Hydrocal 1002-1003 Operation Manual English 01.2010

HYDROCAL 1002-1003
Gas-in-Oil Analysis System with

Transformer Monitoring Functions
Manual for installation and operation
HYDROCAL 1002-1003: Manual for Installation and Operation
Edition 01.2010
Copyright MTE Meter Test Equipment AG

All rights reserved.
The contents of this manual are
subject to change without notice.
All efforts have been made to ensure
the accuracy of this publication but
MTE Meter Test Equipment AG can
assume no responsibility for any errors
or their consequences
Customs tariff number:

9027.1010
HYDROCAL 1002-1003: Manual for installation and operation
Page 1 of 97
Summary
1. General ........................................................................................................................................... 4
2. Mounting of HYDROCAL 1002-1003 unit ........................................................................................ 5
2.1 Locations for installation of HYDROCAL 1002-1003 .................................................................. 5
2.2 Security precautions for installation ........................................................................................... 6
2.3 Preparation for installation ......................................................................................................... 8
2.3.1 Power supply for the unit ..................................................................................................... 8
2.3.2 Requested tools:.................................................................................................................. 8
2.4 Installation of the HYDROCAL 1002-1003 unit .......................................................................... 9
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. .. 11
2.5 Front view of HYDROCAL 1002-1003...................................................................................... 12
2.6 Rear side of HYDROCAL 1002-1003 unit ................................................................................ 13
2.7 Connections on the measuring and controller card .................................................................. 14
2.7.1 HYDROCAL 1002.............................................................................................................. 14
3. Software on Hydrocal unit ............................................................................................................. 18
3.1. General information ................................................................................................................ 18
3.2. Operation of HYDROCAL 1002-1003 by its keyboard ............................................................. 19
3.2.1. Contrast Set-up ................................................................................................................ 19
3.3. Main menu .............................................................................................................................. 20
3.4.
3.5.
3.5.1
3.5.2.
Configuration of user settings ...................................................................................... 21

Display of stored Gas-in-oil measuring values........................................................... 22
Graphic display ...................................................................................................... 22
Table presentation................................................................................................. 23
History of alarms ......................................................................................................... 24

3.6.
3.6.1. Acknowledgment of alarms ............................................................................................... 24
3.7.
3.7.1.
Device set up ............................................................................................................ 25

Menu Transformer data setup ............................................................................... 26
3.7.1.2.
Hot Spot calculation ............................................................................................... 27
3.7.1.3.
Ageing Rate / Loss of Life ...................................................................................... 29
3.7.2.
Configuration of analogue outputs ......................................................................... 29
3.7.3.
Configuration of analogue inputs (external sensors) ............................................. 30
3.7.4.
3.7.5.
Configuration of alarms and digital outputs ............................................................ 33

Unit Setup ............................................................................................................. 36
3.7.5.1.
Flange Heating Base Temperature .................................................................. 37
3.7.5.2.
Flange Heating Base Temperature ..................................................................... 37
3.7.5.3.
Device options .................................................................................................... 37
3.7.5.4.
Clock settings ..................................................................................................... 39

Page 1 of 97
3.7.5.5.
3.7.5.5.1.
Configuration of the communication ................................................................... 40
Alert SMS setup ........................................................................................... 41
Internal modem setup ................................................................................... 41

3.7.5.5.2.
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. Point to Point ............................................................................................................................. 44
I.
RS232 ................................................................................................................................ 44
II. RS485 ................................................................................................................................ 45
III. Modem ............................................................................................................................... 46
B. RS485-Bus ................................................................................................................................ 47
C. Bridge ....................................................................................................................................... 48
I
Bridge Setup....................................................................................................................... 49
II
RS485-Bus Setup ............................................................................................................... 50
D. MODBUS .................................................................................................................................. 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. Installation .............................................................................................................................. 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
Page 2 of 97
4.10.7. Device Setup (Clock settings) ......................................................................................... 78

4.11. Data transmission from / to the HYDROCAL 1002-1003 unit ................................................ 79
4.12. View of results ...................................................................................................................... 81
4.12.1. Sensor selection ............................................................................................................. 81
4.12.2. Time range selection ...................................................................................................... 81
4.12.3. Result window ................................................................................................................ 82
4.12.4. Print and export of results ............................................................................................... 82
4.13. View of alarm status ............................................................................................................. 83
4.13.1. Alarm selection ............................................................................................................... 83
4.13.2. Time range selection ...................................................................................................... 83
4.13.3. Alarm window ................................................................................................................. 84
4.13.4. Status of alarms.............................................................................................................. 84
4.13.5. Print and export of results ............................................................................................... 84
4.14. Online Sensors ..................................................................................................................... 85
5. RS232 / RS 485 Wiring ................................................................................................................. 86
6. Vaisala sensors connection on HYDROCAL 1002 ........................................................................ 87
6.1 MMT318 ................................................................................................................................. 87
6.2 MMT338 .................................................................................................................................. 88
7. HYDROSOFT Scheduler .............................................................................................................. 89
7.1 General ....................................................................................................................................... 89
7.2 Scheduler ................................................................................................................................... 89
7.2.1 Configuring a Transformer for automatic History Data Update .............................................. 89
7.2.1.1 Connection Scheduler Dialog ......................................................................................... 89
7.2.2 Scheduler Status Visualization.............................................................................................. 90
7.2.2.1 Status Icons .................................................................................................................... 90
7.2.2.2 Example ......................................................................................................................... 91
7.2.3 Hydrosoft and the Windows Task Scheduler......................................................................... 92
7.2.3.1 Command Line Options for Windows Task Scheduler .................................................... 93
7.2.4 Internal Operation ................................................................................................................. 93
7.2.5. Data Directory Lock ............................................................................................................. 94
8. Technical data HYDROCAL 1002-1003 ........................................................................................ 95
9. Dimensional Drawings HYDROCAL 1002-1003 ............................................................................ 97
Page 3 of 97
1. General
HYDROCAL 1002-1003 is an on-line Gas-in-Oil Monitoring System for continuous analysis of the
dissolved gases hydrogen (H2) and carbon monoxide (CO) of power transformers. HYDROCAL 1003
allows also in addition Analysis of moisture (H2O) dissolved in transformer oil (absolute humidity in
ppm). The possibility to connect additional sensors with an analogue output signal (0..10V or (04..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 diagnosis of incipient faults in power transformers.
The present operating instructions are divided in the following sections:
Instructions for mounting the HYDROCAL 1002-1003 unit (chapter 2)
Description of software of the HYDROCAL 1002-1003 unit (chapter 3)
Description of Windows software HydroSoft (chapter 4)
RS 232 / RS 485 Wiring (chapter 5)
VAISALA sensors connection on HYDROCAL 1002 (chapter 6)
HYDROSOFT Scheduler (Chapter 7)
Technical data of HYDROCAL 1002-1003 system (chapter 8)
HYDROCAL 1002-1003 dimensional drawings (chapter 9)
Page 4 of 97
2. Mounting of HYDROCAL 1002-1003 unit

2.1 Locations for installation of HYDROCAL 1002-1003
To ensure the correct function of the HYDROCAL 1002-1003 the location of mounting is very important. For a typical transformer, three places are possible:
Pos. 1
On return side of cooling circuit:

Please install the unit on a straight piece of tube on the cooler output between the cooler
and the main oil tank. In order to avoid negative pressure, the unit must absolutely be
mounted on the downstream side (after the bend) of the oil circulation pump.
Remark: Choose this place only in case of continuous oil flux through the cooler.
Pos. 2
Flange below on the transformer tank:

The flange must be at minimum height of 30 cm in order to allow installation and mounting
of HYDROCAL 1002-1003 unit.
Pos. 3
Upper filling valve:

It is possible to mount the HYDROCAL 1002-1003 unit in this position, however it may be
difficult to operate and read the data of the unit.
Remark: Should the unit be mounted on the wall of the cooler, then make sure that
the unit is mounted below the oil level.
Pos. 4
Never install the HYDROCAL 1002-1003 unit on top of the cooler or on the suction
face of the pump.
Page 5 of 97
2.2 Security precautions for installation

The following security precautions must be strictly observed during the installation. Otherwise no warranty claims will be accepted.
Never connect the sensor head to another HYDROCAL 1002-1003 electronic unit other than the delivered one.
The components are delivered as a matched pair and have been calibrated
together in our works. You will find 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 future 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 for oxygenation.
Never use or stock chemicals with hydrocarbon contents near the measuring sensor.
Never clean the measuring head with solvents, because its gases will strongly
impair the measuring accuracy and the sensivity of the sensors.
Page 6 of 97
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 period of time. Remove the unit if 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 10021003 unit.
Galvanized fittings or valves can react with oil, this will produce incorect measuring 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.
Page 7 of 97
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 .
Attention!!!
Faulty or inappropriate handling of the sensor head like perforation of the
membrane, scratches on the membrane or damages by negative pressure, 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 protection 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 loose the measuring head from the unit (6 x screws).
Bucket, oil absorber, cleaning rag
Teflon-band
Drill / screw driver
Digital multimeter
Tin spanner or adjustable tin spanner of 1 for valve and fittings
To seal the thread of the measuring head, only Teflon band must by used. Minimum 4 to 5 layers
must be applied.
Page 8 of 97
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 1 (DIN ISO 228: G 1). The HYDROCAL unit has a 1 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 strong vibrations on the mounting valve, the valve should be relieved by a support.
Then mount the unit according to the following steps:
Loose the knurled thumbscrews and remove the housing of the HYDROCAL 1002-1003 unit.
Disconnect the connection cable of the measuring head from the printed 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!
Page 9 of 97
Clean the internal side of the installation valve.

Wind 4 to 5 layers of Teflon band on the thread of the adapter and mount it on the valve. Make
sure that it is fixed mechanically.
Mount the measuring head on the adapter 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 valve. Make sure that it remains fixed mechanically, but do not use too much force.
Turn the aeration screw to the 12 o clock position.
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 aeration screw 3 4 turns with Allen key No. 4. (Aeration is active).
Open the valve slowly until oil comes out on the proving hole.
As soon as no air bubbles sort on the proving hole, close the aeration screw. Then fully open the
valve. Remove the oil from the measuring head external.
Do not use any solvents for cleaning!

Make sure that no untaught places exist.
Mount the unit on the measuring head, use the 6 pieces of plain washers, lock washers and nuts.
Page 10 of 97
Connect the connection cable to the printed circuit. Check that all pins of the plug go straight into
the socket; pushing the plug in carefully.
Use steel protected cables for power supply, alarm-cables and communication cables and connect
them to the appropriate connectors.
Put the housing in correct position and secure it with the knurled thumbscrews.
Connect the power supply to the HYDROCAL 1002-1003 unit. The display shows the specified
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 heating function, touch carefully the 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 date and time have to be checked on the HYDROCAL 1002-1003
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 012010.doc.
Page 11 of 97
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
Page 12 of 97
2.6 Rear side of HYDROCAL 1002-1003 unit
[1]
[2]
Measuring sensor
with an internal thread of (DIN ISO 228: G1) or as an option (NPT 1)
Connection for power supply
88 VACmin 276 VACmax
Optional: 88 VDCmin 390 VDCmax
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
Pin 2
Pin 3
Pin 4
Pin 5

TxD
CTS
RxD
RTS
GND
Page 13 of 97
2.7 Connections on the measuring and controller card

2.7.1 HYDROCAL 1002
[1]
Analogue inputs
Connector:
X1:1
X1:2
X1:3
X1:4
X1:5
X1:6
X1:7
X1:8
X1:9
X1:10
X1:11
X1:12
X1:13
X1:14
X1:15
X1:16

(Analogue input 1 (-))

(Analogue input 1 (+))
Page 14 of 97
[2]
Oil temperature sensor

Connector:
X2:1
X2:2
[3]
Measuring cell
Connector: Flat plug 20 pin
[4]
Heating resistors
Connector:
(Oil temperature sensor (+))

(Oil temperature sensor (+))
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
X5:4
X5:5
[6]
(L)
(N)
(PE)
Digital outputs
Page 15 of 97
Connector:
[7]
X6:1
X6:2
X6:3
X6:4
x6:5
X6:6
X6:7
X6:8
X6:9
X6:10
X6:11
X6:12
X6:13
X6:14
X6:15
X6:16
X6:17
X6:18
X6:19
X6:20
X6:21
X6:22
X6:23
X6:24

(Relay output 1)
(Relay output 1)
(Relay output 2)
(Relay output 2)
(Relay output 3)
(Relay output 3)
(Relay output 4)
(Relay output 4)
(Opto coupler output 1 (-))
(Opto coupler output 1 (+))
X7:1
X7:2
X7:3
X7:4
X7:5
X7:6
X7:7
X7:8
X7:9
X7:10
X7:11
X7:

(Analogue output 1 (+))

(Analogue output 1 (-))
(Interface RS 485 (-))
(Interface RS 485 (+))
(Analogue Modem (a))
(Analogue Modem (b))
Analogue outputs
Connector:
Page 16 of 97
[8]
Connector ST 301: Interface RS232

X8:1
X8:2
X8:3
X8:4
X8:5
X8:6
X8:7
X8:8
X8:9
X8:10
[9]

(RS232 (free))
(RS232 (free))
(RS232 (TxD))
(RS232 (CTS))
(RS232 (RxD))
(RS232 (RTS))
(RS232 (free))
(RS232 (free))
(RS232 (GND))
(RS232 (free))
GSM/GPRS-module / GSM antenna

Connector Mini-BNC
X9:1
X9:2
X9:3
X9:4
X9:5
X9:6
X9:7
X9:8

(GSM/GPRS-module / GSN antenna)

Page 17 of 97
3. Software on Hydrocal unit

3.1. General information
The gas-in-oil analyzer HYDROCAL 1002-1003 is based on a microprocessor controlled measuring
system. A 32 Bit Coldfire processor with a clock frequency of 50 MHz is used. The software has
been developed with the language C. The system has a static memory of 4 Mbyte for measuring
data. This offers a 2 years time storage capacity for the measuring data. After this period, the oldest
data will be overwritten by the latest values. When using additional external sensors, the storage capacity depends from the number of sensors and the time interval selected for storage. The following
formula can be used to determine the storage capacity:
Memorydepth[days]
4 106 [Byte]
8
5664[Byte / day ] + 288[Byte / day ] Sensorstoragesn [1 Std ]

n =1
With one additional sensor with a time interval of 5 minutes the following calculation results:
Memorydepth[days ]
4 106 [Byte]
4 106 [Byte]
438[days ]
5664[Byte / day ] + 3456[Byte / day ] 9120[Byte / day ]
Also an additional reduction of the storage time takes place by the definition of alarms. Each change
of alarm status requires 12 Bytes.
Attention: To avoid any loss of data, it is proposed to read out regularly
the measuring data by the Windows based software HydroSoft.
Page 18 of 97
3.2. Operation of HYDROCAL 1002-1003 by its keyboard

The HYDROCAL 1002-1003 unit when in use can be operated by its built-in keyboard. For this its
external housing must be removed. Loosen the knurled thumb screws on the front side and remove
carefully the housing. The unit can then be operated by the keyboard as shown below:
HYDROCAL 1002
HYDROCAL 1003
Following the description of functions of the keyboard:

Moves the cursor horizontally
Enter button: Selection of active menus or submenus
Moves the cursor in the tables and contrast set-up from the main display
Alphanumerical input of customer specific data
3.2.1. Contrast Set-up

Contrast of HYDROCAL 1002-1003 display can be setup while pushing on up and down arrow keys
from the main display.
Page 19 of 97
3.3. Main menu

After connection of the HYDROCAL 1002-1003 unit to the power supply, the main menu appears on
the display. The actual measuring values of concentration of hydrogen and carbon monoxide in the
oil are displayed (In addition moisture (H2O) if HYDROCAL1003 is used). If other sensors are connected or an un-acknowledged alarms exists, then the display will change every 5 seconds to these
measuring values.
HYDROCAL 1002
HYDROCAL 1003
In the main menu, the following sub menus can be activated.

User menu
Gas-in-oil-menu
Alarm menu / history of alarms
Configuration menu
Transformer menu: not yet available
External sensor menu: not yet available
Remark:
From the main display under Customer, Station, Transformer and Comment data, you find Serial
Number of the unit (For example: #35414 for the HYDROCAL1002 or #28822 for the HYDROCAL1003) and Firmware version implemented on the unit (For example: V 1.00-1191 for the HYDROCAL 1002 or V 1.00-1031 for the HYDROCAL 1003).
To display immediately external sensor screen, you can push button 2.
To display immediately alert status screen, you can push button 3
Page 20 of 97
3.4.
Configuration of user settings
This is the starting page for customer data, data of installations shown on the below page. The system asks for the password before any amendments can be made (Default password is 999):
First of all, you can define the application language while selecting it by the keyboard. You can
choice between: English, German, French, Russian, Polish and Turkish.
After entering the password by the alphanumeric keyboard and confirmation by the enter key
the menu customer data setup is opened (Default password is 999).
By operation of the arrow keys (

firmed by the enter
) the different fields are selected. Selection is con-
button. The customer data can be modified by the alphanumeric keyboard
and the arrow keys. These amendments are stored by selection of
button or are rejected by
selection of the
. In the main menu (standard display) up to 26 characters can be entered. Only
the first 10 characters will be displayed.
Page 21 of 97
3.5.
Display of stored Gas-in-oil measuring values
In the menu Gas-in-oil an overview in the form of a bar chart with the composition of measured
gases in the oil are shown. The values for H2, CO and H2O indicate their actual measurement values
of the total gas content. This means in this case shown below, that 1663ppm is H2, 1663ppm is CO
and 0.0ppm is H2O.
HYDROCAL 1002
HYDROCAL 1003
The following values are available:

Hydrogen
Carbon monoxide
Moisture (Only for HYDROCAL 1003)
Temperatures:
- 1 Temperature of oil on the sensor

- 2 Temperature in sensor area (ambient temp)
Graphic display
3.5.1
After selection of the measuring quantity, a graph displaying the trend over the time is shown
Following functions are available:

Scroll graph to the right
Scroll graph to the left
Zoom-out with minimum resolution of 3 days / page
Page 22 of 97
Zoom-in with maximum resolution of 8 hours / page

Go to table presentation
Exit
Table presentation
3.5.2.
After selection of presentation in form of a table, the measured values are shown with time and current record number. The most recent measured value is on top of the table.
The following functions for tables are available

Scroll up one line
Scroll up one page
Scroll down one page
Scroll down one line
Scroll one page up / down
Go to trend menu
Exit
Page 23 of 97
3.6.
History of alarms
In the menu history of alarms, all programmed alarms are presented in a table.
All alarms defined are shown together with their status. In the column Date / Time the last change
of status is shown. The followings alarm statuses are available:
OK, Symbol : No active alarm for this measuring value exists.
o If a date exists: For this measuring value an acknowledged alarm existed in the past.
o If no date exists: For this measuring value no alarm existed in the past.
High - Alarm active:
o Symbol : The defined Level 1 for a High - Alarm has been exceeded at the date/time indicated.
o Symbol : The defined Level 2 for a High - High - Alarm has been exceeded in past. The
value has fallen below the limit at the time indicated, however it is still over the limit of Level 1.
High - Alarm inactive, Symbol : The defined level for a High - Alarm has been exceeded in the
past. The value has fallen below the limit at the time indicated.
High - High - Alarm active, Symbol
: The defined level for a High - High - Alarm has been
exceeded at the time indicated.
High - High - Alarm inactive, Symbol : The defined Level 2 for a High - High - Alarm has
been exceeded in the past. The value has fallen below Level 1 at the time indicated.
In history of alarms, the following functions are available:
Acknowledge alarm selected

Scroll up one line
Scroll down one line
Show details of alarm selected: function not yet available
Exit
3.6.1. Acknowledgment of alarms

For confirmation of an alarm, a password is required (Default password is 999).
Page 24 of 97
3.7.
Device set up
First of all, you can define the application language while selecting it by the keyboard. You can
choice between: English, German, French, Russian, Polish and Turkish.
Before any amendment of settings can be made, the system asks for the password (Default password is 999).
After input of password by the alphanumeric keyboard and confirmation with enter
device setup menu is opened:
button, the
The following configurations can be modified:

Transformer data, e.g.: allocation of sensors to algorithms for calculation of life expectancy and input of correction factors
Configuration of Analogue outputs
Configuration of Analogue inputs (extern sensors)
Configuration of alarms
Configuration of the unit
Page 25 of 97
Menu Transformer data setup

3.7.1.
Transformer data can only be programmed by Windows HydroSoft. This data is not necessarily required for operation of the unit. In the menu Transformer Setup, input of correction factor, Ho-Spot
Calculation as well as Ageing Rate / Loss-of-Life Calculation are possible. Parameters can be set
only on the device not in HydroSoft.
Input of correction factor

3.7.1.1.
Results of laboratory analysis can be introduced in this menu. These can be used for calculation of
correction factors for definition of the gas content.

) the different fields can be chosen. For the input
of results of laboratory analysis, first the date of analysis should be entered in the field Sample
Date. Then the average value of gas concentration is calculated and presented. After the results of
laboratory analysis have been introduced in the fields Laboratory Value for H2 and CO, the button
is activated the new correction factor is calculated.
This value can be used. The new values are stored and activated by the button
exit. For the following measured values the new correction factor will then be used.
Store and
Page 26 of 97
3.7.1.2.
Hot Spot calculation
HYDROCAL 1002-1003 can allow Hot-Spot Temperature calculation. For this calculation, it is very
important to know that system needs external sensor reference in addition to the standard initially
purposed with HYDROCAL 1002-1003. These references are: minimum one of Load Current, Top oil
Temperature as well as Cooling Stage (this last reference is not necessary required but can improve
the calculation).
3.7.1.2.1.
External Sensors
After selection of the external sensor submenu, following screen will be displayed:

) the different fields can be chosen. First of
all, you must define each field with required information.
For Load Current, you can select between Load Current and None
Page 27 of 97
For Top Oil Temperature, you can select between Top oil Temperature, Ambient temperature,
Hot-Spot temperature, 1 (Temperature of oil on the sensor), 2 (Temperature in sensor area
(ambient temp)) and None
For Cooling Stage, you can select between Cooling Stage, Ageing rate, Loss of Life and
None
If necessary, you have to define previously external sensor references as analogue input while push-
ing button
(See chapter 3.7.3 for setup).
Then, you must define calculation interval. Calculation interval in the field "Calculation interval" is
edited by arrow keys and confirmed by the alphanumeric keyboard. The sample interval is made in
seconds or by a button in days hours min - seconds. For a double point the
After confirmation by the
- seconds.
button is used.
button, the value will be converted and displayed in days hours min
At the end, the new references and calculation interval are stored and activated by the button
Store and exit.
3.7.1.2.2.
Cooling stage #1

all, you must define each field with required information. Followings information must be entered:
Cooling stage #1 condition
o Sensor reading less / equal: in mA
Hot-Spot Calculation parameters
o Rated Current: Ir in Amp
o Winding Exponent: y
o Gradient at rated Current: gr
o Hot-Spot-Factor: H
o Winding Time Constant: Tw in second
Usually, all data can be known through transformer manufacture technical specifications or can be
also estimated.
At the end, conditions and parameters are stored and activated by the button
Store and exit.
For
Cooling Stage #2 and
Cooling Stage #3, please apply exactly the same procedure in order to setup required information.
Page 28 of 97
3.7.1.3.
Ageing Rate / Loss of Life
After selection of the Ageing Rate / Loss of Life submenu, following screen will be displayed:

all, you must define each field with required information. Followings information must be entered:
Kind of Insulation (Paper): you can select between Normal and Thermally Updated
Hot-Spot Temperature Sensor: you can select between None, 1 (Temperature of oil on the
sensor), 2 (Temperature in sensor area (ambient temp)), Top Oil temperature, Ambient temperature and Hot-Spot temperature
If necessary, you have to define previously Hot-Spot Temperature Sensor as analogue input while
pushing button
(See chapter 3.7.3 for setup).
At the end, setup is stored and activated by the button
Store and exit.
3.7.2.
Configuration of analogue outputs
The HYDROCAL 1002-1003 has 4 analog outputs for measured gas-in-oil concentration as well as
for external sensors values. The output signal is 0-20 mA or 4-20 mA.
First a quantity / variable must be selected. The following functions are available:
Scroll up / down marking
Enter button: selection of active menus or submenus
Page 29 of 97
Store configuration of outputs and exit

Exit
The following measuring quantities are available in the field "Sensor":

H2 concentration
CO concentration
H2 Daily trend
H2 Weekly trend
CO Daily trend
CO Weekly trend
Temperature 1
Temperature 2
All quantities / variables defined under external sensors
The following analog outputs signals are available in the field "Mode":
OFF
020 mA
420 mA
TEST: Allow simulating an output signal between 0 and 20 mA. The following values can be defined in the field "Sensor: 0, 1, 3, 4, 5, 10, 15, 19 et 20 mA
3.7.3.
Configuration of analogue inputs (external sensors)
External sensors within standard outputs (0...10V or 0(4)...20mA) can be connected to the HYDROCAL 1002-1003 analogue inputs. The HYDROCAL 1002-1003 has 8 analogue inputs, the first 4
can be setup in 0(4) ... 20 mA and the last 4 in 0(4)...20 mA or 0...10V (Selectable by jumpers).
Note: No power supply is available for external sensors.
First an input number must be selected. The following functions are available:
Scroll up marking
Scroll down marking
Page 30 of 97
Enter button : selection of active menus or submenus

Exit
As soon as an input is selected and made available for configuration
are available:
, the following functions
Selection of different input possibilities for the input mode [Mode], and the unit [Unit] See below.
Activation of input over alphanumeric keyboard for :
[External Sensor #]
[Sample Interval]
[Min. Value & Max. Value]
[Display Min. & Display Max.]:
[Smooth]
Scroll up
Scroll down
Scroll up / down
Cancel input
Store alarm configuration and exit
Exit without storage
The following inputs signal can be selected by pressing the
button:
The first 4 can be set-up in 0(4)...20 mA or 0..10V (via jumper on electronic board)
The last 4 can be set-up in 0(4)...20 mA
Page 31 of 97
The following unit s can be selected by pressing
button:
(No unit)
ppm
ppm/Day
ppm/Week
C
%
mA
A
KA
V
KV
The external sensors names in the field "External sensor #" are edited by arrow keys and confirmed
by
and the alphanumeric keyboard.
The sample interval in the field "Sample interval" is edited by arrow keys and confirmed by
and the alphanumeric keyboard. The sample interval is made in seconds or by a button in days
hours min - seconds. For minus the
button and for a double point the
button are used.
After confirmation by the

button, the value will be converted and displayed in days hours min
- seconds.
For conversion of input units, the inputs Minimum Value are made under the input signals 0V, 0 mA
or 4 mA and Maximum Value are made under the input signals 10V or 20mA. In addition, the display range can be limited by inputting introduction of Minimum Display and Maximum Display.
Remark: on following display, you could see 4 additional inputs named:
#9: H.-Spot for Hot-Spot Temperature
#10: Ag.Rate for Ageing Rate
#11: L.o.life for loss of Life
#12:
All of them are virtual sensors and any cases have to be considered as real analog inputs. However
these values are displayed on the main display as external sensor (See Chapter 3.3: Main Menu
External sensor setup).
Page 32 of 97
Configuration of alarms and digital outputs

3.7.4.
The HYDROCAL 1002-1003 unit has 12 digital outputs for alarms. The first 4 (Out1 ...4) are 12V
outputs. The on status is 12V and the off status is 0V. The next 8 outputs (Out 5..12) are optically
divided switchers, with status contact closed for on and contact open for off. You can have up
to 16 possibilities to setup Alarms. Alarms can be triggered either by internal gas or temperature sensors or by external sensors. Configuration of alarms is shown on the following pictures:
First a quantity / variable must be selected. For this choice, the following functions are available:
Configuration of SMS transmitting functionality
Scroll up marking
Scroll down marking
Select setting for alarm
Select setting for configuration of alarm
Exit
The following measuring quantities are available:
H2 concentration
CO concentration
H2 Daily trend
H2 Weekly trend
CO Daily trend
CO Weekly trend
Temperature 1
Temperature 2
Page 33 of 97
After a measuring variable has been selected and opened with

functions are available:
for configuration, the following
Selection of different input possibilities for the alarm mode (mode), Action (action1..2)
and choice of the output (clamp1..2)
Activation of input over alphanumeric keyboard for the values: Alarm limit (Level1..2),
Delay (Delay1..2)
Scroll up
Scroll down
Scroll up / down
Cancel alarm
Store configuration of alarm and exit
Exit without storage
Following alarm settings can be chosen by pressing the button
High: An alarm is triggered when Level 1 is exceeded.

High-High: An alarm in 2 steps is triggered. The first alarm is triggered when Level 1 is exceeded;
the second alarm is triggered after exceeding Level 2.
Low: An alarm is triggered when a value falls below the limit defined in Level 1.
Low-Low: An alarm in 2 steps is triggered. Step 1 is alarm is triggered when the measured value
falls below the limit defined in Level 1, the second alarm is triggered below Level 2 when the
measured value falls below the limit defined in Level 2.
Low-high: An alarm in 2 steps is triggered. Step 1 is triggered when the measured value falls below the limit defined in Level 1, the second alarm is triggered after exceeding Level 2.
Range: An alarm is triggered when the measured value is outside the limits defined in Levels 1
and 2.
The alarm limits are edited by arrow keys and confirmed by the
button and the alphanumeric
keyboard. The quantity is defined by the unit. This is ppm for gas concentration and C for temperatures and for external sensors the unit defined for the respective sensor (e.g. Volt, Ampere ...).
The alarm limits must be within the corresponding measuring ranges. This is 0...2000 ppm for gases,
0...+100C for temperatures and for external sensors the limit is defined for the respective sensor.
Delays (Delay1...2) can be programmed to suppress alarms if the limits are exceeded only for a short
time. Input of delay time is made in seconds or by a button in days hours min - seconds. For miHYDROCAL 1002-1003: Manual for installation and operation
Page 34 of 97
nus the
button are used. After confirmation by the
button, the value will be converted and displayed in days hours min - seconds.
For example: if CO Alarm is setup as follow (delay 1: 10min and delay 2: 20min)
In the event of alarms, CO alarms will be activated as follow:

Note: CO measurement interval is 20 min.
Moreover, an alarm can be only activated on a record measurement (For CO: every 20 min).
In fact, an alarm cannot be activated during 2 measurements interval.
The following actions can be selected by pressing the
button:
Log entry: An entry in the history of alarms is made; this has to be confirmed (see history of
alarms).
Output: An output is switched on (If the measured value exceeded the limits in the field "Level 1 &
2"). The status on described above is activated. If the measured value falls under the limit, the
output is switched off again.
Out, hold: An output is switched on (If the measured value exceeded the limits in the field "Level
1 & 2"). The status on described above is activated. If the measured value for this output falls
under the limit, the output remains switched on. Only a manual deleting of alarm allows that the
output is switched off again (see chapter 4.11 or 3.6).
Log & SMS: An entry in the history of alarms is made, this has to be confirmed (see history of
alarms) and an SMS is sent to the number indicated.
Page 35 of 97
Output & SMS: An output is switched on (If the measured value exceeded the configured limits in
the field "Level 1 & 2"). The status on described above is activated. If the measured value falls
under the limit, the output is switched off again. In addition, an SMS is sent to the number indicated.
Out, hold & SMS: An output is switched on (If the measured value exceeded the configured limits
in the field "Level 1 & 2"). The status on described above is activated. If the measured value for
this output falls under the limit, the output remains switched on. Only a manual deleting of alarm
allows that the output is switched off again (see chapter 4.11 or 3.6). In addition, an SMS is sent to
the number indicated.
If it is possible to use the same output for different alarms and therefore, collection alarms can be
defined.
3.7.5.
Unit Setup
The following setup can be modified:

Digital Output Test
Flange Heating Base Temperature
Device Options setup (Backlight display)
Clock settings
Communication settings
Exit
Page 36 of 97
3.7.5.1.
This is for Test of the 10 Digital Outputs.

3.7.5.2.
The configuration of the Flange Heating Base Temperature is made in the following menu:
Input of Base Temperature is made by arrow key. The followings temperature values can be defined:
20C, 25C, 30C, 35C, 40C and 45C.
3.7.5.3.
Device options
The configuration of the Backlight display as well as User Name and Password (String and Numeric
Password) are made in the following menu:
Page 37 of 97
The following functions are available for Display Backlight Timeout:

Store the configuration and exit
Exit
Input of delay time is made in seconds or by a button in days hours min - seconds. For minus the
buttons are used. After confirmation by the
the value will be converted and displayed in days hours min - seconds.
Note: 0 means that the screen will be always enlightened.
button,
Input of new User Name and Password are made by operation of the arrow keys (
) the different fields are selected. Selection is confirmed by the enter
button. The customer
data can be modified by the alphanumeric keyboard and the arrow keys.
Remark:
User Name is used for Modem login. By Default, EMH as User Name is setup
String Password is used also for Modem Login. By default, KWA as String Password is setup
Numeric Password is used for Device Setup menu, Customer Data Setup as well as for communication from HydroSoft Software to the unit (Default password is 999).
Toggling of the main Display is made by operation of the arrow keys (
) the differ-
ent fields are selected. Selection is confirmed by the enter

button. You have followings possibilities:
Standard means that your Main Display will switched every 5 seconds
Slow means that your Main Display will switch every 15 seconds
Very Slow means that your Main display will switch every 25 seconds
These amendments are stored by selection of
button or are rejected by selection of the
Reset
Page 38 of 97
3.7.5.4.
Clock settings
The HYDROCAL 1002-1003 has a sub menu allowing configuration of time, date as well as clock
The following functions are available:

Exit
Input of time in the field " "System Time" is made in - hours - minutes - seconds. For a double point,
used the
button.
Input of date in the field ""System Date" is made in - year - month - days - . For minus the
is used.
The HYDROCAL 1002-1003 has a universal GMT clock in order to modify the time zone.
button
The time zone setup in the field "Clock offset" is made by

button. The time zone values are between -6 and +6 hours. Variable Custom" allows manual setup in the field on the right side. Input of
time is made in - hours - minutes -. For a double point, used the
button.
Note: "None means that GMT clock is not activated.

button:
Input of time mode in the field "Daylight Saving Time Mode" is made by
MET (Middle European Time) adjusts the official local time forward, one hour from its official
standard time for the duration of the spring and summer months.
NONE means that the function is not activated
Page 39 of 97
Configuration of the communication

3.7.5.5.
The configuration of the communication is made in the following menu:

Send a test SMS (not yet available)
Alert SMS setup
Internal modem setup
RS 232 / RS 485 setup
Status information activation (not yet available)
Exit
Note: on the main display, you have the currently communication status.
Page 40 of 97
3.7.5.5.1.
Alert SMS setup
The configuration of the alert SMS transmission is made in the following menu if HYDROCAL 10021003 is equipped within an on-board GSM. This function allows sending SMS in correlation with beforehand definite alarms for gas-in-oil concentrations, temperatures as well as for external sensors
values.
Input of operator name is made in the field "Service Center".

The system has 5 possibilities to send SMS in the field "Recipient 1-5". Input of telephone number is
made by alphanumeric keyboard.
A message in the field "Message" can also be pre-write in order to be sent to the recipient in the
event of alarms.
Note: The SMS mode (in Alarm set-up) must be selected to use this function. Moreover, GSM or
Analogue modem must be also installed on HYDROCAL 1002-1003.
3.7.5.5.2.
Internal modem setup
The modem configuration is made in the following menu if HYDROCAL 1002-1003 is equipped within
an on-board GSM or Analogue modem.

Page 41 of 97
Exit
button:
Input of Modem type in the field "modem Type" is made by
Analog (Internal) means that an analog modem is installed on the unit and you want to use it
GSM (Internal) means that a GSM modem is installed on the unit and you want to use it
IP (internal) means that a IP modem is installed on the unit and you want to use it
3.7.5.5.2.1 Analog Modem
If you select an Analog Modem, following screen will e displayed:
Input of Number of Ring before answer in the field "No. of RINGs be fore Answer:" is made by
button.
Input of Timeout in the field " "Idle Hang-Up Timeout [s]" is made in - hours - minutes - seconds. For a
double point, used the
button.
3.7.5.5.2.2 GSM Modem

If you select a GSM Modem, following screen will e displayed:
Input of Number of Ring before answer in the field "No. of RINGs be fore Answer:" is made by
button.
Input of Timeout in the field " "Idle Hang-Up Timeout [s]" is made in - hours - minutes - seconds. For a
double point, used the
button.
Input of Pin code in the field PIN is made by

meric keyboard and the arrow keys.
button. Pin code can be modified by the alphanubutton or are rejected by selection of the
Page 42 of 97
3.7.5.5.2.3 IP Modem
If you select an IP Modem, following screen will e displayed:
While activating DHCP, it means that IP address of the Hydrocal in DHCP server on the network will
be automatically provided, only a port number has to be provided. This one has to be also set up on
HydroSoft Software. If DHCP is not enabled need IP address, subnet mask, default gateway and port
number in the following menu can be entered.
The input of the idle on the field Hang up timeout (s)", TCP port number in the "TCP Port Number",
the IP address in the "IP Address, subnet mask in the field" Network mask" and the standard gatekey and the numeric keypad.
way in the "Standard Gateway" with the Enter
The baud rate for the RS232 interface must be using internal IP-modems to 57600 baud (see following chapter), IP modem IP is connected to the internal RS232 interface.
Page 43 of 97
3.7.5.5.3.
RS 232 / RS 485 setup
The serial interfaces configuration is made in the following menu.
This section illustrates different ways to communicate with HydroCal devices. There are the following
main connection / communication scenarios:
Host (PC) with one HydroCal device via RS232, RS485 or via Modem
Point-to-Point
Host (PC) with many HydroCal devices via RS485 bus
RS485-Bus
Host (PC) with many HydroCal devices via RS485 bus using a HydroCal bridge
Bridge
SCADA System with online monitoring of one or more HydroCal devices
MODBUS
General
The following sections describe how to configure the Hydrocal devices and the HydroSoft software.
After a short description screen shots of HydroCal and HydroSoft illustrate the setup. Some descriptive comments and hints may follow the screen shots.
The setup of the HydroCal has to be carried out manually on the device.
A. Point to Point
A point-to-point connection / communication is the simplest setup. The host (PC) is connected directly to one HydroCal device. The connection can use the RS232, the RS485 or the modem. The default configuration for a HydroCal device assumes a point-to-point connection. The same applies to
HydroSoft.
I. RS232
The RS232 is used for short connection distances (less than 10m). It provides full duplex and handshaking.
Page 44 of 97
HydroCal
HydroSoft
The setup is very simple. Just assure that the baudrate is matching and that the correct COM port is
chosen in HydroSoft.
II. RS485
The RS485 can be used for long connection distances (up to 200 m). It is implemented as a two-wire
interface with half-duplex and a soft-handshake.
HydroCal
HydroSoft
Assure that the baud rate is matching and that the correct COM port is chosen in HydroSoft. Also
check the RS485 checkbox to indicate the half-duplex connection. A RS485 adapter might require
some special setup of the other checkboxes.
Page 45 of 97
PC RS485 Adapters
Connecting a PC to the RS485 of a HydroCal device usually requires an adapter (interface converter). Depending on the properties of the adapter in use, the RS485 related check boxes in HydroSoft
must be set accordingly.
For communication with a HydroCal device only the two-wire half-duplex mode is of interest. This
mode requires a kind of send/receive-control which is either ART (Automatic Receive Transmit control) or a manual control (e.g. via the RTS signal). Further the adapter may echo the send out data.
The two checkboxes in the HydroSoft Connection dialog must mirror the properties of the adapter:
Ignore Echo
Must be checked, if the adapter echo the send out data
RTS Send Control
Must be checked, if the adapter requires a manual send/receive-control via the RTS signal
(this assumes a RS232 to RS485 adapter is in use)
Answer Delay
If an RS485 adapter with RTS send control is used it may be necessary to set up some answer delay
in the HydroCal device. If everything is configured right and still the communication does not work
this may be due to problems with the send/receive-control. If the adapter does not release the transmitter quick enough, the answer of the HydroCal may be damaged and thus unrecognized.
III. Modem
The modem allows a remote connection using the phone network. From a communication point of
view the connection via modem is very similar to the point-to-point connection via RS232. The connection supports full duplex, but may be limited in speed.
HydroCal
HydroSoft
The HydroCal modem configuration should have been carried as the device left the production. For
HydroSoft select "Connect via:" - "Modem" and fill in the modem connection fields as described in the
user manual, i.e. enter user name, password and phone number and select the modem to use for the
communication.
Page 46 of 97
B. RS485-Bus
Using the RS485 interface it is possible to connect more the one HydroCal to a host. Nonetheless it
is only possible to communicate with one device at a time. The illustration below shows the schematic topology.
Remark: The host (PC) must only be present once (the host connected via the TCP/IP adapter is
only present to show an alternate way to connect to the RS485 bus, as it is offered by third party
network-to-serial bridges).
HydroCal
HydroSoft
On HydroCal device:
Configure the device as "Bus Node"
Page 47 of 97
Set an unique address for each device on the RS485 bus (1..254). Note: Communication with
HYDROCAL 1002-1003 can be made right now with up to 32 units
Setup "Answer Delay" as required by the RS485 adapter in use (see also chapter: PC
RS485 Adapters and Answer delay)
MODBUS must be off
Configure RS485 baudrate
In the HydroSoft connection dialog:

Use "Connect via:" "Com-Port"
Select RS485 baudrate chosen for the devices
Check RS485
Set RS485 related checkboxes are required by the adapter (see also: Answer delay)
Enter correct bus address
C. Bridge
The (RS485-Bus-) bridge is an extension to access a range of HydroCal devices on a RS485 bus. In
this setup the host (PC) is not directly connected to the RS485 bus but is using one of the HydroCal
devices as communication gateway.
The bridge functionality can be used for an RS232 or Modem primary connection as indicated by the
illustration below.
The setup of all HydroCal devices must be according to a standard RS485 bus setup, with one exception. The HydroCal that shall serve as the communication gateway must be configured as a (bus-)
bridge.
Page 48 of 97
I Bridge Setup
HydroCal
HydroSoft
On HydroCal device :
Configure the device as Bus Bridge
Set an unique address (1..254). Note: Communication with HYDROCAL 1002-1003 can be
made right now with up to 32 units
Setup Answer Delay as required by the RS485 adapter in use
MODBUS must be off
Configure RS232 baud rate
Use Connect via: Com-Port
Select RS232 baud rate chosen for the bridge devices
Bridge via Modem
The bridge functionality can also be activated, if the primary connection uses the modem. The corresponding setup for the HydroCal and HydroSoft must be carried out as already described in the
point-to-point section and is not repeated here (see III).
Page 49 of 97
II RS485-Bus Setup
HydroCal
HydroSoft
On HydroCal device :
Configure the device as Bus Node
Set an unique address for each device on the RS485 bus (1..254). Note: Communication with
HYDROCAL 1002-1003 can be made right now with up to 32 units
Setup Answer Delay as required by the RS485 adapter in use
MODBUS must be off
Configure RS485 baud rate
Use Connect via: Bridge
Select the transformer that is equipped with the bridge HydroCal in the Device combo box.
Page 50 of 97
D. MODBUS
If one or more HydroCal devices shall be integrated into a SCADA System for online monitoring, the
MODBUS communication setup might be applicable. MODBUS is currently not supported by HydroSoft, but the setup is shown here for completeness
Since Version V1.00-B0884 of the firmware the MODBUS protocol is available. This section describes the device setup for MODBUS and the MODBUS function code and register mapping.
As a reference example, the setup of an ADAM-4572 1-port Modbus to Ethernet Data Gateway by
Advantech (www.advantech.com) is shown below.
HydroCal
ADAM-4572
On HydroCal device:
Activate MODBUS using the RS485 and the desired mode (RTU/ASCII)
Page 51 of 97
Set an unique MODBUS address for each device (1..247). Note: Communication with HYDROCAL 1002-1003 can be made right now with up to 32 units
Set "Baudrate", "Data Bits", "Parity" and "Stop bits"
Setup "Answer Delay" if required (i.e. if communication problems occur)
Remark:
If the MODBUS protocol on the RS 232 interface is active:
* If the data flow control (RTS / CTS) is not available
* If the internal modem is not available
The following parameters in the configuration menu can be entered
Mode:
This is a toggle button to select the transmission mode (RTU / ASCII) and the serial interface
to use for MODBUS. Available entries are:
- Off (i.e. the proprietary HydroCal protocol is used)
- MODBUS RTU via RS485
- MODBUS ASCII via RS485
- MODBUS RTU via RS232
- MODBUS ASCII via RS232
Address:
This is an edit field to enter the device address.
For MODBUS, values in the range from 1 to 247 are allowed. For the proprietary HydroCal
protocol the addresses can be configured from 1 to 254.
Note: Communication with HYDROCAL 1002-1003 can be made right now with up to 32 units
Baud rate, Data Bits, Parity and Stop Bits

These toggle buttons allow adjusting the coding format of the serial interface for MODBUS
protocol.
Remarks:
o Change of the transmission mode does not set the coding format parameters to
the default values for the selected mode (RTU: 19200,8,E,1; ASCII 19200,7,E,1).
The right configuration has to be configured manually.
o The proprietary HydroCal protocol allows only configuration of the baud rate. The
settings of the Data Bits, Parity and Stop Bits toggle buttons are ignored and the
configuration is fixed to 8-N-1.
Answer delay
Test / Debug Options at the HydroCal Device
In the lower left corner of the configuration screen there is a small MODBUS statistics line with the
following information:
<==> 0 ; count of all MODBUS messages
-> 0 ; count of MODBUS messages for this device
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<- 0 ; count of all MODBUS answers from this device

#! 0 ; count of parity and framing errors in the interface
I Function, Register and Address Mapping
The following MODBUS functions, register- and address ranges are used:
ModbusFunction
Code
ModbusAddress
Dec. / Hex
Register
Address 1)
(5 Digit Dec.)
0x02
Read
Discrete
Inputs
1000 / 3E8
..
1015 / 3F7
11001
..
11016
0x04
Read
Input
Registers
1000 / 3E8
..
1029 / 405
31001
..
31030
2000 / 7D0
2002 / 7D2
2004 / 7D4
..
2059 / 80B
32001
32003
32005
..
32060
3000
..
3015
33001
..
33016
40004001
..
4002-
34001 34002
..
34003 -
0x04
Read
Input
Registers
0x04
Read
Input
Registers
0x04
Read
Input
Registers
HydroCal
Alert status
Alert #1
..
Alert #16
Only the information whether an alert condition is
pending is returned. The level of the alert (e.g. Hi
or Hi-Hi) is not transmitted.
Sensor value
Sensor #1
..
Sensor #30
The sensor assignment is given below the mapping tables.
The sensor value is transmitted as a signed integer. Prior to transmission the real reading is
multiplied by 10 (to have a 1-digit precision). So to
get the 'real' measurement the returned value
must be divided by 10.
An open sensor input is returned as -32768
(0x8000).
Sensor value
Sensor #1
Sensor #2
Sensor #3
..
Sensor #30
The sensor assignment is given above this table.
The sensor value is transmitted as a floating point
value (32 bit, big endian).
An open sensor input is returned as a non signalling NAN (0x7FFFFFFF).
Alert status
Alert #1
..
Alert #16
The full alert status information is returned.
0
no alert
1
level 1 alert (not active)
2
level 2 alert (not active)
3
active level 1 alert
4
active level 2 alert
Query ageing rate
Loss-of-Life in seconds
Time-into-Service in seconds
Page 53 of 97
ModbusFunction
Code
0x06
Write
Single
Register
0x06
Write
Single
Register
0x06
Write
Single
Register
0x03
Read
Holding
Registers
ModbusAddress
Dec. / Hex
4003
Register
Address 1)
(5 Digit Dec.)
34004
0
..
1
40001
..
40002
1000
41001
To test the write functionality there are 2 registers

that may be modified freely. (The reset
initialization values of the registers are 0xA5A5
and 0x5A5A.)
Confirmation / Reset of alerts
Alert status #16 .. #1
42001
The alerts are coded as a bit field and are

presented as a single MODBUS register (alert
#16 -> 0x8000, alert #1 -> 0x0001).
By writing a '0'-Bit at the corresponding position a
probably active alert can be reset. Writing '0000'
resets all alerts.
Switch MODBUS protocol off
MODBUS off
2000
0
..
1
40001
..
40002
1000
2000
41001
42001
HydroCal
A value is returned within 2 MODBUS register as

a 32-bit unsigned integer in big endian format.
Holding Register
Test register #1, #2
It is now possible to switch the MODBUS protocol

off via MODBUS. This is done by writing 0x00FF
(like OFF).
Holding Registers
16-Bit test register #1, #2
Alert status bit pattern #16 .. #1

MODBUS protocol status
Remark: The reading is always 0x0000. If the
MODBUS status is OFF it is not possible to read
this status via MODBUS.
Currently the following assignment of sensor numbers applies:

1
gas sensor H2
2, 3
- reserved 4
gas sensor CO
5
temperature sensor (measurement chamber)
6
temperature sensor (oil)
7
humidity/moisture (only HydroCal 1003 devices)
8
- reserved 9
daily trend gas sensor H2
10, 11
- reserved 12
daily trend gas sensor CO
13
weekly trend gas sensor H2
14, 15
- reserved 16
weekly trend gas sensor CO
17 .. 24 external analog sensors (0..10V, 0/4..20mA inputs)
25 .. 28 virtual sensors (hot spot, ageing rate, etc., since firmware V1.00-B0844)
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MODBUS Communication Examples

This chapter describes working test setups for MODBUS communication. The following hardware
and applications were used to test the MODBUS communication with HydroCal. Both test application
are free for download. The hardware is not the only hardware that is working with HyroCal. The devices are just an example.
Applications (for Microsoft Windows):
QuickMod Modbus scanning tool (Windows based)
AzeoTech, Inc. (www.azeotech.com)
Modpoll Modbus Polling Tool (Command Line Tool)
FOCUS Software Engineering (www.focus-sw.com)
Hardware:
Roline RS232C / RS485 Converter
Roline, IC-485S (12.02.1028), IC-485SI (12.02.1029), (www.rotronic.ch)
ADAM-4572 1-port Modbus to Ethernet Data Gateway
Advantech (www.advantech.com)
I MODBUS/RTU via RS232 (using QuickMod)
This test of HydroCal MODBUS/RTU via RS232 was executed using the QuickMod application. Connection, setup and results are shown below.
Physical Connection
HydroCal and QuickMod Connection Setup:
HydroCal can be set up without any answer delay (due to full duplex on RS232).
The timeout for Quickmod can be short. The answer of HydroCal is received within less than 50
ms (see QuickMod Monitor screen shot below).
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HydroCal and QuickMod Data Screens
The QuickMod Tag # field must be filled with the address 1016 to query the HydroCal external
sensors 1..8 (address=1016..1023, register=1017..1024).
QuickMod Monitor
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II MODBUS/ASCII via RS232 (using Modpoll)

This test of HydroCal MODBUS/ASCII via RS232 was executed using the Modpoll application. Connection, setup and results are shown below.
Physical Connection
HydroCal Setup and Data Screen Dump
HydroCal can be set up without any answer delay (due to full duplex on RS232).
Modpoll Result Screen Dump
The Modpoll utility expects the start reference to be set to the register 1017 to query the HydroCal external sensors 1..8 (address=1016..1023, register=1017..1024).
III MODBUS/RTU via RS485 (using QuickMod)

This test of HydroCal MODBUS/RTU via RS485 was executed using the QuickMod application and
the Roline RS2327RS485 adapter (12.02.1028). Connection, setup and results are shown below.
Physical Connection
The RS232-to-RS485 adapter is configured for 2-wire (referred to as MultiDrop Half Duplex in the
adapter manual). The terminals pairs T+, R+ and T-, R- are short connected (terminal block connectors 1+4, 2+3).
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The RS232-to-RS485 adapter is configured to use RTS send / receive control (SW2 in middle
position to TxRTS/RxRTS, with the underlined text indicating that the signal in not active).
HydroCal and QuickMod Connection Setup:
HydroCal is set up with an answer delay of 100 ms to give enough time for QuickMod to toggle
the RS232-to-RS485 adapter from send to receive.
In the QuickMod configuration dialog, setting RTS Control to Toggle will operate the RS232-toRS485 adapter in the desired way.
HydroCal and QuickMod Data Screens Dumps
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QuickMod
Monitor
IV MODBUS/RTU on RS485-Bus (using Modpoll)

This test of HydroCal MODBUS/RTU on RS485 bus was executed using the Modpoll application and
the ADAM-4572 Ethernet Data Gateway. It demonstrates the ability to connect multiple HydroCal
devices to an RS485 bus. Connection, setup and results are shown below.
Physical Connection / RS485 Bus Topology
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HydroCal (only device #90) and ADAM-4572 Setup:
HydroCal is set up without an answer delay. Each HydroCal on the bus has its own unique address (#90 .. #93, #0 reserved for the bus master).
The timeout for ADAM-4572 can be short. The answer of HydroCal is received within less than
100 ms and the ADAM-4572 uses ART that does not require additional delay.
Modpoll Result Screen Dump (partial)
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Page 61 of 97
4. Windows Software HydroSoft

4.1. Purpose of the program
HydroSoft is a program compatible with MS Windows for use with HYDROCAL 1002-1003 to provide
a comprehensive transformer monitoring system. HydroSoft not only reads and processes the data of
HYDROCAL 1002 but can also used in the configuration of the HYDROCAL 1002 unit. The program
is compatible for use with operating systems MS Windows 2000 / XP (32 Bit operating systems).
HydroSoft offers the following functions:
Reading data from HYDROCAL 1002-1003 unit
Data processing
Export of data to other standard windows programs
Storage on data mediums, read from data medium, archiving of measuring data
Configuration of analogue inputs of HYDROCAL 1002-1003 unit
Configuration of alarms and respective alarm outputs of HYDROCAL 1002-1003
4.2. Remarks for use of this operation handbook

The following operation handbook explains in details the installation and operation of HydroSoft on
your PC. It contains the following sections:
Program Installation and Start up
Program functions
General rules for use as transformer monitoring system
Export and storage of data
4.3. Requirements to the PC

The PC must fulfill the following requirements:
Pentium Processor clock 300MHz

Free disc space for installation on harddisk 20 MB, additional memory space for data storage
RAM memory 256MB
Operating system: Windows 2000 / XP
CD-ROM drive
Interface RS232C
Signals used are RxD, TxD, GND
Serial interface cable 1:1
USB RS232C interface - converter; only converters with all RS232-signals can be used.
.NET Framework 1.1 redistributable must be supported
Microsoft Data Access Components 2.6 (MDAC) or new version must be supported
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4.4. Installation
All components for installation of HydroSoft software package are available on the CD. All components of the software should be installed by the installation program.
Put the CD into the drive and start by Setup.exe. Now the installation program guides you through
the different steps of the installation. After installation the program HydroSoft can be started. Should
the installation program not be executed and ended, not all components will be installed. The missing
components will have to be installed manually (chapter 4.41 and 4.42).
Please act as described following. First install the .NET Framework 1.1
4.4.1. Microsoft .NET .NET Framework 1.1 Redistributable
Install Microsoft .NET Framework 1.1 Redistributable by:
dotnetfx.exe
and follow the instructions.
4.4.2. Microsoft Data Access Components

Install if necessary Microsoft Data Access Components by execution of:
mdac_typ.exe
and follow the instructions.
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4.4.3. Adaptation of installation

If required, you can place the HydroSoft data ("C:\Programme\MTE\HydroSoft\data") into another
root, e.g.:
"C:\Documents and settings\All Users\HydroSoft\data"
Important: The file "root.xml" (contained in the installation data) must exist in the correspondent new
root. The data will be stored in the file Hydrosoft.xml. In case this file does not exist, the system
tries to find a file Data in the installation list. In case this file exists, it will be used as a data list. If
this file does not exist, the correspondent file in the menu File under Set Data Location... must be
selected.
4.5. Functions of HydroSoft program

The program HydroSoft works together with the HYDROCAL 1002-1003 unit. The main functions of
the program are:
Reading of data from HYDROCAL 1002-1003. The data can be read out through the interface RS232C or from a modem integrated in the HYDROCAL 1002 unit (option).
Processing and presentation of measuring data data can be presented in form of trend graphics
or tables (history, see. chapter 4.12). Tables can be exported to MS Excel. Graphs can be printed
directly.
Configuration of HYDROCAL 1002-1003 units.
4.6. Start of program

In case you have introduced a link to the start menu, press Start in the task bar. Open HydroSoft in
the submenu Programs. It is also possible to start the program by HydroSoft.exe If pre-settings are
used; the program is to be found under "C:\Programme\MTE\HydroSoft\.
First of all, you must to select appropriate application language, by Extra->Language
Followings languages can be selected: English, German, French, Spanish, Russian, Chinese and
Turkish.
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4.7. Preparation / rename of a new customer list

Information is presented in a tree format with the customer being at the top. Within a customer,
transformer stations are defined and within a transformer stations, transformers followed by HYDROCAL 1002-1003s are defined. See below.
A customer list is opened automatically by the program. It can be renamed, there are two possibilities:
Either by the menu shown when pressing the right mouse button
Or by File->Customer->Rename
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4.8. Opening a new transformer station

After the customer list has been renamed, a file for a new transformer station can be opened as indicated under chapter 4.7 File->Customer->New Station after selection of the customer list. The
number of stations is not limited.
After opening a file for a new transformer station, the address of the station can be entered. By
double clicking on one of the four Property fields, address data can be inputted.
4.9. Opening a file for a new transformer

To open a new transformer file, an existing transformer station must be selected. Then, similarly as a
transformer station, a new transformer element can be opened and please select which HYDROCAL
version you are using (HYDROCAL 1002, 1003, 1005 or 1008).
The number of transformers for a transformer station is not limited. Then additional details/technical
data can be introduced.
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In addition to the existing fields

Name
Manufacturer
Type
Year
Primary voltage
Secondary voltage
Prim. current
Sec. current
Additional lines can be added by a right mouse click or by the menu Edit->New. The settings can be
put back by Revert. Amendments are stored by Save or by selection of another element in the
tree diagram.
A transformer has the following sub-information:
History: Measured data is presented in form of trend charts or tables. (see
chapter 4.12)
Alarms: Status of alarms are presented in form of trend charts and tables.
Alarms can also be acknowledged. (see chapter 4.12)
Connection/Communication: Settings can be defined. (see chapter 4.9.1 and
4.9.2)
Online Sensors: A direct/online visualisation of the measuring data can be
made
HYDROCAL 1002-1003 settings plus alarms and external sensors can be configured. (see chapter 4.10)
After opening a transformer file and inputting of its data, connection/communication settings should
be inputted.
It must first be defined, whether the connection shall be via modem (option) or by an interface RS232
(Com-Port). Select the Radio Selection field concerned.
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4.9.1. Modem settings

During establishment of a modem connection, the Login Name and the password is requested.
The name EMH and the password KWA are always used as defaults. In the box Device a modem
installed on the PC can be selected for communication. Finally the phone number of the telephone
line connected to the HYDROCAL unit must be introduced.
Attention: When using a GSM-Modem with HYDROCAL 1002-1003, it must be confirmed that a
connection to an analogue modem is possible. The network operator should be able to confirm this. Otherwise a GSM modem (e.g. a cell phone) must be used on the PC side too.
When connection is via a GSM Modem it is possible that communication during data reading
is interrupted due to a communication faults on the GSM network. Under these circumstances
a waiting time of 5 minutes is recommended before re-sending of data. This time is required
to restart the modem in the HYDROCAL 1002-1003 and to make a new connection to the GSM
network.
4.9.2. RS232 interface settings
For local communication over an RS232 interface, the interface number of the PC must be selected.
Transmitting speed is 19200 Baud; this must be entered into the field Baud rate.
4.10. Settings of HYDROCAL 1002-1003 unit

Settings for alarms and external sensors can be programmed by HydroSoft.
The file HYDROCAL contains the following information, these are read out during a connection:
Serial number of HYDROCAL 1002-1003 unit
Firmware version of HYDROCAL 1002-1003 unit
Contains the list where data are stored on the PC
Date of last read data
Customer 1st line
Customer 2nd line
Customer 3rd line
Customer 4th line
Numerical password to modify settings (Default password is 999).
String Password to modify Modem Login (Default String Password is KWA).
User Name to modify settings (Default User name is EMH).
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4.10.1. Alert Setup

In the menu
settings to alarms can be programmed by HydroSoft. Alarms can be
triggered by internal sensors (H2, CO, H2O, Oil temperature, temperature of sensor) or by external
sensors (see chapter 4.11). The recommended temperatures for fault free operation of HYDROCAL
1002-1003. Temperature for sensors and oil below 30C and over 60C are generally not to expected
and indicate a problem in the heating circuit. If temperatures are outside this range, then external
(air) temperature and oil temperature must be considered. Lower sensor temperatures are possible
during severe frosts or when transformers are switched off. Under certain circumstances temperatures higher than 60C can exist with very hot oil in the transformer without being a problem of the
heating circuit. In such a case, the measuring result can have additional error deviations.
A total 16 alarms can be defined on the HYDROCAL 1002-1003 unit. If several alarms use the same
output line, the status of alarms will be connected by an OR- statement, resulting to activate the
corresponding output if an alarm is triggered.
In the overview of alarms, (Alert Setup Overview) the following displays forms can be selected:
Either List / View in form of a list
Or Details view (listing details of alarm settings)
Or Symbol view (presenting alarm settings as symbols)
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Selection is made by the menu and with right mouse click
or by View->View As->...
In the views List and Symbol, the following dialogue can be opened by double clicking on one of
the alarms (in view Details it is not possible to open this dialogue):
First the mode of alarms must be selected under Alert Mode. Following modes are available:
High: An alarm is triggered when Level 1 is exceeded.
High-High: An alarm in two steps is triggered. The 1st alarm is triggered when Level 1 is exceeded; the 2nd alarm is triggered after exceeding Level 2.
Low: An alarm is triggered when a value falls below the limit defined in Level 1.
Low-Low: An alarm in two steps is triggered. Step 1 is alarm is triggered when the measured value falls below the limit defined in Level 1; the second alarm is triggered when the measured value
falls below the limit defined in level 2.
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Low-high: An alarm in two steps is triggered. Step 1 is triggered when the measured value falls
below the limit defined in Level 1; the second alarm is triggered after exceeding Level 2.
Range: An alarm is triggered when the measured value is outside the limits defined in Level 1 and
Level 2.
Once the alarm mode is set then, a sensor must be chosen. All above mentioned internal sensors
are available. If external sensors are connected and configured, these can also be used (see chapter
4.11). The following measuring values are available:
H2 Concentration
CO Concentration
H2 Daily trend
H2 Weekly trend
CO Daily trend
CO Weekly trend
Temperature 1
Temperature 2
All values defined under external sensors
For a clear distinction of an alarm, under Name a name can be inputted.
The alarm levels are entered in the fields Level 1 and if necessary in Level 2. The units defined for
concentration of gases ppm, for temperatures C and for external sensors the unit defined for the
respective sensor (e.g. Volt, Ampere ...) will be used. The alarm limits must be within the respective
measuring ranges. This is 0..2000 ppm for gas concentration, 20..100C for temperatures and for
external sensors the maximum and minimum values of the sensor used.
Delays1..2 can be introduced to suppress alarms during short-time exceeding of limits. Since the
measuring cycle for gas sensors is 20 min, the delay time should not be less than 20 minutes. The
input of delay time is made in seconds or directly in the form [days]-[hours]:[min]:[sec]. The value
introduced will be converted after confirmation in [days]-[hours]:[min]:[sec].
Following actions can be selected:
Log entry: An entry in the history of alarms is made; this has to be confirmed (see history of
alarms).
Output: An output is switched on (If the measured value exceeded the configured limits in the
field "Level 1 & 2"). The status on described above is activated. If the measured value falls under
the limit, the output is switched off again.
Out, hold: An output is switched on (If the measured value exceeded the configured limits in the
field "Level 1 & 2"). The status on described above is activated. If the measured value for this
output falls under the limit, the output remains switched on. Only a manual deleting of alarm allows
that the output is switched off again (see chapter 4.11 or 3.6).
Log & SMS: An entry in the history of alarms is made, this has to be confirmed (see history of
alarms) and an SMS is sent to the number indicated.
Output & SMS: An output is switched on (If the measured value exceeded the configured limits in
the field "Level 1 & 2"). The status on described above is activated. If the measured value falls
under the limit, the output is switched off again. In addition, an SMS is sent to the number indicated.
Out, hold & SMS: An output is switched on (If the measured value exceeded the configured limits
in the field "Level 1 & 2"). The status on described above is activated. If the measured value for
this output falls under the limit, the output remains switched on. Only a manual deleting of alarm
allows that the output is switched off again (see chapter 4.11 or 3.6). In addition, an SMS is sent to
the number indicated.
Data in the tree
are changed after modification of alarm settings. The star indicates
that modifications have been made; this must be transferred to the HYDROCAL 1002-1003 unit for
activation. This means, the settings indicated are not identical to those of HYDROCAL 1002-1003.
With next connection, it is requested whether the settings on HYDROCAL 1002-1003 unit shall be
updated (see chapter 4.11).
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4.10.2. External sensors (see also chapter 3.7.3)

In the menu
, the settings of external sensors are modified. The form of presentation can be chosen as under alarms as
List
Symbol
Details
The menu Sensor properties is opened by double clicking on a value or a symbol. The settings of
internal sensors cannot be modified and are therefore grayed out.
In the box Input Signal, the unit of the input signal can be selected. For the first four inputs (Free
analog #1 to Free analog #4), the following must be chosen:
With option Voltage input: 0...10V anal. In Configurable via jumper on the electronic board
With option Current input: 0...20mA anal In or 4...20mA anal. In
For the next four inputs (Free analog #5 to Free analog #8) values must either be between 0...20mA
anal In or 4...20mA anal. In.
For the next four inputs (Free virtual #11 to Free virtual #14), these four inputs are virtual sensors
and in any case have to be consider as external sensors or bushing sensors. It is used for calculation
of Hot Spot Temperature, Aging Rate and Loss of Life
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After selection of the input unit, the unit of the sensor has to be chosen from this list:
C:
for temperature-sensors e.g. oil temperature, ambient temperature...
ppm: for oil humidity-sensors or other sensors of chemicals
%:
for oil humidity sensors or other sensors of chemicals
V:
for voltmeters
KV:
for voltmeters
MA: for ampere meters
A:
for ampere meters
kA:
for ampere meters
A name can be given to each sensor for ease of use. For conversion of input units, the inputs Minimum Value are made under the input signals 0V, 0 mA or 4 mA and Maximum Value are made
under the input signals 10V or 20mA. In addition, the display range can be limited by inputting introduction of Minimum Display and Maximum Display. Smooth calculation can be used, you can
activate this function.
Data in the tree
are changed after modification of sensor settings. The star indicates that modifications have been made; these must be transferred to the HYDROCAL 1002-1003
unit for activation. This means, the settings indicated are not identical to those of HYDROCAL 10021003. With next connection, it is requested whether the settings on HYDROCAL 1002-1003 unit shall
be updated (see chapter 4.11).
4.10.3. Alert SMS Setup
In the menu
, the configuration of the alert SMS transmission is made if HYDROCAL
1002-1003 is equipped within an on-board GSM / Analogue modem. This function allows sending
SMS in correlation with beforehand definite alarms for gas-in-oil concentrations, temperatures as well
as for external sensors values
Input of operator name is made in the field "Service Center".

The system has 5 possibilities to send SMS in the field "Recipient 1-5". Input of telephone number is
made by the alphanumeric keyboard.
A message in the field "Message" can be pre-write in order to be sent to the recipient in the event of
alarms while using pre-send message. For this, In the field message click on right mouse button
and click on Insert to visualize followings pre-send messages:
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To add pre-send message, you have to click on them. The following possibilities are available:
{#}- Serial Number: means that in the event of alarms, you will receive a SMS with serial
number of the unit
{1}- Custom Line 1: means that in the event of alarms, you will receive a SMS with customer
1st line displayed on the main HYDROCAL 1002-1003 Menu
2nd line displayed on the main HYDROCAL 1002-1003 Menu
3rd line displayed on the main HYDROCAL 1002-1003 Menu
4th line displayed on the main HYDROCAL 1002-1003 Menu
{T}- Long Time: Means that in the event of alarms, you will receive a SMS with Time of alarm
which has been exceeded with following format: hh:mm:ss
{t}- Short Time: Means that in the event of alarms, you will receive a SMS with Time of alarm
which has been exceeded with following format: hh:mm
{D}- Long Date: Means that in the event of alarms, you will receive a SMS with Date of alarm
which has been exceeded with following format: YYYY:MM:DD
{d}- Short Date: Means that in the event of alarms, you will receive a SMS with Date of alarm
which has been exceeded with following format: YY:MM:DD
{A}- Alert Name: means that in the event of alarms, you will receive a SMS with the alarm
Name
{a}- Alert Number: means that in the event of alarms, you will receive a SMS with Alert Number
{l}- Alert Level: means that in the event of alarms, you will receive a SMS with Alert Level (1
for a High alarm or Level 1 and 2 for a High-High alarm or Level 2)
Note: You can combine the variable between them in order to have requested Alarm SMS information (e.g. {#}{1}{T}{D}{A}{l})
A message in the field "Message" can also be free pre-write in order to be sent to the recipient in the
event of alarms.
Note: The SMS mode (in Alarm setup) must be selected to use this function. A GSM / Analogue
modem must be also installed in HYDROCAL 1002-1003.
Data in the tree
are changed after modification of sensor settings and validation
with
. The star indicates that modifications have been made; these must be transferred to
the HYDROCAL 1002-1003 unit for activation. This means, the settings indicated are not identical to
those of HYDROCAL 1002-1003. With next connection, it is requested whether the settings on HYDROCAL 1002-1003 unit shall be updated (see chapter 4.11).
Page 74 of 97
4.10.4. Input of DGA Level Adjustment
Results of laboratory analysis can be introduced in the menu

. These can be used
for calculation of correction factors for definition of the gas content. After opening of transformer
menu page, the correction factors are shown in the fields Cur. Offset.
For the input of results of laboratory analysis, first the date of analysis should be entered in the field
Sample Date. Then the average value of gas concentration is calculated and presented. After the
results of laboratory analysis have been introduced in the fields Laboratory Value for H2 and CO,
the button
is activated the new correction factor is calculated and displayed in the field New
Offset. This value can be used or can be manually adjusted. The new values are stored and activated by
button.
Data in the tree

are changed after modification of sensor settings. The star indicates that modifications have been made; these must be transferred to the HYDROCAL 1002-1003
unit for activation. This means, the settings indicated are not identical to those of HYDROCAL 10021003. With next connection, it is requested whether the settings on HYDROCAL 1002-1003 unit shall
be updated (see chapter 4.11).
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4.10.5. Analog Output Setup
In the menu
, The HYDROCAL 1002-1003 has 4 analog outputs for measured
gas-in-oil concentration, temperatures as well as for external sensors values. The output signal is 020 mA or 4-20 mA.
First a quantity / variable must be selected in the field "Sensor", the following variable are available:
H2 concentration
CO concentration
H2 Daily trend
H2 Weekly trend
CO Daily trend
CO Weekly trend
Temperature 1
Temperature 2
The following analog outputs signals are available in the field "Mode":
OFF
020 mA
420 mA
Data in the tree
with
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4.10.6. Digital Output Setup
In the menu
, you can invert digital outputs status from "On" to "Off" while confirm-
ing by a click on the output number and while validating on
The following actions configured beforehand in chapter 4.10.1(Alert Setup) will be thus carried out as
follows:
Output: An output is switched "off" (If the measured value exceeded the configured limits in the
field "Level 1 & 2"). If the measured value falls under the limit, the output is switched "on" again.
Out, hold: An output is switched "off" (If the measured value exceeded the configured limits in
the field "Level 1 & 2"). If the measured value for this output falls under the limit, the output remains switched "off". Only a manual deleting of alarm allows that the output is switched "on"
again (see chapter 4.11 or 3.6).
Output & SMS: An output is switched "off" (If the measured value exceeded the configured limits
in the field "Level 1 & 2"). If the measured value falls under the limit, the output is switched "on"
again. In addition, an SMS is sent to the number indicated.
Out, hold & SMS: An output is switched "off" (If the measured value exceeded the configured
limits in the field "Level 1 & 2"). If the measured value for this output falls under the limit, the output remains switched "off". Only a manual deleting of alarm allows that the output is switched
"on" again (see chapter 4.11 or 3.6). In addition, an SMS is sent to the number indicated.
Data in the tree
with
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4.10.7. Device Setup (Clock settings)
In the menu
, you can modify the date and the time on each HYDROCAL 1002-1003.
The field "Daylight Saving Time Mode" allows to configure the following time mode :
MET (Middle European Time) adjusts the official local time forward, one hour from its official
standard time for the duration of the spring and summer months.
The field "Clock offset" allows modifying time zone. The time zone values are between -6 and +6
hours. Note: "None " means that the function is not activated.
Moreover, you can synchronize the date and time on each HYDROCAL 1002-1003 with PC clock
while confirming by a click on the field "Synchronize with PC clock" in the following communication
box:
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Data in the tree
with
4.11. Data transmission from / to the HYDROCAL 1002-1003 unit

For transmission of data, the respective transformer menu must be selected in the root. In the lower
part of the window, there are three selection buttons available for communication.
Pressing button
the connection is initiated and the following selection box is opened:
In the dialogue, the following actions can be selected:

Read Configurations: Read configurations from HYDROCAL 1002-1003 unit. This means that
the modifications of alarms and sensor settings made in HydroSoft (indicated by a star) are overwritten by the settings active in the Hydrocal unit.
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Read History and Alerts: All measured and stored values, not downloaded previously, are read
and stored in the database of HydroSoft.
Update Configuration: All sensor and alarm modifications made in HydroSoft are transferred to
the HYDROCAL unit and activated there. Input of a numerical password is necessary for this action (Default password is 999).
Reset Alert: This command resets all alarms on the HYDROCAL unit which have not previously
been acknowledged. Input of a numerical password is necessary for this action (Default password
is 999).
Auto disconnect when done: Disconnects automatically the line after data transmission. It is recommended that this field is always selected when using modem connections in order to save on
transmission costs.
Synchronize with PC clock: synchronize automatically the date and time on the unit with internal
PC clock. Input of a numerical password is necessary for this action (Default password is 999).
After confirmation by the Start button, the status of communication will be presented in the window.
By pressing the button
connection is interrupted. This must be avoided during Login. After
interruption, the log-data must be closed by button

case of communication problems.
. The log-data is used for error tracing in
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4.12. View of results

To view measured results read out, you must select the History field of the respective transformer.
Three operation elements are available (see below picture)
4.12.1. Sensor selection

This window shows the different sensors available on the HYDROCAL unit. Besides the sensor
name, the last measuring value is displayed; this means after having read-out data this is the last
measured value. On the left of the sensor name is an activation mark (e.g.
: H2 sensor is activated for data presentation). By double clicking on a sensor name, the sensor is activated / deactivated for presentation. In this case, the left vertical scale is used. Open by a right mouse button click
on a sensor name the menu for allocation to different Y-axis or deactivation as well as to change the
color.
4.12.2. Time range selection

The time range for presentation is selected in two steps.
Selection of the time range the field Time Span. Available are:
1 hour, 2 hours, 3 hours, 6 hours, 12 hours, 1 day, 2 days, 3 days, 1 week, 2 weeks, 3 weeks, 1
month, 2 months, 3 months, 6 months, 1 year, 2 years and all data.
Selection of date of start by mouse click on a date. Using arrow buttons in the calendar dialogue,
the following or the next month is presented.
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4.12.3. Result window

The result window shows all sensor results activated for presentation. The results are presented in
form of time trend or graph tables. When on the result window, click the right mouse button to open
the menu and select the form desired. There is also the possibility to activate the print-function (only
from trend.....) or export function (only from graph table) and to fade out the sensor and time selection.
4.12.4. Print and export of results

There exist two possibilities to process measuring data for the purpose of documentation:
From the table view, data can be exported to MS Excel or as a text file. Export to Excel can be
activated either from the menu or by File->Export->Excel. Export into a text file is possible only
by File->Export->CSV.
Data can be printed directly from the trend view.
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4.13. View of alarm status

To view alarms, you must select the list Alert under the corresponding transformer. The operation
elements are same as indicated under View of results.
Under Alarm selection the different alarms defined and selected on the HYDROCAL unit can be
activated in form of time trend and table views. In the time range selection, the time to be viewed is
defined and results are presented in the alarm window.
4.13.1. Alarm selection

The alarm selection window presents the different alarms available on the HYDROCAL unit. On the
right side of the alarm name, the last alarm status is shown; this is the current status at the time of
data retrieval. On the right side of the alarm name is to be found a status and activation mark is displayed (e.g. : : alarm status 0 is activated for presentation, : alarm status 0, is deactivated for
presentation, : alarm status 3 is activated). The alarm name can be activated / deactivated for
presentation by a double click. The menu is opened with right mouse button.
4.13.2. Time range selection

The time range for presentation is selected in two steps.
Selection of the time range the field Time Span. Available are:
1 hour, 2 hours, 3 hours, 6 hours, 12 hours, 1 day, 2 days, 3 days, 1 week, 2 weeks, 3 weeks, 1
month, 2 months, 3 months, 6 months, 1 year, 2 years and all data.
Selection of start date by mouse click on a date. Using arrow buttons in the calendar dialogue, the
following or the next month is presented.
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4.13.3. Alarm window

The alarm window shows all alarm status activated for presentation. The results are presented in
form of a time trend chart or a table. When on the alarm window, click right mouse button to open the
menu and select the form desired. There is also the possibility to activate the print-function (only from
time trend chart) or export function (only from table view) and to fade out the sensor and time range
selection.
4.13.4. Status of alarms

Five different alarm status are presented in both View as table and in View as graph. The meaning
of the different status is described as follows:
Status 0: No alarm active, the limits for the alarm have not be exceeded in the past or an alarm
existing has been acknowledged.
Status 1: The limit defined for a High - Alarm was exceeded in the past, but value has fallen
below the limit.
Status 2: The defined Level 2 for a High - High - alarm has been exceeded in past. The value
has fallen below the Level 2, but is still higher than Level 1.
Status 3: The limit defined for a High - Alarm is currently exceeded.
Status 4: The defined level for a High - High - Alarm is currently exceeded.

4.13.5. Print and export of results
There exist two possibilities to process measuring data for the purpose of documentation:
From the table view, data can be exported to MS Excel or as a text file. Export to Excel can be
activated either from the menu or by File->Export->Excel. Export into a text file is possible only
by File->Export->CSV.
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4.14. Online Sensors

To view a direct/online visualisation, you must select the list Online Sensors under the corresponding transformer. The operation elements are same as indicated under View of results.
Under visible sensors the different measuring values (H2, CO, C2H2, C2H4 and H2O) and external
sensors defined in Sensor setup and selected on the HYDROCAL unit can be activated in form of
graphical view.
To activate Online visualisation, you must first of all select the right connection settings (See chapter
4.9) and then click on Start button. You can define followings settings:
Visible Time Span
Graph Width in second (s)
Recording Time Span
Recording time in hour (h)
Page 85 of 97
5. RS232 / RS 485 Wiring

This chapter contains information for the wiring of the connections.
RS232
The connection via RS232 is done using the communication cable that is shipped together with the
HydroCal device. This cable is designed to be directly plugged into a sub-D 9-pin male connector for
an RS232 interface found on standard personal computers (or USB-to-serial adapters).
RS485
The RS485 interface is implemented as a two-wire interface. The two signal wires must be clamped
onto connector #7, pin 5.1 A() and pin 5.2 B(+) inside of the HydroCal. Care must be taken for the
right polarity.
Termination, Biasing, Grounding and Protection of an RS485 Bus

Termination, biasing, grounding and protection of an RS485 Bus is a complex thing and far beyond
the scope of this document. A very good source of information related to these issues can be found
at www.bb-elec.com (see the section Tech Notes).
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6. Vaisala sensors connection on HYDROCAL 1002

The connection of Vaisala moisture sensor is depending of the type
6.1 MMT318
The Vaisala moisture sensor type MMT318 has no integrated power supply. In order to energize it on
Hydrocal 1002, an integrated GSM-/Net module is used. The wiring of cables for power and signal
wires between Hydrocal 1002 and Vaisala moisture sensor is shown as follow on the diagram.
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6.2 MMT338
The Vaisala moisture sensor type MMT338 has an integrated power supply. The wiring of
signal lines between Hydrocal 1002 and Vaisala moisture sensor is shown as follow on the
diagram.
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7. HYDROSOFT Scheduler
7.1 General
Up to version 1.0.16 the transfer of the history data from the Hydrocal device into the Hydrosoft application could only be started manually.
With version 1.0.18 an automatic read-out of the history data is possible. This is managed by the new
scheduler integrated into Hydrosoft.
In conjunction with the task scheduler provided by the Windows operating systems, the history data
can be held up to date automatically.
7.2 Scheduler
The scheduler is active in the background. It periodically checks all transformers for pending history
data transfers. If an update is awaiting a connection to the Hydrocal is established and the history
data read-out is executed.
Remark: It is not possible to update the configuration, to reset alerts or to synchronize the real timer
clock by the scheduler - these actions still must be carried out manually.
7.2.1 Configuring a Transformer for automatic History Data Update

To configure the automatic history data read-out for a transformer, the connection scheduler dialog is
used. To launch the dialog, the transformer main page must be activated by selecting the corresponding transformer in the tree view.
The dialog is accessible via the main menu (Transformer -> Scheduler...) or by clicking the rightmost
button in the control area of the transformer window.
7.2.1.1 Connection Scheduler Dialog
The connection scheduler dialog allow to configure the automatic history data read-out. (For further
details on the setting see 0, 7.2.4 Internal Operation.)
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The checkbox Scheduled Data Read-Out en- or disables the automatic history data update.
The combo box Connect Interval allows the selection of the time span between read-out actions.
After a successful history data update the next connection time is calculated by adding the selected interval time span to the current time.
If the Connect Interval is at least one day, a connection time can be set in the text box Connect
Time. The format for the time is hh:mm:00 (seconds must be zero). When a connect time is set,
the time-of-day for the next connection will be set to the specified value. If no special time-of day
is required, a dash must be entered ('-').
The Data Read Timeout has the same meaning as in the manual communication and defines a
time when the connection has to be regarded as broken - leading to an error abort of the communication. For direct connections 5 seconds should be used - for a modem connection at least 15
seconds are reasonable.
The text box Next Connect at shows the date and time of the next connection.
Remark: If a test of the scheduler communication is desired, a double-click on the text box will
change the date and time so that the communication will be scheduled in the near future (dialog
must be closed with OK to accept the change).
The text box Connect Fail Count shows the number of connection failures.
Remark: A double-click on this text box can be used to reset the failure counter to zero (dialog
must be closed with OK to accept the change).
7.2.2 Scheduler Status Visualization

The status of the scheduler is visualized in the tree view by changing the icons of the customer, the
stations and the transformers.
7.2.2.1 Status Icons
The status of transformers, stations and the customer is reflected by special icons. The following description explains the meaning of the different icons.
7.2.2.1.1 Transformer
The standard icon is used for transformers that are not activated for scheduled history data update.
The read-out status is good. (The number of connection failures is less than 3.)
,
The read-out status is bad. A connection has been tried several times but was not successful.
The icon will be yellow (red) if the number of connection failures is greater then 2 (5).
A read-out is pending. The transformer has been marked for a communication and the history data update will be started in the near future.
- This status overrules the good/bad-status.
The transformer is currently busy in scheduler communication. The history data update is in
progress.
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The transformer is currently busy in a non-scheduler communication (manual connection or online sensor graph running).
- This status overrules the good/bad/pending-status.
7.2.2.1.2 Station
The station icon is derived from the status of the transformers that are members of the station and
activated for scheduled history data update.
If a station does not contain any transformer that is activated for scheduled history data update, it
is shown with the standard icon.
The read-out status of all scheduled transformers of the station is good.

,
The read-out status of at least one scheduled transformer of the station is bad.
A read-out is pending for at least one transformer of the station.

- This status overrules both the good/bad-status.
A transformer in this station is currently busy in a scheduler communication.

7.2.2.1.3 Customer
The customer icon is derived from the status of all transformers activated for scheduled history data
update.
The scheduler is active and idle. No communication is pending or active.
The scheduler is active and waiting for the next pending communication to be started.
A transformer is currently busy in a scheduler communication.

7.2.2.2 Example
The following screen shots illustrate the scheduler operation.
The scheduler is active (clock icon) and has scanned the transformers. The pending communications
(Station1 and Transformer4 icon with clock) are marked. Station2 does not contain any scheduled
transformers.
The scheduler has started the communication for Transformer1 in Station1 (all related icons indicate
the active scheduler communication). The communication buttons in the transformer window control
Page 91 of 97
area are disabled. The control area is shown with an alternate background colour to indicate the busy
status.
The communication with Transformer1 in Station1 has failed more than 5 times. The transformer as
well as the station are marked with failure indication icons (red station, red transformer).
7.2.3 Hydrosoft and the Windows Task Scheduler

To fully automate the history data update, Hydrosoft can be regularly invoked via the task scheduler
available in the Windows operating system.
Windows provides a wizard to set up a task. Follow the instructions to create an entry for Hydrosoft.
The timing setup for the Windows task depends on the personal needs and the setup of the scheduled history data update in Hydrosoft. If for example a daily update is configured in Hydrosoft the
Windows task must also invoke Hydrosoft every day.
After the entry has been created with the help of the wizard, the new command line options may be
applied to tune the Hydrosoft task.
Remark: Prior to setting up a Hydrosoft task it should be checked that the communication setup for
the transformers is correct and it should be proved that the communication is working.
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7.2.3.1 Command Line Options for Windows Task Scheduler

Hydrosoft comes with two new command line options for use in conjunction with the scheduled history data update.
Example:
<path>\Hydrosoft -IdleClose 0:15:00 -Minimized
7.2.3.1.1 IdleClose
The IdleClose command line option can be given to let the application terminate after all history data
updates have be carried out. Following the command line option, a time span argument must be
supplied, that defines the idle close time. The syntax for the close time is [hh:[mm:]]ss.
When the Hydrosoft scheduler scans the transformers for pending history data updates, it determines
the shortest time span, when the next communication has to be started. If this time span is greater
than the idle close time, the application exits. When a daily update is configured a reasonable default
for the idle close time is 15 minutes. This would allow for repeated communication tries (in case of
failure), but exit, when the communication fails too often.
7.2.3.1.2 Minimized
The Minimized command line option can be given to let the application start minimized.
Remark: This option will also suppress the warning message, if the Hydorsoft data directory is in use
by a manually started Hydrosoft application. A Windows task scheduler started instance of Hydrosoft
can immediately exit, if a manually started Hydrosoft application is already running.
7.2.4 Internal Operation

This is a more detailed description of the internal operation of the scheduler (the terms in italics are
related to the data configured in the connection scheduler dialog).
The scheduler runs as a separate thread in the background of Hydrosoft. Approximately every 15
seconds all transformers are checked if scheduled data read-out is active. Once a transformer is active, a further check is made, whether the current time is greater than the next connect at time. This
way a list of pending connections is generated.
If the list of pending connections is non empty, it is processed step by step, i.e. the list is traversed
and all pending connection requests are executed before a new list is build.
For each transformer a try to update the data is done. On success the connect fail count is set to
zero and the next connect at time is updated (current time plus connect interval - optionally aligned to
the connect time).
In case of an error the connect fail count is incremented and the next connect at time is set based on
the current connect fail count. If the count is less than 3, a connection retry with 5 minutes delay is
set, for a count less than 5 the retry is scheduled in 10 minutes. If the count exceeds 5, the next retry
is scheduled to the current time plus the connect interval (- optionally aligned to the connect time, i.e.
the same time as if the connection had succeeded).
When the scheduler detects, that a time span of 3 times the connect interval has expired since the
last start of the application, the connect fail count is reset to 4. This will lead to a double communication try for a transformer with a bad status when the application has not been used for a longer time
period.
Because of the internal operation the following notes apply:
Changes applied through the connection scheduler dialog take some time until they are reflected
in the tree view.
Even if the read-out status of a transformer is bad, there will always be a try to update the data
with the configured connect interval.
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A manual update of the history data does not update the next connect at time of the scheduler.
Even if an update occurs immediately before the next connect at time, the scheduled data readout will still be executed.
A log file 'Scheduler.log' is created in the root if the Hydrosoft data directory. If a problem arises with
the scheduler a look into this file may help finding the cause. The log file entries are always written in
English.
7.2.5. Data Directory Lock

Hydrosoft now protects the data directory by a lock. Once an instance of Hydrosoft is working on a
data directory no second instance of Hydrosoft can operate on the same data.
This locking is introduced to keep data integrity in case a user is running Hydrosoft and a background
instance of Hydrosoft (started via the Windows task scheduler) also tries to work on the data.
Hydrosoft will exit with a return code of 2 if the data directory is locked.
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8. Technical data HYDROCAL 1002-1003

Measuring quantities
Hydrogen H2:
Carbon Monoxide CO:
Moisture-in-Oil H2O:
Measuring range
0 ppm ... 2.000 ppm
0 ppm ... 2.000 ppm
absolute 0 ppm-100ppm
Measuring accuracy
15 % of the measuring value 25 ppm
(related to oil temperature of +55C)
Measurement interval: 20 min.

Operation temperature: Oil temperature:
-20C ... +90C
Ambient temperature:
-50C ... +55C (below -10C display function locked)
Temperature coefficient: 1%/K
Oil pressure:
0-800 kpa, no vacuum allowed
Functions:
Individual gas-in-oil concentration measurement for H2 and CO
Gas trend analysis (chart / bar diagram)
Different alarm level configuration
RS 232 communication and modem communication (GSM, analogue
modem) to central PC Windows software
Outputs:
3 x analogue outputs:
0/4... 20mA (H2 concentration)
0/4... 20mA (CO concentration)
0/4... 20mA (H2O concentration) with HYDROCAL 1003
1 x analogue outputs:
0/4... 20mA (free configurable)
U Max:
6V
Impedance:
300 Ohm
12 x digital outputs:
4 x 12 V relay outputs
Maximum switching values:
220 V DC, 220 V AC, 2 A, 60 W
8 x opto-coupler outputs
Maximum Current: 40 mA
UCE 24 V Rated voltage (35 V maximum)
UEC 7 V (maximal)
Alarms:
H2 Alarm (H)
H2 Daily trend
H2 Weekly trend
CO Alarm (H)
CO Daily trend
CO Weekly trend
(1st level and 2nd level alarm)

1. Alarm level & 2. Alarm level
Inputs:
4 x analogue inputs:
4 x analogue inputs:
0/4 ... 20 mA
0/4 ... 20 mA / 0 ... 10 V
(configurable by jumpers)
Gas-in-oil:
Moisture-in-oil Monitor:
3 x internal gas sensors (redundant system) 2 x H2, 1 x CO

1 x internal moisture sensor
2 x internal temperature sensors (oil temperature, gas temperature)
RS 232 (external connection, no unmounting of protective cover required)
RS 485 (bus-operation or point-to-point operation, MODBUS or proprietary protocol)
Internal on board modem (GSM, 14.4 kBit / analogue 56 kBit)
IP 55
88 VACmin 276 VACmax
Optional: 88 VDCmin 390 VDCmax
Communication:
Protection class:
Power supply:
Page 95 of 97
Dimensions:
Weight:
max. 350 VA, 50/60 Hz

approx. W 215 x H 215 x D 215 mm
approx. 8 kg
Page 96 of 97
9. Dimensional Drawings HYDROCAL 1002-1003
Page 97 of 97

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Gas-in-Oil Analysis System with

HYDROCAL 1002-1003: Manual for Installation and Operation

Copyright MTE Meter Test Equipment AG

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HYDROCAL 1002-1003: Manual for installation and operation

Configuration of user settings ...................................................................................... 21

History of alarms ......................................................................................................... 24

Device set up ............................................................................................................ 25

Hot Spot calculation ............................................................................................... 27

Ageing Rate / Loss of Life ...................................................................................... 29

Configuration of analogue outputs ......................................................................... 29

Configuration of analogue inputs (external sensors) ............................................. 30

Configuration of alarms and digital outputs ............................................................ 33

Flange Heating Base Temperature .................................................................. 37

Flange Heating Base Temperature ..................................................................... 37

Device options .................................................................................................... 37

Clock settings ..................................................................................................... 39

Configuration of the communication ................................................................... 40

Alert SMS setup ........................................................................................... 41

Internal modem setup ................................................................................... 41

4.10.7. Device Setup (Clock settings) ......................................................................................... 78

HYDROCAL 1002-1003: Manual for installation and operation

HYDROCAL 1002-1003: Manual for installation and operation

2. Mounting of HYDROCAL 1002-1003 unit

On return side of cooling circuit:

Flange below on the transformer tank:

Upper filling valve:

HYDROCAL 1002-1003: Manual for installation and operation

2.2 Security precautions for installation

Never close the aeration hole for oxygenation.

HYDROCAL 1002-1003: Manual for installation and operation

Never apply a negative pressure to the measuring head.

HYDROCAL 1002-1003: Manual for installation and operation

Never use a chaining key tool for mounting.

2.3 Preparation for installation

HYDROCAL 1002-1003: Manual for installation and operation

2.4 Installation of the HYDROCAL 1002-1003 unit

Only remove the protection cap (slowly while turning)

HYDROCAL 1002-1003: Manual for installation and operation

Clean the internal side of the installation valve.

Do not use any solvents for cleaning!

HYDROCAL 1002-1003: Manual for installation and operation

Attention, danger of burning!!!

HYDROCAL 1002-1003: Manual for installation and operation

2.5 Front view of HYDROCAL 1002-1003

HYDROCAL 1002-1003: Manual for installation and operation

2.6 Rear side of HYDROCAL 1002-1003 unit

Serial interface RS232

HYDROCAL 1002-1003: Manual for installation and operation

2.7 Connections on the measuring and controller card

(Analogue input 1 (-))

HYDROCAL 1002-1003: Manual for installation and operation

Oil temperature sensor

(Oil temperature sensor (+))

(Analogue output 1 (+))

HYDROCAL 1002-1003: Manual for installation and operation

Connector ST 301: Interface RS232

GSM/GPRS-module / GSM antenna

(GSM/GPRS-module / GSN antenna)

HYDROCAL 1002-1003: Manual for installation and operation

3. Software on Hydrocal unit

5664[Byte / day ] + 288[Byte / day ] Sensorstoragesn [1 Std ]

HYDROCAL 1002-1003: Manual for installation and operation