Brultech GEM User manual

Installation Manual
Document Code: SYS-MAN
Ver 2.2
2017-01-12
©Copyright Brultech Research Inc. 2017
GreenEye/DashBox
System

Introduction
Page 1
TABLE OF CONTENTS
Introduction..................................................................................................................................... 3
Important Notes ................................................................................................................................................................ 3
GEM Models ...................................................................................................................................................................... 3
Base model “GEM” ....................................................................................................................................................... 3
WiFi/Ethernet “GEM-WE”............................................................................................................................................. 3
Ethernet Only “GEM-E”................................................................................................................................................. 3
Important Safety Information .......................................................................................................... 4
Compliance ...................................................................................................................................... 5
FCC Compliance ................................................................................................................................................................. 5
What’s in the Package ...................................................................................................................... 5
GEM Mounting Location................................................................................................................... 6
DashBox Location............................................................................................................................. 7
Option 1: RS-232 cable (Recommended)........................................................................................................................... 7
Option 2: TCP Connection.................................................................................................................................................. 8
Panel Layout .................................................................................................................................... 9
Fields.................................................................................................................................................................................. 9
CT Installation ................................................................................................................................ 10
CT Orientation.................................................................................................................................................................. 10
240V Loads....................................................................................................................................................................... 10
Typical 240V Balanced Loads ..................................................................................................................................... 10
Typical 240V Unbalanced Loads................................................................................................................................. 10
Route the CT Leads .......................................................................................................................................................... 10
CT Termination .............................................................................................................................. 11
GEM Terminal Strips ........................................................................................................................................................ 11
CT Termination ................................................................................................................................................................ 12
Single CT Connection ....................................................................................................................................................... 12
Connecting Two CTs on One Channel.............................................................................................................................. 13
Two Type “A” CT Connection ...................................................................................................................................... 13
Two Type “B” CT Connection ...................................................................................................................................... 14
SPLIT-30 CT Connection .............................................................................................................................................. 14
Power Supply and Wall Transformer .............................................................................................. 14
Communication.............................................................................................................................. 15
RS-232 Cable Installation ................................................................................................................................................. 15
Ethernet Cable Communication....................................................................................................................................... 16
WiFi Communication ....................................................................................................................................................... 17
DashBox Setup............................................................................................................................... 18
DashBox Power Up .......................................................................................................................................................... 18
DashBox WiFi Adapter Setup........................................................................................................................................... 18
Locate DashBox on the Network ..................................................................................................................................... 19
Windows users............................................................................................................................................................ 19
Mac or Linux users...................................................................................................................................................... 19
Set a Static IP Address...................................................................................................................................................... 20
Ethernet Connected .................................................................................................................................................... 20
WiFi Connected........................................................................................................................................................... 20
GEM Setup Page............................................................................................................................. 21

Introduction
Page 2
GEM Connected Via RS-232 (STS Cable) .......................................................................................................................... 21
GEM Connected Via Network (Ethernet or WiFi) ............................................................................................................ 21
WiFi/Ethernet GEM..................................................................................................................................................... 21
Ethernet Only GEM ..................................................................................................................................................... 23
GEM Setup Procedure .................................................................................................................... 24
Configuring CTs ................................................................................................................................................................ 24
CT Settings .................................................................................................................................................................. 24
Multiply by Two .......................................................................................................................................................... 25
HTTP Post Setup............................................................................................................................................................... 25
Packet Setup .................................................................................................................................................................... 26
For RS-232 Serial Communication .............................................................................................................................. 26
For WiFi or Ethernet Communication ......................................................................................................................... 26
Network Setup (GEM with WiFi/Ethernet)...................................................................................................................... 27
For GEM with WiFi/Ethernet option ........................................................................................................................... 27
GEM with Ethernet only option .................................................................................................................................. 27
Net Metering ................................................................................................................................. 28
Setting Channel Polarity .................................................................................................................................................. 28
Toggling the Polarity ........................................................................................................................................................ 28
Effect of the PT on Polarity .............................................................................................................................................. 29
Temperature Sensors ..................................................................................................................... 30
1-Wire Bus ....................................................................................................................................................................... 30
Compatible Sensors ......................................................................................................................................................... 30
Pulse Count.................................................................................................................................... 31
Connection....................................................................................................................................................................... 31
Appendix A .................................................................................................................................... 32
Important Security Info.................................................................................................................................................... 32
Appendix B .................................................................................................................................... 33
DashBox Switch Function................................................................................................................................................. 33

Introduction
Page 3
GreenEye/DashBox System
INTRODUCTION
IMPORTANT NOTES
1. This manual is for installation on single phase or split single phase 120V/240V electrical systems only. The
CT installation described in this manual will not work for three phase service. This also applies to
120V/208V panels which uses two phases of a three phase source.
2. Safety is paramount! Read all safety notices and make sure you fully understand and follow the safety rules.
GEM MODELS
You should first determine which communication option (if any) is installed
in your GreenEye Monitor: “GEM”, “GEM-WE” or “GEM-E”
Base model “GEM”
Strictly uses RS-232 for communication with the DashBox or other
data host. All GEM devices have RS-232 by default.
This model is identifiable by the fact that there is no antenna
connector such as “GEM-WE” model and the lack of the additional
reddish circuit board like the “GEM-E”. See picture on the right.
WiFi/Ethernet “GEM-WE”
Has the option of WiFi, Ethernet or RS-232 for communication with
the DashBox or other data host.
You can easily identify this model by the presence of a WiFi antenna
connector. See picture on the right.
Ethernet Only “GEM-E”
Has the option of Ethernet or RS-232 for communication with the
DashBox or other data host.
This model is easily distinguishable by the presence of the reddish
colored circuit board installed. Notice that the Ethernet connection
is done on the module and NOT the jack on the blue GEM board.
Additionally, the black barrel jack on the module is not used or
functional.

Important Safety Information
Page 4
IMPORTANT SAFETY INFORMATION
All safety rules described below must be obeyed. Read safety information carefully before proceeding with the
installation of the GreenEye Monitor and associated current transformer.
The GREENEYE MONITOR (GEM) is a low voltage device. This requires that all external connected signals be a low
voltage (<50V) and provided by Class II approved power supply.
All of our power supplies are UL, CSA or UL/c approved for use in USA and Canada. Our current
transformers (CT) are UL/c listed. No direct line connections to the GEM are allowed. All signals
must be galvanic isolated from the power-line.
Never install the GEM inside an electrical panel. A separate “low voltage” panel may be used when needed.
The GREENEYE MONITOR (GEM) installation requires the installation of current transformers (CT) 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!
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.
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.
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.
The portion of the CT leads inside the panel must not have any damage, cuts or wear to the outside
insulation.
The CT leads inside the electrical panel 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 when re-installing the panel
cover.
Do not install the CTs in panels with voltages greater than 300V.
Do not install the GREENEYE MONITOR (GEM) in a wet location.
WARNING !
Read All Safety Rules Before Installing!

Compliance
Page 5
COMPLIANCE
FCC COMPLIANCE
The GreenEye Monitor models GEM-W and GEM-E have been tested to Comply with FCC
Standards for Home and Office Use. The processor board inside the DashBox has also been tested
to comply with FCC Part 15.
This device 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.
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
WHAT’S IN THE PACKAGE
STS Cable
GreenEye Monitor
CT Model and Quantity Depends on System
DashBox
12Vac Wall Transformer (PT)
Two 5Vdc Power Adaptor

GEM Mounting Location
Page 6
GEM MOUNTING LOCATION
Find suitable mounting location for the GEM. Do not mount the GEM inside breaker panel!
Make sure the CT lead will reach the furthest circuit breaker.
Determine the best mounting location for the GEM taking into consideration the length of the CT leads. Some CT models
have longer leads than others. The two large main panel CTs such as
SPLIT-100 or SPLIT-200 have longer leads than Micro-CTs do, so it may
be preferable to locate the GEM at the opposite end of the panel feed
where the large CTs are installed. See diagrams below.
WARNING !
NEVER Install the GREENEYE MONITOR (GEM) Unit Inside the Electrical Panel

DashBox Location
Page 7
DASHBOX LOCATION
The possible location for the DashBox depends on the GEM’s communication options (if any) installed. All GEM models
have RS-232 ports and qualify for “Option 1”. This option is recommended because it allows the DashBox to collect data
independent of the network status or even without a network.
OPTION 1: RS-232 CABLE
(RECOMMENDED)
Model: GEM / GEM-WE / GEM-E
This option uses RS-232
communication between the GEM and
the DashBox. All GEM models are
compatible with option.
The STS Cable is 3 feet long therefore
the DashBox should be mounted
within two feet of the GEM.
The STS cable may be extended to
allow the DashBox to be located in
another room. It is recommended to
use CAT 5 or CAT 6 network cable to
extend the RS-232 STS cable.
The DashBox is located within two feet from the GEM
DashBox is located a distance from the GEM by extending the STS Cable
The DashBox is located near the GEM and connects using WiFi

DashBox Location
Page 8
OPTION 2: TCP CONNECTION
Model: GEM-WE / GEM-E
Option 2 uses the network as the path for data
from the GEM to be sent to the DashBox. This
option is only possible with GEM models listed
above.
The GEM can be connected to the network via
Ethernet Cable or in the case of WiFi/Ethernet
GEM models, WiFi connected.
Option 2 is not as reliable as Option 1 which
consists of an RS-232 connection since any
network downtime will affect data collection.
NOTE: GEM-E is not capable of WiFi connection.

Page 9
PANEL LAYOUT
A generalized panel layout sheet is located on the last page of this document. Print a copy and fill in the information for
each breaker. This will greatly simplify setting up the GEM CTs and DashBox channels later. Each field is defined below.
The picture (below) shows part of the channel info sheet on the left and a section of breakers represented.
FIELDS
Panel #
“Panel #” is the breaker slot number on the panel itself
Load Description
“Load Description” is the name of the appliance, outlet, light, etc. connected to this breaker
CT #
“CT #” is the number on the CT leads. This allows the installer to know which CT leads represent each
channel when it comes time to connecting the leads to the GEM.
Not all CTs have numbered labels attached. If this is the case, it is advisable to put a small piece of
masking tape at the end of the CT leads after the CT has been installed and the leads have been routed
outside of the panel
CT Model
“CT Model” is the Brultech model number of the CT
Amps
“Amps” is the amperage rating of the circuit breaker
240V-120V-240V
Circle the voltage that represents the breaker. If it’s a 240V breaker it is typically coupled with a breaker
adjacent to it. In this case, circle the two together as shown in the picture above.