INSTALLATION MANUAL - Multitel

INSTALLATION MANUAL

© All rights reserved. Multitel 2018. Printed in Canada.

INSTALLATION MANUAL

BRANCH CIRCUIT MONITORING BOX

Author: C. April, Y. Létourneau, S. Méthot

Publication date: November 15, 2018

Version 1

Last review: November 15, 2018

INSTALLATION MANUAL

© 2018 Multitel – Branch Circuit Monitoring Box – Installation Manual 2

TABLE OF CONTENTS

Table of Contents .................................................................................................................. 2

Document versions ................................................................................................................ 2

1. Product overview ........................................................................................................... 3 1.1 BCM Box Components ........................................................................................................3

2. Installation assumptions ................................................................................................ 6 2.1 Material provided ..............................................................................................................7

3. BCM box installation ...................................................................................................... 8 3.1 BCM physical installation ...................................................................................................9

4. Wiring the BCM box ..................................................................................................... 10 4.1 Powering the BCM box ..................................................................................................... 10 4.2 Setup the Modbus trunk .................................................................................................. 11 4.3 Setup the SMX slave ID .................................................................................................... 14

5. AC Power CT wiring ...................................................................................................... 15 5.1 CT Installation .................................................................................................................. 15 5.2 CT Lead wires ................................................................................................................... 16 5.3 CT Connections ................................................................................................................ 17

6. DC Power CT wiring – “future section” ......................................................................... 18

DOCUMENT VERSIONS

Version Date

MM/DD/YYYY Description Author

1.0 11/15/2018 Initial release. C. April,

Y.Letourneau, S. Méthot

INSTALLATION MANUAL


1. PRODUCT OVERVIEW The BCM box (Branch Circuit Monitoring) from Multitel enhances the visibility of your power infrastructures and improves power capacity planning. The BCM box is available in two flavors, one for the monitoring of DC power circuits, such a DC power system primary and secondary distribution loads and the other for AC power circuits, such as small 21/42-circuit AC panels or large main power distribution cabinets loads. Both flavors are available in 12, 24, 36 and 48 inputs (number monitored circuits) to adjust to your monitoring application. A good rule of thumb is to leave 10% of free inputs for future needs.

1.1 BCM BOX COMPONENTS

The BCM box uses the SMX-24AI (Smart Expansion Module) from Multitel packaged in a NEMA 1 box for easy wall mounting options. The SMX-24AI provides up to 24 analog inputs each, the BCM-48 will have two SMX-24AI side by side. All SMX-24AI inputs are routed to terminal blocks and wire channels are placed on the edge for routing the numerous CT cables outside the BCM box through available knockouts around the box. All pre-existing wires are fully tested at Multitel factory. Depending on the BCM box model, one or two SMX-24AI module(s) are pre-installed inside the hinged door. Each SMX is reference to X & Y for CT wiring reference (See CT wiring).

INSTALLATION MANUAL


The SMX-24AI analog input channels are factory calibrated according to the type of current transducer. The scaling factor for each analog input channel can also be configured at the factory based on the engineering detail requirements provided ahead of time to Multitel. Note that custom configuration fees may apply. If so, a wiring sheet will be provided along with the BCM box to instruct where each CT is to be wired. The SMX-24AI are communicating Slave Modbus RTU with a Multitel FUSION monitoring device (not include) via an RS-485 two wires communication link. The BCM box for DC Power circuits is compatible to 50mV shunts or specially designed DC Hall Effect Transducers. For AC Power circuits, the CT must have the 0-333mV output standard.

All CT will have a maximum current rating, the analog input scale factor must be adjusted to match the CT current rating. Also, the front end of the analog input circuitry must match the sensor type to perform the proper measurements. Refer to the following table when editing the analog input channel configuration.

APPLICATION TYPE FRONT

END SENSOR

TYPE TRANSDUCER SCALE

BCM box for DC Power

DC Power Current for Branch Circuit Monitoring of PDF and

DC distribution feeds, individual battery string charging & discharging current, etc.

Use 50mV shunts or DC CT providing a 0-4Vdc output

signal.

±50mv

50mV Shunts Shunts value

±10Vdc

50A DC CT 125

100A DC CT 250

250A DC CT 625

500A DC CT 1250

INSTALLATION MANUAL


BCM box for AC Power

AC Current of 21 or 42 circuit panel and large size main

power distribution cabinets.

Strictly use CT providing a 0-333mV output signal.

1.4Vrms

50A AC CT 595

100A AC CT 1189

200A AC CT 2378

400A AC CT 4757

600A AC CT 7135

1500A AC CT

17835

2000A AC CT 23783

INSTALLATION MANUAL


2. INSTALLATION ASSUMPTIONS SAFETY WARNING! Current transformers (CTs) are typically installed in electrical equipment with lethal high voltage levels. For maximum safety, we recommend de-energizing live circuits before installing current transformers (CTs). In all cases, only a licensed electrician should install current transformers. All NFPA and NEC rules should be followed.

• A BCM box installation requires skilled technical staff who are at ease with setting up IP and Modbus network setting, configurating intelligent devices.

• A detailed engineering document shall be provided by the customer or Multitel for each project, detailing installation location, powering options, CT wiring reference, Point description, Modbus communication trunk settings and alarms management (if need be).

• Please refer to the FUSION user manual as this installation outlook does not demonstrate:

o How to navigate thru the FUSION Web browser or Command Line interfaces;

o How to properly configure the FUSION I/O operating parameters; o How to setup/change scaling factors, inverted signs and other small

adjustment to be made during commissioning; o How to upload new FUSION firmware, configuration files or graphic

pages. If the configuration has to be performed in the field, note that the installer must be familiar with the FUSION Web interface and configuration of various operating parameters. This document does not provide information related to FUSION configuration, refer to the FUSION user manual for more detailed information. The SMX-24AI analog input configuration can only be edited from the FUSION Web interface. The Modbus communication between the FUSION and the SMX must be in place in order to edit the SMX-24AI analog input configuration.

INSTALLATION MANUAL


2.1 MATERIAL PROVIDED

The BCM box will be shipped in the OEM enclosure packing. The BCM box is fully assembled, SMX input channels are factory calibrated and ready to be wired and installed. All CTs are optional and must be provisioned according to fit the circuit being measured. If CT’s are provisioned, they will be shipped in a separate box. Note: Contractor/installer shall provide:

• Recommended 48Vdc power cables

• Modbus Trunk cables (see below for recommended cables)

• Cable, butt splices, heat shrink to extend the CT lead wires

• Wall mounting fixtures

• GMT fuse when powering from 48V fuse panel

• All standard tools set, power tools.

INSTALLATION MANUAL


3. BCM BOX INSTALLATION

All BCM boxes share the same mechanical specifications, NEMA Type 1, Hinged door cover with locking mechanism / Knockouts, Size/Dims: 18" x 18" x 6", (or 18" x 24" x 6" for the

M-BCM-72-AC-W) Material/Finish: Steel/Gray. The whole assembly weight ± 36 pounds/ 16.3 kg.

INSTALLATION MANUAL


3.1 BCM PHYSICAL INSTALLATION

The BCM can weight close to 40 pounds, when fixing to install the box on the wall, 2 people should use every safety precaution to prevent the box from slipping or dropping on the floor.

1. Find a suitable place to install the BCM box on the wall like a section of plywood, do not install directly on softer wall material like Drywall.

2. CT cable can be extended to reach more than 100ft, however the wire must have the same specification as the CT wires. 600V / #18AWG / Black & White twisted wire.

3. Use the four holes to secure the box. Wall fixture are not included with the BCM box.

4. The BCM box Chassis Ground shall be wired to the near by frame ground as per the local electrical code.

5. If electrical conduit is required, conduit size should allow for future growth.

INSTALLATION MANUAL


4. WIRING THE BCM BOX The BCM Box will require 4 different wiring tasks, number are referred to terminal blocks on the following image.

1. Redundant -48Vdc power source wiring 2. BRG (Battery Return Ground) wiring 3. Modbus connection to FUSION RS-485 wiring 4. CT wiring (signal wires)

4.1 POWERING THE BCM BOX

The SMX-24AI, DC CT will require a redundant 48Vdc source of power to run. The maximum draw is below 2A.

1. Run a black and red #18 or #20 AWG cable from a redundant 48Vdc fuse panel near by designated by the Customer stakeholder. Fuse A & B side at each a maximum of 2A.

2. An optional Class 2 plug-in power supply can also be used to feed 48Vdc power to the BCM box, please contact your Multitel representative for P/N and pricing information.

3. The BCM box is fused internally at 2A at the power terminal section. Spare fuses are provided in a separate bag.

INSTALLATION MANUAL


Refer to the following images to wire the BCM Box power:

• The -48Vdc A & B wires shall terminate to the fuse terminal blocks labeled (BATT) FEED A and (BATT) FEED B.

• The Battery Return Ground shall be wire to the standard terminal blocks labeled (BRG) FEED A and (BRG) FEED B.

4.2 SETUP THE MODBUS TRUNK

A Modbus cable must be wired to near by FUSION back panel’s RS-485 or MLINK connectors. Modbus is a master/slave networking configuration where FUSION is the master and SMX are the slaves. Other Modbus third-party devices can be networked together on the trunk as long as the communication setting (Baud rate, parity, data/stop bits) are configured properly and have unique slave ID for each slave devices.

• Planned the Modbus ahead, prevent star shaped network, RS-485 network shall be daisy chained from one device to another and strung wires accordingly.

• When connecting slave devices to a FUSION, connect all “-” or “TX/RX-” terminals together, all “+” or “TX/RX+” terminals together. If you swap “-” and “+”, most devices cannot auto-detect the polarity and it will result in communication errors.

• You may put two sets of wires in each screw terminal to make it easier to daisy chain, if you do this, twist the wires tightly together before putting them into the screw terminal to ensure that one wire doesn’t pull free, causing communication problems.

• If you are using shielded cable, the shield should be continuous along the Modbus trunk and only tied to earth ground at the FUSION end. – See diagram below.

INSTALLATION MANUAL


For best results, especially for longer distances, use wire recommended for RS-485.

Internally both SMX are pre-wired to the Modbus terminal blocks located near the Power Input blocks. Installer must wire the desired FUSION RS-485 connection to the BCM RS-485 terminal blocks as follow:

• Connect the positive TX/RX (+) wire to the terminal block labeled RS485 (+) and the negative TX/RX (-) wire to the terminal block labeled RS485 (-).

• For each wire, strip about 1/4″ (6 mm) of insulation off the end of one of the wires, twist the bare strands together, insert the end into the terminal block, and tighten the screw securely.

MANUFACTURER PART NUMBER AWG PAIRS

Belden 9841 24 1

Belden 9842 24 2

Many Cat5 24 4

INSTALLATION MANUAL


INSTALLATION MANUAL


4.3 SETUP THE SMX SLAVE ID

For the FUSION to communicate with each SMX device, each SMX must have a specific Modbus slave ID. The slave ID is differing from the FUSION Module number such as M(X) which is an internal reference. The SMX slave ID can only be set from the SMX front panel rotary switches label “MODBUS ADDRESS”. The Modbus Address ID available range is from 00 to 99. These settings can be predetermined and pre-set at the factory, if the detailed engineering as been provisioned for this installation. Otherwise, a unique slave ID must be set using the rotary switches and SMX shall be configured accordingly in the FUSION Module section.

After the SMX module address is configured, setup communication speed accordingly by setting Rotary switch labeled “Speed/Vitesse” and position accordingly. By default, the factory SMX communication speed setting is 115,2kbds. Any changes to rotary switches will take effect immediately. When ordering multiple SMX modules, Multitel will setup the module addressing.

SPEED ROTARY (FRONT PANEL)

Number Baud Rate

(kbps) Number

Baud Rate (kbps)

1 1,2 5 19,2

2 2,4 6 38,4

3 4,8 7 57,6

4 9,6 8

115,2 (default)

INSTALLATION MANUAL


5. AC POWER CT WIRING Each BCM can provide 12, 24, 36 or 48 standardized CT inputs. Each CT connection is a set of 2 standard terminal blocks having a black and a white stripe, same for DC power and AC power BCM boxes. Note 1: The white stripes terminal blocks are reference to (+) and black stripes to (-). Note 2: The polarity is not important for AC CT, however it must be respected with a DC CT. All terminal blocks designated with a (X)A1 to (X)A24 will belong to the SMX-24AI tagged with the (X). Respectively the same for all terminal blocks with a (Y)A1 to (Y)A24.

5.1 CT INSTALLATION

CAUTION! AC Power BCM box are designed to work only with CTs that have a 0.333 Vac output. This type of CT has a built-in burden resistor that produces a safe low voltage output signal. The use of any other type of CT will result in incorrect power measurements, and may permanently damage the AC Power BCM box.

• Unlike ratio CTs with current outputs, these CTs are internally burdened to produce a safe 0.333 Vac output voltage, therefore, shorting blocks are not needed.

• Connect the white and black CT leads to the corresponding CT input terminals with the white and black stripes.

INSTALLATION MANUAL


In general, split-core CTs open by squeezing the knurled panels to release the latch and pull / rotate the top open. Make sure the mating surfaces are clean. Debris will increase the gap, decreasing accuracy. Place the CT around the conductor and rotate the top back to the closed position until the latch snaps closed. Secure the conductor in the bottom of the CT’s ‘U’ shaped section using a cable tie through the CT’s window and around the conductor.

5.2 CT LEAD WIRES

If the CT lead wires are longer than necessary, they can be shortened. Short CT lead wires help to minimize interference from electrical noise. If the CT lead wires need to be longer than 8 feet, they can be extended. It is generally better to install the BCM box near the conductors being measured instead of extending the CT wires. However, it is possible to extend the CT wires by 100 feet (30 m) or more using shielded twisted-pair cable. To minimize power line noise from interfering with sensitive CT signals, extension wires should be run away from power conductors.

INSTALLATION MANUAL


5.3 CT CONNECTIONS

A BCM Panel can read up to 48 CTs. Each CT connections must be predefined and shall be performed according to detailed engineering notes. To connect the CT lead wires to the BCM terminal blocks:

• first strip about 1/4″ (6 mm) of insulation off the end of one of the wires, twist the bare strands together, insert the end into the terminal block, and tighten the screw securely.

INSTALLATION MANUAL


6. DC POWER CT WIRING – “FUTURE SECTION”

This section of the guide has been left blank intentionally.

INSTALLATION MANUAL - Multitel

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