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ECM-1220 User`s Manual - Power/Energy Monitors

1. Dual Type B CT Connections This technique for coupling two CTs on a single channel only applies to single or split phase services This cannot be done with 3 phase systems unless the 2 CTis monitoring another load located on the same phase See 3 phase section for more information October 7 2012 21 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRULE CO Both CTs must be of the same model For example although Micro 100 and Micro 40 CTs are both Type B CTs they may no be combined on a single channel CT1 Jumper x2 Jumper x2 a OR eNuus aN wth enus ch M LO P CT2 CT2 O Type B CT Connection For single or split phase only It is important to pay attention to the lead polarity when more than one CT is connected to a single channel If a mistake is made with regards to lead polarity there will be no harm or damage as a result The consequence of this is that the current from one CT will be subtracted from the other For example CT1 monitors a 60W load and CT2 monitors a 100W load Improper polarity will cause the GEM to display this as a 40W load instead of 160W which is the sum of both loads It is very easy to correct such a situation Remove the leads of one CT only and swap the two leads insert the black wire where the white wire was previously and vice versa Sometimes it is just as easy to take the 50 50 chance a make a quick ch
2. October 7 2012 www brultech com Brultech Research Inc Copyright O 2012 Brultech Research Inc All rights reserved 51
3. 2012 Brultech Research Inc All rights reserved Brultech Research Inc EBR ULEC H Identify the mounting area for the GREENEYE MONITOR GEM Identify the breaker panel circuits you will be monitoring Occasionally circuit breakers are improperly identified Switch the breaker off to verify that it indeed kills the power to the load in question Any GREENEYE MONITOR GEM input which will host more than one CT requires special attention so that the CT is installed with proper orientation This is explained later in this chapter The diagram below illustrates a very simple installation Typically the installation will involve using more current sensors to measure as many electrical loads as possible October 7 2012 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRULE C H Important Safety Information The GREENEYE MONITOR GEM operates as a Class II low voltage device This requires that all external connected signals be a low voltage lt 50V and provided by Class Il approved power supply and sensors WARNING I All of our power supplies are UL CSA or UL c approved for use in USA and Canada Most of our current transformers CT are UL c listed No direct Read All Of The Safety Rules Before line connections to the GEM are allowed All signals must be galvanic Installing isolated from the power line Never install the GEM inside an electrical panel A separat
4. A 120VAC to 12VAC UL CSA wall transformer North America is used as a potential transformer and is included in the GEM package Since the step down ratio is not identical for all wall transformers of the same model the PT Type setting may altered slightly to improve voltage accuracy This requires a tue RMS DMM connected to the line voltage as a reference The PT Type value is increased or decreased slightly until the voltage displayed by the GEM matches the voltage at the outlet where the PT is connected CAUTION Only galvanic isolated low voltage lt 14VAC PT certified by an accredited laboratory such as UL CSA ETL whichever applies to your Country may be used NEVER connect directly to Line Voltage from the electrical panel Failure to obey these rules can cause injury fire or fatality The GEM has two potential transformer PT inputs e A3 5mm stereo phone jack e A Mini USB jack 3 5mm Phone Jack The 3 5mm PT input is the most commonly used By using its stereo capability this jack may accept two voltage ranges 14VAC and 333mVAC Typically the PT signal to the GEM will be from a 120V 12VAC UL c certified wall transformer It will connect to the GEM using a 3 5mm mono plug Potential transformers will also be available with primary line voltage from 120VAC to 480VAC with an output signal in the 333mV to 666mV range These PTs are fitted with a stereo plug making connection via ring and sleeve only tip not
5. Line3 Line1 CT Phase A Line1 CT Phase C Line1 CT Phase B Line2 CT Phase B Line2 CT Phase A Line2 CT Phase C Line3 CT Phase C Line3 CT Phase B Line3 CT Phase A October 7 2012 30 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc EBr ULNE ECH CT Connection Four Wire WYE System Depending on the CT type used the color code for the connecting leads should be as indicated in the table below When setting up to monitor a three phase WYE system or load only one CT is allowed per channel The technique used to couple two CTs on a single channel only applies for single split phase systems and NOT for three phase systems Type A CT Type B CT Type A CT Type B CT Terminal 1 White Lead Or black with white stripe Terminal 2 White Lead Or black with white stripe Terminal 2 Black Lead Terminal 3 Black Lead Displayed Polarity Once the CTs have been connected and it is time to setup the connected channels the Phase A channel should be setup first This is the CT channel which connects to the same phase as that which the PT is connected to Connect to the GreenEye Monitor using the setup program and make sure you have a connection established See Setup Software manual for more information Select System from the setup program and make sure the Polyphase option is enabled Click Save Settings Select Chan
6. Select Firmware Select the firmware file If the progress bar doesn t move you need to enter upgrade mode which can be done by either 1 Unplug your unit hold down the button and apply power or 2 Clicking the button above If you encounter any problems please contact supportfbrultech com 8 Click Start Depending on the communication link it may take a couple of minutes for the upgrade to complete Pay attention to the trail of dots generated as data is transferred October 7 2012 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved 42 Brultech Research Inc Ro le Ecuy If for any reason the GEM stops responding midway through the upgrade wait several seconds since there may be a pause in data transfer when using WiFi or XBee If there is no response for 1 minute or so and the upgrade has not completed Something may have occurred to corrupt the firmware If so follow the procedure in Recovering from corrupt COM firmware section below Recovering From Corrupt COM Firmware Firmware may become corrupt if data communication is interrupted while upgrading firmware In the event that this happens the GEM will not function properly if at all There is a special procedure used to recover from such scenario Remove power 5VDC from the GEM Remove the CR 2032 battery While holding down the PB switch power up the GEM Once the GEM is powered release thee PB switch The s
7. TOM radio 16 IR un Le HOM oras ii ote 16 FS F UIC e EE 17 Current Transformer CT Installation seososeososeosossosossosossosossosossosossosossosossosossosossosossosossosossosossosossosossosossosossosossosossssosss 18 Jee eg E 18 Wy SPC CO CCG ON WE 20 Site E ONNE ON E 20 Dual pe EF CONTE de EE 20 TYDE B RR al Tee d Le o A A O E 21 A AAA PP e PR UP SEIS 21 O A bo 21 DUT EECC ONN C ION a aa 21 Pulse Count Inputs iii 23 Potential Transformer PT Apuntate 24 SMN Pone IICK EE 24 NI CS Tei catsacee eE uo An o e al EU o T 25 Mel ees Cal TT E 26 October 7 2012 2 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc Bro le ECH Power Supply Access Terminal BIOCK ccsarsuncocscovesmasetensonaeseatonnaiteeennt i aa a eS 26 A A e EA AA 27 SINGLE Split Phase Residential SUSTO EE 28 Three Phase Polyphase 4 Wire Wye Y System RENE 29 CT Connection Four Wire WYE System 31 Mate Be Et e E o OO 31 Three Phase Polyphase 3 Wire Delta A System 32 Communication E 33 BS e ie E 33 COM eege EH NOOC estrato iRoprAicaea 35 Le GE 37 WiELCOMIMUNICA HOOD ION E 37 PRENE MOTUS ee eaer EE T E A EEE EENE EA NEENA EN 38 Combination WiFi and Ethernet Communication OPTION ccccoccnnccnccnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnanininnnos 38 ABEC MONICE OD OI EE 38 Custom Com PCB Header mica E E aE EE TA TEEN EE evo 38 FIP WANS Te iaa E 40 COM Proce
8. jack center positive standard e Optional power connection via mini USB jack instead of barrel jack October 7 2012 48 www brultech com Copyright 2012 Brultech Research Inc All rights reserved BRULE C H Isolation LED Indicators Battery Memory Backup Operating Temperature Humidity Enclosure Material Dimensions Weight GEM Device Only FCC Certification October 7 2012 Brultech Research Inc e The GEM must not be installed in the electrical breaker panel e All connection to the GEM must have galvanic isolation to the power line e Signals to the GEM must be Class2 low voltage e Current transformers CT and the Potential Transformer PT connected to the monitored electrical panel must be UL c listed and suitably rated above the maximum voltage and current to be encountered Tri color system LED left side e Displays system status packet transfer etc Two color communication device status right side e Displays status of the communication module Color sequence depends on the module installed e When no communication modules are installed only the green LED will come on when 5VDC power is present This is due to the jumper connection between pins 2 and 7 of the header 9 e CR 2032 battery used for memory backup when 5VDC power is lost e Typically drains less than 2 uA when GEM is powered down e Life approximately same as battery shelf life e Battery replacement should be done while GEM i
9. prevent dealing with frayed ends Tinning is the process of adding 18 26 AWG Block solder to bond all of the strands together Connecting the CT leads to the terminal strip 1 Align the two lead ends with the terminal holes This can be done one lead at a time however ts seems to be easier inserting both leads at the same time providing they are nicely tinned with no frayed ends 2 Press down on the orange TAB s corresponding to the lead or leads to be inserted using a small flat blade screwdriver October 7 2012 18 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc BROUUIECH 3 Insert the leads into the terminal block while making sure the leads are perpendicular In most cases both CT leads can be inserted at the same time If the lead was stripped back 10mm then the stripped section should be entirely inside the block with only the insulation visible 4 Release the pressure to the spring tab 5 Finally tug slightly on the leads to make sure they are secure SETA F JTA Z The channel number for each block is printed on the circuit board next to each terminal block as shown in the picture right e IMPORTANT Two types of current transformers are compatible with the GEM Types A and B The difference between each type has to do with the type of signal which represents the sensed current TYPE A The measured current is represented b
10. system via opto isolator e Requires DC pulses between 3 5 and 24VDC 5VDC ideal Counter 3 and 4 e Requires dry contact closure from reed switch relay etc e Input is not isolated from the GEM power supply therefore connection to this input must be isolated from the pulse source s power supply This is typical when using reed switches Pulse Frequency Less than 1pps pulse second Subject to change Pulse Width Duration Minimum pulse duration 550ms Subject to change Counter Registers Each counter has a 3 byte up counter Counter wraps around when full Cep pulses Counter Volatility Counter values are stored in RAM and preserved by battery power when a power interruption occurs October 7 2012 46 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved BRULE C H Brultech Research Inc Temperature Sensing Temperature Sensor 8 Channels Channels Sensor Type Uses 1 Wire Bus system Compatible with the following 1 Wire sensor types e DS18B80 e DS18S80 1 Wire Bus Uses three push terminals e GND e DATA e 5 VDC 1 Wire devices are connected in parallel For more info visit http www 1wire org Conversion Interval All temperature sensors perform a temperature conversion every 16 seconds Sensor Read Interval Each enabled temperature sensor is read once every 64 seconds One of eight temperature sensors is read every 8 seconds hence 8 X 8 64 sec Temperature Units The GEM may be configu
11. C require a PT shorting jumper to attenuate PT signal e Stereo plug sleeve and ring connection tip not connected 333 mVAC without PT shorting jumper or 666MVAC with shorting jumper Mini USB Jack Input e PT signal to pins 3 and 4 of mini USB e 333 mVAC without PT shorting jumper or 666mVAC with shorting jumper Potential Transformer GEM supplied with UL c wall transformer with lt 2 degree phase error 45 October 7 2012 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc ES EZKXSUS C H PT Optional PT part number PTO1 may be ordered e 1 accuracy e Input voltages between 120V to 480V e 600V rated leads Load System Types Single and Polyphase systems System Frequency 50Hz or 60Hz Default is 60Hz May be configured for 50Hz via setup software Resolution Power 1 Watt Energy 1 Watt Second 000000277 kilowatt hour Voltage 0 1 Volt NET Metering All channels are capable of NET metering Two sets of watt second counters are used for energy flow direction Watt Second Counters Each channel has two 5 byte incrementing watt second counters one absolute and one polarized Counter wrap around occurs after 2 watt seconds or 305 419 kilowatt hours Pulse Counting Pulse Counting Channels Four Individual pulse counters e Two dry contact inputs e Two DC pulse inputs Counter Input Counter 1 and 2 e Requires DC pulses e Galvanic isolated from GEM
12. GEM and the PC running the GEM setup program the procedure for upgrading the firmware is 1 Verify that the communication link is established by verifying that the GEM setup program s Connection Status indicates Connected inside the green box on the top left window of the program B GreenEye Monitor Setun V1 9 Eck Connection Stalus B Setup Mode WiFi Only TCPAP Server Port Settings amp Channels System Settings Current Settings PT Settings Firmware Version Com firmware ver 1 59 Engine 1 firmware ver 1 35 2 Click System from the left menu GreenEye Monitor Setup V1 9 Connection Status Setup Mode WiFi Only TCPIP Server Port Cr 36591 F 60Hz EUR settings Channels system Settings Current Settings E Temperature Pulse 2 e mm Debug ve Real Time Data Serial Number 01000345 4 Server Discovery FA HTTP Packets Start Real Time i gt Reset Al Counters Set Computer Time Stop Real Time Reset Pulse Counters Set UTE Time 3 Click Refresh and take note of the current firmware version 4 Click Stop Real Time 5 Click Firmware and Advanced This will open a new window 6 Click COM Firmware A window will open October 7 2012 41 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc EBRAR ULEC H Corrupt Firmware 7 Click
13. M is powered up Function F7 is used in situations where communication is lost while upgrading the COM processor s firmware thereby corruption the firmware The push button switch is then pressed while power to the GEM is cycle allowing a fresh start to upgrading the firmware Please follow the appropriate instructions with the setup program before attempting this F8 Function This function is simply a quick press and release of the PB switch while the GEM is in bridge mode When the GEM is forced into bridge mode the SYS LED flashes a slow green When the switch is briefly pressed the GEM resumes normal operation and the LED becomes solid green unless a packet is being sent October 7 2012 17 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc EBR UIE ECH Current Transformer CT Installation Important The current transformers are installed inside the electrical panel The CTs MUST be installed by a qualified individual Read the Safety section at the beginning of this document CT Connection to the Terminal Strip NOTE The CT leads must be stripped approximately 10mm 0 4 and have a gauge size between 18 and 26 AWG 10mm 0 4 The GEM uses spring loaded terminal blocks The CT leads must be stripped the proper length If the leads have stranded wire it is preferable to tin the wire Wire Gauge lle Terminal before hand to
14. T Brultech Research Inc BRolecrr GreenEye Monitor Manual Energy Consumption Monitor With Pulse Counter and Temperature Sensing Inputs October 7 2012 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc Bro le ECH HATE OG De d e E 4 ET 4 A e o A 6 EE 6 VOM SONO Sanare 6 PU EONDU DOV ES a e A e a siege s5evansaccasaarcuovesuasauvansesoarenuedetntebevaniacted 6 Temperature EE 6 COMMUNICA EE 7 MU INET d SU al E 8 Read and UNDERSTAND the safety information sv 8 Power up and establish communication before mstallmg 8 Plan the mounting location for the monitor taking into consideration the CT lead lensrh 8 SEENEN 8 A o A A 10 Beil 11 Overview La volt adentros lao ee ini 12 LIET COMEC on Ee 13 Pe SO e T eeneg 13 3 Potential Transtormer EE eege EE 14 4 Alternate Potential Transformer PT And 5VDC Supply Input occccnncccnnncccnnnnncncnonoccnnnnnnnononoconnnnnnnnnnnnronnnnnnnnnnnrrnnnnnnnonnaaooos 14 OIE WN POMC CA e E EE 14 6 Power Supply Access Teri lesa 14 7 I Wire BUS and RS 232 Ground KC le RE 14 REENEN 14 9 Optional COM Module Header anna ataron prat 14 AS O o rr o EaR a 15 AS ayers Module SOC tratada ade 15 BAR E OM TE 15 13 System and Communication LEDS cccccccccssseccccceeseccccceenecccceeusecccecueseccsseeueccsseueeeceseeuunecsesseueeesssuuaecsessuuneeeeseueneeeeees 15 14 Push Button SW EE 15 a LE 15 PARES FIC
15. alues 2 Process the acquired metrics 3 Forward the data to a host for access via computer internet automation system or smart phone 5 WiFi or XBee A Wireless optional Electrical E ae y Panel Ethernet Connection optional RS 232 Connection IN Sensors 5VDC Power Supply Pulse alt NOTE Only low voltage galvanic isolated signals are connected to the GreenEye Monitor October 7 2012 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRULE C H The current sensors CT are small non obtrusive devices installed in the electrical panel on each circuit breaker circuit Two larger CTs are installed on the power feed from the Utility Company providing total house consumption Optionally other sensors may be connected to provide temperature or water gas consumption Two supplies are used one 5V supply to power the GEM and the second to monitor the power line voltage for accurate true power conversion The GEM converts the data from the sensors and makes it available to a host The host could be one or more of the following e A website dedicated to monitoring displaying and charting consumption information e A local web server We have available a small powerful web server which consumes less than 5Watt to operate That s less than 2 cents per day e Personal website e Local PC e Home automation system e Smart phone via one of the above
16. and SPLIT 200 CTs are both Type A CTs they may no be combined on a single channel It is important to pay attention to the lead polarity when more than one CT is connected to a single channel If a mistake is made with regards to lead polarity there will be no harm or damage as a result The consequence of this is that the current from one CT will be subtracted from the other For example CT1 monitors a 60W load and CT2 monitors a 100W load Improper polarity will cause the GEM to display this as a 40W load instead of 160W which is the sum of both loads It is very easy to correct such a situation Remove the leads of one CT only and swap the two leads insert the black wire where the white wire was previously and vice versa Sometimes it is just as easy to take the 50 50 chance a make a quick check by simply disconnecting one of the CT leads while observing the power watt If the power increases when the CT lead is removed then simply swap the polarity on one CT only This should result in an increase in power providing there is a load on this circuit Type B CT Connection Again what constitutes a Type B CT is the fact that the signal produced is a current signal usually in the milliamp mA range Single CT Connection Type B CT leads connect to terminals 2 and 3 When only one CT is connected to a given channel the lead polarity does not matter Type B Terminal CT Block O 4 anw E Type B CT
17. at allow monitoring 3 phase systems up to 480V When setting up the GEM s input channels one of the parameters required for 3 phase systems is the phase for a given channel A BorC The following paragraph describes how to determine the proper setting 120V 208V Four Wire 3 Phase System CT 1 Breaker Breaker rm 120V 208V SUPPLY K gt L K Source E a Load Outlet In the diagram above CT 3 will be configured for Phase A because the PT is connected between Neutral and Line2 The important step is to note which phase or Line connects to the outlet which powers the PT This is the reference and will always be considered Phase A when configuring the GEM For example in the diagram above the 120V Outlet is October 7 2012 29 www brultech com Copyright 2012 Brultech Research Inc All rights reserved SSES Brultech Research Inc Ea Fi us ME C H connected to Line2 therefore the circuit that CT 3 which is connected to the Line2 load is sensing will be configured for Phase A In this example since Line2 Phase A then Line3 Phase B Line1 Phase C Based on this example the channel that CT 1 is connected to will be configured for Phase B and CT 2 channel will be configured for Phase C To summarize here are the possible combinations 120V Outlet for PT 120V Outlet for PT 120V Outlet for PT connected to Linel connected to Line2 connected to
18. connected This allows the GEM to use the lower PT range There is a two pin jumper located near the 3 5mm jack to change the 333mV range to 666mV This jumper should be pre installed based on the PT being used October 7 2012 24 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc Ec LY Mint USB Jack The mini USB jack is NOT a USB communication port The USB jack is for future option of a combined PT Power Supply The jack is configured such that the GEM may be powered using 5VDC USB power connection The standard USB D and D connections are used to supply 333mVAC potential transformer signal October 7 2012 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc BROpPeEcwH Power Supply Input Power to the GEM is supplied via a 2 1mm X 5 5mm barrel plug from a 5VDC power supply center is Alternately power may be supplied by the mini USB jack instead of the barrel jack not both at the same time These two supplies are connected together on the PCB It is recommended to use the supplied transformer Id a substitute is to be used it MUST be UL CSA USA Canada certified or whatever certification applies to your Country Power Supply Access Terminal Block A terminal block provides access to the GEM s 5VDC and 3 3VDC power supplies It is recommended not to use these terminals unless examples are provide
19. d in this document The purpose of these terminals is to provide power for future options October 7 2012 www brultech com Copyright 2012 Brultech Research Inc All rights reserved B RO JEcA Brultech Research Inc CT Installation All of the Brultech CTs have a marking K gt L except for the Micro CTs This mark is used to specify the orientation of the CT when installed K signifies the source which is where the power is coming from and L is the load which is the device receiving power When the CTs are installed the arrow should point to the load There is no harm if the CTs are installed backwards since this can be corrected by reversing the black white leads when connecting to the GEM Paying attention to orientation will simplify the connection process especially for 240V loads using two CTs and when connecting to 3 phase systems October 7 2012 www brultech com p m K gt L SOURCE K Source White Black L Load CT Orientation For Micro 40 Micro 80 amp Micro 100 Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRULE C H Single Split Phase Residential System Almost every home in North America has its power supplied by a 120V 240V split phase service Line Transformer Feed From Power Company Neutral When installing CTs on a single or split phase system it is recommended to install th
20. e low voltage panel may be used when needed C The GREENEYE MONITOR GEM installation requires the installation of current transformers CT d installed inside the electrical service panel This portion of the installation MUST be performed by a qualified electrician or individual The installer must follow all local safety codes and use proper safety practices and equipment The qualified installer must be aware that main panels may still contain dangerous voltage levels even though the main breaker is in the OFF position The following rules MUST be obeyed e Any work performed inside the electrical panel must be done by an electrician or qualified individual This individual will be familiar with the local electrical code and perform the installation accordingly e NEVER install the GreenEye Monitor GEM inside the electrical panel Only low voltage 12VAC or less galvanic isolated connections are to be made to the GREENEYE MONITOR GEM terminals e The current transformer CT leads must exit the electrical panel through an appropriate box connector strain relief or bushing The CT leads must be properly anchored on the outside of the panel e The portion of the CT leads inside the panel must not have any damage cuts or wear to the outside insulation e The CT leads must be routed in such a way that its insulation will not be rubbing against live terminals Care must be exercised not to pinch the CT leads especially whe
21. e performing firmware upgrades The GEM has two processors COM and ENG Each processor has its own specific firmware with GEM_C or GEM_E as part of the filename followed by the version number Example e COM firmware file GEM_C Firmware 1 59 fmw e ENG firmware file GEM_E Firmware 1 36 fmw It is not always required to upgrade both processors Typically the COM processor may require upgrades as more features are made available The ENG firmware may not need to be upgraded Firmware upgrade is accomplished using a PC in conjunction with the GEM Setup Application This program is a Java jar application which runs on Windows Linux or Apple The PC connects to the GEM using any of the available communication links e Ethernet e WiFi e XBee e RS 232 e USB via serial to USB cable If a USB or Serial connection is used instead of a TCP IP connection a bridge application will need to be used to bridge the Serial connection to a TCP IP connection compatible with the GEM setup program As mentioned earlier it is important to have a good wireless connection when upgrading the firmware If the wireless signal is week or intermittent then it is recommended to move the wireless devices in closer proximity COM Processor Firmware Upgrade The COM processor is the GEM s main processor It is also responsible for coordinating data flow when upgrading the ENG processor There could be a situation whereb
22. eck by simply disconnecting one of the CT leads while observing the power watt If the power increases when the CT lead is removed then simply swap the polarity on one CT only This should result in an increase in power providing there is a load on this circuit October 7 2012 22 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc GRO JE CO Pulse Count Inputs The GEM has four pulse count inputs Pulse counter 1 and 2 are totally isolated from the GEM ground and circuit Either of these two inputs require a DC pulse signal between 3V and 24VDC Pulse counters 3 and 4 are dry contact type counters These inputs require switch contacts not connected to any power source such as relay contacts or magnet switch contacts Very low voltage from the circuit 5VDC is used to complete the circuit Counter 4 Pulse Counter 3 Pulse ont ONN 8 to 24VDC Counter 2 O pulse EE E Counter 1 EJ o Ty j 3 3V to 24VDC ow Pulse Counter Terminal Block October 7 2012 23 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc EBR UIE Ecru Potential Transformer PT Input The potential transformer is responsible for providing a low voltage image of the line voltage to the GEM for accurate true power calculations This signal must be galvanic isolated to maintain safe low voltage to the GEM
23. em such that the arrow points toward the load as illustrated in the diagram below Following this rule will simplify the task of polarizing the CTs if more than one CT is connected to a given channel such as would be the case for 240V loads Some 240V loads may be monitored with a single CT as long as it does not required a neutral conductor which is common for many water heaters baseboard heaters and some water pumps 120V 240V Split Phase System CT 1 Breaker rr Neutral Breaker con Line2 K L f 120V K Source SE Load Outlet October 7 2012 28 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRULE C H Three Phase Polyphase 4 Wire Wye Y System Most commercial and light industrial buildings will have three phase panels Three phase sometimes referred to as polyphase is preferred for powering large motors such as those found in rooftop AC units refrigeration units and machinery The most common system is the 4 wire Y 120V 208V feed as shown in the diagram below The GEM uses a unique method of monitoring the voltage of a three phase system Typically energy monitors require all three voltages to be monitored The GEM simplifies matters by monitoring a single voltage phase The diagram above shows how the simplicity of the installation since the voltage is obtained via a wall transformer Other PT solutions are also available th
24. gt Figure x If command data is sent to the GEM via the RS 232 1 serial port the WiFi module will not hear this command The same applies if data is sent to the GEM via WiFi See diagrams below lp RS 232 1 We RS 232 1 We DW Antenna C O M 1 Antenna A A WiFi Module Ese Module lt Figure x The same concept applies to other shared COM ports October 7 2012 33 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRULE C H Here is a summary of how the COM ports may be shared COM1 is connected to RS 232 1 and may be shared with only one of the following optional devices e WiFi Module e Ethernet Module e Combination WiFi Ethernet Module e Custom PCB connected to the 1 X 10 pin header 3 3V TTL level signal NOTE Improper connection to the header may damage the GEM and void warrantee Consult Brultech before experimenting with this port Custom Com Circuit Brd 1 X 10 Pin Header 3 34 UART TTL signals WiFi Antenna Ethernet Ethernet Cable Module lt OR Module e gt OR OR Combination ien WiFiand _ A Ethernet lt Module Ethernet Cable Serial Cable RS 232 1 lt gt October 7 2012 34 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc 23 RO ECHA COM2 is connected to RS 232 2 and may be shared with only one of the followi
25. ified chunk sizes along with a specified time between chunks Hardware flow control may also be enabled to further protect the module from buffer overrun Custom Com PCB Header There is a footprint on the GEM to accept a custom designed communication circuit board This is available only if the GEM does not have a WiFi or Ethernet module installed The purpose for this footprint is to allow the development of a custom communication circuit board which would allow an alternate communication method such as RS 485 RS 422 Z Wave etc Additionally the PCB developer may wish to include a processor on board to incorporate proprietary API functions security etc The header consists of a 10 pin female socket with a 2mm pitch Green LED hi active Yellow LED hi active 10 COM2 Rx input 1 Ground Common 2 Vec 3 3V 3 COM1 Reset output Low Active 4 COM1 CTS Flow Control input 5 COM1 Tx output 6 COM1 Rx input 7 COM2 Tx output 8 9 NOTE Please contact us for more information before using this header Improper use may damage the GEM October 7 2012 38 www brultech com Copyright 2012 Brultech Research Inc All rights reserved BRULE C H October 7 2012 www brultech com Brultech Research Inc Copyright O 2012 Brultech Research Inc All rights reserved 39 Brultech Research Inc BRULE C H Firmware Upgrades It is very important establish a robust communication link with the GEM befor
26. m Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc B ROpJECcA Where to Start It is very important to plan the installation of the GreenEye Monitor GEM The guide below will help ensure a smooth installation Read and UNDERSTAND the safety information This is the most important step Not only will this help ensure that the installation will be according to local codes but will also prevent injury fire or fatality Power up and establish communication before installing This mainly applies to systems using WiFi or ZigBee wireless communication It is recommended to simply power up the GEM without any sensors connected while in close range to the WiFi router or ZigBee coordinator whichever applies and configure the SSID IP address etc This will help decipher any possible range issues if there are problems with the wireless connection Plan the mounting location for the monitor taking into consideration the CT lead length It is important to consider where the CT leads will be routed when choosing a location to mount the GEM If mounted to far away the CT leads may not reach the terminal strips The best location is usually as shown in the pictures below Main Panel Main Panel E T H H i TH IP IB SPLIT 200 CTs have longer leac 7 A WARNING NEVER Install The GREENEYE MONITOR GEM Unit Inside the Electrical Panel October 7 2012 8 www brultech com Copyright
27. n re installing the panel cover e Do not install the CTs in panels with voltages greater than 300V e Do not install the GREENEYE MONITOR GEM in a wet location October 7 2012 10 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRULE C H Compliance The GreenEye Monitor models GEM W and GEM E have been Tested to Comply with FCC Standards For Home and Office Use This device complies with Part 15 of the FCC Rules Operation is subject to the following two C conditions 1 this device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation Wireless Versions Contains FCC ID OUR XBEE2 USA Wireless Versions Only Contains Model XBee ZNet 2 5 Radio IC 4214A XBEE2 Canada May Contain Roving Networks WiFly Module FCC ID T9J RN171 May Contain FCC ID AZYHF A111 October 7 2012 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc BROpfeEcH Overview Layout The diagram below illustrates various items and sections of the GEM circuit board This chapter describes each numbered section Current Optional Transformer Module Connection System LEDs Ethernet Status LEDs 32 channels CR 2032 Battery Wifi Module Model GEM W only RS 232 Com2 RS 232 Com1 Com GND 1 Wi
28. nels from the setup program then refresh the values by clicking the Update Summary button All CT settings and corresponding phase settings will be displayed Set the CT values type and range then set the phase values as determined by the table above Let s first concentrate on the Phase A channel Select the Real Time Data tab of the setup program Make sure that the load is consuming power and that a wattage value is displayed for phase A If the displayed watt value for phase A is a negative value then you can easily rectify this by unplugging the PT giving it half a turn and re plugging it such that the two prongs are reversed This will cause the negative value to because positive Verify that phase B and C channels have positive values such as phase A now does If this is not the case try changing the phase B channel configuration to C and likewise phase Cto B This should provide positive values for all three phases Given a three phase load the total power for that load will be the sum of all three channels used to monitor it In some cases you may encounter a load such as a water heater using only two of the three phases The procedure is the same Remember that there is a possibility that the heater uses only phases B and C Again the same principle applies simply disregard the unused phase and the total power is the sum of the two phases used October 7 2012 31 www brultech com Copyright O 2012 Brultech Re
29. ng optional devices e Mee Module e Device compatible with the XBee module footprint and pin out e Custom PCB connected to the 1 X 10 pin header 3 3V TTL level signal Improper use may damage the GEM and void warrantee Consult Brultech before experimenting with this port XBee Antenna Custom Com Circuit Brd 2X 10 Pin Header T 1 X 10 Pin Header 2mm Pitch 3 3V UART TTL signals 3 3V UART TTL Module Serial Cable RS 232 2 gt COM Port Bridge Mode For setup purposes there is a method whereby a serial port or communication device can talk directly to one another as long as each is on a different COM port This is done using Bridge Mode This mode creates a virtual connection between a COM1 and COM 2 device Antenna Antenna WIFI XBee ca GEM in Module zo ii B ri d g e M O d ei com ep comz Virtual Connection D E a Oe e Between COM Ports Serial Cable Serial Cable RS 232 1 EH gt RS 232 2 lt lt gt The purpose for this is to enable setup or firmware upgrades for specific communication devices For instance an XBee module s firmware may be upgraded by connecting to RS 232 1 and bridged to communicate directly with the XBee October 7 2012 35 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRoOpleEcwH module Another common use would be to connect to the RS 232 2 port and se
30. o normal operation It is recommended to observe the entire sequence if you are doing this for the first time Once you are familiar with the sequence you can then repeat it and select the desired function as described in the next paragraph If the PB switch is pressed and maintained for 1 2 seconds during one of the flashing sequences the function that corresponds to that sequence will be executed 1 F1 red LED flash The GEM reboots the all installed communication modules including XBee and also prevents packets from being sent for a period of 1 minute 2 F2 green LED flash The GEM sends an ATNRO command to the XBee modules to cause ZigBee to search for an available Personal Area Network PAN 3 F3 yellow LED flash Causes the GEM to search for installed modules and sets the Hardware Settings accordingly This sequence takes one minute to complete F4 F6 Functions The sequence described allows the user to select F4 to F6 functions Press and maintain the PB switch for a few seconds until the SYS LED turns to yellow then quickly release the PB switch Observe the SYS LED as it will e Flash red three times e Flash green three times e Flash yellow three times e GEM returns to normal operation It is recommended to observe the entire sequence if you are doing this for the first time Once you are familiar with the sequence you can then repeat it and select the desired function as described in the next pa
31. options e Your own custom solution We provide API information upon request There is a variety of options available for communication depending on the server option chosen and wireless range The communication options are e Two RS 232 COM ports via push terminal block e Wifi communication optional e Ethernet connection optional e XBee Module for ZigBee communication optional October 7 2012 5 www brultech com Copyright 2012 Brultech Research Inc All rights reserved BRULE C H The sensors Various sensors may be used with the GEM e Current Sensors e Voltage Sensor e Pulse Output Devices e Temperature Sensors Current Sensors Brultech Research Inc Current sensing is done using current transformers referred to as CT throughout this manual The CTs we use require no electrical connection since the sensed electrical current is accomplished by reading the magnetic field of an electrical conductor Voltage Sensors The powerline voltage needs to be measured in order to calculate true power This is accomplished using a single potential transformer referred to as PT throughout this manual The powerline voltage is the voltage present at the electrical receptacle typically 120V or 240V depending on the Country The PT isolates this voltage and reduces it to a safe low voltage value for the GEM to monitor Pulse Output Devices Some water gas and propane meters pr
32. ovide a pulse output This is a simply ON OFF signal which My occurs any time an x amount of a given consumable is used For example a water meter could provide a single on off pulse for each gallon used These pulses are accumulated by the GEM to provide the amount and time of consumption If the meter does not provide a pulse signal then one can be added to existing water gas or other system Check with local utility company for rules and codes The picture on the right shows a typical water meter with pulse output available from http www temcocontrols com Temperature Sensors The GEM uses a 1 Wire bus for temperature sensing and is based on the Maxim Dallas DS18B20 sensors These sensors can share a common 3 conductor cable The picture on the right shows a typical temperature sensor available from http www adafruit com October 7 2012 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRULE C H Communication The GEM offers a multitude of communication options to transfer the monitored data to its destination Two separate ports each providing various communication options are provided RS 232 Ethernet Only optional WiFi Only optional Combination WiFi and Ethernet module optional ZigBee via XBee modules from Digi com optional A PCB header for custom options SH Se e Se October 7 2012 www brultech co
33. r Digi International XBee ZB modules e Accepts any of the three ZB 24 module antenna options e Communicates at 19 200 baud e Hardware flow control may be enabled e GEM setup option provides the option of chunking data to XBee modules in order to limit data flow restrictions inherent with ZigBee protocol Real Time Data e May be configured to push energy usage data at a user defined interval or pull data via API e Various data packet formats available e May be configured to post data using POST or GET methods e Efficient binary packet options available e Packet formats available for custom software development e Custom packet formats may be available based on the project size Setup and Setting Commands e Documentation available listing the commands used to read or write GEM setup parameters Firmware upgrades may be accomplished using any of the communication options above including USB if a serial to USB adaptor is available Custom communication solutions are available via a 10 pin header or XBee socket header providing access to UART TTL COM1 or COM2 ports NOTE Contact Brultech support before attempting to use these headers Improper use may damage the GEM and void warranty Volt and Current e 5VDC 5 UL CSA approved e 1 5A AC Adaptor typically uses less than 200mA depending on communication module used Consumption e Typically less than 1 watt Power Connection e 2 1mm xX 5 5mm barrel
34. r provides access to the UART and power supply providing an interface for alternate communication modules This header should only be used with available modules Please contact Brultech if you wish to design a custom communication interface using this header October 7 2012 14 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc Ro E Ecuy 10 Optional WiFi Module The model GEM W includes a WiFi communication module 11 XBee Module Socket The GEM may be fitted with Digi s XBee or XBee Pro modules providing ZigBee communications An opening is also included in the enclosure in should a module with external antenna is used 12 Battery Holder A CR 2032 battery is used to retain data under power outage conditions 13 System and Communication LEDs The left tri color LED is used for System Status The two color LED on the right side provides Wifi status if this option is present or other status depending on the Ethernet option included 14 Push Button Switch The push button switch stem is accessible from outside the enclosure The purpose of this switch is to provide some optional functions The switch sequence is described below for the following functions F1 Reset all installed communication modules and pause real time data send for 60 seconds F2 Send an ATNRO XBee command to the XBee module if one is present This causes the module to sea
35. ragraph If the PB switch is pressed and maintained for 1 2 seconds during one of the flashing sequences the function that corresponds to that sequence will be executed 4 F4 red LED flash This function applies to a GEM with the WiFi Only option This function sets the GEM in Access Point AP mode with a known IP address of 1 2 3 4 5 F5 green LED flash This function applies to a GEM with the WiFi Only option This function recalls the settings of the last network the GEM was connected to in Infrastructure mode 6 F6 yellow LED flash Causes the GEM to search for installed modules and sets the Hardware Settings accordingly This sequence takes one minute to complete F7 Function Remove power from the GEM by unplugging the 5VDC plug from the GEM Press and maintain the PB switch While doing so plug the power plug back into the GEM then release the PB switch after a couple of seconds or more The SYS LED should glow solid red This indicates that the GEM is waiting and ready for the COM firmware to be October 7 2012 16 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRULE CO programmed in recovery mode If the SYS LED does not glow red then remove the GEM s battery and repeat the cycle Leave the battery out until the new firmware is loaded and the GEM has fully booted The battery should only be re installed while the GE
36. rch and connect to an available ZigBee PAN Personal Area Network F3 Discover installed communication modules and set the GEM hardware accordingly F4 For GEM with WiFi Only option This function sets the GEM in Access Point AP mode with a known IP address of 1 2 3 4 F5 For GEM with WiFi Only option This function recalls the settings of the last network the GEM was connected to in Infrastructure mode F6 Reserved F7 Sets the GEM in recovery mode to force program the firmware in situations where firmware upgrade was aborted and got corrupt F8 Exit from bridge mode Bridge mode creates a serial communication connection between the devices on Com1 and Com2 This includes both RS 232 serial ports This allows the user to access any of the Com module s serial port using RS 232 When in bridge mode the GEM ceases normal operation and stays locked into bridge mode until F8 is executed or GEM power is cycled or a specially timed communication sequence is detected F1 F3 Functions The sequence described allows the user to select F1 to F3 functions described above Briefly press and release the PB switch four times with a one second pause between each The SYS LED will then Flash red three times Flash green three times Flash yellow three times October 7 2012 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRULE C H e GEM returns t
37. re Bus CO DO 5VDC 3 3VDC Supply Access O Power Supply 5VDC lt USB Jack used for optional 5VDC Power PT combined supply 12VAC 333mVAC 50 60 Hz Pulse Counter Channel 3 amp 4 Pulse Counter Channel 1 4 2 Push Button Switch October 7 2012 12 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc s ECH 1 CT Connection Terminals This section is composed of 32 terminal blocks one for each of the power monitoring channels The channel number is printed on the circuit board The terminal blocks have four terminals each This is where the CT leads connect to the GEM The terminals are numbered 1 4 although not marked directly on the terminal block The legend below should be used as a guide The terminal number to be used will vary based on the Type of the CT and the number of CTs connected to a given channel IMPORTANT The CT leads must be stripped back 10mm for proper connection to the terminal block See Connecting CT to the terminal blocks section 2 Pulse Counter Inputs The GEM has four pulse counting inputs Pulse signals may be acquired from certain water gas or electric meters to indicate the amount of consumption Pulse channels 1 and 2 are designed to accept voltage pulses and channels 3 and 4 are pulsed using dry contact closure See Pulse Counting section October 7 2012 13 www brul
38. red for Celsius or Fahrenheit degrees Temperature Resolution 0 5 C resolution Fahrenheit degree values are derived from the C value and converted to 1 decimal point accuracy Communication Standard e RS 232 via COM1 and RS 232 via COM2 Communication e 19 200 baud 8 bits no parity one stop bit 8N1 Ports e GND TX RX no hardware flow control e Connection via push terminals Optional Board SMT Uses Roving Networks RN 171 WiFly Module Soldered WiFi Module e Receive Sensitivity 83dB typical e Output Power 12 dBm e Serial Communication 19 200 baud e On board wire whip antenna Ethernet Module Uses third party Ethernet Module e Supports TCP UDP ICMP IPv4 ARP IGMP PPPoE Ethernet e Client Server and Mixed modes Default is Client mode e 10BaseT 100BaseTX Ethernet PHY e Configured via UDP using simple setup application 47 October 7 2012 www brultech com Copyright 2012 Brultech Research Inc All rights reserved BRULE C H WiFi Ethernet Module XBee ZigBee Module Data Communication GEM Firmware Upgrades Alternate Communication Options GEM System Power Supply Brultech Research Inc Provides Both Wifi and Ethernet Options simultaneously e Support 802 11b g n wireless standards e Output Power o 802 11b 20dBm o 802 11b 18dBm o 802 11b 15dBm e Web Configuration Page e Supports WEP WPA PSK WPA2 PSK WAPI e Encryption WEP64 WEP128 TKIP AES e RP SMA 2dBi external antenna e Socketed fo
39. required COM2 RS 232 should be used October 7 2012 37 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc Ro le Ecuy Ethernet Module Option The Ethernet module provides a robust connection to a network or PC It is typically setup as a client although it may be configured as a server The mode selected mostly depends on the data hosting method selected Currently our options consist only of client mode applications although some customers have created custom software requiring the GEM to be setup as a server The Ethernet module may be configured using the EtherX Configuration software available on our website Combination WiFi and Ethernet Communication Option This preferred option provides a robust WiFi and Ethernet connection Configuration is done via web browser connected to the internal website Both options may be used simultaneously Both options use COM1 leaving COM2 open for RS 232 or XBee module XBee Module Option The XBee module provides a wireless link using ZigBee communication via mesh network The GEM incorporates a module socket for easy installation of the two most popular module types whip antenna or RPSMA antenna connector The baud rate must be changed from XBee s default 9600 baud to 19 200 baud Since the ZigBee protocol has a limited data throughput and the GEM packets are fairly large the GEM may be configured to send ZigBee data in spec
40. s powered up if accumulated watt second counter and time values are to be preserved e Uses EEPROM to store GEM user settings e Battery backup holds CPU ram content during power outages This includes all watt second counter and time registers Better than O 40C TBD 5 to 95 non condensing UL94 VO ABS Plastic 9 1 8 X 7 1 8 X 2 Between 1 2 and 1 4 pounds depending on installed modules The GEM complies with Part 15 of the FCC Rules Operation is subject to the following two conditions 1 this device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation Depending of the GEM options the following wireless modules may be installed in the GEM e Roving Networks WiFly Module FCC ID T9J RN171 e Digi International XBee Module FCC ID OUR XBEE2 e WiFi Module FCC ID AZYHF A111 49 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRULE C H Channel Assignment Worksheet ill aAa O O So CI IO S S Aa NEE Lo OOA S y IO MES MESS IESO O O CI IO MA S a S S Oo EI MES a O O A O MO ME IEA MO FS BE CI ME S aAa O E Oo P P S S S S PIP e kA Es 7 E LA R NJI N e j e 7 LA OW NINI NI NI NIN N ejej ej e e N LO R gt A E October 7 2012 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved 50 BRULE C H
41. search Inc All rights reserved Brultech Research Inc BRULE C H Three Phase Polyphase 3 Wire Delta A System October 7 2012 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc Ro le ECH Communication Link The GEM provides a multitude of hardware communication options such as RS 232 which is standard on all GEM models Optionally WiFi Zigbee XBee module Ethernet or other options are available The other options is based on a header provided with UART access for those requiring a custom solution such as RS 485 Z Wave or other such solution Along with all of the hardware options the GEM offers various packet formats and APIs for communicating with data hosts COM Ports The GEM uses two communication ports COM1 and COM2 In general data from both ports are identical GEM lt gt COM Data l Communication 1 gt COM2 Each COM port is accessible via one of two RS 232 ports RS 232 1 and RS 232 2 Any of the optional communication options described previously will share a com ports with its corresponding RS 232 port For example the RS 232 1 connection will receive the same data as that being sent to the WiFi module This means that when the GEM sends a data packet or response to a command the data will be transmitted via WiFi and RS 232 1 serial port See diagram below gt lx RS 2321 7 e COM Antenna WiFi Module
42. ssor Firmware lege venias NOS 40 Recovering From Corrupt COM FIM TT 43 ENG Processor Firmware Upe rade iaa 43 Recovering From Corrupt ENG Firmware ccccccssccscccsecceeeeeeeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeaaeeseeeseeeeeeeeseeeeeeeeeusenaeesaeseeaess 44 Techical apec LION aida 45 PV Se VN US danita 45 PRI SCO AA PP o A 46 Temperature Sens aaa A ia 47 COMICO e star 47 A A UA 48 Channel Assignment Worksheet ina 50 October 7 2012 3 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc 53 RO ECHA Introduction The GREENEYE MONITOR GEM Home Energy Monitor is a multi channel power meter designed to measure the consumption of residential service panels and or panel circuits The measured data is then transferred to a computer or internet server for storage analysis and real time display The primary function of the GEM is to monitor electrical energy consumed Additional inputs have been included to measure other consumables such as water gas and propane providing there is a pulse signal available from such devices The GEM also provides a 1 Wire Bus which accepts low cost sensors to monitor temperature from various rooms and outdoors The GEM processes all of the measured data then sends it to a host computer server or website for display and analysis Overview The basic function of the GEM is to 1 Read and convert the sensor signals to real world v
43. tech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc BROoplectH 3 Potential Transformer PT Input The GEM may receive the PT signal from the 3 5mm phone jack 3 or via the mini USB connector 4 The 3 5mm jack is a stereo style jack providing two voltage range options depending on the PT used See PT section for more information 4 Alternate Potential Transformer PT And 5VDC Supply Input NOTE This is not a standard USB port for communication This mini USB jack may be used as an alternative to the 3 5mm jack 3 providing the PT signal is in the 333mVAC 333V range This USB jack us dual duty and may also provide an alternative to the 5 Volt DC power supply jack 5 5 GEM Power Supply Input This 2 1mm X 5 5mm barrel jack is for the 5VDC supply connection The center pin is the positive connection 6 Power Supply Access Terminals This four terminal block provides access to the GEM s 5V and 3 3V supply This is reserved for future options and special applications 7 1 Wire Bus and RS 232 Ground Terminal This four terminal block possessed the three connections for the 1 Wire bus and also the Common Ground connection for the RS 232 connection 8 8 RS 232 Connection This four terminal block encompasses the receive RX and transmit TX lines for both RS 232 COM ports 9 Optional COM Module Header This 10 pin 2mm pitch heade
44. tempted again October 7 2012 www brultech com Copyright 2012 Brultech Research Inc All rights reserved 44 BRULE C H Brultech Research Inc Technical Specification Power Metering Number of Channels 32 expansion available in the future Measurement POWER e True or Real Power using high speed volt and current sampling VOLTAGE e True RMS Accuracy Power Energy Measurements e Typically 1 plus CT accuracy Voltage Measurement e Better than 1 with PT Type value trimmed to a reference Sampling Frequency Voltage sampled 20 8 kHz Current sampled 10 4 kHz Maximum Input Current Dependent on current transformer Currents greater than 1 000A may be monitored Current Transformer Type A CT with AC mV output Input e 700 mV max for single CT e 350 mV max for each of two connected CT on a given channel Type B CT with AC mA output e 103 mA max for single CT e 51 5 mA max for each of two connected CT on a given channel NOTE e Exceeding the specified input values will affect channel accuracy e Connecting a Type B CT to terminals designated for TYPE A CTs may cause a channel overload to the point that all channels display unpredictable power values Input Impedance e 1 000 ohms for Type A CT connection Terminals 1 amp 2 and 3 amp 4 e 6 8 ohm burden resistor for Type B CT connection Terminals 2 amp 3 Potential Transformer 3 5mm Jack PT Input Input e Mono plug PT signal 8VAC to 18VAC Voltages greater than 14VA
45. thernet device such as EtherPort or to a serial to USB adaptor Either of these ports may be used at the main communication gateway or simply to configure the GEM the GEM s optional WiFi module or the GEM s optional XBee module The GEM is capable of being put in Bridge Mode which causes Com1 and Com2 to be linked together so that the RS 232 port can talk directly to a module on the opposite port Connection to the RS 232 port is accomplished via terminal blocks 8 in the layout section Typically only one RS 232 port would be used therefore there is only one common GND connection available WiFi Communication Option NOTE This option will soon be discontinued due to erratic performance of Roving Networks RN 171 WiFly Module The model GEM W is equipped with a WiFi module The module is initially configured so that a PC with WiFi can connect to it in ADHOC mode for the purpose of setting it up to access a local wireless router Once this setup is completed the GEM then connects to the WiFi router as a client Before the WiFi module is configured you must determine the destination for the GEM data This destination is where the data will be hosted such as e Aenergy monitoring hosting site check it ca smartenergygroups com etc e Brultech local web server dashboard e Your own personal website e A local computer The WiFi module communicates via COM1 port therefore if RS 232 communication is
46. tup parameters for the WiFi module if present Bridge mode is baud independent which means that the virtual wire section will work at any common baud rate without any required configuration The baud rate setting for each device must however be the same For example if you are bridging an XBee module to setup the WiFi module both devices must be set to the same baud rate Bridge mode does not support hardware flow control When the GEM is in bridge mode it no ceases all operations and only operates as a bridge Bridge mode is exited by a special timed command sequence or simply by momentarily pressing the GEM s push button switch 14 GreenEye Monitor Communication Section The GreenEye Monitor has two communication Optional ports available COM 1 and COM 2 These ports XBee may be shared with optional communication Module modules Optional PCB may be added to provide other communication options such as D abr Optional Ethernet USB Zwave RF etc Communication DB 9 Connector female Uses Pins 2 3 and 5 Rx 2 To Tx Tx2 To Rx Rx1 To Common 1x1 RS 232 Common Antenna WiFi Module Model GEM W only October 7 2012 36 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc BRODEcH RS 232 Port Every GEM device comes with two RS 232 ports The RS 232 port may be used to connect directly to an automation system a Serial to E
47. y a voltage output signal SPLIT 60 SPLIT 100 SPLIT 200 SPLIT 400 TYPE B The measured current is represented by a current output signal Micro 40 Micro 80 Micro 100 SPLIT 170 Because of this difference each CT type has to be connected to the terminal strip of the GEM in a different manner October 7 2012 19 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc 23 RO ECHA Type A CT Connection Again what constitutes a Type A CT is the fact that the signal produced is a voltage usually below 0 333V Single CT Connection Type A CT leads connects to terminals 1 and 2 This applies for any single Type A CT When a single CT is connected to a channel the lead polarity lead color code does not matter Type A Terminal CT Block nwe Dual Type A CT Connections CT1 NEN CT2 aM Ww ff Type A CT Connection For single or split phase only This technique for coupling two CTs on a single channel only applies to single or split phase services This cannot be done with 3 phase systems unless the 2 CT is monitoring another load located on the same phase See 3 phase section for more information October 7 2012 20 www brultech com Copyright 2012 Brultech Research Inc All rights reserved Brultech Research Inc Bro le ECH Both CTs must be of the same model For example although SPLIT 100
48. y the COM processor s firmware becomes corrupt during an upgrade due to interruption in communication If this occurs the GEM will no longer be functional Fortunately there is a procedure to recover from this situation as explained later in this chapter The most recent firmware file may be downloaded from our website Notes indicating issues resolved or features added for each firmware version are also available and should be viewed before upgrading This will discourage needless upgrades if the changes do not affect your application A communication connection between the GEM and a PC running the GreenEye Monitor Setup program will have to be established If the GEM is configured to send data to an online hosting site the communication module may need to be re directed to the PC unless a secondary communication method is available For example if data is forwarded to an online host via WiFi or Ethernet connection GEM COM1 firmware upgrade may be performed using any of the COM2 options such as RS 232 or XBee module If no other COM2 option is readily available the TCP IP connection will need to be redirected from the online data host s IP address to that of the PC The procedure for doing this will depend on the type of communication module used October 7 2012 40 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc Ro le Sen Once a communication link is established between the
49. ystem LED left will glow a solid red Establish a robust communication link between the PC and the GEM a A Make sure the Corrupt Firmware checkbox of the GEM setup program is checked ENG Processor Firmware Upgrade The procedure for upgrading the ENG firmware is the same as that for the COM firmare described above with the following differences 1 Once a communication link is established send a Reboot COM command This is done by clicking the Debug menu and clicking Reboot COM command 2 In step 6 click Engine Firmware button instead of the COM Firmware button If the ENG firmware upgrade fails for any reason and the ENG firmware becomes corrupt the method for recovery is different than that of the COM firmware October 7 2012 43 www brultech com Copyright O 2012 Brultech Research Inc All rights reserved Brultech Research Inc RO le ECH Recovering From Corrupt ENG Firmware Recovery from a failed ENG firmware upgrade is different and simpler than that for the COM corrupt firmware Simply press the PB momentarily so that the SYS LED returns to green then repeat the procedure DO NOT CHECK THE Corrupt Firmware OPTION IN THE SETUP PROGRAM This option only applies to the COM firmware If the GEM is at a remote location and the PB cannot be pressed simply wait for 80 seconds as the GEM will automatically exit the ENG firmware upgrade function Again the ENG firmware upgrade can be at

ECM-1220 User`s Manual - Power/Energy Monitors

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