Professional Documents
Culture Documents
• Every substation is unique making design and drafting a one-off solution for every station
• Miles of copper wires needs to be pulled, spliced and terminated
• Time consuming testing and troubleshooting of thousands of connections must be performed by skilled personnel
The HardFiber System was designed to address these challenges and reduce the overall labor associated with the tasks of designing, documenting, installing
and testing protection and control systems. By specifically targeting copper wiring and all of the labor it requires, the HardFiber System allows for greater
utilization and optimization of resources with the ultimate goal of reducing the Total Life Cost (TLC) for protection & control.
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Traditional Substation
Materials Labor
• Relays • Head Office Engineering
• Copper Cabling and Drafting
Traditional substation designs require large amounts of skilled labor to create engineering drawings, pull and terminate miles of copper cables, and test and
troubleshoot thousands of connections.
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HardFiber System
Extensive amounts of copper cables need to be Many connections need to be made in each Thousands of terminations need to be connected
distributed from each switchyard apparatus back apparatus in the high voltage equipment and tested for each protection and control device
to the control house switchyard found in the control house
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HardFiber Substation
Materials Labor CUT
• Relays • Head Office Engineering P&C LABOR
and Drafting 50%
• Cabling
• Patch Panel • Construction & Installation
• Commissioning and Testing
• On-going Maintenance
The HardFiber System replaces labor-intensive processes with quick installation, off-the-shelf equipment and made-to-order cables.
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HardFiber System
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• Low density copper needs • Outdoor cables carry copper
1000s of terminations wires to control building
Before • Manual, one-by-one installation • Miles of copper wire throughout
by highly skilled workers a typical switchyard
All copper wiring ends at the Brick Outdoor fiber cable replaces copper
wiring in trenches
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HardFiber System
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• Thousands of hand wired • Thousands of connections to
terminations into a rack protection and control devices
• Labor-intensive using specialized • Manual wiring prone to errors and
workers extended testing
Fiber cross connect panels replace Only fiber connections at the relay via
copper terminations the UR IEC 61850 Process Card
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HardFiber System
What is IEC 61850 Process Bus? Adhering to existing practices: Added benefits:
Process Bus is a term used to describe a • Providing a complete system with all the • Reduce dedicated on-site labor with pre-
protection and control system that uses a necessary components for measurement, fabricated material to reduce costs
digital communications architecture to carry control, and protection • Is practical to commission and maintain
information between the switchyard and • Covering all utility substation protection • Is as reliable as existing protection and
protection and control devices in the control applications control systems
building. This information consists of sampled • Being understood and deployed by the • Uses an open IEC 61850 Process Bus
values, equipment status and output commands. current utility workforce architecture that can supports multi-vender
IEC 61850 is the international standard that
applications
defines the specific communication protocol
for Process Bus implementations used for • Is scalable and can be integrated into existing
substation designs
protection and control applications. Copper connections from apparatus are made directly
to Bricks and end in the switchyard
The HardFiber System uses IEC 61850 to communicate measurements and commands between Bricks and relays in the control building over dedicated point-to-
point fiber optic connections that avoids cyber-security issues altogether.
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HardFiber System
System Architecture
The architecture of the HardFiber System is Keeping true to the existing topology of
driven by the mapping of signals between the traditional substations, each protection and
primary apparatus and the protection and control device included in the zone of protection
control devices. will be connected directly to Bricks through
dedicated fiber optic connections.
The measurement of field signals and respective
mapping of these signals, using the open IEC This simple, purpose-driven architecture
61850 communications protocol, back to the that uses the IEC 61850 open standard for
control house is done through a hardened communications, provides dedicated point-
interface device called the HardFiber Brick. to-point connections between the Brick and
protective relays without introducing any
Using made-to-order Outdoor Fiber Cables
issues relating to data synchronization, setting
connecting the Brick to a Cross Connect Panel in
management or Cyber-Security.
the control house provides fast and error-proof
installation without the need for on-site splicing
Each Brick transmits measurements and accepts or terminating.
controls from up to 4 separate protection and
control devices.
The HardFiber System can easily be incrementally scaled to include new equipment as stations evolve. Duplicated Bricks in the switchyard provide a drastic
improvement in reliability and security over today’s technology.
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HardFiber System
The challenge for communication-based Internal diagnostics and self-tests within The HardFiber IEC 61850 Process Bus System is
protection systems becomes making extensions each Brick monitor dozens of critical internal a solution that addresses these very concerns
and modifications without disrupting the subsystems and provide this information several and provides utilities with a means to reduce the
in-service protection and control system. hundred times per second. Duplicate Bricks can labor associated with substation construction
be provisioned to acquire each input signal and expansion, and at the same time uses
By recognizing that the mapping between
twice, allowing protection and control devices technologies and methodologies familiar to
power system signals and protection and
to continuously crosscheck critical protection existing resources and skill sets.
control devices is fundamentally driven by
measurements before executing commands via
the topology of the underlying substation, the
fully redundant outputs.
HardFiber System is optimally partitioned and
connected to allow for additions, modifications With the HardFiber redundant architecture,
and upgrades to the system – without risking each protection and control device can be
interruption or degradation to critical in-service configured to maximize dependability and
protection. security, addressing specific application
requirements.
Dedicated Digital Cores within each Brick allows for application additions and modifications without affecting other devices accepting information from the Brick
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HardFiber System
Technical Specifications
BRICK INPUTS FORM-C RELAY (2) Commands IEC 61850 8-1
AC CURRENT Maximum Voltage 280VDC Commands to Brick sent as properly configured GOOSE
Number of Inputs 4 or 8 Maximum continuous 8A messages as defined in “Multilin Technical Description for
CT rated secondary 1A or 5A current Interoperability”
Nominal frequency 50 Hz or 60 Hz Make and carry for 30A as per ANSI/IEEE C37.90 BRICK OUTDOOR FIBER CABLES
Relay burden < 0.2 VA at rated secondary 0.2s OPTICAL CHARACTERISTICS
Conversion range 0 to 46 × CT rating RMS symmetrical Breaking capacity (L/R=40 ms) Optical Fibers 4
Current withstand 20 ms at 250 times rated DC Voltage DC Current Fiber Type Graded Index, Multimode
1 sec. at 100 times rated 24 V 1A (50/125 mm)
Continuous at 3 times rated 48 V 0.5 A Specification MIL-PRF 49291/1-01
AC VOLTAGE 125 V 0.3 A Maximum Distance 500 m (1650 ft)
VT rated secondary 25.0 to 240.0 V 250 V 0.2 A ELECTRICAL PROPERTIES
Number of Inputs 4 or 0 Operate time <8ms Power Conductors (2)
Nominal frequency 50 Hz or 60 Hz Min. number of 10,000 Size 1.31 mm2 (16 AWG)
Relay burden < 0.25 VA at 120 V, 60 Hz operations Voltage Rating 600 VAC
Conversion range 0 to 260 V RMS BRICK COMMUNICATIONS Shield Aluminium/polyester tape
Voltage withstand continuous at 260 V to neutral, 1 min./ Brick transceiver 1310nm TX/1550 nm RX, 100Mb/s, Drain Wire 0.33 mm2 (22 AWG) stranded tinned
hr at 420 V to neutral bidirectional 1-Fiber 50/125um, copper
CONTACT INPUTS (18) complies with IEEE 802.3 100 MECHANICAL PROPERTIES
Wetting power Brick internal 24VDC power supply Base-BX-U Jacket FR LSZH polyurethane, rodent resistant
External contacts dry contact, dry solid state contact MULTI-MODE MODULE
Voltage threshold 6±1VDC Optical transmit power -14dbm~-8dbm Cable O.D. 12 mm (0.5 in) nominal
Speed Refreshed at sampling rate Maximum optical input -8dbm Maximum Installation 1780 N (400 lbs)
Current Draw > 2.5 mA at 6VDC, 5 mA at 0VDC power Tension
UNIVERSAL DC INPUTS (3) Optical received -30dbm Maximum Operating 670 N (150 lbs)
MODE RTD sensitivity Tension
Types (3-wire) 100 Ω Platinum, 100 & 120 Ω Nickel Terminus Socket terminus M29504/5 Minimum Bend Radius 25 cm (10 in)
Sensing current 2.5 mA BRICK ENVIRONMENTAL (Installation)
Range –50 to +250°C TEMPERATURE RANGES Minimum Bend Radius 12 cm (5 in)
Accuracy ±2°C Storage -40 to +85ºC (Operating)
External lead 25Ω maximum per lead Continuous Operating -40 to +70ºC Cable Weight 164 kg/km (110 lbs/1000 ft)
resistance OTHER ENVIRONMENTAL
MODE DCMV Altitude up to 2000m Storage Temperature -40° to +85°C
Type differential input Installation Category II Operating -40° to +85°C
Range ±5VDC IP rating IP66, NEMA 4X Temperature
Input impedance ≥500k Ω. BRICK TYPE TESTS BRICK COPPER CABLES
Accuracy ±0.2mVDC or 0.1% of reading, Cold IEC 60068-2-1, 16 h at –40ºC ELECTRICAL PROPERTIES
whichever is greater Dry heat IEC 60068-2-2, 16 h at +85ºC Voltage Rating 600V
MODE DCMA Humidity IEC 60068-2-30, 55ºC, >95%, Variant Conductor Information
Current input (mA DC) 0 to –1, 0 to +1, –1 to +1, 0 to 5, 0 to 10, 1, 6 days Cable Type Conductors
0-20, 4-20 Temperature/humidity IEC 60068-2-38, -10°C to +65°C Outputs (CUB) 16 x 1.31 mm2 (16AWG)
0 to 20, 4 to 20 cyclic Inputs (CUC) 29 x 1.31 mm2 (16 AWG)
External resistor 200 Ω ± 0.2 Ω IP rating IEC 60529, NEMA 250 CC55 AC Input Cable 16 x 3.31 mm2 (12AWG)
Conversion range –1 to + 20 mA DC Solar radiation IEC 60068-2-9, MIL-STD-810F (CUD-CC55)
Accuracy ±0.2% of 1mA or 0.2% of reading, Method 505.4 procedure II worldwide CV50 AC Input Cable 8 x 3.31 mm2 (12AWG),8 x
whichever is greater deployment (CUD-CV50) 1.31 mm2 (16AWG)
MODE POTENTIOMETER Vibration IEC 60255-21-1 2G class 2 CC11 AC Input Cable 16 x 1.31 mm2 (16AWG)
Range 2k Ω to 20k Ω Shock and bump IEC 60255-21-2 class 2 (CUD-CC11)
Sensing voltage 5V Seismic IEC 60255-21-3, ANSI/IEEE C37.98 CV10 AC Input Cable 16 x 1.31 mm2 (16AWG)
Accuracy ±5mVdc Insulation ANSI/IEEE C37.90, IEC 60255-5 (CUD-CV10)
BRICK POWER SUPPLY Impulse 5kV impulse MECHANICAL PROPERTIES
Nominal DC voltage 110V to 250V Dielectric strength 3kVAC/1min for AC inputs, Jacket FR PVC
Min/Max DC voltage 88V to 300V 2.3kVAC/1min for others Cable Sizes
Nominal AC voltage 100 to 240V at 50/60Hz Insulation resistance 100MΩ at 500VDC Cable Type Cable O.D.
Min/Max AC voltage 88/264V at 25 to 100Hz Electrostatic discharge ANSI/IEEE C37.90.3, IEC 60255-22-2 Outputs (CUB) 18 mm (0.7 in)
Power consumption <25W Class 4, 8kV C/15kV A Inputs (CUC) 25 mm (1.0 in)
VOLTAGE INTERRUPTION Fast transient CC55 AC Input Cable 23 mm (0.9 in)
Hold-Up time* 0 ms IEC 60255-22-4 2.5kV at 5kHz, 4kV at 2.5kV (CUD-CC55)
Brick recovery time** 1 ms IEEE C37.90.1 4kV for common mode test and CV50 AC Input Cable 23 mm (0.9 in)
Voltage withstand 2* Highest Nominal Voltage for 10ms, transverse mode test (CUD-CV50)
220Vac+20% continuously IEC 60255-22-1 2.5kV for common mode test, 1 kV for CC11 AC Input Cable 18 mm (0.7 in)
BRICK OUTPUTS differential mode test (CUD-CC11)
SOLID-STATE OUTPUT RELAY (4) IEEE C37.90.1 2.5kV for common mode test and CV10 AC Input Cable 18 mm (0.7 in)
Operate and release <100us transverse mode test (CUD-CV10)
time IEC-1000-4-12 2.5kV for common mode test and INDOOR FIBER CABLES
Maximum voltage 280VDC differential mode test OPTICAL PROPERTIES
Maximum continuous 5 A continuous at +45°C, Surge IEC 60225-22-5, 4kV for common mode Optical Fibers 4
current 4 A continuous at +65°C test, 2kV for transverse mode test Fiber Type Graded Index, Multimode (50/125 mm
Make and Carry 300A DC, 0.03s, 25oC Magnetic Field
Current 30A DC, 0.2 s (ANSI C37.90) Immunity MECHANICAL PROPERTIES
20A DC, 1 min, 25oC IEC 61000-4-8 1000A/m for 3s, 100A/m for continuous Jacket FR LSZH polyurethane
Breaking Capacity IEC 61000-4-9 1000A/m Cable O.D. 8 mm (0.3 in) nominal
UL508 Utility App. Industrial App. Radiated immunity Maximum Installation 2180 N (490 lbs)
(Autoreclose IEC 60255-22-3 35V/m at 80/160/450/900MHz Tension
Scheme) IEC 60255-22-3 35V/m from 80M~1000MHz Maximum Operating 490 N (110 lbs)
Operations/ 5000 ops/1 s-On, 5 ops/ 10000 ops/ IEC 50204 35V/m at 900/1890MHz Tension
Interval 9 s-Off 0.2 s-On, 0.2 s-On IEEE C37.90.2 35V/m from 25M~1000MHz Minimum Bend Radius 13 cm (5 in)
1000 ops/0.5 s-On, 0.2 s-Off, 30 s-Off IEC 60255-22-6 35V/m from 150k~80MHz (Installation)
0.5 s-Off within 1 IEC 61000-4-16 30V, 300V/1s from 0~150kHz Minimum Bend Radius 6 cm (2.5 in)
minute Electromagnetic IEC 60255-25/CISPR11/22 class A (Operating)
Break 3.2 A at L/R=10 ms 10 A at L/ 10 A at L/ emission Cable Weight 50 kg/km (34 lbs/1000 ft)
Capability 1.6 A at L/R=20 ms R=40 ms R=40 ms BRICK PRODUCTION TESTS ENVIRONMENTAL
(0 to 250 30 A at L/R= 30 A at L/R= Products go through an environmental test based upon an Storage Temperature -40° to +85°C
VDC) 0.8 A at L/R=40 ms 4ms 4ms Accepted Quality Level (AQL) sampling process Operating -40° to +85°C
LATCHING RELAY (1) APPROVALS Temperature
Maximum voltage 280VDC CE CE LVD 2006/95/EC: EN/IEC 61010-1:
Maximum continuous 6A 2001 / EN60255-5 2000
current CE EMC 89/336/EEC: EN 60255-26
Make and carry for 30A as per ANSI/IEEE C37.90 2004-08 * Maximum interruption duration for which Brick operation is
0.2s IEC 61850 COMMUNICATIONS
unaffected. The Brick complies with type tests applicable to
Breaking capacity (L/R=40 ms) Sampled Values IEC 61850 9-2
Max. Sampling Rate 128 samples/cycle power supply terminals.
DC Voltage DC Current
24 V 1A SV Datasets per SV 8 ** Maximum duration between application of rated power
48 V 0.5 A Frame
SV Fast Dataset 11 Analogue values (Type INT32) supply voltage and Brick ready to provide full service.
125 V 0.3 A
250 V 0.25 A SV Dataset Data Items Samples Per
SV Frame
Operate time <4ms Fast Analogue Values: 11 (INT32)
Min. number of 10,000 Status Indications: 3 x 32 (Packed 8
operations List per IEC 61850 8-1 8.135)
Control mode Separate close and open commands. Slow Analogue Values: 6 (INT16)
Under conflicting commands, the Status Indications: 32 (Packed 1
output shall open List per IEC 61850 8-1 8.1.3.5)
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HardFiber System
Dimensions
Brick
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Dimensions
Cross Connect Panel
Front
Back
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Ordering
Brick
Brick - 4 - HI - **** Brick base unit, 4 digital cores, 125/250 VDC nominal power supply
CT/VT Inputs CC55 5A/5A 8xCT Inputs
CV50 5A 4xCT & 4xVT Inputs
CC11 1A/1A 8xCT Inputs
CV10 1A 4xCT & 4xVT Inputs
Fiber Cables
FOA - 0000 - M*** Outdoor Brick connection cable, four fiber optic cores plus copper DC supply
Cable Length 001 1 meter to 500 meters (3 feet to 1650 feet)
-
500
FOR - 0000 - M*** Indoor relay fiber cable, four fiber optic cores
Cable Length 003
005
010
015
020
025
030
040
050
GEA-12835(E)
English
150211