GARD Pro – Power Line Carrier System...2015/12/01 · GARD Pro PLC Quick Start RFL Electronics...

GARD Pro PLC Quick Start RFL Electronics Inc. December 1, 2015 1 973.334.3100

Table of Contents

Table of Contents .................................................................................................................... 1

1. Overview ............................................................................................................................. 1

2. Input Power Connections ................................................................................................... 2

3. Alarm Relay and Input/Output Module Connections .......................................................... 5

4. System I/O Connections ..................................................................................................... 9

5. Specific Connections for PLC Applications ...................................................................... 11

6. Connecting a laptop to the GARD Pro .............................................................................. 12

7. GARD Pro PLC Commissioning ....................................................................................... 18

8. Reference Data for PLC Applications ............................................................................... 21

1. OverviewThe GARD Pro is a modular system available in a 3U or 6U format that will provide one product for all your teleprotection and line protection needs. The GARD Pro base system consists of the following modules.

• Controller Module

• Display Module

• System I/O Module

• Power Supply Module

• Power Supply I/O Module

• Input/Output Modules

This Quick Start and Installation Guide is specifically written for the GARD Pro system that has the single function PLC modules installed, offering one product for all On/Off and FSK PLC applications. The following modules are installed for this application.

• Front digital PLC Module

• Rear analog PLC Module

GARD Pro – Power Line Carrier System Quick Start and Installation Guide

Because RFL™ and Hubbell® have a policy of continuous product improvement, we reserve the right to change designs and specifications without notice.


Customer Specific System Draw ings

Before beginning the installation and set-up of your GARD Pro refer to the “as supplied drawings” provided with your unit. These drawings provide customer specific information such as how your chassis is populated, jumper settings, input/output mapping, logic information and LED configuration. This drawing has a designation of CD-XXXXX or CD-64032. An example is shown below.

Front view of GARD Pro chassis

Front view of GARD Pro chassis with front panel removed

Rear view of GARD Pro chassis

Jumper Settings (PLC option)

Input/Output mapping

System Jumper Settings

2. Input Power Connections

WARNING!Individual double pole disconnects must be installed between the building or station battery supply and the GARD Pro power supply. This must be done for both the main and back-up supply.

CAUTION

Power supplies are not hot swappable. Power must be disconnected from the appropriate power supply I/O terminal, before installing or removing power supplies from the GARD Pro chassis.

Before attempting to make power connections, make sure the GARD Pro terminal is equipped with a power supply designed to operate at the available input supply voltage. This can be determined by checking the electrical specifications on the outside of the chassis as shown on the following page.



3U GARD Pro shown, position of label on 6U unit similar

This system left the factory configured as follows:

48/125VDC120VAC

250VDC220VAC

48/125VDC120VAC

250VDC220VAC

24VDC

24VDC

Power Supply 1

Power Supply 2

Input Modules 48VDC24VDC 125VDC 250VDCInput Modules can be configured fo 24V, 48V, 125V or 250V by changing jumper positions.See the manual for further information.

Power Supply and Input Module boxes will be checked as per factory configuration.

If an external power supply is being used, check the markings on the external power supply. If the wrong voltage is connected to the power supply, component damage will result.

Before proceeding to make connections ensure that all the modules in the chassis are correctly seated. Remove the front panel of the GARD Pro chassis and using minimal force remove and re-seat all front modules.

After all other connections have been made to the GARD Pro, input power connections can be made to the Power Supply I/O at the rear of the chassis.

Before proceeding to connect power to the GARD Pro ensure that the main and redundant power switches on the rear of the unit are in the “OFF” position and that the power wires to be installed are disconnected at their source.

Input power connections can be either DC station battery voltage (24, 48, 125 or 250VDC) or AC voltage (120VAC or 220VAC), depending on which power supplies are installed in the chassis.



POWER SUPPLY 1

MAJOR MINOR

SW1 SW2

I 0 I 0

+ +- -

POWER SUPPLY 2

Input Power Power Supply 1

Input Power Power Supply 2

Power Supply 1 and 2 input power connections are completely independent for using independent power sources. Both sets of terminals are always provided. Make input power connections as needed according to the number of power supply modules installed.

Station battery positive goes to the “+” terminal and station battery negative goes to the “-“ terminal. If AC input power is used, connections are made to the “+” and “-” terminals and the polarity markings can be neglected.

WARNING!The GARD Pro must be properly grounded as described in the following section before attempting to connect input power. Improper ground connections may result in system malfunctions, equipment damage, or electric shock.

Chassis Ground Connections A protective earth stud at the lower right rear of the GARD Pro chassis is the main ground for the GARD Pro terminal.

Grounding is accomplished by connecting a wire 6AWG or larger between this protective earth stud and rack ground. The grounding wire should be kept as short and straight as possible, to keep its resistance and inductance to a minimum.



MAJOR MINOR

Protective Earth Stud

Before connecting the power at its source and switching on the GARD Pro, check the following:

• Is the GARD Pro grounded correctly?

• Is the installed GARD Pro power supply designed to operate at the available inputsupply voltage?

• Is the polarity of the supply power correct?

• If installed in an enclosed cabinet, is the unit ventilated correctly?

3. Alarm Input/Output Relay and Module Connections

Input/Output Module Before proceeding ensure that the power supply switches are in the “OFF” position and that power is disconnected at its source.

Before making connections to the terminal blocks on the rear of the GARD Pro, configure any additional rear modules that may be present in your system. It is easier to configure the rear panel modules prior to connecting field wiring. The Main Input/Output Module can have three possible plug-on boards; these are an input unit, a solid state output unit and a relay output unit. The input unit and relay output unit have settings for input voltage and relay form position, respectively. Factory set settings can be changed in the field if required; details are given on the following pages.

CAUTION This equipment contains static sensitive devices. Persons working on this equipment must observe electro static discharge (ESD) precautions before opening the unit or working on the rear of the chassis. As a minimum you must do the following: Use anti-static devices such as wrist straps and floor mats.



Main Input/Output Module

Insert Extraction Tool here

Extraction Tool

Remove ScrewRemove Screw

Ensure that the power switch(es) are in the OFF position and that power is disconnected at its source. To remove the input/output Module, remove the two screws shown above. Screw in the extraction tool where shown and using the tool gently slide the module out.

Shown below is the main input/output module removed from the unit.

Extraction Tool

Input UnitRelay Output Unit

24 – Position I/O Terminal Block

Voltage Selection JumpersForm A/B

Switches

124

RF Shield



Note: The following illustrations have the RF Shield removed for clarity.

See below for input unit Voltage selection jumpers.

J12 J11 J10 J9 J8 J724V

24V

24V

24V

24V

24V48V

48V

48V

48V

48V

48V125V

125V

125V

125V

125V

125V250V

250V

250V

250V

250V

250V

24V

J7

48V125V250V

Jumper Setting (typical)with 48V selected

See below for Relay Output Unit form A/B switches.

SW1SW2SW3SW4SW5SW6

K1K2K3K4K5K6

A

B

AAA

BBB B B

A A Slide the switch to move from Form A (normally open) to Form B (normally closed)

FOR

M

AFO

RM

B

SW

1

Switch Setting (typical)

Slider Switches



Rear Terminal Block Connections The terminal blocks on the rear of the GARD Pro chassis are conventional screw-type barrier blocks or compression blocks. RFL recommends that wires be terminated with size 6 ring lugs for added reliability. For actual terminal block configuration refer to system drawing described at the beginning of this document.

123456789101112131415161718192021222324

Typical terminal block with six inputs and six relay outputs

Out 2 Out 1Out 3

In 2 In 1In 3In 4In 5In 6

Out 4Out 5Out 6

Output Input

Major and Minor Alarm Connections The GARD Pro chassis has two SPDT (Form C) relays mounted in the Power Supply I/O module. The terminals are labeled as shown below. The Major Alarm relay terminals are on the left of the figure and the Minor Alarm relay terminals are on the right. The contacts are rated 100mA, 300VDC, resistive load. The alarm relays will respond to alarm and alert conditions. The functionality can be customized by the user as required.

POWER SUPPLY 1

MAJOR MINOR

SW1 SW2

I 0 I 0

+ +- -

POWER SUPPLY 2

Major Alarm Relay Contacts

Common

Normally Closed (Alarm)

Normally Open (Healthy)

Common

Normally Closed (Alarm)

Normally Open (Healthy)

Minor Alarm Relay Contacts

Please note that alarm contacts are independent of power supplies installed and are always provided in all systems.



Under normal operating conditions when the alarm conditions are healthy the relays are energized; in an alarm state the relays will be in the de-energized position.

All relay contacts are labeled in the de-energized position.

4. System I/O ConnectionsThe GARD Pro has a system I/O module used for timing and remote access functions. The connections are shown below. Install as required.



Setting Jumpers for IRIG-B Timing The following table lists the jumpers required on the System I/O Board when the GPS Module is NOT INSTALLED

Jumper Jumper Installed across these two terminals Function

J7 5-6 Must be installed

J8 11-12 Must be installed

13-14 & 15-16 IRIG-B, AGC is in the circuit

13-15 IRIG-B, AGC is bypassed

J10 1-2 Must be open

3-4 For Un-modulated IRIG-B inputs

5-6 & 7-8 For Modulated IRIG-B inputs

9-10 No IRIG-B termination

11-12 50 Ohm IRIG-B termination

13-14 600 Ohm IRIG-B termination

J11 1-2 IRIG-B shield is grounded

3-4 IRIG-B shield is isolated

5-6 Must be installed

9-10 No 1PPS termination

11-12 50 Ohm 1PPS termination

13-14 600 Ohm 1PPS termination

When the GARD Pro is equipped with the optional GPS receiver, the IRIG-B port on the system I/O provides an Un-Modulated IRIG-B signal output.

J11

J101

1

2

215

15

16

16 J3 J12IRIG

NORM NORM

IRIG

J6

J9

J4

J7

J8J13

J14

1

1

SPARES1 2

15 16

1 2

15 16

UNMODMOD

NONE50 OHM600 OHM

TERM

ISOLATEDGROUNDED

50 OHMNONE

600 OHM

GPS Module location (optional) and IRIG-B jumpers

NOTE: For Actual System I/O jumper settings refer to system drawing described at beginning of this document.



5. Specific Connections for PLC Applications

The GARD Pro PLC option is a single function PLC protection unit. The PLC function consists of two plug-in modules: A digital module which plugs into the front of the chassis, and an analog module which plugs into the rear of the chassis. The GARD Pro PLC can be set to function in FSK (DTT, POTT, DCUB), or ON/OFF (DCB) mode. In addition to performing the normal PLC functions, the GARD Pro PLC will monitor the transmit and receive interface to measure transmit power, reflected power, trans-hybrid loss, receive signal strength and SNR. The DSP based transmitter and receiver allows full frequency programming in the range of 30 to 500 kHz.

Electrical connections are made to the rear of the GARD Pro PLC chassis. This quick start guide assumes that the unit has been set-up in its operating location (without any connections being made) with all modules installed. Below is the PLC Analog Module as it would appear in the rear of a 3U chassis.

CAU

TION

STATIC

SEN

SITIVE

PA O

UT

RX

IN

FINE

CO

ARSE

TX/RX

2W

TX

4WRX

GN

D

+15V-15VG

ND

CLI

Terminal block for connecting external CLI meter or auxiliary power source

BNC connectors are connected to the power line coupling equipment

Pin 1



6. Connecting a laptop to the GARD ProThe GARD Pro is delivered with pre-set IP addresses. The front port IP address is fixed, and factory set to 192.168.1.1. The rear port IP address is configurable.

Front Ethernet PortThe IP Address assigned to the front port is 192.168.1.1 for every GARD Pro chassis. DO NOT plug this port into a LAN. You cannot have more than one device with the same address on a network. The front port is strictly for direct connection to a Laptop PC. The Laptop should have an IP Address on the same subnet (192.168.1.x) as described below. The front port has no default gateway configured, so it is not routable. This is done for security purposes

GARD Pro

Standard Ethernet Cable

Laptop/Notebook PC

RJ-45 Ethernet PortRJ-45 Ethernet Port

IP Address: 192.168.1.1

Note: All GARD Pro front Ethernet ports are preconfigured to an IP address of 192.168.1.1 at the factory, and cannot be changed.

1. Connect a standard Ethernet Cable from the RJ-45 Ethernet port on your PC to the front RJ-45Ethernet port on the GARD Pro as shown above.

2. DHCP (Dynamic Host Configuration Protocol) is available when connecting to the frontethernet port on the GARD Pro with a laptop or PC. DHCP will obtain the parametersnecessary for operation in an IP Network. This protocol greatly reduces the systemadministration workload, allowing addressing setup with minimal or no manual configuration.

Remember that operating systems are subject to updates and can vary slightly.

Details on configuring a PC using DHCP and Static IP are given in the Instruction Manual.



First Time Login to the GARD Pro Web Server The GARD Pro PLC system is accessed via a web browser. The following browsers are supported: Google Chrome, Microsoft Internet Explorer and Mozilla Firefox. RFL recommends using versions released after 2013 that support HTML5.

1. Start the web browser on your laptop.

2. In the address bar enter the IP address of the GARD Pro which is 192.168.1.1 (front port) andhit enter (or use the rear port IP address if known).

3. The GARD Pro login page is displayed as shown below.

Username: Admin Password: Admin

4. The default Username and Password are “Admin.” and “Admin.” Case sensitive.

5. Enter credentials as shown above and click the Login button.

GARD Pro GUI Dashboard Shown below is the jumping off page for all GARD Pro management functions initiated by the user through the web GUI. This intuitive interface has been developed to make configuration, commissioning and testing as straight forward as possible for the end user. The menu bar at the left of the screen contains all the functions necessary for system operation. A graphical representation of the



GARD Pro chassis is displayed in the main section of the webpage. This view can be toggled between the front and rear of the chassis. Clicking on individual modules will display their status. Displayed at all times at the top of the screen are the system alarms and power supply status.

User Administration/Password Setup The user “Admin” always has access to all webpages. The “Admin” cannot be removed as a user, and only the “Admin” can access the administrator webpage. Up to 10 users can be added by the administrator, with individual access levels. There are four access levels available, assigned by the “Admin” as shown on the following page.

User Level User Name Password Privilege

Level 3 (admin) Admin (fixed) Full control when connected to the front or rear of the GARD Pro, plus can manage users.

Level 2 (full control) Selectable Full control when connected to the front or rear of the GARD Pro.

Level 1 (local control) Selectable Full control when connected to the front of the unit; read only when connected to the rear.

Level 0 (guest, read only) Selectable Read only.

Navigate to System Management > Users > and select the “Administration” tab.

Clicking these views will display an enlarged view at right.

Chassis Alarm Status

Power Supply alarm status (Main and redundant supply) Note: If a power supply

is not present, it will be grayed out.

Physical location of modules (Slot number)

Clicking on a module will display its status page.

Main navigation Menu



Below is an example administration dialog already populated with users at different “User Levels.” Users can be added or deleted by the admin and each user can be individually password protected. Strong passwords with up to 16 characters may be used. Remember to click “Save” once changes or additions are made.

Click to add users as shown

Click to change a password or upgrade privilegesClick directly on the pencil icon to edit an account

Click to remove a user

Grayed out users are disabled

Changing the Rear IP Address The rear IP address is assigned at the factory for testing purposes but can be changed by the user. For additional security the user MUST be connected to the front Ethernet port and have the proper security access level authorization to change the address of the rear Ethernet port.

Navigate to Configuration > System > and select the “Labels/Ethernet” tab.

Remember to click “Save” once the address information has been set.



Rear IP Address: Displays the current IP address for the rear Ethernet port. Enter the desired address and click ”Save”

Rear Netmask: Displays the current Netmask address for the rear Ethernet port. All systems on the same subnet must use the same subnet mask

Rear Gateway: Allows the user to specify the Gateway used on this network port

File Operations Files may be sent from a PC to the GARD Pro or saved to a PC from the GARD Pro chassis. A “Whole Chassis Configuration” file may be extracted from the GARD Pro and loaded into the GARD Pro emulator, modified and re-loaded into the GARD Pro chassis. Files may also be backed up to a PC as a safety precaution. A “Whole Chassis Configuration” file contains all the settings and system logic for a complete chassis. It can be loaded from a PC to configure the GARD Pro in one step.

Send File to GARD Pro:

Navigate to System Management > File Operations > and select the “Send” tab. The “File Type” field will automatically default to “Whole Chassis Configuration.” Which is the most common file sent to the GARD Pro. Select the type of file to be downloaded from your PC to the GARD Pro from the drop-down menu.



Once the file has been selected click the “Browse” button to navigate to the location on your PC and then click “Send File to Gard.”

Save File to PC:

Navigate to System Management > File Operations > and select the “Save” tab.

The “File Type” field will automatically default to “Whole Chassis Configuration” which is the most common file to be saved to a PC. Select the type of file to be saved to your PC from the drop-down menu. The default file name is allconfigs.zip. Rename the file as needed.

Once the file has been selected click the “Generate File” button and then click “Save File to PC.



7. PLC CommissioningThe GARD Pro PLC is factory-calibrated. The Receiver Calibration is typically the only commissioning procedure required in the field. This calibration is initiated through the user interface. Navigate to Test > Calibrate > and select PLC module as necessary.

WARNING!The following procedure MUST be run with a valid RX signal present at the receive terminal.

(Typically 1 watt Guard signal for FSK and 10 watt block signal for On/OFF)

Receive Auto-Set: This procedure will calibrate the PLC receiver to the actual carrier level received from the line. The procedure is run after all channel elements (traps, tuners, hybrids, etc.) have been installed and tuned. Once the channel has been optimized, this procedure will calibrate the GARD Pro PLC for the nominal carrier receive level (0 dB), setting up operation of things like front-panel CLI meter, Rx alarms, etc. It should only be done at commissioning or any time there is a change made to the PLC system which affects the carrier receive level.

Click this button to run the Receiver Calibration procedure



Follow the steps below to calibrate the receiver.

Click OK

Click Start to run the procedure

Click Done when the procedure is completed

Please refer to the Instruction Manual for other calibration and measurement procedures both initiated through the User Interface and done mechanically on the rear of the Amplifier Module.



Typical PLC Setting and Status Screens Shown below is a typical settings web page used for setting FSK parameters. Transmitter and receiver frequencies as well as alarm thresholds can be set on this web page.

Shown below is the corresponding FSK Status web page.



8. Reference Data for PLC Applications

Trip Transport Delay and Channel Spacing – FSK Mode

2F Operation

Configuration Settings

Nominal Trip Transport Delay (With recommended Settings)

Minimum Permissible Unidirectional Channel Spacing

Minimum Permissible Bidirectional Channel Spacing

Nominal Receive Bandwidth: 200 Hz

Tx Frequency Shift: +/- 100 Hz 12.0 – 13.0 ms 500 Hz 1000 Hz


Tx Frequency Shift: +/- 250 Hz 8.0 ms 1250 Hz 2500 Hz



3F Operation

Configuration Settings

Nominal Trip Transport Delay (With recommended Settings)

Minimum Permissible Unidirectional Channel Spacing

Minimum Permissible Bidirectional Channel Spacing


Tx Frequency Shift: +/- 200 Hz 12.0 – 13.0 ms 700 Hz 1200 Hz







The example illustration below shows the channel spacing in FSK mode for a 200Hz receive band width in unidirectional and bidirectional operation.

Unidirectional

200 Hz

TX Center BW

200 Hz

TX Center BW

200 Hz

TX Center BW

200 Hz 200 Hz

TX Center BW

200 Hz

Unidirectional

700 Hz Minimum Channel Spacing

Shift Up Shift Down

Bidirectional

200 Hz


TX Center BW

200 Hz

RX Center BW

200 Hz

TX Center BW

200 Hz 200 Hz

RX Center BW

200 Hz

Bidirectional

Shift Up Shift Down



Min. Spacing for 2F – 200Hz Bandwidth

Min. Spacing for 3F – 200Hz Bandwidth



Block Transport Delay and Channel Spacing – ON-OFF Mode

Configuration Settings Nominal Block Transport Delay

Minimum Permissible Channel Spacing

Nominal Receive Bandwidth: 500 Hz 5 ms 1 kHz

Nominal Receive Bandwidth: 1000 Hz 3 ms 2 kHz

Nominal Receive Bandwidth: 1500 Hz 1.5 ms 3 kHz



NOTICE

The information in this publication is proprietary and confidential to RFL Electronics Inc. No part of this publication may be reproduced or transmitted, in any form or by any means (electronic, mechanical, photocopy, recording, or otherwise), or stored in any retrieval system of any nature, unless written permission is given by RFL Electronics Inc.

This publication has been compiled and checked for accuracy. The information in this publication does not constitute a warranty of performance. RFL Electronics Inc. reserves the right to revise this publication and make changes to its contents from time to time. We assume no liability for losses incurred as a result of out-of-date or incorrect information contained in this publication.

REVISION RECORD Rev. Description Date Approval

12-1-15 New Document Release 12-1-15 MI

Printed in U.S.A. December 1, 2015

Part Number MCGPROPLCQS

RFL Electronics Inc. 353 Powerville Road ● Boonton Twp., NJ 07005-9151 USA Tel: 973.334.3100 ● Fax: 973.334.3863 Email: [email protected] ● www.rflelect.com

RFL Electronics Inc. is a subsidiary of Hubbell Power Systems, Inc.


mailto:[email protected]

http://www.rflelect.com/

GARD Pro – Power Line Carrier System...2015/12/01 · GARD Pro PLC Quick Start RFL Electronics...

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