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GE Grid Solutions

iBox/iBox Kit

Installation and Maintenance Guide

GE Information

994-0047-5.10-4

2.5. Connecting and Testing Field Wiring

Overview

Introduction

This section describes the process for making and testing field connections to the

iBox.

Summary of Contents for iBox

Page 1: ...GE Grid Solutions iBox iBox Kit Installation and Maintenance Guide 994 0047 Version 5 10 Revision 4 GE Information ...

Page 2: ...any way and 3 General Electric Company withholds permission for making the Documents or any portion thereof accessible via the internet Except as expressly provided herein you may not use copy print display reproduce publish license post transmit or distribute the Documents in whole or in part without the prior written permission of General Electric Company If applicable any use modification repro...

Page 3: ...x 69 2 9 Replacing your iBox 75 Section 3 iBox Kit Installation and Maintenance 77 3 1 Familiarization 77 3 2 Installing the iBox Kit 82 3 3 Configuring the iBox Kit Components 87 3 4 Connecting Field Wiring 132 3 5 Servicing your iBox Kit 134 3 6 Maintaining your iBox Kit Software 135 3 7 Troubleshooting your iBox Kit 138 3 8 Replacing your iBox Kit 139 Section 4 Removing Configuration Data and S...

Page 4: ...iBox iBox Kit Installation and Maintenance Guide GE Grid Solutions 4 994 0047 5 10 4 GE Information Appendix G Error Messages 169 ...

Page 5: ...y s SGConfig configuration utility or details of any software application used in a specific iBox refer to the SGConfig online help Training Tool In addition to the primary purpose of this Installation and Maintenance Guide its secondary purpose is that of a Training Manual for customer training sessions provided by GE Digital Energy or its agents Operating System The procedures in this guide are ...

Page 6: ... 043 D20 D25 iBox Automation Applications PRPI 048 SGConfig online help WESMAINTII User s Guide B014 1UG 68K Monitor User s Guide SWM0023 Application software configuration guides From other manufacturers Digi One User s Guide Digi International ADAM 4000 Data Acquisition Modules User s Manual Advantech DMMS300 DMMS350 DMMS425 3 Phase Multifunction Power Monitors with Advanced Capabilities Install...

Page 7: ...ort GE Grid Solutions Technical Support is open 24 hours a day seven days a week for you to talk directly to a GE representative In the U S and Canada call toll free 1 800 547 8629 International customers please call 1 905 927 7070 Or e mail to multilin tech ge com Product Returns Before you return a product please contact GE Grid Solutions Technical Support to obtain a Return Merchandise Authoriz...

Page 8: ...ully inspect the work area for tools and objects that may have been left inside the equipment The successful operation of this equipment depends upon proper handling installation and operation Neglecting fundamental installation requirements may lead to personal injury as well as damage to electrical equipment or other property Many of the components within the iBox iBox Kits are susceptible to da...

Page 9: ... has been dropped or damaged Return it to GE Digital Energy for inspection and repair Operating Environment iBox iBox Kits are intended for indoor use Do not place these products in environments where unusual environmental conditions exist such as dirt liquids or windblown dust without a secondary protective enclosure For proper fire protection iBox iBox Kits must be installed in an enclosure equi...

Page 10: ...iBox Kit 1 RU 1 75 inches Power and Fusing For proper operation input voltages must be within specified limits Do not apply voltages outside this range since this may lead to premature product failure Always fuse protect field sources Always replace fuses with fuses of the same type and rating Fuse types and ratings are stated in the product specifications Grounding To ensure voltage transients ar...

Page 11: ...stors to protect the iBox s communications ports iBox Cover Never operate an iBox without having its protective cover installed since product performance may be compromised and equipment may be damaged if foreign objects fall into the unit iBox Jumpers Configure the jumpers in your iBox before you connect field inputs and outputs Use of the equipment in a manner not recommended or specified by GE ...

Page 12: ...B15 for digital inputs and control outputs Note Although the standalone iBox is CE Marked GE does not guarantee the CE Mark of third party components of the iBox Kits such as the 10 100BaseT Ethernet Module or the AC and DC Analog Input Modules Ferrite Clamp cabling wiring The following diagram illustrates the cabling wiring loop through an installed ferrite clamp Connection Ferrite Clamp Cable Wi...

Page 13: ...e GE Information 994 0047 5 10 4 13 Section 1 Getting Started Overview Introduction Before you begin installing the iBox review the information in this section including the following topics Description of the iBox Unpacking and inspection Storage Installation Tools ...

Page 14: ...l unit RTU Scalable Architecture The iBox s flexibility makes it an excellent option for Advanced substation monitoring Control Automation applications Features The iBox has three software configurable RS 232 485 serial communication ports All three RS 232 485 serial ports interface to legacy IEDs or Master stations An extensive library of application software is available from GE Digital Energy t...

Page 15: ...ith the system hardware and software Diagnostic software to verify the integrity of the iBox Monitor interface for examining the system in a non operational mode Startup code to verify and initialize the application software Low level maintenance and troubleshooting software Base Applications Standard iBox Base Applications present in every iBox are WIN the system database manager WESMAINT which a...

Page 16: ...m a remote network station WESMAINT is accessed using a VT100 terminal or a PC running terminal emulation software Database Display Through WESMAINT you can access the following Digital inputs and outputs Counters or accumulators Device status Sequence of events SOE and change of state COS data System status information Error log information User login buffer Other application specific information...

Page 17: ...wing prompt appears D25S This mode is accessed only while the iBox is in a maintenance state since forcing an iBox into this mode terminates all running applications When the Monitor is operated from flash the following prompt appears D25A This is the normal mode of operation and it can be accessed via WESMAINT at any time without disrupting unit operation Note Using the 68K Monitor requires detai...

Page 18: ...se to external sources Data Processing Applications Data Processing Applications are configured to select and format data from the system database and forward this data to a SCADA host or master station Data Translation Applications A combination of a DPA and a DCA Data Translation Applications use data from the system database to perform logical operations the results of which create new data Thi...

Page 19: ... compared to previous known data Changes are recorded in the system database then reported to other applications as needed The Plant I O Subsystem Scans and processes up to 8 digital inputs Controls up to two digital outputs and two master trip close relays Requests for digital outputs are accepted and processed as soon as they arrive Fixed Number of Points The Plant I O DCA maintains a fixed numb...

Page 20: ...efully remove the iBox from its shipping package Visually inspect the unit to ensure it has not sustained any visible damage during transit The figure below shows an iBox removed from the shipping package Package Contents The following items are provided as part of your iBox shipment iBox or iBox Kit unit WESMAINT serial cable IBOX iBox Kit Installation and Maintenance Guide 994 0047 CD including ...

Page 21: ...24 V Digital Input and 4 Trip Close Control Outputs 505 0101 48 V Digital Input and 4 Trip Close Control Outputs 505 0102 110 125 V Digital Input and 4 Trip Close Control Outputs 505 0103 24 V Digital Input and 2 Trip Close and 2 Form A Control Outputs 505 0104 48 V Digital Input and 2 Trip Close and 2 Form A Control Outputs 505 0105 110 125 V Digital Input and 2 Trip Close and 2 Form A Control Ou...

Page 22: ... and pulling the battery out of the chassis If you are storing a new iBox which has the battery PULL tab in place you do not need to remove the battery for storage the PULL tab disconnects insulates the battery function Recycling of Batteries The iBox Lithium battery is recyclable and does not contain mercury cadmium or lead in levels above those regulated by the European Union Recycle the battery...

Page 23: ... flat screwdriver with 0 6 x 3 5 mm blade for terminal block wiring A 2 Phillip Server Screwdriver for rack mounting the unit A 1 Phillip Server Screwdriver for removing and installing the communication boards Needle Nose Pliers Wire Cutters Wire Strippers Wire Crimping Tool Panduit CT 1525 or equivalent 6 fork connectors Fork type Panduit part number PV14 6F for 14 16 AWG wire or PV18 6F for 18 2...

Page 24: ... iBox Installation and Maintenance Overview Introduction This section covers the following topics Familiarization of the iBox Installing the iBox Configuring the iBox Testing the iBox Connecting and testing field wiring Servicing the iBox Maintaining the iBox software Troubleshooting the iBox Replacing the iBox ...

Page 25: ...nal block for field I O separable in pairs Operation and Maintenance You can operate and maintain the iBox configuration through the WESMAINT port Inputs Outputs The iBox provides the following Eight digital inputs Four control outputs Digital Inputs The iBox provides the following digital inputs Eight optically isolated status inputs 25VDC or 125VDC with 20 overload Wetting options LED indication...

Page 26: ...ts The iBox provides the following control outputs Four Trip Close pairs or two Trip Close pairs and two Form A contacts Separate Master Trip and Master Close relays Security features Protection against erroneous operation due to single point of failure Select before operate SBO functionality 35W breaking 125VDC 180W breaking 30VDC 6A current handling capability ...

Page 27: ...w the Safety Precautions for guidelines and warnings regarding the safe handling and installation of the product Installation Steps Installing the iBox involves the following main steps Step Action 1 Physically install the iBox 2 Connect power source and serial interfaces 3 Power up the iBox and check for normal operation 4 Configure the iBox using SGConfig 5 Test the iBox 6 Connect and test field...

Page 28: ...h the top cover removed Operation with the top cover removed may alter product performance specifications and result in component damage from foreign matter entry Do not install and or operate the iBox upside down Ensure all nuts and screws are tightened securely Ensure that iBox is protected from falling debris during installation Power Supply Source An IEC 60947 compliant main disconnect switch ...

Page 29: ...faces are free of dirt residue and corrosion Ensure cable shields are grounded at either the iBox functional ground terminal or at the field equipment Do not ground the shields at more than one point because a potential difference may exist between grounds resulting in ground loops and undesirable noise sources To prevent electromagnetic interference from upsetting iBox operation use cables with a...

Page 30: ... surface 2 Install and tighten the four screws holding the iBox firmly in place on the mounting surface 3 Loosen the iBox top cover and remove the battery PULL tab The iBox is delivered with this tab in place to insulate the battery during shipment Mounting and Clearance Leave at least one rack unit RU of space above and below the equipment to allow for cooling air flow and cable routing 1 RU 1 75...

Page 31: ... The maximum wire gauge for terminal blocks is 12 AWG Internal Overcurrent Protection An internal MDL 0 5 A slow blow fuse protects the iBox power supply Power Connection Procedure To connect the power source Step Action 1 Connect ground wire to the ground terminal A 12 AWG green and yellow wire is recommended 2 Connect the DC power supply observing the correct polarity to the positive and negativ...

Page 32: ...es of self diagnostic tests If the iBox fails to boot up properly which indicates that a self diagnostic failure has occurred it might have sustained internal damage during shipping Contact GE Digital Energy for assistance LEDs The POWER and RUN LEDs will both light during the self diagnostic sequence Diagnostics Completed Self diagnostics have completed successfully when the POWER and RUN LEDs ar...

Page 33: ...ion to the PC The WESMAINT interface supports RS 232 signaling and normally operates at a fixed rate of 9600 bps WESMAINT Cable To connect to a PC use a WESMAINT cable GE part number 977 0048 96 or equivalent The schematic for this cable is shown below Terminal DB 9 Female WESMAINT DB 9 Male COM N C TXD RXD N C N C N C N C N C N C RXD TXD N C COM N C N C N C GND 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9...

Page 34: ...ptions IRIG B receivers are available with modulated and or unmodulated output options If the unmodulated output of the receiver is a coaxial connection a converter will be required to interface to the iBox COM Ports COM ports provide the following Variable communication parameters Optional software flow control Optional hardware flow control Out of sequence transmission of one byte of data Suppor...

Page 35: ...Pin RS 232 RS 485 1 CD N C 2 RX RX 3 TX TX 4 N C N C 5 Com GND Com GND 6 N C N C 7 RTS TX 8 CTS RX 9 EARTH GND EARTH GND Radio Key Open Collector Output for COM Port 1 only jumper selected with JP3 installed 2 Wire RS 485 Cable The following schematic shows the cable wiring necessary for 2 wire RS 485 operation Description PIN 1 2 3 4 5 6 7 8 9 N C Data Data N C Common Ground N C Data Data Earth G...

Page 36: ...necessary After creating the device the remaining procedures are the same whether you are working with a copy of an existing configuration or creating a new device configuration Configuration Steps The iBox is configured using the SGConfig configuration system Configuring the iBox involves the following main steps Create or restore a SGConfig project Create and configure the iBox device in the pro...

Page 37: ...Config Project Step Action 1 In your Windows desktop click Start and then click Programs 2 Click SGConfig SGConfig Result SGConfig opens Importing the Factory Configuration 3 Click GE Archive Project Restore 4 Click Restore Result The Restore Project Details window appears 5 Insert your configuration CD in the drive 6 Navigate to the configuration file in the Archive File Name field 7 Click OK Res...

Page 38: ... Device Icon When you create a new iBox device select the iBox device template to see the appropriate configuration screens Procedure Creating a New iBox Device To create a new iBox device Step Action 1 Open the project in which you want to create the iBox device 2 Drag and drop an iBOX device template from Local Repository Device Templates into the project tab area 3 Click Edit group Properties c...

Page 39: ...m port for RS 232 or RS 485 communications Note The 2W 4W selection in SGConfig only affects the interface s internal software control handshaking It does not change the physical characteristics of the communication ports Processor Tab 4 Click the Processor tab 5 On the Firmware tab click the Select button to display the available firmware definitions 6 In the Use Firmware Type field select the fi...

Page 40: ... box appears 3 Double click the DC Configuration icon Result The D25 DC Configuration for iBox dialog box appears 4 On the General tab select the type of digital input board from the First Digital Input board list Select one of C iBox 8 channels 24 V wetting D iBox 8 channels 48 V wetting E iBox 8 channels 125 V wetting The other board settings are preset Result The letter in the Device Code chang...

Page 41: ...s ENTER Result SGConfig prompts you to enter a password 6 Type your password the default is rd and press ENTER Result The following screen appears 7 Enter 2 Result The following screen appears 8 Enter 3 Result The 68K Monitor command prompt appears 9 In the command line type el r then press ENTER Result The iBox clears its error log Tip To speed up the configuration download temporarily change the...

Page 42: ...A confirmation window appears when the download is complete 12 Click Reboot Result The iBox reboots Note If you changed the baud rate to 38400 the WESMAINT communications rate automatically restores to 9600 baud after the iBox reboots You need to manually restore the SGConfig terminal emulator communications rate to 9600 13 From SGConfig click the Connectivity group Disconnect command Note If you ...

Page 43: ...evice Table specifies the remote devices with which the DCA communicates the polling parameters for each remote device and the points configured on each remote device Each record in the Remote Device Table references the appropriate Remote Device Point Mapping Table s and Remote Device Polling Table s Remote Device Point Mapping Table Specifies the number and type of data points associated with ea...

Page 44: ... DNP Digital Input Module That is factory configured with 64 digital inputs That has DNP address 0032 Which is to be polled every 500 ms With every poll we want a full status update To meet these requirements you would configure the DNP DCA as shown in the below table Table Parameter Value Remote Device Table Application Address 0032 Remote Device Point Mapping Table DCA Object Type Binary Input N...

Page 45: ...s section you must have a valid configuration file loaded into the iBox s NVRAM The iBox is typically shipped with a valid configuration file loaded during manufacturing and this file should be still loaded when the unit is delivered to your site In the event that you do not have a valid configuration file loaded into your iBox s NVRAM or the file becomes corrupted before the unit is installed you...

Page 46: ...Ds one for each communication port RX1 RX3 Left side The RECEIVE LED flashes when the iBox is receiving a signal from an outside device There are three receive LEDs one for each communication port RS1 RS3 Left side The Request to Send RTS LED only works on systems configured for RS 232 communications There are three RTS LEDs one for each communication port CS1 CS3 Left side The Clear to Send CTS L...

Page 47: ...ate a simple interface to the iBox With a VT100 compatible terminal emulation program or SGConfig you can access the WESMAINT facility directly Note For further information about using WESMAINT software refer to the WESMAINTII User s Guide Document Number B014 1UG 68K Monitor The iBox s 68K Monitor is a debugging and diagnostics tool that is accessible in two ways As a menu selection available thr...

Page 48: ...t part of the iBox system but you can use terminal emulation software such as HyperTerminal or SGConfig terminal utility for these tests WESMAINT Terminal for Set up Use the following procedure to set up a PC as a WESMAINT terminal Step Action 1 Open HyperTerminal provided with Windows operating system or other VT100 compatible terminal emulation software 2 Verify or set the terminal communication...

Page 49: ...e power cable is properly connected to iBox and power is available 4 The POWER and RUN indicators on the front upper left hand corner illuminate when power to the iBox is turned ON 5 Monitor the VT100 terminal s display Result A series of text scripts displays as the POST routines are performed If you do not see the text scripts check all connections and repeat the procedure iBox Boot Up The iBox ...

Page 50: ...loading Code Files on page 65 for procedures for restoring files 2 Type the User Name westronic and press ENTER 3 Type the Password rd and press ENTER Result The WESMAINT Main Menu appears 4 If a time out occurs press ENTER again to return to the login prompt User Name and Password The user name and password shown above are factory defaults If you cannot log in contact your system administrator to...

Page 51: ...Box Kit Installation and Maintenance Guide GE Information 994 0047 5 10 4 51 2 5 Connecting and Testing Field Wiring Overview Introduction This section describes the process for making and testing field connections to the iBox ...

Page 52: ...ng a sufficient wetting voltage the green LED associated with the DI will light Digital Input Thresholds The following table shows the iBox s ON and OFF state thresholds Verify that inputs do not exceed the maximum overload voltage otherwise the iBox may be damaged Digital Input Options On Threshold Off Threshold Max Overload Voltage Low Voltage Digital Input 24 VDC 14 VDC 5 VDC 24 VDC 20 48 VDC 2...

Page 53: ...at is switched at the input terminals is supplied by an external source The external power source is connected to terminal block TB 10 positions 1 and 2 as shown below All eight digital inputs are bipolar Use care when connecting multiple external power sources since the digital inputs have common returns Wiring Diagram Dry Contact Operation This diagram illustrates the DC input connections from I...

Page 54: ...0101 505 0102 You can wire four trip close outputs as follows Wiring Two Trip Close and Two Digital Outputs Part No 505 0103 505 0104 505 0105 You can wire two trip close and two digital outputs as follows Important iBox digital outputs are not internally fuse protected Remote Local Operation If Then operation is JP2 is installed Remote controls are enabled JP2 is removed Local controls are disabl...

Page 55: ...riptions viewed in WESMAINT will be modified by changes you have made to the point descriptions in the iBox configuration file Procedure Testing Digital Inputs The following procedure accessible through the WESMAINT Main Menu assumes digital inputs for the iBox are wired and wetted Step Action 1 Select 1 Digital Input Display Result The point numbers and optionally point descriptions appear on the...

Page 56: ... made to the point descriptions in the configuration file Use caution when testing digital output points that are connected to external equipment This test may activate or damage external devices such as relays or reclosers and could injure personnel Procedure Testing Digital Outputs From the WESMAINT Main Menu Step Action 1 Select 1 System Data Display 2 Select Digital Output Display Result The p...

Page 57: ... relays click when forced Note For Trip Close operation in Repeat Command field if field input value is other than zero it results in a WIN write request failed error message with status 0x0011 operation not supported for this point Refer to Appendix G Error Messages Notes Note The password shown above is factory default If you cannot log in contact your system administrator to obtain the new pass...

Page 58: ...ox Introduction This section provides information and procedures for maintaining the iBox The iBox does not require any scheduled maintenance other than periodic inspection to ensure that the Unit has sustained no accidental physical damage Airflow is not obstructed and Connectors and cables are intact and firmly attached ...

Page 59: ...ace the fuse Fuse Location The fuse is located in position F1 on the main board To find the fuse remove the iBox top cover and look to the bottom left corner of the main board close to the protective earth terminal Procedure To replace the fuse Step Action 1 Remove power to the iBox 2 Remove the top cover 3 Remove the fuse 4 Replace the fuse with a GE fuse part number 940 0215 The fuse type is MDL...

Page 60: ...board close to the column of relays Battery Type The iBox uses a 3 V BR2 3A lithium battery GE part number 980 0026 Procedure To replace the battery Step Action 1 Remove power to the iBox 2 Remove the top cover 3 Remove the battery by removing the holder clip 4 Replace the battery with a GE battery part number 980 0026 Check that battery has been inserted correctly by verifying the polarity markin...

Page 61: ...aintenance Guide GE Information 994 0047 5 10 4 61 2 7 Maintaining your iBox Software Overview Introduction The iBox is factory pre configured and tested It contains all required operating software and is able to upload and download configuration files ...

Page 62: ...ehavior of the iBox Failure of the iBox software Configuration and Code File Mismatch Code and configuration file mismatch can occur for one of the following reasons The wrong configuration file is downloaded to the unit This can happen through a local SGConfig download for example the downloaded file could have been based on an iBox with a different code file The code file that is downloaded does...

Page 63: ... the base system invalidates the configuration and forces a system reset 4 When the iBox comes back up the base system will sense the now invalid configuration and will either create a default configuration or load a backed up configuration if one is available This process protects the system from file problems that might cause the system to reset before the user can access WESMAINT to rectify the...

Page 64: ... the ESCAPE key Result The following message appears Are you sure you wish to generate a default configuration y n 2 Type Y and press ENTER Result The configuration restores to default Erasing the Configuration File Step Action 1 With a terminal connected to the iBox 68K Monitor type DHW Display HardWare or SI System Information on older units Result A listing of information including the start ad...

Page 65: ...to access the iBox through the WESMAINT port Using a parallel port adapter and software utility connect directly to the iBox BDM Background Debug Mode port This procedure which facilitates very fast downloads is used during the manufacture of the iBox Before Downloading When a new code image is downloaded into the iBox flash memory the amount of memory reserved for the configuration s data region ...

Page 66: ... will suspend all iBox operations Following the download the unit will likely require a configuration download before it becomes operational Consult your system administrator for access and authorization to perform system download procedures In the Application Monitor the D25A prompt displays configuration files can be downloaded but code files cannot To download code the System Monitor the D25S p...

Page 67: ...ilable commands type help ENTER 7 At the Return to the BootROM Operating System yes no prompt type yes and press ENTER Note The monitor is not case sensitive but Y is not acceptable Result The system restarts While the iBox is rebooting the system is disabled Log in to the System Monitor 8 After the restart is complete press ENTER Result The Login prompt appears 9 Type the login name westronic ENT...

Page 68: ... progress indicator such as HyperTerminal you can enable echo to visually display the code file on your monitor as it is transferred This option can usually be found in the communication settings or properties of the communication program Note Enabling echo can slow transfer slightly Start Download 15 Type dl and press ENTER 16 Select Send Text File or comparable command from program menus Note Yo...

Page 69: ...stallation and Maintenance Guide GE Information 994 0047 5 10 4 69 2 8 Troubleshooting your iBox Overview Introduction This section provides instructions on what to do if the system malfunctions or when error messages appear in WESMAINT ...

Page 70: ... in the state of specific digital input points These events are logged to the WESMAINT SOE Buffer Display If WESMAINT Will Not Run In severe cases the WESMAINT application may not run at all If this happens Step Action 1 Access the System Monitor 2 Type EL P 3 Type EL R 4 Reboot the iBox 5 Press ENTER Result A low level error log displays If these tables fail to help remedy the situation or if you...

Page 71: ...toring detects a conflict between desired and actual coil status a coil is not energized when it should be Move the Controls Jumper to the Remote position Verify coil status System Hangs Watchdog failure Attempt Reboot clear CCU error logs Plant I O Watchdog Failure Plant I O Subsystem integrity is faulty Remove and restore power to the iBox Digital output Points are Disabled The Local Remote Jump...

Page 72: ...ted configuration guide for suggestions Start Up Failure RAM check NVRAM check Application checksum or BootROM checksum failed during system start up Use WESMAINT to view the error message and refer to related configuration guide for suggestions System Shut Down RAM NVRAM FLASH or BootROM internal system diagnostics failed Use WESMAINT to view the error message and refer to related configuration g...

Page 73: ...t TFTP Error Configuration was not completed or data corruption has occurred at the server Use WESMAINT to view the error message Applications Not Enabled Configuration was not completed or data corruption has occurred at the server Use WESMAINT to view the error message System Restarts Data download failure Use WESMAINT to view the error message Only diagnostic input can be entered No configurati...

Page 74: ...U4 TX LED does not light Unit is not transmitting any data RTS CRS DCD settings are incorrect Check cabling to modems If connected to a modem or converter ensure RTS CTS DCD are enabled If using a Direct Serial Connection try disabling RTS CTS DCD RX LED does not light Not receiving any data Same as above RS LED does not light RTS line disabled Enable RTS CS LED does not light Modem not working co...

Page 75: ...wdrivers and flashlight Replacement iBox Before Installing Verify that the replacement iBox unit is fitted with the same options and connectors as the original unit before proceeding Refer to Product Identification on page 20 for detailed information Since hazardous voltages can cause shock burns or death Disconnect and lockout all power sources before servicing and removing components Short all c...

Page 76: ...nnections Important When the new unit is installed it is important that these wires are reconnected to the same points from which they were removed Record the position of each wire as it is removed 5 Remove communications cables from the iBox Important Note the location and orientation of each cable as it is removed 6 Remove the disconnected iBox from its mounting position Installing the Replaceme...

Page 77: ...ed to provide DC analog inputs AC analog inputs an Ethernet connection and support for a wide range of power supply input voltages Examples of DC and AC iBox Kits are shown below Power Supply 19 Mounting Plate COM Ports iBox Digital Inputs and Outputs Ethernet Module AC Analog Input Module AC Kit DC Kit COM Ports Digital Inputs and Outputs iBox DC Analog Input Module Protective Earth Terminal AC I...

Page 78: ...strated below other options of the iBox Kit are equipped differently AC Kit Power Supply AC Analog Input Module iBOX Ethernet Module RS 485 PPP 10 100BaseT Ethernet 20 60 VDC 88 264 VAC 88 300 VDC 24 VDC Output RS 485 Modbus RS 232 485 Serial Port RS 232 Maintenance Port 4 Digital Outputs 8 Digital Inputs 3 CT Inputs 3 PT Inputs DC Kit An example configuration of the iBox DC Kit is illustrated bel...

Page 79: ... following digital inputs directly from the iBox Eight optically isolated status inputs 25VDC or 125VDC with 10 overload Wetting options LED indications 4 5 mA typical current burden per input up to 48VDC Maximum 0 5 W heat dissipation per input from current burden of inputs at 125VDC Control Outputs The iBox Kit provides the following control outputs directly from the iBox Four Trip Close pairs o...

Page 80: ... s Surge withstand as per IEEE C37 90 1 ANSI C62 41 True RMS sampling at 64 samples per cycle Isolation 2500 VAC 60 Hz Burden Voltage Current 0 1 VA max Power Supply 6 VA max Power Supply The power supply provides 24 VDC power to all iBox Kit components It can also deliver limited 24 VDC power to customer provided equipment The power supply comes in two input voltage range options 20 60 VDC 7 A ma...

Page 81: ...er however you need to configure the PPP Driver Ethernet Module IP addresses and SCADA protocol e g DNP or IEC addresses You configure the iBox Kit components as follows Component Configuration Method iBox Locally through the iBox maintenance WESMAINT port from a PC running SGConfig If it is equipped with an Ethernet Module the iBox can also be configured through the LAN from a remote PC running S...

Page 82: ...afety Precautions for guidelines and warnings regarding the safe handling and installation of the product Installation Steps Installing the iBox Kit involves the following main steps Step Action 1 Physically install the iBox Kit 2 Connect power source ground and serial interfaces 3 Power up the iBox Kit and check for normal operation 4 Configure the iBox Kit components 5 Test the iBox Kit 6 Connec...

Page 83: ...inch mounting rack 2 Insert but don t tighten the top two mounting screws 3 Slide the iBox Kit over the top mounting screws and drop down into position 4 Insert the bottom mounting screws 5 Tighten all four mounting screws Note iBox Kits should be installed with the equipment modules and LEDs visible from the front of the rack Note Equipment cabling will typically route along the rack channel come...

Page 84: ...Kit protective earth terminal We recommend 12 AWG wire a ring connector and a toothlock washer Power Connection Connect power to the iBox Kit power supply External fuse installation is required Consult the power supply rating section for power ratings iBox Kit DC Protective Earth Terminal DC Output Ground Input iBox Kit AC Protective Earth Terminal Not Connected ...

Page 85: ...de GE Information 994 0047 5 10 4 85 Communications Cabling Communi cations Cabling Ethernet If your iBox is equipped with an Ethernet module connect the LAN to the iBox by plugging a CAT5 cable equipped with an RJ45 connector into the Ethernet module Ethernet Port ...

Page 86: ...s necessary connect the appropriate iBox COM port to your equipment using serial cables with male DB 9 connectors Note COM port assignments for different iBox Kit options are summarized in Appendix B iBox Kit Default Configurations Note The Ethernet module is connected to the COM3 port by a special GE supplied cable GE part number 977 0526 WESMAINT COM 1 COM 2 COM 3 ...

Page 87: ...Module if equipped IP addresses Admin password Pass through switch Configuration ports setting DC Analog Input Module if equipped In most cases you will not have to reconfigure the DC Analog Input Module You may however want to change the following Input type voltage or current Input range Point descriptors AC Analog Input Module if equipped In most cases you will not have to reconfigure the AC An...

Page 88: ...et mask of the LAN iBox and Ethernet Module Gateway address if your iBox is connected to the LAN through a router Factory configuration for your Ethernet Module You can find this on the configuration CD Configuration Sequence Serial Connection If you are operating the iBox Kit through a serial port the process for configuring and testing the iBox Kit components is as follows Restore Config Pro Pro...

Page 89: ...on are as follows Restoring your SGConfig Project on page 91 Configuring Project Properties Serial on page 92 Configuring iBox Device Properties Serial on page 94 Configuring iBox Communications Options Serial on page 95 Configuring the Application Firmware on page 96 Downloading your iBox Configuration Serial on page 97 Configuring the DC Analog Module on page 123 if equipped Configuring the AC A...

Page 90: ... Connection Test iBOX Kit Note The first time you configure the iBox in an iBox Kit you will do it through the WESMAINT serial port Once you have configured the iBox you will be able to download subsequent configurations over the LAN Configuration Procedures LAN connection The procedures for configuring an iBox Kit with a LAN connection are as follows Restoring your SGConfig Project on page 91 Con...

Page 91: ...porting the Factory Configuration 3 Click GE Archive Project Restore 4 Click Restore Result The Restore Project Details window appears 5 Insert your configuration CD in the drive 6 Navigate to the configuration file in the Archive File Name field 7 Click OK Result The configuration file uploads to your PC and your project appears in an SGConfig project tab Next Step If you are operating the iBox K...

Page 92: ...rocedure to configure Project Properties if you are operating the iBox Kit through a serial connection Procedure Configuring Project Properties Serial Step Action 1 In SGConfig click GE Project Properties Result The Select Project window appears 2 Select your project under SGConfig Projects and click OK Result The Project Properties window appears Continued on next page ...

Page 93: ... Configuring Project Properties Serial continued Step Action 3 Select the D2x tab General tab Verify that LAN Based Project is not checked and click OK 4 Click GE Copy Project Result The Copy Project window appears 5 Type in a New Project Name for your project 6 Click OK to save Next Step The next step is Configuring iBox Device Properties Serial on page 94 ...

Page 94: ...evice Properties Serial Procedure Configuring iBox Device Properties Serial Refer to iBox Device Properties on page 36 for instructions on configuring iBox Device Properties when you are connecting to the iBox Kit through a serial port Next Step The next step is Configuring iBox Communications Options Serial on page 95 ...

Page 95: ...ons if you are operating the iBox Kit through a serial connection Procedure Configuring Communi cations Options Serial Step Action 1 In the Project tab area right click the iBox device icon 2 Click Communications group Options command 3 On the Interface tab select Direct Serial under Connection Type and COM1 from the Comm Port list 4 Click OK to save Next Step The next step is Configuring the Appl...

Page 96: ...efer to Configuring Application Firmware on page 40 for directions on how to configure iBox application firmware Next Step If you are operating the iBox Kit through a serial connection the next step is Downloading your iBox Configuration Serial on page 97 If you are operating the iBox Kit through a LAN connection the next step is Downloading your iBox Configuration LAN on page 108 ...

Page 97: ...to Downloading your iBox Configuration on page 41 for instructions on how to download a configuration file to the iBox through the WESMAINT port Next Step If your iBox Kit is equipped with a DC Analog Input Module the next step is Configuring the DC Analog Module on page 123 If your iBox Kit is equipped with an AC Analog Input Module the next step is Configuring the AC Analog Module on page 130 If...

Page 98: ...intenance Guide GE Grid Solutions 98 994 0047 5 10 4 GE Information Configuring Project Properties LAN Introduction Use the following procedure to configure Project Properties if you are operating the iBox Kit through a LAN connection ...

Page 99: ...94 0047 5 10 4 99 Procedure Configuring Project Properties LAN Step Action 1 In SGConfig click GE Project Properties Result The Select Project window appears 2 Select your project under SGConfig Projects and click OK Result The Project Properties window appears Continued on next page ...

Page 100: ...rties LAN continued Step Action 3 Click the D2x General tab 4 On the General tab select LAN Based Project 5 Click the Segments tab On the LAN A tab select LAN A Enabled and enter the IP Address and Subnet Mask Note Even if your LAN has a default gateway you do not need to enter it here 6 Click OK to save Next Step The next step is Configuring iBox Device Properties LAN on page 101 ...

Page 101: ...e Properties if you are operating the iBox Kit through a LAN connection Procedure Configuring Device Properties LAN Step Action 1 Select the iBox device 2 Click Edit group Properties command Result The iBOX Device Wizard appears 3 Verify LAN based device is selected 4 In the Description box type in a name for the iBox 5 In the Serial Number box type i the serial number of the iBox Continued on nex...

Page 102: ...are as shown above and modify them if they are not 9 Click the LAN Settings tab and then click the General tab 10 Confirm the settings are as shown above and modify them if they are not 11 Click the LAN Specific tab 12 Enter the Host Address Note The Host Address is set to PPP IP Address of the Ethernet Module 1 The iBox and Ethernet Module PPP IP addresses are related as outlined in IP Addressing...

Page 103: ...ttings and modify them if necessary Field Value Port COM3 Baud 19 2K Bits per char 8 Parity Type Even Parity Mode None Stop Bits 1 RTS Disable CTS Disable DCD Enable RTS on delay 0 DCD on delay 0 RTS off delay 0 Max PPP receive unit 1500 Restart timer 3 ACCM Disable CHAP Disable Challenge_retries 2 Challenge_period 5 Note You should not need to change any of the above settings from their default v...

Page 104: ... 8 On the Data Translation Applications tab double click the DNP Internet Data Link icon Note If your system uses the IEC 60870 5 104 data link select the appropriate application icon 9 Click the Tables tab 10 In Local Host Name enter 11 Close the DNP Internet Data Link window 12 Click Yes to save your changes 13 Close the Applications window Next Step The next step is Configuring iBox Communicati...

Page 105: ...on and Maintenance Guide GE Information 994 0047 5 10 4 105 Configuring iBox Communications Options LAN Introduction Use the following procedure to configure iBox Communications Options if you are operating the iBox Kit through a LAN connection ...

Page 106: ...Configuring Communi cations Options LAN Step Action 1 In the Project window right click the iBox device icon click Communications and then click Options 2 On the Interface tab click iSCS LAN and LAN A 3 Click the TFTP tab 4 Verify the settings are as shown above and modify them if they are not 5 Click OK to save ...

Page 107: ...ptions LAN Step Action 6 Click Preferences D2x Generic System Preferences Result The SGConfig D2x Generic System Preferences window appears 7 Click the Communications tab then click the LAN tab 8 In LAN A select from the list the source IP address that you will use to communicate with the iBox Kit over the LAN 9 Click OK Next Step The next step is Configuring the Application Firmware on page 96 ...

Page 108: ...the WESMAINT port Refer to Downloading your iBox Configuration on page 41 for instructions on how to download a configuration file to the iBox through the WESMAINT port Note Once you have configured the iBox PPP driver and the Ethernet Module you will be able to download your iBox configuration over the LAN as outlined in Downloading your iBox Configuration over the LAN on page 136 Next Step The n...

Page 109: ... Refer to IP Addressing on page 81 for an explanation You also need to change the Digi One root password Step Action Connecting to the Digi One 1 Connect a PC to the Digi One IAP s RJ45 connector either directly as shown below iBOX Kit Digi One IAP PC running a Web browser IP address in the same subnet as the Ethernet Module Crossover Ethernet Cable or through the network iBOX Kit Digi One IAP PC ...

Page 110: ...erver Note The procedure may vary for Windows XP 2 Click Start point to Settings and then click Control Panel 3 Double click the Internet Options icon 4 Select the Connections tab 5 Click LAN Settings 6 Do one of the following If Use a proxy server for your LAN is not selected you do not have to make any further changes to your Proxy Settings Close all Windows dialog boxes and proceed to Modifying...

Page 111: ...ample if you enter 192 168 all messages sent to IP addresses starting with 192 168 will be sent directly not through the proxy server Note Once you change the Digi One Ethernet IP address you will have to modify Proxy Settings accordingly 9 Click OK and close all windows Changing Pass Through Switch Settings 10 Locate the pass through switch on the bottom of the Digi One IAP Change the switch sett...

Page 112: ... change the Ethernet IP address subnet mask and gateway address Note If a gateway is not used set the gateway address to the Digi One Ethernet IP address Refer to IP Addressing on page 81 for an explanation of iBox Kit IP addressing Example If the Digi One Ethernet IP address is 192 168 1 100 and a gateway is not used change the following lines in the configuration file set config ip 192 168 1 100...

Page 113: ...e Configuring the Digi One continued Step Action Starting the Digi Device Setup Wizard 18 Insert the Digi Software and Documentation CD in your CD ROM drive Result The Digi Device Setup Wizard starts automatically 19 Click Next Result The Setup Wizard discovers Digi devices on the LAN and presents a list of the discovered devices Continued on next page ...

Page 114: ...ess of your Digi One IAP is located on the white label on the bottom or back of the device 21 Click Next Result The Configure Network Settings page appears Configure the Digi One IP Settings 22 Select Use the following IP settings 23 Enter the Digi One Ethernet IP address and subnet mask as shown in the above example Enter a gateway address if one is required Check with your network administrator ...

Page 115: ... 115 Configuring the Ethernet Module continued Procedure Configuring the Digi One continued Step Action 24 Click Next Result The Select Scenario page appears Downloading the Configuration to the Digi One 25 In the drop down list under Scenario List select Custom Configuration Continued on next page ...

Page 116: ...ce Guide GE Grid Solutions 116 994 0047 5 10 4 GE Information Configuring the Ethernet Module continued Procedure Configuring the Digi One continued Step Action 26 Click Next Result The Verify Configuration page appears Continued on next page ...

Page 117: ...ocedure Configuring the Digi One continued Step Action 27 Do one of the following If the configuration parameters are not correct click Back and make the necessary corrections If the configuration parameters are correct click Next Result The Setup Wizard saves the network settings to the Digi One and then reboots the device Continued on next page ...

Page 118: ...d Procedure Configuring the Digi One continued Step Action Connecting to the Digi One Web Server 28 When the reboot completes the Saved configuration successfully screen appears 29 Make sure Register my Digi One IAP on the Digi website is not selected and click Finish Result The Enter Network Password dialog box appears Continued on next page ...

Page 119: ...rmation 994 0047 5 10 4 119 Configuring the Ethernet Module continued Procedure Configuring the Digi One continued Step Action 30 Enter User Name root and Password dbps and click OK Result The Digi One IAP Configuration and Management home page appears Continued on next page ...

Page 120: ...31 Under Administration click Backup Restore Result The Backup Restore page appears 32 Click Browse and enter the location of the Digi One configuration file on your PC 33 Click Restore Result The Digi One receives the configuration file from your PC 34 Click Done Result The Reboot page appears Note The Digi One IAP needs to be rebooted for the new configuration settings to be applied 35 Click Reb...

Page 121: ...assword and click Apply Note The next time you browse to the Digi One Web server you will need to enter user name root and this new password If you forget this password you can reset the Digi One to its default configuration and password user name root password dbps by following the procedure outlined in Resetting the Digi One Configuration on page 153 If you reset the Digi One you will need to re...

Page 122: ...ormation Configuring the Ethernet Module continued Next Step If your iBox Kit is equipped with a DC Analog Input Module the next step is Configuring the DC Analog Module on page 123 If your iBox Kit is not equipped with a DC Analog Input Module the next step is Testing the iBox Kit on page 131 ...

Page 123: ... CD that shipped with your iBox Kit accessible through Manual ADAM 4000 ADAM 4000 pdf Modbus DCA Configuration Guide A059 0CG Available from the GE Digital Energy CD that shipped with your iBox Kit Calculator DTA Configuration Guide A083 0CG Available from the GE Digital Energy CD that shipped with your iBox Kit Before you Start You need the following to configure the ADAM 4017 RS 485 RS 232 conve...

Page 124: ...he vendor s manual Step Action 1 Power down the iBox Kit 2 Disconnect the cable between the ADAM 4017 and iBox COM2 at the ADAM 4017 end 3 Connect the RS 485 side of the RS 485 RS 232 converter to the DATA and DATA terminals on the ADAM 4017 Connect the RS 232 side of the converter to one of your PC s COM ports PC running ADAM 4000 Utility ADAM 4017 RS 485 RS 232 Converter RS 485 RS 232 4 Switch t...

Page 125: ...Configuring the DC Analog Module continued Procedure Configuring the ADAM 4017 continued Step Action 5 Install the ADAM 4000 utility from the Advantech CD accessible through Install Products ADAM 4000 Utility 6 Open the ADAM 4000 Utility Result The ADAM Utility Main Screen appears Continued on next page ...

Page 126: ...ep Action 7 In the left hand pane select the COM port to which the ADAM 4017 is connected and click Search in the toolbar Result The Search Installed Modules dialog box appears 8 Click OK Result The ADAM 4000 Utility searches for and displays devices on the COM port 9 As soon as your ADAM 4017 is displayed in the left hand pane click Stop scan to halt the device search Continued on next page ...

Page 127: ...nts or make the same change to all analog points Refer to the ADAM 4000 Utility Online Help for further information To access this online help your PC must be connected to the Internet Note If you are changing the ADAM 4017 input range from voltage to current or vice versa you will need to power down the device remove its cover and change the jumper setting for the analog input s For detailed inst...

Page 128: ...y the default point descriptions for the DC Analog Inputs to more meaningful descriptions for your system Follow these steps to change the point descriptors of the DC analog inputs Step Action 1 Open the iBox Kit device in SGConfig open the Applications List and click the System Point Database Applications tab 2 Double click the System Point Database icon Result The System Point Database Propertie...

Page 129: ...10 4 129 Configuring the DC Analog Module continued Next Step If your iBox Kit is equipped with a AC Analog Input Module the next step is Configuring the AC Analog Module on page 130 If your iBox Kit is not equipped with a AC Analog Input Module the next step is Testing the iBox Kit on page 131 ...

Page 130: ... equipped with SGConfig available from the GE Digital Energy CD that shipped with your iBox Kit Procedure Modifying the Point Descriptors You may wish to modify the default point descriptions for the AC Analog Inputs to more meaningful descriptions for your system Follow these steps to change the point descriptors of the AC analog inputs Step Action 1 Open the iBox Kit device in SGConfig open the ...

Page 131: ...GREEN LED which operates as follows LED Operation Description OFF Power OFF GREEN Solid Power ON unit is not being polled over the Modbus interface GREEN Flashing Power ON unit is being polled over the Modbus interface at the same rate as the LED is flashing DMMS LEDs Refer to the manufacturer s manual iBox LEDs For information on iBox LED operation refer to LEDs on page 32 for LED operation durin...

Page 132: ...tly to the iBox Refer to Connecting and Testing Field Wiring on page 51 for information on how to connect field wiring to the iBox and how to map and test these connections AC Analog Inputs AC analog inputs are connected to the iBox Kit through the AC Analog Input module as shown below Three Phase Four Wire Wye with Direct Voltage and CTs Three Phase Four Wire Wye with CT and PTs Continued on Next...

Page 133: ...formation 994 0047 5 10 4 133 Connecting Field Wiring continued DC Analog Inputs DC analog inputs are connected to the iBox Kit through the DC Analog Input module as shown below Vin 4 Vin 4 Vin 3 Vin 3 Vin 2 Vin 2 Vin 1 Vin 1 Vin 0 Vin 0 Vin 5 Vin 5 Vin 6 Vin 6 Vin 7 Vin 7 ...

Page 134: ...x on page 58 Connections The other modules in the iBox Kit require very little servicing Verify that connections are tight and LEDs are operating correctly LED Operation For information on the operation of LEDs on iBox components refer to the following sections of this document iBox LEDs refer to LED Descriptions on page 46 Digi One IAP LEDs refer to Digi One IAP LEDs on page 131 ADAM 4017 LEDs re...

Page 135: ... Software Overview The iBox software may need occasional maintenance Although other modules may also contain firmware this firmware will typically not need to be upgraded Maintaining your iBox Software For information about your iBox software and instructions on how to maintain it refer to Maintaining your iBox Software on page 61 ...

Page 136: ...iver and Ethernet Module you can download subsequent changes to the iBox configuration over the LAN To do this configure your PC with an IP address in the LAN s subnet This is illustrated below iBOX Kit Ethernet Module PC running Config Pro with IP address in iBOX Kit subnet LAN iBOX Note Refer to Appendix D Setting your PC IP Address for instructions on how to set your PC s IP address for Windows...

Page 137: ...tion 3 68K Monitor Result The system prompt appears indicating that the Applications Monitor is running 6 At the system prompt type rtb and press ENTER For other available commands type help and press ENTER 7 At the Return to the BootROM Operating System yes no prompt type yes and press ENTER Note The monitor is not case sensitive but Y is not acceptable Result The iBox restarts 8 In SGConfig open...

Page 138: ...ctions LINK OFF RED LED indicates no network cabling DCD Solid GREEN Check cabling connections serial port DSR Solid GREEN Check cabling connections serial port DTR Solid GREEN Check cabling connections serial port RTS Solid GREEN Check cabling connections serial port TX Flashing GREEN Check cabling connections serial port RX Flashing GREEN Check cabling connections serial port ADAM 4017 If you ar...

Page 139: ...n raise and remove the iBox Kit from the rack 6 Check the jumpers and settings on the replacement iBox Kit and make sure they are the same as those on the failed unit 7 Mount the replacement iBox Kit in the rack Insert the lower mounting screws and tighten all mounting screws 8 Reconnect the ground wire to the iBox Kit 9 Reconnect power cabling 10 Reconnect all field wiring exactly as it was conne...

Page 140: ...move the firmware running in the flash memory OR Restarting the device 1 Restart the device by either Turning the power off and on or Typing the boot command at the 68K monitor prompt 2 When messages appear on the 68k monitor prompt press the Esc key a few times within 5 seconds Result The message Are you sure you wish to generate a default configuration y n appears 3 Type y or Y Result The curren...

Page 141: ...configuration data resides on the data storage media e g hard drives memory cards etc of the PC running SGConfig The iBox configuration data can be removed from the PC by either Recommended Physically removing and destroying the data storage media or Using a program to securely wipe i e completely erase the data storage media that is not just reformat or remove the names of the files from the file...

Page 142: ...iBox iBox Kit Installation and Maintenance Guide GE Grid Solutions 142 994 0047 5 10 4 GE Information ...

Page 143: ... 9 F EIA 232 9600 bps Standard Serial Communication Ports 3 DB 9 F EIA 232 485 up to 38400 bps concurrently Software configurable Jumper selectable JP3 Radio Key output on Port 1 36 Vdc max 3 A peak max 0 1 sec ON 10 duty cycle UTC Time Port in place of one serial port DB 9 F EIA 232 Port 2 Digital Inputs General Up to eight bipolar optically isolated 2000 Vrms Burden From 1 9 mA to 5 5 mA max pow...

Page 144: ...8 cm 11 inch Height 19 cm 7 5 inch Depth 4 5 cm 1 75 inch Weight 1 kg 2 2 lb maximum Operating Temperature 40 to 80 C may exceed EN61010 1 metal enclosure temperature of 70 C at ambient temperature of 60 C Storage Temperature 40 to 90 C Humidity Rating 0 to 95 relative humidity non condensing Operating Altitude 0 to 2000 meters Environmental Rating IP20 Installation Overvoltage Category CAT II EN6...

Page 145: ...t For Measurement Control and Laboratory Use Part 1 General Requirements EN60255 5 Dielectric Test Impulse Voltage Test Insulation Resistance EN61000 4 16 Test for Immunity to Conducted Common Mode Disturbances in the Frequency Range 0 Hz to 150 kHz steady state frequency IEEE C37 90 1 1989 SWC capability Field Terminations Wiring Digital Outputs 250 V rated compression termination consisting of a...

Page 146: ...g Altitude 0 2000 meters Protective Earth Terminal Protective earth terminal is provided on the mounting plate Power Supply Input Voltage Options 20 60VDC or 88 264VAC 88 300 VDC Output Voltage 24VDC Overload Protection Current limiting with short circuit protection Connections Screw type terminal block iBox Communi cation Ports Maintenance Port DB 9 F EIA 232 9600 bps Standard Serial Comm unicati...

Page 147: ...ons Modes of operation Dry contact and voltage sense 24 VDC 48 VDC and 110 125 VDC Digital Outputs General Up to four relay outputs configured as either 4 trip close pairs or 2 trip close pairs and 2 Form A contacts Physical Connection 250 V rated compression termination consisting of a header and removable plugs suitable for 12 24 AWG wire rated for 6A 150V Security features Separate Master Trip ...

Page 148: ... 0 to 125 of nominal Accuracy 0 3 Continuous Overload Withstand 200 of nominal Short Duration Overload Withstand 100 A for 3 seconds Surge Withstand As per IEEE C37 90 1 ANSI C62 41 True RMS Sampling 64 samples per cycle Isolation 2500 VAC 60 Hz Burden Voltage and Current 0 1 VA max Power Supply 6 VA max DC Analog Inputs optional Analog Input Options Two DC analog inputs or eight DC analog inputs ...

Page 149: ...OM1 Baud Rate 9600 Communication Type RS 232 Refer to point map tables for more detail Modbus DPA Modbus Address 1 Communication Port COM2 Baud Rate 9600 Communication Type RS 232 Refer to point map tables for more detail DNP DCA iBox DNP 3 0 Master Address 10 iBox DNP 3 0 Slave Address 1 Communication Port COM3 Baud Rate 9600 Communication Type RS 232 The DNP DCA is configured to poll an iBox If ...

Page 150: ...s for more detail WESMAINT User Name westronic Password rd Control Password control Note COM3 is used to connect the AC analog input module to the iBox IBOX Kit with DC Analogs IBOX DCA Configuration Details Comments DNP DPA iBox DNP 3 0 Master Address 10 iBox DNP 3 0 Slave Address 1 Baud Rate 9600 Communication Port COM1 Communication Type RS 232 Refer to point map tables for more detail Modbus D...

Page 151: ...CA is configured to poll an iBox If you connect COM3 to COM1 you can see the DNP DCA polling the DNP DPA WESMAINT User Name westronic Password rd Control Password control Note COM2 is used to connect to the Ethernet Module via PPP TCP IP IBOX Kit with AC Analogs and Ethernet IBOX ACL Configuration Details Comments DNP DPA iBox DNP 3 0 Master Address 10 iBox DNP 3 0 Slave Address 1 Communication Po...

Page 152: ...k 255 255 255 0 Refer to point map tables for more detail WESMAINT User Name westronic Password rd Control Password control Note COM2 is used to connect to the Ethernet Module via PPP TCP IP Note COM3 is used to connect the DC analog input module to the iBox DC Analog Input Ranges For all bipolar inputs regardless of whether the input is bipolar current or voltage the following is always true Inpu...

Page 153: ...r the point of a paperclip press and hold the recessed RESET switch located on the same side of the Digi One as the Ethernet connector 3 While holding down the RESET button restore power to the Digi One Result The Digi One DIAG LED displays a 1 5 1 pattern after about 20 seconds 4 When the 1 5 1 LED pattern is complete release the RESET button Result The Digi One boots up and its configuration res...

Page 154: ...iBox iBox Kit Installation and Maintenance Guide GE Grid Solutions 154 994 0047 5 10 4 GE Information ...

Page 155: ...ck Network and Dial up Connections 3 Double click Local Area Connections 4 Click Properties 5 Select Internet Protocol TCP IP 6 Click Properties 7 Select Use the following IP address 8 Enter an IP address that is in the same subnet as the iBox but not used by any other devices Enter the same subnet mask as the iBox 9 Click OK 10 Click OK in the Local Area Connections window 11 Close Local Area Con...

Page 156: ...iBox iBox Kit Installation and Maintenance Guide GE Grid Solutions 156 994 0047 5 10 4 GE Information ...

Page 157: ...gital Input 4 3 4 3 N A iBox Digital Input 5 4 5 4 N A iBox Digital Input 6 5 6 5 N A iBox Digital Input 7 6 7 6 N A iBox Digital Input 8 7 8 7 DO N A iBox Digital Output 1 0 9 0 N A iBox Digital Output 2 1 10 1 N A iBox Digital Output 3 2 11 2 N A iBox Digital Output 4 3 12 3 DNP DCA IBOX BSC and IBOX LAN DI N A Digital Input 1 on DNP DCA 8 13 8 N A Digital Input 2 on DNP DCA 9 14 9 N A Digital I...

Page 158: ... A Calculator DTA AI N A Scaled Analog Input 1 0 1 0 N A Scaled Analog Input 2 1 2 1 N A Scaled Analog Input 3 2 3 2 N A Scaled Analog Input 4 3 4 3 N A Scaled Analog Input 5 4 5 4 N A Scaled Analog Input 6 5 6 5 N A Scaled Analog Input 7 6 7 6 N A Scaled Analog Input 8 7 8 7 MODBUS DCA IBOX ACA and IBOX ACL AI 278 VOLT PHASE A N INST 0 1 0 279 VOLT PHASE B N INST 1 2 1 280 VOLT PHASE C N INST 2 3...

Page 159: ...1 VA PHASE C INST 23 24 23 302 PF PHASE A INST 24 25 24 303 PF PHASE B INST 25 26 25 304 PF PHASE C INST 26 27 26 317 VOLT PHASE A N AVG 27 28 27 318 VOLT PHASE B N AVG 28 29 28 319 VOLT PHASE C N AVG 29 30 29 320 VOLT PHASE A B AVG 30 31 30 321 VOLT PHASE B C AVG 31 32 31 322 VOLT PHASE C A AVG 32 33 32 323 AMP PHASE A AVG 33 34 33 324 AMP PHASE B AVG 34 35 34 325 AMP PHASE C AVG 35 36 35 326 AMP...

Page 160: ...HASE B N MAX 55 56 55 358 VOLT PHASE C N MAX 56 57 56 359 VOLT PHASE A B MAX 57 58 57 360 VOLT PHASE B C MAX 58 59 58 361 VOLT PHASE C A MAX 59 60 59 362 AMP PHASE A MAX 60 61 60 363 AMP PHASE B MAX 61 62 61 364 AMP PHASE C MAX 62 63 62 365 AMP NEUTRAL MAX 63 64 63 366 WATT MAX 64 65 64 367 VAR MAX 65 66 65 368 VA MAX 66 67 66 369 PF MAX 67 68 67 370 FREQ MAX 68 69 68 395 VOLT PHASE A N MIN 69 70 ...

Page 161: ...6 N A N A N A 437 WATT HOUR BCD COUNTER 5 N A N A N A 438 WATT HOUR BCD COUNTER 4 N A N A N A 439 WATT HOUR BCD COUNTER 3 N A N A N A 440 WATT HOUR BCD COUNTER 2 N A N A N A 441 WATT HOUR BCD COUNTER 1 N A N A N A LogicLinx CT N A KWH counter 32bit 0 N A 0 N A KWH counter 16bit MSB N A 87 N A N A KWH counter 16bit LSB N A 88 N A Notes ADAM 4017 AI CH 00 to 07 are converted by the Calculator DTA in...

Page 162: ...iBox iBox Kit Installation and Maintenance Guide GE Grid Solutions 162 994 0047 5 10 4 GE Information ...

Page 163: ...o work with a DNP3 I O Module on page 43 2 Physically locate and mount DNP3 I O module in a 19 inch rack or cabinet Refer to section Installing DNP3 I O Modules in a Rack on page 164 3 Connect the DNP3 I O module to site ground Refer to section Connecting to Protective Ground on page 165 4 Interconnect the DNP3 I O modules and connect power For low voltage DNP3 I O refer to section Connecting DNP3...

Page 164: ...ment Width 19 inches 483 mm Height 5 25 inches 133 4 mm Depth 2 5 inches 63 5 mm Allow about 14 inches 356 mm of total cabinet depth to provide clearance for cables and maintenance access Rack Mounting Procedure To mount the DNP3 I O module in a rack 1 Determine the location of the DNP3 I O module in a 19 inch mounting rack 2 Install but do not tighten the top two mounting screws Note Install the ...

Page 165: ...f your module for detailed information For example see below DC Analog Input Module 12 AWG GND Wire Site Ground 100 47 97 48 49 50 98 99 TB1 Digital Input Module 12 AWG GRN GND Site Ground 132 63 129 64 65 66 130 131 TB1 Control Output Module 12 AWG GRN GND Site Ground 106 50 103 51 52 53 104 105 TB1 Combination Input Output Module Site Ground 100 47 97 48 49 50 98 99 TB1 12 AWG Green Wire After s...

Page 166: ...unction GND DC1 DC1 TX RX2 TX RX2 Not Used To RTU Master To Power Source Cable iBox RTU Master GE Part Number 977 0502 To iBox RTU Master To Field Equipment To Field Equipment To Field Equipment To Power Source J1 J2 J1 J2 J1 J2 Cable Power Source GE Part Number 997 0500 Standard Cables DB9 male to DB9 male GE part number 977 0089 After DNP3 I O modules have been interconnected you are now ready t...

Page 167: ...ct the DNP3 link cabling between each DNP3 I O module 2 Connect pins 1 and 2 and also pins 3 and 4 if a redundant power supply is used on TB2 to an External Power Supply 40 to 150 VDC as shown below To iBox RTU Master To Field Equipment To Field Equipment To Field Equipment To Ext Power To Ext Power To Ext Power To Ext Power Cable iBox RTU Master GE Part Number 977 0502 External DNP 3 I O Module P...

Page 168: ...olutions 168 994 0047 5 10 4 GE Information Connecting to a iBox The cable from an iBox RTU Master to the first DNP I O Module GE Part Number 977 0502 has the following connections and jumpers Note Make sure the iBox RTU Master is configured for RS 485 2W mode ...

Page 169: ... Control output request time window is too small No Room on Queue 0x0018 The control output request queue is full Not Armed 0x0019 The control request point is not armed Analog Requests Error Codes Error Message Description Analog Output Unsupported Point 0x0010 The analog output point is not supported Analog Output Not Available 0x0011 The analog output is not available Online Configuration in Pr...

Page 170: ...ons 170 994 0047 5 10 4 GE Information Online Configuration Wev List Not Available 0x001D The WEV WIN event list request is not available Online Configuration Out of Timers 0x001E Lacked timed event buffers Online Configuration Sendx Fail 0x001F Message send failed ...

Page 171: ...put section in 2 5 Connecting and Testing Field Wiring 5 January 21 2009 Minor updates throughout to reflect product enhancements 6 March 25 2009 Documented Ethernet module pass through switch and configuration file modifications 5 10 0 February 10 2010 Updated appendices B and E 1 June 6 2014 Corrected ground connections in the drawings of the Digital Outputs section Corrected the ground referenc...

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