Installation and StartUp InsulGard System

®
InsulGard
InsulGard System Installation and Start Up Guideline
Version 1
August 2016
Table of Contents
INSTALLATION STAIRCASE ............................................................................................................................. 3
1. INSULGARD SYSTEM INSTALLATION........................................................................................................... 4
1.1. InsulGard installation and external connection. ................................................................................................ 4
1.2 Installation of the InsulGard Sensors .................................................................................................................10
1.3 Circuits integrity test ............................................................................................................................................13
1.4. InsulGard system installation for a motor ........................................................................................................14
1.5. InsulGard system installation for a switchgear line ........................................................................................18
2. START UP ............................................................................................................................................................19
2.1 Getting ready .........................................................................................................................................................19
2.2 Insulgard Software Installation and Communication Establishing .................................................................19
2.3 Verifying/Correcting Configuration ....................................................................................................................21
2.4 PD Channel Calibration/Verification ...................................................................................................................21
2.5 Baseline Measurement on Energized Object .....................................................................................................24
2.6 Phase Shift Measurement ....................................................................................................................................24
2.7 Load Current Channel Calibration ......................................................................................................................26
2.8 Base Line Measurements.....................................................................................................................................28
APPENDIX 1. PD SYSTEM INSTALLATION CHECKLIST ............................................................................29
APPENDIX 2. INSTALLATION / COMMISSIONING REPORT .....................................................................31
APPENDIX 3. PD SENSORS DESIGNATION IN DATABASE ........................................................................33
APPENDIX 4. DOOR CUTOUT DIMENSIONS FOR DOOR MOUNT INSULGARD ...................................35
2
Installation Staircase
Done!!!
Report on installation/
commissioning
Customer training
and database
synchronisation
Start Up and base line
measurements on
energized equipment
Sensors calibration/
verification
Software Installation,
communication test
Sensors and external

lines connection check
Actual installation
Identify and verify proper power

and communication lines to be
connected to the InsulGard
Identify place and way
of sensors and
InsulGard installation
Check contents against
the packing lists and the
equipment condition for
shipping damage. Verify
Begin that it is exactly the device
with designated for this project
Print and use “PD system installation checklist” from Appendix 1- Link for StartUp and
Commissioning as a guideline and a core of installation report.
3
1. InsulGard System Installation

Always refer to the user manuals included on the Flash drive with the Insulgard. Full set of user manuals are
available for download at www.eaton.com/pd
Installation of the InsulGard (IG) system is based on the physical layout of each monitored object and may include
variations. The typical installation for rotating machines and switchgears is described below.
InsulGards are generally not interchangeable devices. Sensors configurations can vary significantly from project
to project. The InsulGard typically comes preconfigured in based on the configuration worksheet received from the
customer at the time of order entry (see Appendix 3 – add link). Be sure that the Insulgard device is designated for
this particular project and to be connected to this particular set of sensors. Switching InsulGard devices can require
significant reprogramming of database software and InsulGard firmware settings and can lead to errors.
Each installation includes installation of InsulGard (Section 1.1 - Link), partial discharge (PD) and external auxiliary
(Aux) sensors (Section 1.2 - Link) and their connection to Insulgard monitor. Also some external interfaces can be
connected to the Insulgard to remotely get information about the monitor and monitored object condition.
This installation can be done only on de-energized equipment. ALWAYS use appropriate safety practice to
ensure safe work!
1.1. InsulGard installation and external connection.

Your InsulGard device has two parts: Monitor and Sensor Interface Board connected by a flat ribbon cable.
Cables from PD and Auxiliary sensors must be connected directly to the Sensor Interface Board.
1) InsulGard installation options:
a) On the panel in NEMA-4X enclosure with or without transparent windows for outdoor installation (Fig. 1-1a).
This enclosure can be installed before the equipment is de-energized.
b) On a panel (Figure 1-1b) for installation into any custom cabinet including explosion-proof enclosure.
c) Door mount InsulGard (Figure 1-2) with the Sensor Interface Board installed on the back of the InsulGard unit
itself. Usually, this type of assembly is used for indoor installation on a switchgear door. Door cutout
dimensions are in Appendix 4 - Link.
Sensor Interface Board
Outlet for
115VAC
wire for panel Terminals for

grounding power supply
Fuse
a b c
Figure 1-1. a, b – IG installed on the panel and in NEMA 4 enclosure with window; c- panel with removed IG
4
Sensor Interface
Board
a b c d
Figure 1-2. a, b – front and back view of Door mount InsulGard, c, d - front and back view of IG installed on
a switchgear cabinet door.
For a panel mount InsulGard, the Sensor Interface Board is installed on the panel under the Monitor. For sensor
connections, it is necessary to temporarily remove the Monitor from the panel. Put the unit aside until the sensors
are connected.
2) AC power requirements
The required AC voltage is specified on the InsulGard label. The InsulGard requires 1.0 Amp for power.
For a 115VAC application please provide 10 Amps since there is a 115 volt outlet in the enclosure.
3) Best location for InsulGard installation
Usually the best location to minimize cables and conduits length is in the middle of installed sensor. The maximum
distance allowed between the PD sensors and the InsulGard (coaxial cables length) is ~150 feet.
a) For a motor the best location of InsulGard enclosure installation is as close as possible to the motor
termination box and its RTD termination box.
b) For a switchgear line the best location of InsulGard (usually door mount) is in the middle of the line.
4) InsulGard grounding
Insulgard must be reliably grounded at place of its installation.
a) For InsulGard in enclosure bring reliable ground to external grounding bolt on the enclosure
bottom.
b) Door mount InsulGard has a green wire connected to the back side of its case. This wire must
be connected to ground (e.g. to grounded switchgear frame).
5) InsulGard inputs for sensors connection
a) 15 channels (Ch1-Ch15) for PD sensors connection
b) 1 channel (Ch16) for noise cancellation (rarely used)
c) Input for External Temperature sensor (for 100 Ohm Platinum RTD)
d) Input for External Humidity sensor
5
e) Input for Load Current sensor (used for rotating machines)
6) InsulGard outputs
a) Three C type Relays with dry contact indicating the Status of the monito r and Warning / Alarm
conditions of the monitored object
b) 4-20 ma signal that is proportional to PD activity
c) RS 485, USB and Ethernet ports for networking and remote communication
7) External connection in accordance with the wiring diagram
Make all external connections in accordance with the wiring diagram supplied with each
InsulGard.
A typical wiring diagram is shown in Figure 1-3 below. All sensors must be connected to the Sensor
Interface Board. Power and all interfaces should be connected to the corresponding InsulGard
connectors on the right side of the unit, utilizing the installed green plugs.
InsulGard Panel Wiring Diagram Connection to:

Signal
Ch1 + 4-20 mA interface
4-20
Alarm 2 RS - 485 mA
Connector for Flat Cable from
-
Shield
Host
USB
Ch 2
G B A +5
Flat Cable to
Ch 3 RS485 interface
InsulGard
Ch 4
Coax cables from PD Sensors
Alarm relay
Alarm
Ch 5
Device
Ch 6
USB
Ch 7
Alarm 1
Warning
Ch 8
Warning relay
Ethernet
Auxiliary sensor Ch 9
Left Right
connection: Ch 10 side side
Status
white 1
Ch 11
black 2 Status relay
3
RTD
red 4
Ch 12
black 5 S
Ch 13
InsulGard's
6 CT
white 7 S1 connectors DIN-Rail Terminals
Ch 14
red
Power
8 S2 Ref
GNL
9
Ch 15 white
white 10 green N
red 11 +5 H% L
Ch 16
12 S (Noise) Screw on
black
H% Sw Ref back cover 1 2 3
Gnd
Gnd
Fuse
Humidity sensor
Ground Screw green
CT - Load sensor
Green
on the panel
Neutral
Ground
Temperature sensor Outlet

Phase
Ground screw on enclosure

must be connected to local
ground Power 115VAC
There is no outlet for 230VAC application.

Fuse inside InsulGard for 115VAC application:Time-Lag 200mA, 250VAC, 5X20mm type 5ST by BEL Fuse Inc.,
Catalog # 5ST 200.
Fuse inside InsulGard for 230VAC application:Time-Lag 100mA, 250VAC, 5X20mm type 5ST by BEL Fuse Inc.,
Catalog # 5ST 100.
Fuse on the panel: Fast Acting 3.0A, 250VAC, 5x20mm type 5MF by Bel Fuse Inc. Catalog # 5MF 3-R (or equivalent).
Figure 1-3. Typical wiring diagram for panel mount InsulGard

6
A door mount InsulGard has the same wiring diagram as a panel mount, but without Din-Rail terminals. The power
supply voltage is connected straight to the power input of the unit. Door mount InsulGard installed on switchgear
compartment door usually has internal temperature and humidity sensors and doesn’t need external sensors.
8) Panel mount InsulGard removing from its panel for sensor connection
For sensors connection to the Sensor Interface Board on a panel mount InsulGard, the unit must first be removed
from the panel.
To do this:
a) Gently disconnect the flat ribbon cable from the Sensor Interface Board on the left side of the monitor. Use
latching levers on both sides of the connector (see picture below) in small steps to lift the connector and
then pull the connector out of the socket (Figure 1-4).
Figure 1-4
b) Pull out wired green connectors from the right side of the monitor
c) Disconnect the monitor case grounding wire from ground terminal on Din-Rail
d) Unscrew 4 screws on front panel of the monitor and take it off
e) After sensor connection, install Insulgard back on the panel in reverse order
9) External auxiliary sensors (Temperature, Humidity and Load sensors) connection.
Sensors should be connected to the 12 contact terminal on the left side of the Sensor Interface Board as shown in
Figure 1-5 and table below.
Figure 1-5. Auxiliary sensors connection to the Sensor Interface Board
7
Auxiliary sensor connection table:
Contact Sensor Sensors wire Note

# connected
1 Temperature RTD common wire (white wire) Board common
sensor
2 RTD signal wire (black wire) Output dc current ≈ 2mA
100 Ohm
3 Platinum RTD signal wire (red wire) Output dc current ≈ 2mA
4 RTD Cable shield (optional) Board common
5 Load (CT) Signal wire (red wire) Input impedance 100 Ohm,
6 sensor Common wire (black wire) Max input
Board signal ≈ 5mA
common
7 External Usually not used Input impedance > 27kOhm. Input voltage should
Reference not exceed 1VAC
8 n/a test point
9 n/a Board common
10 Humidity Sensor common (white wire) Board common
11 sensor + 5VDC for the sensor (red wire) Output current is limited by 100 Ohm resistor.
12 Output signal (black wire) Input impedance > 27kOhm. Input voltage should
not exceed +5V.
10) PD sensor connection
Coaxial cables from PD sensors should be connected to Ch1-Ch15 inputs (Figure 1-6) on the right side of the
Sensor Interface Board. Ch16 is designated only for noise signal and usually isn’t used.
Please pay special attention to their connection. InsulGard comes preconfigured for certain sequence of the PD
sensor connection to channels 1-15. PD sensors must be connected accordingly. For motor/generator application
connect IPDS sensors on phases A, B and C starting with channel 1 and then connect RTD PD sensors. For
switchgear application, this sequence is shown in the configuration worksheet that the customer provided to Eaton at
the time of order entry. Settings can also be verified in InsulGard software: → section "Unit Settings" → "Settings for
Channel".NOTE: It is important that the coupling capacitor installed on phase A is connected to Channel #1
to obtain phase reference for the InsulGard hardware and firmware. Check that the sensors connected to the
interface board are in sequence: coupling capacitors to the first three channels, then the rest of the sensors.
If necessary, reconnect sensors and make corresponding changes in software/firmware sensor
configuration settings (see Appendix 3 - Link).
Coaxial cable central wire should be connected to an upper terminal and coax cable shield to a corresponding lower
st
terminal labeled ┴ on 1 channel. Use supplied blade crimp terminals on cable shield to avoid “hairs” and a possible
short circuit to the central wire (Figure 1-7). Distribute cables evenly and secure them in place.
Verify that the connection of coaxial cables to the Sensor Interface Board is proper, i.e. no shorts, connections are
tight.
H% / Ref switch must be in the H% position during normal operation (Figure 1-6).
8
H% / Ref switch
Figure 1-6. Sensor cable connection to the Sensor Interface Board installed on the panel and connections to the
relays and interfaces outputs.
Coaxial cable from PD sensors preparation and connection to channel:
Figure 1-7. Coaxial cable preparation and connection to channel
11) AC power connection and connection to relays, to RS485 and 4-20mA interfaces
Use green plugs on the right side of the InsulGard (Figure 1-6 and 1-8). The green plugs can be wired when the
InsulGard is not installed on its panel yet.
Relays "Warning" (Alarm 1) and relay "Alarm" (Alarm 2) close NO contacts if partial discharge level exceeds
predefined thresholds. Relay "Status" has NO contacts closed if InsulGard has AC power and works properly. If
InsulGard lost AC power or works not properly (has Error) its contacts position is shown on the label.
9
RS485 network (if used) should be connected to inputs A (+) and B (-). Don't use terminals G (insulated ground) and
+5 (insulated +5V).
USB port "Device" is used for communication with PC. Port "Host" is not used now.
Figure 1-8 Wires connection to green plugs for power voltage, relays and RS485 interface port.
1.2 Installation of the InsulGard Sensors

Monitored object and InsulGard must be de-energized. The best way to de-energize InsulGard is to de-energize
the incoming power supply line. On a panel mount InsulGard open the fuse located on the DIN-Rail.
All sensors have default cable length of 65’ (20m). Custom lengths may be specified at the time of order entry.
Install all sensors in accordance with their manuals in “InsulGard Sensors Manual”.
1) PD sensors and features of their installation
IPDS RTD-6-PD RFCT
Figure 1-9 PD sensors
10
IPDS - Integrated Partial Discharge Sensors
IPDS sensors are 80pF coupling capacitors (CC) with voltage ratings from 5kV to 38kV and special protection PCB
board built in. For sensor installation:
a) Sensor must be reliably grounded.
b) Correctly connect the coaxial cable to the sensor (Figure 1-10a). Don’t swap connection of the shield and
central wire.
c) Supplied HV jumper cable should be kept as short as possible to keep low the circuit impedance
d) Provide right distances between sensors and their jumper cables connected to different HV phases and also
to grounded surfaces. Rule of thumb: the distance should be the same as IPDS height for given voltage
class. Check clearance between signal cable and HV conductors.
e) For rotating machines, be sure to install sensors on the HV phase leads and not on the neutral side of the
winding.
RFCT Sensor - Radio Frequency Current Transformer
RFCT Sensors can be installed on the shield grounding lead of each AC power phase or one sensor on all three
phase shield grounding leads. Install it in proper direction of the arrow on the sensor’s label to Ground. Be sure that
the wires grounding feeder shields don’t touch grounding surface before they go through the sensor (Figure 1-10b).
From feeders'
shields
Central
These wires must not
conductor
touch ground surface
Coax Cable to
a connection
box
This
Direction to Additional short
Ground ground if original
ground is 2' or longer
Shield
To a closest
frame ground
To the Ground
point
Bus
a. Coax cable connection to IPDS sensor b. RFCT sensor installation on 3 phase ground shield
wires
Figure 1-10
RTD-6 - PD sensor (for rotating machines only)
The RTD-6 sensor uses RTDs (Resistive Temperature Detectors) installed in a rotating machine stator and work as
a local RF antenna for PD pulses. This sensor connects up to 6 RTDs to capture PD signals, which originated in a
stator winding. This sensor is designed for replacing an existing RTD terminal board and does not affect temperature
measurements.
a) Verify that the existing RTD termination box at the Motor frame is large enough to install the RTD module.
Most RTD termination boxes are large enough to accommodate the RTD Module. Mounting dimensions of
the board are:
L*W*H = 7.15” * 2.05” * 0.8”;
mounting holes have diameter 0.25” for #10 screw at 6.65” distance on the board axis;
mounting tabs thickness is 0.25”.
11
b) The RTD-6 module goes in series with the existing motor RTD wiring. Verify that wires from the motor RTDs
are connected to ”RTD In” side of the RTD-6 PD sensor. Verify that the coaxial cable central wire and shield
are connected to PD “+” and “-“ contacts accordingly. Verify that board is reliable grounded..
c) If the existing RTD termination box is not large enough, an auxiliary box will need to be installed next to it to
house the RTD Module and wired in appropriately.
d) Up to six coax cables (12 if 2 modules are used) are required for connection to the Sensor Interface Board.
After connecting RTD wires from stator to RTD PD module (to RTD In side), verify RTD connection and
integrity from RTD Out side of the module (right side). Write results down in the Table 5 in Appendix 2 -
Link.
e) After reconnecting RTD wires to temperature metering, verify proper reading on customer’s metering
system.
2) Auxiliary sensors
a) TS – External Temperature sensor - 3-wire 100 Ohm platinum RTD in protecting shell. For rotating machines
using spare 100 Ohm platinum RTD in stator winding is preferable
b) HS – External Humidity sensor
c) CT - Load (CT) sensor. 5 Amps primary current, ratio 1000:1. Mostly used for rotating machines. CT Sensor
should be installed over secondary wire of an existing metering current transformer.
d) CTF - Split-core Primary Current Transformer (Flex Core) with CT sensor preinstalled on shortening jumper
of Primary CT secondary winding. CTF is used if there is no metering CT in feeder termination compartment
and corresponding metering CT is too far from the InsulGard. Install CTF around a feeder cable of any phase
in a motor feeder termination enclosure. It must be installed over the shielded part of the feeder cable
with cable shield grounding wire coming through the CT. In case of several feeders per phase, install it
only around one of the feeders.
CT sensor CTF sensor

TS and HS sensors
Figure 1-11
12
1.3 Circuits integrity test
1) Check InsulGard Power Supply Voltage
a) The voltage between Line and Neutral contacts of the Insulgard power input must be 115 or 230 VAC +/-
10% in accordance with voltage on InsulGard label.
b) The voltage between Neutral and Ground contacts of the Insulgard power input must be near zero.
c) Verify that wire to the closest Ground has good contact with Ground. The voltage between this Ground and
InsulGard power input ground contact must be near zero.
If insulating transformer is used for power supply to InsulGard check ground connections and voltage between
Line and Neutral only. Using of autotransformer is not recommended, if used, be cautious – neutral should have
ground voltage. Don’t use UPS power.
d) Fill out Table 1 in Appendix 2 with test results (Link).
2) Check external auxiliary sensors connection
a) Units mounted on a panel and inside enclosures will generally have external temperature and humidity
sensors. Check that external sensors are properly wired to the Sensor Interface Board.
b) Measure resistance between temperature sensor inputs. Resistance between contacts 1 and 2 on the
sensor interface board should be ~2 Ohm or less depending on wires length. Resistance between contacts
1 and 3 should be ~100-130 Ohm for platinum RTD.
c) Measure the resistance of connected Load sensor (CT). Resistance between contacts 5&6 on sensor
interface board should be ~30-40 Ohm with sensor connected or ~100 Ohm without.
d) Fill out Table 2 in Appendix 2 with test results - Link .
3) Check PD sensors connection
Measure resistance of each PD sensor across channel terminals on the Sensor Interface Board and fill out
Tables 3, 4 and 5 in Appendix 2 - Link
For IPDS this resistance should be close to 3kOhm.

For RFCT and RTD-6 sensors this resistance should be ~2 ohms or less. Basically it is the resistance of the coax
cable and depends on its length.
13
1.4. InsulGard system installation for a motor
1) Typical Insulgard system for a motor
A typical InsulGard for a motor is usually installed on a panel and in a Nema-4X enclosure. Examples of installation
shown below:
a b
Note: If a conduit is installed on top of the enclosure (b), be sure to use appropriate seals to prevent water from
entering.
For InsulGard installation and sensor connection refer to section 1.1 above - Link. For sensor connection, you must
temporarily remove the InsulGard monitor from the panel and put aside until the sensors are connected.
Typical sensor installation and to InsulGard connection for a motor is shown in Figure 1-12. The sensors are:
a) Three IPDS sensor installed in the motor terminal box
b) One RTD-6 PD Sensor Board installed in motor RTD terminal box. For large motors and generators with
many RTDs, a second board is needed for better monitor stator winding condition
c) External Temperature and Humidity sensors installed in the Motor terminal box
d) Load sensor installed on the wire of secondary winding of motor metering CT. If there is no close motor
metering CT, the CTF sensor can be installed on phase A motor feeder. (If feeder has few cables, install
CTF only on one of them.)
e) Sometimes RFCT sensors can be additionally installed on wires that provide grounding of cable shields for
all three phases cables
For sensor installation refer to section 1.2 and 1.3 above ( Link ) and some additional specifics described
below.
14
Motor terminal box
Motor
Load (CT) sensor 2-wires cable
Motor
to InsulGard.
meetering
CT A phase
3 phases feeder
B phase
C phase
IPDS IPDS IPDS
3 coax. cables
to InsulGard
Channels 1- 3
Temperature sensor Two 3-wires

Humidity sensor cables to
InsulGard
RTD terminal box Up to 6 coax.

Existing wires cables to
Sensor Board
from RTDs in InsulGard
RTD-6 PD
stator winding Channels 4- 9
Existing wires to
temperature
measuring device
3-wires cable from spare

stator winding RTD to
InsulGard (if used instead
of Temperature sensor)
Terminate the coax cables from the PD sensors as follows:
Channel # Sensor Sensor designation

in data base
1 IPDS - Phase A CC_A
2 IPDS - Phase B CC_B
3 IPDS - Phase C CC_C
4 RTD 01 (PD 1 output of RTD-6 sensor) RTm01
10 RTD 07 (PD 1 output of the second RTD-6 sensor if available) RTm07
Figure 1-12. Typical sensor installation and connection for a motor
15
2) Diagram of the main required connections to Insulgard
Motor terminal box RTD terminal box

InsulGard Enclosure
NEMA 4 3 coax cables from coupling 1 coax cable per RTD
capacitors from RTD PD sensor(s)
1 - 3 wire shielded cable 1 - 3 wire shielded cable
Note: AWG22 for Humidity sensor AWG22 for winding RTD
Mount close to a motor main (comes with the sensor) (if provided)
terminal box and RTD 1 - 2 wire shielded cable
termination box to minimize 1 1/2"
1" conduit AWG22 for Load sensor
cable and conduits length conduit (comes with the sensor)
fitting
fitting 1 - 3 wire shielded cable
AWG22 for the Temperature
sensor (if provided, comes
with the sensor)
120 (230) VAC

10 amp
Power Source
1 - 2 conductor, twisted pair 22 AWG for RS485 Network

and/or 1- 2 conductor phone wire for modem remote
communications, if required.
1 - 2 conductor shielded wire for 4 - 20 ma output, if required
1 - 6 conductor cable suitable monitoring of dry contacts for

system status, low alarm and high alarm (minimum 2
conductors if contacts are connected in series or in parallel)
Figure 1-13 Main connection to InsulGard
3) IPDS sensors installation specifics
a) Be sure to install the capacitors on the HV Phase leads and not on the neutral side of the winding.
b) If a motor has surge capacitors, install the HV connection on the motor winding side of the surge capacitors.
See diagrams below.
Right
Motor
Winding
Surge Coupling
Incoming
Cap
Power
Cap
Wrong Wrong
Motor Motor
Coupling Winding Surge Winding
Surge
Cap
Incoming
Cap Cap Coupling

Incoming
Power
Power
Cap
16
c) IPDS installed on phase A should be connected to channel 1 (Ch. 1).
d) If RFCT sensors are used instead of IPDS sensors, look for the corresponding manuals.
4) RTD-6 PD sensor installation in a motor RTDs box
a) Verify that the existing winding RTD termination box at the Motor frame is large enough to install the RTD
module. Most RTD termination boxes are large enough to accommodate the RTD-6 Module.
b) The RTD-6 module goes in series with the existing RTD wiring.
c) Many times the existing RTD terminal board can be removed and the RTD-6 module inserted in its place.
d) If the existing RTD termination box is not large enough, an auxiliary box will need to be installed next to it, to
house the RTD Module and wired in appropriately.
e) Run six coax cables to the InsulGard (12 if 2 modules are supplied for 12 RTDs) and connect to the Sensor
Interface board.
f) Run one 3 conductor 22 AWG shielded cable from a spare or provided winding RTD for temperature
measurement instead of a temperature sensor.
5) Auxiliary sensors installation in the motor termination box
a) Install external Humidity sensors
b) Install external air Temperature sensor if supplied and no winding temperature RTD (platinum 100 Ohm) is
available. Generally, temperature metering should represent winding temperature as close as possible.
Using one of the winding RTDs is preferable. Other options are RTD in hot air, then external Temperature
sensor somewhere inside motor volume and feeder termination box next to the Humidity sensor.
c) The Load Current sensor goes around the secondary connection of the motor primary current transformer.
This option is possible only when the metering CTs are installed over the motor leads in the feeder
connection box. Differential CTs are not applicable for the load current monitoring.
d) If there are no metering CTs, use auxiliary FlexCore CT installed over the shielded part of the incoming
feeder.
NOTE: Make sure wires are not near any high voltage source. Do not use "sticky pad" type of tie
downs!!
Check all sensor connections (refer to section 1.3 - Link )

After all sensors are connected, install IG back on its panel (refer section 1.1 - Link), connect power and make all
other required connection to IG outputs (to relays and interfaces)
17
1.5. InsulGard system installation for a switchgear line

A Door mount InsulGard and two types of PD sensors (IPDS and RFCT) are typically used on switchgear lines.
Door mount InsulGard is usually installed on a switchgear compartment door. See door cut out dimension for IG
installation in Appendix 4. - Link. To minimize cables and conduits length, the best location for InsulGard installation
is in the middle of the installed sensors. Insulgard must be reliably grounded at place of its installation.
By default the temperature and humidity sensors are embedded in the Sensor Interface Board of the door mounted
InsulGard. External sensors are not required with this type of installation.
For PD sensors installation and their connection to InsulGard refer to sections 1.1 – 1.3.
Usually IPDS sensors capture PD pulses that originate in the cubicle where they are installed and the adjacent
cubicle. Because of this, IPDS sensors can be installed in every third cubicle. In practice, sensor location varies
depending on the installation.
The sensor location is typically specified in the configuration worksheet at the time of order entry.
More detail on what it represents and how to fill it in can be found in Appendix 3 - Link.
If for some reason the position of the sensors was changed it is necessary to change the corresponding
sensor designation in the device database.
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2. Start Up
2.1 Getting ready
The purpose of this manual is to provide guidelines for Start Up of an InsulGard system.
The procedures described below assume that InsulGard and all necessary sensors are installed, wired and
properly connected. Some of the operations below are to be performed on de-energized equipment and
other after equipment is back in service! ALWAYS use appropriate safety practice to ensure safe work!
StartUp Procedure Guideline does not replace InsulGard and its sensors Manuals. The procedures described below
Required Items
The following items and set of documentation shipped with InsulGard are required for the functionality tests and start
up:
- Set of documentation shipped with the InsulGard(s) and sensors:

- InsulGard Manual
- InsulGard Software Manual
- Sensors manuals
- IG Wiring Diagram
- “PD sensors configuration table” filled out in Questionnaire for Switchgear line.
- Laptop computer with Windows operation system and preinstalled InsulGard software with database file for this
particular installation.
- USB cable - A to B type.
- Multi-meter to measure resistance from 0.5 Ohm to 10 kOhm and AC/DC voltage up to 250V.
- Special PD calibration generator or other pulse generator with pulse width 50-500ns, repetition rate 1-10 kHz and
magnitude ~10V on 50 Ohm load. Calibration/verification procedure considered optional but highly recommended.
- Print and use “PD system installation checklist” from Appendix 1 as a guideline for StartUp and Commissioning
procedures and a core of the installation report.
Check that all InsulGard connections are done properly and Turn ON IG Power
The InsulGard will boot up, will display Firmware version and start showing parameters on display. Scroll display
parameters using any arrow on InsulGard keypad.
Check for Temperature and Humidity readings. They should reasonably reflect conditions at the sensors installation
location. To measure humidity the switch H% /Ref Switch (Figure 1.6) must be in H% position.
2.2 Insulgard Software Installation and Communication Establishing

InsulGard Software Installation
Refer to the InsulGard Software Manual for software installation and database operation. InsulGard monitor(s)
comes with installation Flash drive with every order. The database is preconfigured for each particular application
and reflects the monitored object structure and sensors’ configuration. If software is already installed on the PC one
need uninstalling the existing software through “Control panel/Add or Remove Programs”. Uninstalling will not
remove any preexisting data.
Use software manuals for additional information. Installation procedure will update the software version and will
update database object structure for the project. At the first run InsulGard software will ask for Template.mdb file
located on the installation CD and will add new objects into the existing database.
19
Important:
 If you already had same customer in preexisting database, software will merge new location(s) and
object(s) from Template.mdb on CD to existing InsulGard.mdb database.
 If your database does not have that customer the software will not update your database and new objects
will not be added.
 In last case we would recommend removing or renaming the file “Insulgard.mdb” in “Program
Files/Insulgard/Data/” before installation. Then InsulGard software will copy Template.mdb file from
installation CD to “Program Files/Insulgard/Data/Insulgard.mdb”. In Vista and Windows 7 data file can be
found in C:\IG_DATA folder.
 For those who handle multiple customers or multiple locations, it is highly recommended to keep
separate databases for each customer and each location of given customer under different names.
Otherwise data base containing multiple objects and multiple locations will grow in size very fast and will
slow down even a powerful computer. Consult to the Software manual for database issues.
Establishing Communication with InsulGard from laptop
Certain familiarity with InsulGard software is required to accomplish the procedures described below. Please refer to
the manuals for InsulGard and InsulGard software.
1. Connect PC and InsulGard with the USB cable. Ethernet communication option is out of the scope of this
procedure. USB connection has been chosen as the simplest and most reliable local communication. You may
have to install communication software first. Refer to the corresponding paragraph of InsulGard User Manual.
2. Start InsulGard software and select appropriate object (you may have more then one InsulGard at the site).
3. In “Unit Settings” tab check InsulGard ModBus address and communication speed. Typically, each device is pre-
configured to the best our knowledge based on the order and additional information received. InsulGard address
is already configured in the device and in database and Baud rate set to default 38400 baud. Otherwise settings
should be changed to be the same in software and hardware.
4. Device setting may be modified by third party if it was an indirect shipment. Or devices assigned for different
projects or for different locations for the same project could be switched. Verify that the proper Insulgard device
has been installed. Commonly there is a sticker on an InsulGard face plate with name of the object and device
address.
5. In “Configuration” Tab check appropriate InsulGard ModBus address and correct communication speed.
6. In “Communications” Tab set correct COMM port for your PC.
You may find your Gadget Serial port number in Control Panel/System/Device Manager/Ports. Port number
represents virtual serial port number assigned during installation of the communication software.
7. Verify communication by clicking ”Get Device Time” or “Get Number of Records” in Communications Tab. Will
also see sign” * ” on InsulGard display, meaning that the device is communicating. Correct date/time if
necessary.
20
2.3 Verifying/Correcting Configuration
Verify that the proper InsulGard device has been installed by sticker on the InsulGard face and comparing serial
numbers in software and on the monitor label.
1. Go to “Unit settings” tab and save the existing settings by clicking “BackUp Settings”. One can always retrieve
those settings if faced a problem.
2. Press the “Get Settings from Device” button located on the Communications Tab. If downloaded settings do not
coincide with database settings it is an evidence of possible modification by third party or switched InsulGard
devices.
3. If you have different settings in the device, database software will display warning message and list parameters
that are different. Write down the differences – it will help to change settings wisely afterwards. Scroll through to
the end of the list – some lines may be out of the window. Click “Update Database with Device Settings” if you
are sure that working with proper object and device and changes must be made.
4. Verify channels activation and sensors’ IDs in software Unit Settings. If the existing database configuration does
not match actual sensors’ configuration in the monitored object, change software configuration to reflect the
actual sensors’ configuration (see Appendix).
5. After correcting settings in software press “Backup Settings” in Unit Settings tab.
6. Send correct settings by pressing “Send Settings to Device” button in Communications Tab.
Set Correct Date and Time
The time and date on the InsulGard was set in Minneapolis, Minnesota. Local time and date must be entered. Also if
a device has spent too much time on a shelf, backup clock battery can be discharged and date/time corrupted:
1. Go to the Communications Tab.
2. If the time and date on your computer is the same as the local time and date, press "Apply PC Time" button.
3. Can make any changes to the time and date in the “Device Time” field to reflect local time.
4. Click "Set Device Time" button.
Erase device memory
Erase all data that might be stored in the InsulGard memory by clicking “Erase Device Memory” in
“Communications” tab.
2.4 PD Channel Calibration/Verification
(Optional but highly recommended.)
Perform calibration/verification by injecting Pulse Signal to the sensors from a calibrating generator and recording
data with InsulGard monitor. It is the only 100% reliable way to verify proper sensors connections and functioning
throughout the whole InsulGard/Sensors system. Errors like wrong sensor cable labeling, switched central wire and
shield of coax cables can’t be verified with ohmmeter. Have PD calibrator or pulse generator with pulse width 100-
500 ns, repetition rate ~1-10 kHz and magnitude ~10 V (@50 Ohm load).
21
Prepare Settings for calibration/verification
1. Copy database file from “Program Files/InsulGard/Data/Insulgard.mdb with new name CalibrationXX.mdb into
the same directory.
2. Start InsulGard software, go to File/Open menu, navigate to CalibrationXX.mdb file and Open it.
3. Chose the object to be calibrated and click on “Update This Equipment”
4. Go to Unit Settings tab and BackUp Settings.
5. Change “Power Frequency Cycles per Acq.” to 5, uncheck “Noise Filter box” and change Data Storage Mode to
“Test Mode” by clicking on “Normal Mode/Test Mode” toggle button.
6. Send setting to the device.
Calibration/Verification procedure
Use GKI-2 pulse generator by Eaton to inject pulse in common mode between the HV conductor and ground using
cable with alligator clips. If different pulse generator used, set the generator pulse parameters: Pulse Magnitude ~10
Volt, Pulse Width – 100 nanoseconds, Pulse repetition rate ~ 1-10 kHz. Magnitude and pulse repetition parameters
are not critical. Pulse width should not exceed 500 ns.
Preparation
1. Connect the output of the pulse generator between either end of the jumper cable of an IPDS sensor and ground
(Figure 2-1). Make sure the ground connection is as short as possible. It is suitable to connect directly to the
closest point on the frame as in the picture below:
2. In case of RFCT sensor, signal should be injected to the feeder terminal(s). Use only phase B if one RFCT
sensor per all three phases installed. If one RFCT per each phase used, test every phase in order. If feeders are
not terminated and RFCT sensors not installed over cables shield grounds, one can test connections and sensor
functioning by shortening the generator leads through RFCT opening.
3. With RTD sensors signal can be injected to one of “RTD In” contacts (except #4) were RTD wires from a stator
are terminated.
22
RFCT
GKI-2 test generator connected to IPDS HV contact Connect test generator to phase B feeder
terminal
Figure 2-1
Calibration Verification steps
1. Switch the generator ON and run “Single Measurement” from Communications tab of the InsulGard software. A
measurement time is proportional to the number of active channels and will take approximately 1.5 minutes for
maximum 15 active channels.
2. Download data from InsulGard by pressing “Read the Latest Device Records” button. Observe phase-resolved
data from this measurement from the “Graphs and Report” Tab. An example of expected data is shown in the
Figure below.
~2V output signal on

IPDS on phase C
23
3. Click on Copy button and Paste the picture into a word document for the records.
4. Write down in PD sensors configuration table (see Appendix 3) approximate magnitude measured in the channel
connected to the sensor under the test. You can expect to see higher magnitudes for the sensor where the
signal injected and lower magnitudes for the rest of channels reflecting pulse cross-coupling and attenuation.
Typical magnitudes for IPDS sensor is ~ 1-2V, for RFCT with pulse injection to feeder termination is ~0.5-1 V.
Those magnitudes can differ significantly depending on size and number of feeders connected to the
termination.
This measurement process should be repeated by injecting signals to every sensor. Response for similar
sensors and similar geometry should be similar.
5. Switch Off and remove the calibrating generator.
6. Click “Recall BackUp” in Unit Settings Tab and send settings to the device to restore the proper settings.
7. We recommend saving calibration data (Calibration XX.mdb) for your records.
8. Erase all data stored in the InsulGard by clicking “Erase Device Memory” in “Communications” tab.
2.5 Baseline Measurement on Energized Object
At this point all signal cables are connected and the InsulGard is powered up, the equipment energized and running
and the software is installed on the PC. Data base configuration is verified and corresponds to the application.
Note: If Calibration/Verification procedure (see above) hasn’t been performed and the equipment already energized,
it is possible to verify what PD sensors are connected to the Sensor Interface Board:
- Check that PD sensor coax cables is not shorted at its termination on the Sensor Interface Board (see Figure 3
above)
- Measure AC voltage across coax cable terminations. The output voltage for IPDS sensor should be ~0.7VAC for
13.8 kV systems (for different system change that value proportionally).
- Then measure output resistance of the cables which have AC voltage near zero.
For RFCT sensor this resistance should be ~ 2 Ohms or less. Basically it is the resistance of the coax cable and
depends on its length. For the shorted coax cable this resistance can be as for RFCT sensor.
For IPDS sensor this resistance should be close to 3kOhm and there is no AC output voltage because shield
and central wire of coaxial cable were swapped at connection to the sensor.
For broken coax cable this resistance should be indefinite.
2.6 Phase Shift Measurement
In order to provide a phase-resolved data, InsulGard uses phase synchronization signal. InsulGard monitor
has the internal connection from power supply AC voltage to the synchronization circuitry. “Synchronous” option
(default) works on monitored objects powered from a regular power system (60/50Hz) in the area. Phase shift
between InsulGard AC power and HV phase in the monitored object should be determined to get proper phase
resolved PD patterns and increase diagnostic capabilities.
If this phase shift is known or determined by any other means (oscilloscope or any phase-meter) it can be
manually entered in the monitor settings from key pad or through the software.
24
InsulGard allows automated detection of phase shift between control power supplied to the device and
phase reference signal coming from phase A coupling capacitor connected to channel #1. If there is no coupling
capacitors a reference signal can be taken from a corresponding Potential Transformer or from any source with
known phase shift to HV system voltage – see Appendix 7 of InsulGard User Manuals. Reference signal must not
exceed 5VAC RMS – use appropriate divider to bring reference signal into preferable range of 0.1-1 VAC. This
operation should be performed one time considering that InsulGard power and system voltage connections have not
been changed during monitoring.
In asynchronous mode InsulGard power is not synchronous with the HV system power and continuous
synchronization signal must be used. It also can be taken from channel#1 coupling capacitor or from any other
synchronous voltage source mentioned above. Some changes must be done to the Sensor Interface Board for
asynchronous application. No phase shit measurements needed for that application. For typical applications 50Hz +-
10Hz enter 275 degrees shift.
Automated phase shift measurement can be done only from the InsulGard keypad:
1. Press Set key to enter the setup mode. The password prompt should appear on the display as shown:
Enter Setup
Password: - - - 0
Enter the password 5421 by using “←” and “→” to move to different digits and “↑” and “↓” to change the values.
Then press “Enter” key. Wait about 20 seconds for the display to change from dashed lines to “Set date” before
pressing any other key. If the wrong password is entered the dashed lines remain on the display until another key is
pressed. When InsulGard is in Set mode, the Set LED will be on.
2. Using “←” and “→”keys scroll to Set Phase Shift and Press Enter:
Manual Input
Phase Shift
3. Use any arrow key to switch from Manual Input to Auto Detect mode:
Auto Detect
Phase Shift
4. Move H%/Ref switch at the bottom of the Sensor Interface Board to Ref position. Then press Enter to start
phase angle shift measurements. Display will update every 15 seconds.
Detecting Phase
-
5. Observe changing readings for 1-2 minutes and calculate average of the displayed values.
0
Note: Typically measured value deviates within the range of +/- 5 . Below are some hints that may help to identify
phase angle measurement problems:
 Phase angle varies on more than +/-10 (low reference signal magnitude or high noise).
0
25
 On display ??? (reference signal is likely close to zero).
 On display continuously 357 (reference signal magnitude is too high).
6. Press Enter any time to stop phase measurements. Set Phase Shift will be displayed. Press Enter twice and
manually enter averaged phase shift angle, press Enter again.
Note: If using other source of phase reference signal rather than the internal connection to the coupling capacitor on
channel #1, correct obtained phase shift value according to the table below:
Phase Reference source Additional Phase Shift
Channel 1 (Coupling Capacitor on Phase A ) 0
PT Phase A 0
PT Phase B -120
PT Phase C -240
PT Phase A-B +30
PT Phase C-B +90
7. Press “Esc” to save changes and leave Set mode.
8. Return H%/Ref switch into H% position.
9. After finishing with phase shift measurement and exiting setting mode in InsulGard go to Unit Settings Tab in the
software and type final phase shift angle value in Phase Reference Shift box or go to Communications Tab in
the software and Get Settings from Device to synchronize settings in the monitor and software. Click “Update
Data base with Device settings” when phase shift settings discrepancy will be displayed.
10. In InsulGard “Unit Settings” Tab save new configuration by clicking “BackUp Settings” button.
Note: Older versions of Insulgard hardware and firmware have deviation from the described above
procedure – consult to the Manuals that came with that device or consult to EE PD.
2.7 Load Current Channel Calibration
This procedure describes the process of calibration of the load current channel. After the calibration InsulGard will
measure running current in percentage of the rated load current. Machine must be running and carry substantial
load. Current calibration must be done after rated current already entered into InsulGard settings. Otherwise set the
rated current, leave set mode and enter set mode again for load calibration.
1. Determine the rated load current rating of the machine from the machine nameplate.
2. Find the load current the machine is currently running (use ampere meter in Motor Control Center or ask an
operator).
3. Divide the value of Step 2 by Step 1 and multiply by 100. This is the percentage of the rated load current the
machine is currently pulling.
26
4. Press Set key on the monitor face plate to enter the setup mode. Password prompt should appear on the display
as shown:
Enter Setup
Password: ---0
Enter the password 5421 by using “←” and “→” to move to different digits and “↑” and “↓” to change the values
and then press Enter key. Wait about 20 seconds for the display to change from dashed lines to “Set date” before
pressing any other key. If the wrong password is entered the dashed lines remain on the display until another key is
pressed. When InsulGard is in “Set” mode, Set LED will be on.
5. Using “←” and “→” keys scroll to Calibrate Current and Press Enter.
Calibrate
Current
Press “Enter”
6. Use any arrow key to switch from Manual Input to Auto Calculate Coefficient.
Enter % of Rated
Current 000.0 %
Enter load current percentage using horizontal arrows to switch between digits and vertical arrows to change the
value. Press Enter. Current coefficient will be calculated. One can verify the coefficient by going to Manual Input
menu.
7. Press Esc to save changes and to leave Set mode. Monitor will display load current “Current xx.x%” close to
percentage entered.
8. Note: If equipment is not running Current Coefficient CK can be calculated if Rated Current Irated and the
metering CT rating Ict are known. Assumption made that metering CT ratio is always Ict : 5. If rated current was
entered in the settings, calculate Current Coefficient and enter it manually as:
CK= 2.2*Ict.
If rated current was not changed in the settings from default Irated=1, calculate Current Coefficient and enter it
manually as:
CK= 2.2*(Ict/Irated)
If only one of Irated and Ict is known use either one for approximate coefficient:
CK= 2.2*I (I entered in the setting) or CK= 2.2 (for default I=1 in settings).
If Irated used, readings will be lower than actual. If Ict used, readings, will be higher than actual. CK can be
corrected later by multiplying by coefficient equal to the actual relative load(%) divided by InsulGard readings.
9. FlexCore primary CT with the Load Current sensor might be installed over 1 feeder of several feeders per
phase. There will be no valid current measurement in this case, but current monitoring will be still sufficient for
PD diagnostics purpose. Multiply CK coefficient by number of feeders in such case.
10. After exiting setting mode in InsulGard go to Communications Tab in the software and Get Settings from Device
to synchronize settings in the monitor and software. Click Update Data base with Device settings when CK
discrepancy will be displayed.
11. In InsulGard “Unit Settings” Tab save new configuration by clicking “Back Up Settings” button.
Note: Older versions of InsulGard hardware and firmware may have deviation from the described
above procedure – consult to the Manuals that came with that device or consult to EE PD.
27
2.8 Base Line Measurements
The final steps include taking phase resolved data records in Test mode and analyzing the data.
1. Erase any pre-existing data in the device memory by pressing “Erase Device Memory” button in the right top on
“Communications” window. It will take about a minute for the device to accomplish.
2. Go to the Unit Settings tab and change the Data Storage Mode from "Normal" (Brief) to "Test” (Full).
3. Go to the Communications Tab on the InsulGard software and press "Send Settings To Device" button to update
the current configuration.
4. On the Communications window press the "Single Measurement" button. This should force the InsulGard to
make a measurement. You should see "--------" across the InsulGard display. This process can take as long as 6
minutes. After finishing measurements InsulGard will return to scrolling mode and will be ready for the next
measurement.
5. Repeat step 4 three more times.
6. Once all measurements are complete, press the "Read The Latest Device Records" button on the
Communications window. This will upload all data to the computer.
7. Go to the Unit Settings screen and change the Data Storage Mode from "Test" to "Normal".
8. If load sensor on a rotating machine is functioning properly check the box next to Load% to suspend InsulGard
measurements while machine is out of operation.
9. Go to the Communications Tab and press the "Send Settings To Device” button" to update monitor
configuration.
Failing to return to Normal mode will lead to storing excessive information in the device memory and
wasting flash memory resource.
10. Analyze the data. Reasonable changes can be made to settings based on data obtained. Send database to
EEPD if any questions.
InsulGard can be left for monitoring
28
Appendix 1. PD System Installation Checklist
# Procedure Result
Installation:
1 Unpack InsulGard and sensors, verify packing lists and
equipment condition
2 Verify that it is the system designated for the object. Temporal Object name:
label on the front panel of an InsulGard shows the object Object nameplate information:
name. The serial number on the InsulGard label should Insulgard serial number
coincide with InsulGard serial number in database software for
this object.
3 Verify power voltage designated on the InsulGard label. (Don’t U=
use UPS power, beware of autotransformers, use insulating
transformer instead if needed.).
4 Identify sensor placement specifics. For switchgear line the
PD sensor placement needs to coincide with worksheet filled
out at the time of order entry. For motors it usually should
coincide with the configuration table in Figure 1-12 Link.
5 Proceed with installation and cable termination in accordance
with corresponding Manuals and “PD Sensor Configuration”
Table.4 or 5 in Appendix 2 Link.
Circuits Integrity Check
6 Check External Ground being brought to the Insulgard (right to
the Door mount unit or to InsulGard panel / enclosure).
7 Measure power supply voltage and write down in the Table 1 Table 1 - Link
in Appendix 2. (If insulating transformer was used for power
supply, check voltage only between Line and Neutral)
8 Check IPDS sensor installation. Make sure the sensors are
reliably grounded. Check clearance between sensors with
jumper cable installed on different phases and also between
them and grounding surfaces. Keep clearance between signal
cables and HV side. Rule of thumb: clearance should be the
same as IPDS height for given voltage class.
9 Check RFCT sensor installation: proper direction to Ground
the arrow on the sensor label and that the wires grounding
feeder shields don’t touch grounding surface before they go
through the sensor.
10 Check RTD-6-PD sensor board installation (only for rotating Table 3 for rotating machines - Link
machines). Fill out the Table 3 in Appendix 2.
11 Check proper connection of PD sensors to the Sensor Table 4 for rotating machines - Link.
Interface Board. Measure resistance of each PD sensor Table 5 for switchgears - Link.
across board terminals and write down in the Table 4 or 5 in
Appendix 2.
12 Check external Temperature and Load (if installed) sensors Table 2 - Link
resistance and fill out Table 2 in Appendix 2. Verify T=
reasonable reading of the temperature and humidity on the H=
InsulGard display after its power ON.
Insulgard Configuration Verification
13 Software and database corresponding to the object have
been installed. Make sure the Modbus address and baud rate
are correct.
14 Verify Communication with the InsulGard through local port.
Set the correct date and local time.
29
15 Change the configuration of the database to the actual PD sensors configuration table
sensors configuration
16 Upload the updated configuration to the InsulGard and save
as Back Up
PD Channel Calibration/Verification (Optional but highly recommended).
17 Prepare monitor by setting calibration configuration

18 Perform calibration/check of the sensors and InsulGard Table 4 or 5 in Appendix 2. Link
functionality by injecting signal to every sensor from pulse Calibration data records
generator. Write down measured signal magnitudes in the
Table 4 or 5 in Appendix 2. Link Save calibration data records.
19 Restore monitor configuration and erase device memory.
This will conclude installation procedure
Base Line Measurements on Energized Equipment
20 StartUp: Phase shift =

1. Software installed, database corresponds to the object -
2. Phase reference measurement is performed, phase
shift calculated
3. Load channel calibration is performed at load - xx%
4. Settings downloaded to the database software -
5. InsulGard memory cleared –
21 Base Line measurements:
1. Base line measurements performed in Test Mode –
2. Data downloaded into database –
3. Data analyzed, necessary changes to the settings have
been made -
4. InsulGard set in Normal Saving Mode and left for
monitoring
22 Customer training
1. Install software to the customer computer
2. Synchronize databases by copying your database to the
customer computer or downloading settings and data to a
customer computer from the Insulgard
3. Train customer to operate InsulGard from his computer and
how to transfer data for analysis.
4. Teach how to transfer data for analysis
23 Prepare and submit the installation/commissioning report
30
Appendix 2. Installation / Commissioning Report

(To fill out below tables you can copy this appendix to word file.)
Write down name of the object and InsulGard s/n.
Table 1
Check power voltage for the monitor.
For panel mount IG switch the breaker on (fuse out).
Check power connections on DIN Rail terminal strip for enclosure and panel mount monitors. For door mount
monitors check power on corresponding fuse block.
Contacts are different for InsulGards of different versions – consult the appropriate winding diagram as needed.
Circuit Voltage between contacts Result Remark

Ground External Ground & Din-Rail terminal 0
1 and 2
Neutral Din-Rail terminal 2 & 3 0
Line Din-Rail terminal 3 & Fuse input 115/230 VAC +-10%
Note: If insulating transformer was utilized for power supply, check voltage between Line and Neutral only.
Table 2
Check Temperature and Load (for motors only) sensors.
Auxiliary sensor Resistance between Result Remark

contacts
Temperature 1&2 <=2 Ohm
RTD 100 Ohm 2&3 100-130 Ohm
Current sensor 6&5 30-50 Ohm
Table 3 (For Rotating Machine applications only)

Integrity of RTD temperature metering circuits could be verified on contacts on right side of an RTD-6 board before
the wires from temperature measuring device will be reconnected to the board:
a. resistance between contacts 2 and 3 for each RTD should be less than 2 Ohm;
b. resistance between contacts 1 and 2 or 3 should be ~100-130 Ohm for platinum RTDs and ~10-15 Ohm for
copper RTDs;
c. resistance between RTD shield contact 4 and any of the contacts 1 , 2, 3 should be >150kOhm.
Write results down in the table below.
Motor Winding Stator Slot # RTD-6-PD Resistance between contacts #

RTD # Input # 1&2 2&3 2&4
1
2
3
4
5
6
31
Table 4. PD sensors configuration for Rotating Machines.

After terminating coax cables from the sensors to the InsulGard Sensor Interface Board check resistance at PD
signal termination strip between central wire and shield of PD sensors coax cables:
Ch Sensor Sensor Pulse Magnitude Comments

# designation in measured recorded by
1) 2 3)
database resistance InsulGard , mV
Default sensors Ohm (optional)
1 CC_A
2 CC_B
3 CC_C
4 RTD 01 RTD-6 board #1
5 RTD 02
6 RTD 03
7 RTD 04
8 RTD 05
9 RTD 06
10 RTD 07 RTD-6 board #2
11 RTD 08 (if applicable)
12 RTD 09
13 RTD 10
14 RTD 11
15 RTD 12
Table 5. PD sensors configuration for switchgear line

The table below helps to avoid errors at PD sensor installation, their cables termination and for report preparation.
Ch Sensor Sensor Pulse Magnitude Vertical section Cubicle/Bus/Feeder

# designation in measured recorded by (Cubicle) original information
1) 2) 3)
database resistance InsulGard , mV name#
Ohm (optional)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Notes:
1. Sensor designation in the database should match information in the configuration worksheet that was populated
at the time of order entry. Correct sensor designation in the database if sensor locations were changed.
2. For IPDS the resistance should be close to 3kOhm. For RFCT and RTD-6 sensors the resistance should be <2
Ohms. Basically it is the resistance of the coax cable and depends on its length.
3. Pulse Magnitude recorded by InsulGard at system calibration (Optional).
32
Appendix 3. PD Sensors Designation in Database

Common rules for sensor designation in InsulGard database:
CC_02 A 2 1 - for upper switchgear cubical part

2 - for bottom switchgear cubical part
- omitted for non divided cubical
Sensor Type: Phase: A, or B, or C, or N - for RFCT sensor

CC_ - IPDS sensor installed on all three feeder shield ground wires
CT_ - RFCT sensor
CTb - RFCT on bottle grounding wire - Switchgear cubical # counted from line left side
RTm - RTD-6 PD sensor (new design) - RTD-6 PD output #
RTD - RTD-6 PD sensor (old design) - can be omitted if applicable
Typically the InsulGard monitor comes preconfigured in accordance with available information on the application and
the configuration worksheet filled out at the time of order entry (see example below of PD sensor location on a
switchgear line). Switching InsulGard devices can require significant reprogramming of database software and
InsulGard firmware settings and can lead to errors.
InsulGard ID: SWG 72YJ573, VS #6

Sensor Type Vertical Position
Combined
Insulgar CC – Coupling Capacitor (IPDS) Cubicle 1 for Top or
Sensor
d CT- CT on cable shield ground Position from 2 for Bottom
Phase: Name
Channe CTb - CT on a bottle shield left to right compartment (if
(A / B / C/ N) (Rule 3)
l# ground (Rule 2) applicable)
(Rule 4)
(Rule 1) (Rule 2)
1 CC 2 2 A CC_02 A2
2 CC 2 2 B CC_02 B2
3 CC 2 2 C CC_02 C2
4 CC 5 2 A CC_05 A2
5 CC 5 2 B CC_05 B2
6 CC 5 2 C CC_05 C2
7 CC 8 2 A CC_08 A2
8 CC 8 2 B CC_08 B2
9 CC 8 2 C CC_08 C2
10 CT 3 1 N CT_03 N1
11 CT 4 2 N CT_04 N2
12 CT 5 2 N CT_05 N2
13 CT 6 2 N CT_06 N2
14 CT 8 2 N CT_08 N2
15 CT 9 2 N CT_09 N2
Sensor designations in this table indicate:

 type of the sensor (CC_ - IPDS)
 place of installation (02 – line up vertical section - cubicle position counted from left to right)
 bus or feeder phase (A), (For RFCT sensors (CT) installed on all three feeder shield ground wires its phase
designated as N – neutral)
 part of the vertical section if applicable (2 - bottom part)
33
Insulgard Settings for Channels in database have same designations of the sensors as in the above table.
If the sensors positions were changed at installation, the sensor designation in the database must be changed
correspondingly.
34
Appendix 4. Door cutout dimensions for Door mount InsulGard
Blue color shows InsulGard front panel dimension.
35

Installation and StartUp InsulGard System

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Installation and StartUp InsulGard System

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InsulGard System Installation and Start Up Guideline

INSTALLATION STAIRCASE ............................................................................................................................. 3

1. INSULGARD SYSTEM INSTALLATION........................................................................................................... 4

1.1. InsulGard installation and external connection. ................................................................................................ 4

1.2 Installation of the InsulGard Sensors .................................................................................................................10

1.3 Circuits integrity test ............................................................................................................................................13

1.4. InsulGard system installation for a motor ........................................................................................................14

1.5. InsulGard system installation for a switchgear line ........................................................................................18

2.1 Getting ready .........................................................................................................................................................19

2.2 Insulgard Software Installation and Communication Establishing .................................................................19

2.3 Verifying/Correcting Configuration ....................................................................................................................21

2.4 PD Channel Calibration/Verification ...................................................................................................................21

2.5 Baseline Measurement on Energized Object .....................................................................................................24

2.6 Phase Shift Measurement ....................................................................................................................................24

2.7 Load Current Channel Calibration ......................................................................................................................26

2.8 Base Line Measurements.....................................................................................................................................28

APPENDIX 1. PD SYSTEM INSTALLATION CHECKLIST ............................................................................29

APPENDIX 2. INSTALLATION / COMMISSIONING REPORT .....................................................................31

APPENDIX 3. PD SENSORS DESIGNATION IN DATABASE ........................................................................33

APPENDIX 4. DOOR CUTOUT DIMENSIONS FOR DOOR MOUNT INSULGARD ...................................35

Sensors and external

Identify and verify proper power

1. InsulGard System Installation

1.1. InsulGard installation and external connection.

1) InsulGard installation options:

Sensor Interface Board

wire for panel Terminals for

3) Best location for InsulGard installation

Insulgard must be reliably grounded at place of its installation.

5) InsulGard inputs for sensors connection

a) 15 channels (Ch1-Ch15) for PD sensors connection

b) 1 channel (Ch16) for noise cancellation (rarely used)

d) Input for External Humidity sensor

e) Input for Load Current sensor (used for rotating machines)

b) 4-20 ma signal that is proportional to PD activity

7) External connection in accordance with the wiring diagram

InsulGard Panel Wiring Diagram Connection to:

Sensor Interface Board

Temperature sensor Outlet

Ground screw on enclosure

There is no outlet for 230VAC application.

Figure 1-3. Typical wiring diagram for panel mount InsulGard

9) External auxiliary sensors (Temperature, Humidity and Load sensors) connection.

Figure 1-5. Auxiliary sensors connection to the Sensor Interface Board

Auxiliary sensor connection table:

Contact Sensor Sensors wire Note

10) PD sensor connection

Coaxial cable from PD sensors preparation and connection to channel:

Figure 1-7. Coaxial cable preparation and connection to channel

1.2 Installation of the InsulGard Sensors

IPDS RTD-6-PD RFCT

Figure 1-9 PD sensors

IPDS - Integrated Partial Discharge Sensors

a) Sensor must be reliably grounded.

RFCT Sensor - Radio Frequency Current Transformer

RTD-6 - PD sensor (for rotating machines only)

b) HS – External Humidity sensor

CT sensor CTF sensor

1.3 Circuits integrity test

1) Check InsulGard Power Supply Voltage

d) Fill out Table 1 in Appendix 2 with test results (Link).

2) Check external auxiliary sensors connection

d) Fill out Table 2 in Appendix 2 with test results - Link .