G500 Substation Gateway Table of contents PRODUCT SUPPORT Access the GE Grid Solutions web site................7 Search GE Grid Solutions technical support library..........7 Contact GE Grid Solutions technical support ............7 GE Grid Solutions address ....................8 Product returns.......................8 ABOUT THIS Purpose ..........................9 DOCUMENT Intended audience ......................9...
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IRIG-B output..............................68 CPU ..................................69 TEMP..................................69 SSD..................................69 STATUS ................................70 Power...................................70 OLED Display ..............................70 Rear indicators......................71 6. SPECIFICATIONS Product specifications ....................73 Environmental specifications..................74 Temperature and Humidity........................74 Altitude................................75 Ingress Protection (IEC 60529) .........................75 Liquid Protection ............................75 GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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G500 FROM SERVICE Removing configuration data on a PC..............82 A. STANDARDS & Compliance Standards ....................83 COMPLIANCE B. CUL C. WARRANTY Warranty........................87 D. LIST OF Acronym Definitions ....................89 ACRONYMS REVISION HISTORY Revision history ......................91 G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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TABLE OF CONTENTS GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
Contact GE Grid Solutions technical support GE Grid Solution Technical Support is open 24 hours a day, seven days a week for you to talk directly to a GE representative. In the U.S. and Canada, call toll-free: 1 800-547-8629...
You are sent the RMA number and RMA documents via fax or e-mail. Once you receive the RMA documents, attach them to the outside of the shipping package and ship to GE. Product returns are not accepted unless accompanied by the Return Merchandise Authorization number.
G500 Online Help • Module layouts, as available • The G500 Substation Gateway Software Configuration Guide (GE part number SWM0101). For the current version of the G500 Instruction Manual, please download a copy from: http://www.gegridsolutions.com/app/ViewFiles.aspx?prod=G500&type=3 G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Indicates practices that are not related to personal injury. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
• The successful operation of this equipment depends upon proper handling, installation, and operation. Neglecting fundamental installation requirements may lead to personal injury as well as damage to electrical equipment or other property. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
If the G500 is used in a manner not specified in this manual, the protection provided by the equipment may be impaired. • Changes or modifications made to the unit not authorized by GE could void the warranty. Warning symbols Table 1 explains the meaning of warning symbols that may appear on the G500 or in this manual.
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Serial: 8 factory installed ports, expandable up to 20 ports, RS-232 and RS-485 are accessible via individual RJ45 connectors. • Ethernet: Six Ethernet interfaces available through SFP cages. Each cage supports: 100/1000BaseT, 100BaseFX or 1000BaseSX. Figure 1: G500 G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
* Storage option A is only available with CPU option A and storage option B is only available with CPU option B. ** Visit the online store for application licenses ordering codes. For latest configuration and options, please visit the online store: http://www.gegridsolutions.com/app/ViewFiles.aspx?prod=G500&type=3. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
UART Card options MCP PCIe UART CARD, 4x PORT (RJ45) RS232/485 [528- These options are only 1001LF] MCP BUILT-IN UART CARD, 4x PORT (RJ45) RS232/485 available when Spare [528-1003LF] type is UART Card G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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CHAPTER 1: INTRODUCTION GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
“zap” the board without you knowing it; a small discharge, imperceptible to the eye and touch, can often be enough to damage electronic components. Extra caution should be taken in cold and dry weather when electrostatic charge easily builds up. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
If damage is observed (usually in the form of bent component leads or loose socketed components), contact GE Technical Support for additional instructions. Depending on the severity of the damage, it may be necessary to return the product to the factory for repair.
The G500 is mounted in 3U slot of a 19” rack by use of 6 screws compliant to IEC60297-3 with STD hole Pattern. Screws Use screws with a shaft diameter close to 5mm. For example, M5 or UNF 10-32 screws. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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For screw torque specification, refer to “General Torque Values for Screws” on page 79. Install 2 of the screws at the same height in the 19” rack. The screws should be screwed in to a distance of about 3 mm between screw head and rack. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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The recommended tool torque settings for zinc-plated mounting screws are: – 10-32 UNF screws use 22.2 in-lb [2.50 Nm] – 12-24 UNC screws use 31.0 in-lb [3.51 Nm] – M5x0.45 screws use 18.1 in-lb [2.04 Nm] G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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The minimum specified spacing to the front and behind the G500 is 5cm (2”). Other spacing requirements are indicated in the following diagram. These requirements are met when the G500 is installed using the provided rack mounting kit. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
The grounding wire should be AWG 12 or lower and not longer than 1 meter. Power input The mating connector is the 5-pin “Phoenix 1942293”. This connector type is required for IP30 compliance. connector G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
The DC input voltage is 100 to 300V. The PSU tolerates a +10%/-12% variation in these values (88 to 330V). With DC input, the PSU has a maximum current consumption of 1.8A. When using AC power, connect the “~”, “N“and “GND” wires according to the following figure. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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The fuse is placed in “N”/ ”-“ connection of the power supply. The fuse is soldered directly onto the product. There is no fuse holder. The fuse should only be replaced by GE personnel. Overvoltage The voltage to the inner loads is protected by a varistor. High increase of the voltage will protection cause the internal current fuse to blow and/or the Varistor to break.
CHAPTER 3: INSTALLING THE G500 The varistor is soldered directly on the product. There is no fuse holder. The varistor should only be replaced by GE personnel. Low Voltage Power Supply The Low Voltage Power Supply only handles DC input, with DC input voltage from 20 to 54V.
If the G500 does not pass one or more of the above tests, the board will fail the POST and display a hexadecimal value on the lower right corner of the screen. Please contact GE’s Grid Solution support with the hexadecimal code in this case.
The RS232 switch panel transfers all serial field connections to the standby G500, which then becomes the active G500. Required components To implement a redundant G500 system, you need the following components Component Function GE part number RS232 Switch Panel Communications switch. 517-0247 Power Supply Power supply to power the RS232 switch panel.
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Figure 2 on page 32. Connect TB4 pins 1 (SET) and 2 (RESET) on the master RS232 switch panel to TB2 pins 1 and 2 on the slave RS232 switch panel using the cable specified (GE part number 970- 0161) or similar.
When connecting to more than 8 field devices, you must double the number of RS232 switch panels used. When using this configuration, follow the instructions in “To set up a redundant system with two RS232 switch panels:” on page 29. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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CHAPTER 3: INSTALLING THE G500 Figure 1: Redundancy Wiring - Single RS232 Switch Panel G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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CHAPTER 3: INSTALLING THE G500 Figure 2: Redundancy Wiring - Dual RS232 Switch Panel (1 of 2) GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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CHAPTER 3: INSTALLING THE G500 Figure 3: Redundancy Wiring - Dual RS232 Switch Panel (2 of 2) G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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CHAPTER 3: INSTALLING THE G500 Figure 4: Redundancy Wiring - Redundant RS232 Switch Panel (1 of 2) GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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CHAPTER 3: INSTALLING THE G500 Figure 5: Redundancy Wiring - Redundant RS232 Switch Panel (2 of 2) G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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CHAPTER 3: INSTALLING THE G500 GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
G500 Substation Gateway. First look at the G500 Front panel The front panel of the G500 provides easy access to the status indicators, user connections and power supply units. Figure 1: G500 front panel G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
The communication cards are powered from the G500. The types of communication cards included in your G500 depend on what was ordered for your substation application. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
DASH: • SOL port • Remote USB • Remote power control • Remote board info The port uses an RTL8111EP network. Drivers are freely available for several operating systems on the Realtek website. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
The cumulative current draw of both ports is limited to 1A due to thermal and power budget restrictions. The maximum cable length for USB 3.0 cables is 3m (=118in). Using longer cables than specified for each port might result in data loss. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
Each display port is capable of supporting two suitable displays via Multi Stream Transport (MST). G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
48VAC or 75VDC with maximum 100mA to comply with IEC 61850-3. If 61850-3 Compliance is not required, the relay may switch up to 300VAC or 300VDC. This Port is isolated from the rest of system in accordance to IEC60950 for use with mains. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
There is a IRIG-B output connector available at the rear of the unit. This output can be used to synchronize external equipment or other units to this unit. The supported IRIG-B formats are 002 and 006. The supported levels are compliant to TTL by a load of 25Ohm or higher. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
13 through 16 Expansion Slot 2 1 through 4 17 through 20 Expansion Slot 3 1 through 4 The serial ports support 4 communication modes • RS232 • RS422 • RS485 4-Wire • RS485 2-Wire GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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RS-232 and RS-485 connections must comply with the following requirements: • Cables must be shielded • D-type connector covers must provide EMC shielding (e.g. metalized plastic or die cast metal covers). G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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Power down system gracefully. Disconnect all hazardous live circuits and sources of electrical power. Remove both power supplies. Remove screws and push lid to the rear until markings on lid and chassis align. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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CHAPTER 4: INTERFACES Pull lid to outside until second marking aligns. Lift lid to remove. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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CHAPTER 4: INTERFACES Remove attachment screws. Pull UART package out of slots (be careful, do not to damage ESD gasket at the rear). GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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CHAPTER 4: INTERFACES Exchange the UART module. 10. Check that the thermal connector pads on the PCB are still in place. If the thermal pads are damaged or missing, contact GE for replacements. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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11. Insert the UART module into slots and attach the UART module by re-installing the screws from the power supply bay. Be careful, do not damage the EMI gasket on the rear of the unit. Otherwise, since damage may result in reduced ESD protection. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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CHAPTER 4: INTERFACES 12. Attach the lid a little to the rear and out of position (In the right position both lid and chassis markings align). G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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CHAPTER 4: INTERFACES 13. Push the lid inwards. 14. Push the lid to the front and attach all screws. For screw torque specification, refer to “General Torque Values for Screws” on page 79. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
The ALARM connector and the both power supply connectors have to be disconnected before housing is opened! Opening cover To change or add the cards open the chassis by performing following steps: Undo the PCIe heat sink screws if tightened. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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CHAPTER 4: INTERFACES Remove the screws and push the cover to the rear until markings on the lid and chassis align. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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CHAPTER 4: INTERFACES Pull the cover outwards until the second markings on the lid and chassis align. Lift the lid to remove. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
This Unit is to be serviced by trained personnel only. Closing cover Attach the lid a little to the rear and out of position (In the right Position both lid and chassis markings align). G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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CHAPTER 4: INTERFACES Then push lid inwards. Push the lid to the front and attach all screws. For screw torque specification, refer to “General Torque Values for Screws” on page 79. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
Open the cover by following the steps from “Opening cover” on page 54: device Loosen the M.2 heat sink screws, pull heat sink up until the keyholes allow removal of the heat sink. Unscrew the M.2 module and remove the module. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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Attach the piggyback gap pads on the top of the new module. Use an M2.5 screw to fasten the M.2 module in the empty G500 slot. Align the heat sink keyholes with the screws and push the heat sink keyholes over the screws. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
Order code section on page 14. The G500 supports up to three PCIe cards. Only PCIe cards supplied with the G500 or ordered from GE should be used. Use of non-G500 PCIe cards can result in unexpected behavior and may cause permanent damage to the equipment.
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Closing cover on page 57. After closing the G500 cover, tighten all heat contact screws that now correspond to occupied PCIe slots. For screw torque specification, refer to “General Torque Values for Screws” on page 79. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
For the mounting position of a USB dongle (maximum dimensions: 53mmx22mmx13mm) dongle see the figure below. In order to withstand standard shock and vibration levels the dongle must be tie-wrapped to the pre-installed mounting structure as shown above. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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CHAPTER 4: INTERFACES GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
G500 Substation Gateway Chapter 5: Indicators Indicators The G500 includes LED indicators for communication interfaces as well as additional indicators for different operational states. Front Indicators G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
Ethernet Port (SFP) LEDs There are six LEDs located on the front of the unit indicate the status of the corresponding rear SFP links: STATUS INDICATIOR No Link 100 MBit no activity Orange GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
Serial Port LEDs Up to 8 numbered LEDs located on the front of the unit indicate the status of the corresponding rear UART ports: STATUS INDICATIOR No traffic Transmitting Green Receiving Transmitting and receiving Orange G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
IRIG-B input watchdog signal IRIG-B output The IRIG-B output option is not available in the G500 v1.00 release. STATUS INDICATIOR IRIG-B output is present and the internal Green clock is synch’ed from an external source GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
All power rails OK, CPU running Green All power rails OK, CPU standby/off Orange One or more power rails has failed TEMP STATUS INDICATIOR No thermal alert Application controlled (temperature warning) Orange Critical temperature Green light indicates activity G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
The G500 provides a monochrome/white OLED display. The OLED display will show the model number “G500” when any button is pressed for five minutes and then will turn off. The OLED display incorporates four buttons which are not supported in the G500 v1.00 release. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
CHAPTER 5: INDICATORS Rear indicators If PCIe cards are installed which support indicator lights, the lights are visible through the holes at the rear of the G500 unit. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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CHAPTER 5: INDICATORS GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
All software selection persist when power cycled. IRIG-B available on all serial interfaces. +12V output available on 2x serial interfaces Port 4 and Port 8. It is limited to 0.5A (6W) with short circuit protection and auto recovery. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
* if PCIe Cards are installed the operating temperature of the system is reduced to 60°C. If non-compliant PCIe Cards are used the user has to take care of proper operation of the plug-in card and the operating temperature of the System may be decreased. GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
The G500 is designed to protect the internal electronics from small amounts of liquid falling vertically or which may accumulate on the top surface of the chassis. Mean Time Between Failure Part GE Part Failure In MTBF in hours Number Time (FIT) @40°C...
Mechanical Specifications Weight Part Weight in kg G500, 0 serial ports, without PSU G500, 4 serial ports G500, 8 serial ports Mounting bracket HV PSU LV PSU Dimensions All dimensions in mm [inch] GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
Exposure to excessive temperature or other extreme environmental conditions might cause damage and/or unreliable operation. To avoid deterioration and early failure of electrolytic capacitors, power up units that are stored in a de-energized state once every 12 months, for one hour continuously. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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CHAPTER 6: SPECIFICATIONS GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
For an RMA: Remove the Solid State Drive (SSD) from the G500 using the reverse of the SSD installation procedure found earlier in this manual; send the G500 unit to GE and safekeep the drive. If the drive is faulty, GE recommends destroying the old drive as per NIST* recommendations.
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Recommended: Physically removing and destroying the data storage media, or • Using a program to securely wipe (that is, completely erase) the data storage media (that is, not just reformat or remove the names of the files from the file allocation table). GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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Devices Installed in Electric Power Substations Communication Networks and IEC 61850-3:2013 Per Standard systems for power Utility Automation-Part 3 SAFETY EN/IEC 60950-1: 2005 Per standard UL marking UL60950-1 2 Ed /CSA NWGQ2 & NWGQ8 C22.2 60950-1-07 GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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APPENDIX B: CUL GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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Appendix C: Warranty Warranty Warranty For products shipped as of October 1st, 2013, G500 warrants most of its GE manufactured products for 10 years. For warranty details including any limitations and disclaimers, see the GE Grid Solutions Terms and Conditions at https://www.gegridsolutions.com/multilin/warranty.htm...
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APPENDIX C: WARRANTY GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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Export Control Classification Number Electro-Magnetic Interference Electro-Static Discharge foot Federal Communication Commission (USA) General Electric Ground, Electrical Grounding GPIO General Purpose I/O Graphics Processing Unit High Availability Seamless Redundancy High Voltage IRIG Inter Range Instrumentation Group G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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UART Universal Asynchronous Receiver Transmitter UEFI Universal Extensible Firmware Interface Universal Serial Bus, a peripheral bus Volt Ampere, Power Video Graphics Array 8P8C Connector with eight Positions eight contacts, also known as RJ-45 GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...
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G500 Substation Gateway Revision History Revision History Revision history Version Revision Date Change Description 1.00 March 25, 2019 Document created April 02, 2019 Order Code and Redundancy wiring drawings are updated. G500 SUBSTATION GATEWAY INSTRUCTION MANUAL GE INFORMATION...
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REVISION HISTORY GE INFORMATION G500 SUBSTATION GATEWAY INSTRUCTION MANUAL...