GE iBox Product manual

GE
Grid Solutions
iBox/iBox Kit
Installation and Maintenance Guide
994-0047
Version 5.10 Revision 4
GE Information

iBox/iBox Kit
Installation and Maintenance Guide
GE Grid Solutions
2
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COPYRIGHT NOTICE
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documentation,” respectively, pursuant to DFAR Section 227.7202 and FAR Section 12.212, as applicable, and are delivered with
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iBox/iBox Kit
Installation and Maintenance Guide
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Contents
About This Document 5
Product Support 7
Safety Precautions 8
Section 1: Getting Started .....................................................................................................................................13
1.1. What is an iBox?.......................................................................................................................14
1.2. Unpacking and Inspection.........................................................................................................20
1.3. Storage ......................................................................................................................................22
1.4. Installation Tools ......................................................................................................................23
Section 2: iBox Installation and Maintenance .....................................................................................................24
2.1. Familiarization ..........................................................................................................................25
2.2. Installing the iBox.....................................................................................................................27
2.3. Configuring your iBox..............................................................................................................36
2.4. Testing your iBox .....................................................................................................................45
2.5. Connecting and Testing Field Wiring.......................................................................................51
2.6. Servicing your iBox ..................................................................................................................58
2.7. Maintaining your iBox Software...............................................................................................61
2.8. Troubleshooting your iBox ....................................................................................................... 69
2.9. Replacing your iBox .................................................................................................................75
Section 3: iBox Kit Installation and Maintenance ..............................................................................................77
3.1. Familiarization ..........................................................................................................................77
3.2. Installing the iBox Kit...............................................................................................................82
3.3. Configuring the iBox Kit Components .....................................................................................87
3.4. Connecting Field Wiring.........................................................................................................132
3.5. Servicing your iBox Kit ..........................................................................................................134
3.6. Maintaining your iBox Kit Software ......................................................................................135
3.7. Troubleshooting your iBox Kit...............................................................................................138
3.8. Replacing your iBox Kit ......................................................................................................... 139
Section 4: Removing Configuration Data and Sensitive Information .............................................................140
4.1. From the iBox Device............................................................................................................. 140
4.2. From the PC Running Configuration Software.......................................................................141
Appendix A: Technical Specifications.................................................................................................143
Appendix B: iBox Kit Default Configurations ...................................................................................149
Appendix C: Resetting the Digi One Configuration ..........................................................................153
Appendix D: Setting your PC IP Address...........................................................................................155
Appendix E: DPA Default Point Mapping .........................................................................................157
Appendix F:Installing and Connecting DNP3 I/O Modules ................................................................................163

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Appendix G:Error Messages...............................................................................................................169

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About This Document
Purpose
What this
document
provides
The iBox/iBox Kit Installation and Maintenance Guide contains information about
two products, the iBox and the iBox Kit.
The document is split into three sections. Section 1: Getting Started provides an
overview of the iBox. Section 2: iBox Installation and Maintenance provides
instructions for installing, configuring, using, maintaining and troubleshooting the
iBox. Section 3: iBox Kit Installation and Maintenance provides similar information
for the iBox Kit.
Some iBox configuration procedures provide details on the SGConfig tool. For the
equivalent information when using SGConfig to configure the iBox, refer to the
SGConfig online help.
SGConfig
Online Help
For topics related to the use of GE Digital Energy's SGConfig* configuration utility,
or details of any software application used in a specific iBox, refer to the SGConfig
online help.
Training Tool In addition to the primary purpose of this Installation and Maintenance Guide, its
secondary purpose is that of a Training Manual for customer training sessions
provided by GE Digital Energy, or its agents.
Operating
System
The procedures in this guide are based on Windows 2000. Some steps and dialog
boxes may vary slightly if you are using Windows XP or Windows 2003.
Intended Audience
Job Titles This guide is intended for use by the SCADA system installers and field engineers
who are responsible for the installation, hardware configuration and maintenance of
SCADA systems containing iBox units and iBox Kits.
Experience &
Abilities
This guide assumes that anyone working with an iBox or iBox Kit has some prior
knowledge of:
•Electrical utility industry
•Personal computer terminology and interconnection skills
•GE Digital Energy products
•Other industry products such as protective relays, meters, and voltage regulators.

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Additional Documentation
For further information about the iBox and its components, refer to the following
documents:
From GE Digital Energy:
•iBox Product Overview (PRPI-043)
•D20, D25, iBox Automation Applications (PRPI-048)
•SGConfig online help
•WESMAINTII+ User’s Guide (B014-1UG)
•68K Monitor User’s Guide (SWM0023)
•Application software configuration guides
From other manufacturers
•Digi One User’s Guide (Digi International)
•ADAM 4000 Data Acquisition Modules User’s Manual (Advantech)
•DMMS300+, DMMS350, DMMS425 3-Phase Multifunction Power Monitors
with Advanced Capabilities Installation, Operation and Programming Manual
(Electro Industries/GaugeTech)

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iBox/iBox Kit
Installation and Maintenance Guide
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Product Support
Getting Help If you need help with any aspect of your GE Grid Solutions product, you have a few
options.
Search GE
Grid Solutions
Web Site
The GE Grid Solutions Web site provides fast access to technical information, such
as manuals, release notes and knowledge base topics.
Visit us on the Web at: http://www.gegridsolutions.com
Search GE
Grid Solutions
Technical
Support
This site serves as a document repository for post-sales requests. To get access to
the Technical Support Web site, go to:
http://sc.ge.com/*SASTechSupport
Contact
Technical
Support
GE Grid Solutions Technical Support is open 24 hours a day, seven days a week for
you to talk directly to a GE representative.
In the U.S. and Canada, call toll-free: 1 800 547 8629
International customers, please call: [phone]
Or e-mail to [e-mail]
Product
Returns
Before you return a product, please contact GE Grid Solutions Technical Support to
obtain a Return Merchandise Authorization number and complete instructions for
return shipments.
A Return Merchandise Authorization (RMA) number must accompany all equipment
being returned for repair, servicing, or for any other reason.
Note: Product returns will not be accepted without a Return Merchandise
Authorization number.
!
If you attempt to resolve problems with your GE product using methods not
recommended by GE Digital Energy, this might result in damage or injury to persons
and property.

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Safety Precautions
Important! Follow all safety precautions and instructions in this manual:
•Only qualified personnel should work on the iBox/iBox Kit. Maintenance
personnel should be familiar with the hazards associated with electrical
equipment.
•NEVER work alone.
•Before performing visual inspections, tests, or maintenance on this equipment,
isolate or disconnect all hazardous live circuits and sources of electric power.
Assume that all circuits are live until they have been completely de-energized,
tested, and tagged. Pay particular attention to the design of the power system.
Consider all sources of power, including the possibility of back feed.
•Turn off all power supplying the equipment in which the iBox/iBox Kit is to be
installed before installing and wiring the iBox/iBox Kit.
•Beware of potential hazards, wear personal protective equipment and carefully
inspect the work area for tools and objects that may have been left inside the
equipment.
•The successful operation of this equipment depends upon proper handling,
installation, and operation. Neglecting fundamental installation requirements
may lead to personal injury as well as damage to electrical equipment or other
property.
•Many of the components within the iBox/iBox Kits are susceptible to damage
from electrostatic discharge. Observe standard ESD (Electrostatic Discharge)
precautions for handling electronic components at all times.
•Read and thoroughly understand this guide before using the iBox/iBox Kit. Save
these instructions for later use and reference.
Failure to observe these instructions may result in death or serious injury.
!
Hazardous
Voltages
Hazardous voltages can cause shock, burns or death.
•Disconnect and lock out all power sources before servicing and removing
components.
•Short all current transformer primaries before servicing.
•Do not remove the safety shields that have been installed to prevent accidental
contact with hazardous voltages.
•Avoid touching iBox/iBox Kit power supplies, since these supplies contain
hazardous voltages.

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Safety Precautions, continued
Product
Warning
Symbols
!
Caution (refer to accompanying documentation)
Caution (risk of electric shock)
Earth/Ground Terminal
Protective Earth Terminal
Power Supply Off (Stand-by Mode)
Power Supply On
Direct Current
Alternating Current
Damaged
Equipment
Do not operate an iBox or iBox Kit if it has been dropped or damaged. Return it to
GE Digital Energy for inspection and repair.
Operating
Environment
iBox/iBox Kits are intended for indoor use. Do not place these products in
environments where unusual environmental conditions exist (such as dirt, liquids, or
windblown dust) without a secondary protective enclosure.
For proper fire protection, iBox/iBox Kits must be installed in an enclosure equipped
with a metal floor with no openings.
An IEC®60947 compliant main disconnect switch (or other equivalent device
complying with IEC 60947-1 / 60947-3) must be as electrically close as practicable
to the iBox power supply.

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!
Protection
during
Maintenance
Ensure iBox/iBox Kits are protected from falling debris during maintenance. Small
metallic particles (such as wire clippings) could fall onto circuit boards and damage
or interfere with the safe and reliable operation of the iBox/iBox Kit.
RF
Interference
The iBox/iBox Kit generates radio frequency (RF) energy that can radiate if it is not
installed and used in accordance with the instructions provided in this guide. This RF
energy may cause harmful interference to radio communications or sensitive circuits.
Operating an inadequately shielded iBox or iBox Kit in a residential area may cause
harmful interference, if this happens, you may be liable to correct the interference.
!
Rack Spacing
When mounting multiple iBox/iBox Kits in a rack (or when mounting an iBox/iBox
Kit in a rack with other equipment), verify that there is at least one rack unit (RU) of
space above and below the iBox/iBox Kit, to allow for cooling airflow, and for
routing cables between field equipment and the iBox/iBox Kit (1 RU = 1.75 inches).
Power and
Fusing
•For proper operation, input voltages must be within specified limits. Do not
apply voltages outside this range, since this may lead to premature product
failure.
•Always fuse-protect field sources.
•Always replace fuses with fuses of the same type and rating. Fuse types and
ratings are stated in the product specifications.
Grounding To ensure voltage transients are properly shunted to ground, you must connect the
iBox’s protective earth terminal to a low-impedance ground point using a braided
cable or heavy solid copper conductor.
When making ground connections, ensure all grounding surfaces are free of dirt,
residue and corrosion. You can use a coating such as Glyptal®to protect connections
from oxidation and dirt deposits.
Cable shields should be grounded to either the iBox/iBox Kit ground terminal or to
field equipment, but not to both. Do not ground cable shields at more than one point,
since potential differences between the ground points will result in ground loops and
undesirable noise sources.
Communica-
tion Cables
•Use shielded cables to prevent electromagnetic interference.
•Route all communication cables away from power-carrying cables, and make
these cables as short as possible.
•Prior to start-up, verify the integrity of all communication cables and
connections.

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Safety Precautions, continued
Surge
Protectors
When connecting the iBox/iBox Kit to communications equipment (for example,
modems or radios), use appropriate surge arrestors to protect the iBox’s
communications ports.
iBox Cover Never operate an iBox without having its protective cover installed, since product
performance may be compromised, and equipment may be damaged if foreign
objects fall into the unit.
iBox Jumpers Configure the jumpers in your iBox before you connect field inputs and outputs.
!
Use of the equipment in a manner not recommended or specified by GE Digital
Energy, may impair the protection provided by the equipment.

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CISPR 11-CE Mark Compliance
Important For CISPR 11, Class A-CE Mark compliance on an iBox installed outside of a
protective enclosure, you must use ferrite clamps on the following:
•Serial communication cables attached to J2, J3, and J4
•Wiring connected to TB2-TB15 for digital inputs and control outputs
Note: Although the standalone iBox is CE Marked, GE does not guarantee the CE
Mark of third-party components of the iBox Kits (such as the 10/100BaseT Ethernet
Module or the AC and DC Analog Input Modules).
Ferrite Clamp
cabling/wiring
The following diagram illustrates the cabling/wiring loop through an installed ferrite
clamp.
Connection
Ferrite Clamp
Cable/Wiring
Part Numbers Order the following part number for each of the external ferrite clamps you require.
Part Number Color
460-0031 White body
460-0049 Black body

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Installation and Maintenance Guide
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Section 1: Getting Started
Overview
Introduction Before you begin installing the iBox, review the information in this section,
including the following topics:
•Description of the iBox
•Unpacking and inspection
•Storage
•Installation Tools

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1.1. What is an iBox?
Product Overview
Introduction The iBox is GE Digital Energy small point count Substation Controller. It combines
advanced functionality, multiple communication ports and local I/O in a compact
package.
The iBox processes both digital inputs and digital outputs. It also provides serial
digital data communication ports to facilitate communications with both a master-
station and local communications. The iBox is specifically designed for SCADA
applications.
The iBox Kit is a rack-mounted, pre-wired, pre-configured RTU based on the iBox,
but with additional (optional) power supply, Ethernet and I/O support.
Integrated
Functions
The iBox can function as a:
•Programmable logic controller (PLC)
•IED gateway
•Data concentrator
•Standalone remote terminal unit (RTU).
Scalable
Architecture
The iBox’s flexibility makes it an excellent option for:
•Advanced substation monitoring
•Control
•Automation applications.
Features The iBox has three software-configurable RS-232/485 serial communication ports.
All three RS-232/485 serial ports interface to legacy IEDs or Master stations.
An extensive library of application software is available from GE Digital Energy to
enable the iBox to interface with a wide range of IEDs.
A UTC port is available for global satellite time synchronization (however, there
are three serial ports, so if you use one as a UTC port, two serial ports remain for
connecting to IEDs).
Maintenance port support provides access to SGConfig, LogicLinx*, and
WESMAINT* utilities.
Meets the robust requirements of the IEEE®, IEC®and CE Mark.
Patent
Protection
The iBox contains a patent protection label as a formal declaration of the US patents
that protect both the product and the technology developed by GE Digital Energy.
MAY BE PROTECTED BY ONE OR
MORE OF THE FOLLOWING US
PATENTS:
5237511, 5303112, 5513061, 5701226.

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System Software
Overview The iBox system software consists of two components:
•Base System
•Applications.
Base System
Software
The Base System software provides a stable operating environment for applications,
which provide specific functionality for the iBox. The Base System is made up of:
•Boot software, resident in the BootROM, and
•Base applications, required for operating the hardware.
iBox
BootROM
BootROM software is stored in EPROM. The BootROM contains:
•Operating system software
•Device drivers to interface the operating system with the system hardware and
software
•Diagnostic software, to verify the integrity of the iBox
•Monitor interface, for examining the system in a non-operational mode
•Startup code, to verify and initialize the application software
•Low-level maintenance and troubleshooting software
Base
Applications
Standard iBox Base Applications, present in every iBox, are:
•WIN, the system database manager
•WESMAINT, which allows the operator to locally examine and control data
•68K Monitor, which provides low-level system maintenance and diagnostic tools
WIN WIN (for WESDAC Interface Node) is the database manager for the iBox System
Point Database. The System Point Database is the heart of the iBox software system.
All data flowing through the iBox is stored in the System Point Database before it is
passed on to its destination.
Continued on next page

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System Software, continued
WESMAINT WESMAINT is the iBox’s primary maintenance and diagnostic tool. You can access
WESMAINT in three ways:
•Through the iBox WESMAINT port
•Through a modem or other serial connection to a programmed COM port
•Over a LAN or serial PPP connection, as a telnet session from a remote network
station
WESMAINT is accessed using a VT100 terminal, or a PC running terminal
emulation software.
Database
Display
Through WESMAINT, you can access the following:
•Digital inputs and outputs
•Counters (or accumulators)
•Device status
•Sequence-of-events (SOE) and change-of-state (COS) data
•System status information
•Error log information
•User login buffer
•Other application-specific information
Other
WESMAINT
Functions
In addition to displaying information, a WESMAINT user can also:
•Set or clear accumulator counts
•Operate digital outputs
•Clear logged information
•Access the iBox 68K Monitor.

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System Software, continued
68K Monitor The iBox 68K Monitor, available through WESMAINT, is a diagnostic tool used to
access system-level functions.
The iBox 68K Monitor is resident in both BootROM and flash memory.
When the Monitor is operated from BootROM, the following prompt appears:
D25S>. This mode is accessed only while the iBox is in a maintenance state, since
forcing an iBox into this mode terminates all running applications.
When the Monitor is operated from flash, the following prompt appears: D25A>.
This is the normal mode of operation, and it can be accessed via WESMAINT at any
time without disrupting unit operation.
Note
Using the 68K Monitor requires detailed knowledge of the iBox architecture and
functionality. Refer to the 68K Monitor User’s Guide (SWM0023) for complete
instructions about command usage and availability.

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Application Software
Background A wide range of applications can be added to the iBox to enhance its functionality.
Software applications fall into three categories:
•Data Collection Applications (DCA)
•Data Processing Applications (DPA)
•Data Translation Applications (DTA)
Data
Collection
Applications
Data Collection Applications are used to import (collect) data from external sources,
and to pass this data to WIN (the system point database manager) for storage in the
system database. DCAs also forward output requests from the system database to
external sources.
Data
Processing
Applications
Data Processing Applications are configured to select and format data from the
system database, and forward this data to a SCADA host or master station
Data
Translation
Applications
A combination of a DPA and a DCA, Data Translation Applications use data from
the system database to perform logical operations, the results of which create new
data. This new data is then placed back in the system database, where it can be used
as input/output data by another application.
Firmware The set of applications installed on an iBox is referred to as its “firmware”.
Firmware is installed in the iBox flash memory prior to shipment. The iBox
operational characteristics can, however, be upgraded at a later date.
Contact your GE Digital Energy representative for more information on firmware
upgrades.

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Plant I/O Subsystem
Plant I/O
Subsystem:
Overview
The iBox Plant I/O Subsystem collects, processes, and stores data related to physical
inputs and outputs. Once it is stored in the system database, I/O point data can be
accessed by other applications.
Plant I/O
Subsystem:
Functions
The Plant I/O Subsystem is responsible for scanning of iBox physical I/O points. For
input type points (digital and accumulator), the data of each scan is compared to
previous known data. Changes are recorded in the system database, then reported to
other applications, as needed.
The Plant I/O Subsystem:
•Scans and processes up to 8 digital inputs
•Controls up to two digital outputs and two master trip/close relays.
Requests for digital outputs are accepted and processed as soon as they arrive.
Fixed Number
of Points
The Plant I/O DCA maintains a fixed number of points in the System Point
Database. The actual number of points is determined by the version of the P097 Plant
I/O Subsystem that has been installed on your iBox.
The hardware options available in the iBox (and the user’s software configuration)
determine if specific system features and data points are available or disabled.

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1.2. Unpacking and Inspection
Shipping
Inspection
Inspect the shipping package before opening it to see if it has sustained any damage
from impact or water. If it has, report it immediately to the carrier without opening
it. Carriers may not assume responsibility for damage after the customer accepts
delivery.
Unpacking Carefully remove the iBox from its shipping package. Visually inspect the unit to
ensure it has not sustained any visible damage during transit.
The figure below shows an iBox removed from the shipping package.
Package
Contents
The following items are provided as part of your iBox shipment:
•iBox or iBox Kit unit
•WESMAINT serial cable
•IBOX/iBox Kit Installation and Maintenance Guide (994-0047)
•CD including the software and copy of user documentation
Product
Identification
Before installing the unit, check that the unit part number is the same as the part
number on the shipping and ordering documents.
Part Number Label
Location