Honeywell 500 User Manual
62-0304-05
Class 500 Advanced KWh/Demand
Meter
INSTALLATION INSTRUCTIONS
APPLICATION
The Class 500 Meter is a 3-element meter with communications. The device is 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.
CLASS 500 ADVANCED KWH/DEMAND METER
SPECIFICATIONS
Input Voltage Configuration:
3-wire (Delta) or 4-wire (WYE)
Mains Voltage Input:
Up to 600 VAC RMS available
Input Power:
6 VA maximum rating
Current Sensor Rating:
Up to 3200 Amp RMS AC available
Power Factor:
.5 leading or lagging
Line Frequency:
50-60 Hz
Metering Accuracy:
Certified to ANSI C12.16
Voltage Operating Range:
+/-10% of rated load
Temperature Range (Class 500):
NEMA 4 (Outdoor) Housing: -20 ºC to +70 ºC
NEMA 12 (Indoor) Housing: -20 ºC to +50 ºC
Relative Humidity Range:
0-95% non-condensing
Altitude:
2000 meters maximum
Voltage Overload:
+25% continuously; +100% for 20 cycles
Outdoor Housing Rating (Model numbers with an R at the
end):
NEMA 4
Indoor Housing Rating (Model numbers without an R at
the end):
NEMA 12
Display Readout:
KWh accumulated
Standard Ranges:
(3 or 4 Wire) 120/208-240V: 100,200,400,800,1600, 3200
Amp
(3 or 4 Wire) 277/480V: 100,200,400,800,1600, 3200 Amp
(4 Wire) 346/600 V: 100,200,400,800,1600, 3200 Amp
RS485 Serial Communication Interface:
Cable Specifications: UL listed/rated telephone cord,
4 conductor, 300VAC, stranded conductors, 22-26 AWG.
Input/Output Voltage: Ground isolated +/-5.4 VDC
Cable Connector: RJ-11 connector
Ckt Input Isolation: 5.3 KVAC
Max Cable Distance: 4000 feet
Max Network Nodes: Maximum cabling nodes 52
including master node
Baud Rate: 9600
Communications Options:
RS232/RS485 (Standard) (Requires E-Mon Energy.)
Telephone Modem (Requires E-Mon Energy.)
Ethernet (Requires E-Mon Energy.)
Modbus RTU or TCP/IP (Requires third-party EMS/BMS.)
BACnet IP or MS/TP (Requires third-party EMS/BMS.)
LONworks TP (Twisted Pair) (Requires third-party EMS/
BMS.)
Current Sensor Overload:
100% for 1 minute without damaging meter
Pollution Degree:
Degree 2 In accordance with IEC 664
Installation (Overvoltage) Category:
Category III
Measurement Category:
Category III
Recommended In-Line Fuse:
Manufacturer: Littelfuse
Mfg Part No.: KLDR.100
Rating:100 mA, time delay. 600 VAC cartridge fuse
Battery Cell:
Description: Non-rechargeable cell used for memory
retention.
Manufacturer: Eagle-picher
Mfg Part No.: LTC - 3 P N
Working Voltage: 3.5 Vdc
Current Capacity: 350 mAHr
Electrolyte: Lithium thionyl nitrate
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CLASS 500 ADVANCED KWH/DEMAND METER
CAUTION
WARNING
WARNING
WARNING
INSTALLATION
VERIFY the input voltage rating and configuration on the unit panel label to ensure it is suitable for the intended electrical service.
Meters labeled for 115/208 volt service MUST NOT be installed on service feeds of 277/480 volt and vice versa.
VERIFY that the Class 500 Meter 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.
Table 1. Sensor arrow color and rating
Sensor Arrow Color Code Sensor
Brown 100 Amp
Red 200 Amp
Yellow 400 Amp
Black 800 Amp
Blue 1600 Amp
White/Black 3200 Amp
Internal circuit card components are extremely sensitive to electrostatic discharge. Prior to handling or touching
the internal circuitry, discharge any static build-up on your person. To discharge yourself, touch a grounded
metal object such as conduit or an earth grounded metal enclosure.
Use of the Class 500 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.
High voltages are present on main power terminal block, TB1. Risk of serious injury and/or electrical shock
exists. Prior to performing any wiring operations, review all the contents of the user’s 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 500 Meter without a
protective earth wire attached securely to the PE terminal screw. After installing the protective earth wiring,
secure the screw tightly (10 N-m torque). NEVER open the front panel of the unit while the unit has MAINS power
applied. Failure to comply can increase the risk of serious injury and for electrical shock.
Internal Electronic Assemblies
The unit is composed of two major subassembly boards: the main power and display boards (See Fig. 1).
NOTE: Units supplied in a NEMA 12 metal enclosure are suitable for indoor applications only. For outdoor installation, use the
NEMA 4 enclosure.
POWER SUPPLY BOARD
DISPLAY BOARD
M28750
Fig. 1. Subassembly boards in the Class 500 Meter.
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CLASS 500 ADVANCED KWH/DEMAND METER
WARNING
MAINS INPUT TERMINALS
TB2, TB3 AND TB4 SENSOR INTERFACES
M28745
Main Power Board
Connections to this board include the MAINS input voltage, current sensors, and external pulse input (See Fig. 2).
The MAINS input terminals are covered with a protective clear shield for safety purposes. The current sensor assemblies
interface to TB2, TB3 or TB4. Each header connector input corresponds to an input voltage phase; therefore, care must be
exercised to ensure each current sensor is connected to the correct input header.
Fig. 2. MAINS power board of the Class 500 Meter.
Display Board
The display board interconnects to the main power board via a flex ribbon cable, and the board mounts on the inside of the
housing door. The only required connection is for RS485 communications. When the meter is operated as a stand-alone unit
using the modem for communications, the RS485 connections are not required. The display board LCD readout indicates the
cumulative kWh value as well as errors associated with the Class 500 Meter, such as low battery or sensor errors.
METER INSTALLATION
Mounting
1. Using appropriate sized mounting hardware, fasten the Class 500 Meter enclosure to the selected mounting surface. The
four housing mounting holes are centered 6.75” H x 4” W.
NOTE: Units installed outdoors must use the NEMA 4—rated enclosure.
Main Power Board Connections
1. Installing a temporary ground for ESD protection: With all the 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 500 Meter protective earth ground: Connect an earth ground wire to the Class 500 Meter protective
earth ground terminal screw located on the bottom right side of the main power board. After installing the protective earth
ground wire, securely fasten the protective earth ground screw.
Failure to attach the protective earth ground wire securely to the enclosure creates a potential shock hazard. Do
not operate the meter without a protective earth ground connection securely installed.
3. Wire entry: Two openings exist on the standard enclosure; one for 1/2” conduit and one for 3/4” conduit. The 3/4” conduit
opening located on the bottom edge of the housing is used to bring in MAINS power and current sensor wiring. The 1/2”
conduit opening located on the top edge of the housing is used to interface the low voltage signals and RS485 communications wiring to the unit. Route the appropriate cabling to and through the respective enclosure opening.
4. Unit MAINS wiring:
a. Remove the clear shield located over terminal block TB1 on the main power board. This shield can be removed by
pressing in on each locking tab located at the top of each standoff. While pressing the tabs inward, lift the shield from
the standoffs. Wire each connection to terminal block TB1 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’s con-
ductors to prevent fraying. Insert the conductors into their respective terminal block position and tighten down the terminal block screw to securely fasten the conductor. Terminal block TB1 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 500 ADVANCED KWH/DEMAND METER
d. Connect the three AC mains power wires (PHASE A, PHASE B, and PHASE C) to their respective positions as labeled
on terminal block TB1. After all conductors are connected to their respective terminal block positions and tightened
down, verify each terminal block screw is securely fastened by gently tugging on each conductor. Verify that no conduc-
5. External switch mechanism/in-line fuse installation:
6. Once the MAINS wiring is complete, close the enclosure front panel and secure the panel to the enclosure using the lock-
NOTE: The unit display, clock, schedule, and other critical configuration parameters will be reset once the unit is completely
7. Using an AC voltmeter, verify that the input voltage readings are within the limits specified in Table 2.
tor wires are frayed or shorting to adjacent terminal block positions.
a. To ensure a safe installation, the Class 500 Meter requires an external switch mechanism, such as a circuit breaker, be
installed to the Class 500 Meter MAINS input wiring. The switch mechanism must be installed in close proximity to the
Class 500 Meter and be easily reachable for the operator.
This device must also be marked as the disconnecting device for the Class 500 Meter.
b. Install 1/10 Amp Slow Activation inline 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 a slow-activating type.
ing mechanism. Activate the external circuit breaker or equivalent switch to apply AC MAINS power to the unit. The Class
500 Meter display should turn on and indicate total kWh accumulation reading.
wired and ready for commissioning. Resetting and configuring these parameters must be done through a host computer,
locally or remotely, via an RS485 or ethernet link.
NOTE: On 3-wire systems the voltages are measured Phase to Phase.
On 4-wire systems the voltages are measured Phase to Neutral.
Table 2. Input voltage limits
Meter Input Voltage/Configuration Normal Voltage Limits (+/-10%)
120/208V, 3Ø, 4 Wire 120 VAC 108 to 132 VAC
277/480V, 3Ø, 4 Wire 277 VAC 249 to 305 VAC
346/600V, 3Ø, 4 Wire 346 VAC 311 to 381 VAC
240V, 3Ø, 3 Wire 240 VAC 216 to 264 VAC
480V, 3Ø, 3 Wire 480 VAC 432 to 528 VAC
8. Remove power from the unit by de-energizing the external switch.
Current Sensor Installation and 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 center of the board, TB2, TB3, and TB4.
TB2: Phase A current sensor input
TB3: Phase B current sensor input
TB4: Phase C current sensor input
The Class 500 meters are shipped with split-core current sensors.
1. Split-core current sensor: This sensor opens so that it can be attached around the circuit conductor being monitored without interrupting power.
2. Split-core current sensors output a 0-2 VAC signal, proportional to the current being measured.
Installing the Split Core Current Sensor Assembly
1. 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.
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.
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