Manual Calisto 2

7/24/2019 Manual Calisto 2

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SUPPORT: + 001.514.739.1967

Installation & Operation Manual


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TABLE OF CONTENTS

1.0 INTRODUCTION .............................................................................................. 3

1.1. DOCUMENTATION SCOPE AND UPDATES .................................................................31.2. GENERAL SAFETY INFORMATION ..........................................................................4

1.3. MONITOR WARRANTY .........................................................................................4

1.4. CALISTO/CALISTO 2 OVERVIEW............................................................................4

1.5. MONITOR MAIN COMPONENTS .............................................................................6

1.6. STANDARD PACKAGE CONTENTS ......................................................................... 10

2.0 INSTALLATION ..............................................................................................112.1. INTRODUCTION .............................................................................................. 11

2.2. SELECTING THE TRANSFORMER VALVES ...............................................................12

2.3. SECURING THE MONITOR.................................................................................. 13

2.4. WIRING THE ELECTRICAL CONNECTIONS .............................................................. 15

2.4.1. CONNECTING THE EARTH GROUND ......................................................... 17

2.4.2. CONNECTING THE MAINS POWER ........................................................... 18

2.4.3. CONNECTING THE ALARM RELAYS .......................................................... 19

2.4.4. CONNECTING THE ANALOG OUTPUTS ...................................................... 21

2.4.5. CONNECTING THE ANALOG INPUT .......................................................... 22

2.4.6. CONNECTING THE RS-485 COMMUNICATION ............................................. 23

2.4.7. CONNECTING THE RS-232 COMMUNICATION ............................................. 25

2.4.8. CONNECTING THE ETHERNET COMMUNICATION ......................................... 26

2.4.9. CONNECTING THE USB COMMUNICATION ................................................. 282.5. CONNECTING THE OIL LINES ............................................................................. 28

2.5.1. PREPARING THE TRANSFORMER VALVES ..................................................29

2.5.2. CONNECTING THE OIL LINES ................................................................. 30

2.5.3. PURGING THE OIL LINES ..................................................................... 32

3.0 START UP .....................................................................................................37

3.1. IMPORTANT CHECKS BEFORE POWER UP .............................................................. 373.2. MONITOR POWER UP .......................................................................................37

3.3. CONFIGURING THE MONITOR ............................................................................38

3.4. DISPLAY INTERFACE ........................................................................................39

3.4.1. ERROR CODES ....................................................................................41

4.0 COLLECTING AN OIL SAMPLE ..........................................................................43

5.0 MAINTENANCE AND SUPPORT .........................................................................47

5.1. SCHEDULED MAINTENANCE RECOMMENDATIONS ...................................................47

5.2. PRODUCT SUPPORT .........................................................................................48

6.0 APPENDIX ....................................................................................................49

6.1. CALISTO/CALISTO 2 - TECHNICAL SPECIFICATIONS ................................................ 49


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LIST OF FIGURES

FIGURE 1: FRONT VIEW (CALISTO 2 MODEL SHOWN) ............................................................6

FIGURE 2: BOTTOM VIEW ................................................................................................7FIGURE 3: CALISTO (C76)/CALISTO 2 (C85) - MAIN INTERNAL COMPONENTS ............................8

FIGURE 4: CALISTO (C76A)/CALISTO 2 (C85A) - MAIN INTERNAL COMPONENTS ........................9

FIGURE 5: MOUNTING DIAGRAM ....................................................................................13

FIGURE 6: INSTALLATION OF SHOCK MOUNTS ...................................................................14

FIGURE 7: CALISTO (C76)/CALISTO 2 (C85) - INTERFACE BOARD COMPONENTS ....................... 15

FIGURE 8: CALISTO (C76A)/CALISTO 2 (C85A) - INTERFACE BOARD COMPONENTS ................... 16

FIGURE 9: EARTH GROUND CONNECTIONS........................................................................17

FIGURE 10: CALISTO (C76)/CALISTO 2 (C85) - POWER CONNECTIONS ...................................18

FIGURE 11: CALISTO (C76A)/CALISTO (C85A) - POWER CONNECTIONS ..................................18

FIGURE 12: ALARM RELAYS AND CONNECTIONS ................................................................19

FIGURE 13: ANALOG OUTPUT CONNECTOR .......................................................................21

FIGURE 14: 4-20 MA ANALOG INPUT CONNECTOR .............................................................22

FIGURE 15: RS-485 CONNECTION ...................................................................................23

FIGURE 16: RS-232 CONNECTION ...................................................................................25

FIGURE 17: CALISTO (C76)/CALISTO 2 (C85) - RJ45 ETHERNET PORT ...................................26

FIGURE 18: CALISTO (C76A)/CALISTO 2 (C85A) - RJ45 ETHERNET PORT ................................ 26

FIGURE 19: USB PORT .................................................................................................28

FIGURE 20: INSTALLATION OF THE ELBOW FITTINGS .........................................................29

FIGURE 21: CONNECTING THE OIL SUPPLY LINE TO THE INLET PORT .....................................30FIGURE 22: CONNECTING THE OIL RETURN LINE TO THE OUTLET PORT .................................. 31

FIGURE 23: MONITOR WITH BOTH VALVES CLOSED ............................................................32

FIGURE 24: QUICK CONNECT OIL SAMPLING TUBE ............................................................. 33

FIGURE 25: CONNECTING THE QUICK CONNECT OIL SAMPLING TUBE TO THE MONITOR .............33

FIGURE 26: FLUSHING THE OIL RETURN LINE ..................................................................34

FIGURE 27: CLOSING THE MONITOR OUTLET VALVE ............................................................ 34FIGURE 28: FLUSHING THE OIL SUPPLY LINE ...................................................................35

FIGURE 29: DISCONNECTING THE QUICK CONNECT OIL SAMPLING TUBE FROM THE MONITOR ....36

FIGURE 30: MONITOR WITH BOTH VALVES OPEN ...............................................................36

FIGURE 31: 6-FOOT LONG A/B TYPE USB CABLE ...............................................................38


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1.0 INTRODUCTION

1.1. DOCUMENTATION SCOPE AND UPDATES

This Installation and Operation Manualprovides information on how to install and

start up a Calisto monitor (models C76 & C76A) or a Calisto 2 monitor (models C85 &

C85A). Instructions are also provided on how to connect alarm relays, input & output

signals, and communication connections. For instructions on how to configure and

operate the Calisto/Calisto 2 using Morgan Schaffers Calisto Manager software, con-sult the Calisto Manager User Guide.

NOTICE

The information provided in this manual is applicable to four

models: Calisto (C76), Calisto (C76A), Calisto 2 (C85) and

Calisto 2 (C85A). When a section is applicable only to a spe-cific model, it will be clearly stated.

An electronic version of this manual is available on the Calisto/Calisto 2 CD supplied

with the monitor, and on Morgan Schaffers website www.morganschaffer.com. Visit

our website or contact us directly for documentation, firmware and software updates.

DISCLAIMER

It is assumed by Morgan Schaffer that users will read the present

Installation and Operation Manualand will understand the operation of

the monitor prior to the installation of the monitor.

All results obtained using a Calisto or Calisto 2 monitor are based uponmaterial and equipment under the responsibility of the client. Morgan

Schaffer assumes no responsibility and makes no warranty or represen-

tation, expressed or implied, as to the condition, productivity or proper

operation of any equipment or other property for which the Calisto or

Calisto 2 monitor may be used or relied upon for any reason whatsoever.
http://www.morganschaffer.com/http://www.morganschaffer.com/


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1.2. GENERAL SAFETY INFORMATION

For your safety, symbols and signal words are used in this manual and on the Calisto/

Calisto 2 monitor to identify hazards. They are defined as follows:

Direct current

Alternating current

Earth ground terminal

Protective conductor terminal (ground)

| On (Power)

O Off (Power)

Caution, possibility of electric shock.

Caution, possibility of personal injury. This manual must be consulted

in all cases where this symbol is marked on the monitor.

WARNINGA WARNING note indicates a potential hazard which, if not avoided,

could result in serious injury or death.

CAUTIONA CAUTION note indicates a potential hazard which, if not avoided,

could result in personal injury or could cause damage to the monitor.

NOTICE

A NOTICE note indicates information that is particularly important for

the optimal functioning of the monitor.

1.3. MONITOR WARRANTY

The Calisto/Calisto 2 monitor is covered by a 3-year warranty from the date of ship-

ment. The gas detection cell and oil circulation pump are covered by a 5-year warranty

from the date of shipment. Refer to the manufacturers certificate of warranty included

with each Calisto/Calisto 2 for more information.

Extended warranties are also available. Contact Morgan Schaffer for more information.

1.4. CALISTO/CALISTO 2 OVERVIEW

Calisto and Calisto 2 are online monitors that can continuously measure the con-

centration of fault gases dissolved in the dielectric insulating fluid of a transformer.

Calisto measures dissolved hydrogen (H2) and moisture (H

2O), while Calisto 2 addi-

tionally measures dissolved carbon monoxide (CO). Continuous monitoring of these


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key gases, particularly at low concentrations, allows early detection of transformer

faults and can play an important role in transformer asset management.

OIL CIRCULATION & FLOW MONITORING

An anti-cavitation reciprocating pump draws oil from the transformer into the Calisto/

Calisto 2 through the oil supply line. Once the oil has been analyzed, it is returned to

the transformer through the oil return line. An oil flow monitoring system provides a

low-flow warning if the flow drops below a pre-set threshold.

CONTINUOUS ENCLOSURE AND OIL TEMPERATURE CONDITIONING

Continuous enclosure and oil temperature conditioning is essential for accurate read-

ings. The temperature of the circulating oil as it passes through the monitor, and

the temperature inside the enclosure are controlled to a set temperature using heat

exchangers and thermo-electric elements.

PRECISE AND ACCURATE GAS MEASUREMENTS

Calisto/Calisto 2 uses an enhanced version of Morgan Schaffers proprietary high-

accuracy thermal conductivity detection (TCD) technology to provide accurate gas

measurements. As oil is pumped past a bundle of PTFE capillary tubes, which form the

gas extraction probe, dissolved gases permeate through the walls of the tubing. The

gases then diffuse along the capillary tubes to form a gas sample inside the detection

cell. Any change of gas concentration in the oil will result in a corresponding change

within the probe and the detection cell.

COMMUNICATION

For an easy integration of the monitor within existing operations, Calisto/Calisto 2

has numerous connection options and comes standard with DNP3 and Modbus com-

munication protocols.

DATA

When the monitor is in operation, date and time-stamped measurements are stored

in the monitors memory at a default frequency of one reading every three hours. The

data can either be viewed on the display, or it can be retrieved and viewed graphically

using the Calisto Manager software.

VACUUM TOLERANCE

The gas sampling, oil circulating and oil temperature conditioning systems have been

designed to sustain vacuum. No action is required to protect the Calisto/Calisto 2

monitor if the transformer is put under vacuum for degassing purposes.


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1.5. MONITOR MAIN COMPONENTS

The main external components of a Calisto/Calisto 2 are shown in Figure 1and Figure

2.

1. Oil outlet port(3/8" OD compression fitting)

2. Display

3. Display buttons

4. Oil sampling port

5. Oil inlet port(3/8" OD compression fitting)

6. Mains supply switch

Figure 1: Front view (Calisto 2 model shown)


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1. Oil outlet port

2. Mains supply switch3. Electrical hubs (x4)

4. Oil inlet port

5. Oil sampling port

6. Air vent out7. Fan assembly

8. Air vent out

Figure 2: Bottom view


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The main internal components of a Calisto (C76)/Calisto 2 (C85) are shown in Figure

3.

1. Oil outlet shut-off valve2. Mains & communication PCB

3. Door ground link

4. Main I/O PCB

5. CPU board

6. Detection cell I/O PCB7. Detection cell

8. Thermal cut-off fuse

9. Oil inlet shut-off valve

10. Protective conductor terminal (ground)

Figure 3: Calisto (C76)/Calisto 2 (C85) - Main internal components


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The main internal components of a Calisto (C76A)/Calisto 2 (C85A) are shown in

Figure 4.

1. Oil outlet shut-off valve

2. Mains PCB

3. Door ground link

4. Main I/O PCB

5. CPU board

6. Detection cell I/O PCB

7. Detection cell

8. Thermal cut-off fuse

9. Communication interface PCB

10. Oil inlet shut-off valve


Figure 4: Calisto (C76A)/Calisto 2 (C85A) - Main internal components


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1.6. STANDARD PACKAGE CONTENTS

The following table lists the items included in a standard Calisto/Calisto 2 package:

Part Number Qty. Description

(various) 1 Calisto/Calisto 2 monitor (standard)

WRE-00067 1 USB cable (6 feet - for local connection)

BCAL-0062 4 S.S. shock mount assembly

BCAL-0054 1 Quick connect oil sampling tube

ECM-00066 1 Thermal cut-off fuse (spare)

BFM-00038 2 Copper tubing 3/8" OD 25 ft (7.6 m)

FLC-00242 2 Brass elbow " NPT (M) 3/8" Tube

FLC-00249 4 Brass sleeve 3/8" Tube (spare)

008-MSMAN 1 Calisto/Calisto 2 Installation and Operation Manual

010-MSMAN 1 Calisto Manager interface software CD + user guide

N/A 1Factory test certificate, Declaration of Conformity,Certificate of Warranty

The following table lists the items included in the package for a Calisto/Calisto 2 for

stainless steel lines:

Part Number Qty. Description(various) 1 Calisto/Calisto 2 monitor for S.S. lines

WRE-00067 1 USB cable (6 feet - for local connection)

BCAL-0062 4 S.S. shock mount assembly

BCAL-0054 1 Quick connect oil sampling tube

ECM-00066 1 Thermal cut-off fuse (spare)

FLC-00022 2 S.S. elbow connector " NPT (M) 3/8" Tube

008-MSMAN 1 Calisto/Calisto 2 Installation and Operation Manual

010-MSMAN 1 Calisto Manager interface software CD + user guide

N/A 1Factory test certificate, Declaration of Conformity,Certificate of Warranty


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2.0 INSTALLATION

2.1. INTRODUCTION

WARNING

Monitors should only be installed by qualified personnel

familiar with the operation and associated hazards. Improper

electrical or hydraulic circuitry may result in personal injury

and/or damage to the monitor and may void the warranty.

CAUTION

Before starting the installation, ensure that the mains supply

switch of the monitor is in the position (OFF).

CAUTION

Calisto/Calisto 2 is shipped filled with new transformer min-

eral oil. Do not open inlet and outlet valves prior to the

installation. The INLET and OUTLET valves are in a horizon-

tal position when closed.

CAUTION

Two persons are recommended for installing the Calisto/

Calisto 2.

There are two possible types of installation: factory installation and field installation.

A factory installation is when a Calisto/Calisto 2 is installed on a new transformer

directly by the transformer manufacturer. A field installation is when a Calisto/Calisto

2 is installed on an existing transformer in the field.

The steps for installing a Calisto/Calisto 2 are:

Selecting the transformer valves (Section 2.2)

Securing the monitor on transformer or suitable structure (Section 2.3)

Wiring the electrical connections (Section 2.4)

Connecting the oil lines (Section 2.5)


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The following tools are required for a standard installation:

Tube cutter (for rigid oil lines)

5/8" and 11/16" open-end wrenches (or an adjustable wrench)

Wire stripper

Small flathead screwdriver

Large flathead screwdriver

2.2. SELECTING THE TRANSFORMER VALVES

Calisto/Calisto 2 requires two oil valves from the transformer.

For a factory installation, most transformer manufacturers will install two in. (1.3

cm) 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.

For a field installation, it is recommended to use the top fill valve as the SUPPLY valve,and the bottom drain valve as the RETURN valve. This can only be done if the top fill

valve is below the top oil level. The alternative is to draw oil from the bottom drain

valve and return it through the top fill valve, but this may not be ideal as an excessive

amount of sludge may be found at the bottom of the transformer.

Consider the following guidelines when selecting the appropriate SUPPLY and RETURN

valves:

To ensure representative sampling of the transformer oil, the distance betweenthe SUPPLY and RETURN valves should be a minimum of 1 m (3 ft).

The SUPPLY and RETURN valves must not be close to a transformer oil circulat-ing pump.

The SUPPLY valve should be at least 0.45 m (18 in.) from the bottom of the maintank.

The valves should have a minimum diameter of " NPT. Female, ball or gatetype valves are recommended.

The oil return line must not exceed 11 m (35 ft) in length.

The oil supply line must be longer than 1 m (3 ft) in length, to limit mechanicalstress.


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2.3. SECURING THE MONITOR

NOTICE

Calisto/Calisto 2 is designed to be installed vertically. It

MUST NOT BE MOUNTED IN ANY OTHER ORIENTATION.

The Calisto/Calisto 2 must be solidly secured to a suitable support. Typically, Unistrut

brackets are used to make a base for mounting the Calisto/Calisto 2. The mounting

structure can be designed to clamp onto the transformer tank, the main control cabi-

net, or on a post installed in the ground or on a concrete base.

For factory installations, the monitor will usually be installed on Unistrut brackets

that are welded to the main transformer tank. It will usually be mounted at eye level,

near the SUPPLY and RETURN valves.

For field installations, it is recommended to mount the monitor on a post bolted to the

concrete base of the transformer. The Morgan Schaffer Calisto Mounting Stand is avail-able as an optional accessory. Refer to the Calisto Mounting Stand Installation Manual

when mounting a Calisto/Calisto 2 on the stand.

The Calisto/Calisto 2 mounting-hole locations are shown in Figure 5. The diameter of

the mounting holes is 9.5 mm (3/8 in.). The depth of the monitor is 309 mm (12.2 in.).

Figure 5: Mounting diagram


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Consider the following guidelines when securing the monitor:

Secure the monitor approximately 1.2 m (4 ft) above ground level for easyaccess to the oil inlet and outlet shut-off valves of the monitor.

A minimum of 60 cm (24 in.) is required for air circulation under the monitor.

It is recommended to install the monitor such that the display is at eye level.

The monitor should be located near the SUPPLY and RETURN valves selected fol-lowing the guidelines listed in Section 2.2. Keep in mind that the monitor mustbe within 11 m (35 ft) from the RETURN valve, and at least 1 m (3 ft) away fromthe SUPPLY valve.

The location of the mounting structure should be chosen to protect the monitorfrom extreme vibrations. Four shock mounts are provided with each monitorand should be used to give the monitor additional protection against vibration(see Figure 6).

Figure 6: Installation of shock mounts


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2.4. WIRING THE ELECTRICAL CONNECTIONS

WARNING

Electrical shock hazard. Only persons with electrical safety

training and certification should undertake the electrical

installation of the monitor, or open the enclosure after the

equipment has been installed.

Power and communication connections to a Calisto/Calisto 2 are made using the

mains connection and communication interface boards. The sections that followexplain how to connect the safety ground, mains power, alarm relays, analog signals,

and communication cables to a Calisto/Calisto 2. The alarm relay assignments, analog

signals and communication connections are configured using Calisto Manager. Refer

to the Calisto Manager User Guidefor instructions.

Figure 7shows the components of the mains connection and communication inter-

face board for a Calisto (C76)/Calisto 2 (C85).

1. Mains power connectors

2. Thermal cut-off fuse connectors

3. Over current fuse

4. Programmable relay terminals

5. Programmable relays with activity LEDs

6. Ethernet communication port

7. Local USB type B port

8. 4-20 mA analog output terminals

9. 4-20 mA analog input terminals

10. RS-232 communication port


12. Ethernet shield earth jumper

Figure 7: Calisto (C76)/Calisto 2 (C85) - Interface board components


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Figure 8shows the components of the mains connection and communication inter-

face boards for a Calisto (C76A)/Calisto 2 (C85A).

1. Mains power connectors

2. Over current fuse

3. Thermal cut-off fuse connectors

4. Programmable relay terminals

5. Programmable relays with activityLEDs

6. Ethernet shield earth jumper

7. Ethernet communication ports (x2)

8. 4-20 mA analog output terminals

9. 4-20 mA analog input terminals



12. Local USB type B port

Calisto/Calisto 2 features a 4-hub detachable electrical entry plate. All entry holes are

22 mm (7/8 in.) in diameter and can accept most in. entry hub fittings. Four water-

proof rubber plugs are provided with the monitor to cover unused holes.

Consider the following guidelines when wiring signal and communication cables:

It is recommended to select shielded cables designed for outdoor use.

Avoid loops and minimize the length of the cables from the hub to the commu-nication interface board of the monitor.

Protect all wires and connectors against mechanical stress.

Proper connectors and fittings must be used to prevent water ingress to themonitor.

Figure 8: Calisto (C76A)/Calisto 2 (C85A) - Interface board components


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2.4.1. CONNECTING THE EARTH GROUND

WARNING

Install the protective earth conductor to the protective conduc-

tor terminal (ground) 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. It is the clients

responsibility to ensure the integrity of the ground cable and client-side ground con-nection. The location of the protective conductor terminal (ground) is shown in Figure

9. To connect the earth ground, secure the protective earth conductor to the green

screw on the right side of the protective conductor terminal (ground) by following the

safety requirements in the international standard IEC 61010.

An additional protective earth ground connection may be made to the chassis using

the hole provided on the right side of the bottom mounting flange of the monitor (see

Figure 9).


2. Additional earth ground connection hole

Figure 9: Earth ground connections


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2.4.2. CONNECTING THE MAINS POWER

The Calisto (C76)/Calisto 2 (C85) monitor accepts 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) (see Figure 10).

The Calisto (C76A)/Calisto 2 (C85A) monitor accepts any supply voltage from 100 to

240 VAC with frequencies in the range of 50 to 60 Hz, and from 100-220 VDC. Mains

power connections are made to connector 1 (neutral or -) and connector 2 (line or +)

(see Figure 11).

The connections must be made according to the following connector ratings:

Rating Nominal value/range

Connection range: 2.08 3.31 mm2solid

Connection range (UL/CSA): 14 12 AWG

Wire strip length: 9 mm (~3/8 in.)

Wire insulation ratings:300V,90C (194F) or better

Flammability: VW-1 or better

Screw type: M2.5

The mains power connection may be made using either solid or stranded conduc-

tors. To help with the connection, it is recommended to install ferrules at the ends of

stranded conductors. Make sure to select ferrules of the correct size for the type of

conductor used.

Figure 10: Calisto (C76)/Calisto 2 (C85) - Power connections

Figure 11: Calisto (C76A)/Calisto (C85A) - Power connections


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To connect the mains power, completely loosen each screw terminal, insert the con-

ductor to the bottom of the terminal slot, and then tighten the screw while holding

the conductor to the bottom of the slot. Failure to hold the conductor to the bottom of

the slot as the screw is tightened may lead to an unsound connection.

The nominal power of Calisto/Calisto 2 is 320 W. The mains supply switch of the

monitor may be used to turn the monitor ON () or OFF (). The monitor should

be wired to draw power from a dedicated circuit breaker with suitable current and

voltage ratings.

2.4.3. CONNECTING THE ALARM RELAYS

WARNING

Electrical shock hazard. Alarm relays may be connected to

hazardous live voltage even if the mains power is OFF or

disconnected.

Calisto/Calisto 2 features five programmable dry-contact output relays which can be

connected in a normally open (NO) or normally closed (NC) configuration (see Figure

12).

Note: Calisto (C76A)/Calisto 2 (C85A) model shown. For

Calisto (C76)/Calisto 2 (C85), connector 16 is a SHIELD.

Figure 12: Alarm relays and connections


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The table below shows the alarm relay connections for the alarm relay terminal strip.

Connector No. Marking Connection Type

1 RLY1_NC Relay 1 normally closed (NC)

2 RLY1_COM Relay 1 common

3 RLY1_NO Relay 1 normally open (NO)













16SHIELD (for C76/C85)N/A (for C76A/C85A)

Shield to earth groundUnused

17 SHIELD Shield to earth ground

18 SHIELD Shield to earth ground

The relay connections must be made according to the following connector ratings:


Connection range: 0.33 2.08 mm2stranded

Connection range (UL/CSA): 22 14 AWG stranded

Wire strip length: 9 mm (~3/8 in.)

Wire insulation ratings:300V,90C (194F) or better


Screw type: M2.5

Terminals marked "RLYx_COM" are all commons and can be looped together into one

single common if all signals route to the same location. Terminals marked "SHIELD"can be used to terminate an alarm cable shield to the earth ground.

If gauge 14 conductors are used, it may be necessary to use 2 entry hubs for the relay

wires, or to modify the entry plate to accept a larger diameter hub and conduit.


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To connect the relay connections, completely loosen each screw terminal, insert the

conductor to the bottom of the terminal slot, and tighten the screw while holding

the conductor to the bottom of the slot.

Recommended use of the alarm relays:

AC Connections DC Connections

Min./Max. switching voltage: 5V/400VAC 5V/300VDC

Rated resistive load: 16A/250VAC

16A/24VDC1A/48VDC0.4A/100VDC

0.3A/(150-300)VDCMin. switching current: 5mA 5mA

Coil-contact dielectricstrength:

5000VAC 5000VAC

2.4.4. CONNECTING THE ANALOG OUTPUTS

Calisto/Calisto 2 features up to three analog outputs (see Figure 13). The 4-20 mA

analog outputs for dissolved hydrogen (H2) and moisture (H2O) are used for Calisto

(C76 and C76A) monitors. Calisto 2 (C85 and C85A) additionally uses the 4-20 mA

analog output dedicated to carbon monoxide (CO).

Pin No. Output Description

1 SHLD Shield to earth ground


3 N/A Unused

4 Moisture (H2O) Positive (+)

5 Moisture (H2O) Negative (-)

6 Hydrogen (H2) Positive (+)

7 Hydrogen (H2) Negative (-)8 Carbon monoxide (CO) Positive (+) (Calisto 2 only)

9 Carbon monoxide (CO) Negative (-) (Calisto 2 only)

Figure 13: Analog output connector


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The analog output connections must be made according to the following connector

ratings:


Connection range: 0.33 1.31 mm2solid/stranded


Wire strip length: 6.5 mm (~1/4 in.)

Wire insulation ratings:150V (300V is preferred to preserve

1500V functional I/O isolation)90C (194F) or better


Screw type: M2.0

It is recommended to remove the connector to simplify wiring the connections, and to

screw the connector back in place after the connections are made.

The maximum length of the wires depends on the resistance of the client load and

the acceptable noise level. The load resistance must be in the range of 0-500 Ohms,including resistance of the wires.

2.4.5. CONNECTING THE ANALOG INPUT

Calisto/Calisto 2 features one 4-20 mA analog input that can be used to provide a

reading of the transformer oil temperature to the monitor (see Figure 14). The 4-20mA analog input supply voltage is +24 VDC.

Pin No. Marking Description


2 Unused

3 - 4-20 mA negative (-)

4 + 4-20 mA positive (+)

Figure 14: 4-20 mA analog input connector


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The 4-20 mA analog input connections must be made according to the following con-

nector ratings:








Screw type: M2.0


screw the connector in place after the connections are made.

The Morgan Schaffer Precision Oil Temperature Probe is available as an optional acces-

sory to collect oil temperature data. Refer to the Precision Oil Temperature ProbeInstallation Manualfor instructions.

2.4.6. CONNECTING THE RS-485 COMMUNICATION

Calisto/Calisto 2 features one RS-485 communication port (see Figure 15).



2 Unused

3 COMM Common signal ground

4 A Line A

5 B Line B

Figure 15: RS-485 connection


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The RS-485 connections must be made according to the following connector ratings:








Screw type: M2.0

The range for RS-485 communication can span up to 4000 ft (1200 m). It is highly

recommended to select an industrial grade shielded twisted pair cable of minimum

0.33 mm2(22 AWG) for RS-485 connections.


screw the connector in place after the connections are made.

For reliable RS-485 communication, the RS-485 common signal ground must be con-

nected on both the Calisto/Calisto 2 monitor (pin 3, marked "COMM") and on the

client RS-485 device. Note that the common signal ground is not a shielding

ground. The RS-485 common signal ground should not be connected to the chas-

sis ground or "SHLD" on the monitor, nor on the client RS-485 device. Since Calisto/

Calisto 2 provides 1500 V isolation, it is recommended to use an RS-485 device thatalso offers good isolation.

CAUTION

Morgan Schaffer cannot be held responsible for a monitor

communication malfunction if the RS-485 cable shield is not

properly connected to pin 1 (SHLD).

The communication interface board provides a 120 Ohm terminating resistor which

may be used to terminate the RS-485 link. To connect the terminating resistor, install

the provided jumper across J6, which is found beneath the RS-485 connector.

Calisto/Calisto 2 supports several protocols over RS-485:

MSSP (Morgan Schaffer Systems Protocol)

DNP3

Modbus


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2.4.7. CONNECTING THE RS-232 COMMUNICATION

Calisto/Calisto 2 features one RS-232 communication port (see Figure 16).


1 SHLD Shield to earth ground2 Unused

3 GND Signal ground

4 RX Received data

5 TX Transmitted data

The RS-232 connections must be made according to the following connector ratings:





Wire insulation ratings:

150V (300V is preferred to preserve



Screw type: M2.0

The maximum recommended range for RS-232 communication is 15 m (50 feet). It is

highly recommended to select an industrial grade shielded twisted pair cable of mini-

mum 0.33 mm2(22 AWG) for RS-232 connections.

The RS-232 signal ground (pin 3, marked GND) should always be wired properly to

ensure a reliable connection.

Calisto/Calisto 2 RS-232 communication only supports Morgan Schaffer Systems

Protocol (MSSP).

Figure 16: RS-232 connection

CO C G CO C O


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2.4.8. CONNECTING THE ETHERNET COMMUNICATION

Calisto (C76)/Calisto 2 (C85) features one RJ45 Ethernet port which allows the moni-

tor to be connected to a computer or a corporate LAN or WAN (see Figure 17).

Calisto (C76A)/Calisto 2 (C85A) features two RJ45 Ethernet ports (see Figure 18). With

two Ethernet ports, all the protocols supported by Calisto/Calisto 2 over Ethernet may

run simultaneously. The J9 Ethernet port is dedicated to the MSSP, DNP3 and Modbus

protocols, while the J4 Ethernet port is for the IEC 61850 protocol.

The Ethernet connection must be made according to the following connector ratings:





Screw type: M2.0

The maximum recommended range for an Ethernet connection is 30 m (100 feet). It is

recommended to use an industrial FTP or ScTP cable suitable for outdoor use (oil and

sun resistant), even if a protective conduit is used.

The RJ45 Ethernet ports can be shielded using jumper J7 (Ethernet shield to earth

ground). 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

clients side. Grounding at both ends may lead to poor communication and/or damage

to the monitor.

Morgan Schaffer cannot guarantee protection from an external surge (such as lightning

Figure 17: Calisto (C76)/Calisto 2 (C85) - RJ45

Ethernet port

Figure 18: Calisto (C76A)/Calisto 2 (C85A) -

RJ45 Ethernet port

or electrical arc) over 1500 V that could infiltrate the Ethernet line It is the clients


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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

Modbus

IEC 61850 PROTOCOL (OPTIONAL)

With the optional IEC 61850 Communication kit, Calisto/Calisto 2 supports the IEC61850 substation protocol. Refer to the IEC 61850 Communication Kit Installation and

Configuration Manualfor more information.

ETHERNET OUTDOOR CONNECTIVITY KIT (OPTIONAL)

The optional Ethernet Outdoor Connectivity Kit allows for an easy and reliable connec-

tion from the monitor to a control panel. It includes an outdoor rated Ethernet cable

with screw-in plugs, as well as all the hardware required to connect the external cable

to the monitors communication interface board.

Consider the following guidelines when installing the Ethernet Outdoor connectivity

kit:

The RJ45 pass-through bulkhead provided requires a 1-inch hole and must be

installed on a control cabinet.

The patch cord shield must be connected to the ground for interference immu-

nity. A Calisto/Calisto 2 monitor ordered with this option will have jumper J7

linking the RJ45 Ethernet port shield to the earth ground. Thus, there is no need

to connect the shield on the client side.

2 4 9 CONNECTING THE USB COMMUNICATION


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2.4.9. CONNECTING THE USB COMMUNICATION

CAUTION

The USB port does not provide high voltage isolation. It

should only be used for local connection using portable

computers.

The Calisto/Calisto 2 communication interface board includes a type B USB port (see

Figure 19). It is convenient to use the USB port for the configuration, setup and main-

tenance of the monitor. A local connection through the USB port is possible with the1.8 m (6 ft) A/B type USB cable supplied with the monitor.

Driver installation is required in order to communicate over USB. Refer to the Calisto

Manager User Guidefor instructions on how to install Calisto Manager and the required

USB drivers on a PC.

2.5. CONNECTING THE OIL LINES

Two 25-foot long (7.6 m) copper tubing oil lines (3/8" OD) are included with each

standard Calisto/Calisto 2 monitor. Stainless steel braided flexible hoses with 3/8"

connectors are available to order separately for Calisto/Calisto 2 monitors for stain-

less steel oil lines.

Consider the following guidelines before connecting the oil lines:

It is recommended to install optional shutoff valves (preferably ball valves)underneath the monitor on the oil supply and return lines. Should it becomenecessary, these valves will simplify the removal of the monitor.

Do not make straight lines between the transformer tank and the monitor.

Include one loop or bend in the oil line. In very cold environments, it is recommended to permanently insulate the oil

lines.

In very hot environments, it is recommended notto insulate the oil lines.

Figure 19: USB port

2 5 1 PREPARING THE TRANSFORMER VALVES


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2.5.1. PREPARING THE TRANSFORMER VALVES

Before installing the oil lines, the transformer valves selected to circulate oil to and

from the monitor must be prepared to accept the elbow tube fittings included in the

standard package contents.

Install the two supplied 3/8" tube to " NPT male elbow fittings to the SUPPLY and

RETURN valves of the transformer. If necessary, use a pipe adapter to fit the " NPT

male end to the transformer valves (see Figure 20).

1. Transformer valve

2. Adapter (if necessary)

3. 3/8" tube to " NPT male elbow fitting

NOTICE

If a Precision Oil Temperature Probe is to be installed with

the monitor, the tee fitting provided with the temperature

probe must be installed on the oil SUPPLY valve insteadof an elbow. Refer to the Precision Oil Temperature Probe

Installation Manual.

Figure 20: Installation of the elbow fittings

2 5 2 CONNECTING THE OIL LINES


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2.5.2. CONNECTING THE OIL LINES

Consider the following guidelines when connecting the oil lines:

Use a counter-torque wrench to avoid damaging the INLET and OUTLET ports onthe monitor. The torque and counter-torque wrenches must be aligned one overthe other as much as possible to cancel induced forces.

If using rigid tubing, a tube cutter must be used to cut oil lines. Other toolsmust be avoided as they can leave burrs, debris and scratches on the surface tobe swaged.

If using rigid tubing, make sure the tubing is straight for several inches where itenters the fitting.

Incorporate at least one shallow bend in the tubing to help with the installation.

STEP 1: Connect the oil supply line.

a. Insert one end of the oil supply line firmly into the monitor INLET port (see

Figure 21).

b. Using an 11/16" wrench and a 5/8" counter-torque wrench, tighten the

compression nut of the INLET port 1 turns from finger tight for

proper sealing.

c. Route the oil supply line to the transformer SUPPLY valve.

d. If using rigid tubing, cut off the excess length using a tube cutter and de-

bur the inside of the tube.

Figure 21: Connecting the oil supply line to the INLET port

e. Insert the free end of the oil supply line into the elbow fitting installed at


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the transformer SUPPLY valve (or the tee fitting assembly when installing a

Precision Oil Temperature Probe). Tighten the compression nut 1 turns

from finger tightto complete the oil supply line installation.

STEP 2: Connect the oil return line.

a. Insert one end of the oil return line firmly into the monitor OUTLET port

(see Figure 22).

b. Using an 11/16" wrench and a 5/8" counter-torque wrench, tighten the

compression nut of the outlet port 1 turns from finger tight for

proper sealing.

c. Route the oil return line to the transformer RETURN valve.

d. If using rigid tubing, cut off the excess length using a tube cutter and de-

bur the inside of the tube.

e. Insert the free end of the oil return line into the elbow fitting installed at

the transformer RETURN valve. Tighten the compression nut 1 turns

from finger tightto complete the oil return line installation.

STEP 3: Secure all oil lines against excessive vibration.

Figure 22: Connecting the oil return line to the OUTLET port

2.5.3. PURGING THE OIL LINES


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2.5.3. PURGING THE OIL LINES

Once all connections are made, the lines and the monitor must be flushed with oil to

remove any air present in the system and to replace the shipping oil inside the moni-

tor with oil from the transformer. 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.

NOTICE

If a Precision Oil Temperature Probe option is to be installed

with the monitor, the Installation section of the Precision

Oil Temperature Probe Installation Manualmust now be fol-

lowed before proceeding to purge the oil lines.

STEP 1: Ensure that both monitor valvesare still closed (valve handles in the hori-

zontal position, see Figure 23), then slowly open both transformer valves.

Figure 23: Monitor with both valves closed

STEP 2: Firmly push the supplied Quick Connect Oil Sampling Tube (see Figure 24)


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into the monitors oil sampling port located next to the oil INLET port (see

Figure 25).

Figure 24: Quick Connect Oil Sampling Tube

Figure 25: Connecting the quick connect oil sampling tube to the monitor

STEP 3: Using a container to collect flushed oil, slowly turn the OUTLET valve counter

l k i ( h h dl ill h b i i d ) fl h h


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clockwise turn (the handle will then be pointing down) to flush the return

line with oil (see Figure 26). To avoid injecting trapped air in the transformer,

flush a minimum of 500 cc of oil.

STEP 4: Once a minimum of 500 cc of oil has been flushed, close the OUTLET valve

by turning it clockwise to the horizontal position (see Figure 27).

Figure 26: Flushing the oil return line

Figure 27: Closing the monitor OUTLET valve


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NOTICE

Before proceeding with Step 5, the following checks shouldbe made:

The earth ground is properly connected.

The mains power is protected by a circuit breaker.

The mains supply switch is in the position (OFF).

Both transformer oil SUPPLY and oil RETURN valves are open.

Both monitor oil INLET and oil OUTLET valves are closed.

STEP 5:

a. Slowly turn the INLET valve counter clockwise turn to the vertical posi-

tion (the handle will then be pointing upwards) (see Figure 28).

b. Using a container to collect flushed oil, turn the mains supply switch tothe (ON) position for the internal oil circulation pump to start flushing

the oil in the supply line. To avoid injecting trapped air in the transformer,

flush a minimum of 500 cc of oil.

c. After 500 cc of oil has been flushed, turn the mains supply switch to the

position (OFF).

Figure 28: Flushing the oil supply line

STEP 6: While the INLET valve is open, remove the Quick Connect Oil Sampling Tube

from the oil sampling port by pushing the locking ring down and pulling the


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from the oil sampling port by pushing the locking ring down and pulling the

Quick Connect Oil Sampling Tube out (see Figure 29).

STEP 7: Open the OUTLET valve. At this step, both transformer valves and both

monitor valves should be openas shown in Figure 30. The monitor is

now ready to be powered up.

Figure 29: Disconnecting the Quick Connect Oil Sampling Tube from the monitor

Figure 30: Monitor with both valves open

3.0 START UP


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3.1. IMPORTANT CHECKS BEFORE POWER UPThe following checks should be made before providing power to the monitor:

Verify that no tools or other equipment have been left inside the monitor.

The earth ground is properly connected.

The mains power is properly connected.

The monitor is protected by an appropriate circuit breaker.

All signal, relay and communication wirings are installed.

Both transformer oil SUPPLY and RETURN valves are open.

Both monitor oil INLET and OUTLET valves are open.

All conduit fittings are fully tightened and rubber plugs are installed on unusedentry holes.

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

Verify that the oil line connections have no leaks.

3.2. MONITOR POWER UP

Once the monitor has been properly installed and the checks in Section 3.1have been

made, the monitor can be powered up by turning the mains supply switch to the

position (ON). A reading will only be displayed on the door display after approxi-

mately five seconds, which is the time delay required for firmware initialization.

NOTICEIf the monitor temperature is below -35C (-31F) at power-

up, the monitor will enter a pre-heating mode where only the

enclosure heaters will be activated. The monitor on-board

computer will start once the enclosure temperature has

reached -5C (23F). This could take several minutes or even

hours in extremely cold environments.

When the Calisto/Calisto 2 is powered on or reset, the monitor first enters an ini-

tialization and power-on self-test sequence. The purpose of this mode is to allow


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tialization and power on self test sequence. The purpose of this mode is to allow

the on-board computer to evaluate temperature conditions and to allow the internal

measurement systems to reach equilibrium. The duration of the initialization is three

hours, or one complete measuring cycle. During the initialization time, the display willindicate .

The measurement cycle will begin once the initialization sequence has been com-

pleted. The most recent validated measurement for hydrogen will be displayed

on the door display. Refer to Section 3.4for a complete description of the

display interface.

3.3. CONFIGURING THE MONITOR

WARNING


training and certification should install the equipment or

open the enclosure once the equipment has been installed.

The Calisto/Calisto 2 is now ready to be configured using the Calisto Manager soft-

ware. Refer to the Calisto Manager User Guidefor instructions on how to connect to,

configure, and view the status of the monitor using Calisto Manager.

For the initial configuration of the monitor, a local connection to the monitor via the

USB port with a portable computer is ideal. The 1.8 m (6 ft) A/B type USB cable pro-

vided with the monitor may be used for the connection (see Figure 31).

Figure 31: 6-foot long A/B type USB cable

3.4. DISPLAY INTERFACE


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The 3-button display interface provides access to three menu sections: realtime

, manufacturer , and database .

To toggle between the menu sections , and: simultaneously press buttons 1 and 2.

To scroll through the fields within the same section: press button 3.

The display will return to the default section after 10 seconds ofinactivity.

When a value is unavailable, it is reported as INIT.

When a value is under the detection limit, it is reported as TOR.

Trends cannot be viewed via the display.

The following table describes the abbreviations used in the display interface:

Abbreviation Description

H2 Validated Hydrogen (PPM)

CO Validated Carbon Monoxide (PPM)

WRS Moisture Relative Saturation (%RS@25C)

WWC Water Content (PPM)

RS1 Moisture Relative Saturation (%RS@T1C)

RS4 Moisture Relative Saturation (%RS@T4C)

T1 Transformer Oil Temperature 1 (C)

T4 Transformer Oil Temperature 4 (C)

Cxx Unit Model Number

xxxxx Unit Serial Number

v x.xx Firmware Version

ID Unit RS-485 ID

yyyymmdd Date YYYYMMDD

TMhhmmss Time HHMMSS

CT Detection Cell Temperature (C)

BT Box Temperature (C)

OT Oil Temperature (C)

ST Heatsink Temperature (C)

REC Record Number

The realtime section displays the most recent readings of the monitor By default the


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The realtime section displays the most recent readings of the monitor. By default, the

display will show the last validated concentration of hydrogen . Press but-

ton 3 to access the following information:

H2 >CO >WRS >WWC >RS1 >RS4 >T1 >T4

The manufacturer section displays useful information about the monitor. Once in the

manufacturer section, press button 3 to access the following information:

Cxx>xxxxx>v x.xx>ID >yyyymmdd>TMhhmmss>CT >BT >OT >ST

The database section displays information for all of the recorded data. Once in the

database section, the records are listed by number, , from the most recent

to the oldest.

Press button 1 to scroll down to older records.

Press button 2 to scroll up to newer records.

Press button 3 to access the following information for a specific record:

H2 >CO >WRS >WWC >RS1 >RS4 >T1 >T4 >yyyymmdd>TMhhmmss

The following table summarizes the display interface:

Button 1 + Button 2

Realtime Manufacturer DatabaseButton 3 H2 Cxx REC=xxx ... REC=001

CO xxxxx H2 H2

WRS v x.xx CO COWWC ID WRS WRS

RS1 yyyymmdd WWC WWC

RS4 TMhhmmss RS1 RS1

T1 CT RS4 RS4

T4 BT T1 T1

OT T4 T4

ST yyyymmdd yyyymmdd

TMhhmmss TMhhmmss

Button 1Button 2

3.4.1. ERROR CODES


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In case of malfunction, an error message will appear on the display of the Calisto/

Calisto 2 monitor. The error messages ER1 and/or ER2 will alternate on the display

along with . The error messages may also be viewed using Calisto Manager.

The error message will display a hexadecimal error code. To interpret a combination

of error codes, convert the hexadecimal number to a binary number and compare it

to the following table:

Binary bit

position 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Error code 8000 4000 2000 1000 800 400 200 100 80 40 20 10 8 4 2 1

Error Code 1

(ER1)Error Name Instructions

1 Outside fanStep 1: Remove any obstruction which may be preventing theexternal fan rotation.

Step 2: Contact Morgan Schaffer for assistance.

2 Inside fan Contact Morgan Schaffer for assistance.

4, 8, 400,4000

Detectioncell

Contact Morgan Schaffer for assistance.

10, 20, 40,

80, 100, 200

Thermal

regulation Contact Morgan Schaffer for assistance.

800Pump

circulationContact Morgan Schaffer for assistance.

1000Moisturesensor

Contact Morgan Schaffer for assistance.

2000Analoginput

Step 1: Use a multimeter to confirm current flow in the 4-20mA input circuit.

Step 2: Verify the 4-20 mA input connections as described inSection 2.4.5.

Step 3: Verify the functionality of the 4-20 mA source.


8000 Oil flow

Step 1: Verify that the oil SUPPLY and RETURN valves of thetransformer and the oil INLET and OUTLET shut-off valves

inside the Calisto/Calisto 2 are open.Step 2: Draw an oil sample from the Quick Connect OilSampling Tube, as described in Section 4.0, and verify oilviscosity.


Error Code 2

(ER2)Error Name Instructions


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(ER2)

1 File system Contact Morgan Schaffer for assistance.

2Heatsink overtemperature Contact Morgan Schaffer for assistance.

3 Plate temperature error Contact Morgan Schaffer for assistance.

4 1V reference error Contact Morgan Schaffer for assistance.

To contact Morgan Schaffer, call at 001.514.739.1967 or email at support@morgan-

schaffer.com.

4.0 COLLECTING AN OIL SAMPLE
mailto:support%40morganschaffer.com?subject=mailto:support%40morganschaffer.com?subject=mailto:support%40morganschaffer.com?subject=mailto:support%40morganschaffer.com?subject=


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Oil samples can be easily collected from Calisto/Calisto 2 using the Quick Connect Oil

Sampling Tube supplied with the monitor.

Items needed:

Quick Connect Oil Sampling Tube (supplied with the monitor)

Glass syringe fitted with a 3-way stopcock valve (typically, 30 cc or a ShakeTest Syringe)

Container to collect flushed oil

STEP 1: Close the OUTLET valve of the Calisto/Calisto 2.

STEP 2: Connect the Quick Connect Oil Sampling Tube to the top port of the syringe

and a second tube to the side port of the syringe for ejecting oil in a

container.

STEP 3: Turn the 3-way stopcock handle toward the top port and push the piston of

the syringe all the way in.


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STEP 4: Connect the Quick Connect Oil Sampling Tube into the monitors oil sampling

port.

STEP 5: Turn the 3-way stopcock handle toward the side port and allow the pressure

inside the Calisto/Calisto 2 monitor to fill the syringe with a few millimetersof oil. Do not pull on the piston to fill the syringe.

STEP 6: Turn the 3-way stopcock handle toward the top port and push the piston to

eject all the air bubbles and most of the oil in the syringe out from the side

port and into a container


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port and into a container.

STEP 7: Repeat steps 5 to 6 to flush the syringe a second time.

NOTICE

Flushing approximately 30 cc of oil to waste is necessary

before taking a sample to discard stagnant oil in the sam-

pling valve assembly.

STEP 8: Turn the 3-way stopcock handle toward the side port and allow the syringe

to be filled with the desired quantity of oil. Do not pull on the piston to fill

the syringe, and make sure to turn the 3-way stopcock handle toward the

syringe before the piston pops out of the syringe.

STEP 9: Turn the 3-way stopcock handle toward the syringe.


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STEP 10: Remove the Quick Connect Oil Sampling Tube from the oil sampling port (by

pushing the locking ring down). The oil sample is ready for analysis.

STEP 11: Repeat steps 2 to 10 if other oil samples are required, or else, open the

OUTLET valve and close the door of the monitor.

NOTICE

In some environments, a protective plug may be requiredto prevent dust or sand from affecting the oil sampling port

mechanism. A Stainless Steel Quick Connect Plug is available

to order separately as an accessory.

5.0 MAINTENANCE AND SUPPORT


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WARNING


training and certification should install the equipment or

open the enclosure once the equipment has been installed.

CAUTION

To prevent water damage to the monitor, it is imperative toclose the door completely by tightening the latch screws

until there is no gap between the latch brackets.

In order to maximize the performance and reliability of the monitor over time, Morgan

Schaffer offers a recommended Maintenance Plan. This Maintenance Plan is not man-

datory and has no impact on the factory warranty of the monitor.

5.1. SCHEDULED MAINTENANCE RECOMMENDATIONS

AFTER COMMISSIONING

One week after commissioning, Morgan Schaffer recommends to download the data-

bank and the event log (.bnk, .log, .mfg) using Calisto Manager, and to send the files by

email to [email protected]. Data will be evaluated to verify the monitor is

functioning well. In 24 to 48 hours, a technical support specialist will contact you with

an evaluation of the monitor.

EVERY 6 MONTHS

It is recommended to download the databank and event log every six months,and to send them to Morgan Schaffer for an evaluation of the monitor.

It is recommended to visit Morgan Schaffers website at www.morganschaffer.comto verify the availability of updates for Calisto Manager.

EVERY YEAR

It is recommended to perform an annual visual inspection of Calisto/Calisto 2. Verifythe following points during the annual inspection:

The door must be fully closed and tightened.

The monitor and transformer valves must be open.

The display must light up when one of the door buttons is pushed.

The pathway for air circulation underneath the monitor must be relatively cleanand not blocked If the air pathway needs to be cleaned use compressed air to
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and not blocked. If the air pathway needs to be cleaned, use compressed air toblow out the particles via the air vents.

No oil should be seen dripping anywhere from the monitor.

The monitor may be wiped with a damp cloth for cleaning purposes. There is no recom-

mendation to prevent corrosion as the monitor is highly resistant to corrosion.

5.2. PRODUCT SUPPORT

If a problem of any nature occurs with your monitor, please take the following steps

prior to contacting us:

Note the model number (C76, C76A, C85 or C85A) and the serial number of themonitor located on the external metal nameplate.

Connect the monitor to a portable computer via the USB port. Download the

databank and the event log files (.bnk, .log, .mfg) using Calisto Manager.

If parts need to be replaced, instructions with safety and protective measures will be

provided. When a fuse or battery needs to be replaced, the replacement part must be

chosen according to the specifications listed below:

Part Specification

Thermal cut-off fuse L50 77C G900, Cantherm

Over current fuse for Calisto (C76)/Calisto 2 (C85)

5HTP 6.3A, 5x20mm, time-lag (T), Bel Fuse Inc.

Over current-fuse for Calisto (C76A)/Calisto 2 (C85A)

047706.3 6.3A, 5x20mm, time-lag (T), Littelfuse

Battery on CPU board CR2032

For product support, please contact Morgan Schaffer Technical Support at:

E: [email protected]: 001.514.739.1967

6.0 APPENDIX
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6.1. CALISTO/CALISTO 2 - TECHNICAL SPECIFICATIONS

Application

Early detection of transformer incipient faults using continuous monitoring of dissolvedhydrogen in insulating fluids.

Monitoring dissolved carbon monoxide as a key indicator of cellulose degradation (Calisto 2only).

Continuous moisture monitoring.Performance

Dissolved gases (H2and CO) in oil measurement

Measurement technology Proprietary Morgan Schaffer cell

Gas extraction technology Oil immersed PTFE tubing

Detection rangeH

2: 2 50,000 ppm

CO: 25 100,000 ppmAccuracy (ref: MS oil standards)

H2: Greater of 5 ppm or 5%

CO: Greater of 25 ppm or 15%

RepeatabilityH

2: Greater of 3 ppm or 3%

CO: Greater of 25 ppm or 10%

ResolutionH

2: 1 ppm

CO: 5 ppm

Step response (typical conditions) H2: 50% in 60 min.CO: 90% in 6 hours

InterferenceH

2: < 0.3% of other gases

CO: < 5% from C2H

2, C

2H

4, 15 years

Operation

Operating temperature range(standard)

-40 to 55C (-40 to 131F)


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( )

Storage temperature range -30 to 75C (-22 to 167F)

Operating oil temperature range -40 to 120C (-40 to 248F)

Oil pressure operation 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)

Construction

Width Height Depth 381 483 325 mm (15 19 12.8 in)

Weight 22.7 kg (50 lbs)

Enclosure S.S. 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" OD copper with brass compression fittings

Air bubble elimination Proprietary Morgan Schaffer system

Enclosure temperature conditioning Thermoelectric feedback

Oil temperature conditioningPassive heat exchangerThermoelectric feedback

Cooling Forced air convection

Safety protectionThermal cut-off fuse, rated at 77C (171F)

Over-current protection fuseOil sampling External quick-connect port with sampling accessories

Installation

Calibration No calibration required

Maintenance Annual visual inspection

Electrical entry holes (standard) 4 22.2 mm (0.875 in) diameter

Commissioning time 2 hours

MountingShock mounts. Morgan Schaffer Calisto MountingStand recommended

Power requirements

Calisto (C76)/Calisto (C85): 100 240 VAC, 50 60Hz, 320 W, 1 (3 kV RMS isolation)

Calisto (C76A)/Calisto (C85A):100 240 VAC, 50 60 Hz, 320 W, 1 ;

100 220 VDC, 320 W (3.9 kV RMS isolation)Power conductor size Max. 2.05 mm (AWG 12)

Oil supply line length 1.5 10.5 m (5 35 ft)

Oil return line length 1.5 10.5 m (5 35 ft)

Communication & Data

Display112 16 pixel display, vacuum fluorescent, day/night, 3 weatherproof, UV resistant buttons


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Local USB 2.0 port (cable provided)

Permanent connection

RS-485 port (1,500 V isolation)RS-232 port (1,500 V isolation)Ethernet port (1,500 V isolation)Additional Ethernet port (C76A & C85A only)Independent H

2, CO and H

2O analog outputs, 4 20

mA (1,500 V isolation)Oil temperature analog input, 4 20 mA (1500 Visolation)

Communication protocolsMSSP (Morgan Schaffer Systems Protocol)Modbus, DNP3 Level 1Optional IEC 61850 kit

Measurement AlarmsProgrammable dual-level and trend alarms for H

2, CO

(Calisto 2 only) and H2O

Alarm Relays5 NO/NC contacts, configurable for setup, self-testand measurement alarm conditions (5A, 240V)

Data update8 readings/day, validated H28 readings/day, validated CO (Calisto 2 only)1 reading/5 sec., continuous H

2 and H

2O

Data storage 3000 (1 year)

Calisto Manager interface software Win 98 / 2000 / NT / XP / Vista / 7

Regulatory

CE MarkingLow Voltage Directive 2006/95/ECEMC Directive 2004/108/ECWEEE Directive 2002/96/EC, amended 2003/108/ECRoHS Directive 2002/95/EU

EMC (Electromagnetic Compatibility)

IEC/EN 61326IEC/EN 61000-6-5 (C76A & C85A only)IEC/EN 61850-3 (C76A & C85A only)FCC part 15 (US)

Class A, ICES-003 (Canada)

Electrical safetyIEC/EN 61010IEC/EN 60255-27 (C76A & C85A only)

Degree of protection IEC/EN 60529, IP56

Vibration IEC 60255-21-1, Class 1

Shipping

Gross weight 30.8 kg (67.8 lbs)Packaging (H W D) 508 584 470 mm (20 23 18.5 in)

Note: Continuous research and improvements may result in specification or appearance changes

at any time.


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Documents

Manual Calisto 2