eGauge Systems LLC EG4xxx Owner's 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 commissioning 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 environment. 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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2.2 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 multipole breaker depending on phases used.
• Black, red, and white stranded AWG 12 wire; length depending on installation 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 distribution 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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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 installation. 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 example, 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 transformers.
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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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 disconnecting 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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The unit also has an Ethernet port (RJ45 connector) which can be used to hardwire the device to a Local Area Network (LAN). It also has two USB ports (TypeA 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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Figure 3: AC Mains Connector
Pin: Name: Description:
1 L1 Wire to phase 1 of building supply.
2 N Wire to building’s Neutral.
3 L2 Wire to phase 2 of building supply for split- and three-phase
installs.
4 Unused. Leave unconnected.
5 L3 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 measured to calculate power used/generated on phase L1, and it carries the powerline 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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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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