Brultech Greeneye Monitor User manual

Brultech Research Inc
October 7, 2012
www.brultech.com Copyright © 2012 Brultech Research Inc. All rights reserved.
1
GreenEye Monitor™Manual
(Preliminary/Incomplete)
Energy Consumption Monitor
With Pulse Counter and Temperature Sensing Inputs

Brultech Research Inc
October 7, 2012
www.brultech.com Copyright © 2012 Brultech Research Inc. All rights reserved.
2
Introduction........................................................................................................................................................................... 4
Overview ................................................................................................................................................................................... 4
The sensors................................................................................................................................................................................ 6
Current Sensors .................................................................................................................................................................... 6
Voltage Sensors .................................................................................................................................................................... 6
Pulse Output Devices............................................................................................................................................................ 6
Temperature Sensors ........................................................................................................................................................... 6
Communication ......................................................................................................................................................................... 7
Where to Start ....................................................................................................................................................................... 8
Read and UNDERSTAND the safety information ....................................................................................................................... 8
Power up and establish communication before installing ........................................................................................................ 8
Plan the mounting location for the monitor, taking into consideration the CT lead length ..................................................... 8
Important Safety Information .............................................................................................................................................. 10
Compliance .......................................................................................................................................................................... 11
Overview / Layout ............................................................................................................................................................... 12
(1) CT Connection Terminals ................................................................................................................................................... 13
(2) Pulse Counter Inputs .......................................................................................................................................................... 13
(3) Potential Transformer (PT) Input ....................................................................................................................................... 14
(4) Alternate Potential Transformer (PT) And 5VDC Supply Input .......................................................................................... 14
(5) GEM Power Supply Input ................................................................................................................................................... 14
(6) Power Supply Access Terminals ......................................................................................................................................... 14
(7) “1-Wire” Bus and RS-232 Ground Terminal ....................................................................................................................... 14
(8) RS-232 Connection............................................................................................................................................................. 14
(9) Optional COM Module Header .......................................................................................................................................... 14
(10) Optional WiFi Module ...................................................................................................................................................... 15
(11) XBee® Module Socket ...................................................................................................................................................... 15
(12) Battery Holder.................................................................................................................................................................. 15
(13) System and Communication LEDs.................................................................................................................................... 15
(14) Push Button Switch .......................................................................................................................................................... 15
Current Transformer (CT) Installation .................................................................................................................................. 17
Important ................................................................................................................................................................................ 17
Type A CT Connection ............................................................................................................................................................. 19
Single CT Connection .......................................................................................................................................................... 19
Dual Type A CT Connections ............................................................................................................................................... 19
Type B CT Connection.............................................................................................................................................................. 20
Single CT Connection .......................................................................................................................................................... 20
Dual Type B CT Connections ............................................................................................................................................... 20
Pulse Count Inputs ............................................................................................................................................................... 22
Potential Transformer (PT) Input ......................................................................................................................................... 23
3.5mm Phone Jack .............................................................................................................................................................. 23
Mini USB Jack...................................................................................................................................................................... 24
Power Supply Input.............................................................................................................................................................. 25
Power Supply Access Terminal Block ...................................................................................................................................... 25
CT Installation ...................................................................................................................................................................... 26
Single/Split Phase Residential System ..................................................................................................................................... 27
Three Phase (Polyphase) 4-Wire Wye(Y) System .................................................................................................................... 28
CT Connection (Four-Wire WYE System) ............................................................................................................................ 30
Displayed Polarity ............................................................................................................................................................... 30

Brultech Research Inc
October 7, 2012
www.brultech.com Copyright © 2012 Brultech Research Inc. All rights reserved.
3
Three Phase (Polyphase) 3-Wire Delta (∆) System.................................................................................................................. 31
Communication Link ............................................................................................................................................................ 32
COM Ports ............................................................................................................................................................................... 32
COM Port Bridge Mode ........................................................................................................................................................... 34
RS-232 Port.............................................................................................................................................................................. 36
WiFi Communication Option ................................................................................................................................................... 36
XBee® Module Option ............................................................................................................................................................. 37
Ethernet Module Option ......................................................................................................................................................... 37
Combination WiFi/Ethernet Option ............................................................................................Error! Bookmark not defined.
Custom Com PCB Header ........................................................................................................................................................ 37
Firmware Upgrades.............................................................................................................................................................. 38
COM Processor Firmware Upgrade ......................................................................................................................................... 38
Recovering From Corrupt COM Firmware............................................................................................................................... 41
ENG Processor Firmware Upgrade .......................................................................................................................................... 41
Recovering From Corrupt ENG Firmware ................................................................................................................................ 42
Technical Specification......................................................................................................................................................... 43
Power Metering....................................................................................................................................................................... 43
Pulse Counting......................................................................................................................................................................... 44
Temperature Sensing .............................................................................................................................................................. 45
Communication ....................................................................................................................................................................... 45
GEM System ............................................................................................................................................................................ 46
Channel Assignment Worksheet .......................................................................................................................................... 48

Brultech Research Inc
October 7, 2012
www.brultech.com Copyright © 2012 Brultech Research Inc. All rights reserved.
4
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 values.
2. Process the acquired metrics.
3. Forward the data to a host for access via computer, internet, automation system or smart phone.
NOTE: Only low voltage, galvanic isolated signals are connected to the GreenEye™Monitor!

Brultech Research Inc
October 7, 2012
www.brultech.com Copyright © 2012 Brultech Research Inc. All rights reserved.
5
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:
A website dedicated to monitoring, displaying and charting consumption information.
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)
Personal website.
Local PC
Home automation system
Smart phone via one of the above options
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:
Two RS-232 COM ports via push terminal block
Wifi communication (optional)
Ethernet connection (optional)
XBee®Module for ZigBee®communication (optional)

Brultech Research Inc
October 7, 2012
www.brultech.com Copyright © 2012 Brultech Research Inc. All rights reserved.
6
The sensors
Various sensors may be used with the GEM:
Current Sensors
Voltage Sensor
Pulse Output Devices
Temperature Sensors
Current Sensors
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 provide a “pulse output”. This is a simply ON-OFF signal which
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

Brultech Research Inc
October 7, 2012
www.brultech.com Copyright © 2012 Brultech Research Inc. All rights reserved.
7
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:
1. RS-232
2. WiFi (optional) *will soon be discontinued due to erratic performance of Roving Networks’RN-171 WiFly Module.
3. Ethernet (optional)
4. Combination WiFi and Ethernet module (optional) *recommended
5. ZigBee® via XBee® modules from Digi.com (optional)
6. A PCB header for custom options

Brultech Research Inc
October 7, 2012
www.brultech.com Copyright © 2012 Brultech Research Inc. All rights reserved.
8
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:
1.

Brultech Research Inc
October 7, 2012
www.brultech.com Copyright © 2012 Brultech Research Inc. All rights reserved.
9
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.
WARNING !
NEVER Install The GREENEYE MONITOR
(GEM) Unit Inside the Electrical Panel

Brultech Research Inc
October 7, 2012
www.brultech.com Copyright © 2012 Brultech Research Inc. All rights reserved.
10
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
(<50V) and provided by Class II approved power supply and sensors.
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
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 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 Of The Safety Rules Before
Installing!