Morgan Schaffer Calisto, Calisto 2 Operation Manual

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Figure 1: Front View (Calisto 2 model shown) ................................................................................................................................... 6

Figure 2: Calisto/Calisto 2 - Bottom View .......................................................................................................................................... 6

Figure 3: Calisto/Calisto 2 - Main Internal Components ................................................................................................................. 7

Figure 4 : Calisto/Calisto 2 - Mounting Diagram............................................................................................................................. 12

Figure 5: Calisto/Calisto 2 - Interface Board Components ........................................................................................................... 15

Figure 6: Calisto/Calisto 2 - Power Connections ............................................................................................................................. 16

Figure 7: Calisto/Calisto 2 - Alarm Relays and Connections ......................................................................................................... 17

Figure 8: Calisto/Calisto 2 - Analog Output Connector ................................................................................................................. 19

Figure 9: Calisto/Calisto 2 - 4-20 mA Analog Input Connector ................................................................................................... 21

Figure 10: Calisto/Calisto 2 - RS-485 Connection ........................................................................................................................... 22

Figure 11: Calisto/Calisto 2 - RS-232 Connection ........................................................................................................................... 24

Figure 12: Calisto/Calisto 2 - RJ45 Ethernet port ........................................................................................................................... 25

Figure 13: Ethernet Outdoor Connectivity Kit Patchcord ............................................................................................................. 25

Figure 14: Tee Fitting Assembly for the Precision Oil Temperature Probe Option ................................................................. 29

Figure 15: Transformer Valve Elbow Fitting .................................................................................................................................... 29

Figure 16: Adapting the Transformer Valve ..................................................................................................................................... 29

Figure 17: Attaching the Copper Tubing to the INLET Port ....................................................................................................... 30

Figure 18: Attaching the Copper Tubing to the OUTLET Port ................................................................................................... 31

Figure 19: Monitor with Both Valves Closed .................................................................................................................................... 32

Figure 20: Quick Connect Oil Sampling Tube ................................................................................................................................. 33

Figure 21: Connecting the Quick Connect Oil Sampling Tube to the monitor ......................................................................... 33

Figure 22: Flushing the Oil RETURN Tube ..................................................................................................................................... 34

Figure 23: Flushing the Oil SUPPLY Tube ....................................................................................................................................... 35

Figure 24: Disconnecting the Quick Connect Oil Sampling Tube from the Monitor .............................................................. 35

Figure 25: Monitor with both Valves Open ...................................................................................................................................... 36

Figure 26: Calisto/Calisto 2 Display Interface Structure ................................................................................................................ 42

Figure 27: 6-Feet Long A/B Type USB Cable.................................................................................................................................. 43

Figure 28: Calisto Access Status Tab with an Error Code .............................................................................................................. 47

Figure 29: Error Code Interpretation Chart ...................................................................................................................................... 48

Figure 30: Calisto Access Settings Tab ............................................................................................................................................... 51

Figure 31: DNP3/RS485 ...................................................................................................................................................................... 53

Figure 32: DNP3/TCP ......................................................................................................................................................................... 53

Figure 33: Calisto/Calisto 2 Access Default Set-Up ........................................................................................................................ 56

Figure 34: Oil Types Selection ............................................................................................................................................................. 61

Figure 35: Calisto Access External Input Settings ........................................................................................................................... 62

Figure 36: Calisto Access Graphic Plotting Panel– H2 ................................................................................................................... 66

Figure 37: Calisto Access Graphic Plotting Panel – CO for Calisto 2 only ................................................................................. 66

Figure 38: Calisto Access Graphic Plotting Panel – H2O .............................................................................................................. 66

Figure 39: Quick Connect Oil Sampling Tube Connected to a 30cc Syringe ............................................................................. 67

Figure 40: 30cc Syringe Connected to the Monitor SAMPLING Port ........................................................................................ 67

DISCLAIMER

The 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 this Installation & Operation Manual and will understand the operation of the instrument prior to installation of the IED.

All results obtained using the 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 the Calisto/Calisto 2 monitor may be used or relied upon for any reason whatsoever.

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 also monitors carbon monoxide. Carbon monoxide and moisture levels may highlight undesirable deterioration of the paper/oil system, and conditions conducive to 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.

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NOTICE

This manual applies to both Calisto and Calisto 2 monitors. Always consider which one you are working with. Some sections of this manual apply to Calisto 2 only and are

expressly marked “for Calisto 2 only”. If not stated, the section applies to both Calisto

and Calisto 2 monitors.

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.

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.

A 3-year warranty covers each new Calisto/Calisto 2 IED. In order to activate this warranty, the user must fill out 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 support@morganschaffer.com once it has been filled out. 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 shipping 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.

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 conditions. 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 gas concentrations 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

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 in 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 25oC (77°F) or %RS at a specific transformer temperature using the Expert Series Calisto Precision Oil Temperature Probe.

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.

Figure 1: Front View (Calisto 2 model shown)

Figure 2: Calisto/Calisto 2 - Bottom View

Figure 3: Calisto/Calisto 2 - Main Internal Components

QTY.

DESCRIPTION

Standard Calisto/Calisto 2 monitor

6-foot male A/B USB 2.0 cable for local connection

Calisto Access interface software CD-ROM

Quick Connect Oil Sampling Tube

Stainless steel vibration mount assembly

Copper tubing – 3/8 O.D. × 25 ft (7.6 m)

Thermal cut-off fuse (spare)

Brass elbow – ½ NPT (M) – 3/8" Tube

Brass nut – 3/8 Tube

One-lokTM brass ferrule – 3/8 Tube

Shipping box

Installation & Operation Manual (softcopy, also available on our website)

Factory Test Certificate

Declaration of Conformity

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 610 mm (24 in.) temperature probe is customized at the moment of the installation of the monitor and does not require any specifications from the client at the time 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 for 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.

Other available options:

 Insulation kit (for -50 to 55°C [-58 to 131°F] 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

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 the 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 to 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.

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 wrenches (or adjustable wrenches)  Knife  Small screwdriver (flat)  Large screwdriver (flat)  Installation kit for Calisto/Calisto 2

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.

Calisto/Calisto 2 must be solidly bolted to a suitable support approximately 1.2 m (4 ft) above ground level to allow easy access to the internal oil sampling valves. A minimum of 60 cm (24 in.) is required for air circulation under the unit.

The mounting structure should be positioned 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 hole 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

NOTICE

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

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

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.

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 line requirements discussed later in this section.

Typically Unistrut® brackets are used to make a base for mounting the Calisto/Calisto 2. The mounting structure can be designed to clamp on to various components of the transformer tank, on the main control cabinet, on a post installed in the ground or on a 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 the stand.

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.

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.

The Calisto/Calisto 2 monitor features a 4-hub detachable electrical entry plate made of stainless steel. All entry holes are 22 mm (7/8 in.) 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.

Opening the Calisto/Calisto 2 enclosure door will provide access to the monitor interface board. Figure 5 shows the main components of the Calisto/Calisto 2 interface board. 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.

Calisto Interface Board Components:

12. Thermal cut-off fuse terminals

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.

1. Main supply terminals

2. Programmable relays with activity LEDs (5)

3. Ethernet shield earth jumper

4. RS-485 communication port

5. RS-232 communication port

6. 4-20mA analog input terminals

7. 4-20mA analog output terminals (3rd channel is for Calisto 2 only)

8. Local USB type B port

9. Ethernet communication port

10. Programmable relay terminal block

11. Main supply fuse (5HT 6.3-R)

Figure 5: Calisto/Calisto 2 - Interface Board Components

RATING

NOMINAL VALUE/RANGE

Connection range

2.50 – 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

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.

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 of 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

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.

The Calisto/Calisto 2 nominal power is 320W. The main supply switch may be used to turn the unit

WARNING

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

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.

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 in Figure 7.

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

The table below describes the alarm relay connections pinout assignment:

CONNECTOR NO.

MARKING

CONNECTION TYPE

RLY1_NC

Relay 1 normally closed (NC)

RLY1_COM

Relay 1 common

RLY1_NO

Relay 1 normally open (NO)

RLY2_NC

Relay 2 normally closed (NC)

RLY2_COM

Relay 2 common

RLY2_NO

Relay 2 normally open (NO)

RLY3_NC

Relay 3 normally closed (NC)

RLY3_COM

Relay 3 common

RLY3_NO

Relay 3 normally open (NO)

RLY4_NC

Relay 4 normally closed (NC)

RLY4_COM

Relay 4 common

RLY4_NO

Relay 4 normally open (NO)

RLY5_NC

Relay 5 normally closed (NC)

RLY5_COM

Relay 5 common

RLY5_NO

Relay 5 normally open (NO)

SHIELD

Shield to earth ground

SHIELD

Shield to earth ground

SHIELD

Shield to earth ground

RATING

NOMINAL VALUE/RANGE

Connection range

0.34 – 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

Flammability

VW-1 or better

Screw type

M2.5

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:

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.

Using gauge 14 conductors to wire the relays may dictate 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 relay wiring as an alternative.

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 relay configurations can also be found at Section 4.2.7.

The 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 to carbon monoxide. All analog outputs are isolated to 1500 V.

The analog output 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 Output 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 analog output connector pinout has the following configuration:

PIN NO.

OUTPUT

DESCRIPTION

SHLD

Shield to earth ground

SHLD

Shield to earth ground

N/A

Unused 4 Moisture (H2O)

Positive (+)

Moisture (H2O)

Negative (-)

Hydrogen (H2)

Positive (+)

Hydrogen (H2)

Negative (-)

Carbon monoxide (CO)

Positive (+) (Calisto 2 only)

Carbon monoxide (CO)

Negative (-) (Calisto 2 only)

RATING

NOMINAL VALUE/RANGE

Connection range

0.34 – 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

Flammability

VW-1 or better

Screw type

M2.0

NOTICE

The analog input can only be used with self-powered 4-20 mA devices and must not be powered by an external source.

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

The load resistance can be anywhere from 0 Ohm to a maximum of 500 Ohms including resistance of the wires. The maximum length of the wires depends on the overall resistance of the load and the acceptable noise level.

The setup of the analog outputs is done using the Calisto Access software. Refer to Figure 33: Calisto Access Default Set-Up for more information.

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.

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

The analog input screw-terminal plug-in connector (Refer to Figure 9) is located on the monitor

PIN NO.

MARKING

DESCRIPTION

SHLD

Shield to earth ground

Unused 3 -

4-20 mA negative (-)

4-20 mA positive (+)

RATING

NOMINAL VALUE/RANGE

Connection range

0.34 – 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 preferred3), 90ºC (194ºF) or better

Flammability

VW-1 or better

Screw type

M2.0

interface board.

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:

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

If the Precision Oil Temperature Probe option 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 analog input temperature range is configured via the Calisto Access software.

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 0.34 mm2 (22 AWG) to set up a communication via RS-485.

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

The RS-485 screw-terminal plug-in connector is located on the monitor interface board (See Figure

PIN NO.

MARKING

DESCRIPTION

SHLD

Shield to earth ground

Unused 3 COMM

Common signal ground

Line A 5 B

Line B

RATING

NOMINAL VALUE/RANGE

Connection range

0.34 – 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 preferred4), 90ºC (194ºF) or better

Flammability

VW-1 or better

Screw type

M2.0

10).

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:

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 ensure 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.

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

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.

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 dampen 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.

Calisto/Calisto 2 features one RS-232 communication port isolated to 1500 V. The maximum recommended range for RS-232 communication is 15m (50 feet).

The RS-232 screw-terminal plug-in connector is located on the monitor interface board (see

PIN NO.

MARKING

DESCRIPTION

SHLD

Shield to earth ground

Unused 3 GND

Signal ground

Received data

Transmitted data

RATING

NOMINAL VALUE/RANGE

Connection range

0.34 – 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 preferred5), 90ºC (194ºF) or better

Flammability

VW-1 or better

Screw type

M2.0

Figure 11).

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

It is highly recommended to select an industrial grade shielded twisted pair cable of minimum 0.34 mm2 (22 AWG) to set up a communication via RS-232.

The RS-232 connector pinout has the following configuration:

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 ensure a reliable connection.

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

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).

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

RATING

NOMINAL VALUE/RANGE

Connection range

0.34 – 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

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 30 m (100 ft).

The Ethernet connection must be made in accordance with the following connector ratings:

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

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.

Morgan Schaffer cannot guarantee protection from an 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.

The 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 the 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.

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.

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 1.3 cm (½ in.), and be located near the monitor.

 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.

 Female, ball or gate type valves with a minimum diameter of ½ NPT are recommended for

the transformer valves.

 The inlet and outlet valves must not be close to a pump.  The oil RETURN line must not exceed 11 m (35 ft).  The oil SUPPLY line must be longer than 1 m (3 ft) to reduce mechanical stress.  The distance between the two transformer valves should be a minimum of 1 m (3 ft).  The inlet valve should be at least 0.45 m (18 in.) 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.

Most transformer manufacturers will install two 1.3 cm (½ in.) 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.

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 can only 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 some suggestions for determining whether the top oil valve is below the 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 tank. 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. Often there is a statement indicating

that the top oil level is X 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.

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

Prior to installing 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

When attaching oil lines to the Calisto/Calisto 2, use a counter-torque wrench to avoid damaging the INLET and OUTLET ports on the monitor. The torque and the counter-torque wrenches 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.

1. Install the first oil line as follows: Unroll a few inches of one of the supplied coils of 3/8″

copper tubing and insert one end firmly into the monitor INLET port (See Figure 17). Using an 11/16 wrench and a 5/8 counter-torque wrench, 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 follows: Unroll a few inches of the second supplied coil of 3/8″

copper tubing and insert one end firmly into the monitor OUTLET port (See Figure 18).

3. Using an 11/16 wrench and a 5/8 counter-torque wrench, 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

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.

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

The 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.

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).

Figure 20: Quick Connect Oil Sampling Tube

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

3. Using a container to collect the flushed oil, slowly turn the OUTLET valve (left side)

counterclockwise 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.

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.

Figure 22: Flushing the Oil RETURN Tube

4. Slowly turn the INLET valve (right side) counterclockwise 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).

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 in Figure 25.

Figure 25: Monitor with both Valves Open

7. The monitor is now ready for configuration. Refer to Section 3.0 POWER UP.

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 a 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 OUTLET 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.

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 0.6 m (24 in.) 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.

NOTICE

If the instrument temperature is below -35oC (-31°F) 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 -5oC (41°F). Reaching the computer start-up temperature could take several minutes or even hours in extremely cold environments.

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 poweron 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 complete measuring cycle. During the entire time of this mode of operation, the door display will indicate <H2= INIT> to inform the user 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.

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 within the same section. Refer to Figure 26 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 the carbon monoxide measurement. By default, moisture is displayed as <WRS=00> for % relative saturation at 25oC (77°F), and the oil temperature will display <OTT=NONE> (inactive by default). Using the Calisto Access software provided, the moisture can be set up 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 Figure 26). This section provides useful information about 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 Figure 26 which shows the structure of the display interface for Calisto/Calisto 2. For a Calisto model C76-00000, the same structure applies, except that 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 <REALTIME> is displayed. <H2=000> will be displayed after a few seconds.

Figure 26: Calisto/Calisto 2 Display Interface Structure

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.

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 1.8 m (6 ft) 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

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

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 the next section before performing the first startup.

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.

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

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 as the one you selected to communicate with.

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

COM4 in this example

Different connection steps may appear depending on your selected communication link. In the event 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

support@morganschaffer.com or by phone at 001.514.739.1967.

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.

Figure 28: Calisto Access Status Tab with an Error Code

The Current Readings subdivision contains various 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 moisture 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 monitor’s external LCD display. Refer to Table 1 for a description of individual error codes.

Figure 29: Error Code Interpretation Chart

ERROR CODE

(HEXADECIMAL)

ERROR

NAME

DESCRIPTION

Outside

Fan

This error only occurs when heat sink temperature (ST on display or OUTT in Calisto Real Time) is higher than

27°C (81°F) 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

support@morganschaffer.com.

Inside Fan

This error occurs when the internal fan is no longer running. Open the door and manually check 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 the 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 the above are correct, please contact Morgan Schaffer for assistance.

Table 1: Individual Error Code

The Current Alarm States subdivision contains the H2, H2O and Trend alarm states. Calisto 2 also

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.

features 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.

The 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.

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.

Figure 30: Calisto Access Settings Tab

The preferred method of adjusting the communication settings is through 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.

RS-485 Communication

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.

To communicate with other devices on an RS-485 network, each monitor must be assigned an RS485 ID (range 01 to 99) which is specific to 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 value [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 support@morganschaffer.com or by phone at

001.514.739.1967.

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 halfduplex 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 support@morganschaffer.com 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

support@morganschaffer.com or by phone at 001.514.739.1967.

ALARM CONDITION

LEVEL

FACTORY DEFAULT

Hydrogen

H2 Validated Alarm 1

H2 Continuous Alarm 1

LOW

1207 ppm

H2 Validated Alarm 2

H2 Continuous Alarm 2

HIGH

2407 ppm

Moisture

H2O Alarm 1

LOW

20%RS @ 25°C (77°F)

H2O Alarm 2

HIGH

40%RS @ 25°C (77°F)

Carbon

Monoxide

(Calisto 2

only)

CO Validated Alarm 1

LOW

1,0807 ppm

CO Validated Alarm 2

HIGH

2,1607 ppm

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 conditions, environment, etc.

For both monitors, alarm limit values can be adjusted for dissolved hydrogen and moisture 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.

Factory default alarm limits are set as follows.

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 the trend periods and trend limits to suit the transformer and the installation.

Alarm levels for H2 and CO are based on the typical concentration values of power transformers given in the

international standard IEC 60599.

Note that short trend periods and low trend limits may increase the likelihood of false trend alarms.

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

ppm/month

Factory settings for trend limit values are given in the table below:

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

Relay Response

Mode

Condition

Logic

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

Validated Alarm

Continuous Alarm

Trend Alarm

O Alarm

O Trend Alarm

Self

Test Error

CO Alarm 1 (Calisto 2 only)

CO Alarm 2 (Calisto 2 only)

CO Trend Alarm (Calisto 2 only)

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

The default configuration of 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

Relay 2

Is energized

When

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

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.

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.

In the absence of on-line %RS measurements, utilities have historically used moisture-in-oil laboratory measurements (in ppm) to evaluate 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 be compared directly with 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 (77°F). 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 (77°F). Changes in %RS@25°C can therefore serve the same role as ppm for transformer condition assessment. Since different oils have different capacities to retain moisture, 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 that is important to 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 operating or shutdown conditions, the %RS at the coldest temperature determines the tendency for water to condense from the oil.

Sometimes the focus is, instead, on the %RS at specific critical locations 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.

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 choose the oil type which most closely resembles their oil, or select

ASTM-3612 which is a general mineral oil type as per the ASTM-3612 standard, or select the Custom

NOTICE

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

Type option to enter the coefficients for their oil in each field.

Figure 34: Oil Types Selection

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

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.

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.

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, the 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.

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.

The download can be interrupted at any time. The data downloaded prior to pressing stop will be saved to the chosen file. Once the download is completed, the 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.

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) Moisture (%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 moisture 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 in 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 (the minimum range is one day). A scrollbar is also available for moving through the graphic.

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

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 the 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

4. Turn the 3-way stopcock handle towards the side port and allow a few ml of oil to enter the

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.

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 the 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

counterclockwise ¼ turn (the handle will then be pointing down). Otherwise, restart the procedure at point 2.

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.

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 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

support@morganschaffer.com. 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.

There is no recommendation to prevent corrosion as the instrument is highly resistant to corrosion.

There is no need to wash down or clean the instrument except for aesthetics considerations.

Calisto/Calisto 2 does not contain any part that requires 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 the instrument to 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

support@morganschaffer.com.

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 the Calisto/Calisto 2 to a laptop 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 support@morganschaffer.com.

Early detection of transformer incipient faults using continuous monitoring of dissolved hydrogen

Measurement technology

Proprietary Morgan Schaffer cell

Gas extraction technology

Oil immersed PTFE tubing

Detection range

H2: 2 – 50,000 ppm CO1: 25 – 100,000 ppm

Accuracy (ref: MS oil standards)

H2: Greater of ± 5 ppm or ± 5% CO1: Greater of ± 25 ppm or ± 15%

Repeatability

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

Resolution

H2: 1 ppm CO1: 5 ppm

Step response (typical conditions)

H2: 50% in 60 min. CO1: 90% in 6 hours

Interference

H2: < 0.3% of other gases CO1: < 6% from C2H2, C2H4,<3% from H2, CH4, , C2H6

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.

in insulating fluids. Monitoring dissolved carbon monoxide as a key indicator of cellulose degradation. Continuous moisture monitoring.

1 – for Calisto 2 only.

Power interruption protection

250 ms advanced power loss system

Expected Operating Life (EOL)

> 15 years

Operating temperature range (standard)

-40 to 55°C (-40 to 131°F)

Storage temperature range

-30 to 75°C (-22 to 167°F)

Operating oil temperature range

-40 to 120°C (-40 to 248°F)

Operating oil pressure range

Full vacuum to 2.7 bar (40 psi)

Operating humidity range

0 – 100% RH

Storage humidity range

5 – 95% RH, non-condensing

Altitude range

Up to 4,000 m (13,000 ft)

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 (171°F) Over current protection fuse

Oil sampling

External quick-connect port with sampling accessories

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. 2.5 mm2 (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)

Display

114×16-pixel vacuum fluorescent, day/night

Local

USB 2.0 type B 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

Alarm Relays

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

Data update

8 readings/day, validated H

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

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

Gross weight

30.8 kg (67.8 lbs)

Packaging (H × W × D)

508 × 584 × 470 mm (20 × 23 × 18.5 in)

1× USB cable type A to B

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. × 7.6 m (25 ft)

1× Thermal cut-off fuse

2× Brass elbow – ½" NPT (M) – 3/8 Tube

1× Extra-strong shipping box

Morgan Schaffer Calisto Mounting Stand

Calisto Precision Oil Temperature Probe (4-20mA)

Insulation Kit (for -50 to 55ºC [-58 to 131°F] 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

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.

Accuracy from -10 to 30oC (14 to 86°F)

±1.5oC (±2.7°F)

Accuracy below -10 (14°F) or above 30oC (86°F)

±3.0oC (±5.4°F)

Long term stability

≤ 0.15% span/year

Oil circulation

Continuous around probe

Protection

Fault signal on sensor break or short circuit

Probe temperature span

-50 to 125oC (-58 to 257°F)

Ambient operating temperature range

-40 to 85oC (-40 to 185°F)

Ambient humidity range

0 – 100 %RH

Transmitter vibration resistant at 4g / 2 – 150Hz

IEC 60068-2-6

Customizable stainless steel 316 temperature probe

Up to 610 mm (24 in) Customizable connection cable and conduit

Up to 10 m (35 ft)

Transmitter isolation

To 3750VAC

Design

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

Identification

Individually serialized

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

Easy installation

No field calibration required

Maintenance-free

Use existing oil supply line to Calisto/Calisto 2

Special slip-through design for probe intrusion8

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

Inlet and outlet connection

Made for 3/8 tube compression fittings

Customizable length

from 0.6 to 10.7 m [2 to 35 ft]

Inner tubing material

High temperature resistant PTFE

Pressure resistance

Up to 172 bar [2500 psi]

Braided stainless steel

Puncture resistant Corrosion proof

IP67 connection

Isolated to 1500 Vrms (on monitor side only)

Customizable cable length (up to 15 m [50 ft])

Oil and water resistant components

UV stabilized components

Category 5e components

Straight-through pair configuration

Datatuff® series cable for harsh environments

Cable jacket: Industrial grade PVC

100% Shielded (Bonded Bedfoil® and drain wire)

Conductors: 0.2 mm2 (AWG 24), solid bare copper

UL1581 rated (-40°C [-40°F]cold bend)

Operating temperature range: -40oC to 75C (-40°F to 167°F)

Installation temperature range: -25oC to 75C (-13°F to 167°F )

Min. bending radius 2.5 cm (1 inch)

Max. pulling tension 11.3 kg (25 lbs)

Immune to EMC

Fast plug-in and secure type of connectors

Morgan Schaffer Calisto, Calisto 2 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual