E-Mon E32-6003200REZ7KIT User Manual

62-0390-02

Class 3200 Meter

ADVANCED KWH/DEMAND METER

INSTALLATION INSTRUCTIONS

E-Mon

850 Town Center Drive

Langhorne, PA 19047

[phone]

www.emon.com

[e-mail]

CLASS 3200 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:
[phone]. You may also reach us via email at [e-mail].

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 3200 METER

TABLE OF CONTENTS

Section 1.0 Introduction 4

Section 2.0 Internal Electronic Assemblies 6

Section 2.1 Main Power Board 6

Section 2.2 Display Board 7

Section 3.0 Meter Technical Specifications 8

Section 4.0 Safety Label Definitions and Information 10

Section 5.0 Precautionary and Safety Information 11

Section 6.0 Meter Installation 12

Section 6.1 Mounting the Class 3200 Meter 12

Section 6.2 Main Power Board Connections 12

Section 6.3 Phasing of Line Voltage 15

Section 6.4 Current Sensor Installation & Wiring 16

Section 6.5 Main Power & Current Sensor Wiring Diagram 18

Section 6.6 Line Voltage/Current Sensor Diagnostics 18

Section 6.7 RS-485 Wiring 19

Section 6.8 RS-232 Communications 22

Section 6.9 Modem Wiring 24

Section 6.10 Modbus RTU Wiring 27

Section 6.11 BACnet MS/TP Wiring 28

Section 6.12 Connecting Class 3200 Meters to USB Key using RS485 28

Section 6.13 Ethernet Communications 29

Section 7.0 Multiple-Load Monitoring 30

Section 8.0 Preventative/Scheduled Maintenance 31

Section 9.0 Lithium Battery Replacement 32

Section 10.0 Class 3200 Meter Operating Modes 34

Section 10.1 Start Up Screens 34

Section 10.2 Normal Mode Display Screens 35

Section 10.3 How to Program the Display Screens 36

Section 11.0 High Voltage Metering 41

Section 12.0 Class 3200 Protocol Definitions 45

Section 13.0 Meter Limited Warranty 51

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CLASS 3200 METER

1.0 INTRODUCTION

The E-Mon D-Mon® Class 3200 meter is a 3-element meter with communications. The
device is used to monitor electric power usage of individual loads after the utility meter
and store kW and kVAR data for automatic meter reading. Installation must only be
performed by qualified personnel and in accordance with these instructions and all
applicable local and national electrical codes. E-Mon and its representatives assume
no responsibility for damages or injury resulting from the improper installation of this
meter.

Verify the input voltage rating and configuration on the unit panel label to ensure that it
is suitable for the intended electrical service. Class 3200 meters labeled for 120/208V
service MUST NOT be installed on service feeds of 277/480 volts or 347/600 and vice
versa.

Verify that the Class 3200 meter’s 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 A

Red 200 A

Yellow 400 A

Black 800 A

Blue 1600 A

White/Black 3200 A

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CLASS 3200 METER

CAUTION

WARNING

Internal circuit 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 enclosure.

Use of this instrument, the E-Mon D-Mon Class 3200 meter, 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 the installation or functional verification opera-

tions, do not immediately remove the unit. Before removing the unit, contact
E-Mon’s technical support and/or engineering department at [phone].
E-Mon’ s technical department will assist you in detailed troubleshooting of
the Class 3200 meter installation and assist you in getting the unit operating
correctly.

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CLASS 3200 METER

2.0 INTERNAL ELECTRONIC ASSEMBLIES

The units are comprised of two major subassembly boards, the main power board and
the display board. Both circuit boards are mounted inside a UL Type 1 or Type 4X
enclosure.

MAIN
POWER
BOARD

DISPLAY
BOARD

M33307

Fig. 1. Internal Electronic Assemblies.

2.1 Main Power Board

Connections to this board include the MAIN Power Input and current sensors.The
MAIN Power Input terminals are positions one through four on the four position screw
terminal block, TB1. These terminals are covered with a protective shield for safety
purposes. The current sensor assemblies interface to TB2, TB3 and TB4. Each
terminal block corresponds to an input voltage phase; care must be exercised to
ensure that each current sensor is connected to the correct terminal block. One three
terminal screw connector is provided for RS-485 communications.

TB1
POSITIONS
1-4

TB2, TB3,
TB4

Fig. 2. Main Power Board Connections.

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RS-485

M33308

CLASS 3200 METER

M33279

DOWN

UP

SELECT

MENU

2.2 Display Board

The display board connects to the main power board via a flex ribbon cable and the
board mounts on the inside of the housing door.

The Class 3200 meter features a 4-line LCD display that indicates multiple meter data
points.

Fig. 3. Display Board.

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CLASS 3200 METER

M33191

EXAMPLE: E 32- 208 200 J RTU KIT

E-MON
CLASS 3200 METER
INPUT VOLTAGE (208V)
CURRENT RATING (200A)

ENCLOSURE (METAL - TYPE 1)
PROTOCOL (MODBUS)
SENSORS (SPLIT-CORE)

3.0 METER TECHNICAL SPECIFICATIONS

Ordering Information: Define brand, class, input voltage, amperage, protocol, and
sensor type in the format A-BB-CCC-DDDD-E-FFF-GGG, where

A = Brand: E for E-Mon
BB = designates Class: 3200 (32), 3400 (34), or 5000 (50) meter
CCC = input voltage: (208, 480, 600, 120 volt for High Voltage)
DDDD = current rating: (100, 200, 400, 800, 1600, 3200, 25HV)
E = enclosure: J = metal (type 1), R = non-metallic (type 4X), M = MMU
FFF= protocol: RTU = Modbus, BAC = BACnet, EZ7 = proprietary
GGG = Sensors: KIT = split-core, SCS = solid-core, “blank” = none supplied

Input Voltage

3-wire (delta) Or 4-wire (wye)

Configuration

Mains Voltage Input Up To 600 VAC RMS available

Input Power 6 VA maximum rating

Current Sensor

Up To 3200 amps RMS AC available

Rating

Power Factor 0.5 leading or lagging

Line Frequency 50-60 Hz

Metering Accuracy ANSI C12.20

Temperature Range -20C to +50C

Relative Humidity

0-95% non-condensing

Range

Altitude 2000 meters maximum

Voltage Overload +25% continuously: +100% For 20 cycles

Current Sensor

100% for 1 minute

Overload

Pollution Degree Degree 2 in accordance with IEC 664

Installation
(Overvoltage)
Category

Measurement
Category

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Category III

Category III

CLASS 3200 METER

3.0 METER TECHNICAL SPECIFICATIONS
(CONTINUED)

Enclosure Material UL Type 1 or Type 4X

Display Readout LCD

Standard Ranges (4-Wire Wye) 208 VAC: 100, 200, 400, 800,1600, 3200 Amp

RS-485 Serial
Communications
Cable

(3-Wire Delta) 240 VAC: 100, 200, 400, 800,1600, 3200 Amp
(4-Wire Wye) 480 VAC: 100, 200, 400, 800,1600, 3200 Amp
(3-Wire Delta) 480 VAC: 100, 200, 400, 800,1600, 3200 Amp
(4-Wire Wye) 600 VAC: 100, 200, 400, 800,1600, 3200 Amp

Cable: UL-listed/rated/3-conductor,

300 VAC, stranded
conductors, 22-26 AWG.

Input/output Voltage: Ground-isolated +/-5.4Vdc

Cable Connector: Screw terminal termination

Circuit Input Isolation: 5.3kVAC

Max Cable Distance: 4000 feet

Max Network Nodes: 64 cabling nodes (including

master)

Baud Rate: 9600, 19200, 38400, 76800

Recommended
In-Line Fuse

Battery Cell: Description: Non-rechargeable cell used for

Manufacturer: Littlefuse

Mfg. Part No: KLDR.100

Rating: 100mA, time-delay, 600VAC

cartridge fuse

memory retention

Manufacturer: Panasonic

Mfg Part No: CR2032

Working Voltage: 3Vdc

Current Capacity 225 mAHr

Electrolyte: Manganese Dioxide Lithium

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CLASS 3200 METER

4.0 SAFETY LABEL DEFINITIONS AND
INFORMATION

The 3200 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 3200 METER

CAUTION

WARNING

WARNING

WARNING

5.0 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 de-energize 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 3200 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 3200 METER

WARNING

6.0 METER INSTALLATION

6.1 Mounting the Class 3200 Meter

Use appropriately sized mounting hardware to fasten the Class 3200 enclosure to the
selected mounting surface. The four housing mounting holes are centered 6.75” H x 4”
W. When the meter is provided in the 4X rated enclosure, the hub must be mounted to
the conduit first before connecting it to the enclosure.

NOTE: Units housed in UL type 1 enclosures must only be installed in indoor loca-

tions, where they will not be affected by the elements.

6.2 Main Power Board Connections

1. Installing a temporary ground for ESD 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. Installing the Class 3200 protective earth ground: Connect an earth ground wire
to the Class 3200 (Type 1 enclosure) protective earth ground lug with a torque of
7 N-m.

Failure to attach the protective earth ground wire securely to the meter creates
a potential shock hazard. Do not loosen or remove the screw securing the
ground lug.

Fig. 4. Main Power Board Connections.

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CLASS 3200 METER

6.2 Main Power Board Connections (continued)

3.

Wire Entry:

enclosures. This opening is used for bringing in MAINS power and for current
sensor wiring. One 1/2” conduit opening on the top of the metal enclosure
CL3200 can be utilized as an interface for the low- voltage signals, pulse input,
or RS-485 communications wiring to the unit. CL3200 meters are available in an
MMU (Multiple Meter Unit) enclosure that holds eight (8) meters. This enclosure
comes without knockouts and allows the user to choose entry points for the wir­ing.

Any unused openings must be sealed with a UL rated plugging device or hub
suitable for the rating of the enclosure - such as NEMA 1 or 4X

4. Unit MAINS wiring:
The four positions on terminal block TB1, located at the bottom left corner of the
main power board, are clearly labeled Phase A, B, C, N (neutral). Earth Ground
MUST be connected to the PCB mounting screw in the lower right corner.
A. Connect the NEUTRAL wire to the appropriate terminal block position.

One 3/4” conduit opening is located on the bottom of the CL3200

.

Fig. 5. Terminal Block TB1, TB2, TB3, and TB4.

NOTE: For 3-wire delta-type applications, do NOT connect the NEUTRAL wire.

Remove the terminal block screw for this position.

B. Earth Ground

Connect the Earth Ground to the PCB mounting screw in lower right corner.

C. External Switch Mechanism/In-Line Fuse Installation

To ensure a safe installation, the Class 3200 meter requires an external
switch mechanism, such as a circuit breaker, be installed on the meter’s
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 3200 meter. 1/10
Amp Slow Activation in line fuses (KLDR.100, UL listed, Littelfuse rated
600V/100ma) must be installed 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.

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CLASS 3200 METER

6.2 Main Power Board Connections (continued)

D. Connect the three AC main power wires (Phases A, B and C) to their respec-

tive positions as labeled on terminal block TB1. After all conductors are con­nected to each of their respective terminal block positions and tightened to 7
in-lb, verify that each terminal block screw is securely fastened by gently tug­ging on each conductor. Verify that no conductor wires are frayed or shorting
to adjacent terminal block positions.

E. Turn ON the AC main power input. The meter display will light up and scroll

through 6 displays. Each display is visible for 5 seconds. Display screens are
as follows:

Screen 1 - Total kilowatt-hours (kWh) consumed
Screen 2 - Peak demand (kW) with date & time stamp
Screen 3 - Actual load (kW)
Screen 4 - RMS Amps
Screen 5 - RMS Volts Phase to Neutral
Screen 6 - RMS Volts Phase to Phase
Screen 7 - Power factor (PF) per phase

F. Verify the voltage readings on Screen 5 using an AC voltmeter. Typical read-

ings shown below are measured phase to neutral (L-N) for 4 wire and phase
to phase (L-L) for 3 wire. Readings should be +/- 10% of nominal.

Meter Type Nominal Voltage Limits (+/- 10%)

208V, 3ø, 4 Wire 120 VAC (L-N) 108 to 132 VAC

480V, 3ø, 4 Wire 277 VAC (L-N) 249 to 305 VAC

600V, 3ø, 4 Wire 347 VAC (L-N) 312 to 380 VAC

240V, 3ø, 3 Wire 240 VAC (L-L) 216 to 264 VAC

480V, 3ø, 3 Wire 480 VAC (L-L) 432 to 528 VAC

NOTE: Meters are powered by phases A and B. The displayed voltages will be the

measured AC voltage between phases.

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CLASS 3200 METER

6.3 Phasing of Line Voltage

The 3-phase AC power input must be in proper phase sequence. If the sequence is
incorrect or a phase is missing, there will be a message on the meter’s display: “PH
Sequence Error” or “PH Missing:. (Refer to the section on Line Voltage Diagnostics if
this message is present.) When the line voltage is connected correctly, the meter’s
display will be blank (no message.)

Wait for the 4-line meter display to scroll to the voltage display. Verify that the meter
reads correct voltages on all three phases. Repeat Step 6.2.4F.

Once the meter displays the correct line voltages and there are no error messages,
you are ready to connect the current sensors to the meter. Before continuing with the
installation, verify that the six screens display as follows:

Screen 1 (kWh): Should read 0.0 kWh; if not, should be reset.

Screen 2 (kW Peak Demand): kW peak should read 0.0 kW. There will not

be a date/time stamp yet. If there is a kW
peak recorded, it should be reset later.

Screen 3 (kW Load): Should read 0.0 kW load.

Screen 4 (Amps per Phase): There should be 0.0 on all three phases.

Screen 5 (Volts RMS Phase to Neutral): See the section 6.2.4.F.

Screen 6 (Volts RMS Phase to Phase): See the section 6.2.4.F.

Screen 7 (Power Factor Per Phase): There should be 0.0 PF on all three phases.

NOTE: The meter will be reset later via the software during “startup” procedures.

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CLASS 3200 METER

M33213

LOAD

SOURCE

6.4 Current Sensor Installation & Wiring

Once the AC voltages have been confirmed to be within acceptable limits, you are
ready to install the current sensors. TB2 is the input for Phase A, TB3 is the input for
Phase B and TB4 is the Phase C input.

The Class 3200 meter can be used with two types of current sensors:

1. Split-core current sensor. This sensor opens so that it can be attached around
the circuit being monitored without interrupting power.

2. Solid-core current sensor. This sensor does not open and requires the monitored
conductor to be removed from the circuit to install the current sensor. This type is
only supplied when specified at time of order.

NOTE: It is recommended that a UL listed current sensor be used for this application.

6.4.1 Installing the Split-Core Current Sensor Assembly

1. Each phase being monitored will require one two-piece current sensor assembly.
Open the two-piece current sensor assembly by releasing the nylon clamp using
a flathead screwdriver.

Fig. 6. Split Core Sensor.

2. Reassemble the current sensor assembly around the conductor(s) to be moni­tored. 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. 7. Split Core Sensor.

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.

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