HYDROCAL 1001+ Composite Gas-in-Oil Sensor With Moisture in Oil Measurement Installation and Operation Manual

HYDROCAL 1001+
Composite Gas-in-Oil Sensor with

Moisture in Oil Measurement
Installation and operation manual
HYDROCAL 1001+ Installation and operation manual Edition RS485 01.2015

MTE Meter Test Equipment AG
Dammstrasse 16
CH-6304 Zug
Switzerland
Phone: +41-41-724 24 48
Fax: +41-41-724 24 25
Email: support@mte.ch
EMH Energie-Messtechnik GmbH

Vor dem Hassel 2
D-21438 Brackel
Germany
Phone: +49-4185-5857-0
Fax: +49-4185-5857-68
Email: info@emh.de
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 Customs tariff number:
or their consequences 9027.1010
HYDROCAL 1008 Manual for Installation and Operation Page 2/114

Table of Content
1. General..................................................................................................................................... 3
2. Installation instructions .......................................................................................................... 4
2.1. Installation positions ............................................................................................................. 4
2.2. Safety precautions ................................................................................................................ 5
2.3. Installation preparation ......................................................................................................... 7
2.3.1. Mechanical connection .................................................................................................. 7
2.3.1.1. Flange connection .................................................................................................. 7
2.3.1.2. Fitting with union nut ............................................................................................... 7
2.3.2. Auxiliary supply connection ........................................................................................... 8
2.3.3. Required tools ............................................................................................................... 8
2.3.4. Sealing the connection thread ....................................................................................... 8
2.3.4.1. Thread seal tape..................................................................................................... 8
2.3.4.2. Thread sealant ....................................................................................................... 9
2.3.4.3. Flat sealing (gasket) ............................................................................................... 9
2.4. Installation .......................................................................................................................... 10
2.4.1. Mechanical installation................................................................................................. 10
2.4.1.1. Direct installation .................................................................................................. 11
2.4.1.2. Indirect installation ................................................................................................ 12
2.4.2. Electrical connection .................................................................................................... 14
2.4.3. Putting into operation ................................................................................................... 15
3. Hardware components.......................................................................................................... 16
3.1. Front view ........................................................................................................................... 16
3.2. Rear view ........................................................................................................................... 17
3.3. Connections of measurement- and controller card.............................................................. 19
3.3.1. Beeper ......................................................................................................................... 22
3.4. Connections of power supply card ...................................................................................... 23
3.5. Wiring of the heating resistors ............................................................................................ 24
3.5.1. Wiring heating resistors for 230 V ................................................................................ 25
3.5.2. Wiring heating resistors for 120 V ................................................................................ 26
4. Firmware ................................................................................................................................ 27
4.1. General information ............................................................................................................ 27
4.2. External user interface ........................................................................................................ 27
4.2.1. Function LED .............................................................................. 28
4.2.2. Gas LED ..................................................................................... 28
4.2.3. Moisture LED .............................................................................. 30

4.3. Internal user interface ......................................................................................................... 31
4.3.1. Normal Operation ........................................................................................................ 32
4.3.1.1. LED & energy save mode ..................................................................................... 32
4.3.1.2. LED Ethernet ........................................................................... 32
4.3.1.3. LED RS485 ............................................................................. 32
4.3.1.4. LED Gas analog output .......................................................... 33
4.3.1.5. LED Moisture analog output .................................................... 33
HYDROCAL 1001 Manual for Installation and Operation Page 1/72

4.3.1.6. LED bar level - Gas .................................................... 34
4.3.1.7. LED bar levels - Moisture ........................................... 46
4.3.2. Special Operation ........................................................................................................ 47

4.3.2.1. Unit Power-On - Boot ........................................................................................... 47
4.3.2.2. Update of Firmware - Downloader ........................................................................ 48
4.3.2.3. Update of Firmware - via TFTP............................................................................. 50
4.3.2.4. Functional Test ..................................................................................................... 51
4.3.2.5. Test Mode ............................................................................................................ 53
4.3.3. Communication Interface Reset ................................................................................... 56
4.4. Default Communication Interface Setup.............................................................................. 57
4.5. Establish a Point-to-Point Ethernet Connection .................................................................. 58
4.5.1. Setup HYDROCAL 1001+ ........................................................................................... 58
4.5.2. Change of TCP/IP Settings on the PC ......................................................................... 58
4.5.2.1. Navigating to the Network Adapter Properties ...................................................... 59
4.5.2.2. Changing the Network Adapter Properties ............................................................ 61
4.5.3. Test of Communication with Hydrosoft ........................................................................ 62
4.5.4. Diagnosis / Trouble Shooting ....................................................................................... 63
4.5.4.1. Basic Checks........................................................................................................ 63
4.5.4.2. Check of PC Network Adapter Setup .................................................................... 63
4.5.4.3. Low Level Connection Test (PING) ...................................................................... 64
4.6. Communication setup ......................................................................................................... 65
4.6.1. RS485 setup................................................................................................................ 65
4.6.1.1. Point-to-Point........................................................................................................ 65
4.6.1.2. Bus Node ............................................................................................................. 66
4.6.1.3. MODBUS RTU ..................................................................................................... 67
4.6.1.4. MODBUS ASCII ................................................................................................... 68
4.6.2. ETHERNET setup ....................................................................................................... 69
4.6.2.1. Static IP ................................................................................................................ 69
4.6.2.2. DHCP Client ......................................................................................................... 70
4.6.3. MODBUS® TCP ........................................................................................................... 71
4.6.3.1. Function, Register and Address Mapping ............................................................. 71
5. Technical data ....................................................................................................................... 73
6. Dimensional Drawings .......................................................................................................... 75
6.1. Dimensions of valve connection ......................................................................................... 76
6.1.1. Connection thread G 1½’’ ISO DIN 228-1 .................................................................... 76
6.1.2. Connection thread 1½’’ NPT ANSI B 1.20.1 ................................................................ 76
HYDROCAL 1001+ Installation and operation manual Page 2/76

1. General
The HYDROCAL 1001+ is a permanently installed composite gas-in-oil sensor for the analysis of
moisture in oil and the following dissolved key fault gases (TDCG = Total Dissolved Combustible
Gases):
Fault gas TDCG contribution
Hydrogen (H2) approx. 20 %
Carbon Monoxide (CO) approx. 30 %
Methane (CH4) <5%
Acetylene (C2H2) 100 %
Ethylene (C2H4) approx. 32 %
Ethane (C2H6) <5%
Moisture in Oil (H2O) 100%
To provide an even more comprehensive transformer monitoring solution, the HYDROCAL 1001+
analyses additionally the content of moisture (H2O) in the transformer oil.
The integration of 6 relevant key gases into a total weighted gas concentration and the measurement
of moisture in oil, enables the HYDROCAL 1001+ to react to most transformer faults and makes the
unit to a compact and cost effective tool used in particular for early transformer fault detection and
preventative maintenance.
The HYDROCAL 1001+ is equipped with 2 analog 0/4 ... 20 mA outputs for the dissolved composite
gas-in-oil and moisture in oil analysis results and 4 digital relay outputs (Gas high alarm, gas high-
high alarm, moisture alarm and function alarm)
Key advantages:
 Composite measurement of hydrogen (H2), carbon monoxide (CO), methane (CH4), acetylene
(C2H2), ethylene (C2H4) and ethane (C2H6) and dissolved moisture (H2O) in the transformer oil
 Relay outputs with light indicators showing potential alarms
 Easy and fast installation without any operational interruption of the transformer
 It provides communication interfaces ETHERNET 10/100Mbit/s (copper-wired or fibre-optical) and
RS485 to support proprietary communication protocols and to be prepared for sub-station com-
munication protocols MODBUS®TCP and MODBUS® serial RTU/ASCII
The construction has been significantly simplified and size has been reduced compared to other
products in the market period.
The present operating instructions are divided in the following sections:

 Installation instructions (chapter 2)
 Hardware components (chapter 3)
 Firmware (chapter 4)
 Technical data (chapter 5)
 Dimensional drawings (chapter 6)

2. Installation instructions
2.1. Installation positions
To ensure the correct function of a HYDROCAL unit the installation position is very important. On a
typical transformer three positions are possible:
Pos. 1 Output side of cooling unit:

Please install the unit on a straight piece of pipe 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 output of the oil circulation pump.
Note: Choose this position only if a continuous oil flux through the cooler is guaranteed
Pos. 2 Draining valve on the transformer tank:
The flange of the draining valve must be at minimum height of 40 cm in order to allow in-
stallation and mounting of HYDROCAL unit.
Pos. 3 Upper filling valve:
It is possible to mount HYDROCAL unit on this position, if the filling level of the oil is min.
100 cm higher than the center of the connection thread.
This position is not recommended, because it may be difficult to operate the unit.
Pos. 4 Input side of cooling unit:
Never install the HYDROCAL unit on top of the cooling unit or on the suction side of
the cooler pump!
Note: On the installation position a good and continuous oil circulation must be present.

2.2. Safety precautions
The following security precautions must be strictly observed during the installation. Otherwise no war-
ranty claims will be accepted.
Never remove the protection cap from the connection thread until you are
ready to mount the unit on the transformer valve.
The protection cap protects the connection unit against dust and from other
impurities. Additionally it protects the connection thread.
Note: Use the protection cap also after dismounting the unit.
Never close the aeration hole for oxygenation. It is situated on the bottom
side of the protection cover.
Never use or stock chemicals with hydrocarbon contents near the meas-
uring sensor.
Never clean the HYDROCAL unit with solvents, because its gases will strongly
impair the measurement accuracy and the sensitivity of the sensors.
Never apply a negative pressure to the connection unit.

Negative pressure can damage the membrane.
Never touch the membrane with fingers or other objects.

Remove the HYDROCAL unit from the valve every time you degas or refill
the transformer. You can also close the transformer valve.
Never operate the HYDROCAL unit on a valve that is closed for a long
period of time. Remove the unit if this cannot be avoided. Please refer to
the de-installation instructions.
Never install the HYDROCAL unit on the suction side of the cooling
pump!!
Never install the HYDROCAL unit on an elbow or curve of a tube.

Turbulences in a tube curve can create a negative pressure, which can dam-
age the membrane.
Never install or remove the HYDROCAL unit without opening the aeration
screw first.
Never use galvanized fittings or valves to mount the HYDROCAL unit.

Galvanized fittings or valves can react with oil, this will produce incorrect
measurement values.
Never clean the HYDROCAL unit with high pressure cleaning equipment.
High pressure cleaning equipment used to clean transformers can seriously
damage the HYDROCAL unit.
Never use a chaining key tool for mounting.

Use of such tools can damage the surface of the connection unit and the
threads. Please use a tin spanner M55 or an adjustable tin spanner for 1 ½“.
Attention!!!
Faulty or inappropriate handling of the connection unit, like malfunction
by negative pressure, paint or solvent liquids make the warranty invalid.

2.3. Installation preparation
Attention!!!
Always open the aeration screw first!!!
Before installation, a visual inspection of the membrane must be carried out. Open the aeration screw
3 to 4 turns while turning CCW with a long Allen key No. 4. Slowly remove the protection cap while
turning CCW and check the membrane. No cuts or tears should exist, the surface must be smooth.
Do not touch the membrane with fingers or with any other objects. Unscrew the knurled thumb
screws, remove the protection cover and check visually the components. For the installation remount
the protection cover and fasten it with the knurled thumb screw.
2.3.1. Mechanical connection
The external thread type of the HYDROCAL connection unit is even G 1½’’ ISO DIN 228-1 or
1½’’ NPT ANSI B 1.20.1 (must be specified when ordering).
The HYDROCAL unit should be installed on a gate valve with full bore or on a ball valve to the trans-
former.
These locking elements are usually provided with a blind flange. Therefore they must be upgraded
before mounting the HYDROCAL unit with a corresponding threaded flange, connection adapter or a
fitting with union nut.
This results in two different mounting ways (direct and indirect).
2.3.1.1. Flange connection
The unit is screwed directly onto the threaded flange, i.e. the unit is rotated around its own axis in
order to fix it. In this type of installation the space around the center of the connection unit must be
free in a diameter of 280 mm.
Note: The thread depth of the threaded flange or the connection adapter should be at least 25 mm.
2.3.1.2. Fitting with union nut
We recommend installing the HYDROCAL unit with a fitting with union nut (flat sealing) to the trans-
former gate / valve. This fitting consists of a threaded flange, a flat sealing union end and a union nut.
In this case the union nut must be rotated to fix the HYDROCAL unit and a gasket is used to seal the
connection. An additional thread sealing with thread seal tape or thread sealant is not or rarely nec-
essary in this case.
Note: Ball valves with union nut are also available (pump ball valve).

2.3.2. Auxiliary supply connection
The HYDROCAL unit is available in 4 different voltage versions (must be specified when ordering).
Depending on the used nominal voltage version there must be an AC or DC power supply with a 3
pin power cable (2.4.2) close to the HYDROCAL unit:
Nominal voltage version HYDROCAL Auxiliary supply voltage
120 V -20% +15% AC 50/60Hz 96 Vmin ... 138 Vmax AC 50/60Hz
230 V -20% +15% AC 50/60Hz 184 Vmin ... 264 Vmax AC 50/60Hz
120 V -20% +15% DC 96 Vmin ... 138 Vmax DC
230 V -20% +15% DC 184 Vmin ... 264 Vmax DC
The power consumption of the HYDROCAL 1001+ unit is max. 250 VA.
Micro-fuse: 120V: T3.15A (slow blow) 230V: T2A (slow blow)
2.3.3. Required tools

The mechanical and electrical installation of the HYDROCAL unit can be executed with following
tools and utilities:
 Long Allen key No. 4  Aeration screw (bleeding screw)
 Digital Multimeter  Checking supply voltage
 Screw driver No. 2  Main connectors supply voltage cable
 Brass brush  Connection unit
 Tin spanner M55 and / or  Connection unit
adjustable tin spanner 1 ½“
 Bucket, oil absorber, cleaning rag,  To absorb/clean the out coming oil
paper towel
 Plastic sheet  To collect dropping parts
2.3.4. Sealing the connection thread

Securing and sealing the connection threads may be implemented in various ways. It should be used
either a thread seal tape or a thread sealant:
2.3.4.1. Thread seal tape
The thread seal tape, also known as Teflon tape or PTFE tape (Polytetrafluoräthylen), is wrapped
tightly around the external thread of the HYDROCAL connection unit. We recommend using a Teflon
tape for coarse thread (100g/m2).
Attention !!!
If you use Teflon tape for sealing the connection thread,
nothing can be adjusted after wards.
!!!! Risk of leakage !!!!

2.3.4.2. Thread sealant
As a thread sealant we recommend the two Henkel products LOCTITE® 7471 (activate) and
LOCTITE® 577 (seal and fix) in combination. The activator LOCTITE® 7471 is used to increase the
rate of cure and is applied before the actual thread adhesive LOCTITE® 577 is applied on 3 to 4 turns
of the external thread of the HYDROCAL connection unit.
Attention !!!
Please follow the instructions of the manufacturer!!!
2.3.4.3. Flat sealing (gasket)

When using a fitting with union nut the sealing and locking of the threaded connection with thread
seal tape or thread sealant is not necessary anymore. In this case the gasket serves as sealing and
the union nut as fixation of the connection.

2.4. Installation
After the installation preparation is completed, the HYDROCAL unit can be installed. The installation
is divided into 3 steps:
 Mechanical installation (2.4.1)
 Electrical connection (2.4.2)
 Putting into operation (2.4.3)
2.4.1. Mechanical installation

The sequence of the mechanical installation depends on which connection type is available on the
transformer side. There are basically 2 types of mechanical installation:
 Direct installation (2.4.1.1)
 Indirect installation (2.4.1.2)
Note: In case there are strong vibrations on the connection valve, the valve should be relieved by a
support.
A good oil flux should exist on the installation position. 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 backplate unit 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).

2.4.1.1. Direct installation
Direct installation means, the unit is screwed directly onto the threaded flange, i.e. the unit is rotated
around its own axis in order to fix it. In this type of installation the space around the center of the
connection unit must be free in a diameter of 280 mm.
The connection thread can be sealed and fixed using either a thread seal tape or a thread sealant.
Attention!!!
Attention!!!
Only remove the protection cap (slowly while turning) when to aeration
screw is open and you are ready to mount the HYDROCAL unit!
Then mount the unit according to the following steps (sequence description with Teflon tape):
 Clean the inside of the threaded flange with a dry cleaning rag or paper towel.
 Clean the outer thread of the connection unit with a dry cleaning rag or paper towel. Remove
any remaining of thread sealing tape completely from the threads. For persistent remaining
you can use the brass brush or use white spirit (pure alcohol). White spirit must dry out com-
pletely before proceeding.
 Wrap 3 to 15 layers of Teflon tape (depending on the tolerance of the two threads) clockwise
(rear view) tightly around the connection thread of HYDROCAL unit. The first thread should
remain free.
 Place the HYDROCAL unit horizontally to the threaded flange. Make sure that the unit is lev-
eled.
 Turn in the HYDROCAL unit 2 to 3 turns clockwise by hand to the threaded flange.
 Now turn in the HYDROCAL unit for another 5 to 6 turns clockwise using a tin spanner M55 or
adjustable tin spanner 1 ½“ and stop when the aeration screw is at about 9 o`clock.
Note: If the turn in was possible without major effort, too less Teflon tape was used. Turn out the
unit, remove Teflon tape completely and perform the installation again.
 Now align the unit clockwise until the position of the aeration screw is at 12 o`clock. Make
sure that the unit is tight in this position.
Note: The alignment of the unit must be only clockwise. Once the unit is turned counterclockwise
during the alignment, the installation procedure must be performed once again! Risk of oil leak-
age!
Attention !!!
Do not exceed 12 o`clock position!
Otherwise you have to remove the HYDROCAL unit, completely remove
the Teflon tape from the connection thread and perform the installation
procedure again!
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 the leaking oil
 Slowly open the transformer valve until oil runs out of the provided hole. Collect the leaking oil
with a bucket.
 Close the aeration screw as soon as no air bubbles sort the provided hole.
 Now open the transformer valve completely.
 Remove thoroughly the oil residues with a dry cleaning rag or paper towel from the unit.
Attention !!!
Do not use solvents for cleaning!
 Check after 30 minutes if the threaded connection is tight (no leakage).
2.4.1.2. Indirect installation

Indirect installation means the HYDROCAL unit is fixed on the fitting by turning the union nut. A gas-
ket is used to seal the connection.
Attention!!!
Attention!!!
Only remove the protection cap (slowly while turning) when to aeration
screw is open and you are ready to mount the HYDROCAL unit!
 Clean the inside of the union nut with a dry cleaning rag or paper towel.
 Clean the outer thread of the connection unit with a dry cleaning rag or paper towel. Remove
any remaining of thread sealing tape completely from the threads. For persistent remaining
you can use the brass brush or use white spirit (pure alcohol). White spirit must dry out com-
pletely before proceeding.
 Place the HYDROCAL unit horizontally to the fitting. Make sure that the unit is leveled and the
gasket inserted.
Attention !!!
Make sure that the gasket is inserted
between HYDROCAL unit and fitting.
 Turn in the union nut by hand to the external thread of the connection unit.
 Now align the unit until the position of the aeration screw is at 12 o`clock.

 Tighten the union nut with a tin spanner M55 or an adjustable tin spanner 1 ½“, while you hold
the HYDROCAL unit in position using a tin spanner M55 or an adjustable tin spanner 1 ½“.
Make sure that the alignment of the HYDROCAL unit is still correct afterwards.
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 the leaking oil.
 Slowly open the transformer valve until oil runs out of the provided hole. Collect the leaking oil
with a bucket.
 Close the aeration screw as soon as no air bubbles sort the provided hole.
 Now open the transformer valve completely.
 Remove thoroughly the oil residues with a dry cleaning rag or paper towel from the unit.
Attention !!!
Do not use solvents for cleaning!
 Check after 30 minutes if the threaded connection is tight (no leakage).

2.4.2. Electrical connection
 Use protective conduits as protection for all cables and connect them to the corresponding
connectors inside of the unit (3.3). All cables have to be provided by the customer.
 For feed through, following cable gland must be used for all cables:
1x M20 SKINTOP® cable gland (Clamping range 7,0 ... 13,0 mm)
1x M25 SKINTOP® cable gland (Clamping range 9,0 ... 17,0 mm)
Attention !!!
For cables with a smaller diameter please use reducing seal inserts to
provide clamping and sealing!
Note: The unit comes with 2 SKINTOP® cable glands (M20 and M25) from the factory!
 Supply voltage connection:

Recommendation for supply voltage cable:
Cable type: PUR-PUR CEE JB 3x1.50 (or equivalent)
Cable diameter : 8,1 mm
Cross section : 1,5 mm2 (of 3 internal wires)

 Communication connection:
The Ethernet communication is either connected via copper wire (RJ45) or fibre optical (SC Du-
plex) (must be specified when ordering).
Copper wire:
Recommendation for Ethernet communication cable (copper):
Cable type: Ethernet cable Cat. 5e with RJ45 connector
Fibre optical:
Recommendation for Ethernet communication cable (fibre optical):
®
Cable type: HITRONIC HQN 1000 Multimode G4 62,5/125 with SC Duplex connector
Bending radius: min. 15 x Ø
RS485 interface:
Recommendation for RS485 interface communication cable:
Cable type: UNITRONIC® BUS LD FD P cable 1x2x0.25 mm2, shielded, purple
 Alarm- and analog outputs:

Recommendation for alarm and analog outputs cable:
Cable type: ÖLFLEX® FD855CP (or equivalent)
Cross section : 0,5 mm2 (of 16 internal wires)
2.4.3. Putting into operation

When the supply voltage for the unit is switched on, a short beep is hearable and after a short time
the LEDs of the internal and external user interface shows the specified conditions confirming that
the HYDROCAL unit is working correctly (4).
 After successful initialization, you can remount the protection cover and fasten it with the
knurled thumb screw.
 The measurement cycles are performed every 20 minutes and are synchronized on the clock
mark; this means the first measurement values are available approx. 2, 22 or 42 min. after the
clock mark.
 To check the heating function, touch carefully the back plate after some minutes.
Attention, danger of burning!!!
Note: To check the correct regulation of the back plate heating use Hydrosoft - Online Sensors - and
check the back plate temperature T2.

3. Hardware components
3.1. Front view
The front consists of the following components:
[1] Protection cover with aeration hole

[2] Knurled thumb screw to fasten the protection cover
[3] Function LED of external user interface
[4] Gas LED of external user interface
[5] Moisture LED of external user interface

3.2. Rear view
[1] Oil unit with connection thread

G 1½” DIN ISO 228-1
or
1½” NPT ANSI B 1.20.1

[2] Supply voltage connection with SKINTOP® cable gland M20
Nominal voltages: 120 V -20% +15% AC 50/60Hz 1) or
230 V -20% +15% AC 50/60Hz 1) or
120 V -20% +15% DC 1) or
230 V -20% +15% DC 1)
Other nominal voltages on request!
Power consumption: max. 250 VA
Micro-fuse at 120V: T3.15A
Micro-fuse at 230V: T2A
Connect the supply voltage cable as followed:
AC Version
Phase: L
Protection earth: PE
Neutral: N
DC Version
Plus conductor: +
Protection earth: PE
Minus conductor: –
Note 1):
120 V  120 V -20% = 96 Vmin 120 V +15% = 138 Vmax
230 V  230 V -20% = 184 Vmin 230 V +15% = 264 Vmax
[3] System connection with SKINTOP® M25 cable gland

Communication (Ethernet / RS485) / Analog outputs / Relay outputs

3.3. Connections of measurement- and controller card
[1] Reset Button [→0] (to zero)

Functional test and alarm acknowledgment (automatic test of LEDs and digital outputs)
Communication interface reset – in conjunction with the test button
[2] Test Button [Test]
Test mode (detailed manual test of analog- and digital outputs)
Communication interface reset – in conjunction with the reset button
[3] LED bar level - Moisture
Moisture concentration indication with 3 single color LEDs
[4] LED bar level - Gas
Gas concentration indication with 4 single color LEDs
[5] Analog output LEDs - Gas concentration
Analog output indication for gas concentration with 2 single color LEDs
[6] Analog output LEDs - Moisture concentration
Analog output indication for moisture concentration with 2 single color LEDs
[7] Ethernet connection LEDs
Status and data traffic indication with 2 single color LEDs
[8] RS485 connection LEDs
Status and data traffic indication with 2 single color LEDs

[9] Function, Gas & Moisture LEDs
of external user interface with 3 multicolor LEDs
[10] Connection ETHERNET communication
Communication connection via Ethernet
Copper wired or Fibre optic

(RJ45) (SC-Duplex)
The connection sockets are mounted directly on the measurement- and controller card
(must be specified when ordering).
[13] Jumper J1 – Function relay contact (when system is okay, relay is switched on )
The function relay output can operate as a closing or opening contact. The configuration is
selected by the jumper J1, which is located near the connection terminal X2:8:
J1:1-2  Pos. 1  Contact is open, when relay is switched on (Normally Closed)
J1:2-3  Pos. 2  Contact is closed, when relay is switched on (Normally Open)

[11] Connection terminal X1: RS485 / analog outputs
Connection for RS485 interface / analog outputs DC (0/4…. 20 mA DC)
X1:1  OUTA  RS485 interface
X1:2  OUTB  RS485 interface
X1:3  GNDio  RS485 interface
X1:4  AO1  Analog output 1 – Gas concentration
X1:5  AO1  Analog output 1 – GNDio
X1:6  AO2  Analog output 2 – Moisture concentration
X1:7  AO2  Analog output 2 – GNDio
Note: Free assignment for both analog outputs.

[12] Connection terminal X2: Relay outputs
Connection for relay outputs (220 VDC/VAC / 2 A / 60 W)
X2:1  DOR1  Relay output 1 – Gas high alarm
X2:2  DOR1  Relay output 1 – Gas high alarm
X2:3  DOR2  Relay output 2 – Gas high-high alarm
X2:4  DOR2  Relay output 2 – Gas high-high alarm
X2:5  DOR3  Relay output 3 – Moisture alarm
X2:6  DOR3  Relay output 3 – Moisture alarm
X2:7  DOR4  Relay output 4 – Function alarm
X2:8  DOR4  Relay output 4 – Function alarm

3.3.1. Beeper
The measurement- and controller card contains a beeper for additional acoustic signalization. The
beeper has three different beep sounds which vary in lengths and sound form:
Icon Description
Short constant beep
Long constant beep with a slightly higher tone pitch
Long oscillating beep (whistle sound)

3.4. Connections of power supply card
[1] Connection terminal X1: Supply voltage / heating resistor

X1:1  Protecting earth (PE) - Green - yellow
X1:2  - (not connected)
X1:3  Neutral (N) - Blue
X1:5  Phase (L) – Black or brown
X1:7  Heating resistor connection - Red
Note: The connection terminal X1 is underneath the shielding cover of the power supply
card.
[2] Micro fuse holder with micro fuse
120 V  T3.15A
230 V  T2A
Note: The micro fuse holder is underneath the shielding cover of the power supply card.

3.5. Wiring of the heating resistors
The HYDROCAL 1001+ unit is available in four supply voltage versions (must be specified when or-
dering).
The solid-state relay varies between supply voltage type (AC and DC):
 For AC supply voltages the solid-state relay crydom D2410 AC 10 A is used (left).
 For DC supply voltages the solid-state relay crydom D5D07 DC 7 A is used (right).
The wiring for the heating resistors varies between supply voltage value (120 V and 230 V):
 Wiring heating resistors for 230 VAC / 230 VDC (3.5.1)
 Wiring heating resistors for 120 VAC / 120 VDC (3.5.2)

3.5.1. Wiring heating resistors for 230 V
Note: The solid-sate relay must correspond to the supply voltage type (AC or DC)!!!

3.5.2. Wiring heating resistors for 120 V
Note: The solid-sate relay must correspond to the supply voltage type (AC or DC)!!!

4. Firmware
4.1. General information
The composite Gas-in-Oil sensor with moisture in oil measurement HYDROCAL 1001+ is based on a
microprocessor controlled measurement system. A 32 Bit „Coldfire“ processor with a clock frequency
of 240 MHz is used. The system has a FLASH memory of 32 Mbyte for permanent storing of the
measurement data, which offers a storage capacity of 2 years. After this period, the oldest data will
be overwritten by the latest values.
Attention !!!
To avoid any loss of data, it is proposed to read out regularly the
measurement data by the Windows based software Hydrosoft.
The HYDROCAL 1001+ does not have a graphical display but is equipped with two user interfaces:
 External user interface (4.2)
 Internal user interface (4.3)
4.2. External user interface

The external user interface is located on the component side of the measurement- and controller
card and is facing toward the front of the HYDROCAL unit. It has 3 multicolor light-emitting diodes
(LED) to reflect the system status (function) and to indicate gas- and moisture concentration as well
as the daily and weekly gas trend.
Function LED (4.2.1)
Gas LED (4.2.2)
Moisture LED (4.2.3)
The icons of the multicolor LEDs have the following signification:

Icon Status Description Color sequence
off LED permanently off -
on White color permanently on -
on Green color permanently on -
on Yellow color permanently on -
on/off fast Yellow color short on (~1 s on / ~¼ s off)
on/off slow Yellow color long on (~2 s on / ~¼ s off)
on Red color permanently on -
on/off fast Red color short on (~1 s on / ~¼ s off)
on/off slow Red color long on (~2 s on / ~¼ s off)
Note: The signification of the LED status you can find in the following tables of the external user in-
terface LED.

4.2.1. Function LED
The HYDROCAL unit contains an internal system monitoring which is assigned to the function LED
and relay output 4 (connection terminal X2:7&8). The following internal error sources are monitored:
 Loss of time
 Data memory not ready
 RTC not ready (buffer capacitor empty)
The multicolor function LED illustrates the status of the internal system monitoring as follow:
Description
System monitoring not active
System monitoring active - system okay - relay switched on
- not defined -
System monitoring active - system has monitored an error - relay switched off
4.2.2. Gas LED

The HYDROCAL unit contains an alarm level monitoring (absolute gas concentration, gas concentra-
tion daily trend and gas concentration weekly trend), which is assigned to the gas LED, the relay out-
put 1 for level 1 (High) alarm (connection terminal X2:1&2) and the relay output 2 for level 2 (High-
High) alarm (connection terminal X2:3&4).
The multicolor LED illustrates the general status (only one alarm triggered) as follow:
Description /
Color sequence
Alarm level monitoring not active
-
No alarm
-
Absolute gas concentration – level 1 (High) alarm is triggered /
-
Absolute gas concentration – level 2 (High-High) alarm is triggered /
-
Gas concentration daily trend – level 1 (High) alarm is triggered /
Gas concentration daily trend – level 2 (High-High) alarm is triggered /
Gas concentration weekly trend – level 1 (High) alarm is triggered /
Gas concentration weekly trend – level 2 (High-High) alarm is triggered /
As the alarms for gas concentration (absolute, daily- and weekly trend) can be present in parallel the
individual status of the gas LED is illustrated as following patterns:
Note: In order to simplify the illustration in the pattern table the level 1 (High) alarm is named as 1
and level 2 (High-High) alarm as 2. No alarm active is named as 0.

Gas
concentration
Icon Color sequence
absolute
weekly
trend
trend
daily
0 0 0 -
1 0 0 -
2 0 0 -
0 1 0
0 2 0
1 1 0
1 2 0
2 1 0
2 2 0
0 0 1
0 0 2
1 0 1
1 0 2
2 0 1
2 0 2
0 1 1
0 1 2
0 2 1
0 2 2
1 1 1
1 1 2
1 2 1
1 2 2
2 1 1
2 1 2
2 2 1
2 2 2

Note: The standard settings for gas concentration absolute alarm (High-High) are:
 Level 1: 500 Level 2: 1000
 Delay 1 [s]: 7200 or 2:00:00 Delay 2 [s]: 43200 or 12:00:00
 Action 1: Output,Hold Action 2: Output,Hold
Note: The standard settings for gas concentration daily trend alarm (High-High) are:
 Level 1: 50 Level 2: 100
 Delay 1 [s]: 43200 or 12:00:00 Delay 2 [s]: 86400 or 1-0:00:00
Note: The standard settings for gas concentration weekly trend alarm (High-High) are:
 Level 1: 100 Level 2: 200
 Delay 1 [s]: 86400 or 1-0:00:00 Delay 2 [s]: 172800 or 2-0:00:00
These settings can be modified in Hydrosoft -> alarm setup.
4.2.3. Moisture LED

The HYDROCAL unit contains also an alarm level monitoring for the moisture concentration, which is
assigned to the moisture LED and the relay output 3 (connection terminal X2:5&6).
The multicolor LED illustrates the status of the alarm level for moisture concentration as follow:
Description
Alarm level monitoring not active
No Alarm
- not defined -
Moisture concentration - level 1 (High) alarm is triggered
Note: The standard settings for moisture concentration alarm (High) are:
 Level 1: 10
 Delay 1 [s]: 7200 or 2:00:00
 Action 1: Output,Hold
These settings can be modified in Hydrosoft -> Alarm setup.

4.3. Internal user interface
The internal user interface consists of 15 single color light-emitting diodes (LEDs) to reflect the sys-
tem status and two push buttons to allow the activation of special functions. Under normal conditions
the LEDs reflect the status of the communication interfaces, analog outputs and gas concentration
(absolute, daily- and weekly trend) and moisture concentration:
During special operations the LEDs are used in another manner to reflect the status or progress of
the related task.
The icons of the single color LEDs (green or red) have the following signification:
Icon Description Color sequence
Green LED permanently off -
Green color permanently on -
Green color short on (~1 s on / ~¼ s off)
Green color long on (~2 s on / ~¼ s off)
Red LED permanently off -

Red color permanently on -
Red color short on (~1 s on / ~¼ s off)
Red color long on (~2 s on / ~¼ s off)
Note: The signification of the LED status you can find in the following tables of the internal user inter-
face. The speed of the toggling or flashing LEDs varies and is defined with e.g. (~1 s on / ~1 s off).

4.3.1. Normal Operation
Normal operation is the default status and is automatically invoked when the unit starts up.
4.3.1.1. LED & energy save mode
As the HYDROCAL 1001+ unit is operating behind a non-transparent protection cover most of the
time the LEDs of the internal user interface are switched off to save energy and release load from the
power supply.
The internal user interface LEDs are turned off 30 minutes after the last time one of the two buttons
was pressed. Pressing one of the two buttons turns on the LEDs again and restarts the timeout of the
LED & energy save mode.
4.3.1.2. LED Ethernet
The Ethernet communication interface is represented by a red- and a green single color LED.
The LEDs illustrates the status of the Ethernet communication interface as follow:
Description
Ethernet interface not active
Ethernet interface active
Ethernet interface deactivated - MAC address not configured
red flashing on - on receive; green shortly off - on transmit
red flashing (~½ s on / ~½ s off) - no cable connected
green and red flashing (~½ s on / ~½ s off) - Request IP-address via DHCP
- not defined -
4.3.1.3. LED RS485
The RS485 communication interface is also represented by a red- and a green single color LED.
The LEDs illustrates the status of the RS485 communication interface as follow:
Description
No transmission
Green shortly flashing on transmit
Red shortly flashing on receive
- not defined -

4.3.1.4. LED Gas analog output
The status and the actual value of the analog output are represented by a red- and a green single
color LED.
The LEDs illustrates the status and the actual value of the analog output as follow:
Description
Analog output not configured

Red LED Green LED
off on output current ≤ 4 mA
Red LED Green LED
off ~1 s on / ~1 s off output current ≤ 8 mA
off ~½ s on / ~½ s off output current ≤ 12 mA
off ~¼ s on / ~¼ s off output current ≤ 16 mA
off ~⅛ s on / ~⅛ s off output current ≥ 16 mA
Sensor signal for analog output not available
- not defined -
4.3.1.5. LED Moisture analog output

The status and the actual value of the analog output are represented by a red- and a green single
color LED.
The LEDs illustrates the status and the actual value of the analog output as follow:
Description
Analog output not configured
Red LED Green LED
off on output current ≤ 4 mA
Red LED Green LED
off ~1 s on / ~1 s off output current ≤ 8 mA
off ~½ s on / ~½ s off output current ≤ 12 mA
off ~¼ s on / ~¼ s off output current ≤ 16 mA
off ~⅛ s on / ~⅛ s off output current ≥ 16 mA
Sensor signal for analog output not available
- not defined -

4.3.1.6. LED bar level - Gas
The HYDROCAL unit contains an additional LED bar level monitoring to give the user a rough over-
view of the absolute gas concentration, gas concentration daily trend and gas concentration weekly
trend. It is completely independent form the alarm level monitoring and is visualized with 1 green-
and 3 red single color LEDs. The gas concentration absolute, gas concentration daily trend and gas
concentration weekly trend have each 3 configurable levels (level 1 ... 3) but their status will be illus-
trated with the same 4 LEDs.
The LEDs illustrates the status of the gas concentration absolute as follow:
Description
Gas sensor not active - measurement function stopped

Gas concentration < Level 1
Gas concentration ≥ Level 3
Gas sensor active - error
As the levels for gas concentration (absolute, daily- and weekly trend) can be reached in parallel the
individual status of the LEDs is illustrated as following color sequences:
Note: To keep it as simple as possible the levels of the gas concentrations (absolute, daily- and
weekly trend) are specified as follow in the color sequence tables:
0 < Level 1 (Level 1 not reached)
1 < Level 2 (Level 1 reached)
2 < Level 3 (Level 2 reached)
3 ≥ Level 3 (Level 3 reached)

Gas Color sequence – LED bar level
concentration
absolute
weekly
trend
trend
daily
0 0 0
1 0 0
2 0 0
3 0 0
0 1 0
0 2 0
0 3 0

concentration
absolute
weekly
trend
trend
daily
0 0 1
0 0 2
0 0 3
0 1 1
0 1 2
0 1 3

concentration
absolute
weekly
trend
trend
daily
0 2 1
0 2 2
0 2 3
0 3 1
0 3 2
0 3 3

concentration
absolute
weekly
trend
trend
daily
1 1 0
1 2 0
1 3 0
2 1 0
2 2 0
2 3 0

concentration
absolute
weekly
trend
trend
daily
3 1 0
3 2 0
3 3 0
1 0 1
1 0 2
1 0 3

concentration
absolute
weekly
trend
trend
daily
2 0 1
2 0 2
2 0 3
3 0 1
3 0 2
3 0 3

concentration
absolute
weekly
trend
trend
daily
1 1 1
1 1 2
1 1 3
1 2 1
1 2 2
1 2 3

concentration
absolute
weekly
trend
trend
daily
1 3 1
1 3 2
1 3 3
2 1 1
2 1 2
2 1 3

concentration
absolute
weekly
trend
trend
daily
2 2 1
2 2 2
2 2 3
2 3 1
2 3 2
2 3 3

concentration
absolute
weekly
trend
trend
daily
3 1 1
3 1 2
3 1 3
3 2 1
3 2 2
3 2 3

concentration
absolute
weekly
trend
trend
daily
3 3 1
3 3 2
3 3 3
Note: The standard settings for LED bar level gas concentration absolute are:
 Level 1: 100 Level 2: 500 Level 3: 1000
Note: The standard settings for LED bar level gas concentration daily trend are:
Note: The standard settings for LED bar level gas concentration weekly trend are:
These settings can be modified in Hydrosoft -> Settings -> LED Bar Levels.

4.3.1.7. LED bar levels - Moisture
The HYDROCAL unit contains an additional LED bar level monitoring to give the user a rough over-
view of the moisture concentration. It is completely independent form the alarm level monitoring and
is visualized with 1 green- and 2 red single color LEDs. The moisture concentration has 2 configura-
ble levels (level 1 ... 2) and their status will be illustrated with the 3 LEDs.
The LED bar levels for moisture concentration are illustrated as follow:
Description
Moisture sensor not active - measurement function stopped
Moisture concentration < Level 1
Moisture concentration < Level 2
Moisture concentration ≥ Level 2
Moisture sensor active - error
Note: The standard settings for LED bar levels moisture concentration are:
 Level 1: 10 Level 2: 20
These settings can be modified in Hydrosoft -> settings -> LED Bar Levels.

4.3.2. Special Operation
During special operations the LEDs are used to reflect the status or progress of the corresponding
task. Following special operations are available on the unit:
 Unit Power-On - Boot (4.3.2.1)
 Update of Firmware - Downloader (4.3.2.2)
 Update of Firmware - via TFTP (4.3.2.3)
 Functional Test (4.3.2.4)
 Test Mode (4.3.2.5)
4.3.2.1. Unit Power-On - Boot

After power on (or reset) of the unit all red LEDs are turned on. The unit is in boot mode that allows a
firmware download operation to be started. This state lasts for approximately 5 seconds with the
green LEDs being used as a timeout bar. When all green LEDs are illuminated the normal firmware is
launched.
Supply voltage on
  a
a   b
b 

4.3.2.2. Update of Firmware - Downloader
Once a firmware download operation is started during the boot sequence, the unit switches to a spe-
cial mode - the so called downloader. This status can be recognized by the following special LED
pattern (2 red LEDs are turned on and 1 green LED is circulating counter clockwise):
   a
a  
A firmware download operation being in progress is indicated by the following special LED pattern (3
red LED are turned on and 1 green LED is circulating clockwise):
   a
a  

The next steps are erasing the EEPROM (optional), writing and verifying the new firmware. Each
step brings up one additional red LED with the green LEDs being used as a progress bar (restarted
in each operation).
If an error occurs all LEDs are turned off and the downloader restarts in the boot timeout sequence.
   a
a    b
b    c
c  

4.3.2.3. Update of Firmware - via TFTP
A firmware update can also occur in the running firmware using the Ethernet interface and the so
called TFTP protocol. The transfer of the firmware image data occur in the background and is not
visualized. The subsequent write and verify operation is indicated by two or three red LEDs with the
green LEDs used as a progress bar. A successful update is followed by an automatic reboot of the
system. An error brings up 4 red LEDs - after some delay normal firmware operation resumes.
When the new firmware is already on the unit an optical and acoustical feedback is given. All green
LEDs are flashing and the beeper is activated in intervals of one second (duration ~4 seconds).
+ … ... ... etc.

4.3.2.4. Functional Test
The functional test is quick unit test which execute an automatic sequence with following order:
 LEDs of internal user interface
 LEDs of external user interface and digital relay output
 LEDs of internal- and external user interface
 Return to normal operation
To invoke the functional test press and hold the reset button until 1+5 beeps have occurred (the 1st
short beep is committing the pressed button, pause, then 4 short beeps and the last beep is longer to
inform of commitment).
PRESS & HOLD RELEASE
The automatic sequence of the functional test is as follow:

I - LEDs of internal user interface
Start     a
a     b
b     c
c     d
LED bar level – Moisture d    e

e    f
LED bar level – Gas

f    g
g    h

II - LEDs of internal user interface and digital relay outputs
h’    i
Relay output 4 (X2:7/8) with Jumper J1 on Pos. 1 (J1:1-2)
h’’    i
Relay output 4 (X2:7/8) with Jumper J1 on Pos. 2 (J1:2-3)
i    j
Relay output 1 (X2:1/2)
j    k
k    l

III - LEDs of internal- and external user interface
All LEDs - ON Internal user interface External user interface
l  m
All LEDs - OFF Internal user interface External user interface
m  End
IV - Return to normal operation
Note: After this sequence all present alarms will be automatically acknowledged.

4.3.2.5. Test Mode
The test mode grants a more detailed test of the HYDROCAL unit outputs. The analog- and digital
outputs along with the corresponding LEDs can be verified. The test points are available in following
order:
 Test Gas concentration Analog output 1 X1:4/5
 Test Moisture concentration Analog output 2 X1:6/7
 Test Function alarm Relay output 4 X2:7/8
 Test Gas high alarm Relay output 1 X2:1/2
 Test Gas high-high alarm Relay output 2 X2:3/4
 Test Moisture alarm Relay output 3 X2:5/6
 Return to normal operation
To invoke the test mode press and hold the test button until 1+5 beeps have occurred (the 1st short
beep is committing the pressed button, pause, then 4 short beeps and the last beep is longer to in-
form of commitment).
Note: After invoking the test mode the first test cycle (Test gas concentration - Start) is automatically
entered.
The active test mode is illustrated with the following special LED pattern on the LED bar level – Gas:
LED bar level – Gas
a    b
b   a

I - Test Gas concentration
Current
Step Description
[mA]
Start - Red on / green on actual value 1 x

1 of 6 Red on / green off 0 1x 5x
2 of 6 Red off / green on 4 1x 5x
3 of 6 Red off / green ~1 s on / ~1 s off 8 1x 5x
4 of 6 Red off / green ~½ s on / ~½ s off 12 1x 5x
5 of 6 Red off / green ~¼ s on / ~¼ s off 16 1x 5x
6 of 6 Red off / green ~⅛ s on / ~⅛ s off 20 1x 5x
a
II - Test Moisture concentration
Current
Step Description
[mA]
a - Red on / green on actual value 1 x

1 of 6 Red on / green off 0 1x 5x
2 of 6 Red off / green on 4 1x 5x
3 of 6 Red off / green ~1 s on / ~1 s off 8 1x 5x
4 of 6 Red off / green ~½ s on / ~½ s off 12 1x 5x
5 of 6 Red off / green ~¼ s on / ~¼ s off 16 1x 5x
6 of 6 Red off / green ~⅛ s on / ~⅛ s off 20 1x 5x
b
III - Test Function alarm
Description Relay-
Step
Jumper J1 on Pos. 1 (J1:1-2) contact
b’ - White color / contact closed X2:7/8 1 x
1 of 2 Red color / contact open X2:7/8 1 x 5x
2 of 2 Green color / contact closed X2:7/8 1 x 5x
Description Relay-
Step
Jumper J1 on Pos. 1 (J1:2-3) contact
b’’ - White color / contact open X2:7/8 1 x
1 of 2 Red color / contact closed X2:7/8 1 x 5x
2 of 2 Green color / contact open X2:7/8 1 x 5x

IV - Test Gas high alarm
Relay-
Step Description
contact
c - White color / contact open X2:1/2 1 x
d
IV - Test Gas high-high alarm
Relay-
Step Description
contact
d - White color / contact open X2:3/4 1 x
e
V - Test Moisture alarm
Relay-
Step Description
contact
e - White color / contact open X2:5/6 1 x
End
VI - Return to normal operation
Note: The test mode is also terminated automatically 15 minutes after the last button operation. To
terminate the test mode prior press and hold both buttons until 1+3 beeps have occurred.

4.3.3. Communication Interface Reset
Because the HYDROCAL 1001+ unit has no display and no alphanumeric keypad, the only way to
configure the unit is via its communication interfaces. If, for whatever reasons, both interfaces are
configured in a way that communication is not possible, an activation sequence can force the Ether-
net communication interface to a defined setup.
To invoke the communication interface reset press and hold the reset button until 1+5 beeps have
occurred (the 1st short beep is committing the pressed button, pause, then 4 short beeps and the last
beep is longer to inform of commitment). Immediately after the long commitment beep press and hold
the test button until 1+5 beeps have occurred (the 1st short beep is committing the pressed button,
pause, then 4 short beeps and the last beep is longer and oscillating to inform of commitment).
PRESS & HOLD RELEASE  PRESS & HOLD RELEASE
„Activation Functional Test“ „Activation Test Mode“
Communication Interface Reset - Activation sequence
Now the communication interface settings are forced to:

 RS485
Settings: 19200 Baud, 8 Bit, No Parity, 1 Stop
Answer delay: 50 ms
MODBUS: off
Bus Mode: point-to-point
 Ethernet
DHCP deactivated (Static IP)
Port No. 49152
IP 192.168.0.1
Mask 255.255.255.0
Note: The setup is only changed temporarily. In order to make permanent changes to the communi-
cation interface setup, a connection has to be established and the requested setup has to be sent to
the unit. To return to normal operation a reset of the unit is required.

4.4. Default Communication Interface Setup
A HYDROCAL 1001+ unit is shipped with the following default setup of the communication interfaces:
 RS485
Settings: 19200 Baud, 8 Bit, No Parity, 1 Stop
Answer delay: 0 ms (no delay)
MODBUS: off
Bus Mode: point-to-point
 Ethernet
DHCP activated (DHCP Client)
Port: 49152
IP: (192.168.1.32)
Mask: (255.255.255.0)
Gateway: (192.168.1.1)
Note: The TCP/IP settings (in brackets) are not used as the DHCP mode is activated.

4.5. Establish a Point-to-Point Ethernet Connection
In order to set up a personal computer (PC) to communicate with a HYDROCAL 1001+ unit via an
Ethernet cable a special setup is required. The HYDROCAL 1001+ as well as the PC must have a
unique address and they must reside in the same network. This is achieved by setting up two spe-
cially formatted numbers - the so called IP address and the network mask (or subnet mask).
This chapter will explain the required steps to change the settings of both the HYDROCAL 1001+ unit
and the PC.
In the example the following settings will be used:

 HYDROCAL 1001+
IP address: 192.168.0.1
Network mask: 255.255.255.0
Port number: 49152
 PC
IP address: 192.168.0.2
Network mask: 255.255.255.0
Port number: - only needed in Hydrosoft -
Other settings can be used but a working configuration must obey the following rules:
 The network mask must be identical on PC / HYDROCAL (e.g. 255.255.255.0)
 The IP address must be identical in the first 3 dot-separated numbers (e.g. 192.168.0)
 The 4th number of the IP address must be different (e.g. 1 and 2)
 The port number must not be 0, 80 (HTTP) or 502 (MODBUS® TCP) (e.g. 49152)
Note: Other settings are also valid but are not in the scope of this description.
4.5.1. Setup HYDROCAL 1001+

As described before, the HYDROCAL 1001+ comes with an activated DHCP option by default
(DHCP is a service in local area networks (LAN) that offers automatic configuration of IP address and
network mask). In a point-to-point connection scenario there is no DHCP service available and so a
so called static setup has to be activated on the unit and on the PC.
4.5.2. Change of TCP/IP Settings on the PC

Most of the time a PC is integrated into a local area network. The network configuration is obtained
by a DHCP server and the user doesn't need to care about the network - the cable is just plugged in
and everything else is done automatically.
When a point-to-point connection is required a manual tuning of the network adapter is needed. Us-
ing the configuration dialogs offered by the Windows Control Panel the settings of the network adapt-
er must be edited.
Note: The screen shots are taken form a PC running under an English (US) Windows 7 operating
system. The paths to open the described dialogs are one way - alternate ways exist but are not de-
scribed here. The older systems (Windows Vista and XP) also have the related dialogs - the path to
get there is different, but the settings at the detail dialog level are the same - a good way to start for
the network dialog search is always the control panel that exist in all windows versions.

4.5.2.1. Navigating to the Network Adapter Properties
Open the Start Menu and activate the Control Panel.
In Control Panel enter Network and Internet
Next enter the Network and Sharing Center

Click on Change adapter settings
The list of available network adapters appears. Depending on the configuration of the PC one or
more items may be present. The network adapter used to connect to the HYDROCAL must be se-
lected.
4.5.2.2. Changing the Network Adapter Properties
Do a right-click on the network adapter to bring up the context menu and choose the bottom level
entry (Properties). The properties page for the network adapter is coming up.
Click into the list in the middle of the dialog and highlight the entry for Internet Protocol Version 4
(TCP/IPv4). Next click the Properties button.
In the up-coming dialog activate the Alternate Configuration tab - (leave the General tab settings un-
changed).

Activate the radio button User configured and enter the IP address and the Subnet mask (the other
fields are not required for HYDROCAL and can remain empty). Remember that the IP address must
be different to the one used in the HYDROCAL device.
Commit the changes by leaving the dialog with the OK button.
Note: A potentially upcoming Windows Network Diagnostics dialog can be closed.

4.5.3. Test of Communication with Hydrosoft
To test the communication the HYDROCAL unit and the PC are connected via an Ethernet cable.
Next Hydrosoft is launched. If needed a new transformer node is created in Hydrosoft. Next the set-
tings of the Communication are changed to Network. Using the data of this example the fields are
filled in as shown in the screen shot.
IP Address: 192.169.0.1
TCP Port: 49152
Note: The Access via field must remain empty
(only used in dial-up networks).

Finally a normal history data update should be executed to ascertain a working connection. In case of
failure the next chapter may help finding the problem.
4.5.4. Diagnosis / Trouble Shooting
If the communication is not working the following hints may be helpful to locate and solve the prob-
lem.
4.5.4.1. Basic Checks
Verify the following points:
 Ethernet cable is properly connected
 Ethernet cable is functional (verify by connecting PC to LAN)
 Rules for IP address setup are followed (4.5)
4.5.4.2. Check of PC Network Adapter Setup
Make sure the PC has chosen the alternate TCP/IP Settings. Navigate to the network adapter as
shown in 4.5.2.1. This time double-click the network adapter in use to bring up the status dialog. In
the status dialog the Details... button brings up the required information.
The IPv4 Address and Subnet Mask must show the values of the alternate setup (4.5.2.2).
Under some circumstances it may take some time until the PC changes to the alternate setup. If a 2-
3 minutes time of waiting does not change the status a reboot of the PC may be helpful.

4.5.4.3. Low Level Connection Test (PING)
To execute a low level connectivity test the command line tool PING can be used.
To invoke PING open the start menu und type cmd into the edit field at the bottom (a greyed text
Search programs and files is shown in the field on entry). Start the command interpreter cmd (also
called DOS window) by pressing enter.
In the command interpreter type the following and execute by pressing enter.
ping 192.168.0.1
The screen shot shows a successful PING - the unit answers. If the unit does not answer and the PC
settings are correct try a reboot of the HYDROCAL device. Optionally execute the Communication
Interface Reset (4.3.3) again.

4.6. Communication setup
4.6.1. RS485 setup
The RS485 interface can be use either for proprietary HYDROCAL protocol or for MOBUS®
serial protocol. The serial communication related settings can be done for each HYDROCAL unit in
the tab „Modbus RS485” of the menu (see Hydrosoft manual).
It can be chosen out of the following four variants:
 Point-to-point (4.6.1.1) PC to one HYDROCAL unit - proprietary protocol
 Bus node (4.6.1.2) PC to several HYDROCAL unit - proprietary protocol
 MODBUS RTU (4.6.1.3) PC to several HYDROCAL units - MODBUS RTU protocol
 MODBUS ASCII (4.6.1.4) PC to several HYDROCAL units - MODBUS ASCII protocol
4.6.1.1. Point-to-Point
The point-to-point setup is used for a communication between PC to one HYDROCAL unit. Please
perform following configuration:
Mode: Off (no Modbus) - deactivated

Address: 0
Answer Delay: 0 ms (depending on the used RS485 adapter)
Serial Setup: 19200 (2400 ... 115200)
Note: The proprietary HYDROCAL protocol allows only configuration of the baud rate. The settings
of the Data Bits, Parity and Stop Bits are fixed to 8-N-1.

4.6.1.2. Bus Node
The Bus Node setup is used for a communication between PC to several HYDROCAL units. Please
perform following configuration to each HYDROCAL unit:
Mode: Off (no Modbus) - activated

Address: 1 ... 254 (enter unique address for each unit)
Answer Delay: 0 ms (depending on the used RS485 adapter)
Serial Setup: 19200 (2400 ... 115200)
Note: As soon the address is unequal 0, the bus node is activated automatically. The proprietary
HYDROCAL protocol allows only configuration of the baud rate. The settings of the Data Bits, Parity
and Stop Bits are fixed to 8-N-1.

4.6.1.3. MODBUS RTU
The connection of multiple HYDROCAL units to a SCADA system can be performed via MODBUS ®
serial. On this HYDROCAL unit MODBUS® serial communication is possible via RS485 interface.
The MODBUS® RTU settings for the serial interface have to be entered in the following menu:
Mode: RTU Mode

Address: 1 ... 247
Answer Delay: 50 ms
Serial Setup: 19200 (2400 ... 115200) Bauderate
8 (7 ... 8) Data Bits
N (None / Odd / Even) Paritiy
1 (1 ... 2) Stop Bits
Note: A unique address (1...247) has to be entered for each unit in the RS485 bus. Actually up to 32
units can be present in the same RS485 bus. Change of the transmission mode does not set the cod-
ing 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 performed manually.

4.6.1.4. MODBUS ASCII
The connection of multiple HYDROCAL units to a SCADA system can be performed via MODBUS ®
serial. On this HYDROCAL unit MODBUS® serial communication is possible via RS485 interface.
The MODBUS® ASCII settings for the serial interface have to be entered in the following menu:
Mode: ASCII Mode

Address: 1 ... 247
Answer Delay: 50 ms
Serial Setup: 19200 (2400 ... 115200) Bauderate
7 (7 ... 8) Data Bits
N (None / Odd / Even) Paritiy
1 (1 ... 2) Stop Bits
Note: A unique address (1...247) has to be entered for each unit in the RS485 bus. Actually up to 32
units can be present in the same RS485 bus. Change of the transmission mode does not set the cod-
ing 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 performed manually.

4.6.2. ETHERNET setup
Ethernet related settings can be done for each HYDROCAL unit in the tab „Ethernet” of the
menu (see Hydrosoft manual).
It can be chosen out of the following two variants:

 Static IP (4.6.2.1)
 DHCP Client (4.6.2.2)
4.6.2.1. Static IP
The network settings can be obtained from your corresponding system administrator!
IP Address
Mask (The setting 255.255.255.0 can be used in general)
Gateway (Normally the automatic assigned setting can be used)
TCP Port Number The TCP port number should be determined by the system administrator as
well. The free range for TCP port numbers is: 49152 ... 65535. Theoretically the
unit allows the following settings: 1 ... 65535. However several TCP port num-
bers are reserved for other applications for example HTTP, FTP, Mail, etc.

4.6.2.2. DHCP Client
By using this setting, the unit obtains the network settings from the DHCP server which is responsible
for the network administration. In this case only the port number can be entered. The network admin-
istrator must allow the automatic TCP/IP address assignment for HYDROCAL in the network
The data in the tree structure which is newly created or modified has to be stored with the
button then. It appears a star right to the symbol which indicates us that a
change was performed and that the data still has to be transferred to the unit. In this moment the
data is unequal and will be aligned with the HYDROCAL unit on the next connection (see Hydrosoft
manual).

4.6.3. MODBUS® TCP
The Ethernet interface allows communication over MODBUS® TCP protocol. Max. two MODBUS®
TCP connections can be active at one time, using the standard Port 502.
MODBUS® TCP is always active.
4.6.3.1. Function, Register and Address Mapping

The following MODBUS functions, register- and address ranges are used:
MODBUS MODBUS Register HYDROCAL
Function Address Address 1)
Code Dec / Hex (5 Digit Dec)
0x02 Alarm status
Read 1000 / 3E8 11001 Alarm #1
Discrete ... ... ...
Inputs 1003 / 3EB 11004 Alarm #4
Only the information whether an alarm condition
is pending is returned. The level of the alarm (e.g.
Hi or Hi-Hi) is not transmitted.
0x04 Sensor value
Read 1000 / 3E8 31001 Sensor #1
Input ... ... ...
Register 1015 / 3F7 31016 Sensor #16
The sensor assignment is given by the proprietary
command SNSR (see below the mapping table).
The sensor value is transmitted as a signed inte-

ger. Prior to transmission the real reading is mul-
tiplied 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 (NAN-value) is returned as
value -32768 (0x8000).
0x04 Sensor value
Read 2000 / 7D0 32001 Sensor #1
Input 2002 / 7D2 32003 Sensor #2
Register 2004 / 7D4 32005 Sensor #3
... ... ...
2030 / 7EE 32031 Sensor #16
The sensor assignment is given by the proprietary

command SNSR (see below the mapping table).
The sensor value is transmitted as a floating point

value (32 bit, big-endian).
An open sensor input is returned as value NAN
(0x7FFFFFFF).
0x04 Alarm status
Read 3000 / BB8 33001 Alarm #1
Input ... ... ...
Register 3003 / BBB 33004 Alarm #4
The full alarm status information is returned.

0 no alarm
1 level 1 alarm (not active)
2 level 2 alarm (not active)
3 level 1 alarm (active)
4 level 2 alarm (active)

MODBUS MODBUS Register HYDROCAL
Function Address Address 1)
Code Dec / Hex (5 Digit Dec)
0x06 Holding Register
Write 0/0 40001 Test register #1, #2
Single ... ...
Register 1/1 40002 To test the write functionality there are 2 registers
that may be modified freely. (The reset initializa-
tion values of the two registers are 0xA5A5 and
0x5A5A.)
0x06 Confirmation / Reset of alarms
Write 1000 / 3E8 41001 Alarm status #4 ... #1
Single
Register The alarms are coded as a bit field and are pre-
sented as a single MODBUS register
(Alarm #4 -> 0x0008, alarm #1 -> 0x0001).
By writing a '0'-Bit at the corresponding position a
probably active alarm can be reset. Writing '0000'
resets all alarms.
0x06 Switch MODBUS protocol off
Write 2000 / 7D0 42001 MODBUS off
Single
Register It is now possible to switch the MODBUS protocol
off via MODBUS. This is done by writing 0x00FF
(like OFF).
0x03 Holding registers
Read 0/0 40001 16-Bit test register #1, #2
Holding ... ...
Register 1/1 40002
1000 / 3E8 41001 Alarm status bit pattern #4 ... #1
2000 / 7D0 42001 MODBUS protocol status

Note: The reading is always 0x0000. If the
MODBUS status is OFF, it is not possible to read
this status via MODBUS.
1)
Modicon® PLC address schematic
Currently the following assignment of sensor numbers (SNSR) applies:

1 Gas sensor
2 ... 4 - reserved -
5 Temperature sensor ϑ1 (T1 gas temperature measurement unit)
6 Temperature sensor ϑ2 (T2 oil temperature oil unit)
7 Moisture in Oil sensor
8 - reserved -
9 Gas sensor daily trend
10 ... 12 - reserved -
13 Gas sensor weekly trend
14 ... 16 - reserved -
Note: Function, Register and Address Mapping is also valid for MODBUS serial.

5. Technical data
General
Auxiliary supply: 120 V -20% +15% AC 50/60 Hz 1) or
230 V -20% +15% AC 50/60 Hz 1) or
120 V -20% +15% DC 1) or
230 V -20% +15% DC 1)
Other nominal voltages on request!
Power consumption: max. 250 VA
Housing:: Aluminium
Dimensions: W 224 x H 195 x D 218 mm
Weight: approx. 4 kg
Operation temperature (ambient): -55°C ... +55°C
Oil temperature (inside Transformer): -20°C ... +90°C
Storage temperature (ambient): -20°C ... +65°C
Oil Pressure: Up to 800 kpa (no negative pressure allowed)
Connection to valve: G 1½" DIN ISO 228-1 or 1½” NPT ANSI B 1.20.1
Safety CE certified
Isolation protection: IEC 61010-1:2002
Degree of protection: IP-55
Measurements
Gas-in-oil measurement
Measuring quantity Range Accuracy 2) 3) TDCG-Contribution
TDCG 0 ... 5.000 ppm ± 15 % ± 20 ppm
Hydrogen H2 ± 10 % ± 15 ppm approx. 20 %
Carbon Monoxide CO ± 20 % ± 25 ppm approx. 30 %
Methane CH4 ± 20 % ± 25 ppm <5%
Acetylene C2H2 ± 20 % ± 25 ppm 100 %
Ethylene C2H4 ± 20 % ± 25 ppm approx. 32 %
Ethane C2H6 ± 20 % ± 25 ppm <5%
Moisture H2O 0 ... 100 ppm ±3% ± 3 ppm
Measurement cycle 20 min
Analog and digital outputs
2 x Analog DC output
Type Control range Default function
(free assignment)
1 x Current DC 4 ... 20 mADC TDCG -Concentration
1 x Current DC 4 ... 20 mADC Moisture in oil concentra-
tion
4 x Digital outputs
Type Control voltage Max. switching capacity
4)
4 x Relay 12 VDC 220 VDC/VAC / 2 A / 60 W

Communication
 ETHERNET 10/100 Mbit/s modem copper-wired / RJ 45 or fibre-optical / SC Duplex (proprietary
or MODBUS® TCP protocol)
 RS485 communication interface (proprietary or MODBUS® serial RTU/ASCII protocol)
Operation principle
 Diffusion principle with gas-permeable TEFLON membrane
 Fuel cell-gas sensor for H2, CO, CH4, C2H2, C2H4 and C2H6
 Thin-film capacitive moisture sensor for H2O measurement
Notes
1)
120 V  120 V -20% = 96 Vmin 120 V +15% = 138 Vmax
230 V  230 V -20% = 184 Vmin 230 V +15% = 264 Vmax
2)
Related to temperatures ambient +20°C and oil +55°C
3)
Accuracy for moisture in oil for mineral oil types
4)
Relay 1: Gas Hi alarm
Relay 2: Gas Hi-Hi alarm
Relay 3: Moisture alarm
Relay 4: System alarm (Function)

6. Dimensional Drawings

6.1. Dimensions of valve connection
6.1.1. Connection thread G 1½’’ ISO DIN 228-1
6.1.2. Connection thread 1½’’ NPT ANSI B 1.20.1

HYDROCAL 1001+ Composite Gas-in-Oil Sensor With Moisture in Oil Measurement Installation and Operation Manual

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HYDROCAL 1001+ Composite Gas-in-Oil Sensor With Moisture in Oil Measurement Installation and Operation Manual

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HYDROCAL 1001+

Composite Gas-in-Oil Sensor with

HYDROCAL 1001+ Installation and operation manual Edition RS485 01.2015

EMH Energie-Messtechnik GmbH

Copyright MTE Meter Test Equipment AG

HYDROCAL 1008 Manual for Installation and Operation Page 2/114

4.2.2. Gas LED ..................................................................................... 28

4.2.3. Moisture LED .............................................................................. 30

4.3.1.3. LED RS485 ............................................................................. 32

4.3.1.4. LED Gas analog output .......................................................... 33

4.3.1.5. LED Moisture analog output .................................................... 33

HYDROCAL 1001 Manual for Installation and Operation Page 1/72

4.3.1.7. LED bar levels - Moisture ........................................... 46

4.3.2. Special Operation ........................................................................................................ 47

HYDROCAL 1001+ Installation and operation manual Page 2/76

Moisture in Oil (H2O) 100%

The present operating instructions are divided in the following sections:

HYDROCAL 1001+ Installation and operation manual Page 3/76

Pos. 1 Output side of cooling unit:

HYDROCAL 1001+ Installation and operation manual Page 4/76

Never apply a negative pressure to the connection unit.

Never touch the membrane with fingers or other objects.

HYDROCAL 1001+ Installation and operation manual Page 5/76

Never install the HYDROCAL unit on an elbow or curve of a tube.

Never use galvanized fittings or valves to mount the HYDROCAL unit.

Never use a chaining key tool for mounting.

HYDROCAL 1001+ Installation and operation manual Page 6/76

HYDROCAL 1001+ Installation and operation manual Page 7/76

2.3.3. Required tools

2.3.4. Sealing the connection thread

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2.3.4.3. Flat sealing (gasket)

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2.4.1. Mechanical installation

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 Check after 30 minutes if the threaded connection is tight (no leakage).

2.4.1.2. Indirect installation

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 Supply voltage connection:

HYDROCAL 1001+ Installation and operation manual Page 14/76

 Alarm- and analog outputs:

2.4.3. Putting into operation

Attention, danger of burning!!!

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[1] Protection cover with aeration hole

HYDROCAL 1001+ Installation and operation manual Page 16/76

[1] Oil unit with connection thread

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[3] System connection with SKINTOP® M25 cable gland

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[1] Reset Button [→0] (to zero)

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Copper wired or Fibre optic

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Note: Free assignment for both analog outputs.

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Short constant beep

Long constant beep with a slightly higher tone pitch

Long oscillating beep (whistle sound)

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[1] Connection terminal X1: Supply voltage / heating resistor

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