GE iSTAT I4 Series User manual

GE
Grid Solutions
iSTAT I4X
Communications Converter
Manual
Publication reference: I4X/EN/CO/D

Service Manual
I4X/EN CO/D
ISTAT I4X
Page 1
CONTENT
1. SAFETY SECTION 4
1.1 Health and Safety 4
1.2 Explanation of symbols and labels 4
2. INSTALLING, COMMISSIONING AND SERVICING 5
3. EQUIPMENT OPERATING CONDITIONS 6
3.1 Current transformer circuits 6
3.2 External resistors 6
3.3 Battery Replacement 6
3.4 Insulation and dielectric strength testing 6
3.5 Insertion of modules and pcb cards 6
3.6 Fibre optic communication 6
4. OLDER PRODUCTS 7
5. DECOMMISSIONING AND DISPOSAL 8
6. TECHNICAL SPECIFICATIONS 9
6.1 Protective fuse rating 9
7. INTRODUCTION 11
7.1 General 11
7.2 iSTAT I4X Family 11
7.2.1 EIA (RS)232 to EIA (RS)485 (2-wire) 11
7.2.2 Ethernet to EIA (RS)232 11
7.2.3 Ethernet to EIA (RS)485 (2-wire) 11
8. CONNECTION MODES 12
8.1 EIA (RS)232 to EIA (RS)485 12
8.2 Ethernet to EIA (RS)232 12
8.3 Ethernet to EIA (RS)485 12
8.4 Status Indication: Power 12
8.5 Status Indication: Ethernet 13
8.6 EIA (RS)232 to computer socket connection 13
9. COMMUNICATION SETTINGS 14
9.1 EIA (RS)232 to EIA (RS)485 14
9.2 Ethernet to EIA (RS)232 14
9.3 Ethernet to EIA (RS)485 14
9.4 Ethernet IP addresses 14
9.5 Programming I4X settings using QDSP and Web browser 15

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9.5.1
QDSP setting software
15
9.5.2 Internet Browser 15
10. TROUBLE SHOOTING 18
10.1 EIA (RS)232 to EIA (RS)485 18
10.2 Ethernet to EIA (RS)232 or EIA (RS)485 18
11. TECHNICAL DATA 19
11.1 EIA (RS)232 communications 19
11.2 EIA (RS)485 communications 19
11.3 Ethernet communications 19
11.4 Universal Auxiliary Supply 19
11.5 Electrical Environment 20
11.6 Environmental withstand 21

Service Manual
I400/EN M/F
iSTAT I400
Page 1
HANDLING OF ELECTRONIC EQUIPMENT
A person’s normal movements can easily generate electrostatic potentials of several
thousand volts. Discharge of these voltages into semiconductor devices when handling
circuits can cause serious damage, which often may not be immediately apparent but the
reliability of the circuit will have been reduced.
The electronic circuits of GE Grid Solutions products are immune to the relevant
levels of electrostatic discharge when housed in their cases. Do not expose them to
the risk of damage by withdrawing modules unnecessarily.
Each module incorporates the highest practicable protection for its semiconductor devices.
However, if it becomes necessary to withdraw a module, the following precautions should be
taken to preserve the high reliability and long life for which the equipment has been designed
and manufactured.
1. Before removing a module, ensure that you are a same electrostatic potential as the
equipment by touching the case.
2. Handle the module by its front-plate, frame, or edges of the printed circuit board.
Avoid touching the electronic components, printed circuit track or connectors.
3. Do not pass the module to any person without first ensuring that you are both at the
same electrostatic potential. Shaking hands achieves equipotential.
4. Place the module on an anti-static surface, or on a conducting surface, which is at the
same potential as you.
5. Store or transport the module in a conductive bag.
More information on safe working procedures for all electronic equipment can be found in
BS5783 and IEC 60147-0F.
If you are making measurements on the internal electronic circuitry of equipment in service, it
is preferable that you are earthed to the case with a conductive wrist strap.
Wrist straps should have a resistance to ground between 500k –10M ohms. If a wrist strap
is not available you should maintain regular contact with the case to prevent the build up of
static. Instrumentation which may be used for making measurements should be earthed to
the case whenever possible.
GE Grid Solutions strongly recommends that detailed investigations on the electronic
circuitry, or modification work, be carried out in a Special Handling Area such as described in
BS5783 or IEC 60147-0F.

Service Manual
I400/EN M/F
iSTAT I400
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ISTAT I4X
Page 4
1.
SAFETY SECTION
This Safety Section should be read before commencing any work on the equipment.
1.1 Health and Safety
The information in the Safety Section of the product documentation is intended to ensure
that products are properly installed and handled in order to maintain them in a safe condition.
It is assumed that everyone who will be associated with the equipment will be familiar with
the contents of the Safety Section.
1.2 Explanation of symbols and labels
The meaning of symbols and labels may be used on the equipment or in the product
documentation, is given below.
Caution: refer to product documentation Caution: risk of electric shock
Protective/safety *earth terminal Functional *earth terminal
Note: This symbol may also be used
for a protective/safety earth terminal if
that terminal is part of a terminal block
or sub-assembly e.g. power supply.
*NOTE: THE TERM EARTH USED THROUGHOUT THE PRODUCT DOCUMENTATION IS
THE DIRECT EQUIVALENT OF THE NORTH AMERICAN TERM GROUND.

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2. INSTALLING, COMMISSIONING AND SERVICING
Equipment connections
Personnel undertaking installation, commissioning or servicing work on this equipment
should be aware of the correct working procedures to ensure safety. The product
documentation should be consulted before installing, commissioning or servicing the
equipment.
Terminals exposed during installation, commissioning and maintenance may present a
hazardous voltage unless the equipment is electrically isolated.
If there is unlocked access to the rear of the equipment, care should be taken by all
personnel to avoid electrical shock or energy hazards.
Voltage and current connections should be made using insulated crimp terminations to
ensure that terminal block insulation requirements are maintained for safety. To ensure that
wires are correctly terminated the correct crimp terminal and tool for the wire size should be
used.
Before energising the equipment it must be earthed using the protective earth terminal, or
the appropriate termination of the supply plug in the case of plug connected equipment.
Omitting or disconnecting the equipment earth may cause a safety hazard.
The recommended minimum earth wire size is 2.5mm2, unless otherwise stated in the
technical data section of the product documentation.
Before energising the equipment, the following should be checked:
− Voltage rating and
polarity;
− CT circuit rating and integrity of
connections;
− Protective fuse
rating;
− Integrity of earth connection (where
applicable)

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3. EQUIPMENT OPERATING CONDITIONS
The equipment should be operated within the specified electrical and environmental limits.
3.1 Current transformer circuits
Do not open the secondary circuit of a live CT since the high level voltage produced may be
lethal to personnel and could damage insulation.
3.2 External resistors
Where external resistors are fitted to relays, these may present a risk of electric shock or
burns, if touched.
3.3 Battery Replacement
Where internal batteries are fitted they should be replaced with the recommended type and
be installed with the correct polarity, to avoid possible damage to the equipment.
3.4 Insulation and dielectric strength testing
Insulation testing may leave capacitors charged up to a hazardous voltage. At the end of
each part of the test, the voltage should be gradually reduced to zero, to discharge
capacitors, before the test leads are disconnected.
3.5 Insertion of modules and pcb cards
These must not be inserted into or withdrawn from equipment whist it is energised since this
may result in damage.
3.6 Fibre optic communication
Where fibre optic communication devices are fitted, these should not be viewed directly.
Optical power meters should be used to determine the operation or signal level of the
device.

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4. OLDER PRODUCTS
Electrical adjustments
Equipment’s that require direct physical adjustments to their operating mechanism to
change current or voltage settings should have the electrical power removed before making
the change, to avoid any risk of electrical shock.
Mechanical adjustments
The electrical power to the relay contacts should be removed before checking any
mechanical settings, to avoid any risk of electric shock.
Draw out case relays
Removal of the cover on equipment incorporating electromechanical operating elements,
may expose hazardous live parts such as relay contacts.
Insertion and withdrawal of extender cards
When using an extender card, this should not be inserted or withdrawn from the equipment
whilst it is energised. This is to avoid possible shock or damage hazards. Hazardous live
voltages may be accessible on the extender card.
Insertion and withdrawal of heavy current test plugs
When using a heavy current test plug, CT shorting links must be in place before insertion or
removal, to avoid potentially lethal voltages.

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5. DECOMMISSIONING AND DISPOSAL
Decommissioning: The auxiliary supply circuit in the relay may include capacitors across
the supply or to earth. To avoid electric shock or energy hazards,
after completely isolating the supplies to the relay (both poles of any
dc supply), the capacitors should be safely discharged via the external
terminals prior to decommissioning.
Disposal: It is recommended that incineration and disposal to water courses is
avoided. The product should be disposed of in a safe manner. Any
products containing batteries should have them removed before
disposal, taking precautions to avoid short circuits. Particular
regulations within the country of operation, may apply to the disposal
of lithium batteries.

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6. TECHNICAL SPECIFICATIONS
6.1 Protective fuse rating
The recommended maximum rating of the external protective fuse for this equipment is 16A,
Red Spot type or equivalent, unless otherwise stated in the technical data section of the
product documentation.
Insulation class:
IEC 61010-1 : 2002 Class II
EN 61010-1 : 2002 Class II
Insulation Category
(Over voltage):
IEC 61010-1 : 2002
Category II (600V), III (300V)
EN 61010-1 : 2002
Category II (600V), III (300V)
Environment:
IEC 61010-1 : 2002
Pollution degree 2 (600V), 3
(300V)
EN 61010-1 : 2002
Pollution degree 2 (600V), 3
(300V)
Compliance is demonstrated by
reference to generic safety
standards.
Product Safety:
73/23/EEC & 2006/95/EC
EN 61010-1 : 2002
Compliance with the European
Commission Low Voltage
Directive.
Compliance is demonstrated by
reference to generic safety
standards.

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7. INTRODUCTION
7.1 General
The iSTAT I4X is a range of communications Interfaces were primarily designed for use with
communicating ISTAT Measurement Transducers or Measurement Centres, but can be used
with other communicating devices, i.e. Micom Relays.
There are three different versions of the I4X, these convert the following signals:
EIA (RS)232 to EIA (RS)485 (2-wire)
Ethernet to EIA (RS)232
Ethernet to EIA (RS)485 (2-wire)
7.2 iSTAT I4X Family
The iSTAT I4X family consists of 3 products
7.2.1 EIA (RS)232 to EIA (RS)485 (2-wire)
The RS232 to RS485 converter is bi-directional; the ‘Master’ unit can be connected to either
the RS232 or RS485 port.
The unit works with any protocol which can be transmitted over both RS232 and RS485 2-
wire systems.
The use of digital technology achieves high reliability over a wide data speed range of 1200
to 115200 bits per second.
7.2.2 Ethernet to EIA (RS)232
The Ethernet to RS232 interface is uni-directional; the ‘Master’ unit must be connected to the
Ethernet port.
The unit works with the Modbus RTU protocol over RS232 and Ethernet.
The use of digital technology achieves high reliability over a wide data speed range of 1200
to 115200 bits per second for the RS232 port.
7.2.3 Ethernet to EIA (RS)485 (2-wire)
The Ethernet to RS485 interface is uni-directional; the ‘Master’ unit must be connected to the
Ethernet port.
The unit works with the Modbus RTU protocol over RS485 and Ethernet.
The use of digital technology achieves high reliability over a wide data speed range of 1200
to 115200 bits per second for the RS485 port.

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8. CONNECTION MODES
8.1 EIA (RS)232 to EIA (RS)485
There are three groups of terminals on the I4X; the auxiliary voltage, the RS232 port and the
RS485 port. These are shown in the table below:
I4X
Auxiliary supply
RS232
port
RS485
port
Output device
Screw
Terminals
13 + ∼ , 14 – ∼
(TX) 26
(RX) 24
(GND) 25
(A) 21
(B) 23
DATA +
DATA -
The maximum cable length between the I4X and the RS232 device is 3 meters.
The maximum number of devices that can be supported using RS485 communications is 32.
The line should be terminated by a 120 ohm resistor.
8.2 Ethernet to EIA (RS)232
There are three groups of terminals on the I4X; the auxiliary voltage, the Ethernet port and
the RS232 port. These are shown in the table below:
I4X
Auxiliary supply
Ethernet
port
RS232
port
Output device
Terminals
13 + ∼ , 14 – ∼
10/100 RJ45
socket
(TX) 26
(RX) 24
(GND) 25
(TX)
(RX)
(GND)
The maximum cable length between the I4X and the RS232 device is 3 meters.
8.3 Ethernet to EIA (RS)485
There are three groups of terminals on the I4X; the auxiliary voltage, the Ethernet port and
the RS485 port. These are shown in the table below:
I4X
Auxiliary supply
Ethernet
port
RS485
port
Output device
Terminals
13 + ∼ , 14 – ∼
10/100 RJ45
socket
(A) 21
(B) 23
DATA +
DATA -
The maximum number of devices that can be supported using RS485 communications is 32.
The line should be terminated by a 120 ohm resistor.
8.4 Status Indication: Power
On each I4X there is a single Power LED that indicates when there is an auxiliary supply
connected. The I4X uses a universal ac/dc power supply that can operate between 24 to
300V DC and 40 to 276V AC. The frequency range of the power supply is 40 to 70Hz.

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8.5 Status Indication: Ethernet
When used with an Ethernet connection, LED’s on the RJ45 plug will indicate the presence
of Ethernet activity. When the network is active the left hand LED will be continuously lit or
blinking for a 10Mb/s connection or activity and the right hand LED for 100Mb/s connection
or activity.
8.6 EIA (RS)232 to computer socket connection
When using RS232 to connect to a computer, the RS232 connection can be made with
either a 9 or 25 pin socket. The connections are shown in the table below:
RS232
Port on I4X
Computer DB9F terminal
(9 pin)
Computer DB25F terminal
(25 pin)
(TX) 26
(RX) 24
(GND) 25
2
3
5
3
2
7

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9. COMMUNICATION SETTINGS
9.1 EIA (RS)232 to EIA (RS)485
The I4X RS232 to RS485 communications interface does not require any settings for its
operation.
However for correct operation when using RS485 the devices that are connected to the I4X
will have to be correctly addressed. When more than one device is connected on the RS485
port each must have a different address number. The maximum number of devices that can
be connected to the RS485 port is 31.
The default serial settings for communicating devices vary and when more than one device
is connected to the I4X they should all have the same serial settings.
9.2 Ethernet to EIA (RS)232
The I4X Ethernet to RS232 communications interface requires that the settings for the
Ethernet and the RS232 ports are configured prior to use in the application. This can be
done using QDSP and a Web browser.
The RS232 settings in the I4X must match those for the RS232 device attached. The RS232
device attached must also be assigned a Modbus device address.
9.3 Ethernet to EIA (RS)485
The I4X Ethernet to RS485 communications interface requires that the settings for the
Ethernet and the RS485 ports are configured prior to use in the application. This can be
done using QDSP and a Web browser.
All of the RS485 devices connected to the I4X must have the same serial settings as the
RS485 port on the I4X. Up to 31 x RS485 devices can be connected to the I4X RS485 port
and each must be assigned a unique Modbus address in the range 1 –247.
9.4 Ethernet IP addresses
When using the Ethernet each device requires a unique IP address. There are two ways of
assigning this address to the I4X:
• Fixed IP
address
• DHCP
address
Fixed IP address: This is the most common method used where the IP address is defined
by the System Administrator. The IP address should be valid for the net, it has to be unique
and in the same subnet as the computer that it being used with. The following information is
required for this addressing:
IP Address
.
.
.
Subnet mask . . .
Gateway . . .
DHCP address: This is an automatic method of assigning IP addresses. When a device
connects to the Ethernet, it will search for the DHCP server which will assign the next
available IP address using the DeviceInstaller program.

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9.5
Programming I4X settings using QDSP and Web browser
9.5.1 QDSP setting software
The QDSP setting software is used to program all iSTAT communicating Measurement
Devices and it can also be used to programme the IP address for the Ethernet interface of
an I4X.
The software is available free-of-charge from the GE Grid Solutions website.
The separate QDSP manual includes the details of how to install the QDSP software on a
PC and how to program the PC’s Ethernet port to allow QDSP to interface to an external
Ethernet device and how to set an IP address in the I4X.
The IP address used for the PC in local mode and in the I4X will depend on the requirements
of the application and may be different from those used in the examples in the QDSP
manual.
9.5.2 Internet Browser
When the IP address has been confirmed in the I4X using QDSP it is now possible to
address the setting pages in the I4X over Ethernet using a web browser.
Open up the preferred web browser and enter the IP address of the I4X into the address line
(i.e. 192.168.0.55) and press <RETURN>. The web interface in the I4X will then be
displayed.
Fitted inside the I4X is a Lantronix device which implements the Ethernet to serial
conversion.
In the index on the left we are only interested in 2 options, ‘Serial Settings’ and ‘Connection’
and in these windows only a few adjustments are required.

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9.5.2.1 Serial settings
In the ‘Serial Settings’ window, only adjust the Baud Rate, Data Bits, Parity and Stop Bits,
these should be set to the same as the serial devices which are connected to the RS232 or
RS485 port. All other settings should not be changed from the defaults.
NOTE: Even when an Ethernet to RS485 converter is being programmed, the ‘Protocol’
setting must remain as ‘RS232’, this is due to the internal construction of the I4X.
When settings are complete click <OK>.