Morgan Schaffer Calisto Installation & Operation Manual
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Morgan Schaffer Calisto Installation & Operation Manual

High accuracy on-line dissolved gas monitor fo transformer incipient fault detection
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Summary of Contents for Morgan Schaffer Calisto

  • Page 3: Table Of Contents

    Figure 35: Calisto Access External Input Settings ........................... 62 Figure 36: Calisto Access Graphic Plotting Panel– H2 ........................66 Figure 37: Calisto Access Graphic Plotting Panel – CO for Calisto 2 only ................. 66 Figure 38: Calisto Access Graphic Plotting Panel – H2O ......................66 Figure 39: Quick Connect Oil Sampling Tube Connected to a 30cc Syringe ................
  • Page 4 Calisto 2 provides the key measurements required to monitor the health of the insulation system, in order that informed service decisions may be taken, and major transformer problems may be avoided.
  • Page 6 An electronic version of this manual is available on the Calisto/Calisto 2 CD supplied with your monitor and at Morgan Schaffer’s web site www.morganschaffer.com. To access this manual on the website, click Instruments under Products. Then click either Calisto or Calisto 2 and then Downloads under the Menu (on the right).
  • Page 7 A 3-year warranty covers each new Calisto/Calisto 2 IED. In order to activate this warranty, the user must fill out the Warranty Registration Form located in the documentation included with each instrument and fax it to Morgan Schaffer at 001.514.739.0434. An electronic version of this form is also available on the Calisto/Calisto 2 CD and can be e-mailed to support@morganschaffer.com...
  • Page 8 Reliable gas extraction and detection technologies are both crucial to produce reliable readings. As the oil within the Calisto/Calisto 2 is conditioned to a precisely regulated temperature, it is pumped past a bundle of PTFE capillary tubes which together form the gas probe. Dissolved gases permeate through the walls of the tubing to form a representative gas sample within the probe.
  • Page 9 Calisto/Calisto 2 can both sustain vacuum. As a result, no action is required to protect the monitor if the transformer is put under vacuum for degassing purposes.
  • Page 10 (nominal flow of 60 ml/min. or 0.95 US gal/hr) located inside the instrument. Figure 1 on the following page shows the general front view of a Calisto/Calisto 2 which features a vacuum fluorescent display (ultra bright at day and night) and the three-button display interface.

  • Page 11: Figure 1: Front View (Calisto 2 Model Shown)

    Figure 1: Front View (Calisto 2 model shown) Figure 2: Calisto/Calisto 2 - Bottom View...

  • Page 12: Figure 3: Calisto/Calisto 2 - Main Internal Components

    Figure 3: Calisto/Calisto 2 - Main Internal Components...
  • Page 13 QTY. DESCRIPTION Standard Calisto/Calisto 2 monitor 6-foot male A/B USB 2.0 cable for local connection Calisto Access interface software CD-ROM Quick Connect Oil Sampling Tube Stainless steel vibration mount assembly Copper tubing – 3/8 O.D. × 25 ft (7.6 m) Thermal cut-off fuse (spare) Brass elbow –...
  • Page 14 Ethernet Outdoor Connectivity Kit Calisto/Calisto 2 features an Ethernet port isolated to 1500 V. The Ethernet Outdoor Connectivity Kit includes all the necessary parts to bring a communication cable from the monitor to a control box switch/hub in an easy and reliable way.
  • Page 15  Insulation kit (for -50 to 55°C [-58 to 131°F] operation)  IEC 61850 Ethernet communication kit  900 MHz radio modem over RS-485  2.4 GHz radio modem over RS-485  Quick-connect dust plug  Calisto MultiTrack software  Extended warranty up to 5 years  On-site commissioning assistance...
  • Page 17 Two persons are recommended for lifting the equipment. NOTICE Calisto/Calisto 2 is designed for industrial use and shall not be connected to the public low-voltage distribution system. Section 2.0 Installation applies to both Calisto and Calisto 2 monitors.

  • Page 18: Figure 4 : Calisto/Calisto 2 - Mounting Diagram

    Calisto/Calisto 2 must be solidly bolted to a suitable support approximately 1.2 m (4 ft) above ground level to allow easy access to the internal oil sampling valves. A minimum of 60 cm (24 in.) is required for air circulation under the unit.
  • Page 19 A Morgan Schaffer Calisto Mounting Stand is available as an optional accessory. Contact Morgan Schaffer for more information.
  • Page 20 Opening the Calisto/Calisto 2 enclosure door will provide access to the monitor interface board. Figure 5 shows the main components of the Calisto/Calisto 2 interface board. All connections to the monitor are made using this board. Items 1, 12 and 11 are respectively the mains power connectors, the thermal cut-off fuse and the over-current fuse.

  • Page 21: Figure 5: Calisto/Calisto 2 - Interface Board Components

    4-20mA analog output terminals (3 channel is for Calisto 2 only) Local USB type B port Ethernet communication port 10. Programmable relay terminal block 11. Main supply fuse (5HT 6.3-R) 12. Thermal cut-off fuse terminals Figure 5: Calisto/Calisto 2 - Interface Board Components...

  • Page 22: Figure 6: Calisto/Calisto 2 - Power Connections

    It is the client’s responsibility to ensure the integrity of the ground cable and client-side ground connection. The Calisto/Calisto 2 monitor is designed to accept any supply voltage from 100 to 240 VAC with frequencies in the range of 50 to 60 Hz. Mains power connections are made to connector 1 (neutral) and connector 2 (line) using either solid or stranded conductors (See Figure 6).

  • Page 23: Figure 7: Calisto/Calisto 2 - Alarm Relays And Connections

    The Calisto/Calisto 2 nominal power is 320W. The main supply switch may be used to turn the unit ON or OFF. A circuit breaker must also be dedicated to the unit for this purpose. Although the Calisto/Calisto 2 is equipped with an internal over-current fuse, it is strongly recommended that a suitable fuse or breaker be installed in the mains supply external to the unit, with rating appropriate to the supply voltage and nominal power.
  • Page 24 The table below describes the alarm relay connections pinout assignment: CONNECTOR NO. MARKING CONNECTION TYPE RLY1_NC Relay 1 normally closed (NC) Relay 1 common RLY1_COM RLY1_NO Relay 1 normally open (NO) RLY2_NC Relay 2 normally closed (NC) Relay 2 common RLY2_COM RLY2_NO Relay 2 normally open (NO)

  • Page 25: Figure 8: Calisto/Calisto 2 - Analog Output Connector

    The analog output screw-terminal plug-in connector is located on the monitor interface board (Refer to Figure 8). Although pin 8 and 9 are present in a Calisto monitor, no signal from this output can be used as Calisto does not report carbon monoxide.
  • Page 26 Calisto Access Default Set-Up for more information. Calisto/Calisto 2 features one 4-20 mA analog input that can be used to provide a reading of the transformer oil temperature to the unit. The 4-20 mA analog input is loop-powered to +13.5 VDC and isolated to 1500 V.

  • Page 27: Figure 9: Calisto/Calisto 2 - 4-20 Ma Analog Input Connector

    The analog input temperature range is configured via the Calisto Access software. Calisto/Calisto 2 features one RS-485 communication port isolated to 1500 V. The RS-485 uses a differential balanced line over twisted pair and can thus span relatively large distances, up to 4000 ft (1200 m).

  • Page 28: Figure 10: Calisto/Calisto 2 - Rs-485 Connection

    “SHLD” when optical or galvanic isolation is used at both ends. Since Calisto/Calisto 2 provides 1500 V isolation, it is recommended to use RS-485 devices that also offer good isolation. The signal ground conductor should be connected to pin 3 (COMM) and should be connected at all ends.
  • Page 29 RS-485 network. Termination resistors are generally not required when communicating with a Calisto/Calisto 2 monitor at the standard speed of 9600bps. To connect the terminating resistor, install the jumper provided across J6 on the monitor interface board, just below the RS-485 connector.

  • Page 30: Figure 11: Calisto/Calisto 2 - Rs-232 Connection

    The Calisto/Calisto 2 RS-232 communication port does not support any protocol other than our proprietary MSSP. Calisto/Calisto 2 features one Ethernet port which allows the unit to be connected to a computer or a corporate LAN or WAN. The port is isolated to 1500 V. The port connector is located on the monitor interface board.

  • Page 31: Figure 12: Calisto/Calisto 2 - Rj45 Ethernet Port

    IEC61850 protocol (optional) Calisto/Calisto 2 supports the IEC61850 substation protocol. This option can be selected at the moment of the order and can also be retrofitted to any Calisto version C76-00000 or Calisto 2. Ethernet Outdoor Connectivity Kit (optional) For an easy and reliable connection, the Calisto/Calisto 2 monitor can be installed with the Morgan Schaffer Ethernet Outdoor Connectivity Kit.
  • Page 32 Refer to Section 4.2.5 Communication Settings of this manual for more information on the above protocols. The Calisto/Calisto 2 interface board includes a Type B USB jack. The USB connection does not provide high voltage isolation and is therefore only suitable for local connection using a laptop computer.
  • Page 33 The valves should have a minimum diameter of 1.3 cm (½ in.), and be located near the monitor. NOTICE When installing a Calisto/Calisto 2 monitor with a Precision Oil Temperature Probe, a special probe fitting must be attached to the transformer valve before installing the oil SUPPLY line. Refer to the Precision Oil Temperature Probe Manual.
  • Page 34 X below the highest manhole cover on the top of the transformer. Compare this measurement to the location of the top oil fill valve. Refer to Figure 1 and Figure 2 to view the oil inlet and outlet ports of the Calisto/Calisto 2 monitor.

  • Page 35: Figure 14: Tee Fitting Assembly For The Precision Oil Temperature Probe Option

    Prior to installing the oil lines, both transformer valves selected to circulate oil to the monitor must be prepared to accept the tube fittings included in the accessories. Figure 15 shows one of the supplied brass elbow fittings 3/8″ tube to ½″ NPT male (stainless steel 316 if stainless steel flexible oil lines were ordered with the monitor).

  • Page 36: Figure 17: Attaching The Copper Tubing To The Inlet Port

    CAUTION When attaching oil lines to the Calisto/Calisto 2, use a counter-torque wrench to avoid damaging the INLET and OUTLET ports on the monitor. The torque and the counter-torque wrenches must be aligned one over the other as much as possible to cancel induced forces.

  • Page 37: Figure 18: Attaching The Copper Tubing To The Outlet Port

    inches where they enter the fittings. Incorporate at least one shallow bend somewhere in the tubing to aid installation. Tighten the tubing at the transformer valve to complete the oil RETURN line installation. Figure 18: Attaching the Copper Tubing to the OUTLET Port 4.

  • Page 38: Figure 19: Monitor With Both Valves Closed

    Before continuing, Section 5.1 of the Precision Oil Temperature Probe Installation Manual must now be followed when the option is to be installed with a Calisto/Calisto 2. 1. Once all connections are made, the lines and the monitor must be flushed with oil to remove any air present in the assembly and to replace the shipping oil inside the monitor with oil from the transformer.

  • Page 39: Figure 20: Quick Connect Oil Sampling Tube

    Figure 20: Quick Connect Oil Sampling Tube Figure 21: Connecting the Quick Connect Oil Sampling Tube to the monitor 3. Using a container to collect the flushed oil, slowly turn the OUTLET valve (left side) counterclockwise ¼ turn (the handle will then be pointing down) to flush the RETURN line with oil (Refer to Figure 22: Flushing the Oil RETURN ).

  • Page 40: Figure 22: Flushing The Oil Return Tube

    Figure 22: Flushing the Oil RETURN Tube NOTICE Before proceeding with Step 5, the following checks should be made:  The earth ground is properly connected.  The mains power is protected by a circuit breaker.  The main supply switch is in the “O” position (OFF). ...

  • Page 41: Figure 23: Flushing The Oil Supply Tube

    Figure 23: Flushing the Oil SUPPLY Tube 5. While maintaining the INLET valve open, remove the Quick Connect Oil Sampling Tube from the oil SAMPLING port by pushing the locking ring up and pulling the fitting (with yellow hose) down (See Figure 24). Figure 24: Disconnecting the Quick Connect Oil Sampling Tube from the Monitor 6.

  • Page 42: Figure 25: Monitor With Both Valves Open

    Figure 25: Monitor with both Valves Open 7. The monitor is now ready for configuration. Refer to Section 3.0 POWER UP.
  • Page 43 (OFF), and that the INLET and OUTLET valves inside the monitor are closed (horizontal position). 1. Bolt the IED to a proper structure or a Morgan Schaffer Calisto Mounting Stand using the provided vibration mounts. 2. Connect the earth ground and mains power.
  • Page 45 The following checks should be made before providing power to the monitor:  Verify that no tools or other equipment are present in the enclosure.  The earth ground is properly connected.  The mains power is properly connected.  All signal, relay and communication wiring is installed. ...
  • Page 46 When the Calisto/Calisto 2 is powered on or reset, the unit first enters an initialization and power- on self-test sequence. The purpose of this mode is to allow the on-board computer to evaluate temperature conditions and to allow the detection cell and moisture sensor to reach equilibrium with the surroundings.
  • Page 47 For more information, refer to Figure 26 which shows the structure of the display interface for Calisto/Calisto 2. For a Calisto model C76-00000, the same structure applies, except that CO will be shown as <CO=N/A>. The unit will return to the default section <REALTIME> after 10 seconds of inactivity.

  • Page 50: Figure 27: 6-Feet Long A/B Type Usb Cable

    Calisto/Calisto 2 can be set up for local, remote (hard wired) or wireless communication (not part of this manual). Calisto/Calisto 2 is supplied with a 1.8 m (6 ft) A/B type USB cable (Refer to Figure 27). The USB port is dedicated to the monitor configuration, setup and maintenance.
  • Page 51 These readings are necessary to retrieve the basic settings of the monitor. After a one minute timeout, the following message will appear if Calisto Access cannot find the port currently used for communication with the IED.
  • Page 52 To confirm which port is used, see My Computer / Properties / Hardware / Device Manager / Ports (COM & LPT). The path for accessing Device Manager may differ, depending on your system. The line representing the Calisto/Calisto 2 is: IAR Virtual COM port, IAR STR912-SK board.
  • Page 53 The Calisto Access Status tab displays information about the currently connected unit. This screen appears once communication is established with that specific unit. In the first subdivision of the Status tab, the Unit Description information is found: the Calisto Model, Serial Number and Firmware Version.

  • Page 54: Figure 28: Calisto Access Status Tab With An Error Code

    (ppm) field displays the last saved hydrogen value while the Continuous H2 (ppm) field shows the actual continuous hydrogen concentration. Also, for Calisto 2 only, the Validated CO (ppm) field displays the last saved carbon monoxide concentration. The H2O (ppm) field displays the actual ppm concentration or the calculated moisture relative saturation, according to the current water measurement mode set in the Measurements tab under H2O Measurements Mode section.

  • Page 55: Figure 29: Error Code Interpretation Chart

    Figure 29: Error Code Interpretation Chart...
  • Page 56 (HEXADECIMAL) NAME This error only occurs when heat sink temperature (ST on display or OUTT in Calisto Real Time) is higher than 27°C (81°F) and the external fan is not running. In that Outside case, the fan is disconnected or has failed. Please contact Morgan Schaffer for assistance, either by phone at 001.514.739.1967 or by e-mail at...
  • Page 57 Schaffer factory defaults. Most of these parameters do not require client modification. However, to take full advantage of the Calisto/Calisto 2 communications, alarms and analog I/Os, it is necessary to adjust some settings to suit the specific transformer and installation.

  • Page 58: Figure 30: Calisto Access Settings Tab

    Figure 30: Calisto Access Settings Tab The preferred method of adjusting the communication settings is through a local connection between a laptop PC and the Calisto/Calisto 2 USB port. A few simple steps are required to configure the communication settings, as discussed below.
  • Page 59 Application Layer Retries parameter to the desired value [0 to 6]. Set the DNP3 Master Address parameter to the desired value [1 to 99]. To allow Calisto/Calisto 2 to generate a Change Event for one of the Binary Inputs or Analog Inputs, set the Class of those to Class 1, otherwise set it to Class 0.

  • Page 60: Figure 32: Dnp3/Tcp

    001.514.739.1967. IEC61850 If the Calisto/Calisto 2 unit has the IEC61850 option installed, it will be possible to change the IP address, subnet mask and gateway of the IEC61850 module. Note that the IP address is normally specific, and that the subnet mask is normally common to a group of Calisto/Calisto 2 units. The subnet mask defines your local network boundaries.
  • Page 61 For both monitors, alarm limit values can be adjusted for dissolved hydrogen and moisture from the Calisto Access interface, under Outputs. In the case of Calisto 2, carbon monoxide alarm limit values can also be adjusted this way. For each transformer being monitored, alarm limit values should reflect the actual concentrations of dissolved gases and moisture in accordance with the client’s policies.
  • Page 62 Calisto/Calisto 2 is equipped with 5 N.O./N.C. dry-contact relays. Flexible relay configuration options are provided under the Outputs tab of the Calisto Access interface, see Figure 33. Each relay has two Response Modes. Usually, the <is energized> Response Mode is used. The <blinks>...
  • Page 63 Logic Relay Response Condition Mode Figure 33: Calisto Access Default Set-Up...
  • Page 64 H2O Alarm 1  H2O Alarm 2  H2O Trend Alarm  CO Alarm 1 (Calisto 2 only)  CO Alarm 2 (Calisto 2 only)  CO Trend Alarm (Calisto 2 only)  2. Self-Test Error Condition. Self Test Errors occur when the monitor detects a problem with its operation.
  • Page 65 Any Alarm Any H2 Alarm Any H2O Alarm Any Validated Alarm Any Continuous Alarm Any Trend Alarm Any Alarm or Self-Test Error Any CO Alarm (Calisto 2 only)
  • Page 66 The default configuration of the relays for Calisto and Calisto 2 is as shown below. RELAY RESPONSE LOGICAL EVENT FOR EVENT FOR MODE CONDITION CALISTO CALISTO 2 Relay 1 Is energized When H2 Validated Alarm 1 H2 Validated Alarm 1...
  • Page 67 Calisto/Calisto 2 instruments use experimentally determined moisture solubility functions for common dielectric fluids. Calisto/Calisto 2 can also report %RS at a standard temperature of 25°C (77°F). For each type of oil, these readings are proportional to the moisture-in-oil ppm readings, related by the moisture solubility of the oil at 25°C (77°F).

  • Page 68: Figure 34: Oil Types Selection

    ASTM-3612 which is a general mineral oil type as per the ASTM-3612 standard, or select the Custom Type option to enter the coefficients for their oil in each field. NOTICE Selecting the wrong oil type or solubility coefficients may lead to inaccurate dissolved gas and moisture readings.

  • Page 69: Figure 35: Calisto Access External Input Settings

    The monitor can be equipped with an external sensor using the 4-20 mA input. In order to activate the Calisto Precision Oil Temperature Probe option, the %RS @ TºC mode and the 4-20 mA sensor type have to be selected under the Measurements tab, Figure 35.
  • Page 70 CAUTION Refer to Section 6.0 of the Precision Oil Temperature Probe Installation Manual to proceed with the configuration of the option if you have installed it. Once properly configured, the external input reading will be displayed as the transformer’s oil temperature (<OTT>...
  • Page 71 To download just a portion of the entire data bank, the download size can be chosen. The available choices are: last week, last month or entire database. When the Start Download button is pressed, the progress of the download will be shown, including the estimated time until completion. The download can be interrupted at any time.
  • Page 72 Downloaded data banks from Calisto/Calisto 2 monitor can be viewed using the graphic tab. The toolbar allows user to: Open data bank (required for any other action) Save data bank (under a different name, or after a merge) Merge one current data bank with another (useful for periodic partial downloads)

  • Page 73: Figure 38: Calisto Access Graphic Plotting Panel – H2O

    Figure 37: Calisto Access Graphic Plotting Figure 36: Calisto Access Graphic Plotting Panel – CO for Calisto 2 only Panel– H2 Figure 38: Calisto Access Graphic Plotting Panel – H2O...

  • Page 75: Figure 39: Quick Connect Oil Sampling Tube Connected To A 30Cc Syringe

    Oil samples can be easily collected from Calisto/Calisto 2 using the supplied Quick Connect Oil Sampling Tube. Refer to Figure 40 for the location of the SAMPLING port. 1. It is recommended to close the OUTLET valve to prevent taking an oil sample with excessive pressure.
  • Page 76 2. NOTICE In some environments, a protective plug may be required to prevent dust or sand from affecting the SAMPLING port mechanism. This part is not included in the standard Calisto/Calisto 2 Accessory Kit and must be ordered separately.
  • Page 78 One week after commissioning, Morgan Schaffer recommends connecting the instrument to a laptop via USB using the Calisto Access software to download the databank and the event log (.bnk, .log, .mfg) and send those files by email to Morgan Schaffer Customer Support at support@morganschaffer.com.
  • Page 79  Note the Serial Number C76-00000 or C85-00000 of the instrument (located on the external metal nameplate).  Connect the instrument to a laptop via the USB port. Run the Calisto Access software and download the databank and the event log files (.bnk, .log, .mfg).
  • Page 81 : 90% in 6 hours : < 0.3% of other gases Interference : < 6% from C ,<3% from H 1 – for Calisto 2 only. Measurement technology Oil immersed RS sensor Detection range 2 ppm - saturation , 2-100% RS Accuracy (ref: MS oil standards for ppm and ±...
  • Page 82 Enclosure SS 304 gauge 16, lockable Anti-cavitation reciprocating pump, Oil circulation 10 - 60 ml/min. Oil flow monitoring Proprietary Morgan Schaffer system 3/8" O.D. copper with brass compression Oil lines (standard) fittings Enclosure temperature conditioning Thermoelectric feedback Passive heat exchanger...
  • Page 83 Communication protocols Modbus, DNP3 Level1 Optional IEC 61850 kit Programmable dual-level and trend alarms for Measurement Alarms , CO (Calisto 2 only) and H 5 NO/NC contacts, configurable for setup, Alarm Relays self-test and measurement alarm conditions (5A, 240V) 8 readings/day, validated H...
  • Page 84 508 × 584 × 470 mm (20 × 23 × 18.5 in) 1× USB cable type A to B 1× CD Calisto Access interface software 1× Calisto & Calisto 2 Installation & Operation Manual 1× Quick Connect Oil Sampling Tube 1×...
  • Page 85 Extended warranty up to 5 years On-site commissioning assistance Morgan Schaffer’s Calisto & Calisto 2 monitors are backed by a 3-year factory warranty. Calisto and Calisto 2 and other MS monitoring systems are available through Morgan Schaffer’s worldwide network agents.
  • Page 86 Accuracy from -10 to 30 C (14 to 86°F) ±1.5 C (±2.7°F) Accuracy below -10 (14°F) or above 30 C (86°F) ±3.0 C (±5.4°F) Long term stability ≤ 0.15% span/year Oil circulation Continuous around probe Protection Fault signal on sensor break or short circuit Probe temperature span -50 to 125 C (-58 to 257°F)
  • Page 87 UL: Recognized component UL 3111-1 Easy installation No field calibration required Maintenance-free Use existing oil supply line to Calisto/Calisto 2 Special slip-through design for probe intrusion For intrusive installation, the Oil Temperature Probe requires either a gate or a ball valve.
  • Page 88 Inlet and outlet connection Made for 3/8 tube compression fittings Customizable length from 0.6 to 10.7 m [2 to 35 ft] Inner tubing material High temperature resistant PTFE Pressure resistance Up to 172 bar [2500 psi] Puncture resistant Braided stainless steel Corrosion proof...
  • Page 89 IP67 connection Isolated to 1500 Vrms (on monitor side only) Customizable cable length (up to 15 m [50 ft]) Oil and water resistant components UV stabilized components Category 5e components Straight-through pair configuration ® Datatuff series cable for harsh environments Cable jacket: Industrial grade PVC ®...

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