Redbusbar CircuitSpy 80 User manual

CircuitSpy 80
Communications Module
Installation & Operation
Manual
1
May 14
Added Portable information
CJD
CJD
0
Feb 14
Initial
DS
CJD
Rev
Date
Revision Description
By
Redbusbar

1 Overview
CircuitSpy allows any worker with a smart phone to measure voltages within a closed electrical panel.
CircuitSpy measures the voltages at each of its feed-through terminals and reports the
measurements, via WiFi, to a web browser.
CircuitSpy allows electrical workers to fault find energised electrical circuits without being exposed to
the risk of arc flash or electric shock. CircuitSpy is available in Portable or Fixed versions. The
Portable unit for fault finding known faults. The Fixed unit for monitoring equipment that is
inconvenient or difficult to access.
A block diagram of CircuitSpy Communications Module is shown in Figure 1.
Figure 1 CircuitSpy Communications Module

2 Warnings
Please note the following warnings in relation to the installation and operation of CircuitSpy:
1. If the equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.
2. The use of CircuitSpy is no substitute for “Testing for Dead” or “Live-Dead-Live Check” prior to
handling electrical conductors. “Testing for Dead” or “Live-Dead-Live Check” is a legal
requirement in most jurisdictions prior to handling electrical conductors.
3. All wiring must be installed by a licensed electrician in accordance with national standards.
4. Measuring terminals are not isolated from adjacent measuring terminals. Measuring terminals
on the one module can be connected to different nominal voltages provided that the
connected voltages return to the same node and are deliberately bonded in the external circuit
eg 240VAC and 110VAC neutrals and 24VDC and 12VDC negatives.
5. Measuring terminals incorporate overvoltage and over current protection internally.
Depending upon the application, wiring connecting CircuitSpy to the circuit node under test
may or may not be protected by upstream protection in the event of a wiring fault.
Consideration should be given at the time of installation whether additional fault protection
devices are necessary at each connection point.
6. During installation, connect measuring terminals in the following order GND, COM, 1 to 8.
7. CircuitSpy does not accurately display composite AC and DC voltages on any one terminal.
For accurate results, ensure that the CircuitSpy voltage mode settings are consistent with the
normal AC or DC characteristics of the measured voltage.
8. Connection and disconnection of all circuit connectors should be performed only while circuits
are de-energised.

3 Installation
3.1 Mechanical Installation
3.1.1 Fixed Unit
CircuitSpy attaches to a conventional “top hat” DIN rail. The case consumes a length of 121mm of
the DIN rail. The width of the case is 45mm. Plastic feet at the base of the CircuitSpy allow easy
installation and removal of the case using a flat blade screwdriver.
CircuitSpy should not be located within 100mm from a radio transmitter or heat radiating device.
3.1.2 Portable Unit
CircuitSpy incorporates two base mounted magnets such that it can be temporarily attached to
ferrous surfaces inside an electrical panel.
3.2 Electrical Installation
3.2.1 Fixed Unit
3.2.1.1 Power Supply
The required power supply for the operation of CircuitSpy is 12VDC with a maximum current capacity
of 0.1A, alternatively 24VDC with a maximum current capacity of 0.06A. Short circuit protection per
CircuitSpy by way of fuse or circuit breaker is not necessary. CircuitSpy incorporates an internal non-
replaceable fuse and reverse polarity protection.
3.2.1.2 Measuring Terminals
CircuitSpy measuring terminals should be connected in the following sequence:
GND –Ground or Earth conductor
COM –Common return conductor for all measuring terminals eg Neutral or 0VDC
1 to 8 - Measuring Terminals
CircuitSpy incorporates eight, line measurement terminals. Each conductor to be monitored is
connected to one feed-through terminal. The feed-through input terminal provides connection
functionality similar to that of a conventional DIN rail terminal. This approach simplifies retrofit
applications and reduces panel space in new installations.
Measuring terminals are not isolated from adjacent measuring terminals. However, input terminals
are isolated from the power supply terminals. The COM terminal provides a return path for all input
terminal current. Input terminals on the one module can be connected to different nominal voltages
provided that the connected voltages return to the same node and are deliberately bonded eg
240VAC and 110VAC neutrals and 24VDC and 12VDC negatives.
Measuring terminals incorporate overvoltage and over current protection. Depending upon the
application, wiring connecting CircuitSpy to the circuit node under test may or may not be protected
by upstream protection in the event of a wiring fault. Consideration should be given at the time of
installation whether additional fault protection devices are necessary at each connection point.
An electrical installation drawing for CircuitSpy is located in Appendix A.
3.2.2 Portable Unit
3.2.2.1 Power Supply

CircuitSpy is powered by a conventional 9V battery, type PP3. Insert the battery being careful to
comply with indicated polarity. CircuitSpy incorporates an internal non-replaceable fuse and reverse
polarity protection.
3.2.2.2 Measuring Terminals
CircuitSpy measuring terminals are arranged in banks to suit typical circuit measurements. Each
bank comprises a printed circuit board comb for as needed connection to the CircuitSpy terminals.
Table 1 below provides a guide that may be helpful when considering a circuit measurement and
selecting suitable terminal banks.
Circuit Measurement
Terminal
Voltage
Type
Voltage
Magnitude
Description
Bank
Location
AC
>50V
Phase to
Neutral
1 Phase
1 x 3 Terminal, Rd, Bk, Gr
Input 8, COM, GND
2 Phases
1 x 3 Terminal, Rd, Bk, Gr
1 x 2 Terminal, Bu, Yl
Input 8, COM, GND
Inputs 6, 7 (6 not used)
3 Phases
1 x 3 Terminal, Rd, Bk, Gr
1 x 2 Terminal, Bu, Yl
Input 8, COM, GND
Inputs 6, 7
DC
>125V
Pos to Neg
1 Node
1 x 3 Terminal, Rd, Bk, Gr
Input 8, COM, GND
2 to 3 Nodes
1 x 3 Terminal, Rd, Bk, Gr
1 x 2 Terminal, Bu, Yl
Input 8, COM, GND
Inputs 6, 7
AC
or
DC
< 50VAC or
< 125VDC
1 Node
1 x 3 Terminal, Rd, Bk, Gr
Input 8, COM, GND
2 to 3 Nodes
1 x 3 Terminal, Rd, Bk, Gr
1 x 2 Terminal, Bu, Yl
Input 8, COM, GND
Inputs 6, 7
4 to 5 Nodes
1 x 3 Terminal, Rd, Bk, Gr
1 x 2 Terminal, Bu, Yl
1 x 3 Terminal, Bu, Yl, Gr
Input 8, COM, GND
Inputs 6, 7
Inputs 3, 4, 5
6 to 8 Nodes
1 x 3 Terminal, Rd, Bk, Gr
1 x 2 Terminal, Bu, Yl
1 x 3 Terminal, Bu, Yl, Gr
1 x 2 Terminal, Rd, Bk
Input 8, COM, GND
Inputs 6, 7
Inputs 3, 4, 5
Inputs 1, 2
Table 1
Each test lead is provided with a 2mm shrouded test plug. The following circuit connectors are
provided:
4 x Terminal Test Plugs –Connection to test socket in DIN rail terminals
4 x Crocodile Clips –Connection to busbar and exposed bolt heads
4 x Magnet Electrodes –Connection to recessed screws and bolts
Connection and disconnection of all circuit connectors should be performed only while the circuit node
under test is de-energised.
3.3 Initialisation
3.3.1 Power Up
Following installation, but before powering CircuitSpy, confirm by measurement that the applied
voltage is within specified ranges. If correct voltage is available, apply power to CircuitSpy and
confirm that the green Power LED is illuminated.
3.3.2 WiFi Connection
Following power up, establish the WiFi connection between CircuitSpy and a WiFi device
incorporating a web browser using the following procedure:
1. Enable WiFi on the mobile device or computer
2. Navigate to the wireless connections settings on the mobile device or computer to view the
available wireless access points

3. Find the wireless access point “CircuitSpy”and connect to this access point. A rescan may be
necessary to display available access points if the device does not automatically refresh
4. The mobile device or computer should display a message confirming that the connection was
successful
5. Navigate to the web browser on the mobile device or computer
6. Enter circuitspy.com into the address bar (URL) of the browser and press enter to navigate to
the operation page of the CircuitSpy. The operation page should be displayed in the browser
as indicated in Figure 2 below. In addition, CircuitSpy WiFi transmission activity is indicated
by the white Comms LED. Each Comms LED flash indicates data transfer to and from
CircuitSpy
Figure 2 Operation Page

4 Configuration
Following initialisation, CircuitSpy should be configured using the following procedure:
1. Tap the Configuration button in the top left hand corner of the CircuitSpy Operation page
2. The CircuitSpy Configuration page, as indicated in Figure 3 below should now be displayed
3. Edit the Panel Name (optional) by tapping on the Panel Name field that is currently displaying
“CircuitSpy”. Refer below for Panel Name guidance
4. Edit the Module Name (optional) by tapping on the Module Name field that is currently
displaying “Module 1”. Refer below for Module Name guidance
5. Edit the Terminal Name for terminal 1 (optional) by tapping on the Terminal Name field that is
currently displaying “Point 1”. Refer below for Terminal Name guidance
6. Select the nominal voltage level for terminal 1 (required for terminal colour animation) by
tapping on the Vnominal Level drop down list that is currently displaying “240V”. Refer below
for Vnominal Level guidance
7. Repeat steps 5 and 6 above for terminals 2 to 8 as required
8. Select the nominal voltage mode for the module (mandatory) by tapping on the Vnominal
Mode drop down list that is currently displaying “AC”. Refer below for Vnominal Mode
guidance
9. Tap the Save button in the bottom right hand corner of the CircuitSpy Configuration page to
save your changes and return to the Operation page.
Any changes to the fields in the configuration page will not be executed until the Save button is
pressed. To cancel any changes made, either navigate back to the operation page, or click on the
Cancel button.
Panel Name: The Panel Name is also the access point name of the CircuitSpy WiFi module. A 32
character limit on the Panel Name field applies. When the Panel Name is modified and saved, WiFi
communication with CircuitSpy is immediately lost. Reconnection to CircuitSpy can be achieved by
repeating the WiFi Connection procedure to the newly named Panel Name (access point). For
installations where more than one CircuitSpy is within WiFi range, each Panel Name must be unique
to allow connectivity to all CircuitSpy devices.
Module Name: A unique name that identifies the terminal strip when terminal strip labels are used eg
X1. The Module Name field could be used for multiple terminal strip identification within the one
electrical panel.
Terminal Name: A unique name that identifies the terminal when terminal labels are used eg X1-23,
24VDC. Alternatively, wire labels corresponding to equipment schematics could be used eg PS236,
K1.
Vnominal Level: The nominal voltage of the terminal when energised. In other words, it is the
highest voltage appearing at the terminal during normal operations. The selected setting is not used
for voltage value spanning. The selected setting is used for colour animation of the background
behind each terminal’s real time voltage measurement value.
Vnominal Mode: The nominal voltage mode of the module. Select from either AC or DC. The
selected setting is used for voltage value calculation, as such it is a mandatory setting. CircuitSpy
does not accurately display combined AC and DC voltages on any one terminal. For accurate results,
ensure that the CircuitSpy voltage mode settings are consistent with the normal AC or DC
characteristics of the measured voltage.

Figure 3 Configuration Page

5 Operation
Following configuration, CircuitSpy can be viewed using the WiFi Connection procedure detailed
above. However, when scanning for available access points the modified Panel Name set during the
Configuration step will now be displayed instead of “CircuitSpy”
CircuitSpy WiFi range is not less than 10m when installed within a metal enclosure, while a 50m
range has been observed on occasion.
5.1 Operation Page
Figure 2 depicts the CircuitSpy Operation page. The Panel Name and the Module Name is displayed
at the top two lines of the page. The section immediately below the module name is the voltage
measurement table that displays the real time voltage present at the eight analogue input terminals.
Below the voltage indicator table is the core temperature of CircuitSpy processor. This temperature
may be used as an estimate of the temperature of the environment within the electrical enclosure.
Normally, the processor core temperature is about 5-10degC above the panel’s internal ambient air
temperature.
5.2 Voltage Measurement Table
The voltage measurement table displays the terminal name in the left-hand column and its
corresponding voltage in the right-hand column. The cells in the voltage column are dynamically
colour-coded and indicate to the user the state of the circuit: energised, de-energised or outside of the
normal on/off voltage range. For all states, the table indicates the actual voltage at the terminals.
Given a user configured nominal voltage, the table will behave as follows:
Voltage is less than or equal to 20% of the nominal voltage, the voltage cell will be green.
Voltage is between 21% and 79% of the nominal voltage, the voltage cell will be yellow.
Voltage is between 80% and 120% of the nominal voltage, the voltage cell will be red.
Voltage is greater than or equal to 121% of the nominal voltage, the voltage cell will be yellow.
For a given applied voltage, changing the nominal voltage (Vnominal) will only influence the colour of
the background of the voltage measurement cells. It will not influence the voltage displayed ie
changing the nominal voltage will not affect scaling, sampling or any other aspect of voltage
measurement. This ensures an accurate measurement of the applied voltage regardless of the
nominal voltage configuration.
It is important that the correct voltage mode, AC or DC, is selected to ensure accurate voltage
readings. For example, if the applied voltage is 12VDC, CircuitSpy will not display 12V when the
CircuitSpy is in AC voltage mode, and vice versa. This characteristic is a function of the analogue
input circuitry used to offer a wide input voltage range.
6 Maintenance
6.1 Calibration
A calibration check of each CircuitSpy voltage measurement terminal is recommended every 2 years.
A means does not exist to modify voltage calibration. An out of calibration condition requires that
CircuitSpy be removed from service and returned to Redbusbar for repair.
6.2 Cleaning
To clean CircuitSpy, wipe down with a soft cloth that is lightly dampened with water. Do not submerse
in water or use chemical or abrasive cleaners.

7 Troubleshooting
Table 2 below aims to provide a means to quickly troubleshoot any problem that you may be
experiencing with CircuitSpy operations.
Symptom
Possible Cause
Remedy
Power is applied but
the green LED is not
illuminated
Power supply voltage not within
range
Power supply input fuse has
blown
Measure the power supply voltage and confirm that it is within
range
Return to Redbusbar for repair.
CircuitSpy webpage
not available or takes a
long time to load or
refresh
Not connected to the wireless
access point
Excessive CircuitSpy WiFi
connections
Interrogate the wireless connections settings on the mobile
device or computer to find the wireless access point and
connect. Default name is CircuitSpy. If the Panel Name has
previously been changed, then look for this name.
If white Comms LED is flashing faster than once per second
then more than one device is connected. Try to remove
devices form the network.
Voltage measurements
do not agree with what
is expected or what a
multimeter displays
CircuitSpy is not configured to
the appropriate Vnominal Mode
for the voltage input at the
points, i.e. AC or DC.
The COM return path is not
functional
An analog input fuse has blown
Navigate to configuration page and change the Vnominal
Mode accordingly.
Investigate why the connected return wire is not offering a
functional return path for the measured terminal. Is there an
open circuit?
Return to Redbusbar for repair.
Table 2

8 Specifications
Application
Remote electrical circuit measurements using a web browser via WiFi. Replaces
DIN Rail Terminals. Metallic and non-metallic panel suitable.
Environment
Altitude - 0m to 2,000m
Temperature - 0C to 70C, 32F to 158F
Humidity –0% to 80%
Use –Indoor
Pollution Degree –2
Power Supply
Fixed - 12VDC, 0.10A or 24VDC, 0.06A
Portable –9V Battery, battery life approximately 2.5hrs continuous
Power Supply Terminals
(Fixed Unit)
Conductors - 0.2 to 2.5mmsq, 24 to 12AWG.
Tightening Torque - 0.5Nm to 0.6Nm.
Rated Temperature - -40C to 105C, -40F to 221F
Inputs
8 Voltage, Non Isolated
Voltage Measurement Range - 0 to 300VAC/DC, 50Hz-400Hz
Current Feedthrough Maximum –12A
Input Safety
CAT III, 300VAC (Line to Neutral)
Input Terminals
(Fixed Unit)
Conductors - 0.2 to 2.5mmsq, 24 to 12AWG.
Tightening Torque - 0.5Nm to 0.6Nm.
Rated Temperature - -40C to 105C, -40F to 221F
Test Leads
(Portable Unit)
1 x 3 Terminal, Rd, Bk, Gr, CAT III, 1kV
1 x 2 Terminal, Bu, Yl, CAT III, 1kV
1 x 3 Terminal, Bu, Yl, Gr, CAT III, 1kV
1 x 2 Terminal, Rd, Bk, CAT III, 1kV
4 x Terminal Plugs
4 x Crocodile Clips
4 x Magnet Electrodes
WiFi Capacity
Maximum 4 simultaneous clients
Minimum WiFi range (external to panel) = 10m
Web Browser
Compatibility
W3C compliant web browsers as follows:
Chrome (Android mobile devices & PCs)
Safari (Apple mobile devices & Macs)
Firefox (Mobile devices)
Note: Internet Explorer currently not supported
Web Browser
Configuration
Panel Name (unique WiFi Access Point)
Module Name
Terminal Name
Voltage Mode (module configurable) –AC or DC
Voltage Level (individually configurable) –12, 24, 32, 48, 110, 120, 220, 230, 240,
277
Web Browser Operation
8 Voltages
Resolution –0 decimal point
Accuracy –±2% FS ±1 digit @ 25C, 77F
Thermal Drift –0.005V/degC, 0.015V/degF
Background Colours
oGreen = 0 to 20% Vnom
oYellow = 21 to 79% Vnom
oRed = 80 to 120% Vnom
oYellow > 120% Vnom
CPU Temperature
Update Time - 1 second
Size
(Fixed Unit)
(Portable Unit)
45W x 121H x 45D, 1.75”W x 4.75”H x 1.75”D
45W x 186H x 45D, 1.75”W x 6.50”H x 1.75”D
Degree of Protection
Terminals = IP2X (IEC 60529 not certified by UL)
Approvals
Australia
Nil
Europe
Nil
USA/Canada
Designed to UL 61010-1 2nd Ed
Designed to CSA 22.2 No. 61010-1-04

Appendix A