Ib02713002e E1

InsulGard® Continuously Online Partial Discharge Monitoring
Installation and Operation Manual IB02713002E Rev. E1 Effective Feb. 2017
InsulGard Installation and Operation Manual

InsulGard Installation and Operation Manual IB02713002E Rev. E1
Effective Feb. 2017
Class A EMC Statements
FCC Part 15
NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference in which case
the user will be required to correct the interference at own expense.
Requesting a Declaration of Conformity
The EC Declaration of Conformity is available upon request for products with a CE mark. For copies of
the EC Declaration of Conformity, contact:
Eaton Predictive Diagnostics

5421 FELTL RD Suite 190
Minnetonka MN 55343
USA
Phone: (952) 912-1331 or (828) 687-3086
Fax: (952) 912-1355
EATON CORPORATION www.eaton.com/pd 2

Effective Feb. 2017
Table of Contents
Foreword................................................................................................................................................................... 7
1 Description ....................................................................................................................................................... 8
1.1 General ..................................................................................................................................................... 8
1.2 Principles of Operation.......................................................................................................................... 10
1.3 Specification........................................................................................................................................... 12
1.4 Important Features and Options ........................................................................................................... 13
1.4.1 Data Structure and storage. ................................................................................................................................ 13
1.4.2 Trend .................................................................................................................................................................. 14
1.4.3 Alarms ............................................................................................................................................................... 14
1.4.4 Continuous Watch Feature................................................................................................................................. 15
1.4.5 Phase Resolved Data and Phase Reference........................................................................................................ 15
1.4.6 Schedule............................................................................................................................................................. 15
1.4.7 Self-test and Self-calibration.............................................................................................................................. 16
1.4.8 PD Intensity and PD pulse repetition rate calculation low level cut-off ............................................................ 16
1.4.9 Auxiliary Inputs ................................................................................................................................................. 16
1.4.10 Measurement Suspend .................................................................................................................................. 16
1.4.11 Communication Options and Device Address .............................................................................................. 17
1.4.12 Software ........................................................................................................................................................ 17
1.4.13 InsulGard configuration (settings) ................................................................................................................ 17
1.5 InsulGard mounting options and sensor connection ........................................................................... 19
1.5.1 Panel mount InsulGard ...................................................................................................................................... 20
1.5.2 Door mount InsulGard ....................................................................................................................................... 26
1.6 Sensors for InsulGard ........................................................................................................................... 27
2 Applications ................................................................................................................................................... 28
2.1 General ................................................................................................................................................... 28
2.2 Motor and Small Generator Applications ............................................................................................. 28
2.2.1 PD sensors at line terminals: .............................................................................................................................. 28
2.2.2 RTD sensors in winding depth ........................................................................................................................... 29
2.2.3 Auxiliary sensors ............................................................................................................................................... 29
2.3 Large Generator Applications ............................................................................................................... 29
2.3.1 PD sensors at line terminals: .............................................................................................................................. 29
2.3.2 RTD sensors in winding depth ........................................................................................................................... 29
2.4 MV Switchgear Applications ................................................................................................................. 30
2.4.1 PD sensors ......................................................................................................................................................... 30
2.4.2 Auxiliary sensors ............................................................................................................................................... 30

Effective Feb. 2017
2.5 Configuration of Alarm Thresholds ..................................................................................................... 31

2.6 Noise Aspects ......................................................................................................................................... 31
2.7 Device Location and Environmental Issues ......................................................................................... 32
2.8 Additional Parameters to Measure ....................................................................................................... 32
2.9 Networking and Communicating with InsulGard ................................................................................ 32
3 On-Site Installation ....................................................................................................................................... 34
3.1 InsulGard system content ...................................................................................................................... 34
3.2 InsulGard system packages ................................................................................................................... 35
3.3 Important Note on Sensor Installation ................................................................................................. 35
3.4 Step 1 - Hardware Installation .............................................................................................................. 35
3.5 Step 2 - Sensors and Power connections .............................................................................................. 37
3.6 Step 3 - Monitor Installation and Final Connections .......................................................................... 37
4 Startup ............................................................................................................................................................ 38
4.1 General ................................................................................................................................................... 38
4.2 Quick setting via the monitor keypad .................................................................................................... 38
4.3 Communications Board Setup .............................................................................................................. 41
4.3.1 USB ................................................................................................................................................................... 41
4.3.2 Ethernet .............................................................................................................................................................. 41
4.3.3 Tips for Communications Setup ........................................................................................................................ 44
5 Troubleshooting............................................................................................................................................. 46
5.1 Troubleshooting Tips ............................................................................................................................. 46
5.2 InsulGard replacement procedure ........................................................................................................ 48
5.3 Error Messages ...................................................................................................................................... 49
5.4 Fuse Replacement.................................................................................................................................. 49
6 Appendix I InsulGard Front Panel Keypad Operation ............................................................................. 51
6.1 Entering Setup ....................................................................................................................................... 51
6.2 Setup via Keypad .................................................................................................................................... 51
6.2.1 Date .................................................................................................................................................................... 51
6.2.2 Time ................................................................................................................................................................... 52
6.2.3 Activate PD Channels ........................................................................................................................................ 52
6.2.4 Parameters to Display ........................................................................................................................................ 53
6.2.5 Set a Sensor Sensitivity...................................................................................................................................... 55
6.2.6 Set Measurement Schedule ................................................................................................................................ 55
6.2.7 Data Saving Mode ............................................................................................................................................. 56
6.2.8 Pulse Width and Interval.................................................................................................................................... 57
6.2.9 Alarm Thresholds .............................................................................................................................................. 58
6.2.10 Rated Voltage................................................................................................................................................ 60

Effective Feb. 2017
6.2.11 Rated Current ................................................................................................................................................ 60

6.2.12 Number of Power Cycles for Data Acquisition............................................................................................. 60
6.2.13 Alarm Relay Mode ........................................................................................................................................ 61
6.2.14 Minimum Noise Channel Magnitude Level .................................................................................................. 61
6.2.15 Display Scroll Time ...................................................................................................................................... 62
6.2.16 ModBus Address ........................................................................................................................................... 62
6.2.17 Continuous Watch Options ........................................................................................................................... 62
6.2.18 Baud Rate ...................................................................................................................................................... 63
6.2.19 Select PDI or Qmax Output .......................................................................................................................... 63
6.2.20 Start/Stop InsulGard ...................................................................................................................................... 64
6.2.21 Phase Shift .................................................................................................................................................... 64
6.2.22 Channel Phase ............................................................................................................................................... 65
6.2.23 Frequency Range .......................................................................................................................................... 66
6.2.24 Suspend for Temperature .............................................................................................................................. 66
6.2.25 Suspend for Voltage ...................................................................................................................................... 66
6.2.26 Suspend for Current ...................................................................................................................................... 67
6.2.27 Trend Window Length .................................................................................................................................. 68
6.2.28 Calibrate Temperature................................................................................................................................... 68
6.2.29 Calibrate Voltage .......................................................................................................................................... 69
6.2.30 Calibrate Current ........................................................................................................................................... 70
6.2.31 Calibrate 4-20mA Loop ................................................................................................................................ 71
6.2.32 Calibrate Humidity Sensor ............................................................................................................................ 72
6.2.33 Noise Filter Offsets ....................................................................................................................................... 73
6.2.34 Channel Low Magnitude Limit ..................................................................................................................... 73
6.2.35 Software Filters ............................................................................................................................................. 75
6.2.36 ModBus Protocol .......................................................................................................................................... 75
6.2.37 Start a Single Measurement .......................................................................................................................... 76
6.2.38 IP Address ..................................................................................................................................................... 76
6.3 Accessing Memory via Keypad .............................................................................................................. 76
6.3.1 Clear Data Memory ........................................................................................................................................... 76
6.3.2 Check Data Saved in Memory ........................................................................................................................... 76
7 Appendix II Synchronization and Phase Reference Shift.......................................................................... 78
7.1 Synchronization ..................................................................................................................................... 78
7.2 Typical Phase Reference Shift for External Synchronization ............................................................. 79
7.3 Determining Phase Reference Shift ...................................................................................................... 79
7.4 InsulGard with Automatically Synchronization Switching....................................................................... 81
8 Appendix III Communications Board Interface ........................................................................................ 84

Effective Feb. 2017
8.1 General ................................................................................................................................................... 84

8.2 Network Configuration.......................................................................................................................... 84
8.3 Change Passwords ................................................................................................................................. 88
8.4 Modbus RTU Configuration ................................................................................................................. 89
8.5 Date/Time Configuration ...................................................................................................................... 89
8.6 FTP Client Configuration ..................................................................................................................... 91
8.7 Email Configuration.............................................................................................................................. 92
8.8 Identification Page ................................................................................................................................ 95
8.9 InsulGard Summary Page ..................................................................................................................... 96
8.10 InsulGard Channels Page ..................................................................................................................... 97
8.11 Alarms .................................................................................................................................................... 98
8.12 Logs ........................................................................................................................................................ 99
8.13 Documentation....................................................................................................................................... 99
8.14 Ethernet Virtual Communications Port .............................................................................................. 100
8.15 Communications Firmware and Upgrade .......................................................................................... 100
8.15.1 Steps for Updating the Communication Firmware via the Web User Interface .......................................... 100
9 Appendix IV USB Device Driver Installation ........................................................................................... 103
10 Appendix V. Ethernet Virtual Communications Port Driver Installation and Configuration ............ 107
10.1 ComPortConfigurator User Manual ................................................................................................... 107

Effective Feb. 2017
Foreword
The purpose of this manual is to describe the functionality of the new generation of InsulGard. New
features include a graphic dot matrix display and more communication options embedded, such as
USB port, Ethernet port over network, webpage and FTP server. It serves as primary guideline for
qualified personnel involved in the onsite installation, start-up, commissioning and continuous
monitoring.
The whole document is organized in the following way:
Section 1 Description introduces the basic functions and operations of InsulGard
Section 2 Application presents the general considerations for InsulGard applications, especially
configuration of different sensors for different applications.
Section 3 On-Site Installation shows the procedures for onsite installation of InsulGard systems.
Section 4 Startup presents the procedures for initial setup using the front panel keypad without a
computer upon completion of InsulGard installation.
Section 5 Troubleshooting provides troubleshooting suggestions in different scenarios.
Section 6 Appendix I InsulGard Front Panel Keypad Operation gives details about how to operate
using the front panel keypad and display on the InsulGard.
Section 7 Appendix II Synchronization and Phase Reference Shift shows the procedures to make
proper synchronization and measure phase shift between InsulGard and monitored object.
The following three sections should be ignored if InsulGard does not include the optional communi
cation board.
Section 8 Appendix III Communications Board Interface presents the features available through the
optional communications board.
Section 9 Appendix IV USB Device Driver Installation gives exact steps to install the driver for
communication between a computer and InsulGard with a USB cable through the USB port on the
communication board.
Section 10 Appendix V. Ethernet Virtual Communications Port Driver Installation gives exact steps
to install the driver and configure the interface to use the Ethernet port on the communications board as
a serial port to communicate between a computer and InsulGard online.

Effective Feb. 2017
1 Description
1.1 General
InsulGard by Eaton Corporation is a standalone microprocessor-controlled continuous partial
discharges monitoring device for use with a wide range of medium voltage power equipment. It works
with 50/60 Hz frequency powered equipment as well as with variable frequency applications. There are
monitor’s options for low frequency measurements down to 5 Hz and high frequency up to 400 Hz
measurements .
Partial discharges (PD) are the small sparks that commonly occur within or on surface of insulation in
various types of medium and high voltage equipment. Over time, PD destroys the insulation, eventually
causing insulation breakdown (full discharge). In general, it takes months or even years before PD will
cause a failure of insulation. Therefore, PD is an important indicator of insulation degradation for
prompt maintenance or repair.
InsulGard is designed to provide an alarm based on PD characteristics at an early stage of insulation
degradation. It measures PD from up to 15 high frequency PD sensors, stores the information in
internal memory and provides various alarm interfaces to the users if any set points are exceeded.
Depending on the application various PD sensors can be used.
InsulGard has three auxiliary inputs for measuring auxiliary parameters of the monitoring equipment:
temperature, load and humidity or voltage, depending on the application. Those parameters will be
correlated with Partial Discharge values for advanced data analysis. Corresponding sensors are
supplied by Eaton.
InsulGard includes a main unit and a Sensor Interface Board connected by flat ribbon cable (Figure
1-1). All sensors have to be connected to the Sensor Interface Board.
Five LEDs on the front panel of the main unit indicate Alarm status: green LED for Normal, yellow LED
for Warning (Alarm 1) and red LED for Alarm (Alarm 2), Setup and Memory operation modes.
A graphic LCD display shows measurement data, setup or memory content and error messages.
During normal operation the display continuously scrolls through the last measured data, auxiliary
parameters and other information.
With the front panel keypad and display, users can operate InsulGard directly without a computer. The
membrane keypad has four navigation ARROW keys (), four function keys: Esc, d Enter,Set
and Memory.
InsulGard has several interfaces (Figure 1-1) to be easily implemented into any alarm and SCADA
system. These options include three C-form relays for Warning (Alarm 1), Alarm (Alarm 2) and Device
Status indication, 4-20mA output, RS485 and two USB interfaces and an Ethernet interface which
enable convenient online communication, webpage display and FTP server for data downloading.

Effective Feb. 2017
15 channels for PD sensors

connection and one channel
for noise signal.
Connector for flat

ribbon cable from
main unit
Inputs for
auxiliary
sensors
connection
b
Figure 1-1 a - Top: InsulGard main unit (right) and Sensor Interface Board (left). Bottom: b - Side
view of the InsulGard.

Effective Feb. 2017
1.2 Principles of Operation

InsulGard has 16 signal channels. Channels 1 to 15 are designated for partial discharge sensors while
channel 16 designated for noise suppression. All sixteen input channels have identical conditioning
circuits (CC) that provide signal isolation, transient suppression, and high-pass filtering of the input
signals. The frequency band of the PD signals for InsulGard is from 1 MHz to 20 MHz.
For each channel InsulGard acquires PD data in the form of three dimensional Phase-Resolved Pulse
Height Distribution (PRPHD) - PD pulse count as a function of pulse magnitude and phase angle of
monitored device voltage (60/50 Hz or voltage phase angle of a Variable Frequency Drive). Data are
sorted into 24 phase windows (150 each) and 21 magnitude windows with magnitude dynamic range of
~70dB.
After data acquisition InsulGard firmware calculates integral PD parameters: Partial Discharge Intensity
(PDI), Maximum Pulse magnitude (Qmax), Pulse Repetition Rate, and rate of upward trends of PDI and
Qmax.
Partial Discharge Intensity (or Apparent PD power) is the value proportional to the power dissipated by
partial discharges and represent “damaging power” of Partial Discharge. PDI measured in watts and
defined as:
Where:
i n T – measurement time
1
PDI  * S *  U i * Vr S - sensitivity of the PD sensor (C/V)
T i 1
n – number of acquired PD pulses
Ui – magnitude of a PD pulse
Vr – rated voltage in the monitored equipment
Qmax – defined as maximum repetitive magnitude of PD pulses. Above that magnitude pulse repetition
rate must be at least 0.2 pulses per power cycle. Such approach will not take high magnitude random
pulses as maximum PD magnitude.
Integral parameters are stored in internal data memory for each measurement, while PRPHD
matrixes are stored only time to time to avoid data memory overfilling. This comprising two saving
modes: Brief and Full or “Normal” and “Test” (in software settings). Each record is accompanied by
time/date stamp and three auxiliary operating parameters: temperature, humidity, load current or
voltage.
Before each measurement, InsulGard performs a self-test. If a problem detected, Status relay dry
contacts open and an appropriate message appears on InsulGard display. Loss of power causes
opening of status relay contacts too.
InsulGard acquires signals from the measurement channels sequentially multiplexing them to a single
signal channel. Each pulse from each sensor is validated by the allowed pulse width. Noncompliant
pulses will be discarded.
After each measurement, PDI, Qmax and Trend levels will be compared to preset Warning and Alarm
thresholds for each active channel. If a warning threshold exceeded warning relay will operate and
yellow LED will lit. If an alarm level is exceeded, InsulGard will trigger an additional measurement. If
alarm condition will be confirmed, a red alarm LED will be turned on and the alarm relay will operate.
Also phase resolved data will be stored in the memory and alarm event will be stored in log file in
device memory.

Effective Feb. 2017
PD measurements can be performed on a time schedule (up to 50 different times per day) or in
specified time interval (from 1 minute to 23 hours 59 minutes) as long as the time interval is longer than
a measurement time. Four scheduled measurements per day are recommended.
Between scheduled measurements, the “Continuous Watch” feature is enabled. All signal sensors are
connected to a summation unit and then to a separate “Continuous Watch” channel. InsulGard
continuously searches for an appearance of high magnitude pulses and pulse series. Magnitude
threshold and repetition rate in series are configurable. If five events of pulse series are detected
between the scheduled measurements, InsulGard will trigger PD measurement and display an alarm, if
confirmed.
To provide correct measurements InsulGard must be synchronized with voltage frequency of the
monitored equipment (see Section 7 Appendix II Synchronization and Phase Reference Shift) and must
have correct settings for the type of equipment, rated voltage, and PD sensors used. All settings can be
made using Setup mode from front panel keypad and display (see Section 6 Appendix I InsulGard
Front Panel Keypad Operation ) or more easiliy using InsulGard PC software supplied with InsulGard
(see InsulGard Software Manual). Eaton supplies monitors preconfigured based on ordering
information.

Effective Feb. 2017
1.3 Specification
General:
Applications HV and MV equipment (motors, including VFD,
switchgear, generators, bus ducts, cable
terminations, transformers, etc.)
Mounting options (1) In NEMA 4X enclosure.
(2) Panel Mount.
(3) Door (Flush) mount.
Installation category II
Pollution Degree 2
Temperature Range -400C - +850C (+700C for enclosure mount).
UL Certified for 00C - +700C ambient
Relative humidity 0%RH – 90%RH
Maximum Altitude (m) 2000
Power Source 115V / 230V AC +/-10%
60 / 50 Hz
Power Consumption of device (VA max) 15 VA
Display Graphic Dot Matrix Display, 2 lines
Keypad 4 arrows and
4 function keys
LEDs InsulGard Status: Normal
Warning (Alarm 1)
Alarm (Alarm 2)
Memory mode
Setting mode
Approximate Size (Length x Width x Height) and Weight:
9.2”x 7” x 2.5” (23.4cm x 17.8 cm x 6.4 cm)
Main Unit
4.2 lb (1.9 kg)
Door Mounted option (Main Unit with Sensor Interface 9.2”x 7” x 4” (23.4cm x 17.8 cm x 10.2 cm)
Board) 4.6 lb (2.1 kg)
14.8” x 12.9” x 4” (37.6 cm x 32.8 cm x 10.2 cm)
Panel Mounted option
10.3 lb (4.7 kg)
17.2” x 15.4” x 8.8”, (43.7 cm x 39.0 cm x 22.3 cm)
Enclosure (NEMA 4X) Mounted option
21.6 lb ( 9.8 kg)
PD Measurement:
Number of PD Channels 15
PD Channel Magnitude Dynamic Range 68dB
Frequency Bandwidth 1-20MHz
Phase-Resolved Pulse Height Distribution (PRPHD):
Number of Magnitude Windows (3.23 dB each) 21
Number of Phase Windows (150 each) 24
Power Frequency at a Monitored Equipment 3-20Hz, 20-400Hz
(including VFD)
Synchronization type Internal and External

Effective Feb. 2017
Maximum Measured Pulse Repetition Rate 367,300 pulses/second

Integral PD Parameters Partial Discharge Intensity (PDI)
Maximum Pulse Magnitude (Qmax)
Pulse Repetition Rate, Trends of PDI and Qmax
Warning by PDI or Qmax
Alarm by PDI or Qmax and by Trends of PDI or Qmax
Number of Noise Channels 1
Continuous Watch (High PD activity) Function Active between measurements
Data Record Types Full/Brief (Test/Normal)
Internal Data Memory 2 MB. Provides up to 1000 days of data storage at 4
measurements per day
Self-test and Self-calibration At powering up and before every measurement
Setup Configurable from keypad and PC
Allowed RG-58 Coaxial Cable Length to PD Sensors Up to 150ft (50m)
Auxiliary Inputs:
Input specified for temperature measurement 1
calibrated for 100 Ω Platinum RTD sensor.
Analog Inputs specified for Current, Voltage or 2
Humidity measurement
Interfaces:
C-form Dry Type Relays for: 3
Device Status 120VAC/ 5 Amps
Warning (Alarm 1) and Alarm (Alarm 2) PD levels 28VDC/ 5 Amps
(fully configurable). For other ratings refer to the relay specification
4–20 mA isolated interface represents Highest PDI or Slope is 1mA per 10%
Max. Magnitude as % of the Alarm Threshold
RS-485 interface optically-isolated (231 addresses). Communication Protocol: ModBus RTU, Binary,
Additional Communication Options USB for communication with PC
Ethernet, Webpage and FTP
Regulatory and Standards Compliance  UL 61010-1: Second Edition Standard for
Electrical Equipment for Laboratory Use, with
revisions dated 2008-10-28
 FCC Part 15, Subpart B, Class A
 CAN/CSA C22.2 No. 61010-1-04, Second
Edition, with revisions through 2008-10-01
 IEC61010-1:2001 and EN61010-1:2001
 EN61326-1, EN61000-3-2, EN61000-3-3
 IEC61000-4-2, IEC61000-4-3, IEC61000-4-4,
IEC61000-4-5, IEC61000-4-6, IEC61000-4-8,
IEC61000-4-11
1.4 Important Features and Options

1.4.1 Data Structure and storage.
A Partial Discharge measurement results in Phase Resolved Partial Discharge Distribution (PRPDD)

Effective Feb. 2017
for every active channel. After each measurement for every active channel, InsulGard calculates
integral PD parameters: Partial Discharge Intensity (PDI), maximum PD magnitude Qmax, Pulse
Repetition rate (pulses per second) and Trend of PD activity (rate of PDI and Qmax change). The
calculated parameters are compared to preset levels for Warning and Alarm operations.
All parameters with date/time stamp are stored in the internal memory for each measurement. Three
auxiliary parameters (temperature, humidity, percentage of full load current or operating voltage) are
added to each record.
Depending on what data will be stored in the internal memory, there are two modes of the Insulgard
operation: Test mode and Normal mode.
Test Mode – during this mode (PRPDD and calculated integral parameters for each channel are stored
in the memory for every measurement. This is very memory-consuming mode, can overfill memory too
soon, so stored data should be downloaded more often. Test mode saving initiated twice a month by
default schedule. Schedule can be changed from keypad or software if necessary. The mode should be
enabled for special testing.
Normal Mode –during most of the measurements InsulGard will store the “Brief” version of PD data -
only integral parameters without PRPDD (except scheduled “Full’ saving mode measurements). This is
a default mode for continuous monitoring.
InsulGard has 2 MB of internal flash memory for data storage. When the memory is filled, the device
starts replacing the oldest data with the latest data. The rate of the memory consumption depends upon
number of active channels, frequency of measurements, and frequency of PRPDD storage. AIf all 15
channels are active, measurements performed four times a day and PRPDD are stored twice a month,
the device holds 17 months of the latest PD data in its internal memory. All stored data and settings can
be accessed from the keypad or remotely from a PC.
1.4.2 Trend
InsulGard calculates trend of the parameter – PDI or Qmax. Trend is calculated as a linear
approximation of data over a specified time interval (default is 90 days). This specified time interval
window is sliding over time while the device is monitoring PD. Trend is normalized to the value of the
parameter change in times per year. Like PDI or Qmax levels, trend also has, Warning and Alarm
thresholds . When the Warning or Alarm level exceeded, the corresponding LEDs on the front panel
and relays will respond in the same manner as when PDI or Qmax levels are exceeded.
1.4.3 Alarms
InsulGard has two configurable alarm levels, Warning (Alarm 1) and Alarm (Alarm 2). There are two
groups of parameters that can generate an alarm. One is the preset levels of PDI or Qmax for Warning
and Alarm. The other is the preset trend levels for PDI or Qmax. Only one of two, PDI or Qmax, can be
configured for alarming at any time.
The same parameter, PDI or Qmax is automatically configured for the 4-20 mA interface output. The 4-
20 mA interface always represent the channel with the highest PD activity in terms of percentage of the
channel alarm level with the slope 1mA/10%. An output of 4mA corresponds to 0% and 14mA
corresponds to 100% of the alarm level.
The alarm level for PDI is represented in terms of mW while the magnitude Qmax is represented in
terms of mV.
Trend is set in terms of times per year for both PDI and Magnitude. Alarm on trend is enabled after a
training period of 1/3 of the trend-sliding window.

Effective Feb. 2017
A warning-level condition activates the corresponding relay and turns On yellow Warning LED
immediately when warning condition is detected. When Alarm level exceeded, InsulGard will initiate an
additional measurement, and only if alarm condition is confirmed alarm relay will operate and alarm
LED will lit. If the Alarm conditions are not confirmed, the LED and Relay status will be set per the last
measurement. If at any measurement the alarming status will be reduced, InsulGard will indicate the
reduced alarming status with both LED and relay.
Alarm and Warning relays can operate in two modes (configurable). Relays lock in the status received
at the last measurements, until the next measurement. Or a relay can operate for a limited configurable
time and then release the contacts. At the next measurement, if an alarm/warning status is detected,
the relay will hold the contacts closed for the same time. There is “never operate” option too (Off).
1.4.4 Continuous Watch Feature

Between the scheduled measurements Continuous Watch feature (High Alarm) is active. All sensors
signals are summarized and connected to the separate High Alarm channel. InsulGard is continuously
counting high magnitude pulses and series of such pulses with predefined number of pulses in series. If
five series of high magnitude pulses detected, InsulGard starts regular PD measurement.
1.4.5 Phase Resolved Data and Phase Reference

In order to provide valid phase-resolved data, InsulGard must be synchronized with a signal that is
synchronous with the voltage on the object being monitored. Phase shift between the voltage on
monitored object and InsulGard power voltage should be obtained for that purpose.
There are two options for synchronization:
In most of cases the power source (115/230 VAC) powering up InsulGard is used as a synchronization
signal. The device has an internal connection of the power circuit voltage to its synchronization circuitry.
This option (default) always works on monitored objects powered from a regular power system
(60/50Hz) in the area. Phase shift between monitor’s power voltage and the object high voltage should
be determined during InsulGard startup and remains valid while the same object is monitored and the
same power circuit is used. InsulGard allows for automated detection of a phase shift between its
power circuit and an external phase reference signal. For detailed information on synchronization and
phase reference shift detection refer to Section 7 Appendix II Synchronization and Phase Reference
Shift.
Be cautious of an UPS power – use it only if the UPS has constant phase shift to the voltage in the
monitored object in Standby mode. If not, InsulGard will be in an “asynchronous” state and can’t
provide accurate phase-resolved measurements..
External synchronization should be continuously used if the InsulGard power supply voltage is not
synchronous with the voltage on the test object. An example of an asynchronous test object is a
variable frequency drive. An external synchronization signal should be continuously provided to the
special synchronization input and appropriate jumpers in the device should be configured. Power
frequency component of a signal applied to the channel #1 can be used for external synchronization if
coupling capacitor is connected to that channel. For more information on synchronization and device
configuration refer to Section 7 Appendix II Synchronization and Phase Reference Shift.
1.4.6 Schedule
PD measurements can be performed at specified times during a day or in specified time intervals.
Typically monitors are shipped with “time basis” schedule enabled and set to make measurements four
times per day. This is sufficient for most of applications. If necessary, InsulGard can be set to measure
up to 50 times per day at scheduled times or in specific time intervals varying from 1 minute to 23 hours

Effective Feb. 2017
59 minutes as long as the time interval is shorter than the time of the measurement.
The time T required for a measurement is T≈ 21*NCh*NC / F, where NCh – number of active channels, NC
– number of cycles per acquisition, F – synchronization frequency. Thus an InsulGard with all 15
channels active set for 60 cycles per acquisition and synchronized by 60 Hz would require
21*15*60/60=315 seconds, or 5 minutes and 15 seconds to complete a measurement.
1.4.7 Self-test and Self-calibration

InsulGard performs a self-test and calibration of PD signal and noise channels when powering up as
well as before every PD measurement. If self-test fails the status relay contacts will open and a
corresponding message will appear on the display.
1.4.8 PD Intensity and PD pulse repetition rate calculation low level cut-off
PDI and pulse count (PPS - pulse per second) are calculated for each channel at every measurement
starting from some preset magnitude level (zone) and up. This feature allows for rejecting background
noise from affecting PDI and pulse count calculations. Low magnitude calculation cutoff threshold can
be set for each channel independently, based on its own background noise level, if any. There are
options to set these values manually or automatically. Automatic low magnitude threshold detection can
be launched only from the keypad (commonly during device start up or during the initial period of
operation).
1.4.9 Auxiliary Inputs

It is well known that operating conditions of monitored equipment can significantly affect PD activity.
Dependence of PD magnitude, repetition rate and PD intensity on temperature, humidity, system
voltage and load current (in rotating machines) can provide valuable information for deeper analysis
and increase diagnostic capabilities of PD monitoring. Calculation of correlations between PD
parameters and operating conditions is a part of InsulGard software.
InsulGard has three auxiliary inputs. One of the inputs is solely designated for temperature
measurement. A 100 Ω platinum RTD can be used as a sensor. See the temperature sensor manual
for details.
Two other inputs can accept any AC or DC signals within a specified voltage range. As factory default,
they are configured for auxiliary sensors for load current and humidity measurement supplied by Eaton
with an InsulGard.
1.4.10 Measurement Suspend

Measurements can be suspended in three different ways:
 Monitoring can be stopped. The “STOPPED” message will be blinking on InsulGard display and Red
Alarm LED will be ON. Monitoring must be resumed through keypad operation or software “Resume”
command by an operator.
 Monitoring can be paused by software “Pause” command. In this case, monitoring will resume
automatically in three hours.
 Auto-suspend mode - can be controlled by any of three auxiliary parameters. The device allows an
user for setting low and high thresholds for these three auxiliary parameters and enable the auto-
suspend mode via keypad or via PC software. InsulGard will stop monitoring when any enabled
auxiliary parameter is outside low - high boundaries range. The auto-suspend mode mostly used to
suspend measurements in rotating machines by load current measurements when the machine is
out of operation. For example, if low threshold for load current is set to 5% of the nominal current,

Effective Feb. 2017
InsulGard will stop making measurement when load current is 0 – means that the monitored
equipment is out of service. This keeps InsulGard from collecting meaningless data which can lead
to incorrect trend calculations.
1.4.11 Communication Options and Device Address

InsulGard has various interfaces that allow for easy implementation into any alarm or SCADA system
as well as for remote communications:
 Three C-form relays dry contacts for Warning (Alarm 1), Alarm (Alarm 2) and Device Status
indication.
 4-20 mA isolated interface can be configured to represent PD Intensity (PDI) or Maximum PD
magnitude (Qmax) to any SCADA system.
 RS-485 optically isolated interface based on ModBus RTU protocol allows remote device
configuration and data downloading. InsulGard can be networked with an existing ModBus
network, allowing for up to 231 addressable devices.
 InsulGard is shipped with the device address #1, otherwise different address was specified. The
address can be changed only from the keypad and set to 1 - 231. In any case, the address must
be unique in a particular local device network.
 InsulGard is supplied with database software that allows automated communication with a
device for data acquisition and analysis. The software allows either direct networking using a
USB/Ethernet to RS485 converter or dial up connection to a device by a regular telephone
landline or a cellular connection using appropriate modems with RS485 interface.
 USB ports (only available with communications board): one USB port (Device) is for a direct link
to a computer for communications with the InsulGard software or for communication board
firmware upgrading, second USB port (Host) is reserved for future use.
 Ethernet port (only available with communications board): It enables direct communication
between computer and InsulGard and implementation into Ethernet network. Convenient online
webpage and FTP server for data downloading or FTP client for data uploading are under
construction.
 Telephone landline or cellular modems with RS485 interface are optional.
 Refer to section 4.3.3 for detailed information regarding connections between the InsulGard and
external equipment.
1.4.12 Software
InsulGard software allows for communicating with InsulGard through a PC on a local RS-485 network
or a modem. It also provides automated or manual data downloading and storage for multiple devices,
device setting, data analysis, and presentation (See InsulGard Software Manual).
1.4.13 InsulGard configuration (settings)

To get most of PD monitoring InsulGard have to be properly configured in accordance with the type of
equipment to be monitored, system voltage, sensors used and preferable mode of monitoring.
InsulGard is typically supplied preconfigured for particular equipment in accordance with
available information received during ordering process.
Monitor configuration can be adjusted by changing firmware settings:

Effective Feb. 2017
 From InsulGard keypad (see Section 6 Appendix I InsulGard Front Panel Keypad Operation ),
 From computer with help of software supplied with InsulGard monitor. The software has
templates to help with configuration for typical applications (see InsulGard Software Manual).
There are few settings that can be configured only through the keypad. Refer to Section 4.1 for details.

Effective Feb. 2017
1.5 InsulGard mounting options and sensor connection

InsulGard is can be shipped in one of the following configurations:
 In NEMA-4X enclosure with or without transparent windows for outdoor installation(Figure 1-2 a).
 On the panel (Figure 1-2 b) for installation in a cabinet. This option is identical to the first one,
except that the panel is not mounted into an enclosure. Can be mounted into any custom cabinet
including explosion-proof enclosure.
 Door mount option. This option is used for indoor installation on a cabinet door (Figure 1-2 c, d,
e). For door mount InsulGard Sensor Interface Board is mounted on the InsulGard back cover
with temperature and humidity sensors typically installed inside Sensor Interface Board.
a b
c d e
Figure 1-2 a, b – IG installed on the panel and in NEMA 4 enclosure with window; c – Door
mount InsulGard, Sensor Interface Board is installed on the back of the InsulGard case,
d, e - Door mount IG installed on a switchgear cabinet door (d - front and e - rear views)

Effective Feb. 2017
1.5.1 Panel mount InsulGard

An example of a panel mounted InsulGard and its wiring diagram for 115 VAC power voltage is shown
in Figure 1-3 a, b, c and Figure 1-4.
The InsulGard panel must be grounded at the place of its installation.
Wire for panel

grounding
a - Front view.

Effective Feb. 2017
b - Left side view.
c - Right side view

Figure 1-3 Panel mounted InsulGard

Effective Feb. 2017
InsulGard Panel Wiring Diagram Connection to:

Signal
Ch1 + 4-20 mA interface
4-20
Alarm 2 RS - 485 mA
Connector for Flat Cable from
Sensor Interface Board
-
Shield
Host
Sensor Interface Board
USB
Ch 2
G B A +5
Ch 3 RS485 interface
Flat Cable to
InsulGard
Ch 4
Coax cables from PD Sensors

Ch 5 Alarm relay
Alarm
Device
Ch 6
USB
Ch 7
Alarm 1
Warning
Ch 8
Warning relay
Ethernet
Auxiliary sensor Ch 9
Left Right
connection: Ch 10 side side
Status
white 1
Ch 11
black 2 Status relay
3
RTD
red 4
Ch 12
black 5 S
Ch 13
InsulGard's
6 CT
white 7 S1 connectors DIN-Rail Terminals
Ch 14
8 S2 Ref red
Power
GNL
9
Ch 15 white
white 10 green
red
N
11 +5 H% Ch 16
L
12 S (Noise) Screw on
black
H% Sw Ref back cover 1 2 3
Gnd
Gnd
Fuse
Humidity sensor
Ground Screw green
CT - Load sensor
on the panel
Green
Outlet
Neutral
Ground
Temperature sensor
Phase
Ground screw on enclosure
must be connected to local
ground Power 115VAC
There is no outlet for 230VAC application.

Fuse inside InsulGard for 115VAC application:Time-Lag 200mA, 250VAC, 5X20mm type 5ST by BEL Fuse Inc.,
Catalog # 5ST 200.
Fuse inside InsulGard for 230VAC application:Time-Lag 100mA, 250VAC, 5X20mm type 5ST by BEL Fuse Inc.,
Catalog # 5ST 100.
Fuse on the panel: Fast Acting 3.0A, 250VAC, 5x20mm type 5MF by Bel Fuse Inc. Catalog # 5MF 3-R (or equivalent).
Figure 1-4 A typical wiring diagram of the panel mounted InsulGard.

Note: For actual installation use the wiring diagram supplied with each InsulGard.
InsulGard must be grounded at the place of installation.
Power line should be connected to the terminals installed on Din Rail as shown on Figure 1-4.

Effective Feb. 2017
Connection to Status, Warning and Alarm relays, to RS485 and 4-20mA interfaces should be made
directly to InsulGard in accordance with the labels on its right side by using plug-in connectors supplied
with an InsulGard (Figure 1-3 c). Right connections to these plugs shown below:
PD and Auxiliary sensors must be connected directly to the Sensor Interface Board.
To access Sensor Interface Board it is necessary temporally remove the InsulGard monitor.
Coaxial cables from PD sensors should be connected to Ch1-Ch15 inputs (Figure 1-5 a). Central wire
should be connected to an upper terminal and coax cable shield to a corresponding lower terminal
labeled ┴ on 1st channel (Figure 1-5 b.). Ch16 is designated only for noise signal and usually isn’t used.
b
~1"
~0.3"
a c

Effective Feb. 2017
d - IDEAL part#45264 STRIP MASTER

e
Figure 1-5. a, b - termination of PD sensors coax cables to the Sensor Interface Board, c – cable
preparation, d – recommended stripper for RG58 cable, e – Humidity/Phase Reference Switch.
Use blade crimp terminals on cable shield to avoid “hairs” and possible short circuit to the central wire.
Distribute cables evenly and secure them in place with cable ties.
Auxiliary sensors (Temperature, Humidity and Load sensors) should be connected to the 12 contacts
terminal on the left side of the Sensor Interface Board as shown in Figure 1- 6 and table below.
Cables from:
Temperature
sensor
Load (CT)
sensor
(for motors)
Humidity
sensor
Figure 1-6. Auxiliary sensors connection to the Sensor Interface Board.

Effective Feb. 2017
Auxiliary sensors connection:
Contact Sensor Sensors wire Note

# connected
1 Temperature RTD common wire (white wire) Board common
sensor
2 RTD signal wire (black wire) Output dc current ≈ 2mA
100 Ohm
3 Platinum RTD RTD signal wire (red wire) Output dc current ≈ 2mA
4 Cable shield (optional) Board common
5 Load (CT) Signal wire (red wire) Input impedance 100 Ohm,
6 sensor Common wire (black wire) Board common
7 External Usually not used Input impedance > 27kOhm. Input voltage should
Reference not exceed 1VAC. Disconnect jumper 1 if
external reference signal is used (Figure 1-7).
8 n/a test point
9 n/a Board common
10 Humidity Sensor common (white wire) Board common
11 sensor + 5VDC for the sensor (red wire) Output current is limited by 100 Ohm resistor.
12 Output signal (black wire) Input impedance > 27kOhm. Input voltage should
not exceed +5V.
H% / Ref switch (Figure 1-5 e and Figure 1-7) must be in the H% position during normal operation. Ref
switch position is used only during phase shift measurement – phase difference between external
reference signal and internal IG synchronization (Section 7 Appendix II Synchronization and Phase
Reference Shift). After that measurement switch must be switched back to the H% position.

Effective Feb. 2017
1.5.2 Door mount InsulGard

In door mount InsulGard version Sensor Interface Board is mounted on the InsulGard back cover
(Figure 1-7)
Jumper J1
Jumpers
J7 & J8
Wire to
local
ground
H% / Ref
Switch
Figure 1-7. Door (Flush) mount InsulGard (back view)
InsulGard must be grounded at the place of installation.

All PD and auxiliary sensors should be connected directly to the Sensor Interface Board as for panel
mount InsulGard (see section 1.5.1). All other connections also are same with panel mount InsulGard
except power line connection. It should be connected directly to InsulGard power input in accordance
with its side label using green plug connector. Power line should have a disconnect device
(switch/breaker) near the unit.
Also for door mount InsulGard the temperature and humidity sensors are usually installed inside Sensor
Interface Board. Jumpers J7 & J8 must be installed in that case.
Notes:

Effective Feb. 2017
Jumper 1 (Figure 1-7) must be removed if external reference signal (e.g. from potential transformer)
applied to contact #7 on Sensor Interface Board (Section 7 Appendix II Synchronization and Phase
Reference Shift).
1.6 Sensors for InsulGard

Wide variety of sensors for InsulGard monitor is manufactured by Eaton Corp.
Basic sensors are:
 IPDS - Integrated Partial Discharge Sensors with voltage ratings 5-38kV - 80pF coupling
capacitors with special protection circuitry built in.
 RFCT - Radio Frequency Current Transformer.
 RTD-6 - PD sensor. Resistive Temperature Detectors installed in a rotating machine stator work
as a local RF antenna for PD pulses. This sensor connects up to 6 RTDs to capture PD signals
originated in a stator winding. It designed as a single board replacing an existing RTD terminal
board and does not affect temperature measurements.
IPDS RTD-6-PD RFCT

Figure 1-8 PD sensors
The auxiliary sensors:
 TS - 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.
 HS - Humidity sensor.
 CT - Load (CT) sensor. 5 Amps primary current, ratio1000:1. Mostly used for rotating machines.
It should be installed over secondary wire of an existent metering current transformer.
 CTF - Split-core Primary Current Transformer (FlexCore) with CT sensor preinstalled on
shortening jumper of Primary CT secondary winding. CTF used if there is no metering CT in
feeder termination compartment and corresponding metering CT is too far from 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 CTF only around one of the feeders.
All above sensors have default cable length of 65’ (20m). Specify other lengths if necessary. See the
sensor manual for detailed information.

Effective Feb. 2017
2 Applications
2.1 General
InsulGard is a versatile device that can be applied to most of medium and high voltage equipment.
Specifics of a particular application (optional components and planning installation) should be taken into
account to achieve high performance of PD monitoring.
Issues that should be considered are:
 Type and specifics of equipment to monitor
 Configuration of PD sensors
 Noise aspects
 Device location and environmental issues
 Additional parameters to measure
 Networking and Communicating to the device
Equipment with voltage ratings of 3kV and higher are considered reliable for PD diagnostic
applications. Marginally, 2300V equipment can be considered, but the technology is inconclusive. It
may or may not detect a significant problem at 2300V. In general, higher voltage provides greater
destructive power for partial discharges and problems can be more reliably detected and predicted.
InsulGard was designed to monitor partial discharges in any MV equipment. Most frequent applications
are in rotating machines, medium voltage switchgears, MV transformers and associated auxiliary
equipment and connections. The connections may include cable terminations and portions of a cable or
a bus feeding a device. InsulGard can also be used on other types of medium voltage and high voltage
equipment. Particular applications of the technology may require special pre-engineering and
adaptation. Consideration should be given while attempting to use InsulGard on high voltage equipment
above 120kV. Noise in the form of aerial corona discharges should be addressed in such cases.
PD sensors configurations are application oriented, although there are some general guidelines can be
applicable. Request Install Consideration and Sensor manuals documentation or/and discuss sensor
installation with an Eaton Electrical application engineer.
2.2 Motor and Small Generator Applications

PD sensors for small generators and medium voltage motors typically include three sensors located at
the line terminals and one or two RTD-PD sensors servicing six to twelve winding RTDs. Because of
significant attenuation of high frequency signals in a motor winding, sensors located at the line
terminals will not detect partial discharge in a winding depth; likewise, the sensors located in winding far
from HV terminals will not sense discharges at the line terminal.
2.2.1 PD sensors at line terminals:

 Coupling Capacitors. Typically Integrated Partial Discharge Sensors (IPDS) by Eaton with 80pF
capacitance, but can use any kind of coupling capacitors. IPDS have sufficient insulation and
connected directly to a motor line terminals. Those sensors exhibit the most noise-immune
characteristics due to their low capacitance and, therefore, can suppress most low frequency
noise by themselves. Using IPDS is a highly recommended option for line terminals.
Note: Installation of line terminal sensors always requires an outage.

Effective Feb. 2017
 Radio Frequency Current Transformers (RFCT) placed on incoming feeders’ shield grounding
conductor (one per phase) or on single-phase surge capacitor grounding conductor (one per
phase). Using a single three-phase surge capacitor is possible, but not recommended because of
low sensitivity to phase-to-phase partial discharge. The later is also valid for RFCT sensors on
three phase feeder shield ground single wire. An advantage of RFCT sensors is that they are non-
invasive (no connection to HV conductors is required). But RFCT sensors are less noise immune
compare to IPDS sensors and more vulnerable to ground network noise. RFCT absolutely should
not be used in Variable Frequency Drives environment with high magnitude and repetition rate
pulse noise.
2.2.2 RTD sensors in winding depth

Besides line terminal area sensors, additional sensors are required to service larger area of a stator
winding. RTD sensors embedded into a stator windings can be used for this purpose. An RTD supplies
a DC temperature signal to a metering device. An RTD and RTD wires also operate as a RF antenna
for high frequency signals generated by partial discharge. High frequency signals can be extracted and
used to for detection of pulses originated by partial discharge in proximity of an RTD.
Eaton developed the RTD-6 PD sensor board with embedded filters to suppress external noise coming
from temperature metering system or induced in control wiring by other equipment. This sensor is
designed as a single board to replace an existing RTD terminal board in the closest to a
motor/generator RTD terminal box. It does not affect temperature measurements, and extracts PD
signals to be detected by InsulGard. Each board can handle up to six RTDs. If there are more than 6
RTDs, additional RTD -6 PD sensor board should be used. An RTD-6 board can be installed online
which requires temporarily disabling temperature alarm or relay system.
2.2.3 Auxiliary sensors

Partial Discharge activity significantly varies with operating parameters. Winding temperature, load
current, and humidity are the three most important parameters to correlate with a detected PD activity.
Correlation of the detected PD activity with those parameters can provide invaluable information for
enhanced diagnostics of insulation condition in a monitored equipment. Preferably use one of the
winding RTDs for temperature measurement.
Note: One InsulGard device is required for a monitored object.
2.3 Large Generator Applications

Large generator application is, in general, similar to a motor or small generator application.
2.3.1 PD sensors at line terminals:

 Coupling capacitors (IPDS) are commonly used as line terminal sensors. A generator equipped
with iso-phase bus duct might have sparking in bus supporting insulators. A digital filter has been
built into InsulGard firmware to distinguish that specific external PD activity from PD activity
coming from a generator. Another option is using two sets of IPDS located at the terminals and at
some distance along iso-phase bus for noise suppression.
2.3.2 RTD sensors in winding depth

 Large machines can have several dozens RTDs embedded in the winding. Use 12 RTDs located
in most electrically stressed parts of the stator winding, and evenly distributed along the stator
winding to obtain maximum coverage of the stator. Making that choice can be a challenge even
when winding diagram and RTD locations are available.

Effective Feb. 2017
 Large generators may have very long signal wires from an RTD to the first RTD termination. Also
different kinds of RTD wires can have different signal propagation qualities. These factors can
significantly affect high frequency signal propagation, attenuating a PD pulse. In order to minimize
signal attenuation; RTD-6 board can be installed at the generator gland, where the RTD wires
come out of the generator frame.
 Certain generators do not have RTDs embedded into a stator winding. For example, large
Westinghouse hydrogen cooled machines have RTDs only in cooling gas pipelines. These RTDs
cannot be used as PD sensors. Verify that RTDs are located in a winding.
Auxiliary parameters are monitored in large generators same way as in motors. In hydrogen cooled
generator hydrogen pressure might be monitored instead of humidity.
2.4 MV Switchgear Applications

Door mount InsulGard option commonly used in indoor switchgear lines.
2.4.1 PD sensors
Three major types of PD sensors are used for switchgear lines:
 Three IPDS sensors (one per phase) are installed, as a rule of thumb, in every third cubicle.
Therefore, each set of three IPDSs assess the cubicle where it is installed, and the cubicles on
each sides. Increasing a distance between IPDS sets might cause some distant PD activity to be
missed. Keep in mind that PD signals attenuate approximately twice from cubicle to cubicle. IPDS
can be installed on a bus side or load side of a breaker. In the case of a load side, the sensor will
not measure PD while the breaker is open, but can be installed without taking the whole bus out of
operation. Installation on main bus requires full outage, but fewer sensors to service switchgear
line. In general, one InsulGard can handle a switchgear line with up to 15 cubicles.
 RFCT sensor(s) installed on the incoming and outgoing feeder shield grounding conductors;
commonly, one per cubicle on all three phase feeder shield ground cable. Phase to phase signals
can be missed in such a configuration. Installing three RFCT sensors (one per phase) can be
considered for most critical feeders. RFCT sensors on cable shields are susceptible to ground
noise and not applicable in high noise environment, particularly with FVD drives.
 Combination of RFCT and IPDS sensors can make most effective sensor configuration. Consider
more sensors in proximity of most critical parts of a line-up.
 Eaton Corporation came up an idea and has implemented usage of stress shields in MV bushings
in switchgear as coupling capacitors. Eaton manufactured switchgear can come equipped with PD
monitoring system as an option. Consult Eaton application engineers on this opportunity.
2.4.2 Auxiliary sensors

Temperature and Humidity should be monitored in switchgear application. By default for door mount
InsulGard in indoor applications temperature and humidity sensors are incorporated into sensors
Interface Board. External sensors will be shipped if requested. If high voltage in the system can vary
more than +/-5%, one can consider monitoring of that voltage too. That option requires reconfiguration
of the jumpers on the Sensor Interface Board and changes in InsulGard and software settings.

Effective Feb. 2017
2.5 Configuration of Alarm Thresholds

The Warning and Alarm thresholds for each PD channel of InsulGard are configurable. Thresholds
depend on the type of PD sensor used (sensor sensitivity), system voltage, type of equipment, sensor
location and adjacent connections. There are no universal standard values for Warning or Alarm
thresholds. The following table shows typical values of the thresholds used as default settings in
several applications:
Application PDI, mW Q MAX , mV

Object type U line, kV Sensor type Warning Alarm Warning Alarm
Switchgear < 5 kV Coupling capacitor, 3 5 50 100
5 -17 kV RFCT 3 10 50 200
>17 to 38 5 20 50 200
kV
Motor/ Small 3 - 7 kV Coupling capacitor, 3 5 50 100
Generator 7-15 kV RTD-6 PD sensor 20 50 200 1000
Generator >15 kV 20 100 200 1000
Since PD measurements in high frequency range are relative in nature, warning and alarm threshold
should be corrected in every given case after initial period of monitoring and subsequent data analysis.
Simple rule of thumb can be used:
- in case of significant PD activity set warning threshold close to average level of PD activity,
set alarm threshold a little below peak values of the detected PD activity, so that threshold will
be exceeded infrequently and phase resolved data will be saved during such events;
- if PD activity is low, set warning level higher then peak readings and set alarm
threshold twice higher then warning threshold.
2.6 Noise Aspects

Noise is a major issue in partial discharge measurement in industrial environment. Noise is site-related.
There is no universal solution for noise suppression in modern state of technology, however most noise
issues can be overcome. InsulGard has been designed with several noise suppressing algorithms and,
along with recommended sensors, is able to suppress most of industrial noise. While planning
InsulGard installation, keep in mind most common noise sources:
 Pulse signals coming from incoming lines and feeders
 PWM power sources for VFD drives (RFCT sensors can’t be used on feeders in such
environment)
 Power thyristor firing
 Switching power supplies in modern metering and protective electronics
 Arcing and sparking somewhere at the facility
 Aerial corona on overhead lines on high voltage substations
 Partial discharges in the adjacent equipment

Effective Feb. 2017
 Ground network noise

 High frequency noise from TV, Radio and communication transmission.
In some cases the source of noise can be identified and additional noise sensor(s) can be connected to
the Noise channel to reject that noise from PD measurements.
2.7 Device Location and Environmental Issues

InsulGard can be shipped with or without an environmental enclosure. Without an enclosure, it can be
used indoors in a relatively clean environment.
In most applications, indoor or outdoor, InsulGard comes in NEMA-4 plastic enclosure protecting the
device from direct rain, sun, and dust. Use stainless steel enclosure in chemically aggressive
environment. Explosion proof enclosure might be required in special cases.
In an indoor switchgear lineup InsulGard can be door mount without an enclosure.
When planning installing InsulGard, consider a non-vibrating location, conveniently located in a
centralized position close to all sensors, control power line and communication lines (phone jack,
conduits/tray to control room for alarms, etc.). It is recommended to keep the length of PD signal
coaxial cables (50 Ohm RG58 or similar) as short as possible to decrease signal attenuation along the
cable. Recommended maximum length is 150’, but it is not a solid limitation.
2.8 Additional Parameters to Measure

Several factors can affect PD activity: temperature, humidity, voltage, mechanical vibration, etc. In
North America system voltage commonly is not an issue. It is stable and does not affect PD
significantly. If more than +/-5% voltage variation is expected, the voltage should be monitored and
correlated to PD activity. Temperature is very important parameter for PD diagnostics of an insulation
condition. Temperature variations change size of voids in solid insulation and surface conductivity
which subsequently cause changes in PD activity. Humidity is also a factor affecting partial discharge,
mostly through changes in surface conductivity, especially if combined with surface contamination. In
hydrogen cooled machines monitoring of hydrogen pressure may be more beneficial than monitoring
humidity. Changes in Load current affect vibration of coils in rotating machines and cause changes in
slot and end-winding discharges. Correlation of PD activity changes to operating parameters can help
distinguishing different types of partial discharge improve diagnostics capabilities and direct corrective
measures.
Also zero load current (or voltage) could be used to suspend monitoring during equipment outage.
2.9 Networking and Communicating with InsulGard

InsulGard equipped with several interfaces allowing for implementation of a monitor into a control
system or into instrumental network:
 Dry contact C-form relays can provide warning, alarm and monitor status signals to an annunciator
or to SCADA system. Always wire at least Alarm (Alarm 2) and Status relays to an annunciation
system. If necessary, all relays can be wired in series or in parallel to the same annunciator.
 4-20 mA interface provides output current proportional to PD activity in PD channel with the
highest PD activity in percentage to that channel alarm level. That signal can be wired to a
SCADA for trending.

Effective Feb. 2017
 RS485 interface – allowing an InsulGard to be implemented into instrumental network with up to

251 devices on network. With the interface a device can be implemented into a SCADA system.
Device settings, measurement control and data downloading can be done through that interface.
RS485 to USB and RS485 to Ethernet converters can be used for communication with local PC or
on Ethernet network. Optional communications board has incorporated USB and Ethernet
interfaces eliminating needs for converters.
 Through the Ethernet port of the optional communications board one can access internal Web
page and data can be downloaded through the FTP server (both are under construction). It also
can be configured as a virtual serial port to be accessed by the InsulGard software.
 Using Landline or cellular modems (optional) provides opportunity for full scale remote
communication to an InsulGard or to InsulGards’ network.

Effective Feb. 2017
3 On-Site Installation
USE Startup manual step-by-step procedures as guidelines in actual installations and checking
and commissioning.
3.1 InsulGard system content

InsulGard monitor
Item Description Comments
InsulGard monitor in enclosure, or panel Specify mounting option and power voltage 115 VAC or 230 VAC.
mount or door mount Preconfigured for internal synchronization (by default) or for
external synchronization (Variable Frequency Drive applications)
Sensors Interface Board Preconfigured for internal synchronization (by default) or for VFD
application (by request). Temperature and Humidity sensors may
be installed inside the board (by default for door mount version)
Communications Board Assembled inside InsulGard
115VAC, 10 A receptacle Included for 115VAC power. Not included for 230VAC power and
in door mount version
Blade Terminals For termination of the coaxial cable shields
Wiring diagram Monitor connections and fuses specific to the monitor
Software CD with software and manuals for the InsulGard and sensors
Manuals Hardcopy
Partial Discharge sensors

IPDS-XX 80 pF XX kV class (5-38 kV) three coupling capacitor set with
mounting kit, 15kV class jumpers and miscellaneous hardware
RFCT-075 Solid core Radio Frequency Current Transformer with 0.75”
opening. Supplied with solidly connected 65’ coax cable
RTD-6 RTD PD sensor board for rotating machine applications
Auxiliary sensors
TS - 3-wire 100 Ohm RTD External Temperature sensor with 65’ cable
HS External Humidity Sensor with 65’ cable
CT Load Current Sensor with 65’ cable (5 Amps primary, ratio 1000:1)
CTF Split-core Primary Current Transformer (FlexCore) with Load
Current Sensor and 65’ cable. Convenient to install in a motor
termination box. Specify current ratio when ordering.
Communication means
Land Line or Cellular Modem with Optional
power supply
RS485/USB converter or Optional
RS485/Ethernet converter with power
supply module
Coax cable
RG58 coax cable In 500’ or 1000’ reels considering default coax cable length 65’ per
PD sensor
Additional not included cables maybe required:

Effective Feb. 2017
 AC power cable 3-wire (11 Amps)

 Twisted pair cables (AWG16-20) for communication
For communication and auxiliary sensors we recommend tray cables from Allied Electronics:
Twisted pair:
Stock # 216-2722 (22AWG) by BELDEN Mfr’s #9322
Stock # 216-2724 (20AWG), by BELDEN Mfr’s #9320 (Preferable for communications over
1000ft)
Stock # 216-2660 (20AWG), by BELDEN Mfr’s #1033A
Shielded 3-wire cable (if T<800C),
Stock # 216-2738 (22AWG), by BELDEN Mfr’s #9363
Stock # 216-2740 (20AWG), by BELDEN Mfr’s #9364
Stock # 216-2666 (18AWG), by BELDEN Mfr’s #1036A
One may order these cables through EE PD. Additional RG-58 coaxial cables can be ordered through
EE PD in 500’ or 1000’ reels.
3.2 InsulGard system packages

For ordering convenience a PD monitoring system can come in standard packages for a particular
application:
 Package for switchgear
 Package for motors
 Package for generators<15kV
 Package for turbo-generator 16-27 kV
 Package for hydro-generator <15 kV
Consult to Eaton sales and application engineers for details
3.3 Important Note on Sensor Installation

InsulGard monitor comes preconfigured to our best knowledge. If not configured properly use templates
in software for typical configurations to configure most of parameters with few necessary corrections
after. These templates assume that all coupling capacitors are connected to the first PD channels in
ABC order. In rotating machines RTD sensors come after coupling capacitors in incremental RTD
number order. Following this rule while connecting sensors to a monitor will simplify configuration later
on. For switchgear application first connect all coupling capacitors to the first PD channels in ABC
sequence, then connect RFCT sensors. Refer to Install Consideration documents for typical
applications.
3.4 Step 1 - Hardware Installation

This section provides general guidelines. Each installation may have its own specifics. Refer to

Effective Feb. 2017
sensors manuals for installation.
 Select a convenient location for the InsulGard enclosure. It should be as close as possible to the
equipment being monitored. Avoid locations with excessive vibrations, heat and direct sun light.
Cable length from PD sensors, generally, should not exceed 150ft (50m). It is usually convenient to
install the device in the center of PD sensors locations, keeping PD signal cable lengths
approximately the same. It is not necessary to have cable lengths exactly the same.
 Take monitor from the panel: gently disconnect InsulGard green plug-in connectors from right side
and flat ribbon cable connector from the sensor interface board, unscrew 4 mounting screw from
faceplate and remove the monitor.
 Install InsulGard enclosure.
 Door mount monitor can be installed into the cut in a cabinet door.
 Run conduits (if necessary) for the cables for PD sensors, communications, alarm relays, 4-20 mA
interface and for the InsulGard power.
 Install Partial Discharge sensors. Follow corresponding installation manual for the sensors.
 Install Current Sensor on the secondary wire of a metering current transformer. Phase A is
preferred, but is not necessary. In absence of a metering CT in feeder termination box use an easy-
to-install primary Core CT over feeder cable. Refer to CT, HS &TS sensors manual.
 Install temperature sensor (if ordered separately) inside the switchgear at a suitable location closely
representing the inside temperature. A rear compartment at the middle of a lineup usually works
well for that. In the case of a motor or generator, preferably use one of the spare winding RTDs
(Platinum 100 Ohm). Run three wire shielded cable from that RTD to InsulGard monitor. Otherwise
locate the temperature sensor at a suitable location closely representing the stator winding
temperature.
 Install humidity sensor (if ordered separately) inside a switchgear at a suitable location closely
representing inside humidity (next to the temperature sensor). In the case of a motor or generator,
humidity sensor typically installed inside feeder/bus terminal enclosure to represent humidity in line
terminals area.
 Install communication equipment: RS485 converters, modems, Ethernet, power supplies (ordered
separately). Run communication cables. Several InsulGards can be networked together via RS-485
network, using one modem or Ethernet converter for all of them.
 When networking several InsulGards together via RS-485, use a daisy-chain configuration. The
chain can be terminated with a 120 Ohm resistor at the end if necessary.
 Run all cables into the InsulGard enclosure. Leave at least 2’ of excess cabling in the enclosure for
easy terminating.
Note: Label all cables on both ends!!!

Effective Feb. 2017
3.5 Step 2 - Sensors and Power connections

 Connect coax cables to all PD sensors according PD sensor installation manual.
Important note
Connect coax cables to IPDS sensors properly: central wire to Signal terminal and shield to
Shield terminal using supplied ring connectors. Swapped central and shield can’t be corrected
after equipment will be energized, there will be no output signal. As a temporary measure one can
swap central wire and shield at the sensor interface board, but it will give more noise.
Sensor cable connections are not user accessible after installation.
 Connect PD sensors coax cables to InsulGard sensor interface board in proper sequence. Refer to
software settings and related information in the Questionnaire filled in ordering process.
 Connect temperature, humidity and load sensors to the monitor in accordance with the supplied
wiring diagram.
Run and terminate InsulGard power cable to a designated breaker or fuse block. Verify that there is
no voltage at the source for safe work. Provide a disconnect device near the unit during installation.
3.6 Step 3 - Monitor Installation and Final Connections

 Check proper sensors connections with a multi-meter. Use the detailed check-list from the Startup
manual.
 Install InsulGard and fasten it to the standoffs with the screws (enclosure/panel mount option).
 Connect flat ribbon cable from InsulGard to the Sensor Interface Board. Make sure that two
connector latches are locked.
 Replace green plug-in connectors and connect communication lines.
 Switch InsulGard power On. “Loading” and firmware version should appear on the device display.
Device is now ready for setup and operation.
 Verify that signal wires and power are connected to the modem or/and converter. They typically
have LEDs indicating power ON.

Effective Feb. 2017
4 Startup
Use Startup Guideline document for PD system installation/verification and practical Startup
procedure.
4.1 General
InsulGard setting can be done from the front panel keypad or from a PC using InsulGard software via
the RS485 port or USB port on the optional communications board. For software settings please refer
to the Software manual.
Setting the device from a PC is easier, but few settings can be changed ONLY from keypad. These
are parameters or procedures that must be set at the factory or during installation/startup:
 Device address on a network (preconfigured)
 Baud Rate (preconfigured)
 Phase Shift detection (startup procedure)
 Current / Voltage channel calibration (startup procedure)
 Low Noise detection/setting (startup procedure, rare used)
 Communication protocol - ModBus RTU(default) or Modbus TCP (rare used)
 Frequency Range (default range 20-400Hz, change only for 3-20Hz application)
 Temperature channel calibration (calibrated at the factory)
4.2 Quick setting via the monitor keypad

InsulGard is pre-configured at the factory for a particular application in accordance with the information
received during ordering process. In most case only phase shift measurements and load current
channel calibration should be performed in field. Setup procedure below describes steps that can be
done during typical installation/commissioning. Specific applications might require some additional
procedures.
The table below lists steps for device settings from monitor’s keypad with reference to more detailed
description of the keypad operation.
Parameter or
Function and Reference to Appendix Action
Procedure
Press Set key. Enter 5421 password by using  and  to move
Enter Setup Password protected access to the monitor to different digits and  and  to change the value. Press Enter.
Mode settings (Set). Your password is 5421 (6.1) Wait about 20 seconds until dashed lines will disappear and Set
Date displayed.
Set date. Note: setting date/time earlier than the
Press Enter. Use  and  to move to different digits and  and 
Set Date date/time of the last saved measurement data
to change the value, then press Enter.
causes Clock Error Alarm. (6.2.1)
Press  to move to Set Time, press Enter. Use  and  to move
Set Time Set time (6.2.2) to different digits and  and  to change the value, then press
Enter.
Use  and  to scroll to Set Device Address. Press Enter. Use
Device Set unique Modbus address. Stand alone device
 and  to move to different digits and  and  to change the
Address has default address 1. (6.2.16)
value and then press Enter.
Voltage is used in PDI calculations. Must be set
Use  and  to scroll to Set Rated Voltage. Press Enter. Use 
before voltage channel calibration. Set voltage,
Rated Voltage and  to move to different digits and  and  to change the value
Escape from Set Mode, then enter Set Mode
and then press Enter.
again for calibration if necessary. (6.2.10)

Effective Feb. 2017
Enter rated current – must for Load Current

Use  and  to scroll to Set Rated Current. Press Enter. Use 
monitoring. Should be set before current channel
Rated Current and  to move to different digits, use  and  to change the value
calibration. Escape from Set Mode, enter Set
and then press Enter.
Mode again for calibration if necessary. (6.2.11)
Activate PD channel that will be used for
monitoring. It is preferable to activate only the Use  and  to scroll to Set Active Channels. Press Enter. Use
Activate necessary channels and leave all the rest  and  to choose a channel, use  and  to switch between On
Channels inactive. If none of channels is active, the device and Off. Press Enter. Noise Filter will be displayed. Use  and
will not start a measurement. The Noise filter  to switch between On and Off. Press Enter.
normally should be On.(6.2.3)
Skip. Otherwise use  and  to scroll to Set Channel
Rarely used. Use default setting 3 nC/V for IPDS Sensitivity. Press Enter. Use  and  to choose a channel, press
Channel
sensors; 10 nC/V for RTD (3nC/V for new RTD Enter, use  and  to switch between digits, use  and  to
Sensitivity
sensor) and 5 nC/V for RFCT sensors. (6.2.5) change the value, press Enter. Press Esc to get to other
channels, or press Esc again to leave Sensitivity menu.
Set associated phase for all active channels
Use  and  to scroll to Set Channel Phase. Press Enter. Use 
Channel or leave phase A. The setting will not affect
and  to choose a channel, use  and  to switch between A, B,
Phase measurement – only data presentation in
C AB, AC and BC, press Enter.
software. Can be changed in software. (6.2.22)
Use  and  to scroll to Set Parameters To Display. Press
Parameters to Set parameters to be displayed on screen.
Enter. Use  and  to choose a parameter, use  and  to chose
Display (6.2.4)
On/Off. Press Enter when finished.
Rare used procedure. Will determine Low
Set Channel
Magnitude Limits for PDI calculation for each
Low
channel. May be useful in high repetition low Skip it.
Magnitude
magnitude noise environment. Limits can be set
Limit
manually or detected automatically. (6.2.34)
Procedure allows for conversion of load current
Use  and  to scroll to Calibrate Current. Press Enter. Use 
signal readings into percentage compare to
Calibrate and  to switch between Manually Input Coefficient and Auto
rated load current. Coefficients for conversion
Current Calculate Coefficient. Press Enter to type-in coefficient manually
can be entered manually or calculated by
or percentage of running load current in Auto mode. Press Enter..
InsulGard firmware. (6.2.30)
Calibrate
Similar to current calibration. Rare used. (6.2.29)
Voltage
Commonly used to suspend measurements
when load current or voltage (rare) readings are
Activate zero – equipment out of service. Suspends
Use  and  to scroll to Set Suspend for
Auxiliary measurements if chosen parameter is out of the
Temperature/Voltage/Current. Press Enter. Use  and  to
Parameters to preset range. Default settings are 5 to 150% of
chose On/Off. Press Enter. If On have been chosen, set Low
Suspend the rated current/voltage. Leave Set mode and
Limit, press Enter, then set High Limit and press Enter.
Measurements check reasonable reading of current/voltage
before enabling that feature otherwise could
have no measurements at all. (6.2.25), (6.2.26)
Determines measurement time in terms of
number of cycles of power frequency.
60 cycles 60 Hz power means 1sec time
exposure for every magnitude window. 60 cycles
Number of is the default value. Commonly decreased to 5 Use  and  to scroll to Set # Of Cycles for Data Meas.. Press
Power Cycles for calibration to save time. Enter, use  and  to switch between digits, use  and  to
per acquisition Measurement time estimate: N of active change the value, press Enter.
channels * 21 magnitude windows * N of cycles /
power frequency. With 15 active channels, N=60
and 60Hz power, measurement time =
15*21*60/60=315sec ≈ 5 minutes. (6.2.12)
Choose PDI or Qmax as the parameter to
represent PD activity and activate
Select PDI or Use  and  to scroll to Set PDI or Qmax Output, Press Enter.
Warning/Alarm operations. Chosen parameter
Qmax Use  and  to switch between PDI and Qmax, Press Enter.
will be on display and brought to 4-20mA output.
(6.2.19)

Effective Feb. 2017
The phase reference shift is the phase angle

between the InsuGard synchronization signal
and a reference signal from the phase A
voltage in the monitored object. InsulGard uses Use  and  to scroll to Set Phase Shift, press Enter. Use any
this value for correct phase-resolved data arrow to switch between Manually Input Phase Shift and Auto
representation in InsulGard software and for Detect Phase Shift. Press Enter. In Manual Input type phase
Detection and subsequent data analysis. If this phase shift is shift in and press Enter. In Auto detect mode press Enter and
setting of known or determined by any tool (UPDA, watch changing data for few minutes. Press Enter to stop
Phase oscilloscope or any phase meter) it could be measurements. Calculate average value. Press Enter to go to
Reference manually entered in InsulGard settings (in Manually Input Phase Shift and type the calculated average
Shift hardware and software). If it is unknown it can value. Press Enter. Deviation more then +- 5 degrees or not
be measured by InsulGard using a reference changing values are symptoms of a problem - see Section 7
signal from phase A of the monitored object or Appendix II Synchronization and Phase Reference Shift for
any other reference signal with known phase complete details.
shift relative to phase A. For this measurement
InsulGard works as simple phase meter. (6.2.21)
Use  and  to scroll to Set Measurement Schedule, Press

Enter. Use  and  to switch between Schedule Per Time of
Default setting is four measurements a day by Day and Schedule Per Time Interval, press Enter. Use  and 
schedule. Up to 50 measurements can be to scroll between up to 50 scheduled measurements, press Enter
Measurement scheduled. Measurement by time interval is and type-in the measurement time, press Enter. Zero time means
Schedule another option - the interval must be greater no measurement. Press Esc to go to upper level menu. In Time
than the time of a single measurement ~ 6 interval menu type Time Interval using  and  to move
minutes! (6.2.6) between different digits and  and  to change the value and then
press Enter.
Use  and  to scroll to Set Data Saving Mode, press Enter.

Use  and  to switch between Full (Test) and Brief (Normal)
Default mode of data saving is Normal (Brief).
mode. Press Enter to set Full mode. When Brief has been
During InsulGard commissioning and special
Set Data Save chosen, press Enter and type-in XX days interval (valid numbers
tests Test mode (Full) saving mode is
Mode are every 01-15 days) to save data in Full mode. Press Enter.
preferable. Remember: Return back to Normal
Type-in On Reading # - the number of the scheduled
mode for regular monitoring! (6.2.7)
measurement from the Measurement Schedule list. Second
measurement in a day is the default setting. Press Enter
The Alarm and Warning Relays modes:
- Disabled (OFF) – a relay will not operate
Use  and  to scroll to Set Alarm Relay Mode, press Enter.
- Enabled (On) – a relay will keep alarm/warning
Use  and  to switch to between Enabled, Disabled and Time
Alarm Relay contacts closed continuously until alarm/warning
Enabled. Press Enter. If Time Enabled have been chosen, type
Mode conditions will not detected anymore
value in Relay On Time XXXX Seconds, press Enter.
- Enabled for Time (t) –alarm/warning relay
contacts will be closed for specified time (in sec.)
after alarm/warning condition detected. (6.2.13)
Exit Setup Press ESC.
Clear Data Clears device data memory. This is necessary at Press simultaneously three arrow keys “”.
Memory the beginning of a PD monitoring to clear Use  and  to switch to Yes, press Enter. Watch Erasing
memory from non related and calibration data. Records message on display changed to Records Erased. Press
(6.3.1) any key.
Enter Setup mode again as was described
Enter setup
above
Set Data Save
Set save mode to Full
Mode
se  and  to scroll to Start a Single Measurement, press
This immediately starts a full measurement. As
Start a Single Enter. Measurements In Progress will be displayed. Wait until that
soon as the measurement completes check that
Measurement message disappear and repeat a single measurement 3 more
the results are reasonable. (6.2.37)
times. Analyze data, make changes in settings if necessary
Set Data Save MUST!!! Otherwise excessive data will overflow InsulGard
Set save mode to Brief
Mode memory and old data will be lost overwritten by newer data
Exit Setup Press ESC.

Effective Feb. 2017
4.3 Communications Board Setup

If the optional communications board is installed some configuration and driver installation must be
completed to gain complete access to all of its features. There are three communication ports
available.
Figure 4-1 Communication Board Ports for InsulGard
4.3.1 USB
1. Device USB port. Port is used for local communications between the InsulGard and a computer
through a USB A/B cable. A software driver must be installed on the computer prior to use. The
complete driver installation instructions can be found at Section 9 Appendix IV USB Device
Driver Installation Host USB port. This port is reserved for future use.
4.3.2 Ethernet
There are several functions available through the Ethernet port including webpage display, FTP upload
or download and operation as a virtual serial port.
Before any settings can be changed, you may need to change your computer’s network setting and
access the InsulGard with an Ethernet cable connected directly between your computer and the
communications board’s Ethernet port. The following are typical steps to initialize the communications.
The default IP address for the communications board is 192.168.1.1. Note, if you plan to access
InsulGard on a LAN, or you need to remote monitor InsulGard online, you will need to change the IP
address to an address compatible with the network where InsulGard is installed.
4.3.2.1 Change on a Computer’s Network Settings

1. Go to “Network Connections”. If a Wireless Network is used, disable it, then right Click on “Local Area
Connection”, and click on “Properties

Effective Feb. 2017
2. Click on “Internet Protocol (TCP/IP)”, then click on “Properties”
3. Before making any changes, please write down the current settings to restore the settings upon

Effective Feb. 2017
completion. Change the settings to what is shown below.
4. Connect your computer to the Ethernet port on InsulGard with an Ethernet cable. Open Internet Explorer,
type in “192.168.1.1” on the address bar and the following screen will appear. Type in “admin” for the
User name and Password and you are ready to go.
4.3.2.2 Webpage
InsulGard information can be accessed via webpages through the Ethernet port,. Some parameters

Effective Feb. 2017
must be configured before connecting to a network. Several other parameters should be customized to
match the particular location. Details can be found at Section 8 Appendix III Communications Board
Interface. The following table provides steps for configuring a typical installation.
Parameter or
Function/Note See section #
Procedure
Date and Time Set the current date and time, synchronization to Network Time Protocol
8.5
servers, date format, time zone, and temperature units.
Network Set Ethernet port configuration if connecting to an Ethernet network. 8.2
Modbus RTU Set Modbus Address and baud rate if connecting to a Modbus RS-485
8.4
network.
Email Configure email server, recipient, and event trigger information for
8.7
periodic and alarm event email generation.
FTP Client Configure FTP server information and upload interval for automatic
8.6
upload of the measurement database.
Access Control Change passwords for web page access 8.3
Web Page Customize location, contact information, and display names for web
8.8, 8.9, 8.10
Customization pages.
4.3.2.3 Remote Communications through a Virtual Serial Port

The Ethernet port can be configured as a virtual serial port which acts exactly the same way as the
USB port does. When connected to a Local Area Network (LAN), InsulGard software can communicate
with InsulGard remotely with use of the serial port number created during the setup procedures. When
users log into the company’s network through a VPN from an outside network, communications with
InsulGard may also be possible depending on the company’s firewall and network settings.
Please follow the steps in Section 10 Appendix V. Ethernet Virtual Communications Port Driver
Installation to set up the virtual serial port on the computer.
4.3.3 Tips for Communications Setup

The following tips only apply to InsulGard with the communications board installed.
1. There is always a waiting time ranging from 20 seconds to 5 minutes before InsulGard software
can communicate with an InsulGard unit after the following operations: InsulGard is powered up
(1 minute), after keypad Memory and Set operations, during and for a short time after a
measurement cycle and Data Erasing command.
2. If communications through the USB port is not successful, unplug the USB cable and then plug
it back into the computer. If using InsulGard software versions 3.XX, exit InsulGard software,
then plug-in USB cable, run software, repeat plug-out/plug-in in communication tab if have no
communication again.
3. During a measurement cycle, InsulGard cannot be accessed using InsulGard software through
the virtual serial port or USB port, however, the webpage will still display the information stored
before the measurement.
4. If you are communicating through a virtual serial port via Ethernet, you may need to check if the
IP address has been changed on the communications board. It is preferable to have a static IP

Effective Feb. 2017
address for the InsulGard.

5. If connecting to a PC running InsulGard Software, ensure the PC COM port is set for the same
baud rate as the Insulgard. Ensure communication parameters on the Insulgard software match
as well.
6. If COM port does not appear on Insulgard software communication page:
a. Disconnect cable for a couple of seconds and reconnect.
b. Exit from the communication page and attempt to reconnect.
c. Restart InsulGard software and attempt to reconnect.
7. The following will result in loss of communication:
a. Attempting to connect or disconnect the Insulgard to or from the PC when the Insulgard
is in setup mode or when a measurement is in progress
b. Attempting to change settings or examine data when the Insulgard is in setup mode or
when a measurement is in progress
c. Attempting to adjust settings from the keypad when the Insulgard is connected to a PC
running product software
8. Communication via USB may not be available on the InsulGard for up to 2 minutes after a unit
power cycle because of internal processing and startup procedures.
9. When connected via a PXG Gateway, during measurement cycles and during setup the PXG
will report “OFFLINE”. This does not indicate a disrepair status on the part of the InsulGard.
When normal operating status is restored, the gateway should report as expected.

Effective Feb. 2017
5 Troubleshooting
5.1 Troubleshooting Tips
Possible problems and probable causes and remedies are listed in the table below:
## Problem Probable Cause Recommended remedy

1 The front panel Lost power -Check incoming power and external fuses;
display is blank. -Check resistance between neutral and line
contacts in InsulGard power input connector
should be ~47 Ohm for 115 VAC and ~157
Ohm for 230VAC versions. Higher resistance
reading may indicate blown internal fuse or
internal transformer problems. If necessary,
replace the fuse. If significantly lower
resistance is measured return the unit to the
Firmware programming factory for repair.
has not completed Try to reprogram in accordance with
successfully Firmware Upgrade manual. If failed, return
the unit for repair.
2 The front panel No data stored in Scroll manually using the arrow keys. Start a
display is not InsulGard memory single measurement to place data in
scrolling. memory.
Internal clock failure Scroll until Time appears on the display
Observe that seconds are changing. If not,
reprogram firmware. If failed, return the unit
for repair.
3 When communicating Date/time settings in the Power InsulGard and let the clock battery get
through software got monitor have been charged. Update date/time from a PC or from
message “Date/Time corrupted because backup InsulGard keypad.
differs from computer battery was drained If the problem persists, return the unit for
time significantly”. without external power for repair.
a long period.
4 Display is blinking, Corrupted Firmware Upgrade firmware. If failed return the unit for
can’t communicate to memory repair.
the device from
software.
5 Flash Error message Corrupted data memory Cycle input power. If doesn’t help upgrade
appears on the front firmware. If doesn’t help either, download
panel display. data and clear InsulGard memory. If the
problem persists return the unit for repair.
6 Error I Channel or Signal or Noise Channel Cycle power, If doesn’t help upgrade
Error N Channel calibration failed firmware. If the problem persists, return the
appears on the front unit for repair.
panel display.
7 Keypad is not Lost contact between front Remove InsulGard back cover, unlock the
working. panel flat cable and the connector push cable out and clean
connector on the contacts, plug cable in gently, lock
processor board connector. Replace the back cover carefully.
Don’t pinch the cable. If the problem
persists, return the unit for repair.

Effective Feb. 2017
8 Communications Device boards may not Verify that you can see randomly blinking
from a PC to complete booting and asterisk in lower right corner of the device
InsulGard failed. internal communication display. It normally appears after 1 minute
setup after powering up. once the device is powered. If you do not
see the asterisk(*), please leave the device
running for another 15 minutes and check for
asterisk again.
Do not enter keypad setup before you see
asterisk after power recycle, as this may
cause 10-15 minutes of additional delay
before the device will begin communicating.
The RS485 network Check and synchronize address in the

address is incorrect. software and in the InsulGard.
Communication baud rate Set the same baud rate in the PC and the
is incorrect. monitor – the default baud rate is 38000.
Serial COM port # in Check the computer port setting and choose
software is incorrect proper COM port # in software
Communication Tab.
The modem or converter Correct the settings according to the

settings are incorrect. manuals.
Virtual serial port has not Install the Gadget Driver from InsulGard
been created. software CD. Disconnect and reconnect the
USB cable between Communication board
and PC.
9 InsulGard is not Control by Load Current Disable control
making (or Voltage) is enabled
measurements. while Load readings are
outside the range (typically
below 5% default value).
Check the current sensor connections.
Load sensor not properly
connected
Rated current was not Set correct rated current and perform
entered in firmware and calibration in accordance with this manual.
Load current channel was
not calibration properly.
The flat ribbon cable Check the flat ribbon cable connections.
between main block and Replace the cable if necessary
the Sensor Interface
Board is not properly
connected on either end,
10 The load current See above See above
readings are
incorrect.

Effective Feb. 2017
11 Temperature, The flat ribbon cable Check the flat ribbon cable connections.
humidity and load between InsulGard and
current are the Sensor Interface board
senseless. is not properly connected
on either end.
12 The temperature Temperature sensor is not Verify connections against winding diagram
readings are properly connected shipped with the monitor. Check the sensors
incorrect connection with an Ohmmeter. Voltage
between contacts 2 and 3 on the Sensor
Interface board should be ~0.25V DC
The flat ribbon cable
between InsulGard and Check the flat ribbon cable connections.
the Sensor Interface board
is not properly connected
on either end.
The temperature Recall the factory settings in Unit Settings

calibration coefficients window, enable editing in “Edit Analog Input
have been corrupted. Calibration Coef.” window and “Send
Settings to Device”
Perform calibration of the Need calibrating resistors 100 and 138.5
temperature channel from Ohm to connect when prompted
keypad
13 Humidity readings The switch on the Sensor Set the switch to H% position
are incorrect Interface board is in the
“Ref.” position.
Check connection against winding diagram.
Humidity sensor is not Check DC voltage between contacts #10 and
connected properly. #12 on the Sensor Interface board. Should
be between 1.5 and 4 V
Humidity calibration
coefficients have been Recall the factory settings in Unit Settings
corrupted. window, enable editing in “Edit Analog Input
Calibration Coef.” window and “Send
Settings to Device”
5.2 InsulGard replacement procedure

1. Backup old configuration in software. Backup database file for the OLD InsulGard.
2. Replace monitor for new one
3. Run InsulGard Software. DO NOT enable editing “Edit Analog Input Calibration Coef.” window
in Unit Settings window in software.
4. Change the “Magnitude Threshold, V” in Continuous Watch in Unit Settings window with the
number on the sticker on the front panel of the NEW InsulGard.
5. Send Settings to Device from Communications window. Get Settings from Device. Click “Update
the Database with the Current Device Configuration”. Backup the Settings. The database
software will have analog coefficients for the NEW InsulGard with the rest of the settings from
the OLD InsulGard. Have to repeat Load Current calibration if Load current was monitored and
old calibration data have not been entered into NEW InsulGard firmware.

Effective Feb. 2017
5.3 Error Messages

InsulGard performs self-test when powered up and before every measurement. If self-test failed, an
error message will be displayed, and the Red LED will lit. InsulGard may display the following error
messages:
 No Synch. Signal -- indicates a loss of the synchronization signal. For external synchronization
mode verify that signal on contact 7 of the Sensor Interface Board is > 0.2VAC. Check jumpers’
position or lost jumper on the sensor interface board or on CPU board #1 in internal
synchronization mode. Refer to Section 7 Appendix II Synchronization and Phase Reference Shift
for details.
 Clock Error – This message indicates there are the data in the device’s internal memory with date
stamp that is later than the current date. This condition corrupt data consistency. Download all
data to the PC software, erase all data in the InsulGard and set correct date and time.
Downloaded data can have date/time inconsistency that hardly can be corrected. Refer to Section
6.2.1 Date and Section 6.2.2 Time for correction procedure via keypad.
 Error | Channel – Indicates that the PD measuring channel has not pass calibration. If this
message appears consistently, the device must be returned for repair.
 Error N Channel – Indicates that the PD noise channel has not pass calibration. If this appears
consistently the device must be returned for repair.
 FLASH Error – Indicates an error reading internal FLASH memory. Download then delete data
accumulated data from device memory. If does not help - the device must be returned for repair.
 STOPPED – Indicates measurements are stopped and the device will not resume measurements
automatically. Please refer to Section 6.2.20 Start/Stop InsulGard for details on resuming
operation from the front panel keypad or refer to the Software manual to resume operation from a
PC.
5.4 Fuse Replacement

If 115/230VAC power is present, external fuse not blown, but the device display is blank and LEDs do
not lit, internal fuse may be blown. If no permanent damage has occurred fuse replacement may correct
the problem.
Cut input power off. Check the resistance between Line and Neutral. For 115VAC applications it should
be ~47 Ohm, for 230VAC applications ~157 Ohm. If open circuit – change the fuse. Lower resistance
indicates power transformer failure and the unit should be returned for repair.
Attention!!! Fuse replacement requires partial disassembly of the device and must be performed
by a qualified person. Contact your local Eaton Electrical representative for assistance.
Fuse replacing procedure:
1. Take InsulGard of an enclosure or panel.
2. Relief flat ribbon cable by removing small cover on top of back cover. Remove InsulGard back
cover.
3. Check and replace fuse:
- for 115 VAC InsulGard use 200mA 5x20 mm, 250VAC rated Time Lag 5ST200-R fuses

Effective Feb. 2017
by BEL Inc.
- for 230 VAC InsulGard use 100mA 5x20 mm, 250VAC rated Time Lag 5ST100-R fuses
by BEL Inc.
4. Carefully reassemble the device and restore connections. Pay particular attention to the flat
cable connecting device’s keypad – don’t pinch it;
5. Check connections and reapply power.
The fuse location is shown in Figure 5-1.
Figure 5-1 Fuse inside InsulGard
Attention!!! If fuse blows again, do not attempt replacing the fuse for a second time. Contact Eaton
representative for device replacement.

Effective Feb. 2017
6 Appendix I InsulGard Front Panel Keypad Operation

6.1 Entering Setup
Important Note. It takes about three minutes to boot Insulgard completely. After powering unit on
please wait until you see randomly blinking asterisk in lower right corner. Do not go into the “Setup
Mode” until you mention randomly blinking asterisk * in lower right corner of the display.
If you do not see the asterisk after 3 minutes, leave the device running for another 10-15 minutes, it
should appear.
Press “Set” key. The password prompt will appear on the display:
Enter Setup
Password: - - - 0
Enter 5421 password by using “” and “” to move to different digits and “” and “” to change the
value and then press Enter. The password is coded into device memory and cannot be changed. Wait
about 20 seconds (until dashed lines will disappear) before pressing any other key. If the wrong
password is entered the dashed lines remain on the display until any key is pressed.
When InsulGard is in “Set” mode, the “Set” LED will be on.
If InsulGard stays in “Set” mode for more than 20 minutes, it will exit to the upper menu and continue
exiting “Set” mode to normal operating mode one step up every 20 minutes.
Access setup options by pressing “” or “” keys, select an option by pressing Enter. Exit the “Set”
mode by pressing ESC. All changes will be saved in the memory upon exit.
The following setting options are listed in the order of pressing “” after entering “Set” mode.
6.2 Setup via Keypad

6.2.1 Date
Set Date

Set the date in InsulGard in MM/DD/YY format. Press Enter.
Date (mm/dd/yy)
02/15/10
Use “” and “”to move between digits. Use “” and “” to change the corresponding values. When
finished, press Enter to confirm and exit. To discard the changes, press ESC to exit.
If there is a data record(s) with date/time stamp later then date/time settings, following message will

Effective Feb. 2017
appear:
Erase Records
After New Date?
You can exit without erasing records by pressing ESC. “Alarm” LED will turn On and “Clock Error” will
be displayed upon exiting Set mode. Press Enter, to delete all measurement records with date/time
stamp later then date/time setting. This feature helps to keep data integrity in case of date/time settings
have been corrupted.
Clearing

If the date is changed to an earlier date by the InsulGard software, the memory will not be cleared, but
“Alarm” LED will be On and “Clock Error” will be displayed.
6.2.2 Time
Set Time

Sets time in InsulGard in HH:MM:SS format. Press Enter.
Time (HH:MM:SS)
02:35:12
Use “” and “”to move between digits. Use “” and “” to change the corresponding values. When
finished, press Enter to confirm and exit. To discard the changes, press ESC to exit.
6.2.3 Activate PD Channels
Set Active
Channels
InsulGard has 15 signal channels. Depending upon the application, some channels are used while the
rest remain inactive. To conserve memory and minimize measurement time do not activate more
channels than necessary. Press Enter:
Channel 01
Off
Use “” and “” to select Channel number, use “” or “” to switch it “On”/“Off”. When all channels
are properly set press Enter to confirm the changes or ESC to discard the changes. Following
message will appear:
Noise Filter
On
Use “” or “” to switch Noise Filter “On”/“Off“, then press Enter.

Effective Feb. 2017
6.2.4 Parameters to Display
Set Parameters
To Display
Chosen parameters will be scrolled on the display when InsulGard is not making a measurement.
Press Enter
Date
Off
Use “” or “” to select “On” or “Off”.
Use “”to scroll through parameters to display then enable/disable parameters to be displayed. All
display options are shown below in order.
Date:
Date
On
Will be displayed as:
Date (mm/dd/yy)
02/15/10
Time:
Time
On
Time
21:45:20
Show Next Scheduled Measurement Time:
Next Meas. Time
On
Next Measurement
10:00
Partial Discharge data:
Channel PD Data
On
The PD data acquired in the last measurement in each active channel will be displayed. Displayed
information can looks as:
Chan %PD Status
230Norm

Effective Feb. 2017
The “Chan” represent Channel number, “%PD” is PDI as a percentage of the preset alarm level. Four
possible situations are reflected by “Status”:
 Low – PDI is below low level and will not be taken into trend calculation;
 Norm – PDI is above low, but below warning level;
 Warn – PDI is above warning, but below alarm threshold;
 Alarm – PDI is above alarm threshold.
The example above shows Channel 2 with PDI 30% of alarm threshold constituting Normal status
If Qmax is the selected parameter for diagnostic, Qmax will be displayed in mV instead of % of alarm
threshold:
Chan Qmax Status
20mV1
Display Frequency. Synchronization will be displayed.
Frequency
On
Frequency
60.00 Hz
Display Temperature:
Temperature
On
A Will be displayed as:
Temperature
20ºC
Display Voltage:
Voltage
On
Will be displayed as a percent of rated voltage:
Voltage
95 %
Display Load Current:
Current
On
Will be displayed as a percent of rated current:
Current
40.0%

Effective Feb. 2017
Display Relative Humidity:

Humidity
On
Will be displayed:
Humidity
20.4 %
6.2.5 Set a Sensor Sensitivity
Set Channel
Sensitivity
InsulGard can use almost any PD sensor operating in 1-20 MHz frequency band. Despite relative
nature of PD measurements in high frequency range default sensitivity settings are entered in the
settings to calculate PD Intensity. It is recommended that you use the same sensitivity for all sensors of
the same type and function. A sensor sensitivity can be determined through off-line sensor calibration.
That calibration has limited value and valid only for PD events next to a sensor. Also different
calibration generators can give significantly different sensitivity.
Default sensitivities are preset for a particular application in settings templates in InsulGard software.
Use the suggested sensitivity for Eaton PD sensors:
1. Coupling Capacitor 3 nC/Volt
2. RFCT on cable drain shield 10 nC/Volt
3. RFCT on surge capacitor ground 5 nC/Volt
4. RTD sensor in motor/small generator 10 nC/Volt
5. RTD sensor in large generator 50 nC/Volt
6. RFVS sensor in switchgear 15 nC/Volt.
Press Enter
Channel 01
10.00 nC/Volt
Use “” or “” to change Channel number. Press Enter. Use “” and “”to move between digits.
Use “” and “” to change the corresponding values. Press Enter. Chose next channel. After all
changes are done, press ESC to exit.
6.2.6 Set Measurement Schedule
Set Measurement
Schedule
Press Enter. Use “” or “” to switch between measurement schedule by Time Table (Time of Day)
or by Time Interval.

Effective Feb. 2017
Schedule Per
Time of Day
Press Enter.
Time of Day # 01
01:00 (HH:MM)
Use “” or “” to scroll between time table items (up to 50 measurement times can be set). Press
Enter. Use “” and “”to move between digits. Use “” and “” to change the corresponding
values. Press Enter. Use “” or “” to move to the next time of a day. Zero time settings means no
measurement set. After completing the schedule press ESC. Default settings are four measurement per
day at 1:00, 7:00, 13:00 and 19:00.
Time Interval Scheduling:
Schedule Per
Time Interval
Press Enter. Use “” or “” to switch between hours and minutes. Use “” or “” to change the
values.
Time Interval
06:00 (HH:MM)
Press Enter to save time interval and exit. Press ESC to discard changes and exit.
Please note that the Time Interval must be NOT LESS than the time for a single measurement.
Otherwise you may create an infinite cycle and will not be able to get out without monitor rebooting.
Estimated measurement time is: t= Ncycle *Nch*21/ F +1 minute, Ncycle – number of power cycles for
acquisition, Nch – number of active channels, F is the power frequency. Six minutes and higher is a
minimum safe interval for default measurement settings and 15 active channels.
6.2.7 Data Saving Mode
Set Data Saving

Mode
Brief saving mode: saving records with header, calculated PD parameters for all measurements and
Phase-Resolved Pulse Height Distributions (PRPHD matrixes) on programmable schedule only.
Full saving mode includes saving PRPHD matrixes for every measurement.
Press Enter:
1. Use “” or “” to choose Full. Press Enter.
Data Saving Mode
Full
2. Use “” or “” to choose Brief. Press Enter.

Effective Feb. 2017
Data Saving Mode

Brief
Set interval in days when data will be saved in Full mode. Use “” or “” to switch between digits.
Use “” or “” to change values. Press Enter
Save Full Data
Every 15 Days
Recommended setting is 15 days (twice a month).
Choose measurement number from the schedule measurement time table when Full mode
measurement will be performed.
On Reading #
02
Use “” or “” to switch between digits. Use “” or “” to change values. Press Enter.
InsulGard will save Full mode data every 15 days (counting from beginning of a month) on second
measurement from the schedule table.
6.2.8 Pulse Width and Interval
Set Pulse Width

Interval
Set allowed PD pulse width and allowed time interval (dead time) between two consecutive pulses.
Pulses with pulse width longer then the limit will not be recorded thus rejecting most of industrial noise
pulses. Time between pulses sets the criteria to reject pulses with long oscillations on their tails and
increases noise rejecting capabilities.
Press Enter
Channel 01

Use “” or “” to change the channel number. Press Enter.
PD Width 640ns
Interval 2560ns
Use “” or “” to switch between PD Width and Interval. Use “” or “” to choose the values.
PD Width selections are:
 640nS – default value, recommended for RTD, IPDS, RFVS and RFCT sensors
 1280nS – for use with long pulses from RFCT sensors on cables
 2560nS - using that selection may result in excessive noise
Interval selections are 640nS, 1280nS or 2560nS (recommended).
After necessary changes for a channel are done, press Enter to confirm and move to the next channel.
After changes for all channels are confirmed, press ESC to exit.

Effective Feb. 2017
6.2.9 Alarm Thresholds
Set Alarm
Thresholds
InsulGard operates the alarm contacts based on the PD parameter level and trend (rate of parameter
change). Two PD parameters are available for alarming: PDI – partial discharge intensity and Qmax –
maximum PD pulse magnitude @ 0.2 PPC repetition rate. Only one parameter can be enabled for
alarming at a time.
 There are three thresholds: Alarm, Warning, and Normal. The Alarm and Warning thresholds
determine when the alarm and warning relays will be operated. The Normal threshold used
internally to suppress trend alarm calculations while the PD parameter is below this level. We
recommend having the following proportion between threshold limits: Warning 25-50% of Alarm,
and Normal 15-25% of Warning. Setting can significantly differ for different objects and should
be corrected after initial period of monitoring.
Press Enter
Channel 01

Use “” or “” to change the channel number. Press Enter.
There are 6 thresholds for PDI and Qmax:
P0 – PDI Normal
P1 – PDI Warning
P2 – PDI Alarm
P3 – Qmax Normal
P4 – Qmax Warning
P5 – Qmax Alarm
P0-Normal PDI
Thresh. 5mW
Use “” or “” to scroll between P0, P1, P2, P3, P4 and P5. Press Enter to change the threshold.
Use “” or “” to switch between digits. Use “” or “” to change values. Press Enter to save
changes.
Press ESC to choose next channel.
To get to Trend thresholds setting scroll to 15th channel and press “” again.
Trend

Press Enter
P0-Warnings
5.00 Times/Yr.

Effective Feb. 2017
Use “” or “” to switch between P0-Warnings and P1-Alarm. Press Enter to change the threshold.
Use “” or “” to switch between digits. Use “” or “” to change values. Press Enter.
Press ESC to exit to upper menu level.

Effective Feb. 2017
6.2.10 Rated Voltage
Set Rated
Voltage
Set rated voltage for the monitored object in Volts. It must be set before the voltage channel calibration.
This parameter also used for PDI (Partial Discharge Intensity) calculation.
Press Enter:
Rated Voltage
013.8kV
Use “” or “” to move between digits, and use “” or “” to change values. Press Enter to confirm
changes and exit, or ESC to discard changes and exit.
6.2.11 Rated Current
Set Rated
Current
Set rated current for the monitored object in Amps. It must be set before the current channel calibration.
Press Enter:
Rated Current
00001.0A
Use “” or “” to move between digits, use “” or “” to change the values. Press Enter to confirm
the changes and exit, or ESC to discard changes and exit.
6.2.12 Number of Power Cycles for Data Acquisition
Set # of Cycles
for Data Meas.
Determines measurement time. The parameter represented in terms of the number of cycles of a power
frequency. Sets measurement time for each magnitude window in measurement sequence. 60 cycles is
default setting. Higher the number – longer measurement will take, higher statistical precision will be.
Measurement time can be estimated as the following: “number of active channels” * “21 magnitude
windows” * “Number of cycles” / “Power frequency”. For 15 active channels, 60 Hz power frequency
and 60 cycles for data acquisition, measurement time will be 315sec (~6 minutes). For saving time
during calibration and monitor resting 5 cycles setting is sufficient.
Press Enter
Number of Power
Cycles 060
Use “” or “” to move between digits, use “” or “” to change values. Press Enter to confirm

Effective Feb. 2017
6.2.13 Alarm Relay Mode
Set Alarm Relay

Mode
Set mode and parameter of alarm and warning relays operation.
Use “” or “” to change modes:
Disabled – relays will not operate.
Enabled – relays will keep contacts closed until alarm or warning condition are present
(until next measurement will show no alarm or warning condition)
Timed Enable – relays will operate for the specified time (in sec.) when an alarm/warning condition
detected
Press Enter
Alarm Relay Mode
Enabled
Press Enter to select that mode.
Or use “” or “” to switch to Disabled mode:
Alarm Relay Mode
Disabled
Press Enter to select that mode.
Or use “” or “” to switch to Time Enabled mode:
Alarm Relay Mode
Timed Enabled
Press Enter to change operating time parameter:
Relay on Time
0010 Seconds
6.2.14 Minimum Noise Channel Magnitude Level
Set Min Noise

Channel Level
This setting is used to set the minimum level for the noise channel. Noise channel level slides down as
the signal channel magnitude window goes down during PD measurements. The noise channel level
will stop at this minimum while PD signal channel will continue to slide until it reaches the lowest
magnitude window.
Press Enter

Effective Feb. 2017
Minimum Noise
Level 0003.0mV
6.2.15 Display Scroll Time
Set Display
Scroll Time
Sets time interval for displaying each item on display before scrolling to the next item.
Press Enter
Scroll Display
Every 03 Secs.
6.2.16 ModBus Address
Set Device
Address
Critical setting for communication with a monitor locally or on network. Can be set only from keypad.
Press Enter:
Device Address
001
6.2.17 Continuous Watch Options
Set Continuous
Watch Options
This feature is enabled between scheduled measurements. During that period all PD inputs are brought
to Continuous Watch channel. Pulses above preset magnitude threshold are counted on 1 sec.
intervals. If number of pulses in an interval exceeds preset amount, it considered a one series. If the
device got preset number of such series, it starts a regular measurement. If an alarm threshold is
exceeded, it stores full measurement data and turns alarm on.
Press Enter to change magnitude threshold:

Effective Feb. 2017
Continuous Watch
Level 007.0 V
changes and move to the next screen, or ESC to discard changes and move to the next screen.
Set number of counts in a series:
Continuous Watch
Count 0010 PPS
6.2.18 Baud Rate
Set Baud Rate


Sets baud rate for RS-485 port.
Press Enter
Baud Rate
38400
Use “” or “” to change between 9600 and 38400 baud. 38400 is default setting. Press Enter to
confirm the selection and exit.
6.2.19 Select PDI or Qmax Output
Set PDI or Qmax

Output
The setting is used to select either PDI (Partial Discharge Intensity) or Qmax (Partial Discharge
Magnitude) as PD activity parameter for all PD channels. That parameter will control warning/alarm
operation and will be brought to 4-20 mA output.
Press Enter
Output Parameter
PD Intensity
To select PDI press Enter. Otherwise, press “” or “” to switch to Pulse Magnitude
Output Parameter
Pulse Magnitude
Press Enter to confirm and exit.

Effective Feb. 2017
6.2.20 Start/Stop InsulGard
Start/Stop
Monitoring
Resumes or Stops the monitoring. Can be used to avoid blank measurements when the monitored
equipment is out of service.
Note: Will be stopped indefinitely. It is the responsibility of an operator to resume monitoring.
Press Enter
Start
Monitoring
Use “” or “” to switch between Start or Stop monitoring. Press Enter to confirm the selection and
exit.
6.2.21 Phase Shift

That is one of only two operations from key pad that necessary to perform in most cases. The rest of
the settings are commonly set at the factory for the project.
Set Phase Shift

Phase shift determines phase shift angle between InsulGard synchronization signal and HV power for
proper representation of phase resolved patterns for advanced diagnostics. By default, InsulGard uses
the internal synchronization from 115/230 VAC power source. External synchronization is optional and
used mostly in variable frequency drives (VFD) application. With external synchronization there is no
need to measure phase shift angle. That angle can be typed into settings in monitor and in software
manually. In case of synchronization from Channel 1 coupling capacitor enter 275 degrees phase shift
(valid for 50Hz+-10Hz frequency range).
Standard procedure describes situation when InsulGard measure phase shift between control power
feeding the monitor and the signal from coupling capacitor on channel1. Phase A coupling capacitor
must be connected to channel 1. The phase shift is measured refer to power supply voltage zero
crossing from negative to positive.
For details refer to the section 7 : Appendix II Synchronization and Phase Reference Shift.
Press Enter
Manual Input
Phase Shift
Use any arrow to switch between Manual Input and Auto Detect modes.
Auto Detect
Phase Shift
Move switch at the bottom of the sensor connection board to Ref position.
Press Enter to begin measurements. Display will update every 15 seconds.

Effective Feb. 2017
Detecting Phase
XXX
Observe changing readings for 1-2 minutes and calculate average of the displayed values.
Note: Typically measured value deviates within the range of +/- 50. Below are some hints that may help
to identify phase angle measurement problems:
 Phase angle varies on more than +/-100 (low reference signal magnitude or high noise).
 On display “???” (reference signal is likely close to zero).
 On display continuously 357 (reference signal magnitude is too high).
Press Enter at any time to stop measurements. Set Phase Shift will be displayed. Press Enter twice to
get to manual Phase Shift editing:
Phase Shift
XXX
Enter calculated averaged phase shift. Use “” or “” to move between digits, use “” or “” to
change values. Press Enter to confirm the changes and exit, or ESC to discard changes and exit.
Note: If using other source of phase reference signal rather then the internal connection to the coupling
capacitor on channel #1, correct obtained phase shift value according to the table below:
Phase Reference source Additional Phase Shift
Channel 1 (Coupling Capacitor on Phase A ) 0
PT Phase A 0
PT Phase B -120
PT Phase C -240
PT Phase A-B +30
PT Phase C-B +90
Switch H%/Ref switch to H% position after completing setting phase reference.
6.2.22 Channel Phase
Set Channel
Phase
Assigns phase and corresponding phase shift to a channel. Doesn’t affect measurements- will shift
phase resolved patterns when represented in diagnostics software. Can be done in software during
interpretation of PD data. Phase A setting will introduce zero phase shift, B=> -1200 shift, C=> -2400,
AB=>300, AC => -30 and BC=> -90.
In some cases a sensor senses all three phases simultaneously - leave Phase A default setting.
Press Enter
Channel 01
Phase A

Effective Feb. 2017
Use “” or “” to change Phase associations. Use “” or “” to change the channel number. When
done, press Enter to confirm changes and exit, or ESC to discard changes and exit.
6.2.23 Frequency Range
Set Frequency
Range
Change only for PD measurement in low frequency power systems below 20 Hz. Rare used. Default
setting > 20 Hz.
Press Enter
Frequency Range
> 20 Hz
Use “”, “”, “” or “” to change between >20 Hz and <20 Hz. Press Enter to confirm the selection
and exit or ESC to discard changes and exit.
6.2.24 Suspend for Temperature
Set Suspend For

Temperature
Used for suspending measurements when temperature readings are outside preset range. Rare used.
Default setting is Off.
Press Enter
Suspend for Temp
Off
Use any arrow key to switch between Off and On. If Off is selected, pressing Enter to confirm and
exit. When On is selected, press Enter
Temperature
Low Limit -500C
Use “” or “” to move between digits. Use “” or “” to change values. Press Enter to confirm or
ESC to discard changes and move to High Limit setting.
Temperature
High Limit 1500C
Use “” or “” to move between digits. Use “” or “” to change values. Press Enter to confirm
The example above means that when suspending is enabled, InsulGard will make measurements only
if temperature readings are between -50 oC and 150oC.
6.2.25 Suspend for Voltage
Set suspend For

Voltage
Used for suspending measurements when voltage readings (in percentage of rated voltage) are outside

Effective Feb. 2017
the preset range. May be used to suspend measurements when the equipment is out of service. Rare
used. Default setting is Off.
Press Enter
Suspend For Volt
Off
Use any arrow key to switch between Off and On. If Off is selected, pressing Enter to confirm and
exit. When On is selected, press Enter
Voltage
Low Limit 005%
Voltage
High Limit 150%
Use “” or “” to move between the digits. Use “” or “” to change the values. After all changes are
made, press Enter to confirm all changes and exit, or ESC to discard any changes and exit.
6.2.26 Suspend for Current
Set Suspend for

Current
Used for suspending measurements when Load Current readings (in percentage of rated current) are
outside the preset range. May be used to suspend measurements when the equipment is out of
service. Used widely on rotating machines. Default setting is Off.
Press Enter
Suspend For Current
Off
Use any arrow key to switch between Off and On. When Off is selected, press Enter to confirm the
selection and exit. When On is selected, press Enter
Current
Low Limit 005%
Current
High Limit 150%

Effective Feb. 2017
6.2.27 Trend Window Length
Set Trend Window

Length
Sets sliding window (in number of 5 days weeks) for trend calculations. Trend calculation are performed
on data obtained between the current date and current date minus Trend Window length. Week
considered being 5 days long.
Press Enter
Trend Window
18 Weeks
Note: 18 week is the default value and corresponds to 90 days period.
6.2.28 Calibrate Temperature
Calibrate
Temperature
Temperature channel is calibrated at the factory for a 100 Ohm Platinum RTD. Field calibration should
not be performed unless absolutely necessary (in case of different RTD have been used).
Calibration requires two precision resistors: 100.0 Ohm representing 00C temperature and 138.6 Ohm
for 1000C temperature . Resistors should be connected as shown in Figure 6-1. Terminals 1 and 2 must
be shortened and the resistor must be connected between the terminals 2 and 3 of the sensor interface
board.
Figure 6-1 Temperature channel calibration
Press Enter to start the calibration.

Connect 00C resistor. Press Enter
Connect Resistor
For 0C ADC 64
Connect a 1000C resistor Press Enter
Connect Resistor
For 100C ADC 208
First coefficient will be displayed:

Effective Feb. 2017
Coefficient
a = 0.690
Press Enter, second calibration coefficient will be shown:
Coefficient
b = -43.448
Press Enter to confirm and exit.
6.2.29 Calibrate Voltage
Calibrate
Voltage
Calibrate voltage channel to present voltage readings in percentage of rated voltage. Rated voltage
must be already entered into the settings. If not, enter the rated voltage, leave Set mode and enter Set
mode again. Firmware allow for automatic calculation of the coefficient (preferable) or manual entry.
1. Automatic Calculation (preferable)
Press Enter, use any arrow key to switch from Manually Input Coefficient to Auto Calculate
Coefficient mode:
Auto Calibrate
Coefficient
Press Enter again.
Enter % of Rated
Voltage 000.0 %
Get running voltage value and enter it as the percentage of the rated voltage (Voper/Vrated *100). Use “”
or “” to move between digits. Use “” or “” to change values. Press Enter. The coefficient will be
calculated and displayed:
Voltage Coeff.
2372.20
Press Enter to save and exit.
2. Manual Entry
Press Enter, use any arrow key to switch between automatic and manual entry modes:
Manually Input
Coefficient
Press Enter
Voltage Coeff.
XXXX.XX
Use “” or “” to move between digits. Use “” or “” to change values. Press Enter to save and

Effective Feb. 2017
exit.
6.2.30 Calibrate Current
Calibrate
Current
Calibrate a CT sensor for load current. The calibration have to be done on site. Sensor must be
connected and the monitored equipment must be energized and carrying a load. Rated current must be
already entered into the settings. If not, enter the rated current, leave Set mode and enter Set mode
again. Firmware allow for automatic calculation of the coefficient (preferable) or manual entry.
Manual entry may be used if the equipment is not running.
1. Automatic calculation (preferable)

Press Enter, use any arrow key to switch from Manually Input Coefficient to Auto Calculate
Coefficient mode:
Auto Calculate
Coefficient
Press Enter
Enter % of Rated
Current 000.0 %
Get running current value and input it as the percentage of rated current (Ioper/Irated *100). Use “” or
“” to move between digits. Use “” or “” to change values. Press Enter. The coefficient will be
calculated and displayed:
Current Coeff.
2341.20
2. Manual Calculation and Entry
Press Enter, any arrow key to switch between automatic and manual entry modes:
Manually Input
Coefficient
Press Enter
Current Coeff.
00001.00
Enter the coefficient. Use “” or “” to switch between digits. Use “” or “” to change values. Press
Enter to save and exit.
Note: Current Coefficient CK can be calculated if Rated Current Irated and the metering CT rating Ict are
known. Assumption made that metering CT ratio is always Ict : 5.

Effective Feb. 2017
If rated current was entered in the settings, calculate Current Coefficient and enter it manually as:
CK= 2.2*Ict.
Wrong CK can be corrected later by multiplying by the coefficient equal to the actual relative load(%)
divided by InsulGard readings.
FlexCore primary CT with the Load Current sensor might be installed over 1 feeder of several feeders
per phase. There will be no valid current measurement in this case, but current monitoring will be still
sufficient for PD diagnostics purpose. Multiply CK coefficient by number of feeders in such case.
6.2.31 Calibrate 4-20mA Loop
Calibrate
4-20 mA Loop
4-20 mA interface is pre-calibrated at the factory. Calibration procedure can be repeated if necessary –
particular metering device reads differently.
In this procedure the device will set 5, 7, 9, 11, 13, 15, 17 and 19 mA on its output. If the receiving
interface reads differently, readings can be entered into InsulGard, which will calculate a linear
approximation coefficients.
Press Enter
Output = 5.0 mA
Actual = 05.00 mA
Change the “Actual” value as read on the receiving interface, use “” or “” to move between digits,
use “” or “” to change values. Repeat editing the rest of calibration point:
Press Enter
Output = 7.0 mA
Actual = 07.00 mA
Press Enter
Output = 9.0 mA
Press Enter
Output = 11.0 mA
Press Enter
Output = 13.0 mA
Press Enter
Output = 15.0 mA

Effective Feb. 2017
Press Enter
Output = 17.0 mA
Press Enter
Output = 19.0 mA
Press Enter, the new calibration coefficients will be shown:
Coefficient
a = 1.0000
Press Enter
Coefficient
b = 0.0000
6.2.32 Calibrate Humidity Sensor
Calibrate
Humidity
Sensor is pre-calibrated at the factory - do not calibrate the humidity channel unless absolutely
necessary.
Press Enter, use any arrow key to switch between three options:
Turn humidity monitoring Off (never used):
Humidity Sensor
Type - Off
Use Voltage input channel for humidity measurements (default setting):
Humidity Sensor
Type - Voltage
Use Current input channel for humidity measurements when want monitoring Voltage and Humidity
instead of Humidity and Current.
Humidity Sensor
Type - Current
Press Enter to make choice between Off and measurement by Voltage or Current channels.
Next two windows will allow entering the calibration coefficients for chosen input.

Effective Feb. 2017
Humidity Offset
838.00
changes and move to Slope setting or ESC to discard changes and move to Slope setting.
Humidity Slope
31.575
changes and exit or ESC to discard changes and exit.
6.2.33 Noise Filter Offsets
Set Noise
Filter Offset
The Noise Filter offset allows setting the noise filter level from –5 to +5 magnitude zones relative to the
signal channel independently for each signal channel. The default level for all channels is set to +1
zone of noise filter offset. Do not change this value unless necessary.
Press Enter
Channel 01
1
Use “” or “” to scroll through the channels. Use “” or “” to change the noise filter offset value for
each channel. After all changes are done, press Enter to confirm all changes and exit, or ESC to
discard any changes and exit.
6.2.34 Channel Low Magnitude Limit
Set Channel Low

Magnitude Limit
PD Intensity and Pulse Repetition Rate are calculated for each channel starting from a certain
magnitude threshold and up to the highest magnitude window (“Zone” in software). Changing that
threshold allows for discarding of low magnitude noise from PDI and pulse repetition rate calculations.
Low magnitude limit has to be set for each channel independently based on the channel’s background
noise level. This procedure applicable only with all sensors connected and a monitored object in
operation.
Note: Magnitude windows are numbered from high to low magnitude following measurement process.
Lowest magnitude corresponds to window #21, highest to #1.
Press Enter:
Use any arrow key to choose between Manually Input and Auto Detect Low Limit.
Manually Input
Low Limit

Effective Feb. 2017
Press Enter.
Channel 01
Low Limit -67.83dB
Use “” or “” to scroll through the channels. Use “” or “” to scroll through the available values in
dB. Reference between magnitude window number, magnitude threshold in mV and in dB is shown in
the following table.
Magnitude windows (zone) threshold for InsulGard
Magnitude window Threshold (V) dB
10.000 0
1 6.894 -3.23
2 4.753 -6.46
3 3.277 -9.69
4 2.259 -12.92
5 1.558 -16.15
6 1.074 -19.38
7 0.740 -22.61
8 0.511 -25.84
9 0.352 -29.07
10 0.243 -32.3
11 0.167 -35.53
12 0.115 -38.76
13 0.080 -41.99
14 0.055 -45.22
15 0.038 -48.45
16 0.026 -51.68
17 0.018 -54.91
18 0.012 -58.14
19 0.009 -61.37
20 0.006 -64.6
21 0.004 -67.83
Make necessary changes in the channels. Press Enter to confirm changes and exit, or ESC to discard
changes and exit.
In Auto Detect mode the device will measure actual signals from each channel with the Noise filter set
Off. It will count all pulses received by the channel and find magnitude threshold with the total number
of pulses above that threshold exceeding 50,000 pulses per second. Low Limit in that channel will be
set to the next higher magnitude threshold. Calculations of PDI and pulse repetition rate will be
performed above that level only.
Choose Auto Detect and press Enter, use “”, “”, “” or “” to choose the auto detect mode as
shown below:
Auto detect
Low Limit
Press Enter. Measurements In Progress will blink and replaced with Noise Level window:
Summarized background noise from all channels will be displayed:
Noise Level
0.0
Press Enter to measure noise in individual channels:

Effective Feb. 2017
Measurements
In Progress
When measurement completed, may scroll through the channels and see result in terms of magnitude
window number:
Channel 01
21
Use “” or “” to scroll through the channels. Press Enter to accept the values and proceed further or
ESC to discard changes and exit.
Align Channels?
Yes
If Yes is selected, procedure will align the thresholds for the channels with the same sensitivity setting
to maximum threshold over those channels.
Before aligning channels, compare the results in channels with the same sensitivity. If they differ by 3
zones or less, select Yes to allow the device for aligning the thresholds for those channels. Otherwise,
select No to leave the values at the detected levels.
Use any arrow key to switch between Yes and No. Then press Enter.
6.2.35 Software Filters
Set Software
Filters
Filters have been developed mostly for coupling capacitor sensors on large turbine generators
equipped with iso-phase bus to discard external PD activity coming from buses toward a generator and
masking internal PD activity in a stator. PD pattern of sparking to a conductor under floating potential
have been targeted. We do not recommend using these filters for other equipment or sensors without
consulting an expert.
Press Enter:
Channel 02
Filter Off (or 1,or 2, or 3)
Use “” or “” to scroll through the channels. Use “” or “” to switch between filter options: Off, 1,
2, or 3. After changes are done, press Enter to confirm changes and exit, or ESC to discard changes
and exit.
6.2.36 ModBus Protocol
Set ModBus
Protocol
InsulGard supports Modbus RTU and Modbus TCP protocols. Press Enter.

Effective Feb. 2017
Modbus Protocol
RTU
Use any arrow key to switch between RTU (default setting) and TCP. Press Enter.
NOTE: The ModBus Protocol must be set to RTU if the optional communications board is
installed. The communications board handles the ModBus TCP protocol separately.
6.2.37 Start a Single Measurement
Start a Single
Measurement
This procedure forces a measurement to start immediately.
Once Enter is pressed, the single measurement starts with Measurements In Progress displayed
during the measurement:
When the measurement completes the display returns to set menu.
6.2.38 IP Address
IP Address
This Command displays communication board IP address. IP address may be used to access the
device over Ethernet. The IP address could not be changed using keypad.
If you see the message that Board 4 is missing, please exit setup and leave the device running until
you see randomly blinking asterisk(*) in the lower right corner, it can take about 1 minute (but up to 15
minutes in rare cases), then you may enter setup again.
6.3 Accessing Memory via Keypad

6.3.1 Clear Data Memory
This operation will erase all data saved in memory. Press three keys simultaneously - “”,“”, “” :
Erase Records?
Yes
Use any arrow key to switch between Yes and No. Press Enter. If No is selected, screen returns to
normal. If Yes is selected, then Erasing Records will be displayed until records will be erased and
Records Erased will be displayed. Press any key to return to normal screen.
6.3.2 Check Data Saved in Memory

Press “Memory” key on the keypad to get number of stored records:

Effective Feb. 2017
2 Records
In Memory
Press Enter:
View Records For
03/10/09
Use “” or “” to move between digits for Year, Day or Month respectively, use “” or “” to change
the date. Press Enter. If there is no data on that day, the data recorded at the time closest to that date
will be shown.
View Records For
03/10/09 14:17
Use “” or “” to scroll through data recorded at different times. Chose the data and press Enter
Chan %PD Status
1 0 1
Use “” or “” to scroll through the channels, and, use “” or “” to switch between Qmax and PDI
(%PD). Press Enter again to return to the previous menu and choose a different record. Press ESC to
exit Memory mode.

Effective Feb. 2017
7 Appendix II Synchronization and Phase Reference Shift

Synchronization signal used in PD measurements and must present all the time.
Loss of synchronization signal stops InsulGard measurements and communication operation
Error message “No Synch. Signal” will be displayed.
Phase reference shift is a phase angle between a synchronization signal and the reference signal
synchronous with phase A voltage of a monitored object. Phase reference shift is used for correct
representation of phase-resolved data in InsulGard software for advanced data analysis.
Incorrect phase reference shift doesn’t affect data acquisition, integral quantities calculations and alarm
operation. Establishing the correct phase reference shift later will provide correct phase-resolved data
analysis of the data acquired earlier.
Correct phase reference shift should be set regardless of the selected synchronization option. Phase
reference shift may be obtained by using InsulGard internal procedure, by a phase meter, oscilloscope
or other instrumentation.
7.1 Synchronization
InsulGard allows external synchronization or internal synchronization from 115/230VAC power supply.
Internal synchronization is the most reliable option since it stops operation only if the power is off. This
is the default option for InsulGard.
External synchronization is used when power supply voltage is not synchronous with voltage in the
monitored object, mostly for Variable Frequency Drive (VFD) applications.
Be cautious when powering InsulGard from a UPS. It is acceptable only when the UPS has a
constant phase shift to the voltage of the monitored object in standby mode. If not, InsulGard
will be “asynchronous” to the monitored object and cannot make reliable measurements. If
unsure about UPS power, external synchronization must be used.
Two jumpers JU1 & JU2 inside InsulGard enclosure (on right side from power supply transformer) are
used to change synchronization type. By default they are positioned for internal synchronization as
shown in Figure 7-1a. Jumpers should be moved to upper position for external synchronization - Figure
7-1 b.
a b
Figure 7-1 Jumpers JU1 & JU2 position for a) Internal and b) External synchronization.

Effective Feb. 2017
External synchronization signal should be connected to the Sensor Interface Board. There are two
external synchronization options:
 Using the signal from a coupling capacitor installed on phase A and connected to PD channel #1.
The signal contains high frequency PD component and power frequency component. Power
frequency component may be used for synchronization and phase reference measurement. For
synchronization jumper J1 has to be installed as shown in Figure 7-2 b (default position).
 Using an external signal source, like a potential transformer (PT). This signal should be connected to
contacts # 7 and #9 (Ground) on auxiliary signals terminals in sensors interface board (Figure 7-2a).
The signal should be in recommended range of 0.2-1VAC and not to exceed 5VAC. Use resistive
divider to bring the signal into recommended range as shown in Figure 7-2 a. Input #7 has 27kOhm
impedance. For that synchronization option jumper J1 (Figure 7-2 b) has to be open.
PT DIVIDER
Fuse
R1
0.1A
50-100 kOhm
R2
1-3 kOhm
Fuse
0.1A
a b c
Figure 7-2. a- Divider for reference voltage from PT connected to the Sensor Interface Board,
b – Jumper J1, c – Switch position for phase reference shift measurement.
7.2 Typical Phase Reference Shift for External Synchronization

The table below presents phase shirt angles for most common external synchronization options. Phase
shift should be manually entered into InsulGard firmware and software settings:
External Synchronization Signal from Phase Shift

Channel 1 (Coupling Capacitor on Phase A) 0
PT Phase A 0
PT Phase B +240
PT Phase C +120
PT Phase A-B (Open Delta) +30
PT Phase C-B (Open Delta) +90
VFD application uses a modified sensor interface board with additional filtering. Phase shift slightly
depends on frequency and varies from 277 to 273 in 40-60 Hz frequency range. For typical applications
50Hz +-10Hz enter 275 degrees.
7.3 Determining Phase Reference Shift

By default InsulGard uses internal synchronization from 115/230 VAC power source. If phase shift
between this voltage and phase A voltage of the monitored object is known it can be manually entered

Effective Feb. 2017
using software or keypad (section 6.2.21 Phase Shift). If it is unknown InsulGard can be used to
measure phase shift in Set mode from keypad. Signal for phase reference measurement can be
obtained from:
 PD channel # 1 (if A phase coupling capacitor connected to Ch#1)
 external source temporarily connected to contacts #7 and #9 (ground) - Figure 7-2a. Temporarily
remove J1 for measurement and return it back upon completion.
Enter Set mode as described in 6.1: Entering Setup . Scroll through the settings to Set Phase Shift:
Set Phase Shift

Press Enter:
Manually Input
Phase Shift
Press Enter for manual input or use any arrow key to switch from manual input to Auto Detect:
Auto Detect
Phase Shift
Set toggle switch on the sensor interface board to Ref position (Figure 7-2 c).
Don’t forget to return it to the H% position upon completion!
Press Enter to start phase angle measurement. The display will be updated with a measured value
every 15 seconds.
Detecting Phase
XXX
Observe changing readings for 1-2 minutes and calculate average of the displayed values.
Note: Typically measured value deviates within the range of +/- 50. Below are some hints that may help
to identify phase angle measurement problems:
 Phase angle varies on more than +/-100 (low reference signal magnitude or high noise).
 On display ??? (reference signal is likely close to zero).
 On display continuously 357 (reference signal magnitude is too high).
Press Enter at any time to stop measurements. Set Phase Shift will be displayed. Press Enter twice to
get to manual Phase Shift editing:
Phase Shift
XXX
Enter calculated averaged phase shift. Use “” or “” to move between digits, use “” or “” to
change values. Press Enter to confirm the changes and exit, or ESC to discard changes and exit.
Note: If using other source of phase reference signal rather then the internal connection to the coupling
capacitor on channel #1, correct obtained phase shift value according to the table below
Additional phase shift number must be added to the calculated average value. New number should be
adjusted to 00-3600 range by adding or subtracting 3600 and resultant number manually entered into

Effective Feb. 2017
InsulGard (see 6.2.21 Phase Shift).
Phase Reference Option Additional Phase Shift

Channel 1 (Coupling Capacitor on Phase A ) 0
PT Phase A 0
PT Phase B -120
PT Phase C -240
PT Phase A-B +30
PT Phase C-B +90
Return switch into H% position upon completion!
7.4 InsulGard with Automatically Synchronization Switching.

(Effective for InsulGard with new Sensor Interface Board shown in Figure 7.3 below)
Newer Insulgard units have two new hardware features:
1. As described above InsulGard can work at two types of synchronization: at internal

synchronization when monitored object has a power voltage frequency the same as the
InsulGard power supply voltage 115/230V-60/50 Hz and at external synchronization used
typically for motors with Variable Frequency Drives (VFD). The type of used synchronization
was previously changed by the position of two jumpers inside InsulGard case (section 7.1).
Using this method, when the source of external synchronization (i.e. drive or motor) was not
energized, the synchronization signal was lost and the InsulGard unit could not function or
communicate.
The InsulGard now features an electronic switch which automatically switches from external to
internal synchronization when there is no external synchronization signal, and switches back to
external synchronization when it appears.
While it is no longer necessary to open the InsulGard unit to reposition jumpers, the Sensor
Interface Board has an additional jumper J3 (Figure 7.3). For external synchronization it must
be installed in the position shown in Figure 7.4a, for internal synchronization it must be
installed in position shown in Figure 7.4b.

Effective Feb. 2017
Figure 7.3 New Sensor Interface Board
J3
Figure 7.4a. External Figure 7.4b. Internal Figure 7.5a. VFD Filter Figure 7.5b. VFD Filter
synchronization synchronization ON Off
2. The Sensor Interface Board now features an additional low pass filter (VFD Filter) which
should be used for external synchronization signal from motor with VFD to remove the effects
of high frequency switching noise. DIP switch settings shown in Figures 7.5 turn this filter on or
off.

Effective Feb. 2017
The filter has two corner frequencies Fcorner (74 Hz and 21 Hz) which corresponds to two
frequency ranges of InsulGard: f >20 Hz and f < 20Hz – Low frequency mode. The filter stop
band (-80dB) is 1.5* Fcorner, that are about 30Hz and 100Hz correspondingly. Three jumpers in
filter circuit allow selection of the filter corner frequency. Usually the manufacturer will install
these jumpers in accordance with VFD frequency for a particular InsulGard application. For
assistance in reconfiguring these jumpers for a given application, please contact EATON
technical support. Please note that, depending on signal frequency, this filter provides a large
phase shift in synchronization signal (Figure 7.6) and correspondingly in PD phase distribution.

Figure 7.6 Filter phase shift.

Effective Feb. 2017
8 Appendix III Communications Board Interface

The communications board is an optional part when InsulGard is being ordered. Sections 8 9 and 10
can be ignored if InsulGard is not equipped with the communications board.
8.1 General
The InsulGard Communications Board provides access through USB and Ethernet interfaces as well as
a tunnel for RS-485 communications. The USB Device interface provides a standard serial
communications port to connect to a local PC. This interface is typically used for local access of
InsulGard data using the InsulGard PC software as well as for upgrading firmware in the
communications board.
The USB Device Driver must be installed on the PC accessing the InsulGard prior to using the USB
Device interface. (See Section 9 Appendix IV USB Device Driver Installation for complete installation
instructions). Once driver is installed, a serial communications port such as COM5 should be assigned
to this interface (the exact port number will vary depending on what other devices are installed on the
PC). When accessing the InsulGard using the InsulGard PC software simply configure this serial port
number on the Communication tab of the software.
NOTE: If the InsulGard or the PC accessing the InsulGard is rebooted or turned off and back on, the
USB cable from the PC to InsulGard must be disconnected and reconnected to reestablish the link.
The USB Host is reserved for future use.
The Ethernet interface supports the following network protocols:
 Modbus TCP/IP on Port 502 for interface to 3rd party building management systems.
 Web Server/HTTP on Port 80 providing on-board web pages viewable with standard browsers
such as Microsoft Internet Explorer (version 7 recommended) or Mozilla Firefox (version 2 or later
recommended).
 SMTP on Port 25 for sending Email across the Internet.
 FTP Server on Port 21 to download InsulGard database file on demand.
 FTP Client to upload InsulGard database file to a server at a specified time/interval.
 SSH Secure Shell on Port 22 for certain administrative tasks.
 Virtual Communication Port for simplified access by the InsulGard PC software. See Section 10
Appendix V. Ethernet Virtual Communications Port Driver Installation for driver installation.
8.2 Network Configuration

The Ethernet Interface requires general configuration to provide access to the Internet for all protocols
as well as specific configurations for several protocols. Prior to configuration provide your local network
administrator with the MAC address of the Ethernet port located on the label on the side of the unit and
request the following:
 MAC Address (copy from label) _________________________
 IP Address (static address*) _________________________
 Subnet Mask _________________________
 Gateway Address _________________________

Effective Feb. 2017
 DNS #1 (name server) IP Address** _________________________

 Domain ____________________
*If you are setting up the InsulGard in a dynamic host configuration protocol (DHCP) environment
the local network administrator must set up the DHCP server to provide a static address each
time the card makes a DHCP request.
** Obtain the Domain Name Server (DNS) IP address and Domain if you plan to use host names.
The number of available Name servers will vary depending on your network. In a DHCP
environment these may be populated automatically when connecting to the network.
If you need e-mail functionality, obtain the SMTP IP address or host name and determine if you
need login/password information to access the server. If using the SMTP host name, verify that
you also have the DNS IP address above.
SMTP (mail server) IP Address or Host Name _________________________
Once you have the required information configure your PCs LAN connection TCP/IP properties with IP
address 192.168.1.2, Subnet Mask 255.255.255.0 and connect the InsulGard to your PC with a CAT5
crossover cable. Note that newer computers may have “autosensing” Ethernet adapters that will work
with a standard CAT5 cable and don’t require a special crossover cable.
Open your web browser and enter InsulGard’s default IP address 192.168.1.1 on the address bar
select Go. A login screen will appear similar to Figure 8-1 Typical login screen. The default User name
and Password for read-only access is user, and for configuration (read/write) access is admin. Log in
using admin and select OK.
Figure 8-1 Typical login screen
To ensure the security of your system, change the user and admin passwords after the initial login.

Effective Feb. 2017
The InsulGard home web page display should appear, similar to Figure 8-2. Note the different areas
and features of the web page that will be referred to throughout this document.
Figure 8-2 PDA home web page
The Enable 60 second auto-refresh feature causes your web browser to read and display the latest
information from the InsulGard every 60 seconds. This feature can be disabled if necessary by
selecting the check box in the header bar so that the check mark disappears. In this case you must
use your browser’s refresh feature (for example the F5 key) to update the web page with the latest
information.
The active alarm notification area indicates that an alarm or warning condition is present. Red alert is
for Alarm events, Yellow alert is for warning events. Relay health indicates the status of the Insulgard
itself.
To configure the network settings, select the Network link from the menu bar. The Network
Configuration page appears similar to Figure 8-3.

Effective Feb. 2017
Figure 8-3 Network Configuration Page
The page shows the current network status for the InsulGard communications board (green indicates
the network is connected; red indicates the network is disconnected).
You can enable or disable the DHCP control as indicated by your network administrator by activating or
deactivating the DHCP Enabled check box. The default is DHCP disabled
If DHCP is disabled enter the IP address, Netmask, and Gateway as provided by your network
administrator. Also if you will be using host names for servers such as the mail server, Network Time
Protocol (NTP) server, Modbus TCP hosts, or FTP Client recipients, enter the IP address of your
network DNS Server(s) in the Nameserver fields as well as the Domain Name. Note that if you
enabled DHCP all of these fields should populate automatically when you connect the InsulGard to your
normal network.
Select Apply and OK to save your changes or Discard to restore the previous setting. If you have set
up the network configuration as indicated by your network administrator you should now disconnect the
InsulGard from your PC and connect it to the normal Local Area Network. Also if necessary reconfigure
your PC and connect to the LAN. Enter the IP address that you have just configured into address line
of your web browser and verify that you can login to the InsulGard.

Effective Feb. 2017
8.3 Change Passwords

There are two user names for web page access, user for read-only and admin for read/write
(configuration). The user names are fixed, but the passwords can be changed to ensure system
security. To change passwords, when logged in as administrator select the Access Control link from
the menu bar. This opens the Access Control Configuration page similar to Figure 8-4.
Figure 8-4 Access Control (Password) Configuration Page
The characters in the password fields appear as asterisks (*). The number of asterisks does not match
the length of the password.
To change the user password, enter the new password twice (replace existing asterisks) in the
Password for the user account fields.
To change the admin password, log in as admin and enter the new password twice (replace existing
asterisks) in the Password for the admin account fields.
Click Apply and then OK to save the new password(s) or Discard to restore the previous password(s).
The passwords update and display as a full row of asterisks.
NOTE After you change the password, you will be prompted to enter the new password the next time
you navigate through the card's Web page.
Note There is no simple means of restoring default passwords, so make sure you remember all
password changes.

Effective Feb. 2017
8.4 Modbus RTU Configuration

The Modbus RTU configuration determines the baud rate and device ID that will be used by external
devices to communicate to the InsulGard via the RS-485 , Modbus TCP over Ethernet, and USB
interfaces. Any changes to these parameter must be coordinated with the external networks
communicating with the InsulGard. To view the Modbus RTU information, when logged in as
administrator select the Modbus RTU link from the menu bar. This opens the Modbus RTU
Configuration page similar to Figure 8-5.
Figure 8-5 Modbus RTU Configuration Page
Modbus RTU Device ID is in the range of 1-247 and the Modbus RTU Baud Rate could be 9600 or
38400. These parameters could be adjusted only from Insulgard keypad. Note that RS-485 networks
with multiple connections and long wiring runs may not work reliably at the higher baud rate.
8.5 Date/Time Configuration

The date and time should be set properly to correlate alarm events and utilize periodic reporting
functions. The communications board can be synchronized to one or more Network Time Protocol
servers. This is the recommended method to ensure accurate timekeeping. When the communications
board is synchronized with the NTP server it will also periodically synchronize the clock on the
measurement board. If it is not synchronized to an NTP server the clocks on the two boards will free
run, resulting in minor discrepancies over long time periods unless you manually reset both clocks

Effective Feb. 2017
periodically. To configure the date/time settings, when logged in as administrator select the Date/Time
link from the menu bar. This opens the Date/Time Configuration page similar to Figure 8-6.
Figure 8-6 Date/Time Configuration Page
To synchronize the card with Network Time Protocol servers select Synchronize with NTP server(s)
and type the IP addresses or host names. You can synchronize the card with up to three NTP servers.
You may need to contact your local network administrator to determine if there are issues with
accessing NTP servers through your corporate IT security firewall.
The NTP status is indicated in parentheses:
 Not running – Indicates that NTP is not running.
 Started, not synchronized – Indicates that NTP is running, but is not yet synchronized with an NTP
server or controlling the local clock.
 Synchronizing with NTP server – Indicates that NTP has synchronized with the local clock, but is
not yet synchronized with an NTP server.
 Synchronized to XX, NTP stratum YY – Indicates that the card is synchronized with an NTP server
at IP address XX that is operating at NTP Stratum YY.
NOTE When NTP status is Synchronized and there is a large discrepancy between the InsulGard time
and the actual time, it may take 5–30 minutes for NTP to reset the card to the proper time.
To set the time based on the time from you PC clock select Set date/time from PC clock.
To set the time manually select Set date/time manually and use the pull-down menus to select the
local date in mm/dd/yyyy format and the local time in hh/mm/ss format.
To customize how the date appears in the data and event logs, select a Date format for logs option
(mm/dd/yyyy, dd/mm/yyyy, yyyy-mm-dd, or dd mmm yyyy). The default is mm/dd/yyyy.
To select the time zone for the card, specify the Timezone for Logs, email, and connected device.

Effective Feb. 2017
To specify how the temperature appears on the Web page, select Fahrenheit or Celsius.
Click Apply and then OK to save the settings, or Discard to restore the previous setting. Refresh the
Web page to view the updated time and formats.
8.6 FTP Client Configuration

The InsulGard communications board provides FTP access to the measurements database file through
both FTP Client and FTP Server applications. The FTP server does not require any special
configuration. It is accessed with standard FTP software applications through the programmed IP
address. The FTP client provides automatic periodic upload of the measurements database file to an
FTP server. This can be useful to push data out through a corporate IT security firewall that may block
incoming FTP requests. To configure the FTP client, when logged in as administrator select the FTP
Client link from the menu bar. This opens the FTP Client Configuration page similar to Figure 8.7.
Figure 8-7 FTP Client Configuration Page
Program the FTP server IP/hostname of the FTP server to send the file to as well as the FTP server
username and FTP server password required to login to the server.
The measurement database file will be stored in the login directory with the default filename
measurement_data.db. To change the directory on the FTP server where the file is placed, or to
change the name of the file enter the directory path and/or filename in the FTP upload path field.
Select Enable SSL if your server is set for Secure Socket Layer transfers.
To verify the FTP server settings are correct select Test FTP file upload, and verify the file transfers
properly. This button can also be used instead of the periodic file upload to force a file transfer on
demand.
Program the Days between upload and Time of day for periodic file upload (HH:MM), then select
Enable periodic file upload to send the database file out at the desired interval and time of day.
Select Apply and OK to save your changes or Discard to restore the previous setting.

Effective Feb. 2017
8.7 Email Configuration

You can use the InsulGard communications board to inform selected e-mail accounts of events and
changes in status as they occur, or to provide a status message at a predetermined time. To configure
e-mail notifications, when logged in as administrator select the General Email link from the menu bar.
This opens the General Email Configuration page similar to Figure 8-8.
Figure 8-8 General Email Configuration Page
Enter the IP address or host name of the SMTP Server IP/hostname (mail server) that will be used to
send the e-mail messages.
If you need to enter a user name and password for the SMTP server, click Advanced SMTP
configuration. If you have made changes to the General Email Configuration page, a confirmation box
opens. Click OK to save the settings; otherwise, click Cancel.
The Advanced SMTP Configuration page will open similar to Figure 8-9.

Effective Feb. 2017
Figure 8-9 Advanced SMTP Configuration Page
Enter the user name and password in the SMTP username and SMTP password fields.
Specify a “from” e-mail address in the SMTP From Address field (for example, InsulGard@192.168.1).
Note that using an improper address may prevent emails from being sent out from your SMTP server.
If you are not sure about these settings contact you local network administrator.
Select Apply to save the settings or Discard to restore the original settings and return to the General
Email Configuration page.
Once the SMTP server configuration is set you may select the Test SMTP server connection button.
This will open a new browser window with diagnostics showing the status of a test message sent to the
server that you configured. Note if the SMTP test is successful, the confirmation displays immediately.
A failed test may take a long time. Close the window if you want to terminate the test.
After the SMTP server is configured properly you need to configure recipients for the emails that will be
generated. You may select the type of emails sent to individual recipients as well as notifications that
will be sent to all recipients.
Begin by selecting 1 of 10 Recipients with the drop-down selection field.
Program the email address of this recipient in the To field.
Select the options for this email recipient by selecting the appropriate check box.
 Send on event active – sends an email when events (typically alarms) occur
 Send on event clear – sends an email when events go away
 Attach event log file for event emails – includes the event history log with email events
 Attach data log file for event emails – includes the data history log with email events
 Attach ID file for event emails – includes the ID file with email events
 Send periodic status email – sends an email including the event log, data log, and ID file at the

Effective Feb. 2017
given time of day repeated at the given number of days. You must program the Days between
periodic status email and Time of day for periodic status email (HH:MM) (in 24 hour format)
fields.
When all options are set select Apply to save the settings for this recipient or Discard to restore the
original settings. You may repeat this procedure for the remaining recipients, selecting Apply after
configuring each recipient.
To remove a recipient select the appropriate number from the Recipients drop down list, delete the
email address in the To field, and select Apply.
After all desired individual recipients have been set up select the Configure button to bring up the
Email Event Trigger Configuration screen similar to Figure 8-10.
Figure 8-10 Email Event Configuration Page
This page allows you to select events that will send email notifications to all recipients. You may select
the appropriate check box for individual options, or use the Select All or De-select All for all options at
one time. The options are:
 InsulGard Summary/Modbus/RTU Device Communication Failure – occurs when the
measurement board quits responding to the communications board
 InsulGard Summary/Relay Health – corresponds to the Status relay on the measurement board
 InsulGard Summary/Red Alert – corresponds to the Alarm relay on the measurement board
 InsulGard Summary/Yellow Alert – corresponds to the Warning relay on the measurement
board
Select Apply and OK to save your changes or Discard to restore the previous setting and return to the
General Email Configuration page. Prior to exiting this page selecting the Test Event Email button will
send an email to all recipients.

Effective Feb. 2017
8.8 Identification Page

The default name for the first item on the Menu Bar is InsulGard. Once the Display Name is modified
as described in this section this name will change. Selecting this item opens the Identification page
similar to Figure 8-11.
Figure 8-11 Identification Page
This page allows you to view and configure fields that will be displayed at various places in the web
pages and emails to help you uniquely identify this unit.
Select Location to change the location displayed in the header bar and notification emails. This
64 character field can be programmed to anything that will help you identify this unit when you
log into the web pages or view emails.
MAC Address is factory programmed and cannot be modified.
Select Who To Contact to change the contact information displayed on this page. This 64
character field can be programmed to anything that you find helpful.

Effective Feb. 2017
8.9 InsulGard Summary Page

One of the benefits provided by the Web interface of the communications board is the ability to see a
quick overview of the InsulGard status. Select the InsulGard Summary link from the menu bar to open
the InsulGard Summary page:
Figure 8-12 InsulGard Summary Page
The elements of this page are described below. Note that all of the categories are expanded to show
all items within it. Simply click on the – beside a category name to collapse the information displayed
under it.
Alarms on Monitored Device and Insulgard Status: Indicates the status of the relays on the
InsulGard:
• Alarm on PD – indicates that monitored PD level exceeds the defined alarm status threshold.
• Monitor Health – Indicates the present health of the InsulGard monitor.
• Warning on PD – indicates that monitored PD level exceeds the defined warning status
threshold.
Auxiliary Parameters: Indicate sync and environmental parameters that are monitored:
• Frequency – indicates monitored synchronization frequency.
• Humidity – Indicates the humidity measured from the last measurement cycle.
• Load – Indicates the load current measured as a percentage of full scale during the last
measurement cycle.
• Temperature – Indicates temperature measured during the last measurement cycle.
InsulGard Internal Link Status: Displays measurement polling times and status
Measurement Overview: Provides a status indication of the current measurement on all channels:

Effective Feb. 2017
• Channel Activation Status – provides a graphic indication of active channels. 1 & blue color
field indicates active, 0 and gray indicates inactive.
• Channel Alarm Status – provides a graphical indication of channels exhibiting alarm status. 1 &
red color field indicates active, 0 and gray indicates inactive.
• Percent of Max PD to Red Level – provides a graphical representation of how close the PDI
level was to the alarm (or red alert) level during the last measurement.
Object information: Indicates the voltage and current for which the Insulgard is rated to measure.
8.10 InsulGard Channels Page

To get a more in-depth view of the partial discharge parameters measured for each channel select the
InsulGard Channels link from the menu bar to open the InsulGard Channels page similar to Figure
8-13.
Figure 8-13 InsulGard Channels Page
This page displays the partial discharge parameters for each channel during the last measurement
cycle. Displayed parameters for each channel include:
 PDI (in mW) – The numeric value is the amount of PDI measured on the channel in mW. The
bar graph is a relative indication showing the highest value of PDI as 100% and all other
channels as a percentage of the it.
 % PDI of Alarm – This is PDI represented as a percentage of the alarm threshold.
 PPS – This is a measure of pulses per second.
 QMAX – this is the level of partial discharge measured as Qmax.

Effective Feb. 2017
8.11 Alarms
When alarms occur the alarm condition is shown at various places in the web pages including the
header bar, the InsulGard Summary page, and the Open Alarms page. To view the Open Alarms page
select the Open Alarms link from the menu bar. Figure 8-14 shows an example Open Alarms Page
with an alarm created by disabling measurements with the InsulGard PC software.
Figure 8-14 Open Alarms Page
This page shows the Device error alert in the header bar and Open Alarms (1) in red on the menu bar
with the number 1 indicating there is 1 alarm. There are a number of options available on the Open
Alarms page.
 Selecting Acknowledge brings up a prompt to enter information regarding acknowledgement of
this alarm. When you enter the note an entry is placed into the Event Log providing a record of
the acknowledgement and the alarm notifications throughout the web pages change from red to
blue. The alarm remains in the Open Alarms list, but the Acknowledge option is no longer
available. This option is typically used when the alarm is still active to show that someone has
seen the alarm and is working on a solution to the problem.
 Selecting Close brings up a prompt to enter information regarding closing this alarm. When you
enter the note an entry is placed into the Event Log providing a record of the closing and the alarm
is removed from the Open Alarms list. Note that if the alarm is still active at the time of closing it
will re-open quickly, so this option is typically used to remove inactive alarms from the open
alarms list.
 Acknowledge All and Close All options are similar to Acknowledge and Close, but affect all
open alarms.
 The Event Log link will open the Event log, which is described in the following section.
 The Parameter line will have a link with the name of the open alarm. Selecting the link will take
you to the Summary page where additional information about the alarm may be available.

Effective Feb. 2017
8.12 Logs
The InsulGard communications board stores historical information about the system in three logs.
 The Data log contains a history of value changes for several measured parameters.
 The Event log contains a history of alarm events when alarms become active or cleared, and
when they are acknowledged and closed by the user.
 The System log contains a history of events related to the communications board such as reboots
and configuration changes.
Selecting the Data link under the Logs category of the menu bar opens a page similar to Figure 8-15.
Selecting the Event or System link will bring up similar pages for these logs.
Figure 8-15 Log Access Page
All three log access pages provide the option to View the log. Selecting this option will open a dialog
box prompting you to open or save the file, depending on the applications available on your PC. The
log files are in “comma separated variable” format which can be viewed with a standard text editor, but
a spreadsheet application will provide more options to sort and display the files.
The Data and Event log access pages also provide the option to Erase the log and start with an empty
log. This can be useful after saving a copy of the log to your PC to minimize the amount of data to
scroll through when new items are added to a log. Selecting Erase the log opens a confirmation box
to guard against accidental erasure. This option is not available for the System log for security reasons
so that any system changes can be tracked to the person who made the change.
8.13 Documentation
The Documentation category of the menu bar provides links to various documentation available
directly from the communications board or from external sources on the Internet. The exact
documentation available may change with new releases of communications board firmware.

Effective Feb. 2017
8.14 Ethernet Virtual Communications Port

The Ethernet Virtual Communications Port driver must be installed on the PC accessing the InsulGard
prior to use. (See 10 Appendix V. Ethernet Virtual Communications Port Driver Installation). Once
installed the driver assigns a serial communications port such as COM6 to this interface (the exact port
number will vary depending on what other devices are installed on the PC). When accessing the
InsulGard using the InsulGard PC software simply configure this serial port number on the
Communication tab of the software. The following instructions describe the installation procedure for
the Ethernet Virtual Communications Port driver.
8.15 Communications Firmware and Upgrade
Figure 8.16 – Insulgard Firmware Page
The firmware page reports the current versions of measurement and communication firmware. The
communication firmware can be updated in the field using this page. The dialog allows you to select an
image file to initiate a firmware upgrade.
NOTE: Not all firmware is compatible with all hardware. Contact Eaton prior to attempting any
firmware upgrades to ensure compatibility with your hardware.
8.15.1 Steps for Updating the Communication Firmware via the Web User Interface
NOTE: These instructions are for communication board firmware only. There is also main unit
firmware that is not able to be updated by this method and may depend on hardware
configuration. DO NOT attempt to upgrade firmware without consulting Eaton Engineering
Service to determine firmware and hardware compatibility.

Effective Feb. 2017
1. Select the Firmware tab from the left panel on the web UI.
2. Select the appropriate .tar file to upgrade the firmware from the Firmware page. Once selected a
confirmation prompt will pop up.
NOTE: The complete firmware upgrade requires a reboot. You may check the Reboot when complete
check-box to schedule a reboot immediately afterwards or you may do it afterwards.
3. Once you provide affirmation to the prompt, the image file will be uploaded to the communication
board and the firmware will be updated.

Effective Feb. 2017
In case you have not checked the Reboot when complete check-box you will need to perform a reboot
to complete the firmware upgrade process.
NOTE: Do not remove supply from the device while the image file gets uploaded or while the device
gets updated.

Effective Feb. 2017
9 Appendix IV USB Device Driver Installation

This section is written for MS Windows 7 and administrative user privileges. For other Windows
environments the process is expected to be consistent.
To install Insulgard USB Virtual Serial Port Driver you must have Insulgard Software installation media
(CD or Flash drive) available. The driver is located in D:\usb_gadget_serial_driver_windows\
On your PC the drive letter may be different (not D)
1. Power on Insulgard and wait for 2 minutes or until you see randomly blinking asterisk in lower right
display corner.
2. Use USB A to B cable to connect Insulgard to PC usb port. Watch Windows status bar, it should display a
message like this if there were no driver installed before.

3. Once it happened, use System Device Manager to install the driver.

4. Right click on “Gadget Serial” and select “Update Driver Software”. In the following dialog, select
“Browse my computer for driver ….”

Effective Feb. 2017

5. Navigate to the driver location on software installation media


Effective Feb. 2017
You may get a warning like one below – select “Install….”

6. Once driver installation completed, you should see a dialog like this. Please mention a Serial Port
number in upper area, it is COM4 in this case. This is a serial number to be selected in the software for
communications.

7. If Insulgard Virtual Serial Port driver installed, the port number also could be found using Device
Manager .

Effective Feb. 2017


Effective Feb. 2017
10 Appendix V. Ethernet Virtual Communications Port Driver

Installation and Configuration
Ethernet Virtual Com Port application should be installed from provided Insulgard Software CD by
running Setup.exe file, located in appropriate folder if Ethernet access to the devices is desired. Current
Ethernet VCP driver only works under 32-bit MS Windows versions.
For 64-bit MS Windows versions we recommend using third party VCP driver software, like Netserial
which could http://pcmicro.com/NetSerial/download_eval.html You will need a license to run the software
for longer than 30 days.
Once configuration of the virtual serial port is completed, user should select created virtual com port
and use it as for usual RS-485 communications.
10.1 ComPortConfigurator User Manual

The purpose of this application is to simplify configuration and installation of Serial over Ethernet
communication driver and service for Insulgard device and software application.
ComPortConfigurator application installs the driver and service and provides UI for adding, deleting of
virtual serial ports as well as service control parameters.
Before using the software, operator must have Insulgard device IP address already assigned. To verify
that the device is accessible use PING command with the device IP address as a parameter, like
ping 192.168.1.1
If the device responds (with replies, not the timeouts), operator may use the software.
The software may be started using desktop shortcut or through Windows start menu command Start 
Programs Com Port RedirectorComPortConfigurator
Once application starts, it will launch the service and display the following panel.

Effective Feb. 2017
Click <Add> button to create a new virtual serial port. Once Dialog panel like one below will be displayed,
operator can select a desired COM port from a dropdown list and enter the assigned device IP address.
Attention! Clicking OK will initiate driver installation.

The installation process consists of two visually identical steps.
User should use the suggested choices, like on the screenshots below as they are not always the same as
Windows default ones.

Effective Feb. 2017
Driver Installation Step 1.
Driver Installation Step 2

Effective Feb. 2017
After installation completed, virtual COM port is ready to use.
<Update> command button on the main configuration panel allows modifying virtual COM port IP address
settings.
<Setting> command button on the main configuration panel provides tools for adjusting service parameters; the
most important one is Autostart. Selecting this option will cause the service to start automatically at Windows
boot.

Effective Feb. 2017
Service Menu Access through System Tray Icon
Start Configuration loads Configuration application

Stop Service suspends service activity
View log – shows service lof entries
Exit – terminates service.

Effective Feb. 2017
These instruction materials are published solely for information purposes and should not be considered all-inclusive. If further
information is required, you should consult an authorized Eaton sales representative. The sale of the product shown in this literature is
subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between the parties.
This literature is not intended to and does not enlarge or add to any such contract. The sole source governing the rights and remedies
of any purchaser of this equipment is the contract between the purchaser and Eaton. NO WARRANTIES, EXPRESSED OR IMPLIED,
INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING
FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS,
AND DESCRIPTIONS CONTAINED HEREIN. In no event will Eaton be responsible to the purchaser or user in contract, in tort
(including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever,
including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional
expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the
information, recommendations and description contained herein.
Eaton Corporation
Electrical Group
1000 Cherrington Parkway
Moon Township, PA 15108-4312
United States
877-ETN CARE (877-386-2273)
www.Eaton.com
© 2010 Eaton Corporation

All Rights Reserved
Printed in USA PowerChain
Publication No. IB02713002E Rev. E 1 Management
February 2017
PowerChain Management is a registered
trademark of Eaton Corporation.
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InsulGard® Continuously Online Partial Discharge Monitoring

Installation and Operation Manual IB02713002E Rev. E1 Effective Feb. 2017

InsulGard Installation and Operation Manual

Class A EMC Statements

Requesting a Declaration of Conformity

Eaton Predictive Diagnostics

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2.5 Configuration of Alarm Thresholds ..................................................................................................... 31

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6.2.11 Rated Current ................................................................................................................................................ 60

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8.1 General ................................................................................................................................................... 84

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15 channels for PD sensors

Connector for flat

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1.2 Principles of Operation

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Maximum Measured Pulse Repetition Rate 367,300 pulses/second

1.4 Important Features and Options

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1.4.4 Continuous Watch Feature

1.4.5 Phase Resolved Data and Phase Reference

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1.4.7 Self-test and Self-calibration

1.4.9 Auxiliary Inputs

1.4.10 Measurement Suspend

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1.4.11 Communication Options and Device Address

1.4.13 InsulGard configuration (settings)

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1.5 InsulGard mounting options and sensor connection

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1.5.1 Panel mount InsulGard

Wire for panel

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b - Left side view.

c - Right side view

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InsulGard Panel Wiring Diagram Connection to:

Sensor Interface Board

Coax cables from PD Sensors

There is no outlet for 230VAC application.

Figure 1-4 A typical wiring diagram of the panel mounted InsulGard.

InsulGard must be grounded at the place of installation.

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d - IDEAL part#45264 STRIP MASTER

Figure 1-6. Auxiliary sensors connection to the Sensor Interface Board.

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Auxiliary sensors connection:

Contact Sensor Sensors wire Note

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1.5.2 Door mount InsulGard

Figure 1-7. Door (Flush) mount InsulGard (back view)

InsulGard must be grounded at the place of installation.