eGauge Systems LLC EG4xxx User manual

eGauge Model
EG4xxx Owner’s Manual
Version 1.0
eGauge Systems LLC
4730 Walnut St, Suite 110
Boulder, CO 80301
http://egauge.net/
877.EGAUGE1
720.545.9767
July 5, 2017

EG4xxx Owner’s Manual 2 INSTALLATION
1 Introduction
Thank you and congratulations to your purchase of an eGauge device! Properly
installed, the device will be able to record and report energy usage and production
for years to come.
The first and second section of this manual describes installation and commis-
sioning of the product. The third section provides operating instructions and is
followed by a section on equipment maintenance. The appendices provide the
device specifications and a reference to troubleshooting information.
Please visit the eGauge support site to verify you have the latest version of this
manual. There, you can also find additional training materials, tutorial videos,
configuration guide, and CT-selection guides:
http://egauge.net/support/
2 Installation
Installation must be performed by a licensed electrician according to all applicable
local, national, and international codes.
CAUTION: The eGauge power connector carries high voltage. For safety, the
device must be installed in a suitably rated enclosure for the installation envi-
ronment. The enclosure must have a screw-on or locking cover that prevents
accidental touch of the power connector.
2.1 What’s included in the box
•1×EG4xxx device
•1×AC Power plug (5-position plug)
•1×DC Power plug (2-position plug)
•0–30×Current transformers (CTs) w/ 8ft wires & plug (as ordered)
•1×HomePlug AV wall-outlet adapter w/5ft Ethernet cable (if ordered)
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2 INSTALLATION EG4xxx Owner’s Manual
2.2 Materials required for installation
•Per phase: Use of proper smallest available breakers or rated fuse taps for
the install per local NEC rules. Usually 15A circuit breaker or single multi-
pole breaker depending on phases used.
•Black, red, and white stranded AWG 12 wire; length depending on instal-
lation location. Thermal resistance to at least 75◦C. Blue wire is needed in
addition for 3-phase installations. Use wire that has insulation rating greater
than the max voltage inside the panel. Note: wire colors may vary based on
country and electrical service.
•Electrical tape
•Conduit and couplings as needed
•Mounting and wire organization hardware as needed
•If installed outside, appropriately rated enclosure (e.g. IPX4/NEMA4)
2.3 Tools required for installation
•#0 slotted screw driver (needed if length of CT-wires needs to be adjusted)
•Circuit-breaker finder (if using HomePlug power-line communication)
•Voltage meter
Additionally, for device commissioning and installation verification:
•Clamp-on AC current meter
•Laptop with Ethernet cable
2.4 Nomenclature and Symbols
In the US, residences typically receive power through split-phase power distribu-
tion which is provided through two hot legs, a neutral, and a protective ground.
Most commercial and industrial buildings receive power through 3-phase power
distribution provided through 3 hot phases, a neutral and protective ground.
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EG4xxx Owner’s Manual 2 INSTALLATION
Throughout the rest of this document, we use the term “phase” to refer both to the
phases of 3-phase power distribution as well as the two legs used in split-phase
power distribution.
The following table describes the symbols used on the device:
Symbol: Description:
Caution, risk of danger.
2.4.1 Measurement Category
Measurement Category III is for measurements performed in the building installa-
tion. Examples are measurements on distribution boards, circuit-breakers, wiring,
including cables, bus-bars, junction boxes, switches, socket-outlets in the fixed
installation, and equipment for industrial use and some other equipment, for ex-
ample, stationary motors with permanent connection to the fixed installation.
2.5 Safety Warnings
Please follow the installation instructions in this manual for wiring diagram and
proper selection of CTs.
To reduce the risk of electric shock:
•Do not connect device to a circuit operating at >277 Vrms to neutral.
•Always open or disconnect circuits from Power Distribution System of
building before installing or servicing the unit or attached current trans-
formers.
2.6 Installation Location
The eGauge is usually installed near the power-distribution panel of a building,
where there is easy access to the power circuits to be measured.
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2 INSTALLATION EG4xxx Owner’s Manual
The eGauge is permanently connected equipment. A 15A circuit-breaker shall be
included (one per phase) in close proximity of the device and within easy reach
of the operator. The breakers shall be marked as the disconnecting device for
eGauge. The breakers shall be wired to the device in compliance with the NFPA 8
National Electrical Code using a conductor size of at least AWG12 and tightened
to 10 ft·lb.
The eGauge is a listed device and must be installed inside a suitable enclosure.
The enclosure eGauge is installed in must be rated according to the environment
it is used in. For example, outdoor installations require an outdoor-rated enclosure
(e.g., IPX4/NEMA4).
Select an installation location that is not exposed to direct sunlight or the elements.
Otherwise, the warranty may be voided.
Do not install the device in a way that would make it difficult to operate the dis-
connecting device (circuit breakers).
2.7 Device Overview
Figure 1: eGauge inputs and outputs
As shown in Figure 1, the eGauge has three input connectors: the AC Mains is a 5-
pin connector used to wire the device to the building supply. The DC Connector
is a 2-pin connector for monitoring or powering from a DC voltage. The CT
Connector is used to connect current transformers (CTs) or other sensors. The
LCD and multi-switch provide some user interface.
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EG4xxx Owner’s Manual 2 INSTALLATION
The unit also has an Ethernet port (RJ45 connector) which can be used to hard-
wire the device to a Local Area Network (LAN). It also has two USB ports (Type-
A Female) to interface to various other IT devices.
An LCD shows a basic user interface with readouts from the set variable registers.
It may be controlled through the multi-switch for basic control and configuration.
2.7.1 LCD
The LCD is an installation aid shown in Figure 2. When powered on, the LCD
will show a eGauge logo as the device boots. During this time the backlight will
flicker showing boot activity. Once the LCD shows the first register screen, the
device is automatically recording data if configured to do so.
Figure 2: eGauge LCD
For a complete list of LCD views, please see the question “What do the different
pages on the LCD mean?” in the Frequently Asked Questions Section at:
http://egauge.net/support/
2.7.2 AC Mains Connector
This connector is shown in Figure 3 and the pin-out is as follows:
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2 INSTALLATION EG4xxx Owner’s Manual
Figure 3: AC Mains Connector
Pin: Name: Description:
1L1 Wire to phase 1 of building supply.
2NWire to building’s Neutral.
3L2 Wire to phase 2 of building supply for split- and three-phase
installs.
4 Unused. Leave unconnected.
5L3 Wire to phase 3 of building supply for three-phase installs.
The AC Mains Connector is CAT III rated (for measurements performed in the
building installation, such as circuit breakers). Pin L1 serves three purposes: it
powers the device (2W typical, 12W maximum), the voltage on the line is mea-
sured to calculate power used/generated on phase L1, and it carries the power-
line signal for communicating with the HomePlug AV wall-plug adapter. The pin
must be wired to the building’s power supply with a voltage in the range from 85–
277Vrms (to neutral). In contrast, pins L2 and L3 are used purely as voltage-taps
so power used/generated on phases L2 and L3 can be calculated. Wiring these pins
is necessary only if there are CTs measuring current(s) on L2/L3. The voltage on
these lines can be 0–277Vrms (Vac or Vdc).
To measure any signal on the AC Mains Connector L1 and N must be powered
with at least 85Vrms. If no voltage is supplied to this port, then the unit will
not measure any signal from L1, L2, or L3. The unit can continue to operate if
powered by the DC port.
2.7.3 DC Connector
This connector is shown in Figure 4 and the pin-out is as follows:
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EG4xxx Owner’s Manual 2 INSTALLATION
Figure 4: DC Connector
Pin: Name: Description:
1+Wire to DC signal.
2-Wire to ground.
The DC Connector CAT III rated for use from -60 – 60Vdc. It can measure the
voltage across that full range but if powered by the DC port, there must be at
least 9Vdc. If an installation utilizes both the AC Mains Connector as well as
DC Connector, and DC power is used to power the unit, there must be more than
12Vdc to ensure unit pulls power from the DC port.
2.7.4 CT Connector
This connector is shown in Figure 5. It provides 15 or 30 positions for the CT
plugs illustrated in Figure 9. The silk-screened numbers indicate which CT should
be connected to which pair of pins. Pins that are to receive the black wire of the
CTs are marked with a circle with black interior, pins for the white wires are
marked with a circle with white interior.
Figure 5: CT Connector
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2 INSTALLATION EG4xxx Owner’s Manual
The CT Connector is rated for wiring one to thirty units of the CTs listed in Sec-
tion B.6. The input voltage rating is 0.333Vrms at the rated current.
NOTE: There is no risk of damage if a CT plug is accidentally inserted such
that it straddles the pins for two different CTs. If this happens, the eGauge will
not be able to measure power properly but otherwise there are no ill effects. To
correct the problem, simply remove and re-insert the plug at the right position.
2.7.5 Ethernet (LAN) and USB Connector
This connector is shown in Figure 6. It provides hard-wired Ethernet connectivity
via an RJ45 plug and two USB host ports via Type-A Female plugs.
Figure 6: Ethernet Connector
The green LED in the top-left corner of the connector turns on (green) when an
Ethernet cable is plugged in and a valid Ethernet carrier signal has been detected.
The LED goes dark briefly whenever data is being exchanged over the cable. The
yellow LED in the top-right corner of the connectors is a speed indicator. It turns
on (yellow) operating at 100Mbps and is off (dark) when operating at 10Mbps.
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EG4xxx Owner’s Manual 2 INSTALLATION
The USB ports are USB2.0 compatible and can supply up to 1A at 5V. They may
be used with various supported IT devices such as RS485-to-USB converters or
WiFi adapters.
2.7.6 Multi-switch
Figure 7 is a close-up of the multi-switch. The user can slide the switch Left or
Right for navigation and push the switch into the unit to select.
Figure 7: Multi-Switch
The multi-switch can be used to navigate the LCD menu system. By default, any
action seen from the multi-switch will wake the backlight to ensure a viewable
interface.
2.7.7 Time Reference
During normal operation, the eGauge maintains accurate time by synchronizing
with an NTP server, such as one of the public servers available at ntp.org. Since
NTP provides atomic-clock accuracy, there is usually no need to set the time man-
ually.
When the NTP server is not accessible, either temporarily (e.g., after a power fail-
ure) or permanently (e.g., at a remote site), the eGauge relies on a Super Capacitor
backed real-time clock to maintain proper time.
The backup is designed only to cover relatively short power outages. The Super
Capacitor takes about 5 minutes to fully charge, and will keep correct time for
approximately 8 hours without power.
When power is restored after such an event, the eGauge will attempt to restore
proper time via the NTP server. If unavailable, and the Super Capacitor is de-
pleted, the device will fall back to using the time that was in effect when the last
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2 INSTALLATION EG4xxx Owner’s Manual
data item was recorded prior to the power failure. The proper time must then be
restored later on, either manually via the device’s Settings→Date & Time page
or by provisioning an NTP server that is accessible.
2.8 Wiring Diagram
2.8.1 Typical Residential (Split-Phase) Installation
Figure 8 is a schematic wiring diagram showing a typical split-phase installation
where the eGauge is used to measure the amount of power being supplied by the
power utility (CTs 1–2) and the power supplied by a single-phase solar inverter
(CT 3). For simplicity, circuit-breakers are not shown.
Figure 8: Wiring Diagram for a Typical Split-Phase Installation
2.8.2 Other Installations
For commercial three-phase installation as well as many other installation and
configuration-scenarios, please refer to the Configuration Guide, available at:
http://egauge.net/support/
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EG4xxx Owner’s Manual 2 INSTALLATION
2.9 Installation steps
1. If you are planning on using the hard-wired Ethernet port, skip to Step 3.
(a) Find a spot at the installation site that has both an available power
outlet and a nearby Ethernet port (for access to the LAN).
(b) Plug the HomePlug AV adapter into the outlet.
(c) Connect the HomePlug AV adapter to the Ethernet port with the sup-
plied Ethernet cable.
2. Use a circuit-breaker-finder to locate the breaker for the outlet into which
the HomePlug AV adapter is plugged into. Designate the breaker’s phase
as L1. In split-phase installations, label the other phase L2. In 3-phase
installations, label the other two phases L2 and L3 (order does not matter,
as long as the labeling is applied consistently throughout the installation).
3. Install the new breaker(s) in the power-distribution panel such that they pro-
vide access to all phases.
4. Open the breakers so there is no power on the breaker contacts.
5. Mount the eGauge inside a suitable enclosure near the power distribution
panel.
6. Wire the 5-position plug as follows:
(a) Black wire: pin labeled L1 to breaker for phase L1.
(b) White wire: pin labeled Nto Neutral.
(c) Red wire: pin labeled L2 to breaker for phase L2.
(d) Blue wire: pin labeled L3 to breaker for phase L3 (3-phase installa-
tions only).
Note: Colors may vary based on country and electrical service type.
7. Insert the 2-pin CT plugs into the CT Connector on the eGauge and record
the amperage of the CT, the phase being measured, and the item being mea-
sured in the table in Appendix D.
NOTE: Ensure that the stickers on the CTs point towards what is being
measured.
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3 COMMISSIONING EG4xxx Owner’s Manual
Figure 9: Correct wiring for 2-pin CT plug
If it is necessary to shorten or lengthen the CT wires, ensure that the CT
wires are connected as shown in Figure 9.
8. Close the newly installed breakers. This should cause the eGauge to power
up and, within a few seconds, the LCD will illuminate and show an eGauge
logo. Once the screen changes to the first register readout, the measure-
ments have started. The user can use the screen to verify a network connec-
tion. At that point, it can be found at http://egauge.net/devices/.
For this to work, the device needs to be able to make an outgoing TCP con-
nection to port 8082 of host d.egauge.net.
9. Label the newly installed breakers as “eGauge Disconnect” so the cus-
tomer can readily find them if it becomes necessary to power-cycle or turn
off the eGauge device for any reason.
IMPORTANT: Labeling the breaker(s) is essential. Do not skip that step.
Occasionally, it may be necessary to power-cycle the device. The breaker(s)
provide the only safe way to do that, so for safety-reasons, it is important that
the end-customer is able to identify the eGauge breaker(s) without having to
open any enclosures.
3 Commissioning
After installation, it is essential to verify that the device is operating properly and
measuring the expected quantities. Each device ships with a default configuration
that may or may not match your installation situation. In general, it is therefore
necessary to adjust the settings to match your situation. Please see the Configura-
tion Guide for details (available at http://egauge.net/support/).
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EG4xxx Owner’s Manual 4 OPERATION
For revenue-grade accuracy compliance, the eGauge must be paired with revenue-
grade CTs tested and supported by eGauge. Please contact eGauge Systems for
details.
Use a laptop or another computer to connect to the device’s built-in web-server
(see next section). Then, as described in the Configuration Guide, Tools→Chan-
nel Checker can be used to confirm that:
1. All voltages have the expected values (use voltage meter to verify).
2. All CTs report the expected currents (use clamp-on current meter to verify).
3. CTs are indeed installed on the phases set under Settings→Installation.
The voltage between the wire that the CT is clamped onto and the power-
plug pin (L1-L3) that corresponds to the phase it is configured for should
be zero Volts.
4. All reported power values have expected polarity and power-factors. As a
general rule, eGauge convention requires that power coming into the site
shows as positive values and power being consumed at or diverted from the
site shows as negative values.
Also confirm that the eGauge dash-board shows a red line for total consumption.
Assuming all power coming into a site is measured by the device, this line should
never dip into the negative. As a final check, it is helpful to turn on and off some
large loads to confirm everything operates as expected. If there is a renewable
energy system on site, turning it on/off should not appreciably affect the red line
(total consumption).
4 Operation
4.1 Accessing your eGauge for the first time
Once the eGauge is installed, you can access it from any computer on your Local
Area Network (LAN) with a compatible web-browser (see spec-sheet). To start,
enter the following Web address into your web-browser:
Microsoft Windows: http://devname/
All other computers: http://devname.local/
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4 OPERATION EG4xxx Owner’s Manual
where devname is the name of the device (e.g., eGauge9999). For example,
to access device eGauge9999, you would enter the following URL into your
browser:
Microsoft Windows: http://egauge9999/
All other computers: http://egauge9999.local/
You may also use the LCD display to find the local IP address of the eGauge on the
network. Use the multi-switch on the main register display to scroll to the last page
containing the hostname and IP address of the eGauge. It will also periodically
display as the register screen changes. Visit the IP address in a web-browser, for
example, http://192.168.2.120/.
An example of the eGauge dashboard can be seen in Figure 10. Tutorials for us-
ing the dashboard are available at http://egauge.net/support/. Online
help is available via the Help link at the top-right of the dashboard.
4.2 Accessing your eGauge from the Internet
To access the eGauge from the Internet, open a compatible web-browser and then
visit the Web page at: http://egauge.net/devices/.
Type the name of your device into the search box on that page (or any unique part
of it) and then click on the the matching entry.
Alternatively, you can directly enter the following web address into your browser:
http://devname.egaug.es/ where devname is the name of your device
(e.g., “eGauge9999”).
You can also use the above URL as an alternative means to connect to your device
directly through your LAN. To accomplish that, click on the LAN Access link on
the top right of the page, once the device’s dashboard has loaded. This directs
your browser to access the device directly (through your LAN rather than going
through egauge.net). This is both faster and allows you to access the device
even at times when your Internet-connection may not be working properly. Please
bookmark the address displayed in the browser after the page referred to by the
LAN Access link has finished loading.
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Figure 10: eGauge dashboard
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4 OPERATION EG4xxx Owner’s Manual
NOTE: From time to time, the address of your eGauge may change and the
bookmark will stop working. Should this happen, repeat the above steps and
update the bookmark with the new address. Usually, this happens infrequently,
if at all. However, since it can happen, we recommend using the connection-
methods described in the previous section whenever possible. Alternatively, a
static (fixed) address can be configured for the device. See the next section for
details.
The eGauge proxy service is best-effort and not guaranteed to be available at all
times. See the Proxy Server Statement on http://www.egauge.net/policy/ for more
details.
4.3 Configuring a Static IP Address
The eGauge normally automatically obtains its IP address and associated infor-
mation through a service called Dynamic Host Configuration Protocol (DHCP). If
you cannot or do not wish to run this service on your LAN, the device will default
to using IP address 192.168.1.88, so the device can be accessed as:
http://192.168.1.88/
Your computer’s IP address must be configured to be on the same range as this
default address. If another device ends up using the same address, or a static IP
address is required, you may configure one from Settings→Network Settings.
Please visit http://egauge.net/support for additional documentation
on connecting directly to an eGauge and assigning a static IP address.
4.4 Verifying the Proper Time
When the Internet is not available to the eGauge, it may be necessary to set the date
and time manually. To verify that the eGauge has the proper time, use a browser
to go to the device’s dashboard (see previous sections), then click on Settings,
then on Date & Time. If the displayed date and/or time is wrong, please enter the
correct values and then click on Save. Please repeat this step from time to time,
especially after prolonged power outages lasting more than a few hours.
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EG4xxx Owner’s Manual 5 MAINTENANCE
4.5 Passwords and Saving Settings
By default, changes may be made using user-name owner and password default.
You must connect to the eGauge directly over the local network before making
changes. This can be accomplished by clicking the LAN Access link in the upper-
right hand menu on the eGauge main interface. Credentials and remote adminis-
tration can be managed in Settings→Access Control.
5 Maintenance
The eGauge is designed to be maintenance free. No preventive maintenance or
inspections are required.
Should it become necessary to clean the eGauge, disconnect it from the building
supply by turning off the breakers labeled “eGauge Disconnect”, remove the
device, and clean it with a soft cloth. If a cleaning fluid is needed, use 70%
isopropyl alcohol. Wait until all cleaning fluid has evaporated before reinstalling
the device and turning the breakers back on.
The device has no replaceable batteries and no replaceable fuses.
CAUTION: If the equipment is used in a manner not specified by eGauge,
the protection provided by the equipment may be impaired.
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A EMI COMPLIANCE EG4xxx Owner’s Manual
A EMI Compliance
A.1 FCC Compliance Statement
This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference in a residential installa-
tion. This equipment generates, uses and can radiate radio frequency energy and,
if not installed and used in accordance with the instructions, may cause harmful
interference to radio communications. However, there is no guarantee that inter-
ference will not occur in a particular installation. If this equipment does cause
harmful interference to radio or television reception, which can be determined
by turning the equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:
•Reorient or relocate the receiving antenna.
•Increase the separation between the equipment and receiver.
•Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
•Consult the dealer or an experienced radio/TV technician for help.
CAUTION: Changes or modifications to the equipment not expressly ap-
proved by eGauge Systems LLC could void the user’s authority to operate the
equipment.
A.2 Canada ICES-003 Compliance
CAN ICES-3 (B)/NMB-3(B)
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EG4xxx Owner’s Manual B SPECIFICATIONS
B Specifications
B.1 Applicable Model Numbers
This manual applies to all eGauge models ranging from EG4000 through EG4999.
B.2 Electrical Rating of the Product
•AC Mains Connector: 85-277Vrms, 1-3 phases, 50-60 Hz, 12W peak (2W
typical).
•DC Connector: 9-60Vdc, 12W peak (2W typical).
B.3 Environmental Conditions
Suitable for indoor and outdoor use (with proper enclosure), Pollution Degree 2,
Measurement Category III. Not to be used at altitudes above 4000m. Voltage
fluctuations not to exceed ±10%. Temperature range: -30 – 70◦C (-22 – 158◦F).
Maximum relative humidity 80% up to 31◦C, decreasing linearly to 50% at 40◦C.
B.4 CE Immunity Statement
Performance criteria: At field-strengths up to 10V/m, no change of state or stored
data, may exhibit temporary variation in analogue input values.
B.5 Regulatory Certificates
UL File Number E344051
IEC/UL 61010-1 Ed. 3.0 B:2010
FCCs Title 47 CFR Part 15 Subpart B Class B
ICES-003 Information Technology Equipment Class B
IEC 61000-6-1 Ed. 3.0 B:2016
IEC 61000-6-3 Ed. 2.1 B:2011
RCM
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