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.

CT Installation
Page 10
CT INSTALLATION
Read the Important Safety Information chapter at the beginning of this document
before proceeding with CT installation!
CT ORIENTATION
The CT orientation is best understood by looking at the picture on
the right. For each of the CT styles the CTs are shown mounted in
opposite direction.
Paying attention to the side of the CT where the leads exit, notice
that in one case this side faces toward the circuit breaker and in the
other case, away from the breaker.
If only one CT is connected to a given channel, the GEM doesn’t care
about orientation.
All CTs may be installed in any direction but once the CTs have been
installed, make note of the CT orientation for both CTs when two CTs
are connected to a 240V load to be monitored by a single channel.
240V LOADS
You can monitor a 240V load with only one CT if the load is balanced.
A balanced load is one that does not use a neutral conductor
therefore the current which flows through one line is identical to that which flows through the other. If you are not sure
if the load is balanced, use two CTs. If using a single CT for the 240V load, orientation is irrelevant.
Typical 240V Balanced Loads
Central air condition system, water heater, baseboard heater, water pump
Typical 240V Unbalanced Loads
Clothe dryer, electric range
ROUTE THE CT LEADS
Neatly route all of the CT leads through one of the many “knock-out” holes of the GEM enclosure. In some installations,
the leads may enter the GEM through the back of the GEM enclosure.
WARNING !
Read and understand the safety information before the CT installation!

CT Termination
Page 11
CT TERMINATION
GEM TERMINAL STRIPS
NOTE: The CT leads must be stripped approximately 10mm (0.4”) and have a
gauge size between 18 and 26 AWG.
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
beforehand to prevent dealing with frayed ends. (Tinning is the process of
adding solder to bond all of the strands together).
The CT leads are inserted into terminal block while pressing down on the
corresponding orange tab (see picture below).
1. Align the two lead ends with the terminal holes. This can be done one lead at a time however it may be easier
inserting both leads at the same time, providing they are 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.
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.

CT Termination
Page 12
CT TERMINATION
The picture on the right shows the terminal block. Each block has four terminals.
Terminal 1 is at the bottom. The terminals that the CT will be connected to are
dependent on the type of CT used.
Two types of current transformers are used with the GEM: Types A and Type B.
The difference between each type has to do with the type of signal which represents the
sensed current:
TYPE A CT:The measured current is represented by a voltage output signal.
(SPLIT-60, SPLIT-100, SPLIT-200, SPLIT-400/600, SPLIT-170)
TYPE B CT:The measured current is represented by a current output signal.
(Micro-40, Micro-50, Micro-80, Micro-100)
SINGLE CT CONNECTION
When only one CT is connected to the GEM it doesn’t matter which color lead goes to each terminal.

CT Termination
Page 13
CONNECTING TWO CTS ON ONE CHANNEL
Two Type “A” CT Connection
The following CT models are “Type A”: SPLIT-30, SPLIT-60, SPLIT-100, SPLIT-200, SPLIT-400/600, SPLIT-170
When connecting two CTs to a given channel, the CT orientation and lead color needs to be taken into account to
prevent the signal of one CT from subtracting from the other.
When two CTs from a 240V load are connected to the GEM as shown in the diagram to the right, the rule for the CT lead
color code is as such:
If the two CTs are installed facing opposite directions:
Terminals 1 & 3 will have the same color lead
Terminals 2 & 4 will have the same color lead
If the two CTs are installed facing the same direction:
Terminals 1 & 4 will have the same color lead
Terminals 2 & 3 will have the same color lead
This rule is based on a 240V load which means that one CT is on phase A and the other on phase B.
If both CTs are connected to two different loads which happen to be on the same phase, then the rule described is the
opposite!
Example:
Two SPLIT-200 CTs are connected to the main feeder. They are installed with both CTs facing the main panel
breaker.
The solid black lead of CT#1 is connected to terminal #1 and the other lead to terminal #2
The solid black lead of CT#2 is connected to terminal #4 and the other lead to terminal #3

Power Supply and Wall Transformer
Page 14
Two Type “B” CT Connection
The following CT models are “Type B”: Micro-40, Micro-50, Micro-80,
Micro-100
When two CTs from a 240V load are connected to the GEM as shown in the
diagram to the right, the rule for the CT lead color code is as such:
If the two CTs are installed facing opposite directions:
Terminals 2 will have the same color lead from each CT
Terminals 3 will have the same color lead from each CT
If the two CTs are installed facing the same direction:
Terminals 2 will have dissimilar color lead from each CT
Terminals 3 will have dissimilar color lead from each CT
This rule is based on a 240V load which means that one CT is on phase A and the other on phase B.
If both CTs are connected to two different loads which happen to be on the same phase, then the rule described is the
opposite!
Example: Two Micro-80 CTs are connected to the electric stove. They are installed with both CTs facing the breaker.
The white lead of CT#1 and the black lead from CT #2 are connected together to terminal #2
The black lead of CT#1 and the white lead from CT #2 are connected together
to terminal #3
SPLIT-30 CT Connection
The SPLIT-30 is a “Type B” CT and the connection method for Type B
described above applies.
The only difference is the addition of a capacitor inserted in terminals 1
and 4.
POWER SUPPLY AND WALL TRANSFORMER
Plug the 5Vdc power supply and the 12Vac wall transformer into a receptacle near the
panel.
1. Plug the 5Vdc cable into the barrel jack (top right of picture)
2. Fully plug the 12Vac cable into the 3.5mm jack (bottom right of picture). It is
absolutely important to make sure that the plug is fully inserted!

Communication
Page 15
COMMUNICATION
Choose one of the following communication options: RS-232, Ethernet or WiFi
RS-232 CABLE INSTALLATION
Model: GEM / GEM-WE / GEM-E
For GEMs with WiFi/Ethernet or Ethernet only option, connect
the STS Cable (RS-232 cable) to COM 2 otherwise use COM 1
for basic GEM model.
1. Connect the STS Cable terminals to the GEM
a. Red wire to GEM’s Rx terminal
b. White wire to GEM’s Tx terminal
c. Black wire to GND terminal
2. Plug the STS Cable 3.5mm plug into port #1 of the
DashBox
3. Connect an Ethernet Cable between the DashBox and
the Network Router

Communication
Page 16
ETHERNET CABLE COMMUNICATION
Model: GEM-WE / GEM-E only
1. Connect an Ethernet Cable between the GEM and the
Network Router
2. Connect an Ethernet Cable between the DashBox and
the Network Router
Two GEM models have an Ethernet connector. The GEM-E
(Ethernet Only model) has an additional circuit board installed
and a dedicated Ethernet jack. The GEM-WE (WiFi/Ethernet
model) has no additional circuit board but does have a WiFi
antenna connector. Its Ethernet jack is on the GEM board.

Communication
Page 17
WIFI COMMUNICATION
Model: GEM-WE only
1. Connect an Ethernet Cable between the DashBox and
the Network Router
The procedure to establish a wireless connection is
explained later in this manual.

DashBox Setup
Page 18
DASHBOX SETUP
DASHBOX POWER UP
1. Connect a network cable between the network router and the DashBox
2. Connect the 5Vdc power supply adapter to the DashBox then plug it into a local receptacle
3. Observe the LED color sequence:
a. Reddish/pink glow for several seconds indicating that the system is booting up
b. Red flashing LED for 30 seconds while the super-capacitor charges
c. Green flashing LED for a few seconds while the system starts all processes
d. Green solid. System is started and ready
DASHBOX WIFI ADAPTER SETUP
If the DashBox is connecting to the network via Ethernet Connection
then proceed to the next chapter: “Locate DashBox on the Network”.
By default the USB/WiFi adapter will be in “Access Point” mode.
1. Make sure the DashBox has booted up with the USB/WiFi
adaptor plugged into the USB jack
2. Search and connect to the WiFi network named “DashBox…”
there may be a number following the name
3. Open your internet browser and enter http://192.168.6.1.
This will connect to the DashBox web interface
4. If this is the first time connecting to the DashBox:
a. Set your “Time Zone” and “Locale”
b. Assign the DashBox a login name and password
c. Set the rate in $ per kilowatt-hour (kWh). This can be
done by taking the total cost of the electric bill and dividing it by the total kWh used during the billing
period. If you’re in a rush, accept the default ($0.20) and change this later.
d. Read and accept the License Agreement
e. Click “Save Settings”
5. Click “Network” on the left side menu, then click “WiFi USB”
6. In the “Network Configuration” box, click the “Network Mode” radio button.
7. In the “Network” box, enter the name (SSID) of the wireless network you wish to connect to
8. Enter the password for the WiFi network in the “Password” box and select the security type from the “Security”
drop-down menu
9. Set “IP Type” to DHCP. This will allow the router to assign an IP address to the DashBox
10. Click the blue “Save Settings” button at the bottom. The system must be rebooted to take effect
11. Click “System” from the left menu then Click “Reboot System”
Your computer should now disconnect from the Access Point since the DashBox is switch from Access Point to Network
mode. Connect to the network now to discover the DashBox which should now be connected to the WiFi network.
DashBox with Optional USB-WiFi Adapter
The DashBox will only work with TP-LINK TL-
WN722N wireless adaptor or any other type
using the AR9271 chipset

DashBox Setup
Page 19
LOCATE DASHBOX ON THE NETWORK
The DashBox IP Address needs to be determined. If you are computer savvy and know how to discover the DashBox IP
Address from the network router go ahead and do so then skip to the next chapter “Set a Static IP Address”.
Windows users
1. Download the “GEM Network Utility” program from http://brultech.com/software and install
2. Use “Run as administrator” option and start the program
3. Click the “Network” tab
4. Click “Search” on the bottom right
The “GEM Network Utility” will discover the IP address for the DashBox as shown below.
Double click on the IP address. This will open the DashBox web page in a browser.
Proceed to the next chapter “Set a Static IP Address”
Mac or Linux users
If you are using a Mac or Linux system, you can download a free “Network Scanner” program called Fing (
https://www.fing.io/ ) or you can connect to your router to view the devices on the network. Look for an IP address
associated with the name “TP-Link” (if you are using the USB to WiFi adaptor). Make note of the IP Address.
Enter this IP Address into your internet browser’s address bar then press “Enter”. This should take you to the DashBox
web page.