Packet Power BGS32 User manual
Packet Power Multi-Circuit Monitor BGS32 User Manual V2.0
© 2021 Packet Power, LLC Page 2 of 29
SECTION 1: GENERAL
HAZARDS
CAUTION
Read all instructions carefully prior to installation.
Always ensure power has been disconnected prior to doing any work.
The BGS32 should be installed only by qualified technicians. Familiarity with and
understanding of all terms used in this manual is assumed.
BGS32 should be deployed in conjunction with proper branch circuit protectors.
The user is responsible for ensuring that all work is performed in accordance with
local electrical codes and regulations and using appropriate tools and materials.
BGS32 should only be connected to the type of power source indicated on the label.
The current transformer(s) used with the BGS32 must be appropriate to the amperage
of the circuit(s) on which they will be used.
Only current transformers approved by Packet Power should be connected to the
BGS32. Using unapproved current transformers could result in inaccurate readings
and damage to the BGS32 device.
Current transformers shall provide two means of isolation from hazardous voltages.
When selecting a current transformer, the voltage and measurement category of the
circuit to be measured must be considered to ensure that the current transformer is
adequately insulated and rated. For 480V circuits, insulation shall be at least 600V
rated. For 240V circuits, insulation shall be at least 300V rated.
Prior to installation, check to make sure the BGS32 has not been damaged.
Following installation in the final product, the connectors on the BGS32 must be
fully enclosed and insulated from the external product enclosure in compliance with
all relevant local electrical codes and regulations.
A safety connection to electrical ground / earth must be used.
Once installed on a conductor, current transformers must be connected to the BGS32.
Failure to do so creates an unsafe condition and will result in damage to the CT.
Follow basic safety precautions to reduce the risk of electrical shock and damage to
equipment.
Store in a clean, dry location. Clean with a dry cloth.
Intended for indoor use only, do not install in a wet location.
Failure to use the product in the specified manner may lead to injury or death and
damage to equipment.
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Packet Power LLC assumes no liability for user’s failure to comply with these safety
guidelines. Please read this entire manual carefully before proceeding.
This symbol is used throughout this manual to indicate critical safety
information. Failure to observe the information following this symbol may
result in injury or death.
CAUTION: This system and the area it is installed in may contain life threatening voltages.
Qualified personnel must disconnect all high voltage wiring before using or servicing the
BGS32.
3∿The BGS32 will be pre-configured to support single-phase, split-phase or three-phase
power as indicated on the product’s label. Only use the device with the indicated
voltage service type.
Do not apply or remove the current clamps from hazardous live conductors.
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Regulatory Information
Monitoring Units
This product has been tested to the following requirements:
CONFORMS TO UL/IEC STD 61010-01, 3rd ed.IEC 61010-2-030 ed. 1.0, EN 61010-1:2010, CSA C22.2 NO. 61010-1
IEC 61010-2-032 - Edition 2 - Issue Date 2002/09/01, EN 61010-1:2001, IEC 61010-1, 3rd Edition
Council Directive 1999/05/EC - European Union (EU) Radio & Telecommunications Terminal Equipment Directive
(R&TTE) ETSI EN 300 220-2 v2.4.1, ETSI EN 300 328 V1.7.1 and ETSI EN 301 489-1 and 301 489-3, Issued:2002/08/01
V1.4.1, EN61326-1, EN6100-3-2, EN6100-3-3, EN301 489-17, AS/NZS CISPR 11
IC RSS-210 Issue 8 Annex 8, RSS-GEN Issue 3
FCC CFR 47.15(c), 15.247(a)
BGS32 Assembly
This product has been tested to the following requirements: UL508A Industrial Control Panel
Class B Device Statement:
Section 15.105(a) of the FCC Rules: 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 when the
equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if
not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.
Section 15.19 of the FCC Rules: 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.
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Using this Manual
This manual contains information about the Packet Power™BGS32 Multi-circuit
Monitoring System (“BGS32”) and associated devices. It is a supplement to information
provided in the support section of Packet Power’s web site www.packetpower.com/support.
The BGS32 must be used in conjunction with a Packet Power Ethernet Gateway. Detailed
information about the Ethernet Gateway can be found on the web site above, including
information needed to access data from the BGS32 for use in a third-party monitoring
application.
All information provided is relevant to every BGS32 model.
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Index
SECTION 1: GENERAL ...................................................................................................... 2
HAZARDS............................................................................................................................ 2
Regulatory Information......................................................................................................... 4
Using this Manual................................................................................................................. 5
Index ..................................................................................................................................... 6
SECTION 2: OVERVIEW ................................................................................................... 7
Service Voltage Service Types............................................................................................. 7
Current Transformers............................................................................................................ 7
Communication..................................................................................................................... 8
Components .......................................................................................................................... 9
SECTION 3: INSTALLATION ......................................................................................... 10
Installation Overview.......................................................................................................... 10
Mounting............................................................................................................................. 11
Voltage Connection ............................................................................................................ 13
CT Interconnect Cables and Boards ................................................................................... 16
CT Leads............................................................................................................................. 16
CTs...................................................................................................................................... 17
SECTION 4: OPERATIONS.............................................................................................. 20
Start Up............................................................................................................................... 20
Operation............................................................................................................................. 20
Shutdown ............................................................................................................................ 21
Troubleshooting.................................................................................................................. 21
SECTION 5: MAINTENANCE ......................................................................................... 23
Equipment Parts List........................................................................................................... 23
Scheduled Maintenance...................................................................................................... 24
Add or Replace a CT........................................................................................................... 24
Dismantling......................................................................................................................... 26
Emergency Measures.......................................................................................................... 26
APPENDIX: SAMPLE PANEL DETAIL......................................................................... 27
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SECTION 2: OVERVIEW
The BGS32 is a power monitoring system designed for installation on select panelboard
circuits or input feeds, high energy loads such as generators, HVAC equipment and
switchgear. The system transmits the monitoring information via a wireless mesh network to
one or more Packet Power Ethernet Gateway (“Gateway”) devices.
Service Voltage Service Types
The BGS32 comes pre-wired for use with one of the following service types:
120V and 230-240V single-phase (L + N + ground)
208V single-phase (L + L + ground)
277V single-phase (L + N + ground)
208/120V three-phase wye (3-wire + N + ground)
208V three-phase delta (3-wire + ground)
240/120V split-phase (2-wire + N + ground)
415/240V three-phase wye (3-wire + N + ground)
480/277V three-phase wye (3-wire + N + ground)
Ensure that the type of voltage service that is present in the equipment you are monitoring
matches the type indicated on the label of the BGS32. The BGS32 cannot be used on 480V
equipment if access to N is not present nor on 600/347V circuits. The BGS32 is powered
from the voltage source it is monitoring.
Current Transformers
The BGS32 is preconfigured for use with split core CTs with rated amperage of 15A to
4000A and 333mV output or Rogowski coil sensors supporting 100A to 4000A. Split core
CTs can be safely used on circuits up to 120% of their nominal rating (for example a 100A
CT can be used on circuits up to 120A).
Use of the CTs on circuits with greater than maximum load will result in degraded accuracy
and damage to the CTs. CTs should not be removed from conductors while under load. Once
installed on a conductor that has load present, the CT must be connected to the BGS32.
Failure to do so will create a safety hazard and result in damage to the CT.
Split core CTs include 24 AWG 600V twisted pair leads that terminate in the CT
Interconnect Boards. The CT Interconnect Boards are connected to the BGS32 using the
provided CT Interconnect Cables (shielded ribbon cable).
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Communication
The BGS32 utilizes Packet Power’s advanced zero-configuration wireless mesh networking
technology which automatically connects the BGS32 to an Ethernet Gateway when
energized. Each Gateway can support up to 25 BGS32s; additional Gateways can be added
for capacity or redundancy.
The BGS32 must be able to establish a wireless connection either directly to a Gateway or to
another Packet Power wireless device.
Data can be accessed from the Gateway in one of two ways:
Third Party Device Data Acquisition - Third party monitoring systems can access data
from a Gateway via SNMP, Modbus TCP/IP, Ethernet/IP, MTConnect, BACnet/IP and
MQTT protocols.
Cloud Based Data Acquisition - Data can be simultaneously exported to the Packet Power
EMX monitoring portal (local or cloud based).
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Components
The BGS32 consists of a NEMA 1 monitoring enclosure, two CT interconnect boards with
loose CT leads or wire harnesses for attaching CTs, and the CTs themselves.
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SECTION 3: INSTALLATION
IMPORTANT
1. Installation should be conducted by a qualified professional according to local
electrical codes.
2. Protective equipment should be used when handling a current transducer (CT) on a
live conductor.
3. Do not make adjustments to the BGS32’s internal wiring.
4. If you believe the BGS32, CTs, interconnect boards or leads have been damaged, do
not attempt to repair or use them. All components are built to spec by Packet Power
and are not intended for alteration in the field.
Please review the complete list of safety instructions in the Hazards sections of this
document.
Installation Overview
The BGS32 does not need to be configured prior to use.
1. Mount the BGS32 to wall or device using mounting tabs provided.
2. Run the voltage lead(s) to the voltage source and connect them to L1, L2, L3, N and
earth.
3. Mount the CT Interconnect Boards near the circuits being monitored.
4. Attach the connector at the end of the CT Interconnect Cable to the applicable CT
Interconnect Board header.
5. Run CT leads from the CT Interconnect Board to the respective circuits.
6. Connect each CT to the appropriate conductor.
7. Connect CT tails to the CT leads.
Once power is supplied, the BGS32 will automatically begin to transmit data.
Thoroughly review the details for each step prior to installation. Contact Packet Power
support with questions.
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Mounting
The BGS32 should be mounted as close as possible to the equipment being monitored.
Mounting locations
Use the mounting tabs provided for wall mount or the chase nipple provided to install
directly onto equipment.
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Enclosure dimensions
Wire exits
The BGS32 has openings for wire exits in the back, bottom and on each side of the enclosure
allowing it to be mounted in a variety of positions relative to the equipment being monitored.
Wire exit location
Description
Bottom
1” NPT (1.375” / 35 mm diameter) hole
Back
1” NPT (1.375” / 35 mm diameter) hole
Left side
1” NPT (1.375” / 35 mm diameter) hole
Right side
1” NPT (1.375” / 35 mm diameter) hole
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Voltage Connection
A three-pole breaker should be used to provide over-current protection and a
means of disconnecting power from the BGS32. If a three-pole breaker is not
used, you must ensure suitable over-current protection is provided.
The BGS32 comes pre-wired. It is configured to work with one of the supported voltage
types. Unless otherwise specified, the unit has inline fuses on each voltage phase. The wire
count and color mix will vary based on the voltage service type (see diagrams on the
following pages).
Voltage leads
18 AWG 600V wires which are connected to a 6-position terminal block inside the
enclosure are provided for use in routing power to the device.
Voltage lead lengths are sized to specification. They may include a voltage
disconnect near the BGS32 that is used to avoid placing strain on the connection to
the terminal block during shipping and installation.
5x20 mm 5A inline fuses are included on L1, L2 and L3 unless otherwise specified.
An optional second voltage source can be included. If a second voltage lead is
included, the voltage leads will be labeled accordingly.
Wire connections
The BGS32 uses different wire colors depending on service type and region. Run the voltage
leads to the voltage source and connect them to L1, L2, L3, N and earth. Reference wire
connections by service type on the following pages.
Verify that the wires are connected to the proper phases for your type of voltage service.
No changes should need to be made to any wiring within the BGS32 device itself.
Grounding
The BGS32 enclosure must be properly connected to earth. A ground wire is provided for
this purpose.
Failure to properly ground the unit could result in a dangerous or fatal
electrocution.
Once power is supplied the BGS32 will automatically begin to transmit data.
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Voltage wire connections by service type
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CT Interconnect Cables and Boards
The CT Interconnect Boards are connected to the BGS32 via the CT Interconnect Cables.
The interconnect cables and boards are labeled to ensure proper connection.
Mount CT Interconnect Boards
The green CT Interconnect Board is fastened to a 72 x 53 x 6.3 mm acrylic base and includes
VHB adhesive tape on the back of the base.
Clean the area thoroughly, then mount the CT Interconnect Boards inside the panel or near
equipment being monitored using the VHB adhesive tape (or mount using 5/32” screws). Be
sure to orient the CT Interconnect Board so the black connector header faces away from the
circuits or panel.
Attach Interconnect Cables to Interconnect Boards
Attach the connector at the end of the CT Interconnect Cable to the corresponding CT
Interconnect Board header. The interconnect cables and boards are labeled to ensure proper
connection.
CT Leads
Split core CTs are connected to the CT Interconnect Board via loose twisted pair leads.
Flexible CT wire harnesses consisting of 16 leads per harness in multiple configurations are
available.
Loose leads are best suited to equipment such as switchgear that has widely- or unevenly-
spaced circuits. Wire harnesses are best installed with evenly-spaced circuits.
Always orient the CT Interconnect board’s
header away from the circuits
CT Interconnect Cable to monitoring unit
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Run CT leads to the circuits
Run the CT leads (or wire harness) to the circuits being monitored and secure as desired. The
leads (or wire harness) will be attached to the CT Interconnect Board. Each CT lead will
have a label (standard labels are CT1, CT2, CT3, etc.).
CTs
The BGS32 supports 9 to 32 split core or Rogowski coil CTs of varied amperage and size.
SPLIT CORE CTs
Split core CT Specifications
CT quantity
9 to 32
CT type
Split core
Accuracy
+/- 1.0%
Inside diameter
Varies by model
Outside dimensions (H x W x D)
Varies by amperage
Rated amperage
15A to 4000A
CT tail length
100 mm or 500 mm to quick disconnect
CT lead length
0.5 to 5 m
CT tail and lead wire
24 AWG, 600V twisted pair
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Connect CTs to conductors
1. Disconnect power to the BGS32 if possible.
If it is not possible to disconnect power, always treat CT leads as though
they carry line voltages. Work on live panels must only be performed by
qualified personnel.
2. Open the split core CT by opening the latch on the side of the CT (Figure 1).
3. Position the CT on the conductor such that the CT lead faces toward the load and
away from the source (Figure 2).
4. Close the CT and ensure the latch has clicked into place.
Connect CT tails to CT leads
CT leads coming from the CT Interconnect Board will typically be labeled CT1, CT2, CT3,
etc. unless otherwise specified. Connect the CT tail to the corresponding CT lead using the
quick connectors. The power monitor automatically detects the correct phase once load is
present. Current-only meters are not phase-specific.
Split core CTs produce an output of 333mV.
ROGOWSKI COIL SENSORS
Rogowski Coil Specifications
CT quantity
9 to 32
CT type
Coil sensor
Accuracy
+/- 1.0%
Maximum conductor diameter
68 mm, 147 mm, 211 mm, 306 mm
Coil length
250 mm, 500 mm, 700 mm, 1000 mm
Rated amperage
100A to 4000A
Cable length
2 m
Cable wire
26 AWG, 1000V wires
Figure 1
Figure 2
The side of the CT
with the leads faces
the load and away
from the source.
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Connect Rogowski coils to conductors
1. Disconnect power to the BGS32 if possible.
If it is not possible to disconnect power, always treat the coil leads as
though they carry line voltages. Work on live panels must only be
performed by qualified personnel.
2. Open the Rogowski coil by pinching the closing unit on the side of the connector.
3. Position the coil on the conductor such that the arrow on the connector faces
toward the load and away from the source.
4. Close the Rogowski coil and ensure the closing unit has clicked into place.
Connect Rogowski coil cables to CT leads
CT leads coming from the CT Interconnect Board will typically be labeled CT1, CT2, CT3,
etc. unless otherwise specified. Connect the Rogowski coil cable to the corresponding CT
lead using the quick connectors. The power monitor automatically detects the correct phase
once load is present. Current-only meters are not phase-specific.
The arrow on the coil
connector faces toward
the load and away from
the source.
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SECTION 4: OPERATIONS
Start Up
The BGS32 ships fully preconfigured. Once power is supplied, the system will automatically
connect to any Gateway that is within range and set to the same radio zone.
Each BGS32 contains up to four component meters. Each meter has LEDs that glow when
powered on. The cover of the BGS32 allows viewing the LEDs making it possible to verify
that all component meters are powered up and that the lights on the units are flashing in a
consistent manner.
Each BGS32 has a unique 16-digit ID number that can be found on a label located on the
outside of the unit in the top left corner. Each component meter also has a unique 16-digit ID
number on the meter’s front label. Once the meter makes a wireless connection to a Gateway,
the readings from that meter can be accessed via the Gateway’s console.
Packet Power provides documentation that is unique to each BGS32 and associates each CT
to its component meter. See Appendix for sample. This documentation is required in order to
access readings using protocols such as SNMP or Modbus. Customers using Packet Power’s
EMX application will be provided with panel maps to load into EMX.
At initial start-up, it is highly recommended to validate correct operations by placing a
known load on each circuit and verifying that the load is correctly reflected by the system,
first at the Gateway console to validate the physical connection, and then in the monitoring
application to validate the mapping logic.
Operation
Normal operation is characterized by the regular flow of monitoring data. This is typically
verified on a continual basis via the site’s monitoring application. Please consult the
monitoring application’s documentation for how to achieve this using your application.
To prevent damage to the BGS32, ensure power is
disconnected whenever abnormal or extreme
power conditions may exist such as during
infrastructure commissioning.
Instructions for accessing the Gateway console can be
found on the Packet Power web site:
https://dox.packetpower.com/Ethernet---Gateway---
Version---4---Web---Console.html
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