EnerSure Installation Guide

Transcription

1 EnerSure Installation Guide

2 Danger!!! The electrical components of this system may contain voltage and /or amperage sufficient to injure or kill. Installation is only to be performed by a licensed, bonded and qualified electrician. All installations and use of this product are the sole responsibility and liability of the purchaser. This Installation Guide is valid for the following firmware: - System Firmware Network Interface Firmware EnerSure Installation Guide Rev10 2

3 Contents The EnerSure Meter Overview... 4 Component Description... 5 Processor... 5 Data Gathering Modules... 6 Current Transformers... 8 Common Current Transformers... 9 Potential Transformer Power Supply Hardware Installation and Wiring Electrical Wiring Instructions 3- Phase RS-485 Wiring U.S. Power Panel Wiring Diagram U.K. Power Panel Wiring Diagram Mounting EnerSure Hardware in an Enclosure EnerSure Meter Startup Connecting the EnerSure Components Assigning IP Address Using the Web Interface Sampling Live Data with Web Interface Power Scaling Troubleshooting Installation Errors Firmware Update Procedure EnerSure Installation Guide Rev10 3

4 The EnerSure Meter Overview The EnerSure system is comprised of the processor, Data Gathering Module (DGM), Potential Transformer (PT), Current Transformers (CT), and the Power Supply. The EnerSure provides true RMS data for Volts, Amps, Power Factor, Watts, and kwh with an accuracy of 1%. Figure 1 EnerSure Module (EnerSure Double Stack Shown- 44 circuits) Dimensions Length Width Height 6.5 in mm 4.60 in mm 3.25 in mm Electrical Properties Current Accuracy ±1% Volts In 24VDC Power Accuracy ±1.5% Amps (Max) 250mA Operating Temperature F 0-38 C Frequency 50-60HZ Certifications EN613226, & 3-3 CE Marked/Tested EnerSure Installation Guide Rev10 4

5 One of Four Ground Posts Component Description Processor Inter-Board Connector Bus Connection PT Connection Figure 2 Processor Board The Processor Module contains the following key items: o Inter-board connector This is the wiring connection point between the processor board and the data gathering module(s) using a 26 pin ribbon cable. o Bus Connection This is the wiring connection point between the processor board and any Bus Tap cards. Connection made through an RJ45 cable. o Central Processor Unit (CPU) This is the main controller of the EnerSure meter. The CPU is an ARM-based processor (Note: the CPU takes approximately 20 sec to reboot after the unit is powered off). o Indicator LEDs these LED s display lights for: o Power on o Data Transfer o Power Connector The power supply for the Processor Board and its attached DGM s, or Bus Tap cards, comes directly from a 120/240VAC- 24 VDC Power Supply. o Ethernet- The EnerSure is IP addressable to support Modbus TCP and SNMP over an Ethernet network. o RS-232 A standard DB9 male connector provides access to the o Processor Board via a direct RS-232 serial connection. o RS-485- provides communication via RS Wire protocol. This communication method allows for multi-drop serial communications. o PT connectors The Potential Transformer provides 3 phase outputs and a neutral output. These outputs are connected to the PT connector terminals with each phase and the neutral terminal having its appropriate wire connected from the PT. EnerSure Installation Guide Rev10 5

6 Data Gathering Modules The Data Gathering Module (DGM) forms the data acquisition component of the EnerSure Module. Each DGM unit contains one utility grade power metering chip per circuit. Twenty two chips per DGM gather information from both the Current Transformers (CT) and the Potential Transformer (PT). This raw data is then calculated into true RMS data and sent to the server. Up to 4 DGM s may be placed on a single Processor Module. Note: Although there are 22 metering chips per DGM the processor module is limited to monitoring 84 circuits at a time. The DGM gathers raw data from the circuits and sends it to a power meter chip for each circuit. The CT s provide a signal proportional to the current of the circuit while the PT provides a signal proportional to the voltage of the circuit. The power meter chip receives the voltage and current data, creates true RMS data from the sampling and calculates the phase angle between the two signals to compute the power factor. The chips sample at a rate of 2,000 times per second allowing for true kwh data. Figure 3 Data Gathering Module (DGM) EnerSure Installation Guide Rev10 6

7 Components of the Data Gathering Module The components of the Data Gathering Module (DGM) are: o Board Selector Jumpers (J46)- This jumper allows you to select which board corresponds to the numbered breakers on your panel. By default, the top board in a multi-dgm unit should be in jumper position 1. This corresponds to the first 22 circuits on your power panel. Also by default, the second board in your stack of DGM s should be jumpered as position two. This board will correspond to circuits in your power panel with the last (bottom) two CT Connector inputs left blank. o - DGM 1- J o - DGM 2- J o - DGM 3- J o - DGM 4- J o The Inter board connector this connector couples each DGM to the Processor Board. When more than 1 DGM is used, a multi-connector ribbon cable brings all the data from each DGM back to the Processor Board. o Filtering circuitry Filtering circuitry is employed to make the best use of the CT and PT signals and ensure a better quality energy reading. o Control logic control logic circuits are provided on each board to allow each circuit to be configured using the EnerSure Configuration Utility Program. This program loads as a standard Microsoft Windows utility and is used to configure the following parameters for each circuit: o Current ratio allows any sized CT to be input to any circuit input o Voltage phase allows any phase of voltage to be assigned to any circuit o 1,2, or 3 phase circuits o Power Monitoring Chips there are 22 power monitoring chips provided on each DGM. One of the chips will be inactive as there are only 42 circuits in a typical panel and 21 circuits in a half-panel. 22 chips are placed to enable the user to choose between one of the bottom two chips as the inactive chip. In doing so, you may make sure that your DGM s correspond exactly to the alignment of a typical circuit panel. o CT Connectors each side of the DGM has 11 pairs of CT connectors. A single CT has two inputs (positive and ground) meaning a total of 22 connectors are located on each side of the board. By default, all 22 CT Connectors on the board with the Board Position Connector in jumper position 1, will correspond to circuits 1-22 on your power panel while only the first 20 CT connectors are used on the board with the Board Position Connector in jumper position 2 as they correspond to your power panel circuits EnerSure Installation Guide Rev10 7

8 Current Transformers Each Current Transformer (CT) can be connected to a circuit by opening or removing the top of the CT and snapping it onto the wire going from the power source to the load. THE CT LABEL ALWAYS* FACES THE POWER SOURCE. Be sure to close the CT tightly or it will affect the readings your EnerSure unit provides. Refer to Figures 5 and 6 to reference pictures of our most commonly used CT s. *Note: We currently offer a variety of CT s capable of monitoring current loads ranging from 0 to 1000 amps. Specific 75A CT s, marked with an arrow, should be oriented using a directional arrow, not the label, see Figure 9 and Step 5 of Hardware Installation and Wiring on page 13 for orientation instructions. The CT s may be simply hung on the wire which they snap around. However, some customers may prefer to use Velcro strips on the bottom or hinged side of the unit, to allow for ease of mounting and removal when necessary. Velcro is non-conductive and should not bring any code issues into play. The white and black lead wires from each CT are associated with specific ports on the DGM. Note that the numbered positions on your breaker panel will correspond to the numbered positions on your EnerSure Data Gathering Modules as follows: Breaker Panel Circuit Number Data Gathering Module Board Data Gathering Module Terminal (Bottom) (Top) 1-18 Each CT output has two wires. In North America, ALWAYS CONNECT THE WHITE WIRE FROM EACH CT TO THE CONNECTOR PORT CLOSEST TO THE RIBBON CABLE ON THE DATA GATHERING MODULE AND CONNECT THE BLACK WIRE TO THE SECOND CT INPUT. ALSO BE SURE TO KEEP THE PAIRED LEAD WIRES TOGETHER. MIXING LEAD WIRES WILL RESULT IN LOSS OF DATA AND POSSIBLE DAMAGE TO THE UNITS. An example of connecting the CT s would be connecting circuit number 1 on your breaker panel to DGM 1, terminal 1. Circuit number 23 is connected to DGM 2, terminal 1. Circuit number 84 is connected to DGM 4 terminal 18. The odd numbered circuits on the DGM are located on the left hand side of the board just as the odd numbered circuits on the power panel are located on the left-hand side and even numbers circuits located on the right hand side. EnerSure Installation Guide Rev10 8

9 Common Current Transformers Figure 4 75A EnerSure Installation Guide Rev10 9

10 Potential Transformer The second external connection to the EnerSure unit comes from the Potential Transformer (PT). TrendPoint offers 3 versions of the PT /240/277 Delta - 120/240/277 Star Europe The PT s role is to monitor each phase of power and a neutral or ground connection in your panel and then transform that voltage into a usable signal that is used for measurement and calculation by the EnerSure module. Note: The PT supplied as standardized equipment with your EnerSure unit must have a neutral connection (Wye) or ground connection (Delta). The PT input is generally connected to either the input phase lugs of the power\ panel if no power is yet supplied to the panel, to three individual breakers (A,B, and C phases), or a single three phase breaker. The latter of the two options allow you to shut-off power to the PT and wire it cold rather than hot for maximum safety. Then, once the wiring is in place, the breaker can be energized to the ON position to power the PT. The output of the PT is arranged in the same fashion as the inputs: 3 individual phase outputs and a neutral. These wires are connected to the PT terminal located on the Processor Board of the EnerSure module as shown in Figures 1 and 2. The Neutral is connected to the far left position, phase 1 (A), phase 2 (B) and phase 3 (C), connected from left to right. Note, you must connect each of the active phases that you are monitoring and you must always connect a neutral to the board. In addition, you must connect a proper ground connection (green wire) to one of the four posts of the EnerSure unit in order to control static and other potentially damaging electrical effects. Note: The input of the standard PT can be 120/208, 277/480, or 240 volts and, while the output signals are 0-400mV. ALL CONNECTIONS CONTAIN LIVE VOLTAGE AND SHOULD ONLY BE PERFORMED BY A LICENSED ELECTRICIAN. EnerSure Installation Guide Rev10 10

11 Figure 7-120/240/277 Wye Potential Transformer (Standard US Spec Shown) Dimensions A B C 5.90 in mm in mm 1.95 in mm Electrical Properties Accuracy ±.5% Rated Current N/A Linearity.5% Current Ratio 1200:1 Max Voltage 300V Frequency 50-60HZ Certifications EN UL Listed CE Marked/Tested TUV Certified EnerSure Installation Guide Rev10 11

12 Power Supply The power supply for the EnerSure units is a Carlo Gavazzi precision power supply. This unit requires a 120/240VAC 50 or 60hz input. The unit is highly noise resistant when the ground connection is attached to a proper site ground (green wire from your power panel). The power supply provides 24 volts DC power via one positive and one negative output terminal. There is no ground output terminal. At 24 volts, the EnerSure unit uses approximately 12 ma 50 ma of power depending on the number of Data Gathering Modules used. Figure 8 24VDC Power Supply Dimensions Length Width Height 4.53 in mm.89 in mm 3.53 in mm Electrical Properties Max Volts In V Volts Out 24VDC Max Amps In 500mA Amps Out.75A Frequency 47-63HZ Power Out 18W Certifications EN , , CE Marked/Tested UL 508, 1310 EnerSure Installation Guide Rev10 12

13 Hardware Installation and Wiring Electrical Wiring Instructions 3- Phase Your EnerSure meter has 3 separate electrical components that you will need to connect in order to use the system- Potential Transformer, Power Supply, and Current Transformers. Removing the green plug connectors on the Processor and DGM board will reveal the port labels. All wiring terminals on the EnerSure device can support copper wiring 24 12AWG.The terminal screws should be tightened to 4.5 lb - inch of torque. 1) Connection the Potential Transformer outputs to the Processor card. a. The output wires of the Potential Transformer can be cut to the desired length. b. Connect phase A, B, C and Neutral (or Ground if a Delta PT) to the 4 terminal connector. Removing the 4 - Terminal connector will reveal the labels for the terminal ports. *** Ensure the PT is not wired in reverse *** 2) Run the Input wires from the PT into the electrical panel being monitored by the EnerSure unit. a. The PT input wires should be connected to a 3-Phase breaker that is installed on the power panel. Although the main power lugs may be used, as the PT is internally fused and the transformers are isolated from the critical load. b. Leave the breaker in the OFF position until all wiring is complete. 3) Connect the 24VDC output from the Power Supply to the 2 terminal input on the Processor Card. 4) Connect the VAC input to the Power Supply a. If the panel being monitored is a 120/208VAC or 240VAC panel, the power supply input can be shared with the PT input wires. b. If the panel being monitored is a 277/480 VAC panel, the Power supply must have a dedicated VAC power feed. 5) Connect the Current Transformers (CT s) to the DGM s. a. CT s should be run from the power panel that is being monitored to the Data Gather Module. b. The CT s are directional and should be installed with the proper orientation. Failure to install CT s with the proper orientation will result in metering errors. i. Most TrendPoint CT s should be installed with the label facing the source of power (the breaker). ii. Specific 75A TrendPoint CT s, see Figure 9, should be installed with the arrow pointing away from the breaker. These are the only TrendPoint CT s with a direction arrow. EnerSure Installation Guide Rev10 13

14 Current Flow Breaker Load Figure 9 - Specific 75A CT s need to be oriented with arrow away from breaker. c. The wires connected to the DGM terminals should be installed in a White/ Black configuration, with the white wire of each CT closest to the ribbon cable connector. d. The CT wires may be cut to length. e. The Phase Selector jumpers on the DGM must be set for the proper phase of power being monitored by the CT. 6) Ensure all wiring connections are secure. Once all wiring has been confirmed energize the Power Supply input and Potential Transformer input. EnerSure Installation Guide Rev10 14

15 RS-485 Wiring EnerSure Processor Cards part number ENS-PC-C02 support RS-485 Modbus RTU communications. To facilitate RS-485 communications the following connections should be made. The EnerSure device can support a multi-drop network on RS wire. 1) Connect the communications wire to the 3- pin terminal block. GND / D- / D+ 2) Ensure jumper connections are made on J19, J20, and J22. If these jumpers are not in place the RS-485 communications will not work on this terminal. J19 J20 J22 GND D- D+ Figure 10 RS-485 Connector and Jumpers THE GROUND CONNECTION TO THE ENERSURE MODULE IS MADE DIRECTLY FROM A STABLE GROUND CONNECTION ON YOUR POWER PANEL DIRECT TO ONE OF THE POST CONNECTIONS OF THE ENERSURE MODULE AS SHOWN IN FIGURE 2. THE GROUND CONNECTION DIRECTLY TO THE ENERSURE MODULE IS ABSOLUTELY MANDATORY AND USE WITHOUT THIS GROUND WILL VOID YOUR WARRANTY AND CREATE A SAFETY HAZZARD. EnerSure Installation Guide Rev10 15

16 U.S. Power Panel Wiring Diagram EnerSure Installation Guide Rev10 16

17 U.K. Power Panel Wiring Diagram EnerSure Installation Guide Rev10 17

18 Mounting EnerSure Hardware in an Enclosure Figure 11 EnerSure Enclosure ***The Minimum Recommended Enclosure Size Is 16x12x6.75*** EnerSure Installation Guide Rev10 18

19 Figure 12 Connection Points for Potential Transformer Hot Install: Insert a new breaker for connection, use lug for Neutral EnerSure Installation Guide Rev10 19

20 Figure 13 Connection Points for Current Transformers (CT) CT Connection Points (300 amp CT Shown) CT wiring fed through the PDU and to the EnerSure module Figure 14 Close-up of CT Connection Points (300A CT Shown) EnerSure Installation Guide Rev10 20

21 Figure 15 Standard 42 Circuit Metering Installation EnerSure Installation Guide Rev10 21

22 EnerSure Meter Startup Connecting the EnerSure Components o Make sure all electronic equipment is properly grounded before connecting any live power. The EnerSure Module should be grounded off one of the four DGM board post connections to site ground. o Record the serial numbers of each EnerSure board before installation. o Re-connect the power supply connector to the Processor. Note: If the circuit breaker powering the power supply is turned on you will immediately see red lights on the processor board. If the board is currently being supplied power please turn the power off. (Note: the CPU takes approximately 20 sec to reboot after the unit is powered off). o Before communicating with the EnerSure module all CT connections should be made and all phase jumper settings on each DGM must be correct for your needs. Jumpers can only be moved while the power to the EnerSure module is turned off. o Apply power to the EnerSure module. o Connect a Cat5 crossover cable from the EnerSure processor board to your computer. o If you are connecting via RS-232 you will need to select the correct communication port, using 9600, N, 8, 1. o For RS-485 use 9600, N, 8, 1. o The factory default network settings are: o IP address o Subnet Mask o Gateway Assigning IP Address o To change the network settings configure your computer to conform to the network settings of the EnerSure meter. o Connect either a crossover or straight thru Ethernet cable from your computer to the meter. o Open your web browser of choice and enter the IP address of the meter into the URL bar and click Enter. o You will be brought to the web interface and prompted to enter a password (adminpass). Enter the password and click Log in. EnerSure Installation Guide Rev10 22

23 o The EnerSure meter web interface allows you to change the IP settings as well as upload new firmware o In the General Settings tab you have options to configure the meter for static or dynamic IP settings. To update the settings, complete the selections and click Save IP settings. The settings are changed immediately and the board does not need to reboot. EnerSure Installation Guide Rev10 23

24 Using the Web Interface o Open your web browser of choice and enter the IP address of the meter into the URL bar and click Enter. o You will be brought to the web interface and prompted to enter a password (adminpass). Enter the password and click Log in. o The EnerSure meter web interface allows you to change the IP settings as well as upload new firmware o From the Circuit Cfg tab, circuit groupings can also be assigned. Checking the Group Circuits box between circuits will group the circuits together. Click Save Configuration when finished. EnerSure Installation Guide Rev10 24

25 Sampling Live Data with Web Interface o After setting up the EnerSure metering parameters it is always good to run some samples of the data in order to confirm the installation was done properly and your system is operating correctly. o To sample live data, click on the Circuit Data tab of the web interface. o Clicking Refresh Now will refresh the data. Power Scaling o There are two selections in the General Settings tab of the web interface. a. High Power Mode b. kwh Resolution o kwh resolution is an administrative function used when the registries of the on board firmware are being overloaded. Leave this setting at at all times. o High Power mode is used when circuits being monitored exceed 655 amps. When High Power mode is activated, by checking the box and Sending the configuration change to the board, the power data received is decreased by a power of 10 for amp and a power of 100 for watts. This process provides needed space when the registries begin overflow at 655 amps. EnerSure Installation Guide Rev10 25

26 Troubleshooting Installation Errors o After setting up communication with the EnerSure module using TP Configuration click Circuit Data and wait approximately 5 seconds, now= click Sample a few times to actively query the circuits. o You will now see live data being sampled. o If you receive error messages in the box next to the sample button you must correct them before proceeding. o If you receive a Wiring or Phase Setting Error go to the DGM tabs and confirm the phases you have set on the DGM s match the phases of the jumper connections for each circuit on the EnerSure module. If the physical settings on the board match the software settings and errors persist this indicates the phase of the circuit the CT is attached to in the PDU/power panel is not the phase you think it is. Contact an electrician to confirm the phases of each circuit in your PDU/power panel. Then correct both the jumper settings per circuit on the EnerSure module as well as the software settings in TP Config. o If you receive a CT Orientation error this means the CT was clamped on the circuit backwards. Contact an electrician to reverse the connection. *** Special Note: 2- Pole Circuits (208VAC) *** 2- pole circuits such as 208 single phase power distributions have special characteristics. In these types of circuits power flows through one leg (Leading) and back through the second leg (Lagging). The EnerSure device identifies the Leading and Lagging leg of the circuit. The lagging leg will not show Power Factor, Watts or kwh accumulation. The complete circuit Power Factor, Watts, and kwh is reflected on the leading leg only. o Once all errors are resolved the EnerSure module setup is complete. (Please call for additional support) EnerSure Installation Guide Rev10 26

27 Firmware Update Procedure Your EnerSure unit has two onboard processors that may require firmware updates. This update procedure will assist with updating the firmware on both processors. Each firmware is loaded through the web interface. To load new firmware: o Open your web browser of choice and enter the IP address of the meter into the URL bar and click Enter. o You will be brought to the web interface and prompted to enter a password (adminpass). Enter the password and click Log in. o In the Firmware Update tab, you can choose which processor (Network or System) you want to load a new firmware onto. o Click the Choose File button (red circles) under the system you want to load a new firmware. Locate the correct firmware from the firmware update package and click OK. Click Upload firmware (orange circles) to upload the firmware to the board. *Note: Both firmware s can be uploaded to the board before clicking the Reboot button. EnerSure Installation Guide Rev10 27