994-0047

994-0047
GE
Digital Energy
iBox/iBox Kit
Installation and Maintenance Guide
994-0047
Version 5.10 Revision 3
GE Information
iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
COPYRIGHT NOTICE
© 2002-2014, General Electric Company. All rights reserved.
The Software Product described in this documentation may only be used in accordance with the applicable License Agreement. The
Software Product and Associated Material are deemed to be “commercial computer software” and “commercial computer software
documentation,” respectively, pursuant to DFAR Section 227.7202 and FAR Section 12.212, as applicable, and are delivered with
Restricted Rights. Such restricted rights are those identified in the License Agreement, and as set forth in the “Restricted Rights
Notice” contained in paragraph (g) (3) (Alternate III) of FAR 52.227-14, Rights in Data-General, including Alternate III (June 1987).
If applicable, any use, modification, reproduction release, performance, display or disclosure of the Software Product and Associated
Material by the U.S. Government shall be governed solely by the terms of the License Agreement and shall be prohibited except to
the extent expressly permitted by the terms of the License Agreement. Any attached hardware schematics and technical descriptions
are for information purposes only.
The information contained in this online publication is the exclusive property of General Electric Company, except as otherwise
indicated. You may view, copy and print documents and graphics incorporated in this online publication (the “Documents”) subject
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The information contained in this online publication is subject to change without notice. The software described in this online
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TRADEMARK NOTICES
GE and
are trademarks and service marks of General Electric Company.
* Trademarks of General Electric Company.
Windows is a registered trademark of Microsoft Corporation; HyperTerminal is a registered trademark of Hilgreave Inc.; Pentium is a
registered trademark of Intel Corporation; Panduit is a registered trademark of Panduit Corporation; IEC is a registered trademark of
Commission Electrotechnique Internationale; IEEE is a registered trademark of The Institute of Electrical and Electronics Engineers
Inc; Modbus is a registered trademark of RT Schneider Automation Inc.; ADAM is a registered trademark of Advantech Corporation.
Digi One is a registered trademark of Digi International Inc.; and Glyptal is a registered trademark of RT Glyptal Inc.
Other company or product names mentioned in this document may be trademarks or registered trademarks of their respective
companies.
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GE Information
iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Contents
About This Document
5
Product Support
7
Safety Precautions
8
Section 1:
1.1.
1.2.
1.3.
1.4.
Section 2:
2.1.
2.2.
2.3.
2.4.
2.5.
2.6.
2.7.
2.8.
2.9.
Section 3:
3.1.
3.2.
3.3.
3.4.
3.5.
3.6.
3.7.
3.8.
Section 4:
Getting Started ..................................................................................................................................... 13
What is an iBox? ....................................................................................................................... 14
Unpacking and Inspection......................................................................................................... 20
Storage ...................................................................................................................................... 22
Installation Tools ...................................................................................................................... 23
iBox Installation and Maintenance ..................................................................................................... 24
Familiarization .......................................................................................................................... 25
Installing the iBox ..................................................................................................................... 27
Configuring your iBox .............................................................................................................. 36
Testing your iBox ..................................................................................................................... 48
Connecting and Testing Field Wiring ....................................................................................... 54
Servicing your iBox .................................................................................................................. 62
Maintaining your iBox Software............................................................................................... 65
Troubleshooting your iBox ....................................................................................................... 73
Replacing your iBox ................................................................................................................. 79
iBox Kit Installation and Maintenance .............................................................................................. 81
Familiarization .......................................................................................................................... 81
Installing the iBox Kit ............................................................................................................... 86
Configuring the iBox Kit Components ..................................................................................... 91
Connecting Field Wiring......................................................................................................... 135
Servicing your iBox Kit .......................................................................................................... 137
Maintaining your iBox Kit Software ...................................................................................... 138
Troubleshooting your iBox Kit ............................................................................................... 141
Replacing your iBox Kit ......................................................................................................... 142
Removing Configuration Data and Sensitive Information ............................................................. 143
4.1. From the iBox Device ............................................................................................................. 143
4.2. From the PC Running Configuration Software....................................................................... 144
Appendix A:
Technical Specifications ................................................................................................. 146
Appendix B:
iBox Kit Default Configurations ................................................................................... 152
Appendix C:
Resetting the Digi One Configuration .......................................................................... 156
Appendix D:
Setting your PC IP Address ........................................................................................... 158
Appendix E:
DPA Default Point Mapping ......................................................................................... 160
Appendix F: Installing and Connecting DNP3 I/O Modules ................................................................................ 166
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iBox/iBox Kit
Installation and Maintenance Guide
Appendix G:
4
GE Digital Energy
Error Messages ............................................................................................................... 172
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GE Information
iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
About This Document
Purpose
What this
document
provides
The iBox/iBox Kit Installation and Maintenance Guide contains information about
two products, the iBox and the iBox Kit.
The document is split into three sections. Section 1: Getting Started provides an
overview of the iBox. Section 2: iBox Installation and Maintenance provides
instructions for installing, configuring, using, maintaining and troubleshooting the
iBox. Section 3: iBox Kit Installation and Maintenance provides similar information
for the iBox Kit.
Some iBox configuration procedures provide details on the ConfigPro tool. For the
equivalent information when using SGConfig to configure the iBox, refer to the
SGConfig online help.
ConfigPro/
SGConfig
Online Help
For topics related to the use of GE Digital Energy's ConfigPro* or SGConfig*
configuration utility, or details of any software application used in a specific iBox,
refer to the ConfigPro or 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 based on Windows 2000. Some steps and dialog
boxes may vary slightly if you are using Windows XP or Windows 2003.
Intended Audience
Job Titles
This guide is intended for use by the SCADA system installers and field engineers
who are responsible for the installation, hardware configuration and maintenance of
SCADA systems containing iBox units and iBox Kits.
Experience &
Abilities
This guide assumes that anyone working with an iBox or iBox Kit has some prior
knowledge of:
• Electrical utility industry
• Personal computer terminology and interconnection skills
• GE Digital Energy products
• Other industry products such as protective relays, meters, and voltage regulators.
GE Information
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Additional Documentation
For further information about the iBox and its components, refer to the following
documents:
From GE Digital Energy:
• iBox Product Overview (PRPI-043)
• D20, D25, iBox Automation Applications (PRPI-048)
• ConfigPro online help
• 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 Installation, Operation and Programming Manual
(Electro Industries/GaugeTech)
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GE Information
iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Product Support
Getting Help
If you need help with any aspect of your GE Digital Energy product, you have a few
options.
Search
Technical
Support
The GE Digital Energy site provides fast access to technical information, such as
manuals, release notes and knowledge base topics. Visit us on the Web at:
Contact
Customer
Service
The GE Digital Energy Service Center is open 24 hours a day, seven days a week for
you to talk directly to a GE representative.
http://www.gedigitalenergy.com/
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 the GE Digital Energy Customer Service
Center to obtain a Return Merchandise Authorization number and complete
instructions for return shipments.
A Return Merchandise Authorization (RMA) number must accompany all equipment
being returned for repair, servicing, or for any other reason.
Note:
Product returns will not be accepted without a Return Merchandise
Authorization number.
!
GE Information
If you attempt to resolve problems with your GE product using methods not
recommended by GE Digital Energy, this might result in damage or injury to persons
and property.
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Safety Precautions
Important!
Follow all safety precautions and instructions in this manual:
• Only qualified personnel should work on the iBox/iBox Kit. Maintenance
personnel should be familiar with the hazards associated with electrical
equipment.
• NEVER work alone.
• Before performing visual inspections, tests, or maintenance on this equipment,
isolate or disconnect all hazardous live circuits and sources of electric power.
Assume that all circuits are live until they have been completely de-energized,
tested, and tagged. Pay particular attention to the design of the power system.
Consider all sources of power, including the possibility of back feed.
• Turn off all power supplying the equipment in which the iBox/iBox Kit is to be
installed before installing and wiring the iBox/iBox Kit.
• Beware of potential hazards, wear personal protective equipment and carefully
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 damage
from electrostatic discharge. Observe standard ESD (Electrostatic Discharge)
precautions for handling electronic components at all times.
• Read and thoroughly understand this guide before using the iBox/iBox Kit. Save
these instructions for later use and reference.
Failure to observe these instructions may result in death or serious injury.
!
Hazardous
Voltages
8
Hazardous voltages can cause shock, burns or death.
• Disconnect and lock out all power sources before servicing and removing
components.
• Short all current transformer primaries before servicing.
• Do not remove the safety shields that have been installed to prevent accidental
contact with hazardous voltages.
• Avoid touching iBox/iBox Kit power supplies, since these supplies contain
hazardous voltages.
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Safety Precautions, continued
Product
Warning
Symbols
!
Caution (refer to accompanying documentation)
Caution (risk of electric shock)
Earth/Ground Terminal
Protective Earth Terminal
Power Supply Off (Stand-by Mode)
Power Supply On
Direct Current
Alternating Current
Damaged
Equipment
Do not operate an iBox or iBox Kit if it 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 equipped
with a metal floor with no openings.
An IEC® 60947 compliant main disconnect switch (or other equivalent device
complying with IEC 60947-1 / 60947-3) must be as electrically close as practicable
to the iBox power supply.
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iBox/iBox Kit
Installation and Maintenance Guide
!
Protection
during
Maintenance
RF
Interference
GE Digital Energy
Ensure iBox/iBox Kits are protected from falling debris during maintenance. Small
metallic particles (such as wire clippings) could fall onto circuit boards and damage
or interfere with the safe and reliable operation of the iBox/iBox Kit.
The iBox/iBox Kit generates radio frequency (RF) energy that can radiate if it is not
installed and used in accordance with the instructions provided in this guide. This RF
energy may cause harmful interference to radio communications or sensitive circuits.
Operating an inadequately shielded iBox or iBox Kit in a residential area may cause
harmful interference, if this happens, you may be liable to correct the interference.
!
Rack Spacing
Power and
Fusing
When mounting multiple iBox/iBox Kits in a rack (or when mounting an iBox/iBox
Kit in a rack with other equipment), verify that there is at least one rack unit (RU) of
space above and below the iBox/iBox Kit, to allow for cooling airflow, and for
routing cables between field equipment and the iBox/iBox Kit (1 RU = 1.75 inches).
•
•
•
Grounding
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.
To ensure voltage transients are properly shunted to ground, you must connect the
iBox’s protective earth terminal to a low-impedance ground point using a braided
cable or heavy solid copper conductor.
When making ground connections, ensure all grounding surfaces are free of dirt,
residue and corrosion. You can use a coating such as Glyptal® to protect connections
from oxidation and dirt deposits.
Cable shields should be grounded to either the iBox/iBox Kit ground terminal or to
field equipment, but not to both. Do not ground cable shields at more than one point,
since potential differences between the ground points will result in ground loops and
undesirable noise sources.
Communication Cables
•
•
•
10
Use shielded cables to prevent electromagnetic interference.
Route all communication cables away from power-carrying cables, and make
these cables as short as possible.
Prior to start-up, verify the integrity of all communication cables and
connections.
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Safety Precautions, continued
Surge
Protectors
When connecting the iBox/iBox Kit to communications equipment (for example,
modems or radios), use appropriate surge arrestors 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.
!
GE Information
Use of the equipment in a manner not recommended or specified by GE Digital
Energy, may impair the protection provided by the equipment.
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GE Digital Energy
CISPR 11-CE Mark Compliance
Important
For CISPR 11, Class A-CE Mark compliance on an iBox installed outside of a
protective enclosure, you must use ferrite clamps on the following:
• Serial communication cables attached to J2, J3, and J4
• Wiring connected to TB2-TB15 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
Cable/Wiring
Ferrite Clamp
Part Numbers
12
Order the following part number for each of the external ferrite clamps you require.
Part Number
Color
460-0031
White body
460-0049
Black body
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GE Information
iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Section 1: Getting Started
Overview
Introduction
GE Information
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
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1.1. What is an iBox?
Product Overview
Introduction
The iBox is GE Digital Energy small point count Substation Controller. It combines
advanced functionality, multiple communication ports and local I/O in a compact
package.
The iBox processes both digital inputs and digital outputs. It also provides serial
digital data communication ports to facilitate communications with both a masterstation and local communications. The iBox is specifically designed for SCADA
applications.
The iBox Kit is a rack-mounted, pre-wired, pre-configured RTU based on the iBox,
but with additional (optional) power supply, Ethernet and I/O support.
Integrated
Functions
The iBox can function as a:
• Programmable logic controller (PLC)
• IED gateway
• Data concentrator
• Standalone remote terminal 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 to
enable the iBox to interface with a wide range of IEDs.
A UTC port is available for global satellite time synchronization (however, there
are three serial ports, so if you use one as a UTC port, two serial ports remain for
connecting to IEDs).
Maintenance port support provides access to ConfigPro/SGConfig, LogicLinx*, and
WESMAINT* utilities.
Meets the robust requirements of the IEEE®, IEC® and CE Mark.
Patent
Protection
The iBox contains a patent protection label as a formal declaration of the US patents
that protect both the product and the technology developed by GE Digital Energy.
MAY BE PROTECTED BY ONE OR
MORE OF THE FOLLOWING US
PATENTS:
5237511, 5303112, 5513061, 5701226.
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
System Software
Overview
The iBox system software consists of two components:
•
Base System
•
Applications.
Base System
Software
The Base System software provides a stable operating environment for applications,
which provide specific functionality for the iBox. The Base System is made up of:
• Boot software, resident in the BootROM, and
• Base applications, required for operating the hardware.
iBox
BootROM
BootROM software is stored in EPROM. The BootROM contains:
• Operating system software
• Device drivers to interface the operating system with 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 allows the operator to locally examine and control data
• 68K Monitor, which provides low-level system maintenance and diagnostic tools
WIN
WIN (for WESDAC Interface Node) is the database manager for the iBox System
Point Database. The System Point Database is the heart of the iBox software system.
All data flowing through the iBox is stored in the System Point Database before it is
passed on to its destination.
Continued on next page
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GE Digital Energy
System Software, continued
WESMAINT
WESMAINT is the iBox’s primary maintenance and diagnostic tool. You can access
WESMAINT in three ways:
•
Through the iBox WESMAINT port
•
Through a modem or other serial connection to a programmed COM port
•
Over a LAN or serial PPP connection, as a telnet session from 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
Other
WESMAINT
Functions
In addition to displaying information, a WESMAINT user can also:
• Set or clear accumulator counts
• Operate digital outputs
• Clear logged information
• Access the iBox 68K Monitor.
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
System Software, continued
68K Monitor
The iBox 68K Monitor, available through WESMAINT, is a diagnostic tool used to
access system-level functions.
The iBox 68K Monitor is resident in both BootROM and flash memory.
When the Monitor is operated from BootROM, the following 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
GE Information
Using the 68K Monitor requires detailed knowledge of the iBox architecture and
functionality. Refer to the 68K Monitor User’s Guide (SWM0023) for complete
instructions about command usage and availability.
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Application Software
Background
A wide range of applications can be added to the iBox to enhance its functionality.
Software applications fall into three categories:
• Data Collection Applications (DCA)
• Data Processing Applications (DPA)
• Data Translation Applications (DTA)
Data
Collection
Applications
Data Collection Applications are used to import (collect) data from external sources,
and to pass this data to WIN (the system point database manager) for storage in the
system database. DCAs also forward output requests from the system database 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. This new data is then placed back in the system database, where it can be used
as input/output data by another application.
Firmware
The set of applications installed on an iBox is referred to as its “firmware”.
Firmware is installed in the iBox flash memory prior to shipment. The iBox
operational characteristics can, however, be upgraded at a later date.
Contact your GE Digital Energy representative for more information on firmware
upgrades.
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Plant I/O Subsystem
Plant I/O
Subsystem:
Overview
The iBox Plant I/O Subsystem collects, processes, and stores data related to physical
inputs and outputs. Once it is stored in the system database, I/O point data can be
accessed by other applications.
Plant I/O
Subsystem:
Functions
The Plant I/O Subsystem is responsible for scanning of iBox physical I/O points. For
input type points (digital and accumulator), the data of each scan is 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 number of points in the System Point
Database. The actual number of points is determined by the version of the P097 Plant
I/O Subsystem that has been installed on your iBox.
The hardware options available in the iBox (and the user’s software configuration)
determine if specific system features and data points are available or disabled.
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1.2. Unpacking and Inspection
Shipping
Inspection
Inspect the shipping package before opening it to see if it has sustained any damage
from impact or water. If it has, report it immediately to the carrier without opening
it. Carriers may not assume responsibility for damage after the customer accepts
delivery.
Unpacking
Carefully 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.
Part Number Label
Location
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 the software and copy of user documentation
Product
Identification
Before installing the unit, check that the unit part number is the same as the part
number on the shipping and ordering documents.
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GE Digital Energy
Unpacking and Inspection, Continued
Part Numbers
This table contains part numbers and descriptions for each iBox variant:
Part Number
iBox Description
505-0100
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
Outputs
Note: Part Numbers are subject to change without notice.
GE Information
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1.3. Storage
Environment
Specifications for storage are:
•
Temperature: -40° to +90°C
•
Relative humidity: 0 to 95%, non-condensing
As a general rule, always store your iBox in an environment compatible with
operating conditions. Refer to Appendix A: Technical Specifications for more
detailed environmental specifications
Exposure to excessive temperature or other extreme environmental conditions might
cause damage and/or unreliable operation.
Battery Life
The iBox battery maintains the unit’s NVRAM contents for over five years, with
system power applied. If you are storing your iBox for extended periods, you should
disconnect the battery by removing the iBox’s top cover and pulling the battery out
of the chassis.
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
according to local waste management regulations.
In accordance with European Directive 2006/66/EC, batteries are marked with the
crossed out wheeled bin, which indicates that they cannot be disposed of as unsorted
municipal waste in the European Union. Users of batteries must use the collection
points available to customers for the return, recycling, and treatment of batteries.
Customer participation is important to minimize the negative effects of batteries to
the environment and sustain available natural resources. For more information see
www.weeerohsinfo.com.
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
1.4. Installation Tools
Tools for the
Job
Before beginning the installation procedure, ensure you have the following tools and
equipment:
• A Windows PC with HyperTerminal (or any Windows based terminal
emulation software) loaded
• Ethernet Cable[s]
• A 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
18-22 AWG wire (or equivalent)
ESD
Protective
Gear
It is recommended that the following ESD gear be used during installation:
• Wrist Straps
• Foot Straps
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Section 2: iBox Installation and Maintenance
Overview
Introduction
24
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
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
2.1. Familiarization
Front Panel
As you look at the iBox, the:
• Left side has four DB9 connectors (serial ports), a three-position separable
terminal block (power connection), and a protective earth terminal.
• Right side has a 28-position terminal 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:
Digital Inputs
The iBox provides the following digital inputs:
• Eight optically isolated status inputs, 25 VDC or 125 VDC, with 20% overload
• Wetting options
• LED indications
• 4-5 mA typical current burden per input (up to 48 VDC)
• Maximum 0.5 W heat dissipation per input from current burden of inputs at
125 VDC
GE Information
•
•
Eight digital inputs
Four control outputs
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Continued on next page
Familiarization, continued
Control
Outputs
The iBox provides the following control outputs:
•
•
•
•
•
26
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
35 W breaking @ 125 VDC, 180 W breaking @ 30 VDC
6 A current handling capability
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
2.2. Installing the iBox
Overview
Safety
Precautions
Before beginning to install the iBox, thoroughly review 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
GE Information
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 ConfigPro / SGConfig.
5
Test the iBox.
6
Connect and test field wiring.
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GE Digital Energy
Installation Guidelines
Installation
Environment
The iBox must be installed in an environment that provides protection against shock
and fire hazard.
The iBox enclosure is intended for indoor use, primarily to provide protection
against accidental contact with the enclosed modules and voltages. Do not place the
product in environments where unusual conditions exist (windblown dust and dirt,
for example) unless you install it in a secondary protective enclosure.
Never operate an iBox in the field with 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 (or other equivalent device
complying with IEC 60947-1 / 60947-3) must be as electrically close as practicable
to the iBox power supply.
For correct iBox power supply operation, the input voltage must be within specified
limits.
The iBox DC power supply draws an inrush current (less than 0.5 A) upon start-up.
Ensure the field source can supply this start-up current without overloading.
Continued on next page
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Installation and Maintenance Guide
GE Digital Energy
Installation Guidelines, continued
Power Fusing
Always replace fuses with the same type and rating used by GE Digital Energy. The
fuse types and ratings are stated in “Fuse Replacement” on page 63.
Always fuse-protect field power sources.
Grounding
and Shielding
To ensure safe operations, you must connect the iBox Protective Earth Terminal to a
low impedance ground using braided cable or heavy solid copper conductor. When
making ground connections, ensure all grounding surfaces 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 an over-all cable shield. Route all communication cables away from powercarrying cables.
Communications Ports
and
Connections
Verify the integrity of all communication cable connections prior to start-up to avoid
damaging the iBox.
Serial ports are protected with surge and noise suppression components.
Always shield communication cables and make them as short as possible.
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Installation and Maintenance Guide
GE Digital Energy
Physical Mounting
Procedure:
Mounting the
iBox
Mounting and
Clearance
30
Step
Action
1
Align the iBox in its proper position on a flat mounting surface.
2
Install and tighten the four screws, holding the iBox firmly in place on
the mounting surface.
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 inches or 44.5 mm).
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Terminal Connections
Power Supply
The iBox’s power supply connection is a three-position terminal block located on the
bottom left side of the iBox. This removable terminal block must be disconnected to
turn off the power supply input. The iBox does not have an ON/OFF switch.
+
–
Chassis
TB1
Functional
Ground/
Chassis
Connect the ground screw terminal to the facility’s ground system before operating
the iBox. Before making this connection, ensure all grounding surfaces are free of
dirt, residue and corrosion. 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:
!
!
GE Information
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 negative connection points on TB1
The chassis ground terminal at the power supply terminal block must not be used as
a protective earth connection.
Make sure the iBox is properly grounded to the protective earth terminal located at
the bottom-left corner of the board. Connection must be provided with a separate
green/yellow wire connected between the iBox and the facility’s ground system.
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System Diagnostics
System
Diagnostics
Once power is applied, the iBox automatically boots and conducts a series of selfdiagnostic tests. If the iBox fails to boot up properly (which indicates that a selfdiagnostic 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 are
on solid.
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Connecting Serial Interfaces
WESMAINT
Port
The iBox is equipped with a WESMAINT port. By attaching a WESMAINT cable
between the WESMAINT port and your PC, the iBox can:
• Provide local maintenance and diagnostic functionality
• Download configuration data from the optional ConfigPro/SGConfig software
With the cable connected, you can also upload diagnostic and operational
information 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
N/C
RXD
TXD
N/C
COM
N/C
N/C
N/C
GND
Standard
Serial
Interfaces
WESMAINT - DB-9 Male
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
COM
N/C
TXD
RXD
N/C
N/C
N/C
N/C
N/C
The iBox has three serial communications ports: COM1, COM2, and COM3
All COM ports have the following standard characteristics:
• Female DB-9-F style connectors
• RS-232 and RS-485 are supported on the same physical connector.
Continued on next page
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GE Digital Energy
Connecting Serial Interfaces, continued
COM1
Options
In addition to the standard characteristics, COM1 has the following optional
characteristics:
• Jumper-selectable (JP3) radio key, open-collector output
• Communication parameters, determined by the protocol application.
COM2
Options
COM2 can optionally be used to connect to a satellite time-code receiver, as follows:
Time code
J3 Pin
Interface
Signal
IRIG-B
8
RS-232
CTS2
Rugby Clock
2
RS-232
RX2
5
RS-232
COM
IRIG-B Output
Options
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
• Support for several I/O timers
• Transmission of break characters
COM Port
Options
The COM1, COM2 and COM3 serial ports are programmed using
ConfigPro/SGConfig for:
• RS-232 or RS-485
• RS-485 2-wire or 4-wire (2W/4W)
Note: The 2W/4W selection in ConfigPro / SGConfig only affects the interface’s
internal software control (handshaking). It does not change the physical
characteristics of the communication ports.
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Installation and Maintenance Guide
GE Digital Energy
Connecting Serial Interfaces, continued
Serial Port
Pinouts
The COM port pin-outs, for both RS-232 and RS-485 configurations, are as follows:
*
2-Wire RS-485
Cable
DB-9 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).
The following schematic shows the cable wiring necessary for 2-wire RS-485
operation.
iBox Connectors J2, J3 or J4
Description
N/C
Data Data N/C
Common Ground
N/C
Data +
Data +
Earth Ground
GE Information
PIN #
1
2
3
4
5
6
7
8
9
- TX / RX
+ TX / RX
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2.3. Configuring your iBox
Overview
Introduction
This section outlines the procedure for creating and configuring a new iBox device in
ConfigPro / SGConfig.
For additional information, refer also to the ConfigPro / SGConfig online help.
Configuration
Template
A sample configuration is included on the CD with the iBox. You can create the
iBox device configuration starting from the sample configuration or create a new
configuration from scratch.
After you successfully create a device configuration, you can use it as a template for
all subsequent iBox configurations. To do so, copy the original configuration file,
and edit the copied file as 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
Before you
Start
36
The iBox is configured using the ConfigPro / SGConfig configuration system.
Configuring the iBox involves the following main steps:
•
Create or restore a ConfigPro / SGConfig project.
•
Create and configure the iBox device in the project.
•
Configure the application firmware.
•
Configure the Plant I/O.
•
Download the configuration to the iBox.
To configure the iBox, you will need the following items:
•
Factory configuration for your iBox. You can find this on the configuration CD
that shipped with your iBox.
•
ConfigPro / SGConfig installed on your PC.
•
Serial number of your iBox, from the iBox circuit board
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Restoring your ConfigPro Project
Introduction
Procedure:
Restoring
your
ConfigPro
Project
This procedure describes how to restore the ConfigPro project that includes the
sample configuration provided with the iBox.
Step
Action
1
In your Windows desktop, click Start, and then click Programs.
2
Click GE Energy, and then click ConfigPro 6.
Result: The ConfigPro main window appears.
Importing the Factory Configuration
3
Click Project, and then click Archive Project.
4
Click Restore.
Result: The Restore Project from ZIP file dialog box appears:
5
Insert your configuration CD in the drive.
6
Click , navigate to the configuration file, and click Select.
Result: The path to the configuration file appears in the Select Source
Project ZIP File box.
7
Click OK.
Result: The configuration file uploads to your PC, and your project
appears in the ConfigPro Main Project window.
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Installation and Maintenance Guide
GE Digital Energy
Creating a New iBox Device
Introduction
Creating an iBox device in ConfigPro/SGConfig has two main steps:
• Create the new device
• Specify the device properties
This procedure assumes that you are using the default firmware already loaded in the
iBox or have created a firmware set.
iBox Device
Icon
When you create a new iBox device, select the iBox device icon in ConfigPro to get
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
Click the iBox icon at the top of the main project window.
3
Point and click in the main project window where you would like to
insert the iBox device icon.
Result: The iBox Device Properties window appears.
Continued on next page
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Procedure: Creating a New iBox Device, continued
Step
Action
4
In the Name box, type a unique name for the device.
5
Under Icon, click the Select button to choose a different icon for this
device.
Note: The choice of icon has no effect on the device configuration. It
is only used as a graphic representation for the device in
ConfigPro. You can change the icon at any time.
6
Continue to “Procedure: Setting iBox Device Properties”.
iBox Device
Properties
Once you have created the iBox device, follow the procedures below for setting the
iBox device properties.
Procedure:
Setting iBox
Device
Properties
To set the iBox device properties:
Step
Action
Hardware Tab
1
In the iBox Device Properties window, click the Hardware tab.
2
Click the Memory tab. You should not need to change the Base System
and Global Variable Area settings. If necessary, change the NVRAM
Area value to suit your specific system.
3
On the Serial I/O tab, configure each com port for RS-232 or RS-485
communications.
Note: The 2W/4W selection in ConfigPro only affects the interface’s
internal software control (handshaking). It does not change the
physical characteristics of the communication ports.
Continued on next page
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Installation and Maintenance Guide
GE Digital Energy
Procedure: Setting iBox Device Properties, continued
Step
Action
Processor Tab
4
Click the Processor tab.
5
On the Firmware tab, click the Select button to display the available
firmware definitions.
In the Select a Firmware Type dialog box, select the firmware definition
that matches your iBox’s applications and click OK.
Result: The Name box displays the name of your firmware selection.
6
7
On the Memory Model tab, check that Derive From iBox Hardware
Setting is selected.
Continued on next page
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Procedure: Setting iBox Device Properties, continued
Step
8
Action
Click OK to complete the creation of the new iBox device.
Result: ConfigPro displays a status bar showing the progress of the
creation process.
New Device
Icon
GE Information
After you complete these steps, an iBox icon, representing your new device, appears
in the main project window. The new iBox device is now ready to be configured.
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Configuring Application Firmware
Overview
The iBox uses the D25 Plant I/O Subsystem (P097) Data Collection Application to
configure the digital inputs. Configure the iBox Plant I/O before you configure the
points in the System Point Database application.
Procedure:
Digital Input
Configuration
To configure the DC digital inputs:
Step
Action
1
Open the iBox device in ConfigPro and click the Data Collection
Applications tab.
2
Double-click the D25 Plant I/O Subsystem icon.
Result: The D25 Plant I/O for iBox dialog box displays.
3
Double-click the DC Configuration
icon.
Result: The D25 DC Configuration for iBox dialog box displays.
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 changes to match your selection.
Note: Refer to the on-line help in ConfigPro/SGConfig for details on
configuring the I/O Configuration and Advanced tabs.
Other
Application
Configuration
42
Configure your other applications before continuing to install the iBox. Each
application has its own configuration process. Refer to the documentation for your
specific applications for configuration information.
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Downloading your iBox Configuration
Procedure:
Downloading
your iBox
Configuration
Step
Action
1
If you have not already done so, connect your PC to the iBox
WESMAINT port and open ConfigPro.
2
In the ConfigPro Project window, click the iBox device icon.
3
Click
(Terminal Emulator icon).
Result: ConfigPro opens a Telnet session with the iBox.
4
Press ENTER.
Result: ConfigPro prompts you to enter a user name.
5
Type westronic and press ENTER.
Result: ConfigPro prompts you to enter a password.
6
Type your password (the default is rd) and press ENTER.
Result: The following screen displays:
7
Enter “2”.
Result: The following screen displays:
8
Enter “3”.
Result: The 68K Monitor command prompt appears.
Continued on next page
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Installation and Maintenance Guide
GE Digital Energy
Downloading your iBox Configuration, continued
Procedure:
Downloading
your iBox
Configuration
(continued)
Step
9
Action
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
baud rate of the WESMAINT serial port from the default 9600 baud to
38400 baud in WESMAINT and ConfigPro.
To change the baud rate:
• In WESMAINT, enter baud 38400 at the 68K command line.
• In the ConfigPro Terminal Emulator window, on the
Communications menu, click Options. On the Port Settings tab, set
the Baud Rate to 38400 and click OK.
10
On the ConfigPro Terminal Emulator Communications menu, click
Connect.
Result: ConfigPro connects to the iBox and the 68K Monitor command
line appears.
11
On the ConfigPro Terminal Emulator Communications menu, click
Download.
Result: The configuration download starts and a progress message
displays.
Once the download is complete, the Confirm dialog box is displayed.
Continued on next page
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Downloading your iBox Configuration, continued
Procedure:
Downloading
your iBox
Configuration
(continued)
Step
12
Action
Click Boot.
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 ConfigPro
terminal emulator communications rate to 9600.
13
On the ConfigPro Communications menu, click Disconnect.
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 ConfigPro
terminal emulator communications rate to 9600.
GE Information
14
On the File menu, click Exit.
15
Physically disconnect your PC from the iBox.
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Configuring the iBox to work with a DNP3 I/O Module
Introduction
Your iBox RTU Master communicates with your DNP3 I/O modules through
the DNP3 Data Collection Application (DCA B023). The DNP DCA collects
data from, and sends control requests to, the DNP3 I/O modules.
Refer to Appendix F: Installing and Connecting DNP3 I/O Modules for
installation and connection instructions.
Use ConfigPro/SGConfig to configure the DNP3 DCA in the iBox so that it
communicates with your DNP3 I/O module. There are three tables to
configure:
•
Remote Device Table: This table contains one record for each DNP
I/O module in the system. The Remote Device 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 each DNP I/O module.
•
Remote Device Polling Table: Specifies the polling type and frequency
for each DNP I/O module.
Instructions and guidelines for configuring your DNP3 DCA can be found in
the following documentation:
• DNP V3.00 DCA - Configuration Guide (B023-0CG)
• ConfigPro/SGConfig online help.
Note: When configuring the Time Sync option:
• Disable Time Sync for the D20A and D20K modules
• If Time Sync is enabled on a D20S module, the polling rate may be a
minimum of 2 seconds (it takes about 850ms to do a Time Sync for each
device).
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Installation and Maintenance Guide
GE Digital Energy
Configuring the iBox to work with a DNP3 I/O Module, continued
Example
Configuration
For example, when configuring your iBox RTU Master to work with a DNP
Digital Input Module, assume that you have a 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
Value
Remote Device Table
Application Address
0032
Remote Device Point
Mapping Table
DCA Object Type
Binary Input
Number of Device Points
64
Poll Data Type
Integrity
Poll Interval
500 ms
Remote Device Polling Table
GE Information
Parameter
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Installation and Maintenance Guide
GE Digital Energy
2.4. Testing your iBox
Overview
Introduction
This section describes a number of system checks that you can perform to verify
your iBox software is functioning properly.
Valid
Configuration
File Required
Before performing any of the tests in this 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 must reload
the file before performing these verification tests.
For help restoring your configuration file, refer to the online help in ConfigPro.
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Installation and Maintenance Guide
GE Digital Energy
LED Descriptions
Overview
You can verify the iBox is operating properly by inspecting the LEDs on the iBox
chassis.
Description
The iBox has the following LED indicators, all of which are GREEN.
LED
GE Information
Location
Description
PWR
Top left
The POWER LED remains lit when the iBox is receiving
power.
RUN
Top left
The RUN LED flashes to indicate CPU bus activity.
Brightness indicates more CPU bus activity.
TX1 – TX3
Left side
The TRANSMIT LED flashes when the iBox is transmitting to
an outside device. There are three transmit LEDs, 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) LED only works on systems
configured for RS-232 communications. There are three CTS
LEDs, one for each communication port.
CD1 – CD3
Left side
The Data Carrier Detect (DCD) LED only works on systems
configured for RS-232 communications. There are three DCD
LEDs, one for each communication port.
I/P1 – I/P8
Right side
Each of the iBox’s eight Digital Inputs (DI) has a LED that
remains lit when the DI is receiving a wetting voltage.
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Diagnostic Tools
General
To operate the iBox, you require the following system components:
• WESMAINT facility
• iBox monitor facility
• ConfigPro / SGConfig configuration system.
WESMAINT
Each iBox has a WESMAINT facility that allows users to examine the iBox
database, applications and communications, and to manipulate the data.
You can, for example, use WESMAINT to examine the state of digital input data, or
to force a digital output ON or OFF.
WESMAINT uses a series of menus and screens that display on a VT100 terminal,
or similar terminal emulator, to create a simple interface to the iBox.
With a VT100-compatible terminal emulation program or ConfigPro / 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 through WESMAINT
• Upon start-up of an iBox that has not been previously configured.
Note:
For further information about using the iBox Monitor, refer to the 68K
Monitor User’s Guide (Document Number SWM0023).
ConfigPro /
SGConfig
50
Use ConfigPro / SGConfig to define the iBox’s operating parameters. You can also
use ConfigPro / SGConfig to download configuration files to the iBox through a
serial connection.
Note:
For further information about ConfigPro / SGConfig, refer to the
ConfigPro / SGConfig online help.
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GE Digital Energy
Boot Test Verification
System
Diagnostics
(POST)
The iBox software includes a Power On Self-Test (POST) process, which runs when
the unit is powered ON and determines whether or not the iBox circuitry is working
properly.
Terminal
Emulation
Software
Terminal emulation software is not part of the iBox system, but you can use terminal
emulation software such as HyperTerminal® or ConfigPro / 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 communications settings as follows:
Data Rate
9600 bps
Data Bits
8
Stop Bits
1
Parity
None
Flow Control
XON/XOFF
Connector Settings
COM1, COM2, as
required for your computer
Continued on next page
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Boot Test Verification, continued
Connect to
the
WESMAINT
port
Step
Action
1
Connect a WESMAINT cable to the female DB-9 WESMAINT port on
the top left side of your iBox.
2
Attach the other end of the WESMAINT cable to the PC’s selected
communications port.
3
Verify the 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 automatically boots as soon as the power is turned on.
If the iBox fails to boot up, it may have sustained damage during shipping. Contact
GE Digital Energy for assistance.
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Log in to WESMAINT
General
When the POST is complete, you can log in to WESMAINT to continue further
testing.
Procedure:
Logging into
Wesmaint
To log into WESMAINT from a PC:
Step
1
Action
Press ENTER
Result: The Welcome screen appears, as does a login prompt.
Note: If the Welcome banner does not appear, and only a <iBoxS
prompt displays, a valid code or configuration file is not loaded
into the iBox’s memory. Stop this procedure and refer to
“Downloading Code Files” on page 69 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 obtain the correct user name and password.
Navigating in
WESMAINT
Use the UP and DOWN arrow keys, or type in the menu number, to select an option
from the Main Menu. Press CTRL+L at any time to log out of WESMAINT
Further
WESMAINT
Information
For further information about using WESMAINT, refer to WESMAINTII+ User’s
Guide (Document Number B014-1UG).
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2.5. Connecting and Testing Field Wiring
Overview
Introduction
54
This section describes the process for making and testing field connections to the
iBox.
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Digital Inputs
Digital Inputs
The iBox has eight digital inputs (DIs).
Wetting Types
All DIs require an input voltage signal large enough to turn on an optical switch. If
the DI is receiving 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
>28 VDC
<10 VDC
48 VDC + 20%
High Voltage Digital Input
110/125 VDC
GE Information
>80 VDC
<20 VDC
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Digital Input Configuration
Digital Input
Field
Connections
Field wiring for all digital input variants are made through the iBox’s terminal
blocks, separable in pairs.
Digital Input
Wetting
Selection
The digital input is wetted (or turned ON) by closing a contact across the two input
termination points. The voltage that 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.
!
Wiring
Diagram:
Dry Contact
Operation
All eight digital inputs are bipolar. Use care when connecting multiple external
power sources, since the digital inputs have common returns.
This diagram illustrates the DC input connections, from Input #1 (TB2) through
Input #8 (TB9). TB10 accepts DC voltages of either polarity. The input voltage level
to TB10 is determined by the purchased option.
TB2
2
TB9
1
2
TB10
1
2
1
+/- V
Input #1
56
Input #8
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External Wetting
Power Supply
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Installation and Maintenance Guide
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Digital Outputs
Operating
Modes
iBox control outputs have two modes of operation:
• Trip/Close (T/C) pairs
• Digital Output (DO) isolation Form A contacts.
Note: Using ConfigPro/SGConfig, you must configure the digital outputs for four
Trip/Close outputs or two Trip/Close and two digital outputs, depending on the part
number.
Wiring Four
Trip/Close
Outputs
You can wire four trip/close outputs, as follows:
TB15
(Part No.
505-0100,
505-0101,
505-0102)
1
TB14
1
2
Close 4
Trip 4
Wiring Two
Trip/Close
and Two
Digital
Outputs
(Part No.
505-0103,
505-0104,
505-0105)
Important
Remote/Local
Operation
GE Information
TB12
TB13
2
1
Close 3
Trip 3
1
2
Close 2
Trip 2
TB11
2
1
Close 1
2
GND
Master T/C
(+/- V)
Trip 1
You can wire two trip/close and two digital outputs, as follows:
TB15
1
TB14
2
1
TB12
TB13
2
1
1
2
Close 2
Digital Out 2
(Form A)
Digital Out 1
(Form A)
Trip 2
TB11
2
1
Close 1
Trip 1
2
GND
Master T/C
(+/- V)
iBox digital outputs are not internally fuse-protected.
If:
Then operation is:
JP2 is installed
Remote (controls are enabled)
JP2 is removed
Local (controls are disabled)
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Digital Input Verification Test
Testing
Digital Inputs
To view digital input changes through WESMAINT, log in to WESMAINT as
outlined in “Boot Test Verification” on page 51.
Note
The quantity and relative position of data points in the iBox’s System Point Database
is determined by the version of the iBox Plant I/O software application present in
your iBox’s firmware.
You can determine the actual point number that you want to test by viewing the point
descriptions in WESMAINT, or through the ConfigPro / SGConfig configuration
tables for your iBox.
The point descriptions viewed in WESMAINT will be modified by changes you
have made to the point descriptions in the iBox configuration file
Procedure:
Testing
Digital Inputs
Navigating
through
WESMAINT
58
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 WESMAINT display
2
Use arrow keys to move up or down to highlight the desired point
number (or press CTRL+G if you already know the point number)
3
Short out the desired input point, and verify, through WESMAINT, that
the point status has changed to ON.
4
Return to Step 2 to test other digital input points
Press N to move to the Next page
Press P to move to the Previous page
Press ESC to move back to the previous menu level.
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Digital Output Verification Test
Testing
Digital
Outputs
To force digital outputs through WESMAINT, first log in to WESMAINT as
described in “Boot Test Verification” on page 51.
Note
The quantity and relative position of data points in the iBox’s System Point Database
is determined by the version of the iBox Plant I/O software application present in the
iBox’s firmware.
You can determine the actual point number that you want to test by viewing the point
descriptions in WESMAINT or in the ConfigPro / SGConfig configuration tables for
your iBox.
The actual point descriptions in WESMAINT will be modified by any changes you
have made to the point descriptions in the configuration file.
!
Procedure:
Testing
Digital
Outputs
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.
From the WESMAINT Main Menu:
Step
Action
1
Select 1 — System Data Display
2
Select Digital Output Display
Result: The point numbers and (optionally) point descriptions appear
on the WESMAINT display.
3
Use arrow keys to highlight the desired point number (or press CTRL+G
if you already know the point number).
Result: The cursor flashes on the specified point number
4
Press CTRL+F when you are ready to force-change the state of the digital
output point.
Extra Security
5
At the Password prompt, type control and press ENTER
Result: The Digital Output Force Display appears.
6
Press CTRL+U to change (update) the relay state.
Continued on next page
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Digital Output Verification Test, continued
Procedure: Testing Digital Outputs, continued
Step
Action
7
Press the SPACE BAR to select Pulse, and press ENTER.
8
In the Off time field, type 500 and press ENTER.
9
In the On time field, type 500 and press ENTER.
10
In the Repeat Command field, type 10 and press ENTER twice.
Result: Listen carefully for an audible click of the point relay. A test is
considered successful if the relays click when forced.
11
For testing Trip/Close type operation, repeat steps 1- 6.
12
Press the SPACE BAR to select Trip/Close, and press ENTER.
13
In the Off time field, type 300 and press ENTER.
14
In the On time field, type 300 and press ENTER.
15
In the Repeat Command field, type the value 0 and press ENTER twice.
Result: Listen carefully for an audible click of the point relay. A test is
considered successful if the 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 password.
Note: The number of times that a control will operate is actually N+1, where N is
the number of repeats entered in the Repeat command field. For a single
operation, with no repeats, type 0. For two operations, type 1.
Test Failure
If relays do not operate:
1. Ensure that the CONTROLS enable jumper is in the REMOTE position. No
error message appears in WESMAINT if the test fails
2. Reboot the iBox, and repeat the procedure
3. Call GE Digital Energy for assistance
Repeat Test
To repeat the test sequence, press CTRL+U, and then press ENTER.
Values entered for the previous test are retained until you exit the menu.
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Test Next
Point
GE Information
To test another point, use the UP or DOWN arrows to cycle through points, then press
CTRL+U to repeat the test.
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2.6. Servicing your iBox
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.
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Fuse Replacement
Fuse Location
Under normal operation, the iBox should not require disassembly. The only time you
should have to open the iBox is to replace 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
GE Information
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 0.5 A 250 V.
5
Replace the cover.
6
Reconnect the power.
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Battery Replacement
Battery
Location
The battery is located in position BT1 on the main board. To find the battery, remove
the iBox top cover, and look to the bottom center-right of the main 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
64
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 markings.
5
Snap the battery holder clip back into place.
6
Replace the cover.
7
Reconnect the power.
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2.7. Maintaining your iBox Software
Overview
Introduction
GE Information
The iBox is factory pre-configured and tested. It contains all required operating
software, and is able to upload and download configuration files.
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About Code and Configuration Files
Background
Important
iBox operation requires two different files:
•
Code File: This file defines the applications that can be supported by the iBox.
•
Configuration File: This file, which is generated using ConfigPro / SGConfig, is
used to enable and configure the applications’ operating characteristics.
The Code File and the Configuration File must be consistent.
Specifically, the configuration file created using ConfigPro / SGConfig must be
based on the same applications (and versions of these applications) from which the
code file was created.
Any differences between the applications in the code and the configuration files may
result in:
• Erratic or unpredictable behavior of the iBox
• Failure of the iBox software
Configuration
and Code File
Mismatch
Preventing
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 ConfigPro / 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 not match the configuration file that is
resident in the iBox memory.
•
The code file or the configuration file has become corrupted, either before or
during download.
Configuration and code file mismatch can be prevented and corrected, as follows.
•
Since mismatch is usually a result of operator error, you can prevent it by
exercising care.
•
Erasing a configuration file that is resident in NVRAM before downloading a
new code file can prevent mismatch.
•
Mismatch may require the regeneration and re-downloading of one or both files.
Continued on next page
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About Code and Configuration Files, continued
System
Response to
File Mismatch
The iBox base system performs the following procedure after each reboot:
1. Every time the iBox reboots, a counter increments
2. If the iBox runs for two minutes without a reboot, the counter clears.
3. If the counter reaches 20, 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 problem.
While a user can always directly default the configuration by pressing <ESC> during
the start-up sequence, this only works if the customer is physically present and
connected to the WESMAINT port.
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Deleting Configuration Files
Erasing a
Configuration
Erase a configuration file from the iBox’s NVRAM before downloading a new code
file into FLASH memory, unless the code file is exactly the same as the one that was
in use before the download.
There are two ways to erase a configuration file from the iBox memory:
Restoring the
Default
Configuration
Step
1
Action
Reboot the iBox. While it is starting, press 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
1
Action
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 address and size of
the NVRAM used for the configuration file, displays. The
NVRAM end address can be calculated by adding the NVRAM
size to the NVRAM start address.
2
Type F 00 <NVRAM Start Address> <NVRAM End Address> and press
ENTER.
Result: The specified range of NVRAM fills with 0s, erasing any
configuration files.
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Downloading Code Files
When to
Download
There are two reasons for downloading code files:
• If the iBox has performed self-diagnostics and determined that the flash memory
is either erased or corrupt, it will display the D25S> prompt on the system
monitor when it requires code files to be downloaded
• If the iBox software program features need to be changed or upgraded, the
existing flash memory can be erased, and new code downloaded.
Programming
Flash Memory
There are three ways to program iBox flash memory (the one you use will depend on
your system options and network type):
Before
Downloading
•
Connect a PC, running terminal emulation software, to the WESMAINT port.
This procedure is described below.
•
Use ConfigPro/SGConfig 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.
When a new code image is downloaded into the iBox flash memory, the amount of
memory reserved for the configuration’s data region, also referred to as the “Base”
region, may not be large enough.
If this occurs, the following message (or a similar message) displays:
The configuration’s data region overlaps the current
Configuration Header (NVHEADER). Relocate the
Configuration Header / NVRAM to <address>, or set data size
to <size> and re-download. Application will NOT be
started.
If this message appears, refer to the ConfigPro / SGConfig online help on how to set
the iBox Device Properties to increase the Base System area.
Note
Using the Windows HyperTerminal for a code download procedure can take up to
two hours to complete.
Continued on next page
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Downloading Code Files, continued
Serial Code
Download:
Requirements
You will need the following before you can download a code file into the iBox flash
memory:
• Windows PC with HyperTerminal (or equivalent) communication software.
• Code file, in Motorola S-record format, on the PC’s hard drive. If the file is
located on a network or floppy drive, the download will be significantly slower.
This file will typically be named either down.shx, or salxxxx.shx.
• WESMAINT cable, for connecting the PC to the iBox WESMAINT port.
Before
Starting the
Download
The serial code download procedure 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> prompt displays) must be running.
Procedure:
Serial Code
Download
Use the following procedure to download a code file to the iBox flash memory:
Step
Action
Access Application Monitor
1
Connect WESMAINT serial cable from PC to the iBox’s WESMAINT
port
2
Start your terminal emulation software, and configure it as follows:
Data Rate
9600 bps
Data Bits
8
Stop Bits
1
Parity
None
Flow Control
XON/XOFF
Connector Settings
COM1, COM2, as
required for your computer
Continued on next page
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Downloading Code Files, continued
Download Procedure, continued
Note
If the iBox does not have a code file loaded, or if it has detected a corrupt flash file,
you will have to go directly to Step 8 and log directly into the monitor.
Step
Action
Launch System Monitor
3
Log into WESMAINT.
4
Select option 2, System Functions.
5
Select option 3, 68K Monitor.
Result: The D25A> prompt appears, indicating that the Application
Monitor is running.
6
At the D25A> prompt type rtb ENTER.
For other available 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 ENTER and password rd ENTER.
Result: The system performs self-diagnostics to ascertain whether any
Flash EPROM memory is in use. The D25S> prompt appears,
indicating the System Monitor is running.
Clear Flash EPROM
10
Type erase and press ENTER (not case-sensitive).
Result: The recommended procedure is to clear flash EPROM
memory, no matter what the system check reveals.
Continued on next page
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Downloading Code Files, continued
Download Procedure, continued
Step
11
Action
Type Y ENTER at the Do you wish to proceed? prompt (not casesensitive).
Result: The system automatically verifies that Flash EPROM memory
has been cleared. The D25S> prompt appears. You can start
the download.
Optional steps to speed up the download time:
12
Type Baud 38400 ENTER (speeds up to 38.4 kbps, may be chosen based
on ambient EMI, cable length, PC and software limits etc.).
Result: The monitor now communicates at 38.4 kbps.
13
Configure HyperTerminal to communicate at the same speed, and
reconnect to the 68K monitor.
Optional step to provide feedback during the download:
14
If the communication software you are using does not have any
“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: You can only download Motorola S-Records.
17
Locate and select a file to download.
18
Press ENTER to invoke the download procedure.
Note: Download can take from 20 to more than 45 minutes, depending
on file size and speed of transfer.
Result: The download completes, and the D25S> prompt appears.
Download Fails
If the transfer does not complete or it stalls, halt and restart the transfer.
Download is
Successful
Reboot the iBox, watching the display on the PC monitor. Note that the iBox
monitor speed returns to 9600 bps, if it was changed during the procedure.
If any error codes display, you may have to repeat the procedure.
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2.8. Troubleshooting your iBox
Overview
Introduction
GE Information
This section provides instructions on what to do if the system malfunctions, or when
error messages appear in WESMAINT.
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Runtime and Startup Errors
Overview
This section provides instructions on what to do if the system malfunctions, or when
error messages appear in WESMAINT.
Note: Plant I/O errors are reported as changes 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 need help
interpreting error messages, contact GE Digital Energy for assistance.
Continued on next page
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Runtime and Startup Errors, continued
iBox Troubleshooting Tips
Symptom
Possible Causes
Suggestions
Active Operations
Aborted
Controls Jumper is in the Local
position (JP2 is removed).
Move the Controls Jumper to
the Remote position (Install
JP2).
Active Requests Aborted
The iBox Plant I/O Subsystem
monitoring detects a conflict
between desired and actual coil
status (a coil is not energized when
it should be).
Verify coil status.
Digital Output Requests
Rejected
Controls Jumper is in the Local
position (JP2 is removed).
Move the Controls Jumper to
the Remote position (Install
JP2).
The iBox Plant I/O Subsystem
monitoring detects a conflict
between desired and actual coil
status (a coil is not energized when
it should be).
Queued Requests Cleared
Verify coil status.
Controls Jumper is in the Local
position.
Move the Controls Jumper to
the Remote position
The iBox Plant I/O Subsystem
monitoring detects a conflict
between desired and actual coil
status (a coil is not energized when
it should be).
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 Jumper is in the
Local position (JP2 is removed).
Move the Local/Remote Jumper
to the Remote position (Install
JP2).
Communication Watch
Dog Failure
Internal system monitors detect
serious errors.
Attempt Reboot, clear CCU
error logs.
Coil Status Check
The iBox Plant I/O Subsystem
monitoring detects a conflict
between desired and actual coil
status.
Verify coil status.
Digital output coils are
not in the state requested
by the software
Hardware Watchdog.
Check Control Voltage source
fuses. Check voltage.
Force from WESMAINT
Control Voltage Not Available,
Coil Status Check, or Hardware
Watchdog error condition.
Check Control Voltage source
fuses. Check voltage. Force
from WESMAINT.
Plant I/O Sub failure
Digital Output Failure
Continued on next page
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Runtime and Startup Errors, Continued
Symptom
76
Possible Causes
Suggestions
NVRAM Check Failure
System start-up fails
Use WESMAINT to view the error
message, and refer to related
configuration guide for suggestions.
Application Checksum
Failure
System start-up fails
Use WESMAINT to view the error
message, and refer to related
configuration guide for suggestions.
BootROM Checksum
Failure
System start-up fails
Use WESMAINT to view the error
message, and refer to related
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 guide for suggestions
Only the System Monitor
is Running
No valid application code is
detected.
Load application code
Code Download Failure
Download interrupted or data
error encountered in
downloaded file.
Clear Flash EPROM memory. Restart
download procedure.
Cannot Download Code
Logged into the Application
Monitor.
Exit Application Monitor, and launch
System Monitor.
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Installation and Maintenance Guide
GE Digital Energy
Initialization Errors
Overview
Several error situations, related to initialization, can occur with file transfers. The
most common case will be that the configuration and code in the Boot File are those
in the memory of the client causing the client to initialize immediately. Other
possibilities exist.
Symptom
Possible Causes
BootROM Error
GE Information
Suggestions
Press escape to reset
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 configuration is detected in either
NVRAM or in EPROM on start-up
Download a configuration
remotely via the system
monitor, and reboot
System error
No configuration is detected in either
NVRAM or in EPROM on start-up
Download a configuration
remotely via the system
monitor, and reboot
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Errors Indicated by LEDs
Overview
The following errors are indicated by the LEDs:
Symptom
Possible Causes
Suggestions
PWR LED does not light
Unit is not receiving power
Confirm that power source is
working
RUN LED does not light
Unit is not receiving power
Confirm that power source is
working
No BootROM
Confirm BootROM installed
at U4XU4
Unit is not transmitting any data
Check cabling to modems.
RTS, CRS, DCD settings are incorrect
If connected to a modem or
converter, ensure RTS, CTS,
DCD are enabled
TX LED does not light
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 correctly
Check modem cabling
CD LED does not light
Not receiving data
Check modem cabling
Ensure modem is receiving
data
I/Px (DI LEDs) do not
light
78
The input device is not operating
properly
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Confirm that the input source
is working properly
GE Information
iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
2.9. Replacing your iBox
Introduction
This section outlines procedures for replacing an iBox.
Equipment
Needed
•
•
Before
Installing
Verify that the replacement iBox unit is fitted with the same options and connectors
as the original unit, before proceeding.
Standard electrician’s tools (screwdrivers and flashlight)
Replacement iBox.
Refer to “Product Identification” on page 20 for detailed information.
!
GE Information
Since hazardous voltages can cause shock, burns or death:
• Disconnect and lockout all power sources before servicing and removing
components
• Short all current transformer primaries before servicing.
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Replacing your iBox, continued
Procedure:
Replacing an
iBox
Use the following procedure to replace an iBox:
Step
Action
Removing the Existing iBox
1
Power down the iBox by unplugging power from TB1.
2
Disconnect ground from the iBox.
3
Ensure no voltage or current is applied to any of the terminals on the
iBox. Use a meter if necessary.
4
Remove field wiring connections
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 Replacement iBox
7
Mount the new iBox.
8
Reconnect the field wiring to the same points as they were on the
original unit.
9
Reconnect any communications cables that were removed to the same
points as they were on the original unit.
10
80
Restore ground and power to the iBox.
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Section 3:iBox Kit Installation and Maintenance
3.1. Familiarization
Overview
In addition to the iBox features, the 19” rack-mountable iBox Kit can be optioned 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.
DC Kit
Power Supply
Protective
Earth Terminal
COM Ports
iBox
19” Mounting
Plate
Digital Inputs
and Outputs
DC Analog
Input Module
AC Kit
AC Analog
Input Module
COM Ports
iBox
Digital Inputs
and Outputs
AC Input
Terminations
Protective Earth
Terminal
Power Supply
Ethernet
Module
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What is an iBox Kit?, continued
Components
The iBox Kit consists of the following components:
•
iBox. See “What is an iBox?” on page 14 for more information.
•
24 VDC Power Supply (20 - 60 VDC or 88 - 300 VDC/88 - 264 VAC input)
•
10/100BaseT Ethernet Module (optional)
•
DC Analog Input Module (optional, eight DC analog inputs)
•
AC Analog Input Module (optional, 3 CT and 3 PT inputs)
An example configuration of the iBox AC Kit is illustrated below (other options of
the iBox Kit are equipped differently):
AC Kit
Ethernet Module
10/100BaseT Ethernet
RS-485/PPP
RS-232/485
Serial Port
20 - 60 VDC
88 - 264 VAC
88 - 300 VDC
Power
Supply
24 VDC Output
iBOX
RS-232
Maintenance Port
8 Digital Inputs
4 Digital Outputs
RS-485/Modbus
AC Analog Input
Module
DC Kit
3 PT Inputs
3 CT Inputs
An example configuration of the iBox DC Kit is illustrated below (other options of
the iBox Kit are equipped differently):
Ethernet Module
10/100BaseT Ethernet
RS-485/PPP
RS-232/485
Serial Port
20 - 60 VDC
88 - 264 VAC
88 - 300 VDC
Power
Supply
24 VDC Output
iBOX
RS-232
Maintenance Port
8 Digital Inputs
4 Digital Outputs
RS-485/Modbus
DC Analog Input
Module
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8 DC Analog Inputs
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
What is an iBox Kit?, continued
Operation and
Maintenance
The iBox Kit can be configured to operate over a LAN or through a serial
connection.
If you configure the iBox Kit to operate over a LAN, you can maintain the iBox
configuration over the LAN or directly through the WESMAINT port. If you operate
the iBox Kit through a serial connection, you can only maintain the iBox
configuration through the WESMAINT port.
Inputs/
Outputs
The iBox Kit provides the following:
Digital Inputs
The iBox Kit provides the following digital inputs, directly from the iBox:
• Eight optically isolated status inputs, 25 VDC or 125 VDC, with 10% overload
• Wetting options
• LED indications
• 4-5 mA typical current burden per input (up to 48 VDC)
• Maximum 0.5 W heat dissipation per input from current burden of inputs at
125 VDC
Control
Outputs
The iBox Kit provides the following control outputs, directly from the iBox:
•
•
•
•
•
•
•
•
•
DC Analog
Inputs
(option)
Eight digital inputs
Four control outputs
Eight DC analog inputs (optional)
Three PT (120/208 V) and three CT (5 A) AC analog inputs (optional)
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
35 W breaking @ 125 VDC, 180 W breaking @ 30 VDC
6 A current handling capability
The iBox Kit provides the following DC Analog Inputs through a DC Analog Input
Module:
•
•
•
•
Eight DC analog inputs
DC voltage options: +1 VDC, +5 VDC, +10 VDC
DC current options: +20 mA, 4–20 mA
14-bit resolution plus sign
Continued on next page
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AC Analog
Inputs
(option)
The iBox Kit provides the following AC Analog Inputs through an AC Analog Input
Module:
•
Single circuit monitoring (wye connected)
•
VRMS, IRMS, Phase Angle, Frequency, Power Factor
•
Real Power (W), Reactive Power (VAR), Apparent Power (VA)
•
Watt-Hour
•
Nominal PT input range: 0 to 150 VLN or 250 VLL
•
Nominal CT input: 5 A
•
Frequency: 50/60 Hz
•
Measurement range: 0 to 125% of nominal
•
Accuracy: 0.3%
•
Continuous overload withstand: 200% of nominal
•
Short duration overload withstand: 100 A for 3 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
GE Digital Energy
Power Supply: 6 VA max
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 max)
• 88 - 300 VDC (1.4 A max) / 88 - 264 VAC (2.1 A max)
Maximum output is 24 VDC / 4 A or 24 VDC @ Vin min. For further clarification
regarding the power supply, consult the manufacturer’s power supply guide as listed
in the Additional Documentation section.
Remote
Maintenance
84
If your iBox Kit is equipped with an Ethernet interface, you can access and configure
the iBox from a remote PC running ConfigPro / SGConfig.
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
What is an iBox Kit?, continued
PPP (Point-toPoint
Protocol)
The iBox uses PPP to communicate through the iBox Kit Ethernet Module to a LAN,
or externally to communications equipment such as a radio.
IP Addressing
When it is equipped with an Ethernet Module, the iBox Kit requires three IP
addresses, two external and one internal, as shown below:
iBOX Kit
iBOX
LAN
IP
#3
Ethernet
Module
IP
#2
PPP
IP
#1
IP #1 and IP #3 are both accessible from the LAN. IP #2 is internal to the iBox Kit
and is not accessible from the LAN. You set IP #2 and IP #3 when you configure the
Ethernet Module. The Ethernet Module calculates IP #1 (equal to IP #2 + 1), and
assigns this address to the iBox through PPP.
Configuration
The iBox Kit ships pre-configured, based on your order; 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
Default
Configuration
Options
GE Information
Configuration Method
iBox
Locally through the iBox maintenance (WESMAINT) port, from a PC
running ConfigPro / SGConfig. If it is equipped with an Ethernet
Module, the iBox can also be configured through the LAN, from a
remote PC running ConfigPro / SGConfig. Refer to “Configuring the
iBox Kit Components” on page 91.
Ethernet Module
Locally through the module’s Ethernet port/Web server, from a
computer running a Web browser. Refer to “Configuring the Ethernet
Module” on page 112.
DC Analog
Input Module
Locally through the device’s RS-485 port, from a computer running
the vendor’s configuration utility. Refer to “Configuring the DC
Analog Module” on page 126.
AC Analog
Input Module
No configuration typically required.
When shipped as part of an iBox Kit, the iBox comes preconfigured for that
particular option, as shown in Appendix B: iBox Kit Default Configurations.
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3.2. Installing the iBox Kit
Overview
Safety
Precautions
Before beginning to install the iBox Kit, thoroughly review the “Safety 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
86
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
Connect and test field wiring.
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Installation and Maintenance Guide
GE Digital Energy
Physical Mounting
Rack Spacing
When mounting the iBox Kit in a rack with other equipment, 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 inches or 44.5 mm).
Required
Clearances
The exterior dimensions of the iBox Kit are:
• 8.75” high x 19" wide x 2" deep (22.2 cm high x 48.3 cm wide x 5.1 cm deep)
Procedure –
Mounting the
iBox Kit
To mount the iBox Kit on a rack:
Step
Action
1
Determine the location of the iBox Kit in the 19-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 through
a space above or below the iBox Kit then connect to the mounting panel,
iBox, power supply, Ethernet Module and I/O module.
Note: An IEC® 60947 compliant main disconnect switch (or other equivalent
device complying with IEC 60947-1 / 60947-3) must be as electrically close
as practicable to the iBox Kit power supply.
You are now ready to connect ground, power, and communications cabling to the
iBox Kit.
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Connections
Ground
Connection
Connect site ground to the iBox Kit protective earth terminal. We recommend 12
AWG wire, a ring connector and a toothlock washer.
iBox Kit (DC)
Protective Earth
Terminal
iBox Kit (AC)
Protective Earth
Terminal
Power
Connection
Connect power to the iBox Kit power supply. External fuse installation is required.
Consult the power supply rating section for power ratings.
DC Output
Ground
Not Connected
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Input
GE Information
iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Communications Cabling
Communications
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
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Communications Cabling, continued
Communications
Cabling Serial
As necessary, connect the appropriate iBox COM port to your equipment using serial
cables with male DB-9 connectors:
WESMAINT
COM 1
COM 2
COM 3
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 GEsupplied cable (GE part number 977-0526.)
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
3.3. Configuring the iBox Kit Components
Introduction
Your iBox Kit modules have been pre-configured based on your order. However,
you need to configure, or confirm the configuration of, the following items:
iBox Kit Module
iBox
Ethernet Module
(if equipped)
DC Analog Input
Module (if equipped)
AC Analog Input
Module (if equipped)
Configurable Settings
•
Project properties
•
Device properties
•
Communications properties
•
SCADA protocol addresses
•
PPP Driver (if applicable)
•
User ID and password
•
IP addresses
•
Admin password
•
Pass-through switch
•
Configuration ports setting
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
In most cases, you will not have to
reconfigure the AC Analog Input Module.
You may, however, want to change the
following:
•
Point descriptors
Note: Configuration procedures vary for the iBox operating over a serial
connection versus a LAN connection. Be sure to follow the appropriate set
of procedures for your type of connection.
Continued on Next Page
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Configuring and Testing your iBox Kit Components, continued
Before you
Start
To configure an iBox Kit with a serial connection, you will need:
•
Factory configuration for your iBox. You can find this on the configuration CD
that shipped with your iBox Kit.
•
ConfigPro/SGConfig installed on your PC.
•
Serial number of your iBox, from the iBox circuit board
To configure an iBox Kit with a LAN connection, you will need, in addition to the
above:
Configuration
Sequence –
Serial
Connection
•
IP address/subnet 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.
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
Project
Configure Application
Firmware
Configure Project
Properties for serial
connection
Download iBOX
configuration through
WESMAINT port
Configure iBOX
Device Properties for
serial connection
Configure AC or DC
Analog Input Module
(if equipped)
Configure iBOX
Communication
Options for serial
connection
Test iBOX Kit
Continued on Next Page
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Configuring and Testing your iBox Kit Components, continued
Configuration
Procedures –
Serial
Connection
GE Information
The procedures for configuring an iBox Kit with a serial connection are as follows:
•
Restoring your ConfigPro Project on page 95
•
Configuring Project Properties - Serial on page 96
•
Configuring iBox Device Properties - Serial on page 98
•
Configuring iBox Communications Options - Serial on page 99
•
Configuring the Application Firmware on page 100
•
Downloading your iBox Configuration - Serial on page 101
•
Configuring the DC Analog Module on page 126 (if equipped)
•
Configuring the AC Analog Module on page 133 (if equipped)
•
Testing the iBox Kit on page 134
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Configuring and Testing your iBox Kit Components, continued
Configuration
Sequence –
LAN
connection
If you are operating the iBox Kit through a LAN, the process for configuring and
testing the iBox Kit components is as follows:
Restore Config Pro
Project
Configure Application
Firmware
Configure Project
Properties for LAN
Connection
Download iBOX
configuration through
WESMAINT port
Configure iBOX
Device Properties for
LAN Connection
Configure Ethernet
Module
Configure iBOX PPP
Driver
Configure AC or DC
Analog Input Module
(if equipped)
Configure iBOX
Communication
Options for LAN
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
94
The procedures for configuring an iBox Kit with a LAN connection are as follows:
•
Restoring your ConfigPro Project on page 95
•
Configuring the Application Firmware on page 100
•
Configuring Project Properties on page 102
•
Configuring iBox Device Properties - LAN on page 104
•
Configuring the iBox PPP Driver on page 107
•
Configuring iBox Communications Options - LAN on page 109
•
Downloading your iBox Configuration - LAN on page 111
•
Configuring the Ethernet Module on page 112
•
Configuring the DC Analog Module on page 126 (if equipped)
•
Configuring the AC Analog Module on page 133 (if equipped)
•
Testing the iBox Kit on page 134
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GE Digital Energy
Restoring your ConfigPro Project
Introduction
This procedure describes how to restore the ConfigPro project that includes the
sample configuration provided with the iBox.
Procedure:
Restoring
your
ConfigPro
Project
Step
Action
1
In your Windows desktop, click Start, and then click Programs.
2
Click GE Energy, and then click ConfigPro 6.
Result: The ConfigPro main window appears.
Importing the Factory Configuration
3
Click Project, and then click Archive Project.
4
Click Restore.
Result: The Restore Project from ZIP file dialog box appears:
5
Insert your configuration CD in the drive.
6
Click , navigate to the configuration file, and click Select.
Result: The path to the configuration file appears in the Select Source
Project ZIP File box.
7
Click OK.
Result: The configuration file uploads to your PC, and your project
appears in the ConfigPro Main Project window.
Next Step
If you are operating the iBox Kit through a serial connection, the next step is:
•
Configuring Project Properties - Serial on page 96
If you are operating the iBox Kit through a LAN connection, the next step is:
•
Configuring Project Properties on page 102
Continued on next page
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Configuring Project Properties - Serial
Introduction
Procedure:
Configuring
Project
Properties Serial
Use the following procedure to configure Project Properties if you are operating the
iBox Kit through a serial connection.
Step
1
Action
In ConfigPro, click Project, and then click Project Properties.
Result: The Select a Project to Edit dialog box appears:
2
Select your project under Project(s) found and click OK.
Result: The Project Properties dialog box appears:
Continued on next page
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Installation and Maintenance Guide
GE Digital Energy
Configuring Project Properties - Serial, continued
Procedure:
Configuring
Project
Properties Serial
[continued]
Next Step
Action
3
Select the LAN tab. On the General tab, verify LAN Based Project is not
checked and click OK.
4
In ConfigPro, click Project, then click Copy Project.
Result: The Copy Project dialog appears:
5
Under To, Name and Description for your project.
6
Next to the Project Directory box, click
and browse to the folder on
your PC to which you want to save your project.
7
Click OK to save.
The next step is:
•
GE Information
Step
Configuring iBox Device Properties - Serial on page 98
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Configuring iBox Device 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:
•
98
Configuring iBox Communications Options - Serial on page 99
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iBox/iBox Kit
Installation and Maintenance Guide
GE Digital Energy
Configuring iBox Communications Options - Serial
Introduction
Use the following procedure to configure iBox Communications Options if you are
operating the iBox Kit through a serial connection.
Procedure:
Configuring
Communications
Options Serial
Next Step
Step
1
In the Project window, right-click the iBox device icon.
2
Click Communications, and then select Communications Options.
3
On the Interface tab, select Direct Serial under Connection Type and
COM1 from the Comm Port list.
4
Click OK to save.
The next step is:
•
GE Information
Action
Configuring the Application Firmware on page 100
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Configuring the Application Firmware
Procedure:
Configuring
Application
Firmware
Refer to “Configuring Application Firmware” on page 42 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 101
If you are operating the iBox Kit through a LAN connection, the next step is:
•
100
Downloading your iBox Configuration - LAN on page 111
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Downloading your iBox Configuration - Serial
Overview
To download your iBox configuration file, connect your PC to the iBox
WESMAINT port.
Procedure:
Downloading
your iBox
configuration
through the
WESMAINT
port
Refer to “Downloading your iBox Configuration” on page 43 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 126
If your iBox Kit is equipped with an AC Analog Input Module, the next step is:
•
Configuring the AC Analog Module on page 133
If your iBox Kit is not equipped with a DC or AC Analog Input Module, the next
step is:
•
GE Information
Testing the iBox Kit on page 134
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Configuring Project Properties - LAN
Introduction
Procedure:
Configuring
Project
Properties LAN
Use the following procedure to configure Project Properties if you are operating the
iBox Kit through a LAN connection.
Step
1
Action
In ConfigPro, click Project, and then click Project Properties.
Result: The Select a Project to Edit dialog box appears:
2
Select your project under Project(s) found and click OK.
Result: The Project Properties dialog box appears:
Continued on next page
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Configuring Project Properties - LAN, continued
Procedure:
Configuring
Project
Properties LAN
[continued]
Step
3
Action
Click the LAN tab.
On the General tab, select LAN Based Project.
4
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.
5
Next Step
The next step is:
•
GE Information
Click OK to save.
Configuring iBox Device Properties - LAN on page 104
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Configuring iBox Device Properties - LAN
Introduction
Procedure:
Configuring
Device
Properties LAN
Use the following procedure to configure iBox Device Properties if you are
operating the iBox Kit through a LAN connection.
Step
1
Action
Right-click the iBox device icon in the Project window and select
Properties.
Result: The iBox Device Properties dialog box appears:
2
Verify LAN Based Device is selected.
3
In the Description box, enter a name for the iBox.
4
In the Serial No box, enter the serial number of the iBox.
Continued on next page
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Configuring iBox Device Properties - LAN, continued
Procedure:
Configuring
Device
Properties
- LAN
[continued]
Step
Action
5
Click the Processor tab.
6
On the Memory Model tab, check that Derive From iBox Hardware
Setting is selected.
7
Confirm the settings are as shown above, and modify them if they are not.
8
Click the LAN Settings tab, and then click the General tab:
9
Confirm the settings are as shown above, and modify them if they are not.
Continued on next page
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Configuring iBox Device Properties - LAN, continued
Procedure:
Configuring
Device
Properties
- LAN
[continued]
Next Step
Step
10
Click the LAN Specific tab:
11
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” on page 85.
Note: Do not change the Ethernet Address settings.
12
Click OK to save.
The next step is:
•
106
Action
Configuring the iBox PPP Driver on page 107
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Configuring the iBox PPP Driver and Internet Data Links
Procedure:
Configuring
the PPP
Driver
Step
Action
1
In the Project window, double-click the iBox device icon.
2
Click the Data Translation Applications tab, and then double-click the
PPP Driver icon.
3
Click the Tables tab.
4
On the PPP main config tab, verify the following settings 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 values. If you do, you also need to make
corresponding changes to the Digi One® Ethernet Module, if
equipped, or to the equipment to which the iBox Ethernet port is
connected. See “Configuring the Ethernet Module” on page 112.
5
On the ConfigPro toolbar, click
Driver window.
6
Click Yes to save your changes.
(Close Window icon) to close the PPP
Continued on next page
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Configuring the iBox PPP Driver and Internet Data Links, continued
Procedure:
Configuring
the PPP
Driver
`(continued)
Next Step
Step
7
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.
8
Click the Tables tab.
9
In Local Host Name, enter *.
10
Click
11
Click Yes to save your changes.
12
Click
to close the DNP Internet Data Link window.
to close the Applications window.
The next step is:
•
108
Action
Configuring iBox Communications Options - LAN on page 109
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Configuring iBox Communications Options - LAN
Introduction
Procedure:
Configuring
Communications
Options - LAN
GE Information
Use the following procedure to configure iBox Communications Options if you are
operating the iBox Kit through a LAN connection.
Step
Action
1
In the Project window, right-click the iBox device icon, click
Communications, and then click Communications 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.
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Configuring iBox Communications Options - LAN, continued
Procedure:
Configuring
Communications
Options - LAN
Next Step
Step
6
On the File menu, click Preferences.
Result: The ConfigPro Preferences dialog box 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.
The next step is:
•
110
Action
Configuring the Application Firmware on page 100
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Downloading your iBox Configuration - LAN
Introduction
The first time you configure your iBox, you will need to connect your PC to the iBox
WESMAINT port, as shown below:
PC running
Config Pro
iBOX Kit
WESMAINT
Port
iBOX
LAN
Ethernet
Module
Procedure:
Downloading
your iBox
configuration
through the
WESMAINT
port
Refer to “Downloading your iBox Configuration” on page 43 for instructions on how
to download a configuration file to the iBox through the WESMAINT port.
Next Step
The next step is:
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
139.
•
GE Information
Configuring the Ethernet Module on page 112
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Configuring the Ethernet Module
Introduction
The following procedure describes the configuration of the Digi One IAP Ethernet
Module.
Procedure:
Configuring
the Digi One
IAP
You need to set the Digi One Ethernet and PPP IP addresses. Refer to “IP
Addressing” on page 85 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:
PC running
a Web browser, IP address in
the same subnet as the
Ethernet Module
iBOX Kit
Crossover Ethernet
Cable
Digi One
IAP
or through the network:
PC running
a Web browser, IP address in
the same subnet as the
Ethernet Module
iBOX Kit
LAN
Straight-through
Ethernet Cable
Digi One
IAP
Continued on next page
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Configuring the Ethernet Module, continued
Procedure:
Configuring
the Digi One
(continued)
Step
Action
Configuring your PC’s Proxy Settings (Windows 2000)
If your PC is configured to use a proxy server, follow the procedure below to add
the Digi One IP address to Exceptions so you can browse directly into the Digi
One Web server.
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:
7
•
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 IP Addresses in
the Digi One Configuration File”.
•
If Use a proxy server for your LAN is selected, proceed to the next
step.
In Proxy Server, click Advanced.
Result: The Proxy Settings dialog box appears:
Continued on next page
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Configuring the Ethernet Module, continued
Procedure:
Configuring
the Digi One
(continued)
Step
8
Action
In Exceptions, add the default Digi One Ethernet IP address,
192.168.1.100.
Note: You can use the wildcard character (*) to specify a range of IP
addresses; for example, 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 setting from the default state OFF to ON
11
Reboot the Digi One IAP. Refer to steps 1 to 4 in Appendix C: Resetting
the Digi One Configuration.
Continued on next page
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Configuring the Ethernet Module, continued
Procedure:
Configuring
the Digi One
(continued)
Step
Action
Modifying the Ports Setting in the Digi One Configuration File
12
Copy the Digi One default configuration file from the configuration CD to
a folder on your PC’s hard drive. This file can be found as follows
\ Digi Default Config \ Digi Default Config.txt
13
Open the Digi One default configuration file in a text editor such as
Notepad
14
Search for all instances of ports=1 and replace with ports=2. There
should be 4 changes.
Modifying IP Addresses in the Digi One Configuration File
15
Near the top of the configuration file, 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 85 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 submask=255.255.255.0
set config gateway=192.168.1.100
16
Modify the Digi One’s PPP IP address. Refer to “IP Addressing” on page
85 for an explanation of the Digi One’s PPP IP address setting.
Example: In the following example, the PPP IP address is set to
192.168.1.19:
set user name=”link1” localipaddr=192.168.1.19 netrouting=off
In this example, the iBox IP address will automatically be set to
192.168.1.20 (192.168.1.19 + 1) over PPP.
17
Save the modified configuration file as DigiDefaultConfig_Modified.txt.
Continued on next page
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Configuring the Ethernet Module, continued
Procedure:
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
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Configuring the Ethernet Module, continued
Procedure:
Configuring
the Digi One
(continued)
Step
Action
20
Select your device.
Note: The MAC address 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 if you are not sure.
Continued on next page
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Configuring the Ethernet Module, continued
Procedure:
Configuring
the Digi One
(continued)
Step
24
Action
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
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Configuring the Ethernet Module, continued
Procedure:
Configuring
the Digi One
(continued)
Step
26
Action
Click Next.
Result: The Verify Configuration page appears:
Continued on next page
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Configuring the Ethernet Module, continued
Procedure:
Configuring
the Digi One
(continued)
Step
27
Action
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
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Configuring the Ethernet Module, continued
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
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Configuring the Ethernet Module, continued
Procedure:
Configuring
the Digi One
(continued)
Step
30
Action
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
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Configuring the Ethernet Module, continued
Procedure:
Configuring
the Digi One
(continued)
Step
Action
Downloading the Configuration File to the Digi One
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 Reboot.
Result: The Digi One reboots.
Continued on next page
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Configuring the Ethernet Module, continued
Procedure:
Configuring
the Digi One
(continued)
Step
Action
36
To confirm that it is correctly configured, ping the Digi One through the
DOS command line.
37
Under Configuration, click Security.
Result: The Security Configuration dialog appears:
38
Enter and confirm your new administrator password 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 156. If you reset the Digi One, you will
need to reconfigure it using the procedure outlined in this section.
Note: You will now be able to configure the Digi One through its Web
server. Refer to the Digi One User’s Guide, which you can obtain
from the Digi Software & Documentation CD.
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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 126
If your iBox Kit is not equipped with a DC Analog Input Module, the next step is:
•
GE Information
Testing the iBox Kit on page 134
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Configuring the DC Analog Module
Overview
The ADAM®-4017+ DC Analog Input Module has been pre-configured based on
your order. Typically, all of the analog inputs will be configured the same way; for
example, they may all be configured to have a voltage range of +1 V.
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
The following procedure is intended as a high-level overview. For detailed
instructions and settings, refer to the following documents:
Before you
Start
•
ADAM 4000 Data Acquisition Modules User’s Manual – Available from the
Advantech 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
You need the following to configure the ADAM-4017+:
•
RS-485/RS-232 converter
•
Cables to connect the RS-232 side of the converter to your PC COM port, and
the RS-485 side of the converter to your ADAM-4017+ DATA+ and DATAterminals.
•
Phillips screwdriver, to disconnect field and communications wires to the
ADAM-4017+.
•
Needle-nose pliers to make jumpering changes, in the event that you want to
change the input types from voltage to current, or vice versa.
•
PC equipped with:
− ADAM-4000 Utility, available from the Advantech CD that shipped with
your iBox Kit
−
126
ConfigPro/SGConfig, available from the GE Digital Energy CD that
shipped with your iBox Kit.
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Configuring the DC Analog Module, continued
Procedure:
Configuring
the ADAM4017+
If you want to change the configuration of some or all of the analog inputs, follow
the procedure below. If necessary, refer to the procedures in the 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.
RS-485
ADAM-4017+
4
RS-232
RS-485/RS-232
Converter
PC running
ADAM-4000
Utility
Switch the operating mode of the ADAM-4017+ from Normal to Init,
then restore power to the unit:
Init/Normal
Switch
Continued on next page
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Configuring the DC Analog Module, continued
Procedure:
Configuring
the ADAM4017+
(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
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Configuring the DC Analog Module, continued
Procedure:
Configuring
the ADAM4017+
(continued)
Step
7
Action
In the left-hand pane, select the COM port to which the ADAM-4017+ is
) in the toolbar.
connected, and click Search (
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
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Configuring the DC Analog Module, continued
Procedure:
Configuring
the ADAM4017+
(continued)
Step
10
Action
Select the ADAM-4017+ device in the left-hand pane.
Result: The ADAM-4017+ configuration displays in the right-hand
pane:
11
Make the desired changes.
Note: You can change the characteristics of individual analog points, or
make the same change to all analog points. Refer to the ADAM4000 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 instructions and settings, refer to the ADAM
4000 Data Acquisition Modules User’s Manual – Available from
the Advantech CD that shipped with your iBox (accessible
through Manual > ADAM 4000 > ADAM-4000.pdf)
Continued on next page
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Configuring the DC Analog Module, continued
Procedure:
Configuring
the ADAM4017+
(continued)
Step
12
Click Update, then OK when you receive the message that the setup was
successful:
13
Remove power to the ADAM-4017+.
14
Change the ADAM-4017+ operating mode switch from Init back to
Normal.
15
Restore power to the ADAM-4017+.
16
Procedure:
Modifying the
Point
Descriptors
Action
In the ADAM-4000 Utility, click
.
Result: The device configuration is now consistent with the change or
changes you made.
17
Remove power to the ADAM-4017+.
18
Disconnect the ADAM-4017+ from the RS-485/RS-232 converter, and
reconnect it to the iBox.
You may wish to modify 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 ConfigPro and click the System Point
Database Applications tab.
2
Double-click the System Point Database icon.
Result: The System Point Database Properties window displays.
3
On the DCA/DTA List tab, select MODBUS DCA and click the
Descriptors button.
Result: The Point Descriptors window appears.
4
Click the Analog Inputs tab on the bottom of the window. Enter new
Point Descriptions as desired. Click OK.
5
On the DCA/DTA List tab, select Calculator DTA and click the
Descriptors button.
Result: The Point Descriptors window appears.
6
Click the Analog Inputs tab on the bottom of the window. Enter new
Point Descriptions as desired. Click OK twice.
Result: ConfigPro updates the configuration tables.
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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 133
If your iBox Kit is not equipped with a AC Analog Input Module, the next step is:
•
132
Testing the iBox Kit on page 134
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Configuring the AC Analog Module
Overview
In most cases, you will not have to reconfigure the AC Analog Input Module. You
may, however, want to change the Point descriptors
The following procedure is intended as a high-level overview. For detailed
instructions and settings, refer to the following documents:
•
DMMS300+, DMMS350, DMMS425 3-Phase Multifunction Power Monitors
with Advanced Capabilities Installation, Operation and Programming Manual
(Electro Industries/GaugeTech) that shipped with your iBox Kit
•
Modbus DCA Configuration Guide (A059-0CG) – Available from the GE Digital
Energy CD that shipped with your iBox Kit
Before you
Start
You need the following to configure the DMMS module:
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.
•
PC equipped with ConfigPro/SGConfig, available from the GE Digital Energy
CD that shipped with your iBox Kit.
Step
Action
1
Open the iBox Kit device in ConfigPro and click the System Point
Database Applications tab.
2
Double-click the System Point Database icon.
Result: The System Point Database Properties window displays.
3
On the DCA/DTA List tab, select MODBUS DCA and click the
Descriptors button.
Result: The Point Descriptors window appears.
4
Click the Analog Inputs tab on the bottom of the window. Enter new
Point Descriptions as desired.
5
Click the Counters tab. Enter new Point Descriptions as desired. Click
OK twice.
Result: ConfigPro updates the configuration tables.
Next Step
The next step is:
•
GE Information
Testing the iBox Kit on page 134
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Testing the iBox Kit
Overview
Digi One IAP
LEDs
ADAM-4017+
LEDs
You can verify the iBox Kit is operating properly by:
•
Inspecting the LEDs on each of the iBox Kit components, and
•
Pinging the Ethernet Module and the iBox from your PC
When operating normally, the Digi One LEDs appear as follows:
LED
Normal Operation
POWER
Solid GREEN
LINK
Solid GREEN
DCD
Solid GREEN
DSR
Solid GREEN
DTR
Solid GREEN
RTS
Solid GREEN
TX
Flashing GREEN
RX
Flashing GREEN
The ADAM-4017+ has a single 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:
Pinging the
Ethernet and
iBox
134
•
“LEDs” on page 32 (for LED operation during self diagnostics)
•
“LED Descriptions” on page 49 (for normal LED operation)
•
“Errors Indicated by LEDs” on page 78 (for information on using LED
indications to troubleshoot iBox problems)
If the iBox Kit modules are operating correctly, and it is configured for LAN
connection, you will be able to ping the Ethernet Module and iBox IP addresses from
your PC.
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3.4. Connecting Field Wiring
Digital Inputs
and Outputs
Digital inputs and outputs are connected directly to the iBox. Refer to “Connecting
and Testing Field Wiring” on page 54 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
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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 5+
Vin 5Vin 6+
Vin 6Vin 7+
Vin 7-
136
Vin 4Vin 4+
Vin 3Vin 3+
Vin 2Vin 2+
Vin 1Vin 1+
Vin 0Vin 0+
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3.5. Servicing your iBox Kit
Overview
This section provides information about servicing your iBox Kit, in particular:
•
•
•
•
Servicing the iBox
LED operation
Location of fuses
Updating your iBox configuration
Procedure:
Servicing the
iBox
For instructions on how to service the iBox, refer to “Servicing your iBox” on page
62.
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:
Procedure:
Replacing
Fuses
GE Information
•
iBox LEDs (refer to “LED Descriptions” on page 49)
•
Digi One IAP LEDs (refer to “Digi One IAP LEDs” on page 134)
•
ADAM-4017+ LEDs (refer to “ADAM-4017+ LEDs” on page 134)
•
DMMS LEDs (refer to the manufacturer’s manual)
For information on the location and replacement of iBox fuses, refer to “Fuse
Replacement” on page 63.
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3.6. Maintaining your iBox Kit 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 65.
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Downloading your iBox Configuration over the LAN
Introduction
Once you have configured the iBox PPP Driver 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:
PC running
Config Pro, with IP
address in iBOX
Kit subnet
iBOX Kit
iBOX
LAN
Ethernet
Module
Note: Refer to Appendix D: Setting your PC IP Address for instructions on how to
set your PC’s IP address (for Windows 2000).
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Downloading your iBox Configuration over the LAN, continued
Procedure:
Downloading
your iBox
Configuration
over the LAN
To download an iBox configuration file over the LAN:
Step
Action
1
In the Project window, click the iBox device icon.
2
Click
(Terminal Emulator icon):
Result: ConfigPro opens a Telnet session with the iBox.
3
Log into WESMAINT.
Result: The WESMAINT main menu appears.
4
Select option 2, System Functions.
Result: The System Functions menu appears.
5
Select option 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 ConfigPro, click .
9
In the Project window, right-click the iBox device icon, click
Communications, and then click Configuration Download.
Result: ConfigPro downloads the new configuration to the iBox.
ConfigPro displays progress messages until the new
configuration has been successfully downloaded.
Note: The iBox does not need to be rebooted for the new configuration
to be effective.
10
140
Exit ConfigPro.
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3.7. Troubleshooting your iBox Kit
Overview
The LED indicators on each iBox Kit device can be used to troubleshoot most iBox
Kit problems. If device configuration files are those supplied with the iBox Kit, most
problems are the result of failed cabling or connection.
iBox
If you are experiencing general problems or are unable to isolate a problem to a
particular iBox Kit module, the problem may lie with the iBox unit. For iBox
troubleshooting guidelines, refer to “Troubleshooting your iBox” on page 73.
Network
Connection
If you are having problems connecting to the network, check the operation of the
Ethernet Module. The following table shows normal LED operation for the Digi One
and provides suggestions for corrective action if LED operation is not normal.
ADAM 4017+
Configuration
GE Information
LED
Normal Operation
Suggestions
POWER
Solid GREEN
LINK
OFF
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
Check power supply/connections
RED LED indicates no network/cabling
If you are having a problem with DC analog inputs, check the operation of the
ADAM-4017+. The following table shows normal LED operation for the ADAM
4017+ and provides suggestions for corrective action if LED operation is not normal.
LED
Description
OFF
Power OFF
Solid GREEN
Power ON, no polling
Flashing Green
Power ON, MODBUS polling
Suggestions
Check power supply/connections
Check cabling if it should be polled
Check cabling if it should not be
polled
Changes to the iBox configuration file may result in incorrect operation. If you are
unable to isolate the problem by inspecting the LEDs and by checking unit cabling,
verify the iBox configuration file against Appendix B: iBox Kit Default
Configurations and modify if appropriate.
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3.8. Replacing your iBox Kit
Procedure:
Replacing an
iBox Kit
To replace an iBox Kit:
Step
Action
1
Disconnect the communication cables from the iBox Kit.
2
Disconnect all field wiring from the iBox Kit.
Tip:
142
Make sure you label these connections carefully, so you can
restore them once the replacement unit is installed.
3
Remove power cabling.
4
Disconnect the ground wire from the iBox Kit.
5
Fully unscrew the lower mounting screws. Loosen the upper mounting
screws, then 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 connected previously.
11
Reconnect the communication cables.
12
Verify that the replacement iBox Kit indicators are functioning properly.
Refer to “LED Operation” on page 137
13
Test your iBox Kit inputs and outputs, using the procedures outlined in
“Connecting Field Wiring” on page 135.
14
Return the failed iBox Kit to GE Digital Energy, following the product
return procedures.
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Section 4: Removing Configuration Data and
Sensitive Information
Overview
In the event that it is necessary to remove the configuration data and sensitive information
from the iBox (for example, the iBox is being disposed of or being returned for
maintenance [i.e., RMA]), this section provides the data removal procedure.
It may also be necessary to remove data from a PC that has run ConfigPro or SGConfig for
the purpose of configuring a iBox. Again, this section provides the data removal procedure.
4.1. From the iBox Device
Method
The configuration data can be removed from these devices by either:
•
Removing the battery from the device for at least 5 minutes.
Result: The configuration data which was backed up in NVRAM is removed, since
the NVRAM is powered by a battery.
Note: This does not remove 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 current configuration file is overwritten with the default
configuration. The 68k monitor is initiated. The configuration has been defaulted
to a factory-based configuration and the user’s configuration has been deleted.
4. Remove the firmware from the flash memory:
a. Login to the device through the 68K monitor (if not already logged in).
b. Type sp to suspend all processes running on the device.
c. Type erase to clear the flash.
Result: This takes several seconds to complete.
Result: The Flash Erased message appears when the erase operation is
completed.
5. Confirm the flash has been erased by typing img at the prompt to view the image
file.
Result: No firmware information should appear.
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4.2. From the PC Running Configuration Software
Method
If ConfigPro or SGConfig have been used to configure the iBox processor,
configuration data resides on the data storage media (e.g., hard drives, memory cards,
etc.) of the PC running ConfigPro or SGConfig.
The iBox configuration data can be removed from the PC by either:
144
•
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
allocation table.
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Appendix A: Technical Specifications
iBox
Power
Requirements
20-60 Vdc
Power Supply Input Options
Power Consumption
7 Watts (maximum)
Inrush Current
Less than 0.5A peak
Power Supply Protection
Input fuse
Reverse polarity protection provided
Communication Ports
Digital Inputs
Maintenance Port
WESMAINT DB-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
General
Up to eight bipolar optically isolated (2000 Vrms)
Burden
From 1.9 mA to 5.5 mA
max. power dissipation is 0.5 W per input
Wetting Options
External wetting - for all input options
Modes of operation:
Dry contact and voltage sense
24 Vdc, 48 Vdc, and 110/125 Vdc
Continued on next page
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Technical Specifications – iBox, continued
Digital
Outputs
Size and
Environment
General
Up to four relay outputs: 4 Trip/Close pairs or 2
Trip/Close pairs and 2 Form A contacts
Security features
Separate Master Trip and Master Close relays
Single point of failure integrity, select-beforeoperate (SBO) functionality. Remote/Local
jumper JP2.
Control Voltage
External
Switching Characteristics
35 W breaking @ 150 Vdc
180 W breaking @ 30 Vdc
Maximum Carrying Current
6A
Dimensions
Width (of Mounting
Panel)
28 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 EN61010-1
Pollution Degree
2
IEC 68-2-1
Cold
IEC 68-2-2
Dry heat
IEC 68-2-6
Vibration
IEC 68-2-30
Damp heat, cyclic (12+12-hour cycle)
MTBF
> 74000 hours @ 40°C
Note: Must be installed in an overall protective enclosure
and/or a protective environment unless the power supply
terminals have a protective cover installed
Note: Increased operating temperature decreases
MTBF of the device
Continued on next page
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Technical Specifications – iBox, continued
EMI/EMC
Compliance
Field
Terminations
& Wiring
CISPR11
Limits and methods of measurement of
electromagnetic disturbance characteristics of
industrial, scientific and medical (ISM) radiofrequency equipment.
EN61000-4-2
Immunity Test
EN61000-4-3
Radiated, radio-frequency, electromagnetic field
immunity Test
EN61000-4-4
Electrical Fast Transient/Burst Immunity Test
EN61000-4-5
Surge Immunity Test
EN61000-4-6
Immunity to conducted disturbances induced by
radio-frequency fields
EN 61000-4-12
Damped Oscillatory Wave Immunity Test (100
kHz/1 MHz)
EN 61010-1
Safety Requirements For Electrical Equipment
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
Digital Outputs
250 V rated compression termination consisting of
a header and removable plugs suitable for 12 – 24
AWG wire rated for 6A/150V
Power Supply Inputs
250 V rated compression termination consisting of
a header and removable plugs suitable for 12 – 24
AWG wire 0.5A/60V
Digital Inputs
250 V rated compression termination consisting of
a header and removable plugs suitable for 12 – 24
AWG wire 0.01A/150V
Protective Earth Terminal
#10 fastener
Note: Ground wire must be the largest gauge of
all wires used for field termination. A
green and yellow 12 AWG wire is
recommended.
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iBox Kit
Physical
Power Supply
iBox
Communication Ports
Dimensions
8.75” high x 19” wide x 2” deep
(22.23 cm high x 48.26 cm wide x 5.08 cm deep)
Mounting
19” rack mounting
Operational
Temperature
iBox: -40° to +80°C
DC Analog Module: -10° to +70°C
AC Analog Module: -20° to +70°C
Ethernet Module: 0° to +60°C
Power Supply: -40° to +80°C
Storage Temperature
-40° to +90°C
Humidity Rating
95% non-condensing at 55°C
Operating Altitude
0 – 2000 meters
Protective Earth
Terminal
Protective earth terminal is provided on the mounting plate
Input Voltage Options
20-60 VDC or 88-264 VAC/88-300 VDC
Output Voltage
24 VDC
Overload Protection
Current limiting with short circuit protection
Connections
Screw-type terminal block
Maintenance Port
DB-9-F, EIA 232 @ 9600 bps
Standard Serial Communication Ports (3)
Ethernet
Interface
(optional)
GE Information
•
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
Port Type
100BaseTX
Speed
10/100 Mbps
Connector
RJ-45
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Technical Specifications – iBox Kit, continued
Digital Inputs
General Up to eight bipolar optically isolated (2000 Vrms)
Physical
Burden
Wetting Options
Digital
Outputs
250 V rated compression termination consisting of a header
and removable plugs suitable for 12 – 24 AWG wire
0.01A/150V
•
From 1.9 mA to 5.5 mA
•
Max. power dissipation is 0.5 W per input
•
External wetting - for all input options
•
Modes of operation:
−
Dry contact and voltage sense
−
24 VDC, 48 VDC, and 110/125 VDC
Up to four relay outputs, configured as either:
General •
•
4 trip/close pairs or
2 trip/close pairs and 2 Form A contacts
250 V rated compression termination consisting of a header
Physical Connection and removable plugs suitable for 12 – 24 AWG wire rated
for 6A/150V
Security features
•
Separate Master Trip and Master Close relays
•
Single point of failure integrity, select-before-operate
(SBO) functionality.
Remote/Local jumper JP2
•
Control Voltage External
Switching Characteristics
•
35 W breaking @ 150 VDC
•
180 W breaking @ 30 VDC
Maximum Carrying 6 A
Current
Continued on next page
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Technical Specifications – iBox Kit, continued
AC Analog
Inputs
(optional)
VRMS, IRMS, Phase Angle, Frequency, Power Factor, Real
Analog Input Options Power (W), Reactive Power (VAR), Apparent Power (VA),
Watt-Hour
Nominal PT Input Range 0 to 150VLN or 250VLL
Frequency 50/60 Hz
Measurement Range 0 to 125% of nominal
Accuracy 0.3%
Continuous Overload
200% of nominal
Withstand
Short Duration Overload
100 A for 3 seconds
Withstand
Surge Withstand As per IEEE C37.90.1, ANSI C62.41
True RMS Sampling 64 samples per cycle
Isolation 2500 VAC/60 Hz
Burden
DC Analog
Inputs
(optional)
•
Voltage and Current: 0.1 VA max
•
Power Supply: 6 VA max
Analog Input Options Two DC analog inputs, or eight DC analog inputs
A/D Resolution 14 bits plus sign
Nominal DC Voltage
±1 VDC, ±5 VDC or ±10 VDC
Input Range Options
Nominal DC Current
±20 mA or 4-20 mA
Input Range Options
Accuracy ±0.2% of full scale @ 25oC
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Appendix B: iBox Kit Default
Configurations
When shipped as part of an iBox Kit, the iBox COM port default configurations are set to one of the
following:
iBox (IBOX-BSC1)
Configuration Details
DNP DPA
Modbus DPA
DNP DCA
WESMAINT
1
Comments
iBox DNP 3.0 Master Address: 10
iBox DNP 3.0 Slave Address: 1
Communication Port: COM1
Baud Rate: 9600
Communication Type: RS-232
Refer to point map tables for more detail.
Modbus Address: 1
Communication Port: COM2
Baud Rate: 9600
Communication Type: RS-232
Refer to point map tables for more detail.
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
you connect COM3 to COM1, you can see the
DNP DCA polling the DNP DPA.
User Name: westronic
Password: rd
Control Password: control
Name of the device within the ConfigPro/SGConfig sample project
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iBox Kit with AC Analogs (IBOX-ACA)
Configuration Details
Comments
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.
Refer to point map tables for more detail.
Modbus DPA
Modbus Address: 1
Communication Port: COM2
Baud Rate: 9600
Communication Type: RS-232
WESMAINT
User Name: westronic
Password: rd
Control Password: control
DNP DPA
Note: COM3 is used to connect the AC analog input module to the iBox.
IBOX Kit with DC Analogs (IBOX-DCA)
Configuration Details
Comments
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.
Refer to point map tables for more detail.
Modbus DPA
Modbus Address: 1
Communication Port: COM2
Baud Rate: 9600
Communication Type: RS-232
WESMAINT
User Name: westronic
Password: rd
Control Password: control
DNP DPA
Note: COM3 is used to connect the DC analog input module to the iBox
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IBOX Kit Ethernet (IBOX-LAN)
Configuration Details
Comments
Refer to point map tables for more detail.
DNP DPA
iBox DNP 3.0 Master Address: 10
iBox DNP 3.0 Slave Address: 1
Communication Port: COM1
Baud Rate: 9600
Communication Type: RS-232
Refer to point map tables for more detail.
DNP DPA
iBox DNP 3.0 Master Address: 10
iBox DNP 3.0 Slave Address: 1
Communication Port: Ethernet
Master IP Address: 192.168.1.200
Slave IP Address: 192.168.1.20
Subnet Mask: 255.255.255.0
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 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
Refer to point map tables for more detail.
DNP DPA
iBox DNP 3.0 Master Address: 10
iBox DNP 3.0 Slave Address: 1
Communication Port: COM1
Baud Rate: 9600
Communication Type: RS-232
Refer to point map tables for more detail.
DNP DPA
iBox DNP 3.0 Master Address: 10
iBox DNP 3.0 Slave Address: 1
Communication Port: Ethernet
Master IP Address: 192.168.1.200
Slave IP Address: 192.168.1.20
Subnet Mask: 255.255.255.0
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 AC Module to the iBox.
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IBOX Kit with DC Analogs and Ethernet (IBOX-DCL)
Configuration Details
Comments
Refer to point map tables for more detail.
DNP DPA
iBox DNP 3.0 Master Address: 10
iBox DNP 3.0 Slave Address: 1
Communication Port: COM1
Baud Rate: 9600
Communication Type: RS-232
Refer to point map tables for more detail.
DNP DPA
iBox DNP 3.0 Master Address: 10
iBox DNP 3.0 Slave Address: 1
Communication Port: Ethernet
Master IP Address: 192.168.1.200
Slave IP Address: 192.168.1.20
Subnet Mask: 255.255.255.0
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:
Input Value
Value Returned to Master
Maximum negative input
-32768
Zero input
0
Maximum positive input
32767
However, for the 4-20 mA input, the following values are returned by the iBox to the
master:
Input Value
GE Information
Value Returned to Master
Any input in the range of 0 to 4 mA
-32768
Half of Full Scale (12 mA)
0
Maximum input (20 mA)
32767
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Appendix C: Resetting the Digi One
Configuration
You can restore your Digi One configuration to the factory default configuration, as follows:
Procedure:
Resetting the
Digi One
Configuration
Step
Action
1
Turn off power to the Digi One.
2
With a pointed object, such as small screwdriver or 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:
RESET Switch
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 resets to default.
The user name resets to root and the password to dbps.
5
156
Reconfigure the unit by following the procedure outlined in
“Configuring the Ethernet Module” on page 112.
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Appendix D: Setting your PC IP Address
Procedure:
Setting an IP
Address in
Windows
2000
158
Step
Action
1
In the Windows 2000 Start menu, click Settings.
2
Click 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 Connection Status.
12
Close Network and Dial-up Connections.
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Appendix E: DPA Default Point Mapping
For point mapping of individual standard iBox kits, please look in the Source column of the table below. Point mapping
corresponding to Plant I/O applies to all types of standard iBox kits.
DCA
DPA
COM1
Source
Data
Type
MODBUS DCA
Register
Address
Point Description
DNP DPA
Point
COM2
MODBUS DPA
Point Address
DNP TCP/IP
DPA Point
N/A
iBox Digital Input #1
0
1
0
N/A
iBox Digital Input #2
1
2
1
N/A
iBox Digital Input #3
2
3
2
N/A
iBox Digital 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
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
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 Input #3 on DNP DCA
10
15
10
N/A
Digital Input #4 on DNP DCA
11
16
11
N/A
Digital Input #5 on DNP DCA
12
17
12
N/A
Digital Input #6 on DNP DCA
13
18
13
N/A
Digital Input #7 on DNP DCA
14
19
14
N/A
Digital Input #8 on DNP DCA
15
20
15
N/A
Digital Output #1 on DNP DCA
4
21
4
N/A
Digital Output #2 on DNP DCA
5
22
5
N/A
Digital Output #3 on DNP DCA
6
23
6
N/A
Digital Output #4 on DNP DCA
7
24
7
Plant I/O
DI
DNP DCA
(IBOX-BSC and IBOX-LAN)
DO
DI
DO
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DCA
DPA
COM1
MODBUS DCA
(IBOX-ACA and IBOX-ACL)
Calculator DTA
MODBUS DCA
(IBOX-DCA and IBOX-DCL)
Source
Data
Type
MODBUS DCA
Register
Address
Point Description
DNP DPA
Point
COM2
MODBUS DPA
Point Address
DNP TCP/IP
DPA Point
0
ADAM-4017 AI CH: 00
N/A
N/A
N/A
1
ADAM-4017 AI CH: 01
N/A
N/A
N/A
2
ADAM-4017 AI CH: 02
N/A
N/A
N/A
3
ADAM-4017 AI CH: 03
N/A
N/A
N/A
4
ADAM-4017 AI CH: 04
N/A
N/A
N/A
5
ADAM-4017 AI CH: 05
N/A
N/A
N/A
6
ADAM-4017 AI CH: 06
N/A
N/A
N/A
7
ADAM-4017 AI CH: 07
N/A
N/A
N/A
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
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
2
281
VOLT PHASE A-B INST
3
4
3
282
VOLT PHASE B-C INST
4
5
4
283
VOLT PHASE C-A INST
5
6
5
284
AMP PHASE A INST
6
7
6
285
AMP PHASE B INST
7
8
7
286
AMP PHASE C INST
8
9
8
287
AMP NEUTRAL INST
9
10
9
288
WATT INST
10
11
10
289
VAR INST
11
12
11
290
VA INST
12
13
12
291
PF INST
13
14
13
292
FREQ INST
14
15
14
293
WATT PHASE A INST
15
16
15
AI
AI
AI
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DCA
DPA
COM1
MODBUS DCA
(IBOX-ACA and IBOX-ACL) continued
Source
162
Data
Type
MODBUS DCA
Register
Address
Point Description
DNP DPA
Point
COM2
MODBUS DPA
Point Address
DNP TCP/IP
DPA Point
294
WATT PHASE B INST
16
17
16
295
WATT PHASE C INST
17
18
17
296
VAR PHASE A INST
18
19
18
297
VAR PHASE B INST
19
20
19
298
VAR PHASE C INST
20
21
20
299
VA PHASE A INST
21
22
21
300
VA PHASE B INST
22
23
22
301
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 NEUTRAL AVG
36
37
36
327
WATT AVG
37
38
37
328
VAR AVG
38
39
38
329
VA AVG
39
40
39
330
PF AVG
40
41
40
331
FREQ AVG
41
42
41
332
WATT PHASE A AVG
42
43
42
333
WATT PHASE B AVG
43
44
43
334
WATT PHASE C AVG
44
45
44
335
VAR PHASE A AVG
45
46
45
336
VAR PHASE B AVG
46
47
46
337
VAR PHASE C AVG
47
48
47
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DCA
DPA
COM1
MODBUS DCA
(IBOX-ACA and IBOX-ACL) continued
Source
Data
Type
MODBUS DCA
Register Address
Point Description
COM2
DNP DPA MODBUS DPA DNP TCP/IP
Point Point Address DPA Point
338
VA PHASE A AVG
48
49
48
339
VA PHASE B AVG
49
50
49
340
VA PHASE C AVG
50
51
50
341
PF PHASE A AVG
51
52
51
342
PF PHASE B AVG
52
53
52
343
PF PHASE C AVG
53
54
53
356
VOLT PHASE A-N MAX
54
55
54
357
VOLT PHASE 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
69
396
VOLT PHASE B-N MIN
70
71
70
397
VOLT PHASE C-N MIN
71
72
71
398
VOLT PHASE A-B MIN
72
73
72
399
VOLT PHASE B-C MIN
73
74
73
400
VOLT PHASE C-A MIN
74
75
74
401
AMP PHASE A MIN
75
76
75
402
AMP PHASE B MIN
76
77
76
403
AMP PHASE C MIN
77
78
77
404
AMP NEUTRAL MIN
78
79
78
405
WATT MIN
79
80
79
AI
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DCA
DPA
COM1
Data
Source
Type
MODBUS DCA
Register
Address
Point Description
DNP DPA
Point
COM2
MODBUS DPA
Point Address
DNP TCP/IP
DPA Point
406
VAR MIN
80
81
80
407
VA MIN
81
82
81
408
PF MIN
82
83
82
409
FREQ MIN
83
84
83
1282
RESET VOLT/AMP/POWER
84
85
84
1284
RESET MAX/MIN/WH
85
86
85
1282
RESET VOLT/AMP/POWER
0
89
0
1284
RESET MAX/MIN/WH
1
90
1
434
WATT HOUR BCD COUNTER 8
N/A
N/A
N/A
435
WATT HOUR BCD COUNTER 7
N/A
N/A
N/A
436
WATT HOUR BCD COUNTER 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
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
LogicLinx
MODBUS DCA
(IBOX-ACA and IBOX-ACL) continued
AI
AO
CT
CT
Notes:
•
ADAM-4017 AI CH: 00 to 07 are converted by the Calculator DTA into two's compliment numbers
which are stored in the system point database (Scaled Analog Input #1 to 8).
•
WATT HOUR BCD COUNTER 1 to 8 of the AC meter are ASCII BCD numbers. These numbers are
converted into KW HOUR (KWH counter 32bit) by LogicLinx to be passed to the DNP master. Then
"KWH counter 32bit" is converted into two 16-bit counters (KWH counter 16bit MSB and KWH
counter 16bit LSB) to be passed to the MODBUS master.
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Appendix F: Installing and Connecting
DNP3 I/O Modules
This Appendix describes how to install and connect DNP3 I/O modules, and connect to the iBox.
For more details on the DNP3 I/O module, refer to the 994-0085 Installation and Maintenance Guide.
Overall Procedure to Install and Connect DNP3 I/O Modules
To install and connect DNP3 I/O modules:
1. Configure the DNP3 DCA in the iBox so that it communicates with your DNP3 I/O module.
Refer to section: Configuring the iBox to work with a DNP3 I/O Module on page 46.
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 167.
3. Connect the DNP3 I/O module to site ground.
Refer to section: Connecting to Protective Ground on page 168.
4 Interconnect the DNP3 I/O modules and connect power:
– For low voltage DNP3 I/O, refer to section: Connecting DNP3 I/O Modules (Low Voltage) on
page 169.
– For high voltage DNP3 I/O where connection is made to an external power supply, refer to
section: Connecting DNP3 I/O modules (High Voltage) on page 170.
5 Turn power on to the module, and test it to make sure it is functioning properly.
It is recommended that you complete the above procedure before connecting and testing your field
wiring.
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Installing DNP3 I/O Modules in a Rack
Rack Spacing
When mounting multiple DNP3 I/O modules in a rack, or when mounting DNP3 I/O modules in a rack
with other equipment , verify that there is at least one rack unit (RU) of space above and below the
DNP03 I/O module to allow for cooling air flow and cable routing (1 RU = 1.75 inches or 44.5 mm).
Required Clearances
The exterior dimensions of the DNP3 I/O module are:
Dimension
Width
Measurement
19 inches (483 mm)
Height
Depth
5.25 inches (133.4 mm)
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 DNP3 I/O module with the LEDs visible from the front of the rack.
3. Slide the DNP3 I/O module over the top mounting screws and drop down into position.
4. Insert the bottom mounting screws.
5. Tighten all four mounting screws.
You are now ready to connect ground to the DNP I/O module. See “Connecting to protective ground” on
page 168.
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Connecting to Protective Ground
Connect your DNP3 I/O module to site ground, using a separate 2.05 mm (12 AWG) Yellow/ Green wire.
Each type of DNP I/O Module has a different ground point, as shown in the
examples below.
The location of the protective ground terminal varies between WESTERM I/O module types. Refer to
Module Layout drawing of your module for detailed information. For example, see below.
47
48
49
50
TB1
97
98
100
99
DC Analog Input Module
12 AWG
GND Wire
Site
Ground
63
64
65
66
TB1
129
130
132
131
Digital Input Module
12 AWG
GRN GND
Site
Ground
50
51
52
53
TB1
103
104
106
105
Control Output Module
12 AWG
GRN GND
Site
Ground
47
48
49
50
TB1
Combination Input
Output Module
97
98
99
100
12 AWG
Green Wire
Site
Ground
After site ground has been connected, you are now ready to connect power, and DNP3 link cabling to the
DNP3 I/O module. See section: Connecting DNP3 I/O Modules (Low Voltage) on page 169 or section:
Connecting DNP3 I/O modules (High Voltage) on page 170.
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Connecting DNP3 I/O Modules (Low Voltage)
For a Low Voltage (LV) DNP3 I/O module, connect the:
•
Interconnect cabling between each DNP3 I/O module, and
•
Power to the last DNP3 I/O module of the chain.
DNP3 I/O Module (LV) Interconnect Cabling
The DNP3 I/O module interconnect cabling is shown below:
Cable
To RTU
Master
To iBox
(RTU
Master)
GE Part
RTU Master
Number
Cable: iBox (RTU Master)
GE Part Number: 977-0502
IP-Server
977-0503
Standard Cables
DB9 male to
DB9 male
(GE part number
977-0089)
Pin Function
1
4
5
6
7
Other
J1
J1
J2
J2
First DNP I/O
Module
To
To Field
FieldEquipment
Equipment
Second DNP I/O
Module
J1
J1
J2
J2
GND
+DC1
-DC1
TX/RX2
TX/RX2
Not Used
To
To Field
FieldEquipment
Equipment
Daisy-chained
to other DNP I/O
Modules
J1
J1
J2
J2
Last DNP I/O
Module
Cable: GE Part Number
977-0500
To Field
Field Equipment
To
Equipment
To Power
Power Source
Source
To
After DNP3 I/O modules have been interconnected, you are now ready to connect power to the DNP3 I/O
modules. See the following subsection: DNP3 I/O module (LV) connection to the Power Source.
DNP3 I/O Module (LV) Connection to the Power Source
Connect the power supply to the last DNP3 I/O module in the chain.
The cable from J2 on the last DNP3 I/O module to the power source (GE part number 977-0500) provides
the connections shown in the following wiring diagram.
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DB9 Male
1
2
GE Digital Energy
Power Supply
Not Connected
3
+V
-V
4 + DC
5 - DC
6
7
8
Not Connected
9
Connecting DNP3 I/O modules (High Voltage)
For a High-Voltage (HV) DNP3 I/O Module, for example: WESTERM D20SZ (517-0249-ML):
1. Interconnect 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 Ext Power
Cable: iBox (RTU Master)
GE Part Number: 977-0502
External DNP 3
I/O Module
Power Supply
To Field Equipment
To Ext Power
To Field Equipment
To Ext Power
To Ext Power
To Field Equipment
Note: The location of the External (Ext) Power Supply terminal varies between WESTERM I/O module
types.
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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.
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Appendix G: Error Messages
When processing an output request, the Plant I/O Subsystem (P097) DCA may not be able to execute the
request. If this occurs, the Plant I/O Subsystem DCA will set the status code returned with the request to
the appropriate error code, and negatively acknowledge (NACK) the control request. This section
describes the possible status codes returned.
Control Requests Error Codes
Error Message
Description
Unsupported Point (0x0010)
Requested control point is not supported.
Unsupported Operation (0x0011)
Requested control operation is not supported for this point.
Output Not Available (0x0012)
The control output is not available for this point.
Queue Not Available (0x0013)
The control output queue is not available.
Invalid Request Parameters (0x0014)
The control output request parameters are not valid for this control point.
Too Much Lead Time (0x0015)
The control output request lead time is too much.
Not Enough Lag Time (0x0016)
The control output request lag time is not enough.
Window Too Small (0x0017)
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 Progress (0x0012)
Another online configuration change is in progress.
Online Configuration Invalid Type (0x0013)
Configured alarm settings do not match the alarm type.
Online Configuration Invalid Settings (0x0014)
Configured alarm settings are out of range.
Online Configuration Alarm Not Available (0x0015)
Specified alarm number is unavailable.
Online Configuration Invalid Alarm Number (0x0016)
Specified alarm number is out of range.
Online Configuration No Alarm Number (0x0017)
No alarm number has been submitted.
Online Configuration Cancelled (0x0018)
Configuration change is cancelled.
Online Configuration Time Out (0x0019)
Configuration change cancelled due to timeout.
Online Configuration Disabled (0x001A)
Online configuration services are disabled.
Online Configuration Change Disabled (0x001B)
Online configuration change service is disabled
Online Configuration Out of Events (0x001C)
Request rejected. Lacked WIN event buffers.
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
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MODIFICATION RECORD
Version
Revision
Date
Author
Change Description
4.00
1
March 23, 2005
C. Jeffrey
Document updated for iBox Kit.
2
August 18, 2005
M. Haska
Updated to reflect new calculator procedures
1
October 21, 2005
S. Tessari,
M. Haska
Updated for ConfigPro 6 and AC Analog Input Module
2
February 8, 2006
A. Poda
Added info regarding CE Mark, protective earth terminal, and
power supplies.
3
April 10, 2006
A. Poda
Updated info about power supply & protective enclosure.
4
October 5, 2006
Sravanthi TCS
Created Appendix G: Error Messages (Control and Analog
requests error codes). Added info regarding Trip/Close
operation in Digital Output Verification Test.
5.00
Refer to Clarify Case# 20060727-0259
5.10
October 11, 2006
Branka
Zivak
Clarify Case: 20060605-0257-1: Updated document to clarify
on DO wiring (Digital Output section in 2.5 Connecting and
Testing Field Wiring).
5
January 21, 2009
M. Haska
Minor updates throughout to reflect product enhancements.
6
March 25, 2009
M. Haska
Documented Ethernet module pass-through switch and
configuration file modifications.
0
February 10, 2010
M. Haska
Updated appendices B and E.
1
June 6, 2014
E. Stuhr
Corrected ground connections in the drawings of the Digital
Outputs section. Corrected the ground reference (chassis
ground) in the first Caution in the Terminal Connections
section.
Add section: Removing Configuration Data and Sensitive
Information from the iBox.
2
July 30, 2014
R. Rees
Added Appendix F: Installing and Connecting DNP3 I/O
Modules
3
Sep 11, 2014
R, Rees
Fixed links.
AUTHENTICATION RECORD
VERSION
REV.
DATE
AUTHOR
CHANGE DESCRIPTION
5.00
6
March 25, 2009
E. Stuhr
Configuring the Ethernet Module section.
5.10
0
February 10, 2010
E. Stuhr
Appendices B and E.
GE Information
994-0047-5.10-3
173
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