Manual Calisto 2 1a5w1a

position (OFF).

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

Caution Two persons are recommended for installing the Calisto/ Calisto 2. There are two possible types of installation: factory installation and field installation. A factory installation is when a Calisto/Calisto 2 is installed on a new transformer directly by the transformer manufacturer. A field installation is when a Calisto/Calisto 2 is installed on an existing transformer in the field. The steps for installing a Calisto/Calisto 2 are: • Selecting the transformer valves (Section 2.2) • Securing the monitor on transformer or suitable structure (Section 2.3) • Wiring the electrical connections (Section 2.4) • Connecting the oil lines (Section 2.5) page 11

The following tools are required for a standard installation: • Tube cutter (for rigid oil lines) • 5/8" and 11/16" open-end wrenches (or an adjustable wrench) • Wire stripper • Small flathead screwdriver • Large flathead screwdriver

2.2. Selecting the Transformer Valves Calisto/Calisto 2 requires two oil valves from the transformer. For a factory installation, most transformer manufacturers will install two ½ in. (1.3 cm) oil valves directly on the main tank close to the location where the monitor will be installed. Both of these valves will generally be accessible from the ground level. For a field installation, it is recommended to use the top fill valve as the SUPPLY valve, and the bottom drain valve as the RETURN valve. This can only be done if the top fill valve is below the top oil level. The alternative is to draw oil from the bottom drain valve and return it through the top fill valve, but this may not be ideal as an excessive amount of sludge may be found at the bottom of the transformer. Consider the following guidelines when selecting the appropriate SUPPLY and RETURN valves: • To ensure representative sampling of the transformer oil, the distance between the SUPPLY and RETURN valves should be a minimum of 1 m (3 ft). • The SUPPLY and RETURN valves must not be close to a transformer oil circulating pump. • The SUPPLY valve should be at least 0.45 m (18 in.) from the bottom of the main tank. • The valves should have a minimum diameter of ½" NPT. Female, ball or gate type valves are recommended. • The oil return line must not exceed 11 m (35 ft) in length. • The oil supply line must be longer than 1 m (3 ft) in length, to limit mechanical stress.

page 12

2.3. Securing the Monitor NOTICE Calisto/Calisto 2 is designed to be installed vertically. It MUST NOT BE MOUNTED IN ANY OTHER ORIENTATION. The Calisto/Calisto 2 must be solidly secured to a suitable . Typically, Unistrut® brackets are used to make a base for mounting the Calisto/Calisto 2. The mounting structure can be designed to clamp onto the transformer tank, the main control cabinet, or on a post installed in the ground or on a concrete base. For factory installations, the monitor will usually be installed on Unistrut® brackets that are welded to the main transformer tank. It will usually be mounted at eye level, near the SUPPLY and RETURN valves. For field installations, it is recommended to mount the monitor on a post bolted to the concrete base of the transformer. The Morgan Schaffer Calisto Mounting Stand is available as an optional accessory. Refer to the Calisto Mounting Stand Installation Manual when mounting a Calisto/Calisto 2 on the stand. The Calisto/Calisto 2 mounting-hole locations are shown in Figure 5. The diameter of the mounting holes is 9.5 mm (3/8 in.). The depth of the monitor is 309 mm (12.2 in.).

Figure 5: Mounting diagram

page 13

Consider the following guidelines when securing the monitor: • Secure the monitor approximately 1.2 m (4 ft) above ground level for easy access to the oil inlet and outlet shut-off valves of the monitor. • A minimum of 60 cm (24 in.) is required for air circulation under the monitor. • It is recommended to install the monitor such that the display is at eye level. • The monitor should be located near the SUPPLY and RETURN valves selected following the guidelines listed in Section 2.2. Keep in mind that the monitor must be within 11 m (35 ft) from the RETURN valve, and at least 1 m (3 ft) away from the SUPPLY valve. • The location of the mounting structure should be chosen to protect the monitor from extreme vibrations. Four shock mounts are provided with each monitor and should be used to give the monitor additional protection against vibration (see Figure 6).

Figure 6: Installation of shock mounts

page 14

2.4. Wiring the Electrical Connections Warning Electrical shock hazard. Only persons with electrical safety training and certification should undertake the electrical installation of the monitor, or open the enclosure after the equipment has been installed. Power and communication connections to a Calisto/Calisto 2 are made using the mains connection and communication interface boards. The sections that follow explain how to connect the safety ground, mains power, alarm relays, analog signals, and communication cables to a Calisto/Calisto 2. The alarm relay assignments, analog signals and communication connections are configured using Calisto Manager. Refer to the Calisto Manager Guide for instructions. Figure 7 shows the components of the mains connection and communication interface board for a Calisto (C76)/Calisto 2 (C85).

Figure 7: Calisto (C76)/Calisto 2 (C85) - Interface board components 1. Mains power connectors

7. Local USB type B port

2. Thermal cut-off fuse connectors

8. 4-20 mA analog output terminals

3. Over current fuse

9. 4-20 mA anaput terminals

4. Programmable relay terminals

10. RS-232 communication port

5. Programmable relays with activity LEDs


6. Ethernet communication port

12. Ethernet shield earth jumper

page 15

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

Figure 8: Calisto (C76A)/Calisto 2 (C85A) - Interface board components 1. Mains power connectors

7. Ethernet communication ports (x2)

2. Over current fuse

8. 4-20 mA analog output terminals

3. Thermal cut-off fuse connectors

9. 4-20 mA anaput terminals

4. Programmable relay terminals


5. Programmable relays with activity LEDs

11. RS-485 communication port 12. Local USB type B port

6. Ethernet shield earth jumper

Calisto/Calisto 2 features a 4-hub detachable electrical entry plate. All entry holes are 22 mm (7/8 in.) in diameter and can accept most ½ in. entry hub fittings. Four waterproof rubber plugs are provided with the monitor to cover unused holes. Consider the following guidelines when wiring signal and communication cables: • It is recommended to select shielded cables designed for outdoor use. • Avoid loops and minimize the length of the cables from the hub to the communication interface board of the monitor. • Protect all wires and connectors against mechanical stress. • Proper connectors and fittings must be used to prevent water ingress to the monitor.

page 16

2.4.1. Connecting the Earth Ground Warning Install the protective earth conductor to the protective conductor terminal (ground) before making any other connections. When uninstalling the unit, remove all other connections before removing the protective earth connection. Protective earth connection is essential to guarantee client safety. It is the client’s responsibility to ensure the integrity of the ground cable and client-side ground connection. The location of the protective conductor terminal (ground) is shown in Figure 9. To connect the earth ground, secure the protective earth conductor to the green screw on the right side of the protective conductor terminal (ground) by following the safety requirements in the international standard IEC 61010. An additional protective earth ground connection may be made to the chassis using the hole provided on the right side of the bottom mounting flange of the monitor (see Figure 9).

Figure 9: Earth ground connections 1. Protective conductor terminal (ground) 2. Additional earth ground connection hole

page 17

2.4.2. Connecting the Mains Power The Calisto (C76)/Calisto 2 (C85) monitor accepts any supply voltage from 100 to 240 VAC with frequencies in the range of 50 to 60 Hz. Mains power connections are made to connector 1 (neutral) and connector 2 (line) (see Figure 10).

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

The Calisto (C76A)/Calisto 2 (C85A) monitor accepts any supply voltage from 100 to 240 VAC with frequencies in the range of 50 to 60 Hz, and from 100-220 VDC. Mains power connections are made to connector 1 (neutral or -) and connector 2 (line or +) (see Figure 11).

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

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

Rating

Nominal value/range

Connection range:

2.08 – 3.31 mm2 solid

Connection range (UL/CSA):

14 – 12 AWG

Wire strip length:

9 mm (~3/8 in.)

Wire insulation ratings:

300V, 90ºC (194ºF) or better

Flammability:

VW-1 or better

Screw type:

M2.5

The mains power connection may be made using either solid or stranded conductors. To help with the connection, it is recommended to install ferrules at the ends of stranded conductors. Make sure to select ferrules of the correct size for the type of conductor used. page 18

To connect the mains power, completely loosen each screw terminal, insert the conductor to the bottom of the terminal slot, and then tighten the screw while holding the conductor to the bottom of the slot. Failure to hold the conductor to the bottom of the slot as the screw is tightened may lead to an unsound connection. The nominal power of Calisto/Calisto 2 is 320 W. The mains supply switch of the monitor may be used to turn the monitor ON (<|>) or OFF ( ). The monitor should be wired to draw power from a dedicated circuit breaker with suitable current and voltage ratings.

2.4.3. Connecting the Alarm Relays Warning Electrical shock hazard. Alarm relays may be connected to hazardous live voltage even if the mains power is OFF or disconnected. Calisto/Calisto 2 features five programmable dry- output relays which can be connected in a normally open (NO) or normally closed (NC) configuration (see Figure 12).

Figure 12: Alarm relays and connections Note: Calisto (C76A)/Calisto 2 (C85A) model shown. For Calisto (C76)/Calisto 2 (C85), connector 16 is a SHIELD.

page 19

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

Connector No. Marking

Connection Type

1

RLY1_NC

Relay 1 normally closed (NC)

2

RLY1_COM

Relay 1 common

3

RLY1_NO

Relay 1 normally open (NO)

4

RLY2_NC


5

RLY2_COM

Relay 2 common

6

RLY2_NO


7

RLY3_NC


8

RLY3_COM

Relay 3 common

9

RLY3_NO


10

RLY4_NC


11

RLY4_COM

Relay 4 common

12

RLY4_NO


13

RLY5_NC


14

RLY5_COM

Relay 5 common

15

RLY5_NO


16

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

Shield to earth ground Unused

17

SHIELD

Shield to earth ground

18

SHIELD


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

Rating

Nominal value/range

Connection range:

0.33 – 2.08 mm2 stranded


22 – 14 AWG stranded

Wire strip length:

9 mm (~3/8 in.)


300V, 90ºC (194ºF) or better

Flammability:

VW-1 or better

Screw type:

M2.5

Terminals marked "RLYx_COM" are all commons and can be looped together into one single common if all signals route to the same location. Terminals marked "SHIELD" can be used to terminate an alarm cable shield to the earth ground. If gauge 14 conductors are used, it may be necessary to use 2 entry hubs for the relay wires, or to modify the entry plate to accept a larger diameter hub and conduit.

page 20

To connect the relay connections, completely loosen each screw terminal, insert the conductor to the bottom of the terminal slot, and tighten the screw while holding the conductor to the bottom of the slot. Recommended use of the alarm relays:

AC Connections

DC Connections

5V/400VAC

5V/300VDC

Rated resistive load:

16A/250VAC

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

Min. switching current:

5mA

5mA

Coil- dielectric strength:

5000VAC

5000VAC

Min./Max. switching voltage:

2.4.4. Connecting the Analog Outputs Calisto/Calisto 2 features up to three analog outputs (see Figure 13). The 4-20 mA analog outputs for dissolved hydrogen (H2) and moisture (H2O) are used for Calisto (C76 and C76A) monitors. Calisto 2 (C85 and C85A) additionally uses the 4-20 mA analog output dedicated to carbon monoxide (CO).

Figure 13: Analog output connector

Pin No.

Output

Description

1

SHLD


2

SHLD


3

N/A

4

Moisture (H2O)

5

Moisture (H2O)

Negative (-)

6

Hydrogen (H2)

Positive (+)

7

Hydrogen (H2)

Negative (-)

Unused Positive (+)

8

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

9

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

page 21

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

Rating

Nominal value/range

Connection range:

0.33 – 1.31 mm2 solid/stranded


22 – 16 AWG

Wire strip length:

6.5 mm (~1/4 in.)


150V (300V is preferred to preserve 1500V functional I/O isolation) 90ºC (194ºF) or better

Flammability:

VW-1 or better

Screw type:

M2.0

It is recommended to remove the connector to simplify wiring the connections, and to screw the connector back in place after the connections are made. The maximum length of the wires depends on the resistance of the client load and the acceptable noise level. The load resistance must be in the range of 0-500 Ohms, including resistance of the wires.

2.4.5. Connecting the Anaput Calisto/Calisto 2 features one 4-20 mA anaput that can be used to provide a reading of the transformer oil temperature to the monitor (see Figure 14). The 4-20 mA anaput supply voltage is +24 VDC.

Figure 14: 4-20 mA anaput connector

Pin No.

Marking

1

SHLD

2

page 22

Description Shield to earth ground Unused

3

-

4-20 mA negative (-)

4

+

4-20 mA positive (+)

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

Rating

Nominal value/range

Connection range:



22 – 16 AWG

Wire strip length:

6.5 mm (~1/4 in.)



Flammability:

VW-1 or better

Screw type:

M2.0

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

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

Figure 15: RS-485 connection

Pin No.

Marking

1

SHLD

2

Description Shield to earth ground Unused

3

COMM

Common signal ground

4

A

Line A

5

B

Line B

page 23

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

Rating

Nominal value/range

Connection range:



22 – 16 AWG

Wire strip length:

6.5 mm (~1/4 in.)



Flammability:

VW-1 or better

Screw type:

M2.0

The range for RS-485 communication can span up to 4000 ft (1200 m). It is highly recommended to select an industrial grade shielded twisted pair cable of minimum 0.33 mm2 (22 AWG) for RS-485 connections. It is recommended to remove the connector to simplify wiring the connections, and to screw the connector in place after the connections are made. For reliable RS-485 communication, the RS-485 common signal ground must be connected on both the Calisto/Calisto 2 monitor (pin 3, marked "COMM") and on the client RS-485 device. Note that the common signal ground is not a shielding ground. The RS-485 common signal ground should not be connected to the chassis ground or "SHLD" on the monitor, nor on the client RS-485 device. Since Calisto/ Calisto 2 provides 1500 V isolation, it is recommended to use an RS-485 device that also offers good isolation.

CAUTIOn Morgan Schaffer cannot be held responsible for a monitor communication malfunction if the RS-485 cable shield is not properly connected to pin 1 (SHLD). The communication interface board provides a 120 Ohm terminating resistor which may be used to terminate the RS-485 link. To connect the terminating resistor, install the provided jumper across J6, which is found beneath the RS-485 connector. Calisto/Calisto 2 s several protocols over RS-485: • MSSP (Morgan Schaffer Systems Protocol) • DNP3 • Modbus page 24

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

Figure 16: RS-232 connection

Pin No.

Marking

1

SHLD

Description Shield to earth ground

2

Unused

3

GND

Signal ground

4

RX

Received data

5

TX

Transmitted data

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

Rating

Nominal value/range

Connection range:



22 – 16 AWG

Wire strip length:

6.5 mm (~1/4 in.)



Flammability:

VW-1 or better

Screw type:

M2.0

The maximum recommended range for RS-232 communication is 15 m (50 feet). It is highly recommended to select an industrial grade shielded twisted pair cable of minimum 0.33 mm2 (22 AWG) for RS-232 connections. The RS-232 signal ground (pin 3, marked “GND”) should always be wired properly to ensure a reliable connection. Calisto/Calisto 2 RS-232 communication only s Morgan Schaffer Systems Protocol (MSSP).

page 25

2.4.8. Connecting the Ethernet Communication Calisto (C76)/Calisto 2 (C85) features one RJ45 Ethernet port which allows the monitor to be connected to a computer or a corporate LAN or WAN (see Figure 17). Calisto (C76A)/Calisto 2 (C85A) features two RJ45 Ethernet ports (see Figure 18). With two Ethernet ports, all the protocols ed by Calisto/Calisto 2 over Ethernet may run simultaneously. The J9 Ethernet port is dedicated to the MSSP, DNP3 and Modbus protocols, while the J4 Ethernet port is for the IEC 61850 protocol.

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

Ethernet port

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

Rating

Nominal value/range

Connection range:



22 – 16 AWG

Wire strip length:

6.5 mm (~1/4 in.)

Screw type:

M2.0

The maximum recommended range for an Ethernet connection is 30 m (100 feet). It is recommended to use an industrial FTP or ScTP cable suitable for outdoor use (oil and sun resistant), even if a protective conduit is used. The RJ45 Ethernet ports can be shielded using jumper J7 (Ethernet shield to earth ground). An FTP or ScTP shield must be connected to earth ground at only one end. Jumper J7 should only be connected if the cable shield remains disconnected on the client’s side. Grounding at both ends may lead to poor communication and/or damage to the monitor. Morgan Schaffer cannot guarantee protection from an external surge (such as lightning page 26

or electrical arc) over 1500 V that could infiltrate the Ethernet line. It is the client’s responsibility to isolate the Ethernet line on the client side. Calisto/Calisto 2 s several protocols over Ethernet: • MSSP (Morgan Schaffer Systems Protocol) • DNP3/T • Modbus IEC 61850 protocol (optional) With the optional IEC 61850 Communication kit, Calisto/Calisto 2 s the IEC 61850 substation protocol. Refer to the IEC 61850 Communication Kit Installation and Configuration Manual for more information. Ethernet Outdoor Connectivity Kit (optional) The optional Ethernet Outdoor Connectivity Kit allows for an easy and reliable connection from the monitor to a control . It includes an outdoor rated Ethernet cable with screw-in plugs, as well as all the hardware required to connect the external cable to the monitor’s communication interface board. Consider the following guidelines when installing the Ethernet Outdoor connectivity kit: • The RJ45 -through bulkhead provided requires a 1-inch hole and must be installed on a control cabinet. • The patch cord shield must be connected to the ground for interference immunity. A Calisto/Calisto 2 monitor ordered with this option will have jumper J7 linking the RJ45 Ethernet port shield to the earth ground. Thus, there is no need to connect the shield on the client side.

page 27

2.4.9. Connecting the USB Communication Caution The USB port does not provide high voltage isolation. It should only be used for local connection using portable computers. The Calisto/Calisto 2 communication interface board includes a type B USB port (see Figure 19). It is convenient to use the USB port for the configuration, setup and maintenance of the monitor. A local connection through the USB port is possible with the 1.8 m (6 ft) A/B type USB cable supplied with the monitor.

Figure 19: USB port

Driver installation is required in order to communicate over USB. Refer to the Calisto Manager Guide for instructions on how to install Calisto Manager and the required USB drivers on a PC.

2.5. Connecting the Oil Lines Two 25-foot long (7.6 m) copper tubing oil lines (3/8" OD) are included with each standard Calisto/Calisto 2 monitor. Stainless steel braided flexible hoses with 3/8" connectors are available to order separately for Calisto/Calisto 2 monitors for stainless steel oil lines. Consider the following guidelines before connecting the oil lines: • It is recommended to install optional shutoff valves (preferably ball valves) underneath the monitor on the oil supply and return lines. Should it become necessary, these valves will simplify the removal of the monitor. • Do not make straight lines between the transformer tank and the monitor. Include one loop or bend in the oil line. • In very cold environments, it is recommended to permanently insulate the oil lines. • In very hot environments, it is recommended not to insulate the oil lines.

page 28

2.5.1. Preparing the Transformer Valves Before installing the oil lines, the transformer valves selected to circulate oil to and from the monitor must be prepared to accept the elbow tube fittings included in the standard package contents. Install the two supplied 3/8" tube to ½" NPT male elbow fittings to the SUPPLY and RETURN valves of the transformer. If necessary, use a pipe adapter to fit the ½" NPT male end to the transformer valves (see Figure 20).

Figure 20: Installation of the elbow fittings 1. Transformer valve 2. Adapter (if necessary) 3. 3/8" tube to ½" NPT male elbow fitting

NOTICe If a Precision Oil Temperature Probe is to be installed with the monitor, the tee fitting provided with the temperature probe must be installed on the oil SUPPLY valve instead of an elbow. Refer to the Precision Oil Temperature Probe Installation Manual.

page 29

2.5.2. Connecting the Oil Lines Consider the following guidelines when connecting the oil lines: • Use a counter-torque wrench to avoid damaging the INLET and OUTLET ports on the monitor. The torque and counter-torque wrenches must be aligned one over the other as much as possible to cancel induced forces. • If using rigid tubing, a tube cutter must be used to cut oil lines. Other tools must be avoided as they can leave burrs, debris and scratches on the surface to be swaged. • If using rigid tubing, make sure the tubing is straight for several inches where it enters the fitting. • Incorporate at least one shallow bend in the tubing to help with the installation. STEP 1:

Connect the oil supply line. a. Insert one end of the oil supply line firmly into the monitor INLET port (see Figure 21).

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

b. Using an 11/16" wrench and a 5/8" counter-torque wrench, tighten the compression nut of the INLET port 1¼ turns from finger tight for proper sealing. c. Route the oil supply line to the transformer SUPPLY valve. d. If using rigid tubing, cut off the excess length using a tube cutter and debur the inside of the tube. page 30

e. Insert the free end of the oil supply line into the elbow fitting installed at the transformer SUPPLY valve (or the tee fitting assembly when installing a Precision Oil Temperature Probe). Tighten the compression nut 1¼ turns from finger tight to complete the oil supply line installation. STEP 2:

Connect the oil return line. a. Insert one end of the oil return line firmly into the monitor OUTLET port (see Figure 22).

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

b. Using an 11/16" wrench and a 5/8" counter-torque wrench, tighten the compression nut of the outlet port 1¼ turns from finger tight for proper sealing. c. Route the oil return line to the transformer RETURN valve. d. If using rigid tubing, cut off the excess length using a tube cutter and debur the inside of the tube. e. Insert the free end of the oil return line into the elbow fitting installed at the transformer RETURN valve. Tighten the compression nut 1¼ turns from finger tight to complete the oil return line installation. STEP 3:

Secure all oil lines against excessive vibration.

page 31

2.5.3. Purging the Oil Lines Once all connections are made, the lines and the monitor must be flushed with oil to remove any air present in the system and to replace the shipping oil inside the monitor with oil from the transformer. The Calisto/Calisto 2 monitor is equipped with a proprietary gas accumulator which will vent any air bubbles present in the incoming oil once the monitor is in operation.

NOtice If a Precision Oil Temperature Probe option is to be installed with the monitor, the Installation section of the Precision Oil Temperature Probe Installation Manual must now be followed before proceeding to purge the oil lines. STEP 1:

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

Figure 23: Monitor with both valves closed

page 32

STEP 2:

Firmly push the supplied Quick Connect Oil Sampling Tube (see Figure 24) into the monitor’s oil sampling port located next to the oil INLET port (see Figure 25).

Figure 24: Quick Connect Oil Sampling Tube

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

page 33

STEP 3:

Using a container to collect flushed oil, slowly turn the OUTLET valve counter clockwise ¼ turn (the handle will then be pointing down) to flush the return line with oil (see Figure 26). To avoid injecting trapped air in the transformer, flush a minimum of 500 cc of oil.

Figure 26: Flushing the oil return line

STEP 4:

Once a minimum of 500 cc of oil has been flushed, close the OUTLET valve by turning it clockwise to the horizontal position (see Figure 27).

Figure 27: Closing the monitor OUTLET valve

page 34

Notice Before proceeding with Step 5, the following checks should be made: • The earth ground is properly connected. • The mains power is protected by a circuit breaker. • The mains supply switch is in the position (OFF). • Both transformer oil SUPPLY and oil RETURN valves are open. • Both monitor oil INLET and oil OUTLET valves are closed. STEP 5: a. Slowly turn the INLET valve counter clockwise ¼ turn to the vertical position (the handle will then be pointing upwards) (see Figure 28). b. Using a container to collect flushed oil, turn the mains supply switch to the <|> (ON) position for the internal oil circulation pump to start flushing the oil in the supply line. To avoid injecting trapped air in the transformer, flush a minimum of 500 cc of oil. c. After 500 cc of oil has been flushed, turn the mains supply switch to the position (OFF).

Figure 28: Flushing the oil supply line

page 35

STEP 6:

While the INLET valve is open, remove the Quick Connect Oil Sampling Tube from the oil sampling port by pushing the locking ring down and pulling the Quick Connect Oil Sampling Tube out (see Figure 29).

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

STEP 7:

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

Figure 30: Monitor with both valves open

page 36

3.0 START UP 3.1. Important Checks before Power Up The following checks should be made before providing power to the monitor: • that no tools or other equipment have been left inside the monitor. • The earth ground is properly connected. • The mains power is properly connected. • The monitor is protected by an appropriate circuit breaker. • All signal, relay and communication wirings are installed. • Both transformer oil SUPPLY and RETURN valves are open. • Both monitor oil INLET and OUTLET valves are open. • All conduit fittings are fully tightened and rubber plugs are installed on unused entry holes. • that there are no excessive vibrations on the complete system. • that the oil line connections have no leaks.

3.2. Monitor Power Up Once the monitor has been properly installed and the checks in Section 3.1 have been made, the monitor can be powered up by turning the mains supply switch to the <|> position (ON). A reading will only be displayed on the door display after approximately five seconds, which is the time delay required for firmware initialization.

Notice If the monitor temperature is below -35°C (-31°F) at powerup, the monitor will enter a pre-heating mode where only the enclosure heaters will be activated. The monitor on-board computer will start once the enclosure temperature has reached -5°C (23°F). This could take several minutes or even hours in extremely cold environments.

page 37

When the Calisto/Calisto 2 is powered on or reset, the monitor first enters an initialization and power-on self-test sequence. The purpose of this mode is to allow the on-board computer to evaluate temperature conditions and to allow the internal measurement systems to reach equilibrium. The duration of the initialization is three hours, or one complete measuring cycle. During the initialization time, the display will indicate

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