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InsulGard Manual
InsulGard Manual
InsulGard Manual
IB02713002E Rev. C
Effective August 2011
IB02713002E Rev. C
Effective August 2011
Table of Contents
Foreword................................................................................................................................................................... 7
1
Description ....................................................................................................................................................... 8
1.1
General..................................................................................................................................................... 8
1.2
Principles of Operation.......................................................................................................................... 10
1.3
Specification........................................................................................................................................... 12
1.4
1.4.1
1.4.2
Trend..................................................................................................................................................................14
1.4.3
Alarms ...............................................................................................................................................................14
1.4.4
1.4.5
1.4.6
Schedule.............................................................................................................................................................16
1.4.7
1.4.8
PD Intensity and PD pulse repetition rate calculation low level cut-off ............................................................16
1.4.9
1.4.10
1.4.11
1.4.12
Software ........................................................................................................................................................17
1.4.13
1.5
1.5.1
1.5.2
1.6
Sensors for InsulGard ........................................................................................................................... 27
Applications ................................................................................................................................................... 28
2.1
General................................................................................................................................................... 28
2.2
2.2.1
2.2.2
2.2.3
2.3
2.3.1
2.3.2
2.4
MV Switchgear Applications................................................................................................................. 30
2.4.1
PD sensors .........................................................................................................................................................30
2.4.2
IB02713002E Rev. C
Effective August 2011
2.5
2.6
2.7
2.8
2.9
Networking and Communicating with InsulGard................................................................................ 33
On-Site Installation ....................................................................................................................................... 34
3.1
3.2
3.3
3.4
3.5
3.6
Step 4 - Monitor Installation and Final Connections .......................................................................... 37
Startup............................................................................................................................................................ 38
4.1
General................................................................................................................................................... 38
4.2
4.3
4.3.1
USB ...................................................................................................................................................................41
4.3.2
Ethernet..............................................................................................................................................................41
4.3.3
Troubleshooting............................................................................................................................................. 46
5.1
Troubleshooting Tips............................................................................................................................. 46
5.2
5.3
5.4
Fuse Replacement.................................................................................................................................. 49
Appendix I InsulGard Front Panel Keypad Operation............................................................................. 51
6.1
6.2
6.2.1
Date....................................................................................................................................................................51
6.2.2
Time...................................................................................................................................................................52
6.2.3
Activate PD Channels........................................................................................................................................52
6.2.4
6.2.5
6.2.6
6.2.7
6.2.8
6.2.9
6.2.10
Rated Voltage................................................................................................................................................58
IB02713002E Rev. C
Effective August 2011
6.2.11
6.2.12
6.2.13
6.2.14
6.2.15
6.2.16
ModBus Address...........................................................................................................................................61
6.2.17
6.2.18
Baud Rate......................................................................................................................................................62
6.2.19
6.2.20
Start/Stop InsulGard......................................................................................................................................63
6.2.21
6.2.22
6.2.23
Frequency Range...........................................................................................................................................65
6.2.24
6.2.25
6.2.26
6.2.27
6.2.28
Calibrate Temperature...................................................................................................................................67
6.2.29
6.2.30
Calibrate Current...........................................................................................................................................69
6.2.31
6.2.32
6.2.33
6.2.34
6.2.35
6.2.36
6.2.37
6.3
6.3.1
6.3.2
Synchronization ..................................................................................................................................... 77
7.2
7.3
Determining Phase Reference Shift...................................................................................................... 79
Appendix III Communications Board Interface ........................................................................................ 81
8.1
General................................................................................................................................................... 81
8.2
Network Configuration.......................................................................................................................... 81
IB02713002E Rev. C
Effective August 2011
8.3
Change Passwords................................................................................................................................. 85
8.4
8.5
8.6
8.7
Email Configuration.............................................................................................................................. 88
8.8
8.9
8.10
8.11
Alarms .................................................................................................................................................... 96
8.12
Logs ........................................................................................................................................................ 97
8.13
Documentation....................................................................................................................................... 97
8.14
Ethernet Virtual Communications Port................................................................................................ 98
9
Appendix IV USB Device Driver Installation............................................................................................. 99
10 Appendix V Ethernet Virtual Communications Port Driver Installation and Configuration............. 106
10.1
IB02713002E Rev. C
Effective August 2011
Foreword
The purpose of this manual is to describe the functionality of the new generation of InsulGard. New
features include a graphic dot matrix display and more communication options embedded, such as
USB port, Ethernet port over network, webpage and FTP server. It serves as primary guideline for
qualified personnel involved in the onsite installation, start-up, commissioning and continuous
monitoring.
The whole document is organized in the following way:
Section 1 Description introduces the basic functions and operations of InsulGard
Section 2 Application presents the general considerations for InsulGard applications, especially
configuration of different sensors for different applications.
Section 3 On-Site Installation shows the procedures for onsite installation of InsulGard systems.
Section 4 Startup presents the procedures for initial setup using the front panel keypad without a
computer upon completion of InsulGard installation.
Section 5 Troubleshooting provides troubleshooting suggestions in different scenarios.
Section 6 Appendix I InsulGard Front Panel Keypad Operation gives details about how to operate
using the front panel keypad and display on the InsulGard.
Section 7 Appendix II Synchronization and Phase Reference Shift shows the procedures to make
proper synchronization and measure phase shift between InsulGard and monitored object.
The following three sections should be ignored if InsulGard does not include the optional
communication board.
Section 8 Appendix III Communications Board Interface presents the features available through the
optional communications board.
Section 9 Appendix IV USB Device Driver Installation gives exact steps to install the driver for
communication between a computer and InsulGard with a USB cable through the USB port on the
communication board.
Section 10 Appendix V Ethernet Virtual Communications Port Driver Installation gives exact steps
to install the driver and configure the interface to use the Ethernet port on the communications board as
a serial port to communicate between a computer and InsulGard online.
IB02713002E Rev. C
Effective August 2011
1 Description
1.1
General
IB02713002E Rev. C
Inputs for
auxiliary
sensors
connection
b
Figure 1-1 a - Top: InsulGard main unit (right) and Sensor Interface Board (left). Bottom: b - Side
view of the InsulGard.
IB02713002E Rev. C
Effective August 2011
1.2
Principles of Operation
InsulGard has 16 signal channels. Channels 1 to 15 are designated for partial discharge sensors while
channel 16 designated for noise suppression. All sixteen input channels have identical conditioning
circuits (CC) that provide signal isolation, transient suppression, and high-pass filtering of the input
signals. The frequency band of the PD signals for InsulGard is from 1 MHz to 20 MHz.
For each channel InsulGard acquires PD data in the form of three dimensional Phase-Resolved Pulse
Height Distribution (PRPHD) - PD pulse count as a function of pulse magnitude and phase angle of
monitored device voltage (60/50 Hz or voltage phase angle of a Variable Frequency Drive). Data are
sorted into 24 phase windows (150 each) and 21 magnitude windows with magnitude dynamic range of
~70dB.
After data acquisition InsulGard firmware calculates integral PD parameters: Partial Discharge Intensity
(PDI), Maximum Pulse magnitude (Qmax), Pulse Repetition Rate, and rate of upward trends of PDI and
Qmax.
Partial Discharge Intensity (or Apparent PD power) is the value proportional to the power dissipated by
partial discharges and represent damaging power of Partial Discharge. PDI measured in watts and
defined as:
Where:
i =n
1
PDI = * S * U i * Vr
T
i =1
T measurement time
S - sensitivity of the PD sensor (C/V)
n number of acquired PD pulses
Ui magnitude of a PD pulse
Vr rated voltage in the monitored equipment
Qmax defined as maximum repetitive magnitude of PD pulses. Above that magnitude pulse repetition
rate must be at least 0.2 pulses per power cycle. Such approach will not take high magnitude random
pulses as maximum PD magnitude.
Integral parameters are stored in internal data memory for each measurement, while PRPHD
matrixes are stored only time to time to avoid data memory overfilling. This comprising two saving
modes: Brief and Full or Normal and Test (in software settings). Each record is accompanied by
time/date stamp and three auxiliary operating parameters: temperature, humidity, load current or
voltage.
Before each measurement, InsulGard performs a self-test. If a problem detected, Status relay dry
contacts open and an appropriate message appears on InsulGard display. Loss of power causes
opening of status relay contacts too.
InsulGard acquires signals from the measurement channels sequentially multiplexing them to a single
signal channel. Each pulse from each sensor is validated by the allowed pulse width. Noncompliant
pulses will be discarded.
After each measurement, PDI, Qmax and Trend levels will be compared to preset Warning and Alarm
thresholds for each active channel. If a warning threshold exceeded warning relay will operate and
yellow LED will lit. If an alarm level is exceeded, InsulGard will trigger an additional measurement. If
alarm condition will be confirmed, a red alarm LED will be turned on and the alarm relay will operate.
Also phase resolved data will be stored in the memory and alarm event will be stored in log file in
device memory.
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IB02713002E Rev. C
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PD measurements can be performed on a time schedule (up to 50 different times per day) or in
specified time interval (from 1 minute to 23 hours 59 minutes) as long as the time interval is longer than
a measurement time. Four scheduled measurements per day are recommended.
Between scheduled measurements, the Continuous Watch feature is enabled. All signal sensors are
connected to a summation unit and then to a separate Continuous Watch channel. InsulGard
continuously searches for an appearance of high magnitude pulses and pulse series. Magnitude
threshold and repetition rate in series are configurable. If five events of pulse series are detected
between the scheduled measurements, InsulGard will trigger PD measurement and display an alarm, if
confirmed.
To provide correct measurements InsulGard must be synchronized with voltage frequency of the
monitored equipment (see Section 7 Appendix II Synchronization and Phase Reference Shift) and must
have correct settings for the type of equipment, rated voltage, and PD sensors used. All settings can be
made using Setup mode from front panel keypad and display (see Section 6 Appendix I InsulGard
Front Panel Keypad Operation ) or more easiliy using InsulGard PC software supplied with InsulGard
(see InsulGard Software Manual). Eaton supplies monitors preconfigured based on ordering
information.
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1.3
Specification
General:
Applications
Mounting options
Installation category
II
Pollution Degree
Temperature Range
Relative humidity
0%RH 90%RH
2000
Power Source
15 VA
Display
Keypad
4 arrows and
4 function keys
LEDs
PD Measurement:
Number of PD Channels
15
68dB
Frequency Bandwidth
1-20MHz
21
24
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IB02713002E Rev. C
3-20Hz, 20-400Hz
Synchronization type
Warning
367,300 pulses/second
Partial Discharge Intensity (PDI)
Maximum Pulse Magnitude (Qmax)
Pulse Repetition Rate, Trends of PDI and Qmax
by PDI or Qmax
Alarm
Full/Brief (Test/Normal)
Setup
Up to 150ft (50m)
3
120VAC/ 5 Amps
28VDC/ 5 Amps
For other ratings refer to the relay specification
Integral PD Parameters
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Effective August 2011
1.4
1.4.1
A Partial Discharge measurement results in Phase Resolved Partial Discharge Distribution (PRPDD)
for every active channel. After each measurement for every active channel, InsulGard calculates
integral PD parameters: Partial Discharge Intensity (PDI), maximum PD magnitude Qmax, Pulse
Repetition rate (pulses per second) and Trend of PD activity (rate of PDI and Qmax change). The
calculated parameters are compared to preset levels for Warning and Alarm operations.
All parameters with date/time stamp are stored in the internal memory for each measurement. Three
auxiliary parameters (temperature, humidity, percentage of full load current or operating voltage) are
added to each record.
Depending on what data will be stored in the internal memory, there are two modes of the Insulgard
operation: Test mode and Normal mode.
Test Mode during this mode (PRPDD and calculated integral parameters for each channel are stored
in the memory for every measurement. This is very memory-consuming mode, can overfill memory too
soon, so stored data should be downloaded more often. Test mode saving initiated twice a month by
default schedule. Schedule can be changed from keypad or software if necessary. The mode should be
enabled for special testing.
Normal Mode during most of the measurements InsulGard will store the Brief version of PD data only integral parameters without PRPDD (except scheduled Full saving mode measurements). This is
a default mode for continuous monitoring.
InsulGard has 2 MB of internal flash memory for data storage. When the memory is filled, the device
starts replacing the oldest data with the latest data. The rate of the memory consumption depends upon
number of active channels, frequency of measurements, and frequency of PRPDD storage. AIf all 15
channels are active, measurements performed four times a day and PRPDD are stored twice a month,
the device holds 17 months of the latest PD data in its internal memory. All stored data and settings can
be accessed from the keypad or remotely from a PC.
1.4.2
Trend
InsulGard calculates trend of the parameter PDI or Qmax. Trend is calculated as a linear
approximation of data over a specified time interval (default is 90 days). This specified time interval
window is sliding over time while the device is monitoring PD. Trend is normalized to the value of the
parameter change in times per year. Like PDI or Qmax levels, trend also has, Warning and Alarm
thresholds . When the Warning or Alarm level exceeded, the corresponding LEDs on the front panel
and relays will respond in the same manner as when PDI or Qmax levels are exceeded.
1.4.3
Alarms
InsulGard has two configurable alarm levels, Warning (Alarm 1) and Alarm (Alarm 2). There are two
groups of parameters that can generate an alarm. One is the preset levels of PDI or Qmax for Warning
and Alarm. The other is the preset trend levels for PDI or Qmax. Only one of two, PDI or Qmax, can be
configured for alarming at any time.
The same parameter, PDI or Qmax is automatically configured for the 4-20 mA interface output. The 420 mA interface always represent the channel with the highest PD activity in terms of percentage of the
channel alarm level with the slope 1mA/10%. An output of 4mA corresponds to 0% and 14mA
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IB02713002E Rev. C
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Between the scheduled measurements Continuous Watch feature (High Alarm) is active. All sensors
signals are summarized and connected to the separate High Alarm channel. InsulGard is continuously
counting high magnitude pulses and series of such pulses with predefined number of pulses in series. If
five series of high magnitude pulses detected, InsulGard starts regular PD measurement.
1.4.5
In order to provide valid phase-resolved data, InsulGard must be synchronized with a signal that is
synchronous with the voltage on the object being monitored. Phase shift between the voltage on
monitored object and InsulGard power voltage should be obtained for that purpose.
There are two options for synchronization:
In most of cases the power source (115/230 VAC) powering up InsulGard is used as a synchronization
signal. The device has an internal connection of the power circuit voltage to its synchronization circuitry.
This option (default) always works on monitored objects powered from a regular power system
(60/50Hz) in the area. Phase shift between monitors power voltage and the object high voltage should
be determined during InsulGard startup and remains valid while the same object is monitored and the
same power circuit is used. InsulGard allows for automated detection of a phase shift between its
power circuit and an external phase reference signal. For detailed information on synchronization and
phase reference shift detection refer to Section 7 Appendix II Synchronization and Phase Reference
Shift.
Be cautious of an UPS power use it only if the UPS has constant phase shift to the voltage in the
monitored object in Standby mode. If not, InsulGard will be in an asynchronous state and cant
provide accurate phase-resolved measurements..
External synchronization should be continuously used if the InsulGard power supply voltage is not
synchronous with the voltage on the test object. An example of an asynchronous test object is a
variable frequency drive. An external synchronization signal should be continuously provided to the
special synchronization input and appropriate jumpers in the device should be configured. Power
frequency component of a signal applied to the channel #1 can be used for external synchronization if
coupling capacitor is connected to that channel. For more information on synchronization and device
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Schedule
PD measurements can be performed at specified times during a day or in specified time intervals.
Typically monitors are shipped with time basis schedule enabled and set to make measurements four
times per day. This is sufficient for most of applications. If necessary, InsulGard can be set to measure
up to 50 times per day at scheduled times or in specific time intervals varying from 1 minute to 23 hours
59 minutes as long as the time interval is shorter than the time of the measurement.
The time T required for a measurement is T 21*NCh*NC / F, where NCh number of active channels, NC
number of cycles per acquisition, F synchronization frequency. Thus an InsulGard with all 15
channels active set for 60 cycles per acquisition and synchronized by 60 Hz would require
21*15*60/60=315 seconds, or 5 minutes and 15 seconds to complete a measurement.
1.4.7
InsulGard performs a self-test and calibration of PD signal and noise channels when powering up as
well as before every PD measurement. If self-test fails the status relay contacts will open and a
corresponding message will appear on the display.
1.4.8
PDI and pulse count (PPS - pulse per second) are calculated for each channel at every measurement
starting from some preset magnitude level (zone) and up. This feature allows for rejecting background
noise from affecting PDI and pulse count calculations. Low magnitude calculation cutoff threshold can
be set for each channel independently, based on its own background noise level, if any. There are
options to set these values manually or automatically. Automatic low magnitude threshold detection can
be launched only from the keypad (commonly during device start up or during the initial period of
operation).
1.4.9
Auxiliary Inputs
It is well known that operating conditions of monitored equipment can significantly affect PD activity.
Dependence of PD magnitude, repetition rate and PD intensity on temperature, humidity, system
voltage and load current (in rotating machines) can provide valuable information for deeper analysis
and increase diagnostic capabilities of PD monitoring. Calculation of correlations between PD
parameters and operating conditions is a part of InsulGard software.
InsulGard has three auxiliary inputs. One of the inputs is solely designated for temperature
measurement. A 100 platinum RTD can be used as a sensor. See the temperature sensor manual
for details.
Two other inputs can accept any AC or DC signals within a specified voltage range. As factory default,
they are configured for auxiliary sensors for load current and humidity measurement supplied by Eaton
with an InsulGard.
1.4.10 Measurement Suspend
Measurements can be suspended in three different ways:
Monitoring can be stopped. The STOPPED message will be blinking on InsulGard display and Red
Alarm LED will be ON. Monitoring must be resumed through keypad operation or software Resume
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IB02713002E Rev. C
Effective August 2011
command by an operator.
Monitoring can be paused by software Pause command. In this case, monitoring will resume
automatically in three hours.
Auto-suspend mode - can be controlled by any of three auxiliary parameters. The device allows an
user for setting low and high thresholds for these three auxiliary parameters and enable the autosuspend mode via keypad or via PC software. InsulGard will stop monitoring when any enabled
auxiliary parameter is outside low - high boundaries range. The auto-suspend mode mostly used to
suspend measurements in rotating machines by load current measurements when the machine is
out of operation. For example, if low threshold for load current is set to 5% of the nominal current,
InsulGard will stop making measurement when load current is 0 means that the monitored
equipment is out of service. This keeps InsulGard from collecting meaningless data which can lead
to incorrect trend calculations.
1.4.11 Communication Options and Device Address
InsulGard has various interfaces that allow for easy implementation into any alarm or SCADA system
as well as for remote communications:
Three C-form relays dry contacts for Warning (Alarm 1), Alarm (Alarm 2) and Device Status
indication.
RS-485 optically isolated interface based on ModBus RTU protocol allows remote device
configuration and data downloading. InsulGard can be networked with an existing ModBus
network, allowing for up to 231 addressable devices.
InsulGard is shipped with the device address #1, otherwise different address was specified. The
address can be changed only from the keypad and set to 1 - 231. In any case, the address must
be unique in a particular local device network.
InsulGard is supplied with database software that allows automated communication with a
device for data acquisition and analysis. The software allows either direct networking using a
USB/Ethernet to RS485 converter or dial up connection to a device by a regular telephone
landline or a cellular connection using appropriate modems with RS485 interface.
USB ports (only available with optional communications board): one USB port (Device) is for a
direct link to a computer for communications with the InsulGard software or for communication
board firmware upgrading, second USB port (Host) is reserved for future use.
Ethernet port (only available with optional communications board): It enables direct
communication between computer and InsulGard and implementation into Ethernet network.
Convenient online webpage and FTP server for data downloading or FTP client for data
uploading are under construction.
1.4.12 Software
InsulGard software allows for communicating with InsulGard through a PC on a local RS-485 network
or a modem. It also provides automated or manual data downloading and storage for multiple devices,
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IB02713002E Rev. C
Effective August 2011
device setting, data analysis, and presentation (See InsulGard Software Manual).
1.4.13 InsulGard configuration (settings)
To get most of PD monitoring InsulGard have to be properly configured in accordance with the type of
equipment to be monitored, system voltage, sensors used and preferable mode of monitoring.
InsulGard is typically supplied preconfigured for particular equipment in accordance with
available information received during ordering process.
Monitor configuration can be adjusted by changing firmware settings:
From InsulGard keypad (see Section 6 Appendix I InsulGard Front Panel Keypad Operation ),
From computer with help of software supplied with InsulGard monitor. The software has
templates to help with configuration for typical applications (see InsulGard Software Manual).
There are few settings that can be configured only through the keypad. Refer to Section 4.1 for details.
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IB02713002E Rev. C
1.5
In NEMA-4X enclosure with or without transparent windows for outdoor installation(Figure 1-2 a).
On the panel (Figure 1-2 b) for installation in a cabinet. This option is identical to the first one,
except that the panel is not mounted into an enclosure. Can be mounted into any custom cabinet
including explosion-proof enclosure.
Door mount option. This option is used for indoor installation on a cabinet door (Figure 1-2 c, d,
e). For door mount InsulGard Sensor Interface Board is mounted on the InsulGard back cover
with temperature and humidity sensors typically installed inside Sensor Interface Board.
Figure 1-2 a, b IG installed on the panel and in NEMA 4 enclosure with window, c Door
mount InsulGard, Sensor Interface Board is installed on the back of the InsulGard case, d, e Door mount IG installed on a switchgear cabinet door (d - front and e - rear views)
19
IB02713002E Rev. C
1.5.1
An example of a panel mounted InsulGard and its wiring diagram for 115 VAC power voltage is shown
in Figure 1-3 a, b, c and Figure 1-4.
The InsulGard panel must be grounded at the place of its installation.
a - Front view.
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IB02713002E Rev. C
Effective August 2011
21
IB02713002E Rev. C
8 S2
9
10
11 +5
Ref
Ch14
Ch15
H%
12 S
Sw
H%
Ch13
Ref
Ch16
(Noise)
LOAD-GND-BLACK 5
H%(GND)-WHITE 6
H%(+5V)-RED
H%(SIG)-BLACK
4-20mA- (+)
10
4-20mA- (-)
10
11
RS485-A(+)
11
12
RS485-B(-)
Humidity
sensor
12
13
ALARM - NC
14
15
ALARM - COM
15
16
ALARM - NO
16
17
WARNING-NC
17
18
WARNING-COM
18
19
WARNING-N0
19
20
STATUS-NC
20
21
STATUS-COM
19
22
STATUS-NO
22
23
NOT/USED
23
24
NOT/USED
24
L
B
Alarm
Alarm 2
14
L
L
+5
A
CT-Load
sensor
B
G
4-20
mA
RS - 485
USB
Host
InsulGard's
connectors
GR
N
25
RED
26
27
Ground Screw
on back cover
LINE
28
29
WHITE
NEUTRAL
30
GREEN
31
GREEN
GROUND
115 VAC
CT
7 S1
LOAD-SIG-RED
RED
Ch12
RTD-RED
RTD
Temperature
Sensor
GREEN
5
6
WHITE
3
4
RTD
Ch11
RTD-BLACK
Ch10
Ch9
RTD-WHITE
13
Alarm 1
Ch8
Warning
Ch7
Status
Ch6
Power
Ch5
USB
Ch4
Ch3
Device
Ch2
Ethernet
Connector to InsulGard
ALL
BLUE
Shield
Signal
Ch1
GREEN
Connect Panel
to Local Ground
DIN RAIL
GROUND
FUSES:
Inside Insulgard for 115VAC application: Time-Lag 200mA, 250VAC, 5X20mm type 5ST by BEL Fuse Inc. , Catalog # 5ST 200.
On the panel: Fast Acting 3.0A, 250VAC, 5x20mm type 5MF by Bel Fuse Inc. Catalog # 5MF 3-R (or equivalent).
Figure 1-4 A typical wiring diagram of the panel mounted InsulGard for 115VAC power voltage.
Note: For actual installation use the wiring diagram supplied with each InsulGard.)
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IB02713002E Rev. C
All connections (excluding coaxial cables from PD sensors and connection to USB and Ethernet ports)
must be done to the terminal strip on the right side of the panel in accordance with panel wiring
diagram supplied with each InsulGard. The table below: shows connection for typical wiring diagram of
Figure 1-4.
Terminal #
Connections
1
RTD sensor termination
Note
White wire (common)
output
10
output
11
RDA(+)
12
RDB(-)
13
Not connected
14
15
16
17
18
19
20
21
22
23
Spare terminal
Not connected
24
Spare terminal
Not connected
25
26
27
28
29
30
31
Coaxial cables from PD sensors (and from the noise sensor if used) must be connected directly to the
Sensor Interface Board (5 a). Connect the coaxial cables to their respective terminals at the Sensor
Interface Board. Central wire connected to an upper terminal, coax cable shield connected to a
corresponding lower terminal (labeled on 1st channel).
To access Sensor Interface Board one should temporally remove the InsulGard monitor.
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IB02713002E Rev. C
~1"
~0.3"
a
IDEAL part#45264 STRIP MASTER
Figure 1-5 a, b - termination of PD sensors coax cables to the Sensor Interface Board, c cable
preparation, d recommended stripper for RG58 cable, e Humidity/Phase Reference Switch.
Use blade crimp terminals on shield to avoid hairs and possible short circuit to the central wire.
Distribute cables evenly and secure them in place with cable ties.
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IB02713002E Rev. C
Effective August 2011
H% / Ref switch (Figure 1-5 e) must be in the H% position during normal operation. Ref switch position
is used only during phase shift measurement phase difference between external reference signal and
internal IG synchronization (Section 7 Appendix II Synchronization and Phase Reference Shift). After
that measurement switch must be switched back to the H% position.
1.5.2
In door mount version Sensor Interface Board is mounted on the InsulGard back cover (Figure 1-6).
Jumper J1
Jumpers
J7 & J8
Wire to
local
ground
H% / Ref
Switch
Figure 1-6 Door (Flush) mount InsulGard (back view)
InsulGard must be grounded at the place of installation.
Power line and output signals (Status, Warning (Alarm1) and Alarm (Alarm2) relays, RS485 and 420mA interfaces) should be connected to InsulGard directly by plug-in connectors supplied with an
InsulGard in accordance with the labels on the right side (Figure 1-3 c).
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IB02713002E Rev. C
All sensors should be connected directly to the Sensor Interface Board. Coaxial cables from PD
sensors should be connected to Ch1-Ch15 inputs. Auxiliary sensors should be connected to the 12
contacts connector on the left side of the Sensor Interface Board as shown in Figure 1-7 and table
below.
Cables from:
Temperature
sensor
Load (CT)
sensor
(for motors)
Humidity
sensor
Sensor
connected
Temperature
sensor
2
3
4
5
6
7
100 Ohm
Platinum RTD
Load (CT)
sensor
External
Reference
8
9
10
11
n/a
n/a
Humidity
sensor
12
Sensors wire
Note
Board common
test point
Board common
Board common
Output current is limited by 100 Ohm resistor.
Input impedance > 27kOhm. Input voltage should
not exceed +5V.
Notes:
H% / Ref switch must be in the H% position during normal operation. Ref switch position is used
only during phase shift measurement phase difference between external reference signal and
inner IG synchronization (Section 7 Appendix II Synchronization and Phase Reference Shift).
After this measurement switch must be switched back to the H% position.
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Jumper 1 (Figure 1-6) must be removed if external reference signal (e.g. from potential
transformer) applied to contact #7 on Sensor Interface Board (Section 7 Appendix II
Synchronization and Phase Reference Shift).
For door mount InsulGard temperature and humidity sensors are usually installed inside Sensor
Interface Board. Jumpers J7 & J8 must be installed that case.
1.6
Wide variety of sensors for InsulGard monitor are manufactured by Eaton Corp.
Basic sensors are:
IPDS - Integrated Partial Discharge Sensors with voltage ratings 5-38kV capacitors with special protection circuitry built in.
80pF coupling
IPDS
RTD-6-PD
RFCT
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2 Applications
2.1
General
InsulGard is a versatile device that can be applied to most of medium and high voltage equipment.
Specifics of a particular application (optional components and planning installation) should be taken into
account to achieve high performance of PD monitoring.
Issues that should be considered are:
Configuration of PD sensors
Noise aspects
Equipment with voltage ratings of 3kV and higher are considered reliable for PD diagnostic
applications. Marginally, 2300V equipment can be considered, but the technology is inconclusive. It
may or may not detect a significant problem at 2300V. In general, higher voltage provides greater
destructive power for partial discharges and problems can be more reliably detected and predicted.
InsulGard was designed to monitor partial discharges in any MV equipment. Most frequent applications
are in rotating machines, medium voltage switchgears, MV transformers and associated auxiliary
equipment and connections. The connections may include cable terminations and portions of a cable or
a bus feeding a device. InsulGard can also be used on other types of medium voltage and high voltage
equipment. Particular applications of the technology may require special pre-engineering and
adaptation. Consideration should be given while attempting to use InsulGard on high voltage equipment
above 120kV. Noise in the form of aerial corona discharges should be addressed in such cases.
PD sensors configurations are application oriented, although there are some general guidelines can be
applicable. Request Install Consideration and Sensor manuals documentation or/and discuss sensor
installation with an Eaton Electrical application engineer.
2.2
PD sensors for small generators and medium voltage motors typically include three sensors located at
the line terminals and one or two RTD-PD sensors servicing six to twelve winding RTDs. Because of
significant attenuation of high frequency signals in a motor winding, sensors located at the line
terminals will not detect partial discharge in a winding depth; likewise, the sensors located in winding far
from HV terminals will not sense discharges at the line terminal.
2.2.1
Coupling Capacitors. Typically Integrated Partial Discharge Sensors (IPDS) by Eaton with 80pF
capacitance, but can use any kind of coupling capacitors. IPDS have sufficient insulation and
connected directly to a motor line terminals. Those sensors exhibit the most noise-immune
characteristics due to their low capacitance and, therefore, can suppress most low frequency
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noise by themselves. Using IPDS is a highly recommended option for line terminals.
Note: Installation of line terminal sensors always requires an outage.
Radio Frequency Current Transformers (RFCT) placed on incoming feeders shield grounding
conductor (one per phase) or on single-phase surge capacitor grounding conductor (one per
phase). Using a single three-phase surge capacitor is possible, but not recommended because of
low sensitivity to phase-to-phase partial discharge. The later is also valid for RFCT sensors on
three phase feeder shield ground single wire. An advantage of RFCT sensors is that they are noninvasive (no connection to HV conductors is required). But RFCT sensors are less noise immune
compare to IPDS sensors and more vulnerable to ground network noise. RFCT absolutely should
not be used in Variable Frequency Drives environment with high magnitude and repetition rate
pulse noise.
2.2.2
Besides line terminal area sensors, additional sensors are required to service larger area of a stator
winding. RTD sensors embedded into a stator windings can be used for this purpose. An RTD supplies
a DC temperature signal to a metering device. An RTD and RTD wires also operate as a RF antenna
for high frequency signals generated by partial discharge. High frequency signals can be extracted and
used to for detection of pulses originated by partial discharge in proximity of an RTD.
Eaton developed the RTD-6 PD sensor board with embedded filters to suppress external noise coming
from temperature metering system or induced in control wiring by other equipment. This sensor is
designed as a single board to replace an existing RTD terminal board in the closest to a
motor/generator RTD terminal box. It does not affect temperature measurements, and extracts PD
signals to be detected by InsulGard. Each board can handle up to six RTDs. If there are more than 6
RTDs, additional RTD -6 PD sensor board should be used. An RTD-6 board can be installed online
which requires temporarily disabling temperature alarm or relay system.
2.2.3
Auxiliary sensors
Partial Discharge activity significantly varies with operating parameters. Winding temperature, load
current, and humidity are the three most important parameters to correlate with a detected PD activity.
Correlation of the detected PD activity with those parameters can provide invaluable information for
enhanced diagnostics of insulation condition in a monitored equipment. Preferably use one of the
winding RTDs for temperature measurement.
Note: One InsulGard device is required for a monitored object.
2.3
Large generator application is, in general, similar to a motor or small generator application.
2.3.1
Coupling capacitors (IPDS) are commonly used as line terminal sensors. A generator equipped
with iso-phase bus duct might have sparking in bus supporting insulators. A digital filter has been
built into InsulGard firmware to distinguish that specific external PD activity from PD activity
coming from a generator. Another option is using two sets of IPDS located at the terminals and at
some distance along iso-phase bus for noise suppression.
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2.3.2
Large machines can have several dozens RTDs embedded in the winding. Use 12 RTDs located
in most electrically stressed parts of the stator winding, and evenly distributed along the stator
winding to obtain maximum coverage of the stator. Making that choice can be a challenge even
when winding diagram and RTD locations are available.
Large generators may have very long signal wires from an RTD to the first RTD termination. Also
different kinds of RTD wires can have different signal propagation qualities. These factors can
significantly affect high frequency signal propagation, attenuating a PD pulse. In order to minimize
signal attenuation; RTD-6 board can be installed at the generator gland, where the RTD wires
come out of the generator frame.
Certain generators do not have RTDs embedded into a stator winding. For example, large
Westinghouse hydrogen cooled machines have RTDs only in cooling gas pipelines. These RTDs
cannot be used as PD sensors. Verify that RTDs are located in a winding.
Auxiliary parameters are monitored in large generators same way as in motors. In hydrogen cooled
generator hydrogen pressure might be monitored instead of humidity.
2.4
MV Switchgear Applications
PD sensors
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2.4.2
Auxiliary sensors
Temperature and Humidity should be monitored in switchgear application. By default for door mount
InsulGard in indoor applications temperature and humidity sensors are incorporated into sensors
Interface Board. External sensors will be shipped if requested. If high voltage in the system can vary
more than +/-5%, one can consider monitoring of that voltage too. That option requires reconfiguration
of the jumpers on the Sensor Interface Board and changes in InsulGard and software settings.
2.5
The Warning and Alarm thresholds for each PD channel of InsulGard are configurable. Thresholds
depend on the type of PD sensor used (sensor sensitivity), system voltage, type of equipment, sensor
location and adjacent connections. There are no universal standard values for Warning or Alarm
thresholds. The following table shows typical values of the thresholds used as default settings in
several applications:
Application
PDI
Warning
(mw)
Sensor Type
PDI
Alarm
(mw)
Qmax
Warning
(mV)
Qmax Alarm
(mV)
Coupling Capacitor
10
50
100
Coupling Capacitor
10
30
100
500
RTD
10
30
100
500
Coupling Capacitor
20
100
200
1000
RTD
20
100
200
1000
5 kV Switchgear
Coupling Capacitor
50
100
15 kV Switchgear
RFVS
10
50
200
15 kV Switchgear
Coupling Capacitor
10
50
200
38 kV Switchgear
RFCT
20
50
200
Since PD measurements in high frequency range are relative in nature, warning and alarm threshold
should be corrected in every given case after initial period of monitoring and subsequent data analysis.
Simple rule of thumb can be used:
- in case of significant PD activity set warning threshold close to average level of PD activity,
set alarm threshold a little below peak values of the detected PD activity, so that threshold will
be exceeded infrequently and phase resolved data will be saved during such events;
- if PD activity is low, set warning level higher then peak readings and set alarm
threshold twice higher then warning threshold.
2.6
Noise Aspects
Noise is a major issue in partial discharge measurement in industrial environment. Noise is site-related.
There is no universal solution for noise suppression in modern state of technology, however most noise
issues can be overcome. InsulGard has been designed with several noise suppressing algorithms and,
along with recommended sensors, is able to suppress most of industrial noise. While planning
InsulGard installation, keep in mind most common noise sources:
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2.7
InsulGard can be shipped with or without an environmental enclosure. Without an enclosure, it can be
used indoors in a relatively clean environment.
In most applications, indoor or outdoor, InsulGard comes in NEMA-4 plastic enclosure protecting the
device from direct rain, sun, and dust. Use stainless steal enclosure in chemically aggressive
environment. Explosion proof enclosure might be required in special cases.
In an indoor switchgear lineup InsulGard can be door mount without an enclosure.
When planning installing InsulGard, consider a non-vibrating location, conveniently located in a
centralized position close to all sensors, control power line and communication lines (phone jack,
conduits/tray to control room for alarms, etc.). It is recommended to keep the length of PD signal
coaxial cables (50 Ohm RG58 or similar) as short as possible to decrease signal attenuation along the
cable. Recommended maximum length is 150, but it is not a solid limitation.
2.8
Several factors can affect PD activity: temperature, humidity, voltage, mechanical vibration, etc. In
North America system voltage commonly is not an issue. It is stable and does not affect PD
significantly. If more than +/-5% voltage variation is expected, the voltage should be monitored and
correlated to PD activity. Temperature is very important parameter for PD diagnostics of an insulation
condition. Temperature variations change size of voids in solid insulation and surface conductivity
which subsequently cause changes in PD activity. Humidity is also a factor affecting partial discharge,
mostly through changes in surface conductivity, especially if combined with surface contamination. In
hydrogen cooled machines monitoring of hydrogen pressure may be more beneficial than monitoring
humidity. Changes in Load current affect vibration of coils in rotating machines and cause changes in
slot and end-winding discharges. Correlation of PD activity changes to operating parameters can help
distinguishing different types of partial discharge improve diagnostics capabilities and direct corrective
measures.
Also zero load current (or voltage) could be used to suspend monitoring during equipment outage.
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2.9
InsulGard equipped with several interfaces allowing for implementation of a monitor into a control
system or into instrumental network:
Dry contact C-form relays can provide warning, alarm and monitor status signals to an annunciator
or to SCADA system. Always wire at least Alarm (Alarm 2) and Status relays to an annunciation
system. If necessary, all relays can be wired in series or in parallel to the same annunciator.
4-20 mA interface provides output current proportional to PD activity in PD channel with the
highest PD activity in percentage to that channel alarm level. That signal can be wired to a
SCADA for trending.
RS485 interface allowing an InsulGard to be implemented into instrumental network with up to
251 devices on network. With the interface a device can be implemented into a SCADA system.
Device settings, measurement control and data downloading can be done through that interface.
RS485 to USB and RS485 to Ethernet converters can be used for communication with local PC or
on Ethernet network. Optional communications board has incorporated USB and Ethernet
interfaces eliminating needs for converters.
Through the Ethernet port of the optional communications board one can access internal Web
page and data can be downloaded through the FTP server (both are under construction). It also
can be configured as a virtual serial port to be accessed by the InsulGard software.
Using Landline or cellular modems (optional) provides opportunity for full scale remote
communication to an InsulGard or to InsulGards network.
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IB02713002E Rev. C
3 On-Site Installation
USE Startup manual step-by-step procedures as guidelines in actual installations and checking
and commissioning.
3.1
InsulGard monitor
Item Description
Comments
Specify mounting option and power voltage 115 VAC or 230 VAC.
Preconfigured for internal synchronization (by default) or for
external synchronization (Variable Frequency Drive applications)
Communications Board
115VAC, 10 A receptacle
Included for 115VAC power. Not included for 230VAC power and
in door mount version
Blade Terminals
Wiring diagram
Software
Manuals
Hardcopy
RFCT-075
RTD-6
Auxiliary sensors
TS - 3-wire 100 Ohm RTD
HS
CT
CTF
Communication means
Land Line or Cellular Modem with
power supply
Optional
RS485/USB converter or
RS485/Ethernet converter with power
supply module
Optional
Coax cable
RG58 coax cable
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3.2
For ordering convenience a PD monitoring system can come in standard packages for a particular
application:
3.3
InsulGard monitor comes preconfigured to our best knowledge. If not configured properly use templates
in software for typical configurations to configure most of parameters with few necessary corrections
after. These templates assume that all coupling capacitors are connected to the first PD channels in
ABC order. In rotating machines RTD sensors come after coupling capacitors in incremental RTD
number order. Following this rule while connecting sensors to a monitor will simplify configuration later
on. For switchgear application first connect all coupling capacitors to the first PD channels in ABC
sequence, then connect RFCT sensors. Refer to Install Consideration documents for typical
applications.
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3.4
This section provides general guidelines. Each installation may have its own specifics. Refer to
sensors manuals for installation.
Select a convenient location for the InsulGard enclosure. It should be as close as possible to the
equipment being monitored. Avoid locations with excessive vibrations, heat and direct sun light.
Cable length from PD sensors, generally, should not exceed 150ft (50m). It is usually convenient to
install the device in the center of PD sensors locations, keeping PD signal cable lengths
approximately the same. It is not necessary to have cable lengths exactly the same.
Take monitor from the panel: gently disconnect InsulGard green plug-in connectors from right side
and flat ribbon cable connector from the sensor interface board, unscrew 4 mounting screw from
faceplate and remove the monitor.
Door mount monitor can be installed into the cut in a cabinet door.
Run conduits (if necessary) for the cables for PD sensors, communications, alarm relays, 4-20 mA
interface and for the InsulGard power.
Install Partial Discharge sensors. Follow corresponding installation manual for the sensors.
Install Current Sensor on the secondary wire of a metering current transformer. Phase A is
preferred, but is not necessary. In absence of a metering CT in feeder termination box use an easyto-install primary Core CT over feeder cable. Refer to CT, HS &TS sensors manual.
Install temperature sensor (if ordered separately) inside the switchgear at a suitable location closely
representing the inside temperature. A rear compartment at the middle of a lineup usually works
well for that. In the case of a motor or generator, preferably use one of the spare winding RTDs
(Platinum 100 Ohm). Run three wire shielded cable from that RTD to InsulGard monitor. Otherwise
locate the temperature sensor at a suitable location closely representing the stator winding
temperature.
Install humidity sensor (if ordered separately) inside a switchgear at a suitable location closely
representing inside humidity (next to the temperature sensor). In the case of a motor or generator,
humidity sensor typically installed inside feeder/bus terminal enclosure to represent humidity in line
terminals area.
Install communication equipment: RS485 converters, modems, Ethernet, power supplies (ordered
separately). Run communication cables. Several InsulGards can be networked together via RS-485
network, using one modem or Ethernet converter for all of them.
When networking several InsulGards together via RS-485, use a daisy-chain configuration. The
chain can be terminated with a 120 Ohm resistor at the end if necessary.
Run all cables into the InsulGard enclosure. Leave at least 2 of excess cabling in the enclosure for
easy terminating.
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3.5
Important note
Connect coax cables to IPDS sensors properly: central wire to Signal terminal and shield to
Shield terminal using supplied ring connectors. Swapped central and shield cant be corrected
after equipment will be energized, there will be no output signal. As a temporary measure one can
swap central wire and shield at the sensor interface board, but it will give more noise.
Sensor cable connections are not user accessible after installation.
Connect PD sensors coax cables to InsulGard sensor interface board in proper sequence. Refer to
software settings and related information in the Questionnaire filled in ordering process.
Connect temperature, humidity and load sensors to the monitor in accordance with the supplied
wiring diagram.
Run and terminate InsulGard power cable to a designated breaker or fuse block. Verify that there is
no voltage at the source for save work. Provide a disconnect device near the unit during installation.
3.6
Check proper sensors connections with a multi-meter. Use the detailed check-list from the Startup
manual.
Install InsulGard and fasten it to the standoffs with the screws (enclosure/panel mount option).
Connect flat ribbon cable from InsulGard to the Sensor Interface Board. Make sure that two
connector latches are locked.
Replace green plug-in connectors and connect communication lines.
Switch InsulGard power On. Loading and firmware version should appear on the device display.
Device is now ready for setup and operation.
Verify that signal wires and power are connected to the modem or/and converter. They typically
have LEDs indicating power ON.
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IB02713002E Rev. C
4 Startup
Use Startup Guideline document for PD system installation/verification and practical Startup
procedure.
4.1
General
InsulGard setting can be done from the front panel keypad or from a PC using InsulGard software via
the RS485 port or USB port on the optional communications board. For software settings please refer
to the Software manual.
Setting the device from a PC is easier, but few settings can be changed ONLY from keypad. These
are parameters or procedures that must be set at the factory or during installation/startup:
Device address on a network (preconfigured)
Baud Rate (preconfigured)
Phase Shift detection (startup procedure)
Current / Voltage channel calibration (startup procedure)
Low Noise detection/setting (startup procedure, rare used)
Communication protocol - ModBus RTU(default) or Modbus TCP (rare used)
Frequency Range (default range 20-400Hz, change only for 3-20Hz application)
Temperature channel calibration (calibrated at the factory)
4.2
InsulGard is pre-configured at the factory for a particular application in accordance with the information
received during ordering process. In most case only phase shift measurements and load current
channel calibration should be performed in field. Setup procedure below describes steps that can be
done during typical installation/commissioning. Specific applications might require some additional
procedures.
The table below lists steps for device settings from monitors keypad with reference to more detailed
description of the keypad operation.
Parameter or
Procedure
Action
Enter Setup
Mode
Set Date
Set Time
Device
Address
Rated Voltage
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IB02713002E Rev. C
Rated Current
Activate
Channels
Channel
Sensitivity
Channel
Phase
Parameters to
Display
Set Channel
Low
Magnitude
Limit
Calibrate
Current
Calibrate
Voltage
Activate
Auxiliary
Parameters to
Suspend
Measurements
Number of
Power Cycles
per acquisition
Select PDI or
Qmax
Skip it.
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IB02713002E Rev. C
Detection and
setting of
Phase
Reference
Shift
Measurement
Schedule
Alarm Relay
Mode
Exit Setup
Clear Data
Memory
Enter setup
Start a Single
Measurement
Use and to scroll to Set Phase Shift, press Enter. Use any
arrow to switch between Manually Input Phase Shift and Auto
Detect Phase Shift. Press Enter. In Manual Input type phase
shift in and press Enter. In Auto detect mode press Enter and
watch changing data for few minutes. Press Enter to stop
measurements. Calculate average value. Press Enter to go to
Manually Input Phase Shift and type the calculated average
value. Press Enter. Deviation more then +- 5 degrees or not
changing values are symptoms of a problem - see Section 7
Appendix II Synchronization and Phase Reference Shift for
complete details.
Press ESC.
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4.3
If the optional communications board is installed some configuration and driver installation must be
completed to gain complete access to all of its features. There are three communication ports
available.
USB
1. Device USB port. Port is used for local communications between the InsulGard and a computer
through a USB A/B cable. A software driver must be installed on the computer prior to use. The
complete driver installation instructions can be found at Section 9 - Appendix IV USB Device
Driver Installation.
2. Host USB port. This port is reserved for future use.
4.3.2
Ethernet
There are several functions available through the Ethernet port including webpage display, FTP upload
or download and operation as a virtual serial port.
Before any settings can be changed, you may need to change your computers network setting and
access the InsulGard with an Ethernet cable connected directly between your computer and the
communications boards Ethernet port. The following are typical steps to initialize the communications.
The default IP address for the communications board is 192.168.1.1. Note, if you plan to access
InsulGard on a LAN, or you need to remote monitor InsulGard online, you will need to change the IP
address to an address compatible with the network where InsulGard is installed.
4.3.2.1 Change on a Computers Network Settings
1. Go to Network Connections. If a Wireless Network is used, disable it, then right Click on Local Area
Connection, and click on Properties
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3. Before making any changes, please write down the current settings to restore the settings upon
completion. Change the settings to what is shown below.
4. Connect your computer to the Ethernet port on InsulGard with an Ethernet cable. Open Internet Explorer,
type in 192.168.1.1 on the address bar and the following screen will appear. Type in admin for the
User name and Password and you are ready to go.
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4.3.2.2 Webpage
InsulGard information can be accessed via webpages through the Ethernet port,. Some parameters
must be configured before connecting to a network. Several other parameters should be customized to
match the particular location. Details can be found at Section 8 Appendix III Communications Board
Interface. The following table provides steps for configuring a typical installation.
Parameter or
Procedure
Function/Note
See section #
Set the current date and time, synchronization to Network Time Protocol
servers, date format, time zone, and temperature units.
8.5
Network
8.2
Modbus RTU
8.4
8.7
FTP Client
8.6
Access Control
8.3
Web Page
Customization
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users log into the companys network through a VPN from an outside network, communications with
InsulGard may also be possible depending on the companys firewall and network settings.
Please follow the steps in Section 10 Appendix V Ethernet Virtual Communications Port Driver
Installation to set up the virtual serial port on the computer.
4.3.3
The following tips only apply to InsulGard with the optional communications board.
1. There is always a waiting time ranging from 20 seconds to 5 minutes before InsulGard software
can communicate with an InsulGard unit after the following operations: InsulGard is powered up
(1 minute), after keypad Memory and Set operations, during and for a short time after a
measurement cycle and Data Erasing command.
2. If communications through the USB port is not successful, unplug the USB cable and then plug
it back into the computer. If using InsulGard software versions 3.XX, exit InsulGard software,
then plug-in USB cable, run software, repeat plug-out/plug-in in communication tab if have no
communication again.
3. During a measurement cycle, InsulGard cannot be accessed using InsulGard software through
the virtual serial port or USB port, however, the webpage will still display the information stored
before the measurement.
4. If you are communicating through a virtual serial port via Ethernet, you may need to check if the
IP address has been changed on the communications board. It is preferable to have a static IP
address for the InsulGard.
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5 Troubleshooting
5.1
Troubleshooting Tips
Possible problems and probable causes and remedies are listed in the table below:
##
1
Problem
The front panel
display is blank.
Probable Cause
Lost power
Firmware programming
has not competed
successfully
2
No data stored in
InsulGard memory
Recommended remedy
-Check incoming power and external fuses;
-Check resistance between neutral and line
contacts in InsulGard power input connector
should be ~47 Ohm for 115 VAC and ~157
Ohm for 230VAC versions. Higher resistance
reading may indicate blown internal fuse or
internal transformer problems. If necessary,
replace the fuse. If significantly lower
resistance is measured return the unit to the
factory for repair.
Try to reprogram in accordance with
Firmware Upgrade manual. If failed, return
the unit for repair.
When communicating
through software got
message Date/Time
differs from computer
time significantly.
Display is blinking,
cant communicate to
the device from
software.
Corrupted Firmware
memory
Error I Channel or
Error N Channel
appears on the front
panel display.
Keypad is not
working.
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Communications
from a PC to
InsulGard failed.
InsulGard is not
making
measurements.
Communication rate is
incorrect.
Disable control
10
See above
See above
11
Temperature,
humidity and load
current are
senseless.
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IB02713002E Rev. C
The temperature
readings are
incorrect
Humidity readings
are incorrect
5.2
1. Backup old configuration in software. Backup database file for the OLD InsulGard.
2. Replace monitor for new one
3. Run InsulGard Software. DO NOT enable editing Edit Analog Input Calibration Coef. window
in Unit Settings window in software.
4. Change the Magnitude Threshold, V in Continuous Watch in Unit Settings window with the
number on the sticker on the front panel of the NEW InsulGard.
5. Send Settings to Device from Communications window. Get Settings from Device. Click Update
the Database with the Current Device Configuration. Backup the Settings. The database
software will have analog coefficients for the NEW InsulGard with the rest of the settings from
the OLD InsulGard. Have to repeat Load Current calibration if Load current was monitored and
old calibration data have not been entered into NEW InsulGard firmware.
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5.3
Error Messages
InsulGard performs self-test when powered up and before every measurement. If self-test failed, an
error message will be displayed, and the Red LED will lit. InsulGard may display the following error
messages:
No Synch. Signal -- indicates a loss of the synchronization signal. For external synchronization
mode verify that signal on contact 7 of the Sensor Interface Board is > 0.2VAC. Check jumpers
position or lost jumper on the sensor interface board or on CPU board #1 in internal
synchronization mode. Refer to Section 7 Appendix II Synchronization and Phase Reference Shift
for details.
Clock Error This message indicates there are the data in the devices internal memory with date
stamp that is later than the current date. This condition corrupt data consistency. Download all
data to the PC software, erase all data in the InsulGard and set correct date and time.
Downloaded data can have date/time inconsistency that hardly can be corrected. Refer to Section
6.2.1 Date and Section 6.2.2 Time for correction procedure via keypad.
Error | Channel Indicates that the PD measuring channel has not pass calibration. If this
message appears consistently, the device must be returned for repair.
Error N Channel Indicates that the PD noise channel has not pass calibration. If this appears
consistently the device must be returned for repair.
FLASH Error Indicates an error reading internal FLASH memory. Download then delete data
accumulated data from device memory. If does not help - the device must be returned for repair.
STOPPED Indicates measurements are stopped and the device will not resume measurements
automatically. Please refer to Section 6.2.20 Start/Stop InsulGard for details on resuming
operation from the front panel keypad or refer to the Software manual to resume operation from a
PC.
5.4
Fuse Replacement
If 115/230VAC power is present, external fuse not blown, but the device display is blank and LEDs do
not lit, internal fuse may be blown. If no permanent damage has occurred fuse replacement may correct
the problem.
Cut input power off. Check the resistance between Line and Neutral. For 115VAC applications it should
be ~47 Ohm, for 230VAC applications ~157 Ohm. If open circuit change the fuse. Lower resistance
indicates power transformer failure and the unit should be returned for repair.
Attention!!! Fuse replacement requires partial disassembly of the device and must be performed
by a qualified person. Contact your local Eaton Electrical representative for assistance.
Fuse replacing procedure:
1. Take InsulGard of an enclosure or panel.
2. Relief flat ribbon cable by removing small cover on top of back cover. Remove InsulGard back
cover.
3.
for 115 VAC InsulGard use 200mA 5x20 mm, 250VAC rated Time Lag 5ST200-R fuses
by BEL Inc.
for 230 VAC InsulGard use 100mA 5x20 mm, 250VAC rated Time Lag 5ST100-R fuses
by BEL Inc.
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IB02713002E Rev. C
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4. Carefully reassemble the device and restore connections. Pay particular attention to the flat
cable connecting devices keypad dont pinch it;
5. Check connections and reapply power.
The fuse location is shown in Figure 5-1.
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IB02713002E Rev. C
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Entering Setup
Press Set key. The password prompt will appear on the display:
Enter Setup
Password: - - - 0
Enter 5421 password by using
and
to move to different digits and
and
to change the
value and then press Enter. The password is coded into device memory and cannot be changed. Wait
about 20 seconds (until dashed lines will disappear) before pressing any other key. If the wrong
password is entered the dashed lines remain on the display until any key is pressed.
When InsulGard is in Set mode, the Set LED will be on.
If InsulGard stays in Set mode for more than 20 minutes, it will exit to the upper menu and continue
exiting Set mode to normal operating mode one step up every 20 minutes.
Access setup options by pressing
or
keys, select an option by pressing Enter. Exit the Set
mode by pressing ESC. All changes will be saved in the memory upon exit.
The following setting options are listed in the order of pressing
after entering Set mode.
6.2
6.2.1
Date
Set Date
Date (mm/dd/yy)
02/15/10
Use
and
to move between digits. Use
and
to change the corresponding values. When
finished, press Enter to confirm and exit. To discard the changes, press ESC to exit.
If there is a data record(s) with date/time stamp later then date/time settings, following message will
appear:
Erase Records
After New Date?
You can exit without erasing records by pressing ESC. Alarm LED will turn On and Clock Error will
be displayed upon exiting Set mode. Press Enter, to delete all measurement records with date/time
stamp later then date/time setting. This feature helps to keep data integrity in case of date/time settings
have been corrupted.
Clearing
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IB02713002E Rev. C
If the date is changed to an earlier date by the InsulGard software, the memory will not be cleared, but
Alarm LED will be On and Clock Error will be displayed.
6.2.2
Time
Set Time
Time (HH:MM:SS)
02:35:12
Use
and
to move between digits. Use
and
to change the corresponding values. When
finished, press Enter to confirm and exit. To discard the changes, press ESC to exit.
6.2.3
Activate PD Channels
Set Active
Channels
InsulGard has 15 signal channels. Depending upon the application, some channels are used while the
rest remain inactive. To conserve memory and minimize measurement time do not activate more
channels than necessary. Press Enter:
Channel 01
Off
Use
and
to select Channel number, use
or
to switch it On/Off. When all channels
are properly set press Enter to confirm the changes or ESC to discard the changes. Following
message will appear:
Noise Filter
On
Use
or
to switch Noise Filter On/Off, then press Enter.
6.2.4
Parameters to Display
Set Parameters
To Display
Chosen parameters will be scrolled on the display when InsulGard is not making a measurement.
Press Enter
Date
Off
Use
or
to select On or Off.
Use
to scroll through parameters to display then enable/disable parameters to be displayed. All
display options are shown below in order.
EATON CORPORATION www.eaton.com/pd
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IB02713002E Rev. C
Date:
Date
On
Will be displayed as:
Date (mm/dd/yy)
02/15/10
Time:
Time
On
Will be displayed as:
Time
21:45:20
Show Next Scheduled Measurement Time:
Next Measurement
10:00
Partial Discharge data:
Channel PD Data
On
The PD data acquired in the last measurement in each active channel will be displayed. Displayed
information can looks as:
Chan
2
%PD
30
Status
Norm
The Chan represent Channel number, %PD is PDI as a percentage of the preset alarm level. Four
possible situations are reflected by Status:
Low PDI is below low level and will not be taken into trend calculation;
The example above shows Channel 2 with PDI 30% of alarm threshold constituting Normal status
If Qmax is the selected parameter for diagnostic, Qmax will be displayed in mV instead of % of alarm
threshold:
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IB02713002E Rev. C
Chan
2
Qmax
Status
0mV
Frequency
On
Will be displayed as:
Frequency
60.00 Hz
Display Temperature:
Temperature
On
A Will be displayed as:
Temperature
20C
Display Voltage:
Voltage
On
Will be displayed as a percent of rated voltage:
Voltage
95 %
Display Load Current:
Current
On
Will be displayed as a percent of rated current:
Current
40.0%
Display Relative Humidity:
Humidity
On
Will be displayed:
Humidity
20.4 %
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6.2.5
Set Channel
Sensitivity
InsulGard can use almost any PD sensor operating in 1-20 MHz frequency band. Despite relative
nature of PD measurements in high frequency range default sensitivity settings are entered in the
settings to calculate PD Intensity. It is recommended that you use the same sensitivity for all sensors of
the same type and function. A sensor sensitivity can be determined through off-line sensor calibration.
That calibration has limited value and valid only for PD events next to a sensor. Also different
calibration generators can give significantly different sensitivity.
Default sensitivities are preset for a particular application in settings templates in InsulGard software.
Use the suggested sensitivity for Eaton PD sensors:
1. Coupling Capacitor 3 nC/Volt
2. RFCT on cable drain shield 10 nC/Volt
3. RFCT on surge capacitor ground 5 nC/Volt
4. RTD sensor in motor/small generator 10 nC/Volt
5. RTD sensor in large generator 50 nC/Volt
6. RFVS sensor in switchgear 15 nC/Volt.
Press Enter
Channel 01
10.00 nC/Volt
Use
or
to change Channel number. Press Enter. Use
and
to move between digits.
Use
and
to change the corresponding values. Press Enter. Chose next channel. After all
changes are done, press ESC to exit.
6.2.6
Set Measurement
Schedule
Press Enter. Use
or
to switch between measurement schedule by Time Table (Time of Day)
or by Time Interval.
Schedule Per
Time of Day
Press Enter.
Time of Day # 01
01:00 (HH:MM)
Use
or
to scroll between time table items (up to 50 measurement times can be set). Press
Enter. Use
and
to move between digits. Use
and
to change the corresponding
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IB02713002E Rev. C
Schedule Per
Time Interval
Press Enter. Use
or
to switch between hours and minutes. Use
or
to change the
values.
Time Interval
06:00 (HH:MM)
Press Enter to save time interval and exit. Press ESC to discard changes and exit.
Please note that the Time Interval must be NOT LESS than the time for a single measurement.
Otherwise you may create an infinite cycle and will not be able to get out without monitor rebooting.
Estimated measurement time is: t= Ncycle *Nch*21/ F +1 minute, Ncycle number of power cycles for
acquisition, Nch number of active channels, F is the power frequency. Six minutes and higher is a
minimum safe interval for default measurement settings and 15 active channels.
6.2.7
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IB02713002E Rev. C
On Reading #
02
Use
or
to switch between digits. Use
or
to change values. Press Enter.
InsulGard will save Full mode data every 15 days (counting from beginning of a month) on second
measurement from the schedule table.
6.2.8
Channel 01
Use
or
to change the channel number. Press Enter.
PD Width 640ns
Interval
2560ns
Use
or
to switch between PD Width and Interval. Use
or
to choose the values.
PD Width selections are:
640nS default value, recommended for RTD, IPDS, RFVS and RFCT sensors
1280nS for use with long pulses from RFCT sensors on cables
Alarm Thresholds
Set Alarm
Thresholds
InsulGard operates the alarm contacts based on the PD parameter level and trend (rate of parameter
change). Two PD parameters are available for alarming: PDI partial discharge intensity and Qmax
maximum PD pulse magnitude @ 0.2 PPC repetition rate. Only one parameter can be enabled for
alarming at a time.
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IB02713002E Rev. C
There are three thresholds: Alarm, Warning, and Normal. The Alarm and Warning thresholds
determine when the alarm and warning relays will be operated. The Normal threshold used
internally to suppress trend alarm calculations while the PD parameter is below this level. We
recommend having the following proportion between threshold limits: Warning 25-50% of Alarm,
and Normal 15-25% of Warning. Setting can significantly differ for different objects and should
be corrected after initial period of monitoring.
Press Enter
Channel 01
Use
or
to change the channel number. Press Enter.
There are 6 thresholds for PDI and Qmax:
P0 PDI Normal
P1 PDI Warning
P2 PDI Alarm
P3 Qmax Normal
P4 Qmax Warning
P5 Qmax Alarm
P0-Normal PDI
Thresh.
5mW
Use
or
to scroll between P0, P1, P2, P3, P4 and P5. Press Enter to change the threshold.
Use
or
to switch between digits. Use
or
to change values. Press Enter to save
changes.
Press ESC to choose next channel.
To get to Trend thresholds setting scroll to 15th channel and press
again.
Trend
Press Enter
P0-Warnings
5.00 Times/Yr.
Use
or
to switch between P0-Warnings and P1-Alarm. Press Enter to change the threshold.
Use
or
to switch between digits. Use
or
to change values. Press Enter.
Press ESC to exit to upper menu level.
6.2.10 Rated Voltage
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Set Rated
Voltage
Set rated voltage for the monitored object in Volts. It must be set before the voltage channel calibration.
This parameter also used for PDI (Partial Discharge Intensity) calculation.
Press Enter:
Rated Voltage
013.8kV
Use
or
to move between digits, and use
or
to change values. Press Enter to confirm
changes and exit, or ESC to discard changes and exit.
6.2.11 Rated Current
Set Rated
Current
Set rated current for the monitored object in Amps. It must be set before the current channel calibration.
Press Enter:
Rated Current
00001.0A
Use
or
to move between digits, use
or
to change the values. Press Enter to confirm
the changes and exit, or ESC to discard changes and exit.
6.2.12 Number of Power Cycles for Data Acquisition
Set # of Cycles
for Data Meas.
Determines measurement time. The parameter represented in terms of the number of cycles of a power
frequency. Sets measurement time for each magnitude window in measurement sequence. 60 cycles is
default setting. Higher the number longer measurement will take, higher statistical precision will be.
Measurement time can be estimated as the following: number of active channels * 21 magnitude
windows * Number of cycles / Power frequency. For 15 active channels, 60 Hz power frequency
and 60 cycles for data acquisition, measurement time will be 315sec (~6 minutes). For saving time
during calibration and monitor resting 5 cycles setting is sufficient.
Press Enter
Number of Power
Cycles 060
Use
or
to move between digits, use
or
to change values. Press Enter to confirm
changes and exit, or ESC to discard changes and exit.
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IB02713002E Rev. C
Press Enter
Relay on Time
0010 Seconds
Use
or
to move between digits, use
or
to change values. Press Enter to confirm
changes and exit, or ESC to discard changes and exit.
6.2.14 Minimum Noise Channel Magnitude Level
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IB02713002E Rev. C
Minimum Noise
Level 0003.0mV
Use
or
to move between digits, use
or
to change values. Press Enter to confirm
changes and exit, or ESC to discard changes and exit.
Set Display
Scroll Time
Sets time interval for displaying each item on display before scrolling to the next item.
Press Enter
Scroll Display
Every 03 Secs.
Use
or
to move between digits, use
or
to change values. Press Enter to confirm
changes and exit, or ESC to discard changes and exit.
Set Device
Address
Critical setting for communication with a monitor locally or on network. Can be set only from keypad.
Press Enter:
Device Address
001
Use
or
to move between digits, use
or
to change values. Press Enter to confirm
changes and exit, or ESC to discard changes and exit.
Set Continuous
Watch Options
This feature is enabled between scheduled measurements. During that period all PD inputs are brought
to Continuous Watch channel. Pulses above preset magnitude threshold are counted on 1 sec.
intervals. If number of pulses in an interval exceeds preset amount, it considered a one series. If the
device got preset number of such series, it starts a regular measurement. If an alarm threshold is
exceeded, it stores full measurement data and turns alarm on.
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IB02713002E Rev. C
Continuous Watch
Level 007.0 V
Use
or
to move between digits, use
or
to change values. Press Enter to confirm
changes and move to the next screen, or ESC to discard changes and move to the next screen.
Set number of counts in a series:
Continuous Watch
Count 0010 PPS
Use
or
to move between digits, use
or
to change values. Press Enter to confirm
changes and exit, or ESC to discard changes and exit.
Baud Rate
38400
Use
or
to change between 9600 and 38400 baud. 38400 is default setting. Press Enter to
confirm the selection and exit.
6.2.19 Select PDI or Qmax Output
Output Parameter
PD Intensity
To select PDI press Enter. Otherwise, press
or
to switch to Pulse Magnitude
Output Parameter
Pulse Magnitude
Press Enter to confirm and exit.
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IB02713002E Rev. C
Start/Stop
Monitoring
Resumes or Stops the monitoring. Can be used to avoid blank measurements when the monitored
equipment is out of service.
Note: Will be stopped indefinitely. It is the responsibility of an operator to resume monitoring.
Press Enter
Start
Monitoring
Use
or
to switch between Start or Stop monitoring. Press Enter to confirm the selection and
exit.
6.2.21 Phase Shift
That is one of only two operations from key pad that necessary to perform in most cases. The rest of
the settings are commonly set at the factory for the project.
Phase shift determines phase shift angle between InsulGard synchronization signal and HV power for
proper representation of phase resolved patterns for advanced diagnostics. By default, InsulGard uses
the internal synchronization from 115/230 VAC power source. External synchronization is optional and
used mostly in variable frequency drives (VFD) application. With external synchronization there is no
need to measure phase shift angle. That angle can be typed into settings in monitor and in software
manually. In case of synchronization from Channel 1 coupling capacitor enter 275 degrees phase shift
(valid for 50Hz+-10Hz frequency range).
Standard procedure describes situation when InsulGard measure phase shift between control power
feeding the monitor and the signal from coupling capacitor on channel1. Phase A coupling capacitor
must be connected to channel 1. The phase shift is measured refer to power supply voltage zero
crossing from negative to positive.
For details refer to the section 7 : Appendix II Synchronization and Phase Reference Shift.
Press Enter
Manual Input
Phase Shift
Use any arrow to switch between Manual Input and Auto Detect modes.
Auto Detect
Phase Shift
Move switch at the bottom of the sensor connection board to Ref position.
Press Enter to begin measurements. Display will update every 15 seconds.
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IB02713002E Rev. C
Detecting Phase
XXX
Observe changing readings for 1-2 minutes and calculate average of the displayed values.
Note: Typically measured value deviates within the range of +/- 50. Below are some hints that may help
to identify phase angle measurement problems:
Phase angle varies on more than +/-100 (low reference signal magnitude or high noise).
On display ??? (reference signal is likely close to zero).
On display continuously 357 (reference signal magnitude is too high).
Press Enter at any time to stop measurements. Set Phase Shift will be displayed. Press Enter twice to
get to manual Phase Shift editing:
Phase Shift
XXX
Enter calculated averaged phase shift. Use
or
to move between digits, use
or
to
change values. Press Enter to confirm the changes and exit, or ESC to discard changes and exit.
Note: If using other source of phase reference signal rather then the internal connection to the coupling
capacitor on channel #1, correct obtained phase shift value according to the table below:
Phase Reference source
PT Phase A
PT Phase B
-120
PT Phase C
-240
PT Phase A-B
+30
PT Phase C-B
+90
Set Channel
Phase
Assigns phase and corresponding phase shift to a channel. Doesnt affect measurements- will shift
phase resolved patterns when represented in diagnostics software. Can be done in software during
interpretation of PD data. Phase A setting will introduce zero phase shift, B=> -1200 shift, C=> -2400,
AB=>300, AC => -30 and BC=> -90.
In some cases a sensor senses all three phases simultaneously - leave Phase A default setting.
Press Enter
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IB02713002E Rev. C
Channel 01
Phase A
Use
or
to change Phase associations. Use
or
to change the channel number. When
done, press Enter to confirm changes and exit, or ESC to discard changes and exit.
6.2.23 Frequency Range
Set Frequency
Range
Change only for PD measurement in low frequency power systems below 20 Hz. Rare used. Default
setting > 20 Hz.
Press Enter
Frequency Range
> 20 Hz
Use
,
,
or
to change between >20 Hz and <20 Hz. Press Enter to confirm the selection
and exit or ESC to discard changes and exit.
6.2.24 Suspend for Temperature
Temperature
Low Limit -500C
Use
or
to move between digits. Use
or
to change values. Press Enter to confirm or
ESC to discard changes and move to High Limit setting.
Temperature
High Limit 1500C
Use
or
to move between digits. Use
or
to change values. Press Enter to confirm
changes and exit, or ESC to discard changes and exit.
The example above means that when suspending is enabled, InsulGard will make measurements only
if temperature readings are between -50 oC and 150oC.
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IB02713002E Rev. C
Voltage
Low Limit 005%
Use
or
to move between digits. Use
or
to change values. Press Enter to confirm or
ESC to discard changes and move to High Limit setting.
Voltage
High Limit 150%
Use
or
to move between the digits. Use
or
to change the values. After all changes are
made, press Enter to confirm all changes and exit, or ESC to discard any changes and exit.
6.2.26 Suspend for Current
Current
Low Limit 005%
Use
or
to move between digits. Use
or
to change values. Press Enter to confirm or
ESC to discard changes and move to High Limit setting.
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Current
High Limit 150%
Use
or
to move between digits. Use
or
to change values. Press Enter to confirm
changes and exit, or ESC to discard changes and exit.
Trend Window
18 Weeks
Use
or
to move between digits. Use
or
to change values. Press Enter to confirm
changes and exit, or ESC to discard changes and exit.
Note: 18 week is the default value and corresponds to 90 days period.
Calibrate
Temperature
Temperature channel is calibrated at the factory for a 100 Ohm Platinum RTD. Field calibration should
not be performed unless absolutely necessary (in case of different RTD have been used).
Calibration requires two precision resistors: 100.0 Ohm representing 00C temperature and 138.6 Ohm
for 1000C temperature . Resistors should be connected as shown in Figure 6-1. Terminals 1 and 2 must
be shortened and the resistor must be connected between the terminals 2 and 3 of the sensor interface
board.
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IB02713002E Rev. C
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Connect Resistor
For 0C ADC 64
Connect a 1000C resistor Press Enter
Connect Resistor
For 100C ADC 208
First coefficient will be displayed:
Coefficient
a = 0.690
Press Enter, second calibration coefficient will be shown:
Coefficient
b = -43.448
Press Enter to confirm and exit.
Calibrate
Voltage
Calibrate voltage channel to present voltage readings in percentage of rated voltage. Rated voltage
must be already entered into the settings. If not, enter the rated voltage, leave Set mode and enter Set
mode again. Firmware allow for automatic calculation of the coefficient (preferable) or manual entry.
1. Automatic Calculation (preferable)
Press Enter, use any arrow key to switch from Manually Input Coefficient to Auto Calculate
Coefficient mode:
Auto Calibrate
Coefficient
Press Enter again.
Enter % of Rated
Voltage 000.0 %
Get running voltage value and enter it as the percentage of the rated voltage (Voper/Vrated *100). Use
or
to move between digits. Use
or
to change values. Press Enter. The coefficient will be
calculated and displayed:
Voltage Coeff.
2372.20
Press Enter to save and exit.
2. Manual Entry
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Press Enter, use any arrow key to switch between automatic and manual entry modes:
Manually Input
Coefficient
Press Enter
Voltage Coeff.
XXXX.XX
Use
or
to move between digits. Use
or
to change values. Press Enter to save and
exit.
Calibrate
Current
Calibrate a CT sensor for load current. The calibration have to be done on site. Sensor must be
connected and the monitored equipment must be energized and carrying a load. Rated current must be
already entered into the settings. If not, enter the rated current, leave Set mode and enter Set mode
again. Firmware allow for automatic calculation of the coefficient (preferable) or manual entry.
Manual entry may be used if the equipment is not running.
1. Automatic calculation (preferable)
Press Enter, use any arrow key to switch from Manually Input Coefficient to Auto Calculate
Coefficient mode:
Auto Calculate
Coefficient
Press Enter
Enter % of Rated
Current 000.0 %
Get running current value and input it as the percentage of rated current (Ioper/Irated *100). Use
or
to move between digits. Use
or
to change values. Press Enter. The coefficient will be
calculated and displayed:
Current Coeff.
2341.20
Press Enter to save and exit.
2. Manual Calculation and Entry
Press Enter, any arrow key to switch between automatic and manual entry modes:
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IB02713002E Rev. C
Manually Input
Coefficient
Press Enter
Current Coeff.
00001.00
Enter the coefficient. Use
or
to switch between digits. Use
or
to change values. Press
Enter to save and exit.
Note: Current Coefficient CK can be calculated if Rated Current Irated and the metering CT rating Ict are
known. Assumption made that metering CT ratio is always Ict : 5.
If rated current was entered in the settings, calculate Current Coefficient and enter it manually as:
CK= 2.2*Ict.
Wrong CK can be corrected later by multiplying by the coefficient equal to the actual relative load(%)
divided by InsulGard readings.
FlexCore primary CT with the Load Current sensor might be installed over 1 feeder of several feeders
per phase. There will be no valid current measurement in this case, but current monitoring will be still
sufficient for PD diagnostics purpose. Multiply CK coefficient by number of feeders in such case.
Calibrate
4-20 mA Loop
4-20 mA interface is pre-calibrated at the factory. Calibration procedure can be repeated if necessary
particular metering device reads differently.
In this procedure the device will set 5, 7, 9, 11, 13, 15, 17 and 19 mA on its output. If the receiving
interface reads differently, readings can be entered into InsulGard, which will calculate a linear
approximation coefficients.
Press Enter
Output =
5.0 mA
Actual = 05.00 mA
Change the Actual value as read on the receiving interface, use
or
to move between digits,
use
or
to change values. Repeat editing the rest of calibration point:
Press Enter
Output =
7.0 mA
Actual = 07.00 mA
Press Enter
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IB02713002E Rev. C
Output =
9.0 mA
Actual = 09.00 mA
Press Enter
Output =
11.0 mA
Actual = 11.00 mA
Press Enter
Output =
13.0 mA
Actual = 13.00 mA
Press Enter
Output =
15.0 mA
Actual = 15.00 mA
Press Enter
Output =
17.0 mA
Actual = 17.00 mA
Press Enter
Output =
19.0 mA
Actual = 19.00 mA
Press Enter, the new calibration coefficients will be shown:
Coefficient
a = 1.0000
Press Enter
Coefficient
b = 0.0000
Press Enter to save and exit.
Calibrate
Humidity
Sensor is pre-calibrated at the factory - do not calibrate the humidity channel unless absolutely
necessary.
Press Enter, use any arrow key to switch between three options:
Turn humidity monitoring Off (never used):
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IB02713002E Rev. C
Humidity Sensor
Type - Off
Use Voltage input channel for humidity measurements (default setting):
Humidity Sensor
Type - Voltage
Use Current input channel for humidity measurements when want monitoring Voltage and Humidity
instead of Humidity and Current.
Humidity Sensor
Type - Current
Press Enter to make choice between Off and measurement by Voltage or Current channels.
Next two windows will allow entering the calibration coefficients for chosen input.
Humidity Offset
838.00
Use
or
to move between digits. Use
or
to change values. Press Enter to confirm
changes and move to Slope setting or ESC to discard changes and move to Slope setting.
Humidity Slope
31.575
Use
or
to move between digits. Use
or
to change values. Press Enter to confirm
changes and exit or ESC to discard changes and exit.
Set Noise
Filter Offset
The Noise Filter offset allows setting the noise filter level from 5 to +5 magnitude zones relative to the
signal channel independently for each signal channel. The default level for all channels is set to +1
zone of noise filter offset. Do not change this value unless necessary.
Press Enter
Channel 01
1
Use
or
to scroll through the channels. Use
or
to change the noise filter offset value for
each channel. After all changes are done, press Enter to confirm all changes and exit, or ESC to
discard any changes and exit.
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Manually Input
Low Limit
Press Enter.
Channel 01
Low Limit -67.83dB
Use
or
to scroll through the channels. Use
or
to scroll through the available values in
dB. Reference between magnitude window number, magnitude threshold in mV and in dB is shown in
the following table.
Magnitude windows (zone) threshold for InsulGard
Magnitude window
Threshold (V)
dB
(zone)
10.000
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
6.894
4.753
3.277
2.259
1.558
1.074
0.740
0.511
0.352
0.243
0.167
0.115
0.080
0.055
0.038
0.026
0.018
0.012
0.009
0.006
0.004
-3.23
-6.46
-9.69
-12.92
-16.15
-19.38
-22.61
-25.84
-29.07
-32.3
-35.53
-38.76
-41.99
-45.22
-48.45
-51.68
-54.91
-58.14
-61.37
-64.6
-67.83
Make necessary changes in the channels. Press Enter to confirm changes and exit, or ESC to discard
changes and exit.
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IB02713002E Rev. C
In Auto Detect mode the device will measure actual signals from each channel with the Noise filter set
Off. It will count all pulses received by the channel and find magnitude threshold with the total number
of pulses above that threshold exceeding 50,000 pulses per second. Low Limit in that channel will be
set to the next higher magnitude threshold. Calculations of PDI and pulse repetition rate will be
performed above that level only.
Choose Auto Detect and press Enter, use
,
,
or
to choose the auto detect mode as
shown below:
Auto detect
Low Limit
Press Enter. Measurements In Progress will blink and replaced with Noise Level window:
Summarized background noise from all channels will be displayed:
Noise Level
0.0
Press Enter to measure noise in individual channels:
Measurements
In Progress
When measurement completed, may scroll through the channels and see result in terms of magnitude
window number:
Channel 01
21
Use
or
to scroll through the channels. Press Enter to accept the values and proceed further or
ESC to discard changes and exit.
Align Channels?
Yes
If Yes is selected, procedure will align the thresholds for the channels with the same sensitivity setting
to maximum threshold over those channels.
Before aligning channels, compare the results in channels with the same sensitivity. If they differ by 3
zones or less, select Yes to allow the device for aligning the thresholds for those channels. Otherwise,
select No to leave the values at the detected levels.
Use any arrow key to switch between Yes and No. Then press Enter.
Set Software
Filters
Filters have been developed mostly for coupling capacitor sensors on large turbine generators
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equipped with iso-phase bus to discard external PD activity coming from buses toward a generator and
masking internal PD activity in a stator. PD pattern of sparking to a conductor under floating potential
have been targeted. We do not recommend using these filters for other equipment or sensors without
consulting an expert.
Press Enter:
Channel 02
Filter Off (or 1,or 2, or 3)
Use
or
to scroll through the channels. Use
or
to switch between filter options: Off, 1,
2, or 3. After changes are done, press Enter to confirm changes and exit, or ESC to discard changes
and exit.
Set ModBus
Protocol
InsulGard supports Modbus RTU and Modbus TCP protocols. Press Enter.
Modbus Protocol
RTU
Use any arrow key to switch between RTU (default setting) and TCP. Press Enter.
NOTE: The ModBus Protocol must be set to RTU if the optional communications board is
installed. The communications board handles the ModBus TCP protocol separately.
6.2.37 Start a Single Measurement
Start a Single
Measurement
This procedure forces a measurement to start immediately.
Once Enter is pressed, the single measurement starts with Measurements In Progress displayed
during the measurement:
When the measurement completes the display returns to set menu.
6.3
6.3.1
This operation will erase all data saved in memory. Press three keys simultaneously -
,
,
:
Erase Records?
Yes
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Use any arrow key to switch between Yes and No. Press Enter. If No is selected, screen returns to
normal. If Yes is selected, then Erasing Records will be displayed until records will be erased and
Records Erased will be displayed. Press any key to return to normal screen.
6.3.2
2 Records
In Memory
Press Enter:
Use
or
to scroll through the channels, and, use
or
to switch between Qmax and PDI
(%PD). Press Enter again to return to the previous menu and choose a different record. Press ESC to
exit Memory mode.
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7.1
Synchronization
InsulGard allows external synchronization or internal synchronization from 115/230VAC power supply.
Internal synchronization is the most reliable option since it stops operation only if the power is off. This
is the default option for InsulGard.
External synchronization is used when power supply voltage is not synchronous with voltage in the
monitored object, mostly for Variable Frequency Drive (VFD) applications.
Be cautious when powering InsulGard from a UPS. It is acceptable only when the UPS has a
constant phase shift to the voltage of the monitored object in standby mode. If not, InsulGard
will be asynchronous to the monitored object and cannot make reliable measurements. If
unsure about UPS power, external synchronization must be used.
Two jumpers JU1 & JU2 inside InsulGard enclosure (on right side from power supply transformer) are
used to change synchronization type. By default they are positioned for internal synchronization as
shown in Figure 7-1a. Jumpers should be moved to upper position for external synchronization - Figure
7-1 b.
Figure 7-1 Jumpers JU1 & JU2 position for a) Internal and b) External synchronization.
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External synchronization signal should be connected to the Sensor Interface Board. There are two
external synchronization options:
Using the signal from a coupling capacitor installed on phase A and connected to PD channel #1.
The signal contains high frequency PD component and power frequency component. Power
frequency component may be used for synchronization and phase reference measurement. For
synchronization jumper J1 has to be installed as shown in Figure 7-2 b (default position).
Using an external signal source, like a potential transformer (PT). This signal should be connected to
contacts # 7 and #9 (Ground) on auxiliary signals terminals in sensors interface board (Figure 7-2a).
The signal should be in recommended range of 0.2-1VAC and not to exceed 5VAC. Use resistive
divider to bring the signal into recommended range as shown in Figure 7-2 a. Input #7 has 27kOhm
impedance. For that synchronization option jumper J1 (Figure 7-2 b) has to be open.
PT
DIVIDER
Fuse
0.1A
R1
50-100 kOhm
R2
1-3 kOhm
Fuse
0.1A
Figure 7-2.
7.2
a- Divider for reference voltage from PT connected to the Sensor Interface Board,
b Jumper J1, c Switch position for phase reference shift measurement.
The table below presents phase shirt angles for most common external synchronization options. Phase
shift should be manually entered into InsulGard firmware and software settings:
External Synchronization Signal from
Phase Shift
PT Phase A
PT Phase B
+240
PT Phase C
+120
+30
+90
VFD application uses a modified sensor interface board with additional filtering. Phase shift slightly
depends on frequency and varies from 277 to 273 in 40-60 Hz frequency range. For typical applications
50Hz +-10Hz enter 275 degrees.
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7.3
By default InsulGard uses internal synchronization from 115/230 VAC power source. If phase shift
between this voltage and phase A voltage of the monitored object is known it can be manually entered
using software or keypad (section 6.2.21 Phase Shift). If it is unknown InsulGard can be used to
measure phase shift in Set mode from keypad. Signal for phase reference measurement can be
obtained from:
PD channel # 1 (if A phase coupling capacitor connected to Ch#1)
external source temporarily connected to contacts #7 and #9 (ground) - Figure 7-2a. Temporarily
remove J1 for measurement and return it back upon completion.
Enter Set mode as described in 6.1: Entering Setup . Scroll through the settings to Set Phase Shift:
Press Enter:
Manually Input
Phase Shift
Press Enter for manual input or use any arrow key to switch from manual input to Auto Detect:
Auto Detect
Phase Shift
Set toggle switch on the sensor interface board to Ref position (Figure 7-2 c).
Dont forget to return it to the H% position upon completion!
Press Enter to start phase angle measurement. The display will be updated with a measured value
every 15 seconds.
Detecting Phase
XXX
Observe changing readings for 1-2 minutes and calculate average of the displayed values.
Note: Typically measured value deviates within the range of +/- 50. Below are some hints that may help
to identify phase angle measurement problems:
Phase angle varies on more than +/-100 (low reference signal magnitude or high noise).
On display ??? (reference signal is likely close to zero).
On display continuously 357 (reference signal magnitude is too high).
Press Enter at any time to stop measurements. Set Phase Shift will be displayed. Press Enter twice to
get to manual Phase Shift editing:
Phase Shift
XXX
Enter calculated averaged phase shift. Use
or
to move between digits, use
or
to
change values. Press Enter to confirm the changes and exit, or ESC to discard changes and exit.
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Note: If using other source of phase reference signal rather then the internal connection to the coupling
capacitor on channel #1, correct obtained phase shift value according to the table below
Additional phase shift number must be added to the calculated average value. New number should be
adjusted to 00-3600 range by adding or subtracting 3600 and resultant number manually entered into
InsulGard (see 6.2.21 Phase Shift).
Phase Reference Option
PT Phase A
PT Phase B
-120
PT Phase C
-240
PT Phase A-B
+30
PT Phase C-B
+90
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8.1
General
The InsulGard Communications Board provides access through USB and Ethernet interfaces. The
USB Device interface provides a standard serial communications port to connect to a local PC. This
interface is typically used for local access of InsulGard data using the InsulGard PC software as well as
for upgrading firmware in the communications board.
The USB Device Driver must be installed on the PC accessing the InsulGard prior to using the USB
Device interface. (See Section 9 Appendix IV USB Device Driver Installation for complete installation
instructions). Once driver is installed, a serial communications port such as COM5 should be assigned
to this interface (the exact port number will vary depending on what other devices are installed on the
PC). When accessing the InsulGard using the InsulGard PC software simply configure this serial port
number on the Communication tab of the software.
NOTE: If the InsulGard or the PC accessing the InsulGard is rebooted or turned off and back on, the
USB cable from the PC to InsulGard must be disconnected and reconnected to reestablish the link.
The USB Host is reserved for future use.
The Ethernet interface supports the following network protocols:
Modbus TCP/IP on Port 502 for interface to 3rd party building management systems.
Web Server/HTTP on Port 80 providing on-board web pages viewable with standard browsers
such as Microsoft Internet Explorer (version 7 recommended) or Mozilla Firefox (version 2 or later
recommended).
SMTP on Port 25 for sending Email across the Internet.
FTP Server on Port 21 to download InsulGard database file on demand.
FTP Client to upload InsulGard database file to a server at a specified time/interval.
SSH Secure Shell on Port 22 for certain administrative tasks.
Virtual Communication Port for simplified access by the InsulGard PC software. See Section 10
Appendix V Ethernet Virtual Communications Port Driver Installation for driver installation.
8.2
Network Configuration
The Ethernet Interface requires general configuration to provide access to the Internet for all protocols
as well as specific configurations for several protocols. Prior to configuration provide your local network
administrator with the MAC address of the Ethernet port located on the label on the side of the unit and
request the following:
MAC Address (copy from label) _________________________
IP Address (static address*) _________________________
Subnet Mask _________________________
Gateway Address _________________________
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The InsulGard home web page display should appear, similar to Figure 8-2. Note the different areas
and features of the web page that will be referred to throughout this document.
PDA Time (UTP and
local) and equipment
location
Monitored Equipment
Active
Alarm
Notification Area
Header Bar
Data
menus
are expandable
and collapsible
Hover the mouse
over
items
for
additional detail or
help
Menu Bar
NOTE
Alarm
information
displays in red text; alarms
are always visible even when
menus are collapsed
Status Bar
rd
Link to 3 Party
Licensing information
Link to Eaton
Web Site
The Network
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8.3
Change Passwords
There are two user names for web page access, user for read-only and admin for read/write
(configuration). The user names are fixed, but the passwords can be changed to ensure system
security. To change passwords, when logged in as administrator select the Access Control link from
the menu bar. This opens the Access Control Configuration page similar to Figure 8-4.
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8.4
The Modbus RTU configuration determines the baud rate and device ID that will be used by external
devices to communicate to the InsulGard via the RS-485 , Modbus TCP over Ethernet, and USB
interfaces. Any changes to these parameter must be coordinated with the external networks
communicating with the InsulGard. To configure the Modbus RTU interface, when logged in as
administrator select the Modbus RTU link from the menu bar. This opens the Modbus RTU
Configuration page similar to Figure 8-5.
8.5
Date/Time Configuration
The date and time should be set properly to correlate alarm events and utilize periodic reporting
functions. The communications board can be synchronized to one or more Network Time Protocol
servers. This is the recommended method to ensure accurate timekeeping. When the communications
board is synchronized with the NTP server it will also periodically synchronize the clock on the
measurement board. If it is not synchronized to an NTP server the clocks on the two boards will free
run, resulting in minor discrepancies over long time periods unless you manually reset both clocks
periodically. To configure the date/time settings, when logged in as administrator select the Date/Time
link from the menu bar. This opens the Date/Time Configuration page similar to Figure 8-6.
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8.6
The InsulGard communications board provides FTP access to the measurements database file through
both FTP Client and FTP Server applications. The FTP server does not require any special
configuration. It is accessed with standard FTP software applications through the programmed IP
address. The FTP client provides automatic periodic upload of the measurements database file to an
FTP server. This can be useful to push data out through a corporate IT security firewall that may block
incoming FTP requests. To configure the FTP client, when logged in as administrator select the FTP
Client link from the menu bar. This opens the FTP Client Configuration page similar to Figure 8.7.
8.7
Email Configuration
You can use the InsulGard communications board to inform selected e-mail accounts of events and
changes in status as they occur, or to provide a status message at a predetermined time. To configure
EATON CORPORATION www.eaton.com/pd
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e-mail notifications, when logged in as administrator select the General Email link from the menu bar.
This opens the General Email Configuration page similar to Figure 8-8.
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given time of day repeated at the given number of days. You must program the Days between
periodic status email and Time of day for periodic status email (HH:MM) (in 24 hour format)
fields.
When all options are set select Apply to save the settings for this recipient or Discard to restore the
original settings. You may repeat this procedure for the remaining recipients, selecting Apply after
configuring each recipient.
To remove a recipient select the appropriate number from the Recipients drop down list, delete the
email address in the To field, and select Apply.
After all desired individual recipients have been set up select the Configure button to bring up the
Email Event Trigger Configuration screen similar to Figure 8-10.
board
Select Apply and OK to save your changes or Discard to restore the previous setting and return to the
General Email Configuration page. Prior to exiting this page selecting the Test Event Email button will
send an email to all recipients.
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8.8
Identification Page
The default name for the first item on the Menu Bar is InsulGard. Once the Display Name is modified
as described in this section this name will change. Selecting this item opens the Identification page
similar to Figure 8-11.
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8.9
One of the benefits provided by the Web interface of the communications board is the ability to see a
quick overview of the InsulGard status. Select the InsulGard Summary link from the menu bar to open
the InsulGard Summary page similar to Figure 8-12.
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Display Name which is shown at the top of this page and on the menu bar has the default value
InsulGard Summary. This 64 character field can be programmed to anything that will help you
identify this web page.
Field Replaceable Unit parameter that is displayed only on this page. This 64 character field can
be programmed to anything that you find helpful
The Measure category provides information from the last measurement cycle of the measurement
board as follows:
Channel Activation Status shows which channels were turned on for the last measurement
cycle. A 1 in the box indicates that channel was active, while a 0 indicates it was turned off.
Channel configuration is handled through the front panel or via the InsulGard PC software.
Current provides the load current measured as a % of full scale during the last measurement
cycle.
Frequency provides the monitored units frequency measured during the last measurement cycle.
Max PDI Channel Number shows the channel with the highest Partial Discharge Intensity during
the last measurement cycle.
Percent of Max PDI to red level provides a graphical representation of how close the PDI level
was to the alarm level during the last measurement cycle.
The Measure/Alarm/Recent Events category shows the status for the InsulGard alarms and warnings.
The Red Alert is for Alarm events, Yellow Alert if for Warning events, and Relay Health indicates
status of the InsulGard itself.
The Measure Date/Time category shows the Last Measurement time which is the time of the last
measurement cycle and Last poll time which is the last time the communications board polled the
measurement board for new data.
The Measure/Temperature category displays the Relative Humidity and Temperature measured
during the last measurement cycle.
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8.11 Alarms
When alarms occur the alarm condition is shown at various places in the web pages including the
header bar, the InsulGard Summary page, and the Open Alarms page. To view the Open Alarms page
select the Open Alarms link from the menu bar. Figure 8-14 shows an example Open Alarms Page
with an alarm created by disabling measurements with the InsulGard PC software.
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8.12 Logs
The InsulGard communications board stores historical information about the system in three logs.
The Data log contains a history of value changes for several measured parameters.
The Event log contains a history of alarm events when alarms become active or cleared, and
when they are acknowledged and closed by the user.
The System log contains a history of events related to the communications board such as reboots
and configuration changes.
Selecting the Data link under the Logs category of the menu bar opens a page similar to Figure 8-15.
Selecting the Event or System link will bring up similar pages for these logs.
8.13 Documentation
The Documentation category of the menu bar provides links to various documentation available
directly from the communications board or from external sources on the Internet. The exact
documentation available may change with new releases of communications board firmware.
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4. Select Install from a list or specific location (Advanced), click Next, and the following
window will be displayed.
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5. Select Dont search. I will choose the driver to install., click Next, and the following window
will be displayed.
6. Select Ports (COM & LPT), click Next, and the following window will be displayed.
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8. Click Browse to select the driver from the location we copied in step 1. The following window
will be displayed.
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9. Navigate to C:\WINDOWS\ system32 \drivers directory, select gserial and click Open. The
following window will be displayed.
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12. Click Continue Anyway and the following windows will be displayed.
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is an example showing Gadget Serial assigned to COM5. Make a note of this number as you
will need it to configure the InsulGard PC software to communicate through this USB interface.
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10
Ethenet Virtual Com Port application should be installed from provided Insulgard Software CD by
running Setup.exe file, located in appropriate folder if Ethernet access to the devices is desired.
Once configuration of the virtual serial port is completed, user should select created virtual com port
and use it as for usual RS-485 communications.
Once application starts, it will launch the service and display the following panel.
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Click <Add> button to create a new virtual serial port. Once Dialog panel like one below will be displayed,
operator can select a desired COM port from a dropdown list and enter the assigned device IP address.
User should use the suggested choices, like on the screenshots below as they are not always the same as
Windows default ones.
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<Update> command button on the main configuration panel allows modifying virtual COM port IP address
settings.
<Setting> command button on the main configuration panel provides tools for adjusting service parameters; the
most important one is Autostart. Selecting this option will cause the service to start automatically at Windows
boot.
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These instruction materials are published solely for information purposes and should not be considered all-inclusive. If further
information is required, you should consult an authorized Eaton sales representative. The sale of the product shown in this literature is
subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between the parties.
This literature is not intended to and does not enlarge or add to any such contract. The sole source governing the rights and remedies
of any purchaser of this equipment is the contract between the purchaser and Eaton. NO WARRANTIES, EXPRESSED OR IMPLIED,
INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING
FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS,
AND DESCRIPTIONS CONTAINED HEREIN. In no event will Eaton be responsible to the purchaser or user in contract, in tort
(including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever,
including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional
expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the
information, recommendations and description contained herein.
Eaton Corporation
Electrical Group
1000 Cherrington Parkway
Moon Township, PA 15108-4312
United States
877-ETN CARE (877-386-2273)
www.Eaton.com
2010 Eaton Corporation
All Rights Reserved
Printed in USA
Publication No. IB02713002E Rev. C
August 2011
PowerChain
Management
PowerChain Management is a registered
trademark of Eaton Corporation.
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