Morgan Schaffer Calisto User manual

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

III
The Calisto/Calisto 2 monitor is designed to be permanently installed on critical transformers for
continuous measurement of dissolved fault gases in dielectric insulating fluids. Calisto and Calisto 2
monitor hydrogen and moisture. Hydrogen is a reliable indicator of a recent or existing fault, as all
fault types produce it to a greater or lesser extent.
Calisto 2 also monitors carbon monoxide. Carbon monoxide and moisture levels may highlight
undesirable deterioration of the paper/oil system, and conditions conducive to such deterioration.
Calisto 2 provides the key measurements required to monitor the health of the insulation system, in
order that informed service decisions may be taken, and major transformer problems may be
avoided.
DISCLAIMER
The Calisto/Calisto 2IED (Intelligent Electronic Device) has been carefully designed
and engineered to provide maximum accuracy while continuously monitoring the
concentration of dissolved gases in transformer oil.
It is assumed by Morgan Schaffer that users will read this Installation &Operation Manual
and will understand the operation of the instrument prior to installation of the IED.
All results obtained using the Calisto/Calisto 2monitor are based upon material and
equipment under the responsibility of the client. Morgan Schaffer assumes no
responsibility and makes no warranty or representation, expressed or implied, as to the
condition, productivity or proper operation of any equipment or other property for
which the Calisto/Calisto 2monitor may be used or relied upon for any reason
whatsoever.

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An electronic version of this manual is available on the Calisto/Calisto 2CD supplied with your
monitor and at Morgan Schaffer’s web site www.morganschaffer.com. To access this manual on the
website, click Instruments under Products. Then click either Calisto or Calisto 2 and then
Downloads under the Menu (on the right). In order to use the electronic manual efficiently,
proceed as follows after opening Acrobat Reader®:
1. Click Window, Show Bookmarks.
2. Click View, Fit Width.
3. Click View, Continuous.
When necessary, use the Zoom command to view drawing or picture details.
This Installation &Operation Manual provides the required information for installing and setting up a
Calisto monitor version C76-00000 or a Calisto 2 monitor version C85-00000 for operation. All
types of signals, alarm relays and communications are also covered. Users should visit Morgan
Schaffer’s website regularly at www.morganschaffer.com or contact us directly for documentation,
firmware and software updates.
NOTICE
This manual applies to both Calisto and Calisto 2 monitors. Always consider which one
you are working with. Some sections of this manual apply to Calisto 2 only and are
expressly marked “for Calisto 2 only”. If not stated, the section applies to both Calisto
and Calisto 2 monitors.

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A 3-year warranty covers each new Calisto/Calisto 2IED. 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 [email protected]
once it has been filled out. Upon receiving the registration form, Morgan Schaffer will confirm the
validity period of the warranty. End users may also visit our website and electronically register their
monitor. In the main menu, under Products, click Instruments and then Calisto or Calisto 2. On
the right side of the menu, click Registration. The warranty can be activated at any time within the
6-month period following the shipping date from Morgan Schaffer. Additional information must be
provided by the end-user if registration of the warranty is performed after the activation period.
Extended warranties are available from Morgan Schaffer. Extended warranty confirmations will be
provided at the time of their purchase or when the standard Warranty Registration Form is received.

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

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measurements, without any field calibration, for the lifetime of the instrument. The Calisto and
Calisto 2 detection cells take validated measurements for hydrogen and carbon monoxide (Calisto 2
only) every three hours. Validated measurements are continuously zeroed to guarantee long-term
stability and low-level detection accuracy. A continuous measurement of the hydrogen concentration
is also performed for both monitors, to indicate any variation in hydrogen concentration which may
occur between validated readings.
Vacuum tolerance is made possible because of the intrinsic properties of the capillary tubing used
to form the gas sample and because the oil circulating and conditioning systems inside the
Calisto/Calisto 2 can both sustain vacuum. As a result, no action is required to protect the monitor
if the transformer is put under vacuum for degassing purposes.
Precise moisture measurement is achieved using a capacitive thin-film sensor immersed directly
in circulating oil to continuously measure dissolved moisture. Moisture content can be reported in
parts per million (ppm), %RS at 25oC (77°F) or %RS at a specific transformer temperature using the
Expert Series Calisto Precision Oil Temperature Probe.

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

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

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Figure 3: Calisto/Calisto 2 - Main Internal Components

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

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Calisto Mounting Stand
For a fast and easy installation, Morgan Schaffer has designed a pedestal-style
mounting stand for Calisto/Calisto 2. This stand is highly corrosion resistant
and includes all required hardware to perform the installation in less than one
hour.
Precision Oil Temperature Probe –Standard Edition
The Precision Oil Temperature Probe was specifically developed to meet
client demands to report the %RS in oil at a specific transformer temperature
in a truly accurate and reliable way. The 610 mm (24 in.) temperature probe is
customized at the moment of the installation of the monitor and does not
require any specifications from the client at the time of the order. Refer to
Appendix I for the complete technical specifications.
Stainless Steel Braided Flex Lines
The Stainless Steel Braided Flex Lines are a popular customizable option for
the Calisto/Calisto 2 configuration that has the advantage of being highly
resistant to corrosion and easy to install. Refer to Appendix I for the
complete technical specifications.
Ethernet Outdoor Connectivity Kit
Calisto/Calisto 2 features an Ethernet port isolated to 1500 V. The Ethernet
Outdoor Connectivity Kit includes all the necessary parts to bring a
communication cable from the monitor to a control box switch/hub in an
easy and reliable way. Refer to Appendix I for the complete technical
specifications.

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Other available options:
Insulation kit (for -50 to 55°C [-58 to 131°F] operation)
IEC 61850 Ethernet communication kit
900 MHz radio modem over RS-485
2.4 GHz radio modem over RS-485
Quick-connect dust plug
Calisto MultiTrack software
Extended warranty up to 5 years
On-site commissioning assistance

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The following steps must be undertaken to properly install a Calisto/Calisto 2 IED on a
transformer:
Mounting of the monitor on a transformer or structure
Electrical connections: power, alarms, signals and communication
Attachment of oil circulation lines between transformer valves and IED
Flushing of the oil lines with oil to remove air
The following tools are usually required for a standard installation:
Pipe cutter (for copper oil lines only)
Pipe wrench, 5/8 and 11/16 wrenches (or adjustable wrenches)
Knife
Small screwdriver (flat)
Large screwdriver (flat)
Installation kit for Calisto/Calisto 2
WARNING
IED’s should only be installed by qualified personnel familiar with their operation and
associated hazards. Improper electrical or hydraulic circuitry may result in personal
injury and/or instrument damage and may void the warranty.
Two persons are recommended for lifting the equipment.
NOTICE
Calisto/Calisto 2 is designed for industrial use and shall not be connected to the public
low-voltage distribution system.
Section 2.0 Installation applies to both Calisto and Calisto 2 monitors.
CAUTION
All IEDs are filled with new transformer mineral oil when shipped. DO NOT OPEN
INLET AND OUTLET VALVES PRIOR TO INSTALLATION.

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This section will provide guidelines on where to install the monitor on the transformer. Two
different scenarios will be discussed. One will be based on the Calisto/Calisto 2 being shipped
directly from a new transformer manufacturer or transformer rewinder (Factory Installed) and the
other is based on a field retrofit.
Calisto/Calisto 2 must be solidly bolted to a suitable support approximately 1.2 m (4 ft) above
ground level to allow easy access to the internal oil sampling valves. A minimum of 60 cm (24 in.) is
required for air circulation under the unit.
The mounting structure should be positioned to protect the monitor from extreme vibrations. A
typical location would be the side of the transformer control box. Vibration mounts (4) are provided
with each monitor and should be used to provide the instrument with additional protection against
possible vibrations. If the monitor is field installed, the use of a post bolted to the concrete base of
the transformer is an ideal configuration. The Calisto/Calisto 2 mounting hole locations are shown
in Figure 4. Standard dimensions are in inches and dimensions in brackets are in millimetres.
Figure 4 : Calisto/Calisto 2 - Mounting Diagram

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Electronic mounting and installation drawings are included in the CD provided.
In most cases the factory will install the monitor on Unistrut® brackets that are welded to the main
transformer tank. Calisto/Calisto 2 is generally installed at eye level and two additional ½ inch valves
are welded directly to the main tank near the monitor for the oil supply and return.
In most cases the top oil fill valve and the main drain valve are located on the same side of the main
tank. It is best to install the monitor near the bottom drain valve. Of course this location will vary as
needed based on the oil line requirements discussed later in this section.
Typically Unistrut®brackets are used to make a base for mounting the Calisto/Calisto 2. The
mounting structure can be designed to clamp on to various components of the transformer tank, on
the main control cabinet, on a post installed in the ground or on a concrete base. A Morgan Schaffer
Calisto Mounting Stand is available as an optional accessory. Contact Morgan Schaffer for more
information.
A complete Installation Manual is included with the Morgan Schaffer Calisto Mounting Stand
accessories. Refer to this manual when mounting a Calisto/Calisto 2 on the stand.
NOTICE
The IED is designed to be installed vertically (as shown in this manual). The unit
MUST NOT BE MOUNTED IN ANY OTHER ORIENTATION.

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The following section explains in detail the monitor interface board and how to connect the mains
power, safety ground, alarm relays, analog signals, and communication cables to a Calisto/Calisto 2
monitor.
The Calisto/Calisto 2 monitor features a 4-hub detachable electrical entry plate made of stainless
steel. All entry holes are 22 mm (7/8 in.) in diameter and can accept most ½ in. entry hub fittings.
Four waterproof rubber entry hole plugs are provided with the instrument to cover unused holes.
Opening the Calisto/Calisto 2 enclosure door will provide access to the monitor interface board.
Figure 5 shows the main components of the Calisto/Calisto 2 interface board. All connections to
the monitor are made using this board.
Items 1, 12 and 11 are respectively the mains power connectors, the thermal cut-off fuse and the
over-current fuse.
Items 10 and 2 are the programmable NO/NC dry-contact relays with their respective connectors.
Items 4, 5, 6 and 7 are respectively the RS-485, RS-232, 4-20 mA analog input and 4-20 mA analog
output connectors.
WARNING
Electrical shock hazard. Only persons with electrical safety training and certification
should install the equipment or open the enclosure once the equipment has been
installed.
NOTICE
It is recommended to select a shielded cable suitable for outdoor use for all
communication and signal wiring. For any configuration, the installer must follow these
guidelines:
Minimize the length of cable from the hub to the interface board (avoid loops).
Protect against mechanical stress on wires and connectors attached to the
interface board.