 Ethernet port

For installing an Ethernet link, it is recommended to use an industrial FTP or ScTP cable suitable for outdoor use (oil and sun resistant), even if a protection conduit is used. Proper connectors and fittings must be used to preserve the ingress protection of the monitor. This type of connection should not span over 100 ft (30m). The Ethernet connection must be made in accordance with the following connector ratings:

RATING NOMINAL VALUE/RANGE Connection range 0.5 – 1.5 mm2 solid/stranded Connection range (UL/CSA) 22 – 16 AWG Wire strip length 6.5 mm (~1/4 in.) Screw type M2.0

An FTP or ScTP shield must be connected to earth ground at only one end. Jumper J7 should only be connected if the cable shield remains disconnected on the client’s side. Grounding at both ends may lead to poor communication and/or damage to the instrument. IEC61850 protocol (optional) Calisto/Calisto 2 supports the IEC61850 substation protocol. This option can be selected at the moment of the order and can also be retrofitted to any Calisto version C76-00000 or Calisto 2. Ethernet Outdoor Connectivity Kit (optional) For an easy and reliable connection, the Calisto/Calisto 2 monitor can be installed with the Morgan Schaffer Ethernet Outdoor Connectivity Kit. This kit includes an IP68 industrial Ethernet shielded patchcord (custom length, refer to Figure 13) fitted with screwable end connectors and all required hardware to interconnect the monitor to a control panel. No protective conduit is required for this highly abrasion, oil and UV resistant cable.

Figure 13: Ethernet Outdoor Connectivity Kit Patchcord

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26 Version 1.10

Morgan Schaffer cannot guarantee protection from external surge (such as lightning or electrical arc) over 1500 V that could infiltrate the Ethernet line. It is the client’s responsibility to isolate the Ethernet line on the client side. Calisto/Calisto 2 supports several protocols over Ethernet:

MSSP (Morgan Schaffer Systems Protocol); DNP3/TCP (widely used protocol specific to the electric utility industry); Modbus (widely used protocol in general automation industry);

Refer to Section 4.2.5 Communication Settings of this manual for more information on the above protocols.

2.3.9. Connecting the USB Communication Calisto/Calisto 2 interface board includes a Type B USB jack. The USB connection does not provide high voltage isolation and is therefore only suitable for local connection using a laptop computer. This connection is convenient for initial configuration of communication and other settings. Driver installation is required in order to communicate over USB. Refer to 4.2.1 Installing Calisto Access Software.

INSTALLATION NOTES

Below are guidelines for the installation of the Ethernet Outdoor Connectivity Kit:

The RJ45 pass-through bulkhead provided requires a 1-inch hole and must be installed on a control cabinet.

UV stabilized cable ties are provided to secure the Ethernet patchcord.

Avoid installing the patchcord in any working or walking area.

The patchcord shield must be connected to the ground for interference immunity. A Calisto/Calisto 2 monitor ordered with an Ethernet Outdoor Connectivity Kit will have jumper J7 linking the onboard RJ45 receptacle shield to the earth ground. Thus, the client has no need to connect the shield on his side.

Avoid sharp bends to the cable.

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2.4 Installing the Oil Lines To ensure representative sampling of the transformer oil, it is important that the oil inlet and outlet valves on the transformer be distant as stated in the following section, to prevent oil re-circulation. The valves should have a minimum diameter of ½", and be located near the monitor.

2.4.1. General Considerations Optional shutoff valves (preferably ball valves) are recommended below the monitor on the

oil RETURN and SUPPLY lines to isolate the monitor if unmounting is required.

Minimum diameter of the valves of ½ NPT female, ball or gate valve type recommended;

The inlet and outlet valves must not be close to a pump;

The oil RETURN line must not exceed 35 ft (11 m);

The oil SUPPLY line must be longer than 3 ft (1 m) to reduce mechanical stress;

The distance between the two transformer valves should be a minimum of 3 ft (1 m);

The inlet valve should be at least 18 inches (0.45 m) above the main tank bottom;

Do not make straight lines between the transformer tank and the monitor. Include one loop or bend in the oil line;

In very hot conditions, it is strongly recommended not to insulate the oil lines;

In very cold conditions, it is strongly recommended to permanently insulate the oil lines.

2.4.2. Factory Installation Most transformer manufacturers will install two ½ inch oil valves directly on the main tank close to the location where the monitor will be installed. Both of these valves will generally be accessible from the ground level.

NOTICE

When installing a Calisto/Calisto 2 monitor with a Precision Oil Temperature Probe, a special probe fitting must be attached to the transformer valve before installing the oil SUPPLY line. Refer to the Precision Oil Temperature Probe Manual.

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28 Version 1.10

2.4.3. Field Retrofit Calisto/Calisto 2 requires two oil valves from the transformer. Typically the top oil fill valve and the bottom main drain valves are used. The preferred method is to draw oil from the top fill valve and return the oil through the bottom main drain valve. This only can be done if the top oil fill valve is below the top oil level. If the top oil valve is above the top oil level it will be necessary to draw oil from the bottom main drain valve and return it through the top oil fill valve. Drawing oil from the bottom main drain valve can pose some problems if there is an excessive amount of sludge from oil decomposition in the bottom of the transformer. Also, condensed water may accumulate at the bottom of very wet transformers.

Here are suggestions to determine if the top oil valve is below the top oil level:

How to determine if the top oil valve is below the transformer top oil level

Contact the transformer manufacturer

Contact the responsible party within your organization

Review the Outline drawings of the transformer and look for notes or review the instruction book supplied with the transformer.

Some transformers have a conservator tanks. A conservator tank is a large cylindrical or rectangular tank that sits above the transformer main tank. A pipe connects the conservator tank to the main transformer tank. If this is the case, the top oil valve on the main tank will be below the top oil level.

Compare the location of the oil level gauge to the location of the top oil fill valve. If the location of the oil level gauge is above the location of the top oil fill valve, most likely the top oil fill valve is below the top oil level. If the top oil valve is higher than the location of the oil level gauge, most likely the top oil fill valve is NOT below the top oil level.

Review the small print on the transformer nameplate. Many times there is a statement stating that the top oil level is X inches below the highest manhole cover on the top of the transformer. Compare this measurement to the location of the top oil fill valve.

Refer to Figure 1 and Figure 2 to view the oil inlet and outlet ports of the Calisto/Calisto 2 monitor.

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2.4.4. Preparing the Transformer Valves Prior to install the oil lines, both transformer valves selected to circulate oil to the monitor must be prepared to accept the tube fittings included in the accessories. Figure 15 shows one of the supplied brass elbow fittings 3/8″ tube to ½″ NPT male (stainless steel 316 if stainless steel flexible oil lines were ordered with the monitor). If required, use a pipe adapter to fit the ½″ NPT male end to the transformer SUPPLY and RETURN valves (Refer to Figure 16).

Figure 15: Transformer Valve Elbow Fitting

Figure 16: Adapting the Transformer Valve

CAUTION

If a Precision Oil Temperature Probe is to be installed with the monitor, a provided tee fitting must be installed instead of an elbow on the oil SUPPLY valve. Refer to the Precision Oil Temperature Probe Installation Manual.

Figure 14: Tee Fitting Assembly for the Precision Oil Temperature Probe Option

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2.4.5. Attaching the Oil Lines

1. Install the first oil line as follow: Unroll few inches of one of the supplied coiled 3/8″ copper tubing and insert one end firmly into the monitor INLET port (See Figure 17). Using a 11/16 key and a 5/8 counter-torque key, tighten the compression nut 1¼ turns from finger tight for proper sealing. Route the tubing properly to the transformer SUPPLY valve and cut off the excess length using a pipe cutter. Deburr the inside of the tube to prevent flow restriction. Both ends of the tubing should be straight for several inches where they enter the fittings. Incorporate at least one shallow bend somewhere in the tubing to aid installation. Tighten the tubing at the transformer SUPPLY valve (or at the tee fitting assembly when installing a Precision Oil Temperature Probe option) to complete the oil SUPPLY line installation.

Figure 17: Attaching the Copper Tubing to the INLET Port

2. Install the second oil line as follow: Unroll few inches of the second supplied coiled 3/8″ copper tubing and insert one end firmly into the monitor OUTLET port (See Figure 18).

3. Using a 11/16 key and a 5/8 counter-torque key, tighten the compression nut 1¼ turns

from finger tight for proper sealing. Route the tubing properly to the transformer RETURN valve and cut the excess length of tubing using a pipe cutter. Deburr the inside of

CAUTION

When attaching oil lines to the Calisto/Calisto 2, use a counter-torque key to avoid damaging the INLET and OUTLET ports on the monitor. The torque and the counter-torque keys must be aligned one over the other as much as possible to cancel induced forces. A pipe-cutter must be used to cut the oil lines. Other tools must be avoided as they can leave burrs, debris and scratches on the surface to be swaged.

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the tube to prevent flow restriction. Both ends of the tubing should be straight for several inches where they enter the fittings. Incorporate at least one shallow bend somewhere in the tubing to aid installation. Tighten the tubing at the transformer valve to complete the oil RETURN line installation.

Figure 18: Attaching the Copper Tubing to the OUTLET Port

4. Secure all oil lines against excessive vibration.

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2.4.6. Purging the Oil Lines

1. Once all connections are made, the lines and the monitor must be flushed with oil to remove any air present in the assembly and to replace the shipping oil inside the monitor with oil from the transformer. To do so, ensure that both monitor valves are still closed (valve handles in the horizontal position, refer to Figure 19), then slowly open both transformer valves.

Figure 19: Monitor with Both Valves Closed

2. Firmly push the supplied Quick Connect Oil Sampling Tube (fitted with ¼" yellow plastic tubing, refer to Figure 20) into the monitor’s oil SAMPLING port located at the bottom of the enclosure (beside the oil INLET port, refer to Figure 21).

CAUTION

Before continuing, Section 5.1 of the Precision Oil Temperature Probe Installation Manual must now be followed when the option is to be installed with a Calisto/Calisto 2.

NOTICE

Calisto/Calisto 2 monitor is equipped with a proprietary gas accumulator which will vent any air bubbles present in the incoming oil, once the monitor is in operation.

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Figure 20: Quick Connect Oil Sampling Tube

Figure 21: Connecting the Quick Connect Oil Sampling Tube to the monitor

3. Using a container to retain flushed oil, slowly turn the OUTLET valve (left side) counter clockwise ¼ turn (the handle will then be pointing down) to flush the RETURN line with oil (Refer to Figure 22: Flushing the Oil RETURN ). To avoid injecting trapped air in the transformer, flush a minimum of 500 cc of oil and then close the OUTLET valve by turning it clockwise to the horizontal position.

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34 Version 1.10

Figure 22: Flushing the Oil RETURN Tube

4. Slowly turn the INLET valve (right side) counter clockwise ¼ turn to the vertical position to

flush the SUPPLY line with oil. Now, turn the main supply switch to the <I> (ON) position to start the internal oil circulation pump to enable flushing (See Figure 23). To avoid injecting trapped air into the transformer, wait until a minimum of 500 cc of oil is flushed again and turn the main supply switch to the <O> position (OFF).

NOTICE

Before proceeding with Step 5, the following checks should be made: The earth ground is properly connected; The mains power is protected by a circuit breaker; The main supply switch is in the “O” position (OFF); Both transformer oil supply and oil return valves are open; Both monitor oil INLET and oil OUTLET valves are closed.

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Figure 23: Flushing the Oil SUPPLY Tube

5. While maintaining the INLET valve open, remove the Quick Connect Oil Sampling Tube from the oil SAMPLING port by pushing the locking ring up and pulling the fitting (with yellow hose) down (See Figure 24).

Figure 24: Disconnecting the Quick Connect Oil Sampling Tube from the Monitor

6. Open the OUTLET valve (left side). At this stage, both transformer valves and both monitor valves should be open as shown on Figure 25.

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Figure 25: Monitor with both Valves Open

7. The monitor is now ready for configuration. Refer to Section 4.0 INSTRUMENT SETUP AND OPERATION.

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2.5 Installation Summary Before starting the installation, ensure that the monitor main supply switch is in the <O> position (OFF), and that the INLET and OUTLET valves inside the monitor are closed (horizontal position).

1. Bolt the IED to a proper structure or Morgan Schaffer Calisto Mounting Stand using the provided vibration mounts.

2. Connect the earth ground and mains power.

3. Connect the alarm relays (if required).

4. Connect the analog 4-20mA outputs (if required).

5. Connect the analog 4-20 mA input (if required).

6. Connect the RS-485 or RS-232 or Ethernet line (if required).

7. Prepare the transformer SUPPLY and RETURN valves.

8. Connect the copper tubing (or stainless steel braided hoses) to the transformer valves and to the corresponding oil INLET and OUTLETS ports.

9. Connect the supplied Quick Connect Oil Sampling Tube to the sampling port and use a container to purge the oil RETURN line.

10. Open both transformer valves.

11. Open the OUTLET valve and purge 500 cc of oil from the monitor RETURN line.

12. Close the OUTLET valve.

13. Open the INLET valve and power ON the monitor to pump oil through the SAMPLING port. Purge 500 cc and power OFF the monitor.

14. Disconnect the Quick Connect Oil Sampling Tube from the SAMPLING port (do not close the INLET valve).

15. Open the OUTLET valve.

16. The monitor is ready to be configured. Refer to Section 4.0 INSTRUMENT SETUP AND OPERATION.

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3.0 POWER UP

3.1 Important Checks Before Power Up The following checks should be made before providing power to the monitor:

Verify that no tools or other equipment are present in the enclosure;

The earth ground is properly connected;

The mains power is properly connected;

All signal, relay and communication wiring is installed;

The monitor is protected by an appropriate circuit breaker;

Both transformer oil SUPPLY and RETURN valves are open;

Both instrument oil INLET and OUTLET valves are open;

All conduit fittings are fully tightened (rubber plugs are present on unused entry holes);

Verify that the instrument has a 24-inch (0.6 m) minimum clearance from the ground;

Verify that there are no excessive vibrations on the complete system;

Verify that the oil line connections have no leaks.

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40 Version 1.10

3.2 Instrument Power Up Once the instrument has been properly installed and the checks in Section 3.1 have been made, the instrument can be started by providing power to the unit and placing the main supply switch to the <I> position (ON). A delay of approximately 5 seconds will occur before a reading is displayed on the door display. This time is required by the instrument for firmware initialization.

When the Calisto/Calisto 2 is powered on or reset, the unit first enters an initialization and power-on self-test sequence. The purpose of this mode is to allow the on-board computer to evaluate temperature conditions and to allow the detection cell and moisture sensor to reach equilibrium with the surroundings. The duration of the initialization is 3 hours or one whole measuring cycle. During the entire time period of this mode of operation, the door display will indicate <H2= INIT> to inform of this normal condition. After completing this initialization sequence, the unit will then enter into its normal mode of detection and measurement, thereby displaying the last validated measurement for hydrogen <H2=000>. Carbon monoxide (Calisto 2 only) and moisture measurements can also be viewed on the display using the 3-button display interface. Refer to Section 3.3 for a complete description of the display interface operation. All readings will then be updated after the next measurement cycle, and subsequently time-stamped and stored as new validated measurement records in the on-board databank.

NOTICE

If the instrument temperature is below -35 oC at start-up, the IED will enter into a pre-heating mode where only the enclosure heaters will be activated. The instrument on-board computer will start once the enclosure temperature has reached -5 oC. Reaching the computer start-up temperature could take several minutes or even hours in extremely cold environments.

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3.3 Display Interface The 3-button display interface provides access to three different “sections” of information: Realtime <REALTIME>, Manufacturer <MANUFACT> and Database <DATABASE>. Buttons 1 and 2 pushed simultaneously are used to toggle between sections. Button 3 is used to scroll between fields in within the same section. Refer to for a complete overview of the display interface structure. Data are shown as examples only. Realtime Section By default, the instrument will show the last validated concentration of hydrogen <H2=000> under the section <REALTIME>. For a quick overview of all current measurements, button 3 must be pressed three times to see consecutively the carbon monoxide <CO=000>, the moisture <WRS=00> and the oil temperature <OTT=00>. With a Calisto version C76-00000, <CO=N/A> will be displayed while trying to access carbon monoxide measurement. By default, moisture is displayed as <WRS=00> for % relative saturation at 25oC, and the oil temperature will display <OTT=NONE> (inactive by default). Using the provided software Calisto Access, the moisture can be setup to show a % relative saturation at user selectable temperature <WST=00> or a concentration in ppm <WWC=00>. Note that user selectable temperature requires a Calisto Precision Oil Temperature Probe connected through the 4-20mA analog input. Refer to Section 4.2.11 External Input Sensor Configuration. Manufacturer Section To browse the monitor’s Manufacturer section, press once on buttons 1 and 2 simultaneously from the default display to access all the instrument information. Press Button 3 to access each field of the Manufacturer section (Refer to). This section provides useful information on the instrument such as the Serial Number, the firmware version and the date of manufacturing. The unit will return to the default section <REALTIME> after 10 seconds of inactivity. Database Section To browse the monitor’s database, press buttons 1 and 2 simultaneously twice from the default display to access all recorded data. Press Button 3 to access the record number and then press Button 1 to scroll down all data one by one starting from the most recent record to the oldest record: example <REC=299> to <REC=001>. Press Button 2 to scroll up to the newest record. At any time at any record number, Button 3 can be pressed to scroll through the fields of a specific record. For more information, refer to which shows the structure of the display interface for Calisto/Calisto 2. For a Calisto model C76-00000, the same structure applies excepted CO will be shown as <CO=N/A>. The unit will return to the default section <REALTIME> after 10 seconds of inactivity. Trends cannot be seen via the display. At any time, the user may get back to the current readings by pressing Buttons 1 and 2 simultaneously until displaying <REALTIME>. <H2=000> will be displayed after few seconds.

POWER UP

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INSTRUMENT SETUP AND OPERATION

Version 1.10 43

4.0 INSTRUMENT SETUP AND OPERATION

4.1 Connecting Locally Over USB Calisto/Calisto 2 can be set up for local, remote (hard wired) or wireless communication (not part of this manual). Calisto/Calisto 2 is supplied with a 6-foot (2-meter) A/B type USB cable (Refer to Figure 27). The USB port is dedicated to the monitor configuration, setup and maintenance.

Before connecting the USB cable to the monitor, open the door and access the monitor interface board. Connect the USB cable to the interface board port type B and to your portable computer port type A.

Figure 27: 6-Feet Long A/B Type USB Cable

WARNING

Electrical shock hazard. Only persons with electrical safety training and certification should install the equipment or open the enclosure once the equipment has been installed.


44 Version 1.10

4.2 Calisto Access Software This section describes the use of the Calisto Access software to quickly configure and commission a Calisto/Calisto 2.

4.2.1. Installing Calisto Access Software To install Calisto Access, insert the Calisto/Calisto 2 CD-ROM and wait for the Setup window to appear. Follow the on-screen instructions. At the Choosing Components step of the Calisto Access installation, make sure to check the USB Drivers box. A notification window may appear, choose the Continue Anyway option. At the end, Calisto Access setup will give the choice to immediately launch Calisto Access or not. Refer to next section before performing the first startup.

4.2.2. Connecting to the Monitor Prior to starting Calisto Access, your computer should be properly connected to the monitor using the supplied USB cable and proper drivers should be installed when asked by the operating system6

.

Press the Start button, select Programs, choose the Morgan Schaffer group and press on the Calisto Access icon. The software will automatically try to locate the proper communication port that is linked to the monitor. The screen shown below will appear if no problems are encountered during the communication initialization sequence.

Once a Calisto/Calisto 2 unit has been detected, the following screen will indicate the progression of the initial information readings from the unit. These readings are necessary to retrieve the basic settings of the monitor.

After a one minute timeout, the following message will appear if Calisto Access cannot find the port currently used for communication with the IED.

6 If having issues with the USB connection or material, refer to the help document on Morgan Schaffer website.



Version 1.10 45

Click OK, check the cable connections at both computer and IED ends and try to initiate communication manually. To do so, in the Communication/Configuration menu, click Modify. Be sure that in the Communication Link window the configuration is as follows: RS232 None None RS232.

Click Use this configuration. Select the serial COM port value from the Computer Port combo-box. It must be the same COM port with the one you selected to communicate.

To confirm which port is used, see My Computer / Properties / Hardware / Device Manager / Ports (COM & LPT). The path may differ depending on your system to get access to Device Manager. The line representing the Calisto/Calisto 2 is: IAR Virtual COM port, IAR STR912-SK board.


46 Version 1.10

Different connection steps may appear depending on your selected communication link. In the case that the error message reappears, close and re-start the application. If the issue is still not resolved, please contact Morgan Schaffer for assistance, either by e-mail at [email protected] or by phone at 001.514.739.1967.

4.2.3. Calisto/Calisto 2 Status The Calisto Access Status tab displays information about the currently connected unit. This screen appears once communication is established with that specific unit. In the first subdivision of the Status tab, the Unit Description information is found: the Calisto Model, Serial Number and Firmware Version.

COM4 in this example



Version 1.10 47

Figure 28: Calisto Access Status Tab with an Error Code

The Current Readings subdivision contains different measurements and trend values. The Validated H2 (ppm) field displays the last saved hydrogen value while the Continuous H2 (ppm) field shows the actual continuous hydrogen concentration. Also, for Calisto 2 only, the Validated CO (ppm) field displays the last saved carbon monoxide concentration. The H2O (ppm) field displays the actual ppm concentration or the calculated water relative saturation, according to the current water measurement mode set in the Measurements tab under H2O Measurements Mode section. In case of malfunction, an error message will appear in the Status tab, see Figure 28. An error code will be displayed along with the instrument components involved. The Error Code Interpretation Chart, found in Figure 29, explains the hexadecimal-based error code. This chart lists all possible error bits, their position and description. For example, the 8002 error code shown in Figure 29 is only an illustration of an error combination that could occur. This error code will also appear on the external monitor LCD display. Refer to Table 1 for description of individual error codes.


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Figure 29: Error Code Interpretation Chart


Version 1.10 49

ERROR CODE

(HEXADECIMAL) ERROR NAME DESCRIPTION

1 Outside Fan

This error only occurs when heat sink temperature (ST on display or OUTT in Calisto Real Time) is higher than 27°C and the external fan is not running. In that case, the fan is disconnected or has failed. Please contact Morgan Schaffer for assistance, either by phone at 001.514.739.1967 or by e-mail at [email protected].

2 Inside Fan

This error occurs when the internal fan is no longer running. Open the door and check manually the air flow. If no air circulation is found, the fan must be replaced. Please contact Morgan Schaffer for assistance.

4, 8, 400, 4000 Detection Cell Please contact Morgan Schaffer for assistance.

10, 20, 40, 80, 100, 200 Thermal Regulation Please contact Morgan Schaffer for assistance.

1000 Moisture Sensor Please contact Morgan Schaffer for assistance.

2000 External Input

This error occurs when analog input is not properly connected or missing. - Verify the current in the 4-20mA circuit with a

multimeter. - Verify connections for 4-20mA input pinout refer

to Figure 9. - Validate the 4-20mA generator functionality. If all above are correct, please contact Morgan Schaffer for assistance.

8000 Oil Flow

This error occurs when the oil flow is below the pre-set threshold. - Verify that all valves are open (transformer and

Calisto/Calisto 2). - Take an oil sample using the Quick Connect Oil

Sampling Tube as described in Section 5.0, and validate oil viscosity value.

If all above are correct, please contact Morgan Schaffer for assistance.

Table 1: Individual Error Code



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Current Alarm States subdivision contains the H2, H2O and Trend alarm states. Calisto 2 features also alarm states for CO. An alarm state is <ON> when the current reading exceeds the corresponding alarm level. Alarm levels are configured in the Outputs tab, as discussed in Section 4.2.6. Current Relay States subdivision shows the actual state of the five output relays. A red LED icon turns on when a relay is ENERGIZED. Hardware LEDs with the same functions can be seen on the entry panel. The relationship between alarm and relay states is configured in the Outputs tab, as discussed in Section 4.2.7.

4.2.4. Entering Transformer Information New Calisto/Calisto 2 units are shipped with numerous operating parameters configured to Morgan Schaffer factory defaults. Most of these parameters do not require client modification. However, to take full advantage of the Calisto/Calisto 2 communications, alarms and analog I/Os, it is necessary to adjust some settings to suit the specific transformer and installation. To modify the unit information parameters, establish communication using Calisto Access (refer to Section 4.2.2 Connecting to the monitor) and edit the information in the Owner, Location, Transformer ID, Date and Time fields.

NOTICE

Fields can be accessed using the mouse pointer or using the TAB key. New data will only be sent to the IED if the ENTER key is pressed. Moving to the next field without pressing the ENTER key will cancel changes made to the previous field.


Version 1.10 51

Figure 30: Calisto Access Settings Tab

4.2.5. Communication Settings The preferred method of adjusting the communication settings is though a local connection between a laptop PC and the Calisto/Calisto 2 USB port.

A few simple steps are required to configure the communication settings, as discussed below.

Calisto/Calisto 2 units have three available ports that can be accessed and set to different baud rates simultaneously and independently of each other. If a unit reboots, all ports will keep their baud rate setting if it has been changed.


52 Version 1.10

RS-485 Communication To communicate with other devices on an RS-485 network, each monitor must be assigned an RS-485 ID (range 01 to 99) which is specific on that network. In a RS-485 network consisting of multiple Calisto/Calisto 2 units, every unit is then available for connection. The RS-485 ID is used as the monitor ID for all protocols: DNP3/RS485, DNP3/TCP, Modbus, MSSP (Morgan Schaffer Systems Protocol). Ethernet Communication Each Calisto/Calisto 2 unit has an Ethernet interface, which requires a specific IP address, subnet mask and gateway. Note that the IP address is normally specific, and that the subnet mask is normally common to a group of Calisto/Calisto 2 units. The subnet mask defines your local network boundaries. To obtain an appropriate IP Address and Subnet Mask for your monitor, contact your network administrator.

DNP3 Protocol If you are using RS-485 communication, select the DNP3 protocol in the RS-485 protocol field and press the Configure button which appears. If you are using Ethernet communication, press the Configure DNP3/TCP button. In both cases, a DNP3 Configuration window will appear, refer to Figure 31 for RS-485 and to Figure 32 for Ethernet. The Requires Data Link Confirmation parameter can be set to <ALWAYS> or <NEVER>. In the first case, Request Link Reset is enabled while in the second case it is disabled. Also, set the Maximum Application Layer Retries parameter to the desired value [0 to 6]. Set the DNP3 Master Address parameter to the desired one [1 to 99]. To allow Calisto/Calisto 2 to generate a Change Event for one of the Binary Inputs or Analog Inputs, set the Class of those to Class 1, otherwise set it to Class 0. If using DNP3 on Ethernet, the TCP Connection Timeout (minutes) has to be set. Only one connection is accepted by Calisto/Calisto 2 on the DNP3 port: 20000. Once established, this connection has to be maintained by sending a “keep-alive” DNP3 message within the timeout specified by the TCP Connection Timeout value. To obtain the implementation table or for any other questions concerning the DNP3 protocol, please contact Morgan Schaffer either by e-mail at [email protected] or by phone at 001.514.739.1967.

CAUTION To ensure reliable operation in the face of possible security threats, the Calisto/Calisto 2 should not be connected to the Internet without encryption or password protection. If there is a concern about the security of the LAN, a VPN router may be used to connect the Calisto/Calisto 2 to the LAN with encryption security.



Version 1.10 53

Figure 31: DNP3/RS485

Figure 32: DNP3/TCP

Modbus Protocol Modbus protocol can be activated on the RS-485 communication port of Calisto/Calisto 2 and only using the default settings, i.e. baud rate 9600, 8 Data bits (RTU); 7 Data bits (ASCII), No parity and 1 Stop bits. Both RTU and ASCII transmission modes are supported. The communication has half-duplex functionality such that a new query must await the response to the previous query. The Modbus/TCP protocol can be accessed through port 502 at Ethernet 1. The Modbus/TCP connection will automatically be closed by Calisto/Calisto 2 if no other query is issued within a three hour period. To obtain the implementation table or for any other questions concerning the Modbus protocol, please contact Morgan Schaffer either by e-mail at [email protected] or by phone at 001.514.739.1967. IEC61850 If the Calisto/Calisto 2 unit has the IEC61850 option installed it will be possible to change the IP address, subnet mask and gateway of the IEC61850 module. Note that the IP address is normally specific, and that the subnet mask is normally common to a group of Calisto/Calisto 2 units. The subnet mask defines your local network boundaries. To obtain an appropriate IP Address and Subnet Mask for your monitor, contact your network administrator. To obtain the implementation table and the ICD file or for any other questions concerning the IEC61850 protocol, please contact Morgan Schaffer either by e-mail at [email protected] or by phone at 001.514.739.1967.




54 Version 1.10

4.2.6. Setting Alarm Limits For both monitors, alarm limit values can be adjusted for dissolved hydrogen and water from the Calisto Access interface, under Outputs. In the case of Calisto 2, carbon monoxide alarm limit values can also be adjusted this way. For each transformer being monitored, alarm limit values should reflect the actual concentrations of dissolved gases and moisture in accordance with the client’s policies.

NOTICE

Morgan Schaffer recommends the following to establish the best levels of alarm limit and trend values: Work with the transformer manufacturer; Consult an industry expert; Carry out a statistical analysis of gas levels on a population of similar transformers

being used in similar loading, environment, etc.


Version 1.10 55

Factory default alarm limits are set as follows.

ALARM CONDITION LEVEL FACTORY

DEFAULT DETECTION

RANGE

Cali

sto H

ydro

gen H2 Validated Alarm 1

H2 Continuous Alarm 1 LOW 250 ppm 2 – 50,000 ppm

H2 Validated Alarm 2 H2 Continuous Alarm 2 HIGH 500 ppm 2 – 50,000 ppm

Wat

er H2O Alarm 1 LOW 30 %RS @ 25 °C 0 – 100 %

H2O Alarm 2 HIGH 60 %RS @ 25 °C 0 – 100 %

Cali

sto

2

Hyd

roge

n H2 Validated Alarm 1 H2 Continuous Alarm 1 LOW 250 ppm 2 – 50,000 ppm

H2 Validated Alarm 2 H2 Continuous Alarm 2 HIGH 500 ppm 2 – 50,000 ppm

Wat

er H2O Alarm 1 LOW 30 %RS @ 25 °C 0 – 100 %

H2O Alarm 2 HIGH 60 %RS @ 25 °C 0 – 100 %

Car

bon

Mon

oxid

e CO Validated Alarm 1 LOW 500 ppm 25 – 100,000 ppm

CO Validated Alarm 2 HIGH 1,000 ppm 25 – 100,000 ppm

Trend values are calculated from the databank of validated readings, by linear regression across the most recent trend period (day, week, or month). A trend of INIT is reported if fewer than 8 validated readings are available in the trend period. The trend calculation accommodates missed readings, as may occur if the unit is turned off during part of the trend period. It is the client’s responsibility to set trend periods and the trend limits to suit the transformer and the installation. Note that short trend periods and low trend limits may increase the likelihood of false trend alarms. Factory settings for trends limit values are given in the table below:

ALARM CONDITION

FACTORY DEFAULT TREND UNIT

Trend

H2 Trend Alarm 500 ppm/month CO Trend Alarm (Calisto 2 only) 2,000 ppm/month

H2O Trend Alarm 50 ppm/month


56 Version 1.10

4.2.7. Relay Output Configuration Calisto/Calisto 2 is equipped with 5 N.O./N.C. dry-contact relays. Flexible relay configuration options are provided under the Outputs tab of the Calisto Access interface, see Figure 33. Each relay has two Response Modes. Usually, the <is energized> Response Mode is used. The <blinks> Response Mode can be useful to confirm dynamically that relay connections are operational. Each relay response can be inverted if the Logic parameter is changed from the default <when>, to <when not>. Finally, the Condition to which the relay responds can be selected from a drop-down list which includes Alarms, Errors and some combinations of Alarms and Errors.

Figure 33: Calisto Access Default Set-Up

Condition Relay Response

Mode

Logic


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The Conditions which can be assigned to each relay are:

1. Alarm Conditions. Alarms occur when measurements exceed configured limits. (See Section 4.2.6. Setting Alarm Limits)

H2 Validated Alarm 1 H2 Validated Alarm 2 H2 Continuous Alarm 1 H2 Continuous Alarm 2 H2 Trend Alarm H2O Alarm 1 H2O Alarm 2 H2O Trend Alarm CO Alarm 1 (Calisto 2 only) CO Alarm 2 (Calisto 2 only) CO Trend Alarm (Calisto 2 only)

2. Self-Test Error Condition. Self Test Errors occur when the monitor detects a problem with its operation. Examples include oil flow, fan or 4-20 mA input errors.

3. Always. Can be used for testing, or as an indication that the unit is running. 4. Combination Conditions. Combinations of Alarms and/or Errors, as shown in the table

below. Any Alarm Any H2 Alarm Any CO Alarm (Calisto 2 only) Any H2O Alarm Any Validated Alarm Any Continuous Alarm Any Trend Alarm Any Alarm or Self-Test Error


58 Version 1.10

H2

Val

idat

ed A

larm

1H

2 V

alid

ated

Ala

rm 2

H2

Cont

inuo

us A

larm

1H

2 Co

ntin

uous

Alar

m 2

H2

Tren

d A

larm

H2O

Alar

m 1

H2O

Alar

m 2

H2O

Tre

nd A

larm

Self-

Test

Err

orCO

Ala

rm 1

(Cal

isto

2 on

ly)

CO A

larm

2 (C

alist

o 2

only)

CO T

rend

Ala

rm (

Cali

sto

2 on

ly)

Any Alarm X X X X X X X X X X X

Any H2 Alarm X X X X X

Any H2O Alarm X X X

Any Validated Alarm X X X X

Any Continuous Alarm X X X X

Any Trend Alarm X X X

Any Alarm or Self-Test Error

X X X X X X X X X X X X

Any CO Alarm (Calisto 2 only)

X X X


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The default configuration for the relays for Calisto and Calisto 2 is as shown below.

RELAY NO.

RESPONSE MODE

LOGICAL CONDITION

EVENT FOR CALISTO

EVENT FOR CALISTO 2

Relay 1 Is energized When H2 Validated Alarm 1 H2 Validated Alarm 1 Relay 2 Is energized When H2 Validated Alarm 2 H2 Validated Alarm 2 Relay 3 Is energized When H2O Alarm 1 CO Validated Alarm 1 Relay 4 Is energized When H2O Alarm 2 CO Validated Alarm 2 Relay 5 Is energized When Self-test Error Any H2O Alarm

4.2.8. Fail-Safe Configurations Two different “fail-safe” relay configurations may be of particular interest: First, any of the relays may be configured to be “energized-when-always”. This relay then serves as an indicator that the Calisto/Calisto 2 has lost power or stopped running. Second, any relay can be configured to indicate loss of power OR a relay Condition, by selecting the “energized-when not-condition”. When deciding on the use of N.O. or N.C. contacts, the fail-safe wiring configuration is that which normally has current flow through the relay. In this way, an open circuit caused by a broken or disconnected wire can also be detected.

NOTICE

Since the relays are controlled by the instrument firmware, fail-safe configurations will generate client alarms when the instrument reboots or enters a pre-heating cycle.


60 Version 1.10

4.2.9. Selecting the Water Measurement Mode In the absence of on-line %RS measurements, utilities have historically used moisture-in-oil laboratory measurements (in ppm) to evaluate of the average water content in their transformer oil and cellulose. Taken in combination with oil quality test results, asset managers were able to qualitatively assess their risk level based on the minimum and maximum operating temperatures of their transformers. This approach can be used with the Calisto/Calisto 2 IED. The advantage of monitoring dissolved moisture content in ppm is that on-line measurements can directly be compared to laboratory measurements. The moisture in ppm will vary proportionally with the load. In order to provide highly accurate moisture readings in ppm, Calisto/Calisto 2 instruments use experimentally determined moisture solubility functions for common dielectric fluids. Calisto/Calisto 2 can also report %RS at a standard temperature of 25°C. For each type of oil, these readings are proportional to the moisture-in-oil ppm readings, related by the moisture solubility of the oil at 25°C. Changes in %RS@25°C can therefore serve the same role as ppm for transformer condition assessment. Since different oils have different capacity to retain water, the %RS@25°C readings allow easy comparison of relative saturation in different transformers running with different oil types. Many transformer experts prefer to monitor the %RS at a temperature of importance for the transformer. For example, a transformer operating in a desert climate could have high ppm levels of water, but have a comfortably low %RS@T given its high average operating temperature. To take another extreme, in cold conditions of operation or shutdown, the %RS at the coldest temperature determines the tendency for water to condense from the oil. Sometimes the focus is rather on the %RS at specific critical location on the transformer. The rate of degradation of paper insulation is widely believed to correlate with the moisture level in the paper. The %RS in the oil, evaluated at the temperature of the paper, provides an estimate of the working %RS in the paper. To facilitate accurate %RS@T measurements, the Calisto Precision Oil Temperature Probe is recommended. To change the Calisto/Calisto 2 water measurement mode, start Calisto Access, click on the Measurement tab, and select the desired mode.

4.2.10. Selecting the Oil Type Oil characteristic coefficients are used by Calisto/Calisto 2 to calculate the dissolved gas and moisture. For most accurate readings, it is therefore necessary to configure the monitor’s oil type to agree with the type of oil in the transformer. Under the Measurements tab, Calisto Access provides a drop-down list of common oil types: Voltesso 35, Technol US 4000, Nytro 10 GBN, Midel 7131, Silicone, Envirotemp FR3 and Luminol TRI. By selecting the oil type, the experimentally determined characteristic coefficients for that oil type are configured in the Calisto/Calisto 2. Clients with other types of oil may chose the oil type which most closely resembles their oil, or select


Version 1.10 61

ASTM-3612 which is a general mineral oil type as per ASTM-3612 standard or select the Custom Type option to enter the coefficients for their oil in each field.

Figure 34: Oil Types Selection

NOTICE Selecting the wrong oil type or solubility coefficients may lead to inaccurate dissolved gas and moisture readings.


62 Version 1.10

4.2.11. External Input Sensor Configuration The monitor can be equipped with an external sensor using the 4-20 mA input. In order to activate the Calisto Precision Oil Temperature Probe option, the %RS @ TºC mode and the 4-20 mA sensor type have to be selected under the Measurements tab, Figure 35. The 4-20 mA signal is read through a 12 bit resolution A/D converter. For proper oil temperature readings, the correct limits must be configured using the Analog (4-20mA) Input Settings subdivision. When the Calisto Precision Oil Temperature Probe is used, enter <-50> in the Temperature at 4mA (ºC) field and <125> in the Temperature at 20mA (ºC) field. Press ENTER between each modification to validate the new values.

Figure 35: Calisto Access External Input Settings


Version 1.10 63

Once properly configured, the external input reading will be displayed as the transformer’s oil temperature (<OTT> on the LCD) and the External Temperature field will appear in the Status tab after 2 minutes, displaying the value of the oil temperature.

4.2.12. Downloading Data Once a connection has been established with the monitor, the unit’s data bank can be downloaded under the Download menu by selecting the Data Bank item. The following screen will appear for a few seconds.

If there is data available for download, user will be prompted for a file name and a location to store the retrieved databank. Please remember this file path in order to be able to display and/or print the saved data bank later on.

CAUTION

Refer to Section 6.0 of the Precision Oil Temperature Probe Installation Manual to proceed with the configuration of the option if you have installed it.

NOTICE The 4-20 mA analog input is isolated to 1500V and self-powered to 13.5V.

NOTICE If another user is already using the data bank, you will not be able to download it. The other user could be using the unit’s front panel or another type of connection. Also, if connection is lost in the middle of a download, the database will remain locked for five minutes.


64 Version 1.10

To download just a portion of the entire data bank, the download size can be chosen. The available choices are: last week, last month or entire database. When the Start Download button is pressed, the progress of the download will be shown, including the estimated time until completion.

At anytime during download, download can be interrupted. The data downloaded prior to pressing stop will be saved to the chosen file. Once download is completed, user can press the OK button to return to the main screen. Moreover, the data bank will automatically be loaded and displayed in the graphic plotting panel, and the window will be maximized to your screen.


Version 1.10 65

4.2.13. Graphic Display of Data Bank Downloaded data banks from Calisto/Calisto 2 monitor can be viewed using the graphic tab. The toolbar allows user to:

Open data bank (required for any other action) Save data bank (under a different name, or after a merge) Merge one current data bank with another (useful for periodic partial downloads) Print data bank (portrait or landscape, color or monochrome, all pages or selection) View data bank (in numerical/textual columns format, ready to print)

Selection of display:

Hydrogen (in ppm) Carbon Monoxide (in ppm) (Calisto 2 only) Water (%RS at 25°C, ppm or %RS at transformer °C) External input sensor (usually the transformer °C) With baselines (bar graph) Without baselines (line graph)

The X scale adjustments:

Best fit Reduce (minimum two weeks) Increase

The Y scale adjustments:

Best fit Reduce (minimum 250 ppm, 100% RS or 50°C) Increase

Other tools:

Calculate relative water saturation Trend tool (adds least square linear regression lines) Clear trends (removes all visible linear regression lines)

Moving the mouse through the graphic will display a vertical line cursor. It indicates the reference point for the information label highlighted on the top left corner. Also, when the trend tool is activated, click once to set the trend starting point and click a second time to set its ending point (minimum range is one day). A scrollbar is also available to move through the graphic.


66 Version 1.10

Figure 36: Calisto Access Graphic Plotting Panel– H2

Figure 37: Calisto Access Graphic Plotting Panel – CO for Calisto 2 only

Figure 38: Calisto Access Graphic Plotting Panel – H2O

COLLECTING AN OIL SAMPLE

Version 1.10 67

5.0 COLLECTING AN OIL SAMPLE Oil samples can be easily collected from Calisto/Calisto 2 using the supplied Quick Connect Oil Sampling Tube. Refer to Figure 40 for the location of the SAMPLING port.

1. It is recommended to close the OUTLET valve to prevent taking an oil sample with excessive pressure.

2. Attach the supplied Quick Connect Oil Sampling Tube to a glass syringe - typically 30cc

capacity or a Shake Test® Syringe - fitted with a three-way stopcock.

Figure 39: Quick Connect Oil Sampling Tube Connected to a 30cc Syringe

3. With the syringe piston fully depressed and three-way stopcock handle positioned towards the syringe, connect the assembly to the instrument oil SAMPLING port.

Figure 40: 30cc Syringe Connected to the Monitor SAMPLING Port

COLLECTING AN OIL SAMPLE

68 Version 1.10

4. Turn the 3-way stopcock handle towards the side port and allow a few ml of oil to enter the syringe. Turn the 3-way stopcock handle towards the oil sampling tube and eject ALL air bubbles and most of the oil through the stopcock side port. Do not leave more than 1 or 2 ml of oil in the syringe.

5. Move the stopcock handle toward the side port and allow the system pressure to force the syringe piston back to the desired volume, then close the syringe stopcock (handle towards syringe), then detach the syringe and sampling tube. The oil sample is ready for analysis.

6. Remove the Quick Connect Oil Sampling Tube from the oil SAMPLING port by pushing

the locking ring up and pulling the fitting (with yellow hose) down.

7. If you do not need another oil sample, open the OUTLET valve slowly turning it counter clockwise ¼ turn (the handle will then be pointing down). Otherwise restart the procedure at point 2.

NOTICE

Flushing approximately 30cc of oil to waste is necessary before sampling to discard stagnant oil in the sampling valve assembly.

NOTICE

In some environments, a protective plug may be required to prevent dust or sand from affecting the SAMPLING port mechanism. This part is not included in the standard Calisto/Calisto 2 Accessory Kit and must be ordered separately.

MAINTENANCE AND SUPPORT

Version 1.10 69

6.0 MAINTENANCE AND SUPPORT

The Calisto/Calisto 2 is virtually maintenance free. However, in order to maximize the performance and reliability of the instrument over time, Morgan Schaffer offers a recommended Maintenance Plan. This Maintenance Plan is not mandatory and has no impact on the factory warranty of the instrument. Scheduled Maintenance Recommendations: After Commissioning One week after commissioning, Morgan Schaffer recommends connecting to the instrument to a laptop via USB using the Calisto Access software to download the databank and the event log (.bnk, .log, .mfg) and send those files by email to Morgan Schaffer Customer Support at [email protected]. Data will be evaluated to verify the integrity of the instrument. In 24 to 48 hours, the client will be contacted by a product specialist to provide the status of the instrument. Every 6 Months

1. It is recommended to download the instrument databank and event log every six months and to send them to Morgan Schaffer for performance evaluation.

2. It is recommended to visit Morgan Schaffer’s website at www.morganschaffer.com and verify the availability of updates for the Calisto Access software.

Every Year It is recommended to perform a yearly visual inspection of Calisto/Calisto 2. Following are points to be checked during that inspection:

The door must be fully closed and tightened;

The instrument and transformer SUPPLY and RETURN valves must be open;

The door display must be illuminated;

The pathway for air circulation beneath the instrument must be relatively clean and not blocked. If the air pathway needs to be cleaned, use compressed air to blow out the particles via the air vents. Refer to Figure 2 for the location of these air vents.

No oil should be seen dripping anywhere from the instrument.

WARNING

Electrical shock hazard. Only persons with electrical safety training and certification should install the equipment or open the enclosure once the equipment has been installed.



MAINTENANCE AND SUPPORT

70 Version 1.10

There is no recommendation to prevent corrosion as the instrument is highly resistant to corrosion. There is no need to washdown or clean the instrument except for aesthetics considerations. Calisto/Calisto 2 does not contain any part that requires a specific maintenance. Support If a problem of any nature occurs with your monitor, please take the following steps prior to contacting us:

Note the Serial Number C76-00000 or C85-00000 of the instrument (located on the external metal nameplate);

Connect to the instrument with a laptop via the USB port. Run the Calisto Access software and download the databank and the event log files (.bnk, .log, .mfg).

Contact Morgan Schaffer for immediate support by phone at 001.514.739.1967 or by email at [email protected]. If, for any reason, the monitor does not respond, a person with electrical safety training and certification can undertake the following steps: Check all connections and verify that power is being supplied to the instrument using a multimeter. If a proper voltage is being supplied to the monitor then verify the thermal fuse integrity (main contacts 3 and 4 on Figure 6). If the thermal fuse is blown, it irreversibly cuts power to the unit. The thermal fuse is easily field-replaceable using the supplied spare by pulling the activated fuse out of its location and disconnecting it. Once the spare thermal fuse is installed, quickly connect with a laptop to the Calisto/Calisto 2 and download the databank and the event log files. Turn OFF the instrument and contact Morgan Schaffer for immediate support by phone at 001.514.739.1967 or by email at [email protected].



APPENDIX I - TECHNICAL SPECIFICATIONS

Version 1.10 71


Standard Calisto/Calisto 2 On-line Monitor (LAST REVISED: April 2nd, 2010)

Application Early detection of transformer incipient faults using continuous monitoring of dissolved hydrogen in insulating fluids. Monitoring dissolved carbon monoxide as a key indicator of cellulose degradation. Continuous moisture monitoring.

Performance

DISSOLVED GASES (H2 AND CO1) IN OIL MEASUREMENT

Measurement technology Proprietary Morgan Schaffer cell Gas extraction technology Oil immersed PTFE tubing

Detection range H2

CO1: 25 – 100,000 ppm : 2 – 50,000 ppm

Accuracy (ref: MS oil standards) H2

CO1: Greater of ± 25 ppm or ± 15% : Greater of ± 5 ppm or ± 5%

Repeatability H2: Greater of ± 3 ppm or ± 3% CO1: Greater of ± 25 ppm or ± 10%

Resolution H2

CO1: 5 ppm : 1 ppm

Step response (typical conditions) H2

CO1: 90% in 6 hours : 50% in 60 min.

Interference H2

CO1: < 5% from C2H2,<3% from CH4, C2H4, C2H6

: < 0.3% of other gases

1 – for Calisto 2 only.

MOISTURE (H2O) IN OIL MEASUREMENT

Measurement technology Oil immersed RS sensor Detection range 2 ppm - saturation , 2-100% RS Accuracy (ref: MS oil standards for ppm and RS) ± 3 ppm or ± 3% RS

Repeatability ± 2 ppm or ± 2% RS Resolution 1 ppm, 1% RS Step response (typical conditions) 95% in 20 min.


72 Version 1.10

Reliability Power interruption protection 250 ms advanced power loss system Expected Operating Life (EOL) > 15 years

Operation Operating temperature range (standard) -40 to 55°C Storage temperature range -30 to 75°C Operating oil temperature range -40 to 120°C Oil pressure operation range Full vacuum to 40 psi Operating humidity range 0 – 100% RH Storage humidity range 5 – 95% RH, non-condensing Altitude range Up to 4,000 m

Construction Width × Height × Depth 381 × 483 × 325 mm (15 × 19 × 12.8 in) Weight 22.7 kg / 50 lbs Enclosure SS 304 gauge 16, lockable

Oil circulation Anti-cavitation reciprocating pump, 10 - 60 ml/min.

Oil flow monitoring Proprietary Morgan Schaffer system

Oil lines (standard) 3/8" O.D. copper with brass compression fittings

Enclosure temperature conditioning Thermoelectric feedback

Oil temperature conditioning Passive heat exchanger Thermoelectric feedback

Cooling Forced air convection

Safety protection Thermal cut-off fuse, rated at 77°C Over current protection fuse

Oil sampling External quick-connect port with sampling accessories


Version 1.10 73

Installation Calibration No calibration required Maintenance Annual visual inspection Electrical entry holes (standard) 4 × 22.2 mm (0.875 in) diameter Commissioning time 2 hrs

Mounting Vibration mounts. Morgan Schaffer Calisto Mounting Stand recommended

Power requirements 100 – 240 VAC, 50 – 60 Hz, 320 W, 1 Ø Power conductor size Max. 2.05 mm (AWG 12) Oil supply line length 1.5 – 10.5 m (5 – 35 ft) Oil return line length 1.5 – 10.5 m (5 – 35 ft)

Communication & Data Display 114×16-pixel vacuum fluorescent, day/night Local USB 2.0 port (cable provided)

Permanent connection

RS-485 port (1,500 V isolation) RS-232 port (1,500 V isolation) Ethernet port (1,500 V isolation) Independent H2, CO and H2O analog outputs, 4 – 20 mA (1500 V isolation) Oil temperature analog input, 4– 20 mA (1500 V isolation)

Communication protocols MSSP (Morgan Schaffer Systems Protocol) Modbus, DNP3 Level1 Optional IEC 61850 kit

Measurement Alarms Programmable dual-level and trend alarms for H2, CO (Calisto 2 only) and H2O

Alarms Relays 5 NO/NC contacts, configurable for setup, self-test and measurement alarm conditions (5A, 240V)

Data update 8 readings/day, validated H2

8 readings/day, validated CO (Calisto 2 only) 1 reading/5 sec., continuous H2 and H2O

Data storage 3000 (1 year) Calisto Access interface software Win 98 / 2000 / NT / XP / Vista / 7


74 Version 1.10

Regulatory

CE Marking

Low Voltage Directive 2006/95/EC EMC Directive 2004/108/EC WEEE Directive 2002/96/EC, amended 2003/108/EC RoHS Directive 2002/95/EU

EMC (Electromagnetic Compatibility) IEC/EN 61326 FCC part 15 (US) Class A, ICES-003 (Canada)

Electrical safety IEC/EN 61010 Degree of protection IEC/EN 60529, IP56 Vibration IEC 60255-21-1, Class 1

Shipping Gross weight 30.8kg (67.8 lbs)

Packaging (H × W × D) 508 × 584 × 470 mm (20 × 23 × 18.5 in)

Standard Package 1× USB cable

1× CD Calisto Access interface software 1× Calisto & Calisto 2 Installation & Operation Manual 1× Quick Connect Oil Sampling Tube 1× Factory Test Certificate 4× S. S. vibration mount assembly 2× Copper tubing – 3/8" O.D. × 25ft (7.6 m) 1× Thermal cut-off fuse 2× Brass elbow – ½" NPT (M) – 3/8 Tube 1× Extra-strong shipping box


Version 1.10 75

Options Morgan Schaffer Calisto Mounting Stand

Calisto Precision Oil Temperature Probe (4-20mA) Insulation Kit (for -50 to 55ºC operation) Stainless steel braided flex lines IEC 61850 Ethernet communication kit 900 MHz radio modem over RS-485 2.4 GHz radio modem over RS-485 Ethernet outdoor connectivity kit Quick-connect dust plug Calisto Multitrack software Extended warranty up to 5 years On-site commissioning assistance

WARRANTY AND SUPPPORT Morgan Schaffer’s Calisto & Calisto 2 monitors are backed by a 3-year factory warranty. Calisto and Calisto 2 and other MS monitoring systems are available through Morgan Schaffer’s worldwide network agents. Continuing research and improvements may result in specification or appearance changes at any time.


76 Version 1.10

Precision Oil Temperature Probe – Standard Edition (LAST REVISED: March 22nd, 2010)

Performance Accuracy from -10 to 30oC ±1.5oC; Accuracy Below -10 or Above 30oC ±3.0oC Long term stability ≤ 0.15% span/year Oil circulation Continuous around probe Protection Fault signal on sensor break or short circuit

Operating Conditions Probe temperature span -50 to 125oC Ambient operating temperature range -40 to 85oC Ambient humidity range 0 – 100 %RH Transmitter vibration resistant at 4g / 2 – 150Hz IEC 60068-2-6

Construction Customizable stainless steel 316 temperature probe Up to 24 in (610 mm)

Customizable connection cable and conduit Up to 35 ft (10 m) Transmitter isolation To 3750VAC

Design

Corrosion proof Water-tight Oil and water resistant UV stabilized components

Identification Individually serialized


Version 1.10 77

Approvals

EMC immunity EN 61 326-1 NAMUR NE 21

3-point calibration Traceable to NIST Transmitter certification CSA : Approved for Class 2252 03 UL : Recognized component UL 3111-1

Installation Easy installation No field calibration required Maintenance-free Use existing oil supply line to Calisto/Calisto 2 Special slip-through design for probe intrusion7

7 For intrusive installation, the Oil Temperature Probe requires either a gate or a ball valve.


78 Version 1.10

Stainless Steel Braided Flex Lines (LAST REVISED: March 9th, 2007)

Performance Inlet and outlet connection Made for 3/8 tube compression fittings Customizable length from 2 to 35 ft Inner tubing material High temperature resistant PTFE Pressure resistance Up to 2500 psi

Braided stainless steel Puncture resistant Corrosion proof


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Ethernet Outdoor Connectivity Kit (LAST REVISED: February, 2007)

Construction

Connectors

IP67 connection Isolated to 1500 Vrms (on monitor side only) Customizable cable length (up to 50 ft) Oil and water resistant components UV stabilized components Category 5e components Straight-through pair configuration

External ethernet cable

Datatuff® series cable for harsh environments Cable jacket : Industrial grade PVC 100% Shielded (Bonded Bedfoil® and drain wire) Conductors : AWG 24, solid bare copper UL1581 rated (-40C cold bend)

Installation and Operation Operating temperature range : -40oC to 75°C Installation temperature range : -25oC to 75°C Min. bending radius 1 inch Max. pulling tension 25 lbs Immune to EMC Fast plug-in and secure type of connectors

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