Setra Power Battalion 48 Operating Manual
October 2017
Operator’s Guide
Power Squad 12
Power Battalion 48
Networked Metering Systems
and
Headstart
Software
ii
Operator’s Guide: Power Squad 12 & Battalion 48 Power Meters ©2017 Setra Systems, Inc. All rights
reserved.
This manual may not be reproduced or distributed without written permission from Setra Systems.
Windows®, Windows® 7, Windows® 8, Windows® 10, and Notepad® are registered trademarks of
Microsoft Corporation.
Setra Systems | 159 Swanson Road | Boxborough, MA 01719 USA
Phone 1-800-257-3872 | www.setra.com
iii
Table of Contents
TABLE OF CONTENTS
Table of Contents .............................................................................................................. iii
Introduction ....................................................................................................................... 5
Unpacking the Unit .......................................................................................................................... 5
Power Meter Anatomy .................................................................................................................... 6
Power Meter Safety Summary and Specifications ........................................................................... 7
Symbols on Equipment .................................................................................................................... 7
Symbols in Documentation .............................................................................................................. 7
Meter SAFETY .................................................................................................................... 9
Planning For Field Installation .......................................................................................... 10
Project Manager Aspects ............................................................................................................... 10
Configuration & Data Viewing Options ................................................................................... 10
Information Access by Interface Type ..................................................................................... 11
Meter Configuration Overview ...................................................................................................... 12
Meter Installation Overview ......................................................................................................... 12
Verification & Communication Overview ...................................................................................... 13
RTU Programming and Scripting Overview .................................................................................... 13
Meter Configuration - Details ........................................................................................... 14
Install the Software ........................................................................................................................ 14
Connect the Meter using USB (Power & Communications) .......................................................... 14
Alternate Connection .............................................................................................................. 15
Headstart Software Overview ........................................................................................................ 16
Headstart Documentation ............................................................................................................. 17
Headstart Documentation—Instructional Videos ............................ Error! Bookmark not defined.
Configuring Electrical Components using Headstart Software ......... Error! Bookmark not defined.
Configuring Communications using Headstart .............................................................................. 18
Web Application Overview ............................................................................................................ 19
Connect to Web Application using USB .................................................................................. 19
Connect to Web Application using Ethernet ........................................................................... 19
Meter Installation - Details ............................................................................................... 20
Meter Mounting Configurations .................................................................................................... 20
Installation Sequence .............................................................................................................. 21
Connecting Voltage ................................................................................................................. 23
Wiring the Meter in a 3-wire, Split ɸ Service Panel....................................................................... 24
Wiring the Meter in a 4-wire, 3 ɸ Service Panel ............................................................................ 25
Current Transformer Basics ........................................................................................................... 26
Wiring the CTs to the Meter .......................................................................................................... 27
Communication & Verification - Details ............................................................................ 28
Physical Connections on an RS-485 Multidrop Network ............................................................... 28
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Table of Contents
Communication Verification .......................................................................................................... 29
Headstart/ Web Application .................................................................................................... 29
Physical Interface Verification ....................................................................................................... 30
Serial Setup Verification .......................................................................................................... 30
LAN Ethernet Network Verification ......................................................................................... 30
DHCP ........................................................................................................................................ 30
STATIC IP .................................................................................................................................. 30
Protocol Verification ...................................................................................................................... 31
Modbus Settings ............................................................................................................................ 31
Modbus RTU Settings .............................................................................................................. 31
Modbus TCP Settings ............................................................................................................... 31
BACnet Settings .............................................................................................................................. 31
BACnet MSTP ........................................................................................................................... 31
BACnet IP ................................................................................................................................. 31
Pulse Outputs ................................................................................................................................. 32
Open Collector Output ............................................................................................................ 32
ALARM (SPDT) ................................................................................................................................ 33
12 Volt Auxiliary Power .................................................................................................................. 33
Security PIN Protection .................................................................................................................. 34
Access Restriction Limitations ................................................................................................. 34
Headstart – UnRestricted Access ............................................................................................ 34
USING THE PERMISSION REGISTERS........................................................................................ 34
Read Only Permission Register ................................................................................................ 34
Read/Write Permission Register ............................................................................................. 35
Verification of CT Installation ........................................................................................................ 36
Installation Phase Verification ................................................................................................. 36
Phase Checking By Phaser Plot ................................................................................................ 37
CT Orientation Check ..................................................................................................................... 38
RTU Programming and Scripting - Details .......................................................................... 39
Register Organization..................................................................................................................... 39
Element vs System Scope ........................................................................................................ 39
Configuring Element and Channel Register for Service Types ................................................ 40
Configuring System Registers .................................................................................................. 41
Modbus Protocol Commands ........................................................................................................ 42
BACnet ........................................................................................................................................... 43
Appendix A— LCD Menu Navigation ................................................................................. 44
Appendix B—Enclosure Dimensions ................................................................................. 47
Appendix C—Mounting Templates ................................................................................... 48
Appendix D—Technical Specifications .............................................................................. 51
5
INTRODUCTION
There are two meters in the Setra Power Meter Series: the Power Squad 12 (SPS12) and the Power
Battalion 48 (SPB48). These meters monitor the voltage, current, power, energy, and many other
electrical parameters on single and three-phase electrical systems. Both meters use direct connections
to each phase of the voltage and current transformers to monitor each phase of the current.
Information on energy use, demand, power factor, line frequency, and more are derived from these
voltage and current inputs.
The Setra power meters are not meant to be a standalone energy recorders; rather they are connected
as a slave device to a data logger, Remote Terminal Unit (RTU), or Building Management host network.
The meter communication interfaces include Ethernet (LAN) and RS-485 serial. BACnet MS/TP and
Modbus RTU are the two communication protocols that operate over an RS-485 serial network and
BACnet IP and Modbus TCP are supported over Ethernet. A USB port is also provided as the preferred
connection for on-site configuration and can be run concurrently with an RTU.
Unpacking the Unit
The Power Squad 12 & Power Battalion 48 can be ordered with optional product features which are
identifiable on the part number label.
Part Numbering Scheme
Each Setra power meter shipment also includes the following items:
▪ Meter with Options Installed – Serial Number, MAC ID, and FCC ID indicated on side label.
▪ Pluggable Connectors (2 voltage, 50 three-position terminals, 3 two-position terminals)
▪ Thumb drive containing Headstart Software, Register List, Manual, Tutorial Videos
▪ Certificate of Calibration (COC) for each unit
6
Introduction
Power Meter Anatomy
All user connections are made on the circuit board. Connectors are identified by function and include
polarity markers.
Element ID
Element ID
LCD Display
Navigation
Buttons
Plate
Ground
Serial #
Model #
MAC ID(s)
Voltage
Input 1
Voltage
Input 2
SPB48 (mounting plate version shown)
7
Introduction
Power Meter Safety Summary and Specifications
This general safety information is to
be used by both the Logger operator
and servicing personnel. Setra
Systems, Inc. assumes no liability for
user’s failure to comply with these
safety guidelines.
SPS12-B-y-z, SPS12-C-y-z
SPB48-B-y-z, SPB48-C-y-z
SPS12-C-y-z
SPB48-C-y-z
The Meter Family conforms to the
following:
Setra Power Meter Series:
Conforms to UL Std 61010-1, 3rd
Edition
Certified to CSA Std C22.2 No.
61010-1, 3rd Edition
Setra Power meters need to be installed in a user-supplied UL Listed/ uR Recognized enclosure in order to comply with
NEC and local electrical codes.
The Setra Power Meter is an Over-Voltage Category III device. Use approved protection when operating the device.
CAUTION: THIS METER MAY CONTAIN LIFE THREATENING VOLTAGES. QUALIFIED PERSONNEL MUST DISCONNECT
ALL HIGH VOLTAGE WIRING BEFORE SERVICING THE METER WITH THE HIGH VOLTAGE TOUCH SAFE
COVER REMOVED.
Symbols on Equipment
Denotes caution. See manual for a description of the meanings.
DENOTES HIGH VOLTAGE. RISK OF ELECTRICAL SHOCK. LIFE THREATENING VOLTAGES MAY BE PRESENT.
QUALIFIED PERSONNEL ONLY.
Equipment protected throughout by double insulation (IEC 536 Class II).
Symbols in Documentation
Contains additional information pertinent to current subject
DO NOT EXCEED 346V Line to Neutral or 600 volts Line to Line. This meter is equipped to
monitor loads up to 346V L-N. Exceeding this voltage will cause damage to the meter and
danger to the user. Always use a Potential Transformer (PT) for voltages in excess of 346V LN or 600 volts line to line. The Setra meters are 600 Volt Over Voltage Category III device.
8
Introduction
MAINTENANCE
There is no required maintenance with the Power Squad 12 or Battalion 48. Abide by the following items:
Cleaning: No cleaning agents, including water, shall be used on the Power Squad 12 or Battalion 48.
If the meter appears damaged or defective, first disconnect all power to the meter. Then call or email technical
support for assistance.
Setra Systems, Inc.
Boxborough, MA USA
Phone: 1-800-257-3872
www.setra.com
Email: techsupport@setra.com
9
METER SAFETY
Building Service Safety Requirements (Load Center, etc.)
Equipment intended for use with field-installed current transformers that could be installed in panel
boards or switchgears shall observe the following:
Always open or disconnect circuit from power-distribution system (or service) of building before
installing or servicing current transformers.
A circuit breaker used as a disconnect must meet the requirements of IEC 60947-1 and IEC 60947-3
(Clause 6.11.4.2)
Current transformers may not be installed in equipment where they exceed 75 percent of the wiring
space of any cross-sectional area within the equipment.
Current transformers may not be installed in an area where they block ventilation openings.
Current transformers may not be installed in an area of breaker arc venting.
Not suitable for Class 2 wiring method nor intended for connection to Class 2 equipment.
Secure current transformer and route conductors so that they do not directly contact live terminals or
bus.
CTs shall be listed to UL2808
Meter Installation Safety Requirements
Setra meters must be installed in accordance with local electrical codes.
Use copper conductors only.
Connection to the mains terminals shall be made with 14 AWG minimum wire gauge.
External secondary inputs and outputs should be connected to devices meeting the requirements of
IEC 60950
The following additional requirements apply for Recognized board versions of the Setra meter
1) For use only with Listed Energy-monitoring Current Transformers
2) Associated leads of the current transformers shall be maintained within the same overall
enclosure.
3) Unless the current transformers and its leads have been evaluated for REINFORCED
INSULATION, the leads must be segregated or insulated from different circuits.
4) The current transformers are intended for installation within the same enclosure as the
equipment. These may not be installed within switchgears and panel boards” or similar.
10
Planning for Field Installation
PLANNING FOR FIELD INSTALLATION
Project Manager Aspects
Meter installation often includes coordination between individuals or groups of people with different
responsibilities. Spend a few minutes considering who will be executing each portion of the installation
and what tools are needed at each stage. Things to consider include determining how to communicate
with the meter, setting address configuration, installing Headstart, access to passwords, etc. The more
tasks completed before installation means less time in the field. The following section gives an overview
of these activities followed by details in the next section.
CONFIGURATION & DATA VIEWING OPTIONS
The Power Squad 12 and Battalion 48 meters have three methods for configuration and data viewing.
The most powerful interface is provided with a PC, Laptop or Tablet running Windows and is encouraged
for complex installations. The second interface is intended for smart phones or tablets that can connect
over USB or Ethernet. The third interface (LCD) is intended for intermittent end user observation and is
restricted in capability. The RTU can also be used for configuration if communication settings are already
established. The feature set of each interface is summarized next.
11
Planning for Field Installation
INFORMATION ACCESS BY INTERFACE TYPE
Setra Interface Options
Customer
Device
PC or Laptop Running
Headstart Software
Smart Device or Tablet
via
WebPage
LCD on Meter
(if equipped)
RTU
(Host System)
Modbus /BACnet
When
Used
Meter Setup
Field Visit
Field Visit
End User
Building
System
Real Time Values
All Meter Parameters
Waveform Capture
Harmonic Analysis
All Element View
Phasor Plot
All Meter Parameters
Multi Element View
Voltage
Current
VA
VAR
kWh
Single Element View
All Meter Parameters
Configuration
Entire Meter
Visual Guides
Copy / Paste
Entire Meter
Text Based
Communications Only
Entire Meter
Register Based
Security PINs
Enforced
Factory Support – Level 3
Read Only – Level 1*
Read / Write – Level 2*
Read Only – Level 1*
Read / Write Level 2*
(limited to communication)
Factory Support – Level 3
* If PINs are configured
12
Planning for Field Installation
Meter Configuration Overview
▪ Work performed ahead of the installation saves time in the field and results in fewer
mistakes!
Tools
Typical Work
• Desktop or Laptop PC
• USB Type AB Cable (preferred) or
Ethernet & USB wall charger (> 500 mA)
• Thumb Drive (Headstart Installer)
• Electrical Schematics of project
• Installation of Headstart Software
• Connect USB/Ethernet cable from PC to
meter
• Establish communication with meter
• Firmware update (if desired)
• Configure software for anticipated meter
setup
• Field wiring documentation
Meter Installation Overview
▪ Performed by licensed electrician.
Tools
Typical Work
• Mounting hardware (customer supplied)
• Wiring & supplies, labels, wire ties
• Tablet, Smart Device, or
Laptop PC
• Multi Meter, Current Clamp
• Camera
• Mechanical mounting
• Electrical installation
• Install voltage cover
• Apply power to meter
• Confirm basic operation of meter
13
Planning for Field Installation
Verification & Communication Overview
▪ Can be modified with power applied to the meter.
Tools
Typical Work
• Tablet, Smart Device (Web Page Based), or
Laptop PC (Headstart Software)
• On site trouble shooting
• Multi Meter, Current Clamp
• Camera
• Locate the power meter
• Confirm RTU device
• Add wire terminations (if required)
• Confirm meter communication settings
• Meter health metrics (check for setup
errors)
• Analytics (Headstart Software)
• Correct instrumentation
• Set security PINs
• Checklist
RTU Programming and Scripting Overview
Tools
Typical Work
• Laptop PC (Remote Access to RTU)
• Remote trouble shooting
• Register List
• Confirm meter communication settings
• Confirm communication protocols
• Exercise remote connectivity
• Run configuration scripting
• Confirm data integrity
14
METER CONFIGURATION - DETAILS
This section is written to support setting up the SPS12 and SPB48 in an office
environment and configuring the power meter for a pre-determined configuration. In
many cases the setup is standardized for an organization or project. In other cases, the
setup can be documented and forwarded to an electrician as a wiring schedule. The
setup can also be performed on site and reflect “as built” configurations.
Install the Software
Insert the Headstart thumb drive into the computer or download from https://www.setra.com
The installer should start automatically. If it does not, browse the thumb drive and locate the
HeadstartInstaller.exe program. Start the installer by double-clicking HeadstartInstaller.exe and follow
the installer instructions.
Connect the Meter using USB (Power & Communications)
Preferred Connection via USB AB Cable
The preferred method for configuring the meter from a locally connected computer is through the USB
interface which provides power to the meter as well as communications. The meter will draw 500mA
from the USB port which may overload “out of spec” USB hosts. If the meter fails to power from USB,
the alternate method (described below) must be used.
1) Plug the meter into the USB port (Setra Systems will appear on the LCD (if equipped).
2) Launch the Headstart application and press the “CONNECT USING USB” button on the pop-up
window.
The meter should now be communicating. Headstart is an intuitive application, read the Headstart
overview section (below) for additional information on configuring the meter.
15
Meter Configuration
ALTERNATE CONNECTION
If configuration using USB is not available, the Ethernet connection can also be used provided the meter
can be powered from a voltage source such as a customer-supplied USB wall charger (>500mA) or from
AC power, if the meter is already installed.
Alternate Connection
1) Connect the meter to an Ethernet LAN Router running a DNS Server.
2) Apply power to the meter.
3) Observe the IP address displayed on the LCD screen (Splash Screen) or navigate to About Meter
using the meter push button interface (see Appendix A).
You may also connect directly to a Laptop or Desktop PC, but your IP Address and Subnet must
match the meter to connect to it (summarized below).
4) Launch the Headstart application and press the “CONNECT USING ETHERNET” button on the pop
up window.
5) The meter should now be communicating. Headstart is an intuitive application; read the
Headstart overview section (below) for additional information on configuring the meter.
16
Meter Configuration
Headstart Software Overview
Headstart is a Windows application and is the most versatile software tool for configuring and verifying
a Setra meter. All functions and menus are accessed under the central drop-down list which has a
content filter for viewing basic metering data or extended data that can be helpful in
troubleshooting. The information displayed in the drop-down list for each filter setting is summarized
below.
Display Data
Real Time Values
Power
Energy
Demand
Real Time Values
Power
Energy
Demand
Power Factor
Waveform Capture
Harmonics
Meter Setup
Communication Setup
Connect to Meter
Advanced
About the Meter
Meter Setup
Communication Setup
Connect to Meter
Advanced
About the Meter
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