E-Mon E20-6003200J-D-KIT User Manual
62-0389-05
Class 2000 Meter
KWH & KWH/DEMAND METER
INSTALLATION INSTRUCTIONS
E-Mon
850 Town Center Drive
Langhome, PA 19047
(800)334-3666
www.emon.com
CLASS 2000 METER
Dear Valued Customer,
We are pleased that you chose to buy one of our products, and want you to be just as
pleased with owning it. Before installing your new E-Mon product, please read the
information on the following pages carefully.
We believe that you will find the E-Mon D-Mon meters easy to install and to use for
monitoring and evaluating your electrical usage.
To be sure that you are 100% satisfied with your products, we provide toll-free
technical and sales support Monday through Friday, 8:00 am to 7:30 pm, EST: (800)
334-3666. You may also reach us via e-mail at info@emon.com.
If you have questions, we can handle them quickly and effectively with a telephone call.
Please let us try to help you BEFORE you remove your meter. And to help us help you,
we ask that you have all relevant information on hand when you call (model or part
numbers, nature of difficulty, etc.)
Be sure to forward this manual to the owner after installation is complete, so that they
may use it as a reference guide when reading the E-Mon D-Mon meter.
Thank you.
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CLASS 2000 METER
TABLE OF CONTENTS
Section 1.0 Pre-Installation Information 4
Section 2.0 Safety Label Definitions and Information 6
Section 3.0 Precautionary and Safety Information 7
Section 4.0 Meter Installation 8
Section 4.1 Mounting the Meter 8
Section 4.2 Main Power Board Connections 8
Section 4.3 Current Sensor Installation & Wiring 11
Section 4.4 MAINS Line Voltage & Current Sensor Wiring
Diagrams
Section 4.5 Installation Overview 15
Section 4.6 Check Polarity of the Current Sensor 15
Section 5.0 Monitoring Multiple Loads with One Meter 19
Section 6.0 KWh Meter Features & Functions 21
Section 6.1 KWh Meter Display Features 21
Section 6.2 How to Read the kWh Meter 22
Section 6.3 KWh Meter Hardware Functions 23
Section 6.4 Class 1000 and Class 2000 Pulse Output Removable
Two-Screw Terminal Plug
Section 7.0 KWh/Demand Meter Features & Functions* 26
Section 7.1 KWh/Demand Meter Display Functions 26
Section 7.2 How to Read the kWh/Demand Meter 27
Section 7.3 Demand Display Set-Up 28
Section 7.4 Demand Reset 30
Section 7.5 Test Mode 32
Section 8.0 Preventative/Scheduled Maintenance 34
Section 9.0 Lithium Battery Replacement Instructions 35
Section 10.0 Troubleshooting Guide 37
Section 10.1 Line Voltage Diagnostics 38
Section 11.0 High Voltage Metering 41
Section 12.0 Frequently Asked Questions 44
Section 13.0 Meter Technical Specifications 46
Section 14.0 Meter Limited Warranty 49
* Applies to meters equipped with the Demand option.
14
24
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CLASS 2000 METER
1.0 PRE-INSTALLATION INFORMATION
The E-Mon D-Mon® Class 2000 kWh/Demand meter is a 3-element meter used to
monitor electric power usage of individual loads after the utility meter. Installation
must only be performed by qualified personnel and in accordance with these
instructions and all applicable local and national electrical codes. E-Mon or its
representatives assume no responsibility for damages or injury resulting from the
improper installation of this meter.
Meters are supplied in a UL Type 1 steel enclosure appropriate for indoor installation
where it will not be affected by the elements, such as moisture and extreme
temperatures.
Units designated by the “R” suffix on the model number have an extended
environmental operating range and are enclosed in a NEMA 4X enclosure to
accommodate outdoor environments.
Verify the input voltage rating and configuration on the meter label to ensure it is
suitable for the intended electrical services. For example, Class 2000 meters labeled
for 208V service MUST NOT be installed on service feeds of 480V and vice versa.
Verify the current sensors are sized suitably for the load to be monitored. Compare the
color of the arrows on the current sensors to the chart below to confirm the correct
current sensor is being used.
Sensor Arrow Color Code Sensor Rating
Brown 100 Amp
Red 200 Amp
Yellow 400 Amp
Black 800 Amp
Blue 1600 Amp
White/Black 3200 Amp
Meter Labeled: Works On:
120/240V 120/240V, 1 Phase
208V 208V, 3 Phase
240V 240V, 3 Phase
400V (380, 415) 400V, 3 Phase
480V 480V, 3 Phase
600V 600V, 3 Phase
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CLASS 2000 METER
CAUTION
WARNING
M33177
MAIN POWER
BOARD
DISPLAY AND
KEYBOARD
Internal circuit card components are extremely sensitive to electrostatic
discharge. Prior to handling or touching internal circuitry, discharge any
static buildup on your person. To discharge yourself, touch a grounded
metal object such as conduit or an earth grounded metal enclosure.
Use of this instrument, Class 2000, in a manner inconsistent with this
manual or not specified by the manufacturer in writing, can cause
permanent damage to the unit and/or serious injury to the operator. The
protection and safety features provided by this equipment may become
impaired or otherwise compromised.
NOTE: If any trouble arises during installation or functional verification opera-
tions, do not immediately remove unit. Before removing the unit, contact E-Mon’s technical support department at (800) 334-3666. E-Mon’s
technical department will assist you in detailed troubleshooting of the
Class 2000 installation.
1.1 Internal Electronic Assemblies
The unit is comprised of a Main Power Board, Display Board and Keyboard. All circuit
cards are mounted inside a UL Type 1 (standard) or NEMA 4X (optional) enclosure.
Fig. 1. Power Supply Board and Display Board.
NOTE: Units are supplied in a UL Type 1 metal enclosure suitable for indoor
applications only. Units supplied in the optional NEMA 4X fiberglass
enclosure are suitable for either indoor or outdoor applications, within
the defined specifications. Refer to Section 12.0 for a definition of suitable environmental conditions for indoor and outdoor units.
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CLASS 2000 METER
1.1.1 Main Power Board
Connections to this board include the MAINS Input Voltage, Current Sensors, external
IDR interface and Isolated Pulse Output. The MAINS input terminals are covered with
a protective shield for safety purposes. The current sensor assemblies interface to
three header connectors, labeled A, B, and C along with conductor color indication.
Each header connector input corresponds to an input voltage phase, so care must be
taken to ensure each current sensor is connected to the correct input header.
TB3
TB1
Fig. 2. Standard Configuration.
TB2
TB4
M33178
1.1.2 Display Board
The display connects to the main power board via a flex-ribbon cable and is mounted
on the inside of the enclosure door. The LCD readout indicates the cumulative kWh
and instantaneous kW value on kWh meters. The LCD readout indicates cumulative
kWh, peak demand and instantaneous kW values on kWh/ Demand meters).
2.0 SAFETY LABEL DEFINITIONS AND INFORMATION
The Green Class meter may contain one or more of the following labels. Operator(s)
should familiarize themselves with the meaning of each label to minimize risk.
The presence of this label is a cautionary indicator identifying a
danger risk. The manual should be consulted prior to proceeding.
The presence of this label indicates an electrical shock hazard exists
in the location or area where the label is placed. Prior to proceeding,
the MAINS power must be disconnected and the manual consulted for
safety information.
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CLASS 2000 METER
CAUTION
WARNING
WARNING
WARNING
3.0 PRECAUTIONARY AND SAFETY INFORMATION
Internal circuit card components are extremely sensitive to electrostatic
discharge. Be careful not to touch internal circuitry prior to discharging
any static buildup on your person. To discharge yourself, touch a
grounded metal object such as conduit or an earth-grounded metal
enclosure.
High voltages present on main PCB terminal block TB1 screw terminals.
Risk of serious injury and/or electrical shock exists. Prior to performing
any wiring operations, review all contents of the user manual and deenergize the MAINS power switch. Only qualified personnel should
perform installation wiring. Installation wiring must comply with all local
and national electrical codes.
Failure to ground the enclosure creates a possible shock hazard. Do not
operate the Class 2000 meter without a protective earth wire attached
securely to the PE terminal screw. After installing protective earth wiring,
secure the screw tightly (7in-lb torque.)
NEVER open front panel of unit while unit has MAINS power applied.
Failure to comply can increase the risk of serious injury and/or electrical
shock.
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CLASS 2000 METER
3 (76)
7-1/2
(191)
M33627
6 (152)
4 (102)
6-3/4
(171)
4.0 METER INSTALLATION
4.1 Mounting the Meter
Using the appropriate sized mounting hardware, fasten the Class 2000 meter
enclosure to the selected mounting surface. The four mounting holes are centered
6.75” H x 4” W. The mounting hole spacing is identical for either the UL Type 1 or
NEMA 4X enclosure.
NOTE: Only the NEMA 4X plastic enclosed unit is suitable for outdoor environ-
mental conditions. Units housed in UL Type 1 JIC steel enclosures must
only be installed in indoor environments where it will not be affected by
the elements, such as moisture and extreme temperatures.
Fig. 3. Enclosure Dimensions.
4.2 Main Power Board Connections
1. Install a temporary ground for ESD (Electrostatic Discharge) protection. With all
circuits de-energized, connect a temporary protective earth ground connection
for ESD protection. Prior to performing any unit wiring, be sure to discharge any
static on your person.
2. Install the Class 2000 Protective Earth Ground. Connect an earth ground wire to
the Class 2000 protective earth ground terminal screw located on the right side
of the line voltage terminal block. After installing the protective earth ground wire,
securely fasten the protective earth ground screw.
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CLASS 2000 METER
WARNING
Failure to attach the protective earth ground wire securely to the
enclosure creates a potential shock hazard. Do not operate the Class
2000 meter without a protective earth ground connection securely
installed.
3. Wire Entry.
a. Two openings exist on the unit enclosure, one for 1/2” conduit and one for 3/
4” conduit. The 3/4” conduit opening located on the bottom of the enclosure
is used to bring in MAINS Power (voltage lines to power meter) and current
sensor wiring. The 1/2” conduit opening located on the top of the enclosure
is used to interface low voltage signals, such as the IDR interface and isolated pulse output. (Outdoor enclosures equipped with one 3/4” conduit
opening on bottom of enclosure only.)
b. Route the appropriate cabling to and through the respective enclosure open-
ing. The conduit and fittings interfacing the enclosure entrances must be UL
listed and properly sized to the enclosure port diameter, The interfacing fitting must use a gasket seal ring to interface between the conduit fitting and
the enclosure entry point. After installing the conduit fitting and conduit, verify
that the conduit fittings are aligned properly to their respective enclosure
entrance ports and tightened securely to prevent moisture entry. VERIFY
that each conduit slip nut is securely tightened to its respective conduit fitting.
c. Outdoor applications require the use of the optional 4X enclosure. The same
principles outlined for indoor meter installations as defined in the aforementioned paragraph carry over and apply to outdoor installations with one
exception. The exception is that the conduit and fittings for outdoor installations require an outdoor material rating and approval for 4X applications.
4. Unit MAINS Wiring (Voltage Wiring Connections)
a. Remove the shield located over the phase A,B and C screw terminals on the
main power board. This shield can be removed by pulling back on the latch
on the right side of the shield and lifting up on the front. Wire each connection to the terminal block with stranded wire 14-12 AWG, rated at 600 VAC.
b. Strip back all wire insulation to expose between 1/4” and 3/8” of the copper
conductors. Gently twist each wire to prevent fraying. Insert the conductors
into their respective terminal block position and tighten down the terminal
block screw to securely fasten the conductor. The terminal block is clearly
labeled PHASE A, PHASE B, PHASE C and NEUTRAL.
c. Connect the NEUTRAL wire to the appropriate terminal block position.
NOTE: For Delta MAINS input wiring, DO NOT connect the NEUTRAL wire.
Remove the terminal block screw for this position.
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CLASS 2000 METER
d. Connect the AC mains power wires (Phase A, Phase B and Phase C) to their
respective positions as labeled on terminal block.Tighten the screws to 7 inlb of torque.
e. After all conductors are connected to their respective terminal block positions
and tightened down, verify that each terminal block screw is securely fastened by gently tugging on each conductor. Verify no conductor wires are
frayed or are shorting to adjacent terminal block positions.
5. External Switch Mechanism/In-Line Fuse Installation
a. To ensure a safe installation, the Class 2000 meter requires an external
switch mechanism, such as a circuit breaker, be installed on the Class 2000
MAINS input wiring. The switch mechanism must be installed in close proximity to the meter and easily reachable for the operator. This device must
also be marked as the disconnecting device for the Class 2000 meter.
b. Install 1/10 Amp Slow Activation in line fuses with the suitable voltage rating
for each conductor phase at the MAINS input to the meter. The fuses must
be labeled to indicate voltage and current rating as well as element characteristics. The fuse element must be slow activating type.
6. Once the MAINS wiring is complete, replace the clear Lexan protective shield
over terminal block TB1 and close the enclosure front panel. Secure the enclosure cover using the locking mechanism. Activate the external circuit breaker or
equivalent switch to apply AC MAINS power to the unit.
7. The Class 2000 meter display should turn on and indicate total kWh accumulation reading.
NOTE: On demand meters (meters ordered with "-D-") the unit display, clock
and other critical configuration parameters will be set once the unit
installation and wiring is complete.
8. Using an AC Voltmeter, verify the input voltage readings are within the limits
specified below.
Meter Input Voltage
Configuration Nominal Voltage Limits (+/- 10%)
120/208V, 3 Ph, 4 Wire 120 VAC (L-N) 108 to 132 VAC
277/480V, 3 Ph, 4 Wire 277 VAC (L-N) 249 to 305 VAC
240V, 3 Ph, 3 Wire 240 VAC (L-L) 216 to 264 VAC
480V, 3 Ph, 3 Wire 480 VAC (L-L) 432 to 528 VAC
347/600V, 3 Ph, 4 Wire
347 VAC (L-N) 540 to 660 VAC
(WYE Only)
9. Remove power from the unit by de-energizing the external switch.
NOTE: For 3-Wire systems, the voltages are measured Phase to Phase. On 4-
Wire systems the voltages are measured Phase to Neutral.
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CLASS 2000 METER
4.3 Current Sensor Installation & Wiring
Once the AC voltages have been confirmed to be within acceptable limits, you are
ready to install the current sensors. The MAIN power board contains three header
connectors located at the bottom right of the board. The connectors are labeled A, B,
and C along with conductor color indication. This format must be followed in order for
the meter to function correctly.
The Class 2000 meter will be used with one of two basic types of current sensors:
a. Split-Core Current Sensor: This sensor opens so that it can be attached
around the circuit conductor being monitored without interrupting power.
Unless otherwise specified, all Class 2000 meters are supplied with this
sensor type.
b. Solid-Core Current Sensor: This sensor does not open and requires the
monitored conductor be removed from the circuit to install the current sensor.
This type is only supplied when specified at time of order.
NOTE: The unit serial label specifies if the unit is set up for split or solid core
current sensors. See ordering information for details.
Both types of current sensors output a 0-2 VAC signal proportional to the current being
measured.
The current sensors must be matched with the voltage phases. The A phase sensor
must be monitoring the same phase as the A phase voltage. B & C phase sensors
must also monitor the same phase as their respective voltage inputs.
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CLASS 2000 METER
M33213
LOAD
SOURCE
4.3.1 Installing the Split-Core Current Sensor Assembly
Each phase being monitored will require one two-piece current sensor assembly.
Therefore, a three-phase meter will require three (3) assemblies. Open the two-piece
current sensor assembly by releasing the nylon clamp using a flat head screwdriver.
Fig. 4. Split-Core Current Sensor Assembly.
1. Reassemble the current sensor assembly around the conductor(s) to be moni-
tored. Ensure the current sensor halves marked “Load” are both facing the load
side of the conductor. The colored arrow will be on the source side of the conductor being monitored and MUST be pointed in a clockwise direction around
the conductor being monitored. Tighten the nylon clamp to complete the assembly.
Fig. 5. Arrow On The Current Sensor Assembly.
IMPORTANT:
When looking from the source side of the conductor(s) being monitored, you
should see the arrow on the current sensor assembly. The arrow should be
pointing in a clockwise direction around the conductor(s) being monitored. If
the arrow is not positioned on the source side, inaccurate readings will result.
62-0389-05 12
CLASS 2000 METER
4.3.2 Installing the Solid-Core Current Sensor Assembly
The optional solid-core current sensors can be installed in the same applications as
the standard split-core units, however, the conductors that they are monitoring must
first be disconnected.
NOTE: Under no circumstances is this operation to take place without shutting
off the power to the conductor(s) being monitored.
With the power off, disconnect the conductor from its breaker or terminal. Slide the
solid-core current sensor over the conductor, making sure that the indicator on the
sensor is pointing in the direction of the load. After this is done, reconnect the
conductor and verify that it is properly installed.
Run the black and white wires from the solid-core current sensors and install them
according to the standard installation diagram. When this is completed, the power to
the monitored conductor can be turned back on.
Fig. 6. Solid-core Current Sensor.
4.3.3 Current Sensor Wiring
Once all the current sensors are installed on their appropriate phase conductors, you
can begin terminating the current sensors on to the Class 2000 main power board.
The current sensor leads can be extended up to 2,000 feet (using #14-22 AWG wire)
for remote monitoring applications. Consult your local electrical codes for proper wire
sizing (#22 AWG twisted pair wire with a black and white conductor, rated for 600 VAC
recommended.)
The current sensor connection points are located on the bottom right of the main
power board. Three removable plugs exist, one for each current sensor phase input.
The header portions of the connectors are labeled A, B and C. Text on the plastic cover
of each of the connectors instruct you which terminal of the plug is for the white
conductor and which terminal is wired to the black conductor. Once each current
sensor is wired to its respective plug, insert each plug into the appropriate header,
verifying polarity as they are installed (see section 4.6).
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CLASS 2000 METER
LINE VOLTAGE
CURRENT SENSORS
N
LOAD SOURCE
M33185
3-PHASE, 4-WIRE INSTALLATION DIAGRAM
NOTES:
LINE VOLTAGE CONNECTIONS: #14-12 AWG
SENSOR CONNECTIONS: B = BLACK LEAD W = WHITE LEAD
NEUTRAL NOT USED IN DELTA SYSTEM. REMOVE NEUTRAL TERMINAL
BLOCK SCREW FOR DELTA SYSTEMS.
1/10A 600 VAC INLINE FUSE PER CONDUCTOR. LITTLEFUSE PART
NUMBER KLDR.100.
1
1
1
1
C
W B W B
N
PE
W B
LINE VOLTAGE
CURRENT SENSORS
LOAD SOURCE
M33186
3-PHASE, 3-WIRE INSTALLATION DIAGRAM
NOTES:
LINE VOLTAGE CONNECTIONS: #14-12 AWG
SENSOR CONNECTIONS: B = BLACK LEAD W = WHITE LEAD
NEUTRAL NOT USED IN DELTA SYSTEM. REMOVE NEUTRAL TERMINAL
BLOCK SCREW FOR DELTA SYSTEMS.
1/10A 600 VAC INLINE FUSE PER CONDUCTOR. LITTLEFUSE PART
NUMBER KLDR, 100.
1
1
1
1
W B W B
N
PE
W B
4.4 MAINS Line Voltage & Current Sensor Wiring Diagrams
Fig. 7. 3-Phase, 4-Wire Installation Diagram.
Fig. 8. 3-Phase, 3-Wire Installation Diagram.
62-0389-05 14
CLASS 2000 METER
M34224
METER TERMINAL
BLOCK CONNECTIONS
CURRENT SENSOR AND
VOLTAGE CONNECTIONS
4.5 Installation Overview
Fig. 9. Install Overview.
4.6 Check Polarity of the Current Sensor.
Verify all phases are loaded by at least 1% of meter rated load, check the polarity of
the sensors.
Test the sensors wires one pair at a time, verifying polarity, phase rotation and
correspondence to line input.
The A/C line voltage power may be left on to the meter as long as the protective clear
shield is installed to cover the line side meter power supply terminals for safety. Extra
care must be taken when working around live circuits.
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CLASS 2000 METER
1. Disconnect the Gray current sensor plugs for current sensor B and C phase
inputs (see Fig. 10).
POWER LED
PULSE LED
ERROR LED
M34955
Fig. 10. Error LED
With only the A sensor wires connected to the sensor A input verify if the error LED is
clear (Green LED is off).
If Error LED is clear then the A sensor input leads polarity is correct.
If the Error LED does not clear, then disconnect the gray plug and reverse the input
leads for A sensor by putting the white leads on the black input and the black leads on
the white input, (swapped polarity). If it clears, the “Sensor Error” then mark this pair
with a piece of masking tape as the A sensor and note polarity. Next disconnect the
gray plug for the A input. Marking them with tape as A and noting the polarity.
62-0389-05 16
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