Eaton InsulGard Instruction Manual

InsulGard®
InsulGard System Installation and Start Up Guideline
Version 1
April 2018

InsulGard System Installation and Start Up Guideline
2
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

InsulGard System Installation and Start Up Guideline
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Installation Staircase
Print and use “PD system installation checklist” from Appendix 1- Link for StartUp and
Commissioning as a guideline and a core of installation report.
Done!!!
Begin
with
Check contents against
the packing lists and the
equipment condition for
shipping damage. Verify
that it is exactly the device
designated for this project
Identify place and way
of sensors and
InsulGard installation
Identify and verify proper power
and communication lines to be
connected to the InsulGard
Actual installation
Sensors and external
lines connection check
Software Installation,
communication test
Sensors calibration/
verification
Start Up and base line
measurements on
energized equipment
Customer training
and database
synchronisation
Report on installation/
commissioning

InsulGard System Installation and Start Up Guideline
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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.
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
Sensor Interface Board
Terminals for
power supply
Outlet for
115VAC
Fuse
wire for panel
grounding

InsulGard System Installation and Start Up Guideline
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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
Sensor Interface
Board

InsulGard System Installation and Start Up Guideline
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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 monitor 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.
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).
3
InsulGard Panel Wiring Diagram Connection to:
Connector for Flat Cable from
InsulGard
Coax cables from PD Sensors
Ch1
Ch 2
Ch 4
Ch 3
Ch 5
Ch 6
Ch 8
Ch 7
Ch 9
Ch 10
Ch 12
Ch 11
Ch 13
Ch 14
Ch 16
(Noise)
Ch 15
Sensor Interface Board
RTD
CT
H%
S
+5
S
Ref
5
S1
S2
6
7
8
9
10
11
12
4
3
2
1
Signal
Shield
H% Ref
Sw
Ground Screw
on the panel
Ground screw on enclosure
must be connected to local
ground
red
white
white
white
red
black
black
black
Humidity sensor
CT - Load sensor
Temperature sensor
Auxiliary sensor
connection:
green
Power 115VAC
Neutral
Ground Phase
1
InsulGard's
connectors
Flat Cable to
Sensor Interface Board
Alarm
Warning
+
4-20
mA
Alarm 2
GL
N
Power -
+5
G B A
RS - 485
Status Alarm 1
DIN-Rail Terminals
Ethernet Device Host
USB
USB
4-20 mA interface
RS485 interface
Alarm relay
Warning relay
Status relay
green
Green
red
white
Screw on
back cover 2
Left
side Right side
N
L
Gnd
Gnd
Fuse
Outlet
Figure 1-3. Typical wiring diagram for panel mount InsulGard

InsulGard System Installation and Start Up Guideline
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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

InsulGard System Installation and Start Up Guideline
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Auxiliary sensor connection table:
Contact
#
Sensor
connected
Sensors wire
Note
1
Temperature
sensor
100 Ohm
Platinum
RTD
RTD common wire (white wire)
Board common
2
RTD signal wire (black wire)
Output dc current ≈ 2mA
3
RTD signal wire (red wire)
Output dc current ≈ 2mA
4
Cable shield (optional)
Board common
5
Load (CT)
sensor
Signal wire (red wire)
Input impedance 100 Ohm,
Max input signal ≈ 5mA
6
Common wire (black wire)
Board common
7
External
Reference
Usually not used
Input impedance > 27kOhm. Input voltage should
not exceed 1VAC
8
n/a
test point
9
n/a
Board common
10
Humidity
sensor
Sensor common (white wire)
Board common
11
+ 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
terminal labeled ┴on 1st 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).

InsulGard System Installation and Start Up Guideline
9
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.
H% / Ref switch

InsulGard System Installation and Start Up Guideline
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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

InsulGard System Installation and Start Up Guideline
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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).
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”.
From feeders'
shields
To the Ground
Bus
Additional short
ground if original
ground is 2' or longer
To a closest
frame ground
point
Coax Cable to
a connection
box
This
Direction to
Ground
Central
conductor
Shield
These wires must not
touch ground surface

InsulGard System Installation and Start Up Guideline
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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.
TS and HS sensors
CT sensor
CTF sensor
Figure 1-11

InsulGard System Installation and Start Up Guideline
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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.

InsulGard System Installation and Start Up Guideline
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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.

InsulGard System Installation and Start Up Guideline
15
Existing wires to
temperature
measuring device
Temperature sensor
Humidity sensor Two 3-wires
cables to
InsulGard
Existing wires
from RTDs in
stator winding
Up to 6 coax.
cables to
InsulGard
Channels 4- 9
Motor terminal box
RTD terminal box
IPDS
A phase
Load (CT) sensor
Motor
meetering
CT
3 coax. cables
to InsulGard
Channels 1- 3
IPDSIPDS
C phase
B phase
2-wires cable
to InsulGard.
3 phases feeder
Motor
RTD-6 PD
Sensor Board
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
5
RTD 02 (PD 2 output of RTD-6 sensor)
RTm02
6
RTD 03 (PD 3 output of RTD-6 sensor)
RTm03
7
RTD 04 (PD 4 output of RTD-6 sensor)
RTm04
8
RTD 05 (PD 5 output of RTD-6 sensor)
RTm05
9
RTD 06 (PD 6 output of RTD-6 sensor)
RTm06
10
RTD 07 (PD 1 output of the second RTD-6 sensor if available)
RTm07
11
RTD 08 (PD 2 output of the second RTD-6 sensor if available)
RTm08
12
RTD 09 (PD 3 output of the second RTD-6 sensor if available)
RTm09
13
RTD 10 (PD 4 output of the second RTD-6 sensor if available)
RTm10
14
RTD 11 (PD 5 output of the second RTD-6 sensor if available)
RTm11
15
RTD 12 (PD 6 output of the second RTD-6 sensor if available)
RTm12
Figure 1-12. Typical sensor installation and connection for a motor

InsulGard System Installation and Start Up Guideline
16
2) Diagram of the main required connections to Insulgard
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.
InsulGard Enclosure
NEMA 4
Note:
Mount close to a motor main
terminal box and RTD
termination box to minimize
cable and conduits length
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)
1" conduit
fitting
1 1/2"
conduit
fitting
Motor terminal box
3 coax cables from coupling
capacitors
1 - 3 wire shielded cable
AWG22 for Humidity sensor
(comes with the sensor)
1 - 2 wire shielded cable
AWG22 for Load sensor
(comes with the sensor)
1 - 3 wire shielded cable
AWG22 for the Temperature
sensor (if provided, comes
with the sensor)
RTD terminal box
1 coax cable per RTD
from RTD PD sensor(s)
1 - 3 wire shielded cable
AWG22 for winding RTD
(if provided)
Motor
Winding
Coupling
Cap
Surge
Cap
Incoming
Power
Right
Motor
Winding
Incoming
Power
Coupling
Cap Surge
Cap
Wrong
Motor
Winding
Coupling
Cap
Surge
Cap
Incoming
Power
Wrong

InsulGard System Installation and Start Up Guideline
17
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)

InsulGard System Installation and Start Up Guideline
18
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.

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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.