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Installation & Operation Manual

SUPPORT: + 001.514.739.1967

Table of Contents
1.0 INTRODUCTION............................................................................................... 3
1.1.
Documentation Scope and Updates..................................................................3
1.2.
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...............................................................................................11
2.1. 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.................................................. 28
2.5. 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............................................................... 37
3.2. 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

Revision 4

page 1

List of Figures
Figure 1: Front view (Calisto 2 model shown).............................................................6
Figure 2: Bottom view.................................................................................................7
Figure 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...................................... 30
Figure 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............................................................. 34
Figure 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

page 2

1.0 INTRODUCTION
1.1. Documentation Scope and Updates
This Installation and Operation Manual provides 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, consult 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 specific 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 Manual and 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 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 or
Calisto 2 monitor may be used or relied upon for any reason whatsoever.

page 3

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)

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.

WARNING

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


could result in serious injury or death.

CAUTION

A 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 shipment. 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 concentration of fault gases dissolved in the dielectric insulating fluid of a transformer.
Calisto measures dissolved hydrogen (H2) and moisture (H2O), while Calisto 2 additionally measures dissolved carbon monoxide (CO). Continuous monitoring of these
page 4

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 readings. 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 highaccuracy 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 communication 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.

page 5

1.5. Monitor Main Components


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

Figure 1: Front view (Calisto 2 model shown)

1. Oil outlet port


(3/8" OD compression fitting)

4. Oil sampling port

2. Display

5. Oil inlet port


(3/8" OD compression fitting)

3. Display buttons

6. Mains supply switch

page 6

Figure 2: Bottom view

1. Oil outlet port

5. Oil sampling port

2. Mains supply switch

6. Air vent out

3. Electrical hubs (x4)

7. Fan assembly

4. Oil inlet port

8. Air vent out

page 7

The main internal components of a Calisto (C76)/Calisto 2 (C85) are shown in Figure
3.

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

1. Oil outlet shut-off valve

6. Detection cell I/O PCB

2. Mains & communication PCB

7. Detection cell

3. Door ground link

8. Thermal cut-off fuse

4. Main I/O PCB

9. Oil inlet shut-off valve

5. CPU board

10. Protective conductor terminal (ground)

page 8

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


Figure 4.

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

1. Oil outlet shut-off valve

7. Detection cell

2. Mains PCB

8. Thermal cut-off fuse

3. Door ground link

9. Communication interface PCB

4. Main I/O PCB

10. Oil inlet shut-off valve

5. CPU board

11. Protective conductor terminal (ground)

6. Detection cell I/O PCB

page 9

1.6. Standard Package Contents


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

Part Number

Qty.

Description

(various)

Calisto/Calisto 2 monitor (standard)

WRE-00067

USB cable (6 feet - for local connection)

BCAL-0062

S.S. shock mount assembly

BCAL-0054

Quick connect oil sampling tube

ECM-00066

Thermal cut-off fuse (spare)

BFM-00038

Copper tubing 3/8" OD 25 ft (7.6 m)

FLC-00242

Brass elbow " NPT (M) 3/8" Tube

FLC-00249

Brass sleeve 3/8" Tube (spare)

008-MSMAN

Calisto/Calisto 2 Installation and Operation Manual

010-MSMAN

Calisto Manager interface software CD + user guide

N/A

Factory 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.

(various)

Calisto/Calisto 2 monitor for S.S. lines

Description

WRE-00067

USB cable (6 feet - for local connection)

BCAL-0062

S.S. shock mount assembly

BCAL-0054

Quick connect oil sampling tube

ECM-00066

Thermal cut-off fuse (spare)

FLC-00022

S.S. elbow connector " NPT (M) 3/8" Tube

008-MSMAN

Calisto/Calisto 2 Installation and Operation Manual

010-MSMAN

Calisto Manager interface software CD + user guide

N/A

Factory test certificate, Declaration of Conformity,


Certificate of Warranty

page 10

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 <O> position (OFF).

Caution
Calisto/Calisto 2 is shipped filled with new transformer mineral oil. Do not open inlet and outlet valves prior to the
installation. The INLET and OUTLET valves are in a horizontal 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)
page 11

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 between
the 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 circulating pump.
The SUPPLY valve should be at least 0.45 m (18 in.) from the bottom of the main
tank.
The valves should have a minimum diameter of " NPT. Female, ball or gate
type 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 mechanical
stress.

page 12

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 cabinet, 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 available 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

page 13

Consider the following guidelines when securing the monitor:


Secure the monitor approximately 1.2 m (4 ft) above ground level for easy
access 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 following the guidelines listed in Section 2.2. Keep in mind that the monitor must
be within 11 m (35 ft) from the RETURN valve, and at least 1 m (3 ft) away from
the SUPPLY valve.
The location of the mounting structure should be chosen to protect the monitor
from extreme vibrations. Four shock mounts are provided with each monitor
and should be used to give the monitor additional protection against vibration
(see Figure 6).

Figure 6: Installation of shock mounts

page 14

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 follow
explain 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 Guide for instructions.
Figure 7 shows the components of the mains connection and communication interface board for a Calisto (C76)/Calisto 2 (C85).

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


1. Mains power connectors

7. Local USB type B port

2. Thermal cut-off fuse connectors

8. 4-20 mA analog output terminals

3. Over current fuse

9. 4-20 mA analog input terminals

4. Programmable relay terminals

10. RS-232 communication port

5. Programmable relays with activity LEDs

11. RS-485 communication port

6. Ethernet communication port

12. Ethernet shield earth jumper

page 15

Figure 8 shows the components of the mains connection and communication interface boards for a Calisto (C76A)/Calisto 2 (C85A).

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


1. Mains power connectors

7. Ethernet communication ports (x2)

2. Over current fuse

8. 4-20 mA analog output terminals

3. Thermal cut-off fuse connectors

9. 4-20 mA analog input terminals

4. Programmable relay terminals

10. RS-232 communication port

5. Programmable relays with activity


LEDs

11. RS-485 communication port


12. Local USB type B port

6. Ethernet shield earth jumper

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 waterproof 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 communication 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 the
monitor.

page 16

2.4.1. Connecting the Earth Ground


Warning
Install the protective earth conductor to the protective conductor 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 connection. 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).

Figure 9: Earth ground connections


1. Protective conductor terminal (ground)
2. Additional earth ground connection hole

page 17

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).

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

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).

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

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

Rating

Nominal value/range

Connection range:

2.08 3.31 mm2 solid

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 conductors. 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.
page 18

To connect the mains power, completely loosen each screw terminal, insert the conductor 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 (<O>). 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).

Figure 12: Alarm relays and connections


Note: Calisto (C76A)/Calisto 2 (C85A) model shown. For
Calisto (C76)/Calisto 2 (C85), connector 16 is a SHIELD.

page 19

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

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)

10

RLY4_NC

Relay 4 normally closed (NC)

11

RLY4_COM

Relay 4 common

12

RLY4_NO

Relay 4 normally open (NO)

13

RLY5_NC

Relay 5 normally closed (NC)

14

RLY5_COM

Relay 5 common

15

RLY5_NO

Relay 5 normally open (NO)

16

SHIELD (for C76/C85)


N/A (for C76A/C85A)

Shield to earth ground


Unused

17

SHIELD

Shield to earth ground

18

SHIELD

Shield to earth ground

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

Rating

Nominal value/range

Connection range:

0.33 2.08 mm2 stranded

Connection range (UL/CSA):

22 14 AWG stranded

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

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.

page 20

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

5V/400VAC

5V/300VDC

Rated resistive load:

16A/250VAC

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

Min. switching current:

5mA

5mA

Coil-contact dielectric
strength:

5000VAC

5000VAC

Min./Max. switching voltage:

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).

Figure 13: Analog output connector

Pin No.

Output

Description

SHLD

Shield to earth ground

SHLD

Shield to earth ground

N/A

Moisture (H2O)

Moisture (H2O)

Negative (-)

Hydrogen (H2)

Positive (+)

Hydrogen (H2)

Negative (-)

Unused
Positive (+)

Carbon monoxide (CO) Positive (+) (Calisto 2 only)

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

page 21

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

Rating

Nominal value/range

Connection range:

0.33 1.31 mm2 solid/stranded

Connection range (UL/CSA):

22 16 AWG

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

Flammability:

VW-1 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 4-20
mA analog input supply voltage is +24 VDC.

Figure 14: 4-20 mA analog input connector

Pin No.

Marking

SHLD

page 22

Description
Shield to earth ground
Unused

4-20 mA negative (-)

4-20 mA positive (+)

The 4-20 mA analog input connections must be made according to the following connector ratings:

Rating

Nominal value/range

Connection range:

0.33 1.31 mm2 solid/stranded

Connection range (UL/CSA):

22 16 AWG

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

Flammability:

VW-1 or better

Screw type:

M2.0

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


screw the connector in place after the connections are made.
The Morgan Schaffer Precision Oil Temperature Probe is available as an optional accessory to collect oil temperature data. Refer to the Precision Oil Temperature Probe
Installation Manual for instructions.

2.4.6. Connecting the RS-485 Communication


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

Figure 15: RS-485 connection

Pin No.

Marking

SHLD

Description
Shield to earth ground
Unused

COMM

Common signal ground

Line A

Line B

page 23

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

Rating

Nominal value/range

Connection range:

0.33 1.31 mm2 solid/stranded

Connection range (UL/CSA):

22 16 AWG

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

Flammability:

VW-1 or better

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.
It is recommended to remove the connector to simplify wiring the connections, and to
screw the connector in place after the connections are made.
For reliable RS-485 communication, the RS-485 common signal ground must be connected 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 chassis 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 that
also 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
page 24

2.4.7. Connecting the RS-232 Communication


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

Figure 16: RS-232 connection

Pin No.

Marking

SHLD

Description
Shield to earth ground

Unused

GND

Signal ground

RX

Received data

TX

Transmitted data

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

Rating

Nominal value/range

Connection range:

0.33 1.31 mm2 solid/stranded

Connection range (UL/CSA):

22 16 AWG

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

Flammability:

VW-1 or better

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 minimum 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).

page 25

2.4.8. Connecting the Ethernet Communication


Calisto (C76)/Calisto 2 (C85) features one RJ45 Ethernet port which allows the monitor 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.

Figure 17: Calisto (C76)/Calisto 2 (C85) - RJ45 Figure 18: Calisto (C76A)/Calisto 2 (C85A) RJ45 Ethernet port

Ethernet port

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

Rating

Nominal value/range

Connection range:

0.33 1.31 mm2 solid/stranded

Connection range (UL/CSA):

22 16 AWG

Wire strip length:

6.5 mm (~1/4 in.)

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
page 26

or electrical arc) over 1500 V that could infiltrate the Ethernet line. It is the clients
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 IEC
61850 substation protocol. Refer to the IEC 61850 Communication Kit Installation and
Configuration Manual for more information.
Ethernet Outdoor Connectivity Kit (optional)
The optional Ethernet Outdoor Connectivity Kit allows for an easy and reliable connection 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 immunity. 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.

page 27

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

Figure 19: USB port

Driver installation is required in order to communicate over USB. Refer to the Calisto
Manager User Guide for 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 stainless 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 become
necessary, 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 not to insulate the oil lines.

page 28

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).

Figure 20: Installation of the elbow fittings


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 instead
of an elbow. Refer to the Precision Oil Temperature Probe
Installation Manual.

page 29

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 on
the monitor. The torque and counter-torque wrenches must be aligned one over
the other as much as possible to cancel induced forces.
If using rigid tubing, a tube cutter must be used to cut oil lines. Other tools
must be avoided as they can leave burrs, debris and scratches on the surface to
be swaged.
If using rigid tubing, make sure the tubing is straight for several inches where it
enters 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).

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

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 debur the inside of the tube.
page 30

e. Insert the free end of the oil supply line into the elbow fitting installed at
the transformer SUPPLY valve (or the tee fitting assembly when installing a
Precision Oil Temperature Probe). Tighten the compression nut 1 turns
from finger tight to 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).

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

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 debur 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 tight to complete the oil return line installation.
STEP 3:

Secure all oil lines against excessive vibration.

page 31

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 monitor 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 Manual must now be followed before proceeding to purge the oil lines.
STEP 1:

Ensure that both monitor valves are still closed (valve handles in the horizontal position, see Figure 23), then slowly open both transformer valves.

Figure 23: Monitor with both valves closed

page 32

STEP 2:

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

page 33

STEP 3:

Using a container to collect flushed oil, slowly turn the OUTLET valve counter
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.

Figure 26: Flushing the oil return line

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 27: Closing the monitor OUTLET valve

page 34

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 mains 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.
STEP 5:
a. Slowly turn the INLET valve counter clockwise turn to the vertical position (the handle will then be pointing upwards) (see Figure 28).
b. Using a container to collect flushed oil, turn the mains supply switch to
the <|> (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
<O> position (OFF).

Figure 28: Flushing the oil supply line

page 35

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

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

STEP 7:

Open the OUTLET valve. At this step, both transformer valves and both
monitor valves should be open as shown in Figure 30. The monitor is
now ready to be powered up.

Figure 30: Monitor with both valves open

page 36

3.0 START UP
3.1. Important Checks before Power Up
The following checks should be made before providing power to the monitor:
Verify that no tools or other equipment 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 unused
entry 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 3.1 have 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 approximately five seconds, which is the time delay required for firmware initialization.

Notice
If the monitor temperature is below -35C (-31F) at powerup, 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.

page 37

When the Calisto/Calisto 2 is powered on or reset, the monitor first enters an initialization and power-on self-test sequence. The purpose of this mode is to allow
the on-board computer to evaluate temperature conditions and to allow the 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 will
indicate <H2=INIT>.
The measurement cycle will begin once the initialization sequence has been completed. The most recent validated measurement for hydrogen will be displayed
<H2=xxx> on the door display. Refer to Section 3.4 for a complete description of the
display interface.

3.3. Configuring the Monitor


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 now ready to be configured using the Calisto Manager software. Refer to the Calisto Manager User Guide for 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 provided with the monitor may be used for the connection (see Figure 31).

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

page 38

3.4. Display Interface


The 3-button display interface provides access to three menu sections: realtime
<REALTIME>, manufacturer <MANUFACT>, and database <DATABASE>.
To toggle between the menu sections <REALTIME>, <MANUFACT> and
<DATABASE>: 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 <REALTIME> after 10 seconds of
inactivity.
When a value is unavailable, it is reported as INIT.
When a value is under the detection limit, it is reported as <LDL.
When a value is over the top of range, 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

page 39

<REALTIME>
The realtime section displays the most recent readings of the monitor. By default, the
display will show the last validated concentration of hydrogen <H2=xxx>. Press button 3 to access the following information:
H2 > CO > WRS > WWC > RS1 > RS4 > T1 > T4
<MANUFACT>
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
<DATABASE>
The database section displays information for all of the recorded data. Once in the
database section, the records are listed by number, <REC=xxx>, 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
Button 3

Manufacturer

H2

Cxx

CO

xxxxx

Database
REC=xxx
H2

REC=001
H2

WRS

v x.xx

CO

CO

WWC

ID

WRS

WRS

RS1

yyyymmdd

WWC

WWC

RS4

TMhhmmss

RS1

RS1

T1

CT

RS4

RS4
T1

T4

BT

T1

OT

T4

T4

ST

yyyymmdd

yyyymmdd

TMhhmmss

TMhhmmss

Button 1

page 40

...

Button 2

3.4.1. Error Codes


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 <H2=xxx>. 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

8000

4000

2000

1000

800

400

200

100

80

40

20

10

position
Error code

Error Code 1
(ER1)

Error Name

Instructions

Outside fan

Step 1: Remove any obstruction which may be preventing the


external fan rotation.
Step 2: Contact Morgan Schaffer for assistance.

Inside fan

Contact Morgan Schaffer for assistance.

4, 8, 400,
4000

Detection
cell

Contact Morgan Schaffer for assistance.

10, 20, 40,


80, 100, 200

Thermal
regulation

Contact Morgan Schaffer for assistance.

800

Pump
circulation

Contact Morgan Schaffer for assistance.

1000

Moisture
sensor

Contact Morgan Schaffer for assistance.


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

2000

Analog
input

Step 2: Verify the 4-20 mA input connections as described in


Section 2.4.5.
Step 3: Verify the functionality of the 4-20 mA source.
Step 4: Contact Morgan Schaffer for assistance.
Step 1: Verify that the oil SUPPLY and RETURN valves of the
transformer and the oil INLET and OUTLET shut-off valves
inside the Calisto/Calisto 2 are open.

8000

Oil flow

Step 2: Draw an oil sample from the Quick Connect Oil


Sampling Tube, as described in Section 4.0, and verify oil
viscosity.
Step 3: Contact Morgan Schaffer for assistance.

page 41

Error Code 2
(ER2)

Error Name

Instructions

File system

Contact Morgan Schaffer for assistance.

Heatsink over
temperature

Contact Morgan Schaffer for assistance.

Plate temperature error

Contact Morgan Schaffer for assistance.

1V reference error

Contact Morgan Schaffer for assistance.

To contact Morgan Schaffer, call at 001.514.739.1967 or email at support@morganschaffer.com.

page 42

4.0 COLLECTING AN OIL SAMPLE


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 Shake
Test 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.

page 43

STEP 3:

Turn the 3-way stopcock handle toward the top port and push the piston of
the syringe all the way in.

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 millimeters
of oil. Do not pull on the piston to fill the syringe.

page 44

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.

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 sampling 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.

page 45

STEP 9:

Turn the 3-way stopcock handle toward the syringe.

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 required
to 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.

page 46

5.0 MAINTENANCE AND SUPPORT


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.

CAUTION
To prevent water damage to the monitor, it is imperative to
close 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 mandatory 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 databank and the event log (.bnk, .log, .mfg) using Calisto Manager, and to send the files by
email to support@morganschaffer.com. 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.
com to verify the availability of updates for Calisto Manager.
Every Year
It is recommended to perform an annual visual inspection of Calisto/Calisto 2. Verify
the following points during the annual inspection:
The door must be fully closed and tightened.
The monitor and transformer valves must be open.
page 47

The display must light up when one of the door buttons is pushed.
The pathway for air circulation underneath the monitor 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.
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 recommendation 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 the
monitor 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: support@morganschaffer.com
T: 001.514.739.1967

page 48

6.0 APPENDIX
6.1. Calisto/Calisto 2 - Technical Specifications
Application
Early detection of transformer incipient faults using continuous monitoring of dissolved
hydrogen in insulating fluids.
Monitoring dissolved carbon monoxide as a key indicator of cellulose degradation (Calisto 2
only).
Continuous moisture monitoring.

Performance
Dissolved gases (H2 and CO) in oil measurement
Measurement technology

Proprietary Morgan Schaffer cell

Gas extraction technology

Oil immersed PTFE tubing

Detection range

H2: 2 50,000 ppm


CO: 25 100,000 ppm

Accuracy (ref: MS oil standards)

H2: Greater of 5 ppm or 5%


CO: Greater of 25 ppm or 15%

Repeatability

H2: Greater of 3 ppm or 3%


CO: Greater of 25 ppm or 10%

Resolution

H2: 1 ppm
CO: 5 ppm

Step response (typical conditions)

H2: 50% in 60 min.


CO: 90% in 6 hours

Interference

H2: < 0.3% of other gases


CO: < 5% from C2H2, C2H4,<3% from H2, CH4, C2H6

Moisture (H2O) in oil measurement


Measurement technology

Oil immersed RS sensor

Detection range

2 ppm - saturation, 2-100% RS

Accuracy (ref: MS oil standards for


ppm and RS)

3 ppm or 3% RS

Repeatability

2 ppm or 2% RS

Resolution

1 ppm, 1% RS

Step response (typical conditions)

95% in 20 min.

Reliability
Power interruption protection

250 ms advanced power loss system

Expected Operating Life (EOL)

> 15 years

page 49

Operation
Operating temperature range
(standard)

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

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 conditioning

Passive heat exchanger


Thermoelectric feedback

Cooling

Forced air convection

Safety protection

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


Over-current protection fuse

Oil 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

Mounting

Shock mounts. Morgan Schaffer Calisto Mounting


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

Power requirements

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)

page 50

Communication & Data


Display

112 16 pixel display, vacuum fluorescent, day/


night, 3 weatherproof, UV resistant buttons

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 H2, CO and H2O analog outputs, 4 20
mA (1,500 V isolation)
Oil temperature analog input, 4 20 mA (1500 V
isolation)

Communication protocols

MSSP (Morgan Schaffer Systems Protocol)


Modbus, DNP3 Level 1
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 H2
8 readings/day, validated CO (Calisto 2 only)
1 reading/5 sec., continuous H2 and H2O

Data storage

3000 (1 year)

Calisto Manager interface software

Win 98 / 2000 / NT / XP / Vista / 7

Regulatory
CE Marking

Low Voltage Directive 2006/95/EC


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

IEC/EN 61326
IEC/EN 61000-6-5 (C76A & C85A only)
EMC (Electromagnetic Compatibility) IEC/EN 61850-3 (C76A & C85A only)
FCC part 15 (US)
Class A, ICES-003 (Canada)
Electrical safety

IEC/EN 61010
IEC/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.

page 51

8300 Staint-Patrick, Suite 150, LaSalle, Quebec Canada H8N 2H1


T: +001.514.739.1967 |
F: +001.514.739.0434 |
E: info@morganschaffer.com

www.morganschaffer.com | Support: + 001.514.739.1967