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ELECTRICAL

PREDICTIVE DIAGNOSTICS DIVISION

5421 Feltl Road, Ste 190, Minnetonka, MN 55343
Phone (952) 912-1331 or -1358, Fax (952) 912-1355;
Web-site: www.partial-discharge.com;

e-mail: [email protected]

InsulGard

USER’S MANUAL

EEPD, 2002, 2003, 2004, 2005

Version 2-0X

Revision 1.1

(December 2005)

Summary of Contents for InsulGard

Page 1: ...ION 5421 Feltl Road Ste 190 Minnetonka MN 55343 Phone 952 912 1331 or 1358 Fax 952 912 1355 Web site www partial discharge com e mail chpd eaton com InsulGardTM USER S MANUAL EEPD 2002 2003 2004 2005...

Page 2: ...pplication Issues 16 2 1 1 Type and specifics of equipment to monitor 16 2 1 2 Configuration of PD Sensors 16 2 1 3 Noise Aspects 17 2 1 4 Device Location and Environmental Issues 17 2 1 5 What Additi...

Page 3: ...dictive Diagnostics 6 1 2 Revision 1 56 6 2 Phase Reference Shift 57 6 2 1 Internal Synchronization 57 6 2 2 External synchronization 59 6 3 Auxiliary input configuration 60 7 Appendix 3 Temperature C...

Page 4: ...nel number Accuracy of maximum PD magnitude measurement 0 75dB 3 2dB Error message on set clock earlier then preexisting data in InsulGard memory Displays CLOCKErr and turn on RED alarm LED Also opens...

Page 5: ...ns are done with additional switch located at the bottom of sensor interface board InsulGardTM revision 1 can be identified by the presence of described switch or by a wiring diagram identification la...

Page 6: ...ee auxiliary inputs for PD data correlation to additional parameters One of the inputs is designated for temperature where the other two are commonly used for load voltage or humidity depending upon t...

Page 7: ...pening status relay contacts InsulGard measures signals from signal inputs sequentially multiplexing them to a single metering channel Each pulse from each sensor is validated by the allowed pulse wid...

Page 8: ...tage Current or Humidity 2 Alarm C form Dry Type Relay Contacts Yellow and Red alarms fully configurable 2 120VAC 5 Amps 28VDC 5 Amps 1 Device Status Dry Type C form Relay Contacts 1 120VAC 5 Amps 28V...

Page 9: ...e mounted on aluminum plate with selected communication options or in panel mount version These options may include RS485 RS232 converter Figure 2 landline Figure 1 3 or cellular modem radio modem Fig...

Page 10: ...rms 1 Memory mode 1 Set Display Keypad Figure 1 Figure 2 RS485 RS232 Converter Radio modem InsulGard Back view Sensor Interface Board PD signal connection Auxiliary signal Flat ribbon cable to sensor...

Page 11: ...ers are stored in the internal memory for each measurement Additionally three auxiliary parameters temperature of full load current and operating voltage or humidity are assigned to the measurement da...

Page 12: ...nted in terms of mV Trend is set in terms of times per year for both PDI and Magnitude Alarm on trend is enabled after a training period of 1 3 of the trend sliding window Yellow and Red alarms operat...

Page 13: ...shift between power voltage and object high voltage should be determined during InsulGard startup and can be used at all times while the same object is monitored and the same power circuit is used In...

Page 14: ...calibration of PD and noise channels In the case of a fault an error message will be displayed and the status relay contacts will open Error status can be remotely requested though interface 1 3 11 PD...

Page 15: ...extends beyond the allowed boundaries Measurement will be automatically resumed at the next scheduled time if parameters will comply to allowed boundaries This feature is widely used to suspend measu...

Page 16: ...e connections may include cable terminations and portions of cable and portions of bus feeding an object InsulGard can be used for additional variations of medium voltage and high voltage equipment bu...

Page 17: ...a chemically aggressive medium or a company policy requires a stainless steel enclosure NEMA 4X please specify this while ordering InsulGard Also you may use if specified NEMA4X plastic enclosure wit...

Page 18: ...al attenuation in motor winding Therefore sensors located at the line terminals will not produce valuable information on a winding depth likewise a sensor embedded into a winding will not sense discha...

Page 19: ...ar cubicle In this case you can consider installing a FlexCore CT around a cable of the phase A in the motor terminal enclosure The FlexCore CT is installed over the shielded part of a cable and there...

Page 20: ...tance of CT or PT to a bus is used as a small coupling capacitor This sensor is the easiest to install however it is susceptible to many noises produced by modern metering and relaying electronics The...

Page 21: ...has several useful configuration templates allowing simple configuration a majority of standard applications These templates for rotating machines assume that all coupling capacitors connected sequen...

Page 22: ...l cable sheaths Included 20 Temperature sensor TS RTD 100 Ohm Pt Optional 1 Comes as default for switchgear applications Installed permanently on the sensor interface board Load current Sensor CT 5 Am...

Page 23: ...mmunication cables Twisted pair cables AWG16 20 for modem and for voltage and current sensors if exceed 25 and a 3 wire shielded cable AWG 16 22 for the temperature sensor if exceeds 25 We recommend f...

Page 24: ...stall the voltage sensor at the secondary of the closest PT associated with the monitored equipment Note Do not connect to PT at this time Install an RTD sensor if ordered separately inside switchgear...

Page 25: ...or Label positive polarity terminal or dot Note Do not connect to PT at this time Connect the humidity sensor according to its description A humidity sensor has three wires 5 Volt Ground and Signal Ma...

Page 26: ...ary signal connections such as temperature current humidity and voltage The 32 terminal strip TB1 right is dedicated for PD sensor connections using coaxial cables In the InsulGard enclosure the senso...

Page 27: ...d 32 Coax Cable RG 58 TB3 Sensor interface board Pre Revision 1 Revision 1 Note 1 RTD common wire Same For two wire RTD terminal 1 should shortened with the terminal 2 2 RTD common wire Same 3 RTD sig...

Page 28: ...w Alarm Relay Alarm 1 Same NO 9 Yellow Alarm Relay Alarm 1 Same Common 10 Yellow Alarm Relay Alarm 1 Same NC 11 Red Alarm Relay Alarm 2 Same NO 12 Red Alarm Relay Alarm 2 Same Common 13 Red Alarm Rela...

Page 29: ...om PD Sensors 1 16 Ch1 Ch2 Ch4 Ch3 Ch5 Ch6 Ch8 Ch7 Ch9 Ch10 Ch12 Ch11 Ch13 Ch14 Ch16 Noise Ch15 T Sensor Interface Board RTD CT PT NC H S 5 S Ref 5 S1 S2 6 7 8 9 10 11 12 4 3 2 1 Cables from Temperatu...

Page 30: ...oard RTD CT H S 5 S Ref 5 S1 S2 6 7 8 9 10 11 12 4 3 2 1 Cables from Temperature sensor TS Current sensor CT Humidity sensor HS red blk white red blk red white blk X1 X2 PC cable to temporary brought...

Page 31: ...power supply RS 485 Interface 4 20 mA output and the output relays utilize molded connectors supplied with the kit All these connectors are pre wired to the terminal board refer to Figure 2 and Figur...

Page 32: ...tallation plug the InsulGard cord into an outside 115 230V AC receptacle Loading should appear on the device display Device is now ready for setup and operation In a panel installed design check addit...

Page 33: ...before starting this Transmission Baud Rate Temperature channel calibration Normally calibrated in the factory if RTD type information is provided Voltage channel calibration Current channel calibrat...

Page 34: ...ssword and press ENTER Wait for about 20sec The first option to appear is the date time setup Use the right and left arrow keys to scroll the setup parameters Date Time Note that IG with Firmware vers...

Page 35: ...all the rest inactive If none of channels is active the device will not start a measurement Noise channel normally should be ON Scroll setup parameters until CHAnnELS appears Press Enter CH01 On OFF...

Page 36: ...ters until ChPHASE appears Press Enter CH01 will appear Press Enter PHASE A will appear Use keys to set the phase assignment for the current channel The options available are A B C AB AC BC When done...

Page 37: ...with the same sensitivity If NO is selected and Enter is pressed the device will keep unique values for each channel as it was detected Calibration for Current and Voltage Channels The goal of the pro...

Page 38: ...ill appear Use keys to set the number of power cycles of 60 or 50 Hz for the measurement When done press Enter Set 4 20 mAmps Output Commonly PDI is the best parameter to represent the overall PD acti...

Page 39: ...g 300 3750 Subtracting 3600 150 150 in case of internal Humidity sensor must be temporally disconnected Place temporal jumper between terminals 8 Ref and terminal 12 S of H Temporally connect the phas...

Page 40: ...rval in format XX XX hh mm using keys Military format 24 hour is used Maximum interval can be 23 hours and 50 minutes Press Enter OR Select rEG t and press Enter t01 00 00 will appear Set t01 to a des...

Page 41: ...e firmware version 2 0 or later supports RTU TCP versions of MODBUS protocol All earlier versions support only RTU version Scroll setup parameters until HodbuS appears Press Enter tYPE rtU will appear...

Page 42: ...s Alarm LEDs will change their colors correspondingly to alarm status obtained in the particular measurement When the desired date and time is selected press Enter 01 XXX Y for PDI or 01Q XXX for Q02...

Page 43: ...ErrornCH PD noise channel did not pass calibration If appears consistently the device must be repaired FLASHErr the error reading from internal flash memory May be fixed by deleting data from device...

Page 44: ...on the front panel holding the device Unscrew two screws on the back cover and disconnect flat ribbon cable from the device Unscrew four screws holding the device back cover and carefully remove the...

Page 45: ...t date is set The prompt is EditArCH If Enter is pressed all later data will be erased if Cancel is pressed new date will be set without data erasing and then in normal mode CLOCHErr will be displayed...

Page 46: ...consequent measurements and on schedule As default the device is set to measure four times a day at 4 00AM 10 00AM 4 00PM and 10 00PM Up to 50 times per day can be set Scroll setup parameters until t...

Page 47: ...sets allowed pulse WIDTH and dP required PAUSE between pulses Both settings have a choice of three settings 1 2 and 3 As default dI 1 and dP 3 are recommended Scroll setup parameters until PLS PAr ap...

Page 48: ...ey and P1 020 00 will appear Press Enter Digit will start flashing Using keys to change the threshold numerical value refer to respective units below When done press Enter Press Esc When done with all...

Page 49: ...ss Enter ndEV 001 will appear Use keys to set the required device address Do not exceed 231 When done press Enter Watch Function Settings InsulGard has a Continuos Watch feature This option is enabled...

Page 50: ...Phase Shift By default InsulGard uses the internal phase reference from its 115 230 VAC power source External phase reference is also available for specific applications such as variable frequency dri...

Page 51: ...s selected tLO 0050 appears Use keys to set LOW temperature limit deg C Press Enter tHI 1000 will appear Use keys to set HIGH temperature limit When done press Enter Voltage Scroll setup parameters un...

Page 52: ...displayed U XXXX XX Press Enter If press Enter in manual mode U 0001 00 will appear Use keys to enter manually the coefficient kV When done press Enter Scroll setup parameters until CALibr I appears...

Page 53: ...annels can be scrolled and measured value displayed for each channel Press Enter The prompt AliGn Y will appear Use to choose from Yes Y and No N If YES is selected and Enter is pressed the device wil...

Page 54: ...ement Selecting Modbus RTU or TCP protocol The firmware version 2 0 or later supports RTU and TCP versions of MODBUS protocol All earlier versions support only RTU version Scroll setup parameters unti...

Page 55: ...th the voltage on the monitored object This happens in VFD applications or isolated systems such as 25Hz systems Be cautious if power an InsulGard from UPS unless UPS has constant phase shift to the v...

Page 56: ...minal for an external signal the jumpers J1 and J2 should be removed disconnecting Ref from PD channel 1 a b c Figure 6 2 Default jumper position as shown Pre Revision 1 6 1 2 Revision 1 As default ju...

Page 57: ...ground a b c Figure 6 3 Default jumper position as shown Rev 1 6 2 Phase Reference Shift Phase Reference shift is a phase angle between IG synchronization signal and the phase A voltage on the monito...

Page 58: ...to Ref position to the right Note do not forget to return it into Humidity mode after completion If an external signal is needed for the procedure it should be connected to the terminal 7 and common t...

Page 59: ...measurement InsulGard displays dashes with some consistency in firmware version 2 00 and higher or 0 in older versions Signal is likely close to zero InsulGard reads 357 0 most of time in firmware pr...

Page 60: ...puts are configurable for Load Current or Humidity J4 and for System Voltage or Humidity J5 Most common configuration is Current and Humidity The jumper position is shown in the figure 6 4 J4 configur...

Page 61: ...Configuration Jumpers configuring InsulGard for different RTD resistance are inside the enclosure Jumper position should be selected according to pictogram printed on PCB The figure 7 1 shows jumper c...

Page 62: ...rrect password must be entered in order to enter the setup mode Using keys enter password and press ENTER Wait approximately 20sec The first option to appear is the date time setup Use the right and l...

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