MTE HYDROCAL 1002 Specification sheet

HYDROCAL HYDROCAL
1002-1003: 1002-1003:
Manual Manual
for for
Installation Installation
and and
Operation Operation
Edition Edition
01.201001.2010
HYDROCAL 1002-1003HYDROCAL 1002-1003
Gas-in-Oil Analysis System withGas-in-Oil Analysis System with
Transformer Monitoring FunctionsTransformer Monitoring Functions
Manual for installation and operationManual for installation and operation

HYDROCAL HYDROCAL
1002-1003: 1002-1003:
Manual Manual
for for
installation installation
and and
operation operation
Page Page
1 1
of of
9797
Copyright MTE Meter Test Equipment AGCopyright MTE Meter Test Equipment AG
All rights reserved.All rights reserved.
The contents of this manual areThe contents of this manual are
subject to change without notice.subject to change without notice.
All efforts have been made to ensureAll efforts have been made to ensure
the accuracy of this the accuracy of this
publication butpublication but
MTE Meter Test Equipment AG canMTE Meter Test Equipment AG can
assume assume
no no
responsibility responsibility
for for
any any
errors errors
Customs Customs
tariff tariff
number:number:
or or
their their
consequences consequences
9027.10109027.1010

HYDROCAL HYDROCAL
1002-1003: 1002-1003:
Manual Manual
for for
installation installation
and and
operation operation
Page Page
1 1
of of
9797
Copyright MTE Meter Test Equipment AGCopyright MTE Meter Test Equipment AG
All rights reserved.All rights reserved.
The contents of this manual areThe contents of this manual are
subject to change without notice.subject to change without notice.
All efforts have been made to ensureAll efforts have been made to ensure
the accuracy of this the accuracy of this
publication butpublication but
MTE Meter Test Equipment AG canMTE Meter Test Equipment AG can
assume assume
no no
responsibility responsibility
for for
any any
errors errors
Customs Customs
tariff tariff
number:number:
or or
their their
consequences consequences
9027.10109027.1010

HYDROCAL HYDROCAL
1002-1003: 1002-1003:
Manual Manual
for for
installation installation
and and
operation operation
Page Page
1 1
of of
9797
SummarySummary
1. 1.
GeneGene
ral ral
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................................
. .
44
2. Mounting of HYDROCAL 1002-1003 unit ........................................................................................ 52. Mounting of HYDROCAL 1002-1003 unit ........................................................................................ 5
2.1 Locations for installation of HYDROCAL 1002-1003 .................................................................. 52.1 Locations for installation of HYDROCAL 1002-1003 .................................................................. 5
2.2 Security precautions for installation ........................................................................................... 62.2 Security precautions for installation ........................................................................................... 6
2.3 Preparation for installation ......................................................................................................... 82.3 Preparation for installation ......................................................................................................... 8
2.3.1 Power supply for the unit ..................................................................................................... 82.3.1 Power supply for the unit ..................................................................................................... 8
2.3.2 Requested tools:2.3.2 Requested tools:
..............................
................................
............................
................................
................................
..............................
................................
...... ......
88
2.4 Installation of the HYDROCAL 1002-1003 unit .......................................................................... 92.4 Installation of the HYDROCAL 1002-1003 unit .......................................................................... 9
Note: For additional information for mounting and un-mounting, please refer to the documentNote: For additional information for mounting and un-mounting, please refer to the document
named: “HC named: “HC
1002-1003 Special Additional Instructions Mounting & 1002-1003 Special Additional Instructions Mounting &
Un-mounting 01-2010.doUn-mounting 01-2010.do
c”. .. 11c”. .. 11
2.5 Front view of HYDROCAL 1002-1003...................................................................................... 122.5 Front view of HYDROCAL 1002-1003...................................................................................... 12
2.6 Rear side of HYDROCAL 1002-1003 unit ................................................................................ 132.6 Rear side of HYDROCAL 1002-1003 unit ................................................................................ 13
2.7 Connections on the measuring and controller card .................................................................. 142.7 Connections on the measuring and controller card .................................................................. 14
2.7.1 HYDROCAL 1002 .............................................................................................................. 142.7.1 HYDROCAL 1002 .............................................................................................................. 14
3. Software on Hydrocal unit ............................................................................................................. 183. Software on Hydrocal unit ............................................................................................................. 18
3.1. General information ................................................................................................................ 183.1. General information ................................................................................................................ 18
3.2. Operation of HYDROCAL 1002-13.2. Operation of HYDROCAL 1002-1
003 by its keyboard 003 by its keyboard
..................
....................
....................
..................
....................
....................
... ...
1919
3.2.1. Contrast Set-up ................................................................................................................ 193.2.1. Contrast Set-up ................................................................................................................ 19
3.3. 3.3.
Main Main
menu ..................menu ..................
................................
................................
..............................
................................
................................
............................
............... ...............
2020
3.4.3.4.
Configuration of user settings ...................................................................................... 21Configuration of user settings ...................................................................................... 21
3.5.3.5.
Display of stored „Gas-in-oil“ measuriDisplay of stored „Gas-in-oil“ measuri
ng values ng values
......................
......................
....................
..................
......................
....... 22....... 22
3.5.13.5.1
Graphic display ...................................................................................................... 22Graphic display ...................................................................................................... 22
3.5.2.3.5.2.
Table Table
presentation presentation
..................
....................
....................
..................
......................
......................
....................
..................
....................
........ ........
2323
3.6.3.6.
History of alarms ......................................................................................................... 24History of alarms ......................................................................................................... 24
3.6.1. Acknowledgment of alarms ............................................................................................... 243.6.1. Acknowledgment of alarms ............................................................................................... 24
3.7. 3.7.
Device Device
set set
– –
up up
................
......................
..................
..................
......................
....................
..................
....................
....................
..................
....................
.. ..
2525
3.7.1.3.7.1.
Menu Transformer data setup ............................................................................... 26Menu Transformer data setup ............................................................................... 26
3.7.1.2. 3.7.1.2.
Hot Hot
Spot Spot
calculation calculation
................
....................
......................
..................
..................
......................
..................
....................
....................
........ ........
2727
3.7.1.3. 3.7.1.3.
Ageing Ageing
Rate Rate
/ /
Loss Loss
of of
Life Life
..................
......................
..................
..................
......................
..................
....................
....................
........ ........
2929
3.7.2. 3.7.2.
Configuration Configuration
of of
analogue analogue
outputs outputs
..................
....................
......................
..................
..................
......................
..................
..... .....
2929
3.7.3. 3.7.3.
Configuration Configuration
of of
analogue analogue
inputs inputs
(external (external
sensors) sensors)
..................
......................
......................
..................
..... .....
3030
3.7.4.3.7.4.
Configuration of alaConfiguration of ala
rms and digital outputs rms and digital outputs
....................
..................
....................
....................
..................
....................
.. ..
3333
3.7.5. 3.7.5.
Unit Unit
Setup Setup
..................
......................
..................
..................
......................
....................
..................
....................
....................
..................
......................
. .
3636
3.7.5.1. 3.7.5.1.
Flange Flange
Heating Heating
Base Base
Temperature Temperature
..................
..................
......................
....................
..................
....................
........ ........
3737
3.7.5.2. 3.7.5.2.
Flange Flange
Heating Heating
Base Base
Temperature Temperature
..................
....................
..................
....................
....................
..................
......................
. .
3737
3.7.5.3. 3.7.5.3.
Device Device
options options
......................
..................
..................
......................
....................
..................
....................
....................
..................
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.. ..
3737
3.7.5.4. 3.7.5.4.
Clock Clock
settings settings
................
....................
....................
..................
....................
......................
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..... .....
3939

HYDROCAL
1002-1003:
Manual
for
installation
and
operation
Page
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3.7.5.5.
Configuration of the communication ................................................................... 40
3.7.5.5.1.
Alert
SMS
setup
.........
...........
...........
..........
.........
..........
..........
.........
..........
..
41
3.7.5.5.2.
Internal
modem
setup
..........
.........
..........
...........
.........
.........
...........
.........
.....
41
3.7.5.5.2.1 Analog Modem ......................................................................................................... 42
3.7.5.5.2.2 GSM Modem ............................................................................................................ 42
3.7.5.5.2.3 IP Modem ................................................................................................................. 43
3.7.5.5.3.
RS
232
/
RS
485
setup
.........
...........
..........
.........
..........
..........
.........
...........
.
44
A.
Poin
t
to
Poin
t .................
................
................
...............
................
................
..............
............... 44
I.
RS23
2
.............
..............
................
................
................
...............
................
................
......
44
II.
RS48
5
.............
..............
................
................
................
...............
................
..............
........
45
III.
Mode
m
..............
................
................
..............
................
................
...............
................
....
46
B.
RS48
5-Bu
s
.............
..............
................
................
................
...............
................
..............
........
47
C.
Bridg
e
...............
................
..............
................
................
..............
................
.................
...........
48
I
Bridg
e
Setup ...........................
..............
.................
................
................
..............
...............
49
II
RS485-Bus Setup ............................................................................................................... 50
D.
MODB
US
...............
..............
................
................
.................
..............
................
..............
........
51
Test / Debug Options at the HydroCal Device ............................................................................ 52
I
Function, Register and Address Mapping ........................................................................... 53
MODBUS Communication Examples ............................................................................................. 55
I
MODBUS/RTU via RS232 (using QuickMod) ..................................................................... 55
II
MODBUS/ASCII via RS232 (using Modpoll) ....................................................................... 57
III
MODBUS/RTU via RS485 (using QuickMod) ..................................................................... 57
IV
MODBUS/RTU on RS485-Bus (using Modpoll) .................................................................. 59
4.
Windows Software HydroSoft ................................................................................................. 62
4.1. Purpose of the program .......................................................................................................... 62
4.2. Remarks for use of this operation handbook ........................................................................... 62
4.3. Requirements to the PC.......................................................................................................... 62
4.4.
Insta
llati
on
................
...............
................
................
..............
................
................
...............
..
63
4.4.1. Microsoft .NET .NET Framework 1.1 Redistributable
.........
..........
.........
..........
...........
....... 63
4.4.2. Microsoft Data Access Components ................................................................................. 63
4.4.3. Adaptation of installation ................................................................................................... 64
4.5. Functions of HydroSoft program ............................................................................................. 64
4.6. Start of program ...................................................................................................................... 64
4.7. Preparation / rename of a new customer list ........................................................................... 65
4.8. Opening a new transformer station ......................................................................................... 66
4.9. Opening a file for a new transformer ....................................................................................... 66
4.9.1. Modem settings ................................................................................................................ 68
4.9.2. RS232 interface settings ................................................................................................... 68
4.10. Settings of HYDROCAL 1002-1003 unit ............................................................................... 68
4.10.1. Alert Setup ...................................................................................................................... 69
4.10.2. External sensors (see also chapter 3.7.3) ....................................................................... 72
4.10.3. Alert SMS Setup ............................................................................................................. 73
4.10.4. Input of DGA Level Adjustment ....................................................................................... 75
4.10.5. Analog Output Setup ...................................................................................................... 76
4.10.6. Digital Output Setup........................................................................................................ 77

HYDROCAL HYDROCAL
1002-1003: 1002-1003:
Manual Manual
for for
installation installation
and and
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Page Page
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9797
4.10.7. Device Setup (Clock settings) ......................................................................................... 784.10.7. Device Setup (Clock settings) ......................................................................................... 78
4.11. Data transmission from / to the HYDROCAL 1002-1003 un4.11. Data transmission from / to the HYDROCAL 1002-1003 un
it it
......................
..................
....................
....................
........ 79........ 79
4.12. View of results ...................................................................................................................... 814.12. View of results ...................................................................................................................... 81
4.12.1. Sensor selection ............................................................................................................. 814.12.1. Sensor selection ............................................................................................................. 81
4.12.2. Time range selection ...................................................................................................... 814.12.2. Time range selection ...................................................................................................... 81
4.12.3. Result window ................................................................................................................ 824.12.3. Result window ................................................................................................................ 82
4.12.4. Print and export of results ............................................................................................... 824.12.4. Print and export of results ............................................................................................... 82
4.13. View of alarm status ............................................................................................................. 834.13. View of alarm status ............................................................................................................. 83
4.13.1. Alarm selection ............................................................................................................... 834.13.1. Alarm selection ............................................................................................................... 83
4.13.2. Time range selection ...................................................................................................... 834.13.2. Time range selection ...................................................................................................... 83
4.13.3. Alarm window ................................................................................................................. 844.13.3. Alarm window ................................................................................................................. 84
4.13.4. Status of alarms .............................................................................................................. 844.13.4. Status of alarms .............................................................................................................. 84
4.13.5. Print and export of results ............................................................................................... 844.13.5. Print and export of results ............................................................................................... 84
4.14. Online Sensors ..................................................................................................................... 854.14. Online Sensors ..................................................................................................................... 85
5. RS232 / RS 485 Wiring ................................................................................................................. 865. RS232 / RS 485 Wiring ................................................................................................................. 86
6. Vaisala sensors connection on HYDROCAL 1002 ........................................................................ 876. Vaisala sensors connection on HYDROCAL 1002 ........................................................................ 87
6.1 6.1
MMTMMT
318 318
............................
............................
................................
................................
..............................
................................
................................
............................
........ ........
8787
6.2 6.2
MMTMMT
338 338
..............................
............................
................................
................................
..............................
................................
................................
............................
........ ........
8888
7. HYDROSOFT Scheduler .............................................................................................................. 897. HYDROSOFT Scheduler .............................................................................................................. 89
7.1 7.1
GeneGene
ral ral
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................................
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........... ...........
8989
7.2 7.2
SchedSched
uler uler
................................
............................
................................
................................
..............................
................................
................................
............................
........ ........
8989
7.2.1 Configuring a Transformer for automatic History Data Update 7.2.1 Configuring a Transformer for automatic History Data Update
....................
......................
..................
..................
....... 89....... 89
7.2.1.1 Connection Scheduler Dialog ......................................................................................... 897.2.1.1 Connection Scheduler Dialog ......................................................................................... 89
7.2.2 Scheduler Status Visualization7.2.2 Scheduler Status Visualization
..............................
................................
............................
................................
................................
..............................
.. ..
9090
7.2.2.1 Status Icons .................................................................................................................... 907.2.2.1 Status Icons .................................................................................................................... 90
7.2.27.2.2
.2 .2
ExamExam
ple ple
..........................
................................
............................
..................................
................................
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................................
............... ...............
9191
7.2.3 Hydrosoft and the 7.2.3 Hydrosoft and the
Windows Task Scheduler Windows Task Scheduler
..................
......................
......................
....................
..................
....................
......................
.. ..
9292
7.2.3.1 Command Line Op7.2.3.1 Command Line Op
tions for Windows Task Scheduler tions for Windows Task Scheduler
....................
....................
..................
....................
....................
... ...
9393
7.2.4 Internal Operation ................................................................................................................. 937.2.4 Internal Operation ................................................................................................................. 93
7.2.5. Data Directory Lock ............................................................................................................. 947.2.5. Data Directory Lock ............................................................................................................. 94
8. Technical data HYDROCAL 1002-1003 ........................................................................................ 958. Technical data HYDROCAL 1002-1003 ........................................................................................ 95
9. Dimensional Drawings HYDROCAL 1002-1003 ............................................................................ 979. Dimensional Drawings HYDROCAL 1002-1003 ............................................................................ 97

HYDROCAL HYDROCAL
1002-1003: 1002-1003:
Manual Manual
for for
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9797
1. General1. General
HYDROCAL 1002-1003 is an on-line Gas-in-Oil Monitoring System for continuous analysis of theHYDROCAL 1002-1003 is an on-line Gas-in-Oil Monitoring System for continuous analysis of the
dissolved gases hydrogen (Hdissolved gases hydrogen (H
22
) and carbon monoxide (CO) of ) and carbon monoxide (CO) of
power transformers. HYDROCAL 1003power transformers. HYDROCAL 1003
allows also in addition Analysis of moisture (Hallows also in addition Analysis of moisture (H
22
O) dissolved in transformer oil (absolute humidity inO) dissolved in transformer oil (absolute humidity in
ppm). The possibility to connect additional sensors with an analogue output signal (0..10V or (0-ppm). The possibility to connect additional sensors with an analogue output signal (0..10V or (0-
4..20mA), e.g. for temperature or oil humidity complete the product. The HYDROCAL 1002-10034..20mA), e.g. for temperature or oil humidity complete the product. The HYDROCAL 1002-1003
system together with the Windows-based software HydroSoft is a powerful tool for detection and di-system together with the Windows-based software HydroSoft is a powerful tool for detection and di-
agnosis of incipient fagnosis of incipient f
aults in power transformers.aults in power transformers.
The present operating instructions are divided in The present operating instructions are divided in
the following sections:the following sections:
••
Instructions for Instructions for
mounting the mounting the
HYDROCAL 100HYDROCAL 100
2-1003 un2-1003 un
it (chapter it (chapter
2)2)
••
Description oDescription o
f software of f software of
the HYDROCAL the HYDROCAL
1002-1003 1002-1003
unit (chapunit (chap
ter 3)ter 3)
••
Description Description
of of
Windows soWindows so
ftware Hyftware Hy
droSoft (chdroSoft (ch
apter apter
4)4)
••
RS 232 RS 232
/ RS / RS
485 485
Wiring (chaWiring (cha
pter 5pter 5
))
••
VAISALA sensoVAISALA senso
rs conners conne
ction on ction on
HYDROCAL 1HYDROCAL 1
002 (chap002 (chap
ter 6)ter 6)
••
HYDROSOFT HYDROSOFT
Scheduler Scheduler
(Chapter (Chapter
7)7)
••
Technical Technical
data of Hdata of H
YDROCAL 1YDROCAL 1
002-1003 002-1003
system (chasystem (cha
pter 8)pter 8)
••
HYDROCAL HYDROCAL
1002-1003 1002-1003
dimensional dimensional
drawingdrawing
s (chaps (chap
ter 9)ter 9)

HYDROCAL HYDROCAL
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2. Mounting of HYDROCAL 1002-1003 unit2. Mounting of HYDROCAL 1002-1003 unit
2.1 Locations for installation of HYDROCAL 1002-10032.1 Locations for installation of HYDROCAL 1002-1003
To ensure the correct function of the HYDROCAL 1002-1003 the location of mounting is very impor-To ensure the correct function of the HYDROCAL 1002-1003 the location of mounting is very impor-
tant. For a typical transformer, three places are possible:tant. For a typical transformer, three places are possible:
Pos. Pos.
1 1
On On
return return
side side
of of
cooling cooling
circuit:circuit:
Please install the unit on a Please install the unit on a
straight piece of tube on the cooler output between the straight piece of tube on the cooler output between the
coolercooler
and the main oil tank. In and the main oil tank. In
order to avoidorder to avoid
negative pressurenegative pressure
, the unit must, the unit must
absolutelyabsolutely
bebe
mountedmounted
on theon the
downstream sidedownstream side
(after the bend) of the oil circulation pump.(after the bend) of the oil circulation pump.
Remark: Choose this place only in case of continuous oil flux through the cooler.Remark: Choose this place only in case of continuous oil flux through the cooler.
Pos. Pos.
2 2
Flange Flange
below below
on on
the the
transformer transformer
tank:tank:
The flange must be at minimum height of The flange must be at minimum height of
30 cm in order to allow installation and mounting30 cm in order to allow installation and mounting
of HYDROCAL 1002-1003 unit.of HYDROCAL 1002-1003 unit.
Pos. Pos.
3 3
Upper Upper
filling filling
valve:valve:
It is possible to mount theIt is possible to mount the
HYDROCAL 1002-1003 unit in this position, however it may beHYDROCAL 1002-1003 unit in this position, however it may be
difficult to operate and read the data of difficult to operate and read the data of
the unit.the unit.
Remark: Should the unit be mounted on the wall of the cooler, then make sure thatRemark: Should the unit be mounted on the wall of the cooler, then make sure that
the unit is mounted below the oil lthe unit is mounted below the oil l
evel.evel.
Pos. 4 Pos. 4
Never insNever ins
tall the tall the
HYDROCAL HYDROCAL
1002-1003 1002-1003
unit on unit on
top of top of
the coolethe coole
r or r or
on the on the
suctionsuction
face of the pump.face of the pump.

HYDROCAL
1002-1003:
Manual
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and
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2.2 Security precautions for installation
The following security precautions must be strictly observed during the installation. Otherwise no war-
ranty claims will be accepted.
Never connect the sensor head to another HYDROCAL 1002-1003 elec-
tronic unit other than the delivered one.
The components are delivered as a
matched pair and have been c
alibrated
together in our works. You will f
ind the serial numbers on the units, on the
packing material and /or on the data sheets. Please ensure you note down
these serial numbers for fut
ure reference.
Never remove the protection cap from the sensor before you are ready to
mount the unit on the valve of the transformer
.
The protection cap protects the membrane of the sensor against dust and other
foreign bodies. Additionally it protects
the thread of the
measuring head and/or
adapters.
Note: Use the protection cap also after dismounting of the unit.
Never touch the membrane with fingers or other objects.
Never close the aeration hole f
or oxygenation
.
Never use or stock chemicals with hydrocarbon contents near the mea-
suring sensor.
Never clean the measuring head with solvents, because its gases
will strongly
impair the measuring accuracy and the sensivity of the sensors.

HYDROCAL
1002-1003:
Manual
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Never apply a negative pressure to the measuring head.
Negative pressure can damage the
unit.
Remove the HYDROCAL 1002-1003 unit from the valve every time you
degas or refill the transformer.
Never install the HYDROCAL unit on a
valve that is closed for a long pe-
riod of time. Remove the unit i
f this cannot be avoided
.
Never install the HYDROCAL 1002-1003 on the suction side of the cooling
pump!
Never install the HYDROCAL 1002-1003 unit on an elbow or curve of a
tube.
The unit can
be damaged by negative pressure produced by turbulences in
curves.
Never install or
remove the HYDROCAL 1002-1003 without opening first
the aeration screw.
Never use galvanized fittings or valves to mount the HYDROCAL 1002-
1003 unit.
Galvanized fittings or valves can react with
oil, this will produce incorect mea-
suring values.
Never clean the HYDROCAL
1002-1003 unit with high pressure cleaning
equipment.
High pressure cleaning equipment used to
clean transformers can seriously
damage the HYDROCAL 1002-1003 unit.

HYDROCAL
1002-1003:
Manual
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Never use a chaining key tool for mounting.
Use of such tools
can damage the surface of the measuring head and the
threads
.
Please use an adjustable
thin spanner for 1 ½“.
Attention!!!
Faulty or inappropriate handling of the
sensor head like perforation of the
membrane, scratches on the membrane or damages by negative pres-
sure, paint or solvent liquids make the warranty invalid.
2.3 Preparation for installation
Before installation, a visual inspection of the membrane must be carried out made. Remove the pro-
tection cap and check the membrane. No cuts or tears should exist, the surface must be smooth.
Under no circumstances should the membrane be touched with fingers or with any other means.
2.3.1 Power supply for the unit
The HYDROCAL 1002-1003 unit requires an auxiliary power supply of 110 / 230V close to the unit.
The power needed is max. 350 VA.
2.3.2 Requested tools:
•
Long
Allen key
, size
4 for
aeration
screw
•
Long Allen key
, size 5 to loo
se the measurin
g head fro
m the unit (6
x screws).
•
Bucket,
oil
absorber,
cleaning
rag
•
 Teflon-band
•
Drill
/
screw
driver
•
Digital
multimeter
•
Tin spanne
r or adjustabl
e tin spanner
of 1 ½
“ for valve a
nd fittings
To seal the thread of the measuring head, only Teflon band must by used. Minimum 4 to 5 layers
must be applied.

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2.4 Installation of
the HYDROCAL 1002-1003 unit
Attention!!!
Mount the measuring head horizontally on the
valve. The aeration screw
must then be in the 12 o clock position.
Please mount the HYDROCAL 1002-1003 unit on a valve with full opening (full bore valve) or a ball
valve with an internal thread of 1½” (DIN ISO 228: G 1½). The HYDROCAL unit has a 1½’’ thread
(Dimensional drawings, see. chapter 6).
A good oil flux
should exist on the mounting location.
If necessary, use a reduction piece (adapter). In
order to have a sufficient oil flux on the membrane, the diameter of the valve should be not less than
25 mm. For optimal working conditions, the valve diameter should not be more than 76 mm. The
valve must be on earth potential.
Attention!!!
The distance between the oil main
stream and the measuring head shall
not be more than 6 times the length of
valve diameter.
(Distance 150 mm at Valve-
∅
25 mm / Distance 228 mm at Valve-
∅
38 mm /
Distance 300mm at Valve-
∅
50 mm / Distance 450mm at Valve-
∅
76 mm).
In case there exist s
trong vibrations on the mounting valve, the valve should be relieved by a support.
Then mount the unit according to the following steps:
•
Loose the knur
led thumbscrews
and remove
the housin
g of the HYDROCAL
1002-1003
unit.
•
Disconnect the conne
ction cable of the
measuring hea
d from the p
rinted circuit.
•
Loose the
measuring
head
from the
unit.
Only remove the protection cap (slowly while turning)
when you are ready to mount the measuring head!

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•
Clean the
internal
side of
the installatio
n valve.
•
Wind 4 to 5 layer
s of Teflon band on the
thread of the adap
ter and mount it on
the valve. Make
sure that it is
fixed mechanically.
•
Mount the measuring h
ead on the adap
ter taking care. Not to use too much force. In case no
adapter is required, wind 4 – 5 layers of Teflon band on the thread of the measuring head and
mount it on the v
alve. Make sure that it remains fixed mechanically, but do
not use too much force.
•
Turn the
aeration screw
to the 12
o clock po
sition.
Attention!!!
The following steps must be done according to the company procedures.
Work carefully in order to prevent air entering into the transformer. Use a
bucket to catch oil coming out.
•
Unscrew the ae
ration screw 3
– 4 turns with
Allen key No. 4. (
Aeration is a
ctive).
•
Open the
valve slowly
until oil co
mes out on
the proving
hole.
•
As soon as no air bu
bbles sort on the pro
ving hole, close
the aeration screw. T
hen fully open the
valve. Remove the oil from the m
easuring head external.
Do not use any solvents for cleaning!
•
Make
sure tha
t no
untaught
places
exist.
•
Mount the unit on the
measuring head, use
the 6 pieces of plain wa
shers, lock washers and nu
ts.

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•
Connect the connectio
n cable to the printed
circuit. Check that all pi
ns of the plug go straigh
t into
the socket; pushing the plug in carefully.
•
Use steel protected
cables for pow
er supply, ala
rm-cables and co
mmunication cable
s and connect
them to t
he appropriate connectors.
•
Put the housing
in correct p
osition and se
cure it with the
knurled thu
mbscrews.
•
Connect the power supp
ly to the HYDROCAL 1002-100
3 unit. The display shows the spe
cified
conditions confirming that the HYDROCAL 1002-1003 is
functioning correctly.
•
The measuring cycle
of the HYDROCAL 1002-1003
unit is synchronized on
the hour mark, this
means the first measuring value is available approx. 2, 22 or 42 min. after the hour mark and can
be read on the display.
•
To check the h
eating function, to
uch carefully th
e heat plate
after some
minutes.
Attention, danger of burning!!!
The heating plate should now be warm. Should the resistor heating not function correctly then check
its contacts.
•
After first
start-up, in
all cases d
ate and
time have
to be che
cked on
the HYDROCA
L 1002-1
003
display and eventually have to be adjusted manually in clock settings (chapter 3.7.5.3) or with
HydroSoft (chapter 4.10.7).
Note:
For additional information for mounting and un-mounting, please refer to the document
named: “HC 1002-1003 Special Additional Instructions Mounting & Un-mounting 01-
2010.doc”.

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2.5 Front view of HYDROCAL 1002-1003
On the front side of
the HYDROCAL 1002-1003 unit the following operating elements are available
.
[1] LCD-display
with 240 x 320 pixels
[2]
Screw
mounting
to mount the cover
[3]
Alphanumeric
keyboard
to enter numbers and text
[4] Arrow-buttons
to move in the menus, for data input and contrast set-up from the main display (Up an
Down)
[5]
Enter
button
to confirm and stop functions and data

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2.6 Rear side of HYDROCAL 1002-1003 unit
[1]
Measuring
sensor
with an internal thread of (DIN ISO 228: G1) or as an option (NPT 1½)
[2]
Connection for power supply
88 VAC
min
… 276 VAC
max
Optional: 88 VDC
min
… 390 VDC
max
max. 350 VA, 50/60 Hz
[3]
System
outputs
for digital and
analogue inputs and outputs
Communication output
for communication via
analogue or GSM/GPRS-modem
[4]
Serial
interface
RS232
Connector: 5 pin plug
Pin 1

TxD
Pin 2

CTS
Pin 3

RxD
Pin 4

RTS
Pin 5

GND

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2.7 Connections on the measuring and controller card
2.7.1 HYDROCAL 1002
[1]
Analogue
inputs
Connector:
X1:1

(Analogue input 1 (-))
X1:2

(Analogue input 1 (+))
X1:3

(Analogue input 2 (-))
X1:4

(Analogue input 2 (+))
X1:5

(Analogue input 3 (-))
X1:6

(Analogue input 3 (+))
X1:7

(Analogue input 4 (-))
X1:8

(Analogue input 4 (+))
X1:9

(Analogue input 5 (-))
X1:10

(Analogue input 5 (+))
X1:11

(Analogue input 6 (-))
X1:12

(Analogue input 6 (+))
X1:13

(Analogue input 7 (-))
X1:14

(Analogue input 7 (+))
X1:15

(Analogue input 8 (-))
X1:16

(Analogue input 8 (+))

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[6]
Digital
outputs
[2]
Oil
temperature
sensor
Connector:
X2:1

(Oil temperature sensor (+))
X2:2

(Oil temperature sensor (+))
[3]
Measuring
cell
Connector: Flat plug 20 pin
[4]
Heating
resistors
Connector:
X4:1 to X4:6

Connection of the heating resistors, depending from the supply
voltage:
With 230V

in
series
With 110V

in
series
-
parallel
[5]
Power
supply
Connector:
X5:1

 (L)
X5:2

 (N)
Note: The connection [5] is connected to
a filter module from
where the connection to the
power supply 110VAC/230VAC and
PE is made as follow:
X5:3

(L)
X5:4

(N)
X5:5

(PE)

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Connector:
X6:1

(Relay output 1)
X6:2

(Relay output 1)
X6:3

(Relay output 2)
X6:4

(Relay output 2)
x6:5

(Relay output 3)
X6:6

(Relay output 3)
X6:7

(Relay output 4)
X6:8

(Relay output 4)
X6:9

(Opto coupler output 1 (-))
X6:10

(Opto coupler output 1 (+))
X6:11

(Opto coupler output 2 (-))
X6:12

(Opto coupler output 2 (+))
X6:13

(Opto coupler output 3 (-))
X6:14

(Opto coupler output 3 (+))
X6:15

(Opto coupler output 4 (-))
X6:16

(Opto coupler output 4 (+))
X6:17

(Opto coupler output 5 (-))
X6:18

(Opto coupler output 5 (+))
X6:19

(Opto coupler output 6 (-))
X6:20

(Opto coupler output 6 (+))
X6:21

(Opto coupler output 7 (-))
X6:22

(Opto coupler output 7 (+))
X6:23

(Opto coupler output 8 (-))
X6:24

(Opto coupler output 8 (+))
[7]
Analogue
outputs
Connector:
X7:1

(Analogue output 1 (+))
X7:2

(Analogue output 1 (-))
X7:3

(Analogue output 2 (+))
X7:4

(Analogue output 2 (-))
X7:5

(Analogue output 3 (+))
X7:6

(Analogue output 3 (-))
X7:7

(Analogue output 4 (+))
X7:8

(Analogue output 4 (-))
X7:9

(Interface RS 485 (-))
X7:10

(Interface RS 485 (+))
X7:11

(Analogue Modem (a))
X7:

(Analogue Modem (b))

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[8]
Connector
ST
301:
Interface
RS232
X8:1

(RS232 (free))
X8:2

(RS232 (free))
X8:3

(RS232 (TxD))
X8:4

(RS232 (CTS))
X8:5

(RS232 (RxD))
X8:6

(RS232 (RTS))
X8:7

(RS232 (free))
X8:8

(RS232 (free))
X8:9

(RS232 (GND))
X8:10

(RS232 (free))
[9]
GSM/GPRS-
module
/
GSM
antenna
Connector Mini-BNC
X9:1

(GSM/GPRS-modul
e
/
GSN
antenna)
X9:2

(GSM/GPRS-modul
e
/
GSN
antenna)
X9:3

(GSM/GPRS-modul
e
/
GSN
antenna)
X9:4

(GSM/GPRS-modul
e
/
GSN
antenna)
X9:5

(GSM/GPRS-modul
e
/
GSN
antenna)
X9:6

(GSM/GPRS-modul
e
/
GSN
antenna)
X9:7

(GSM/GPRS-modul
e
/
GSN
antenna)
X9:8

(GSM/GPRS-modul
e
/
GSN
antenna)