INSTALLATION, CONFIGURATION AND OPERATION AND OPERATION MANUAL 1000 EnviroGrid Controller RM2-1000 EnviroGrid Controller INSTALLATION, CONFIGURATION AND OPERATION
, CONFIGURATION AND OPERATION INSTRUCTIONS DESCRIPTION A network of EnviroGrid Controllers provides control for connected electrical loads with the target of of EnviroGrid Controllers provides control for connected electrical loads with the target of of EnviroGrid Controllers provides control for connected electrical loads with the target of Smoothing out Peak electrical usage (Peak Demand) Smoothing out Peak electrical usage (Peak Demand) Providing the ability to reduce electrical usage (Demand Response) based on a control Providing the ability to reduce electrical usage (Demand Response) based on a control Providing the ability to reduce electrical usage (Demand Response) based on a control signal Function Communications Control Sensors Description Description 2.4 GHz band (2405MHz 2480MHz) channel selectable channel selectable External modem capability to send monitoring data or receiv monitoring data or receive control requests Repeater functionality to extend range of network Repeater functionality to extend range of network Up to 800 metre (875 yards) communication distance communication distance 1 2 stage control of HVAC units (Internal relays relays up to 30VAC) 3 or more stage control of HVAC units (external relays) ernal relays) High Voltage control of resistive heaters (Up Up to 600VAC with High Voltage control of Domestic Hot Water tanks (
external contactors) High Voltage control of Domestic Hot Water tanks (Up to 600VAC with external contactors) 1 2 stage control of Heat Pumps Thermostatic control of freezer units (Internal Internal relays up to 30VAC) 0-100% duty cycle settings Adaptive duty cycle mode Up to 3 phase 600VAC monitoring 0-15 Amps per phase low current monitoring 15 Amps per phase low current monitoring 0-30 Amps per phase medium current monitoring 30 Amps per phase medium current monitoring 0-65 Amps per phase high current monitoring current monitoring Custom designed very high current monitoring Custom designed very high current monitoring 2008 Copyright REGEN Energy Inc. opyright REGEN Energy Inc. Page 1 INSTALLATION INSTALLATION, CONFIGURATION AND OPERATION AND OPERATION MANUAL CAUTION: Ensure Power CAUTION: Ensure Power is disconnected before installing!
disconnected before installing!
types of installations, e.g. resistive heater types of installations, e.g. resistive heater banks or HVAC units with more than 2 banks or HVAC units with more than 2 stages requiring more than 2 stages requiring more than 2 control relays. Materials Provided for Installation for Installation The following materials are provided provided for installation of an EnviroGrid controller:
installation of an EnviroGrid controller:
Tools for Installation 1. EnviroGrid controller front cover, including front cover, including pre-programmed integrated circuit board programmed integrated circuit board 2. EnviroGrid controller back cover EnviroGrid controller back cover 3. EnviroGrid Terminal Block (to connect EnviroGrid Terminal Block (to connect wiring to the controller) EnviroGrid waterproof gasket (to seal the 4. EnviroGrid waterproof gasket (to back cover on to the front cover back cover on to the front cover 5. 4 screws of type pan head hex #4 pan head hex #4-40,to secure the back cover 6. Antenna of type 5.5 dBi RP-SMA SMA 7. Antenna extension cable with magnetic magnetic mount (if the antenna cannot be secured
(if the antenna cannot be secured directly to the controller and provide clear directly to the controller and provide clear communications with other controllers) communications with other controllers) 8. Tie wrap (to secure wire inside controller
(to secure wire inside controller case) 9. 1 3 CTs (CR3110-1000) as required (to as required (to attach to the power mains) 10. Molex 39-01-3022 power connector power connector Specific tools are required for installation of an for installation of an EnviroGrid controller:
Flat head precision screwdriver screwdriver to secure wires to the terminal block wires to the terminal block 1.5mm hex screwdriver to fasten screws to fasten screws through the back cover to the front cover cover to the front cover Volt meter with positive and negative pin positive and negative pin-
point leads and a clamp-on inuctive on inuctive measurement tool, to test voltage and line to test voltage and line amperage of the attached load amperage of the attached load Appropriate screwdriver and screws to Appropriate screwdriver and screws to mount the controller to th mount the controller to the appropriate surface. The screws should be surface. The screws should be Wirestrippers for AWG 18 wire, to prepare for AWG 18 wire, to prepare the cable for attachment to the controller ble for attachment to the controller at the attached load. Molex crimping tool 63811 63811-1000 - universal or 63811-5000 for 18-24 AWG wires 24 AWG wires housing Controller Wiring 11. Molex 39-00-0039 contact pins
(qty 2) Additional Materials Required Additional Materials Required 1. Indoor/Outdoor 18AWG UL approved 12 Indoor/Outdoor 18AWG UL approved 12 conductor stranded wire for connecting the for connecting the sensors, relays, and power. 2. Additional contactors or power Additional contactors or power transformers may be required for certain transformers may be required for certain 2008 Copyright REGEN Energy Inc. opyright REGEN Energy Inc. Use 18 AWG stranded outdoor 12 conductor Use 18 AWG stranded outdoor 12 conductor cable to hook up the sensors, relays and power cable to hook up the sensors, relays and power supply. The cable should have a 9.5mm to The cable should have a 9.5mm to 10.5mm outer diameter and be rated for 10.5mm outer diameter and be rated for Indoor/Outdoor. To hook up the wire, remove the back of the controller by unscrewing the the back of the controller by unscrewing the four screws on the back of t he controller (hex screw 1.5mm). See Fig. 1 Page 2 INSTALLATION, CONFIGURATION AND OPERATION AND OPERATION MANUAL NOTE: Ensure the cable passes through the NOTE: Ensure the cable passes through the opening in the gasket that seals seals the back cover to the front case. Power Inputs:
9.5VDC 42VDC 8VAC 30VAC Use the connector/contact contact pins provided Channels:
1 channel per phase Connected to CR3110-
-3000 Split Core current transformer from CR Magnetics current transformer from CR Magnetics Relay:
0 30VAC 1 Amp Dry Contact Attach a tie wrap around the cable to provide Attach a tie wrap around the cable to provide strain relief and trim the end. See Fig. 3 end. See Fig. 3 PWR C H 1 C H 2 C H 3 R L Y 1 R L Y 2 Fig. 3 Controller Location Select an appropriate location Select an appropriate location when installing the controller. Keep at least 1-
-foot distance between the controller/cabling and any high between the controller/cabling and any high voltage power lines to minimize interference voltage power lines to minimize interference Fig. 1 Use the terminal block to attach the cable. See minal block to attach the cable. See Fig. 2 C H 1 C H 2 C H 3 R L Y 1 R L Y 2 PWR TERMINAL BLOCK Fig. 2 Cable colour coding. See Table 1 Colour Function RED Power BLUE Power BLACK Channel 1 WHITE Channel 1 BLACKK/WHITE Channel 2 WHITE/BLACK Channel 2 RED/BLACK Channel 3 BLUE/BLACK Channel 3 GREEN Relay 1 ORANGE Relay 1 GREEN/BLACK Relay 2 ORANGE/BLACK Relay 2 Table 1 2008 Copyright REGEN Energy Inc. opyright REGEN Energy Inc. Page 3 with radio communications. Use 4 screws to Use 4 screws to attach the controller as illustrated in Fig. 4 attach the controller as illustrated in Fig. 4 INSTALLATION, CONFIGURATION AND OPERATION AND OPERATION MANUAL Fig. 5 Fig. 4 Note that the controller antenna cannot be cannot be mounted inside a metal enclosure as the metal as the metal will not allow the radio communication signal to will not allow the radio communication signal to penetrate well. Cable Routing especially roof-top It may be necessary especially when dealing It may be necessary especially when dealing with outdoor situations especially roof HVAC units, to route the cable from the outside HVAC units, to route the cable from the outside where the controller is mounted, to the inside where the controller is mounted, to the inside of the equipment where the control board is. In of the equipment where the control board is. In such a case it may be necessary to drill a hole in essary to drill a hole in the HVAC rooftop enclosure. This hole should rooftop enclosure. This hole should have a weatherproofing cable gland inserted have a weatherproofing cable gland inserted
(size PG13.5). The cable should be routed
(size PG13.5). The cable should be routed through this gland and the gland tightened. through this gland and the gland tightened. Antenna Installation Attach the mag mount antenna SMA Plug SMA Plug shown in Fig. 5 to the controller as illustrated in to the controller as illustrated in Fig. 6 below. Ensure to only finger tighten the Ensure to only finger tighten the wire and do not over tighten or the antenna or the antenna could be damaged. Fig. 6 Mount the magnetic base so that it has line of magnetic base so that it has line of sight to the other controllers in the network. If sight to the other controllers in the network. If line of sight mounting is impossible, ensure all line of sight mounting is impossible, ensure all the antennas in the network are positioned as the antennas in the network are positioned as close to perpendicular as possible as possible to all other controllers in the network. Sensor Connection The sensors measure current in each phase The sensors measure current in each phase to which they are attached. If connected to a
. If connected to a single load, each sensor is typically attached to single load, each sensor is typically attached to the incoming power mains to the load. If the incoming power mains to the load. If multiple loads are being controlled (as may be multiple loads are being controlled (as may be the case for resistive electric heating), multiple electric heating), multiple heaters may be measured by the sensor by heaters may be measured by the sensor by running each of the heater power lines through running each of the heater power lines through the sensor with the understanding that a single the sensor with the understanding that a single sensor can only measure a single phase sensor can only measure a single phase 2008 Copyright REGEN Energy Inc. opyright REGEN Energy Inc. Page 4
(Multiple power lines that are on the same power lines that are on the same phase may be measured by a single sensor phase may be measured by a single sensor Fig. 7 REGEN uses the CR3110-3000 split core current 3000 split core current transformer from CR Magnetics as the sensor. transformer from CR Magnetics as the sensor. The wiring diagram below (Fig. 7) shows how The wiring diagram below (Fig. 7) shows how the sensors are connected for single phase, two the sensors are connected for single phase, two phase and three phase systems (both with and phase and three phase systems (both with and without a neutral). 2008 Copyright REGEN Energy Inc. opyright REGEN Energy Inc. INSTALLATION, CONFIGURATION AND OPERATION AND OPERATION MANUAL Relay Connection The relays provided by REGENs EnviroGrid The relays provided by REGENs EnviroGrid Controller are dry contact relays rated for 1 Controller are dry contact relays rated for 1 Amp per relay at 30VAC. Common equipment Amp per relay at 30VAC. Common equipment that the controllers are connected to include the controllers are connected to include resistive heaters, air conditioners, chillers resistive heaters, air conditioners, chillers and domestic hot water tanks. For a typical roof domestic hot water tanks. For a typical roof-top packaged air conditioner, Fig. 8 shows the packaged air conditioner, Fig. 8 shows the connection for a typical 2 stage unit. If the unit connection for a typical 2 stage unit. If the unit only has 1 stage, the Orange/Black and only has 1 stage, the Orange/Black and Green/Black wires are left unconnected. Green/Black wires are left unconnected. Green (CBL) Old Y 1 connection Orange (CBL) Orange/Black (CBL) HVAC Terminal HVAC Terminal Block Y1 Y2 Existing Control Wires Y1/Y2
(Typically Thermostat) Green/Black (CBL) Old Y 2 Connection Fig. 8 Equipment that has more than 2 stages or Equipment that has more than 2 stages or requires high voltage/high current control requires high voltage/high current control must be outfitted with an external relay/contactor be outfitted with an external relay/contactor with a 24VAC control voltage. The wiring with a 24VAC control voltage. The wiring diagram for a typical multi-stage HVAC rooftop stage HVAC rooftop unit is illustrated in Fig. 9. 24 VAC Power Green (CBL) Orange (CBL) Orange/Black (CBL) Green/Black (CBL) 24 VAC Power Fig. 9 Old Y1 connection Old Y2 Connection Old Y3 Connection Y1 Y2 Y3 Y4 Y5 Y6 HVAC Terminal Block Old Y4 connection Old Y5 Connection Old Y6 Connection Page 5 INSTALLATION, CONFIGURATION AND OPERATION AND OPERATION MANUAL For a typical resistive heater connection, the For a typical resistive heater connection, the wiring is shown in Fig. 10. AC Main Heater 1 AC Main Heater 2 AC Main Heater 3 AC Main Heater 3 AC Main Heater 2 AC Main Heater 1 AC Main Heater 4 AC Main Heater 5 AC Main Heater 6 24 VAC Power Green (CBL) Orange (CBL) Orange/Black (CBL) Green/Black (CBL) 24 VAC Power AC Main Heater AC Main Heater 6 AC Main Heater AC Main Heater 5 AC Main Heater AC Main Heater 4 Fig. 10 In this case (Fig. 10) the contactor is placed in In this case (Fig. 10) the contactor is placed in series with the AC Mains power used to series with the AC Mains power used to supply the resistive heaters. Power Connection The Blue and Red wires on the cable are used to The Blue and Red wires on the cable are used to power the controller. They are connected to an power the controller. They are connected to an external power supply (isolated transformer). external power supply (isolated transformer). Most HVAC equipment have such a power such a power supply. Both AC and DC connections are supply. Both AC and DC connections are acceptable. Voltage ranges for DC are 9.5VDC acceptable. Voltage ranges for DC are 9.5VDC 42VDC or for AC are 8VAC 30VAC. The 30VAC. The connection order/wiring colour is irrelevant is irrelevant. 2008 Copyright REGEN Energy Inc. opyright REGEN Energy Inc. Page 6 INSTALLATION, CONFIGURATION AND OPERATION AND OPERATION MANUAL CONFIGURATION System Phase Voltage Setting Phase Voltage Setting Powering Up powered on, the unit will enter into Now that the controllers CTs, relays, power ntrollers CTs, relays, power feed and antenna have been connected feed and antenna have been connected, any disconnects or breakers powering the load disconnects or breakers powering the load should be turned on. The EnviroGrid controller The EnviroGrid controller has an ON and an OFF button on the front has an ON and an OFF button on the front panel. Press the ON button to power on the panel. Press the ON button to power on the unit. Once powered on, the unit will its configuration mode. The particular its configuration mode. The particular configuration step will be enunciated by configuration step will be enunciated by with the given step displayed on the LCD panel (e.g. on the LCD panel (e.g. configuration step #1 will flash 001 on the LCD configuration step #1 will flash 001 on the LCD panel). Subsequently, the configuration step will the configuration step will wait for user input for 5 seconds before wait for user input for 5 seconds before accepting the previously defined value. The up value. The up and down arrows are used to adjust the value, and down arrows are used to adjust the value, and the Enter key is used to accept the value. is used to accept the value. The front panel is shown in Fig. 11. 3-phase 575VAC 3-phase 600VAC 1-phase 220VAC 1-phase 120VAC 332 346 220 120 Table 2 Config Setting 002 Sensor Range Sensor Range up/down arrow will cycle this The sensors are adapted for accuracy therefore The sensors are adapted for accuracy therefore it is important to select the appropriate range it is important to select the appropriate range. Using the up/down arrow will cycle configuration option through the described in Table 3 below. Note that it is the Note that it is the maximum amperage per phase that is relevant, maximum amperage per phase that is relevant, not the overall amperage for the load. not the overall amperage for the load. Config Value Sensor Range Sensor Range the settings 11 22 33 0-15 0-30 0-65 Amps Amps Amps Table 3 Often, electrical loads will have an will have an informational plate indicating maximum informational plate indicating maximum Amperage per phase. Config Setting 003 Relay Sense Relay Sense Depending on the type of equipment being Depending on the type of equipment being connected to, the load will be disabled if will be disabled if the control relay circuit is open, whereas in other
, whereas in other cases the load will be disabled if the control cases the load will be disabled if the control relay circuit is closed.. The settings The settings for the EnviroGrid relay sense are shown in Table 4. are shown in Table 4. Config Value Relay Sense Relay Sense 01 00 Open = disabled Open = disabled Open = enabled Open = enabled Table 4 Fig. 11 Config Setting 001 Phase Voltage Phase Voltage specifies the phase This configuration setting specifies voltage used for computing power consumption voltage used for computing power consumption as measured by the sensors. Note that one Note that one must identify the phase voltage (i.e. voltage per must identify the phase voltage (i.e. voltage per phase), and not simply the overall voltage for phase), and not simply the overall voltage for the load. The up arrow will increment the value The up arrow will increment the value by 10 and the down arrow will decrement the by 10 and the down arrow will decrement the value by 1. Typical settings are shown in Table 2 are shown in Table 2 below. 2008 Copyright REGEN Energy Inc. opyright REGEN Energy Inc. Page 7 Config Setting 004 Repeater Repeater Selection group of EnviroGrid controllers power When a group of EnviroGrid controllers up, all controllers must be able to communicate up, all controllers must be able to communicate with the coordinator (which is typically the with the coordinator (which is typically the first node to be powered up). This node first node to be powered up). This node should have line of site (or be within communication have line of site (or be within communication range) of all other nodes. If this is not possible, range) of all other nodes. If this is not possible, a node that is within communication range of is within communication range of the coordinator and the target node may be set the coordinator and the target node may be set as a repeater. Repeaters repeat all messages repeat all messages from the coordinator and the target node (as from the coordinator and the target node (as well as all other nodes within range). This has well as all other nodes within range). This has the effect of increasing the network range. The reasing the network range. The settings for this configuration option are shown tion option are shown in Table 5. Config Value Controller Type Controller Type 00 11 22 End node Repeater Coordinator Capable Coordinator Capable Table 5 Config Setting 005 Channel Channel Selection 2405MHz to
. If poor communications range is The controller allows the selection of the The controller allows the selection of the radio channel to be used for communication. channel to be used for communication. Available channels range from 2405MHz 2480MHz. If poor communications range experienced, changing the channel may experienced, changing the channel may alleviate the problem. Note that all controllers alleviate the problem. Note that all controllers in the network must communicate on the same in the network must communicate on the same INSTALLATION, CONFIGURATION AND OPERATION AND OPERATION MANUAL channel. The configuration options are specified channel. The configuration options are specified in Table 6. Config Value Radio Channel Radio Channel 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 2405MHz 2405MHz 2410MHz 2410MHz 2415MHz 2415MHz 2420MHz 2420MHz 2425MHz 2425MHz 2430MHz 2430MHz 2435MHz 2435MHz 2440MHz 2440MHz 2445MHz 2445MHz 2450MHz 2450MHz 2455MHz 2455MHz 2460MHz 2460MHz 2465MHz 2465MHz 2470MHz 2470MHz 2475MHz 2475MHz 2480MHz 2480MHz Table 5 Config Setting 006 Sensor Test Sensor Test If desired, this configuration setting may be If desired, this configuration setting may be used to test the power consumption used to test the power consumption measured by each of the sensor channels. The power each of the sensor channels. The power consumption is measured in 10 Watt consumption is measured in 10 Watt increments (0-9990 Watts). To the various channels, use the up arrow. the various channels, use the up arrow. To scroll through 2008 Copyright REGEN Energy Inc. opyright REGEN Energy Inc. Page 8 OPERATION Joining the Network INSTALLATION, CONFIGURATION AND OPERATION AND OPERATION MANUAL TRAFFIC: This indicator will flicker when the
: This indicator will flicker when the device receives any wireless traffic in the device receives any wireless traffic in the configured wireless channel configured wireless channel LOAD ON: A solid light indicates that the
: A solid light indicates that the Upon completion of the configuration process, Upon completion of the configuration process, load is drawing power an EnviroGrid controller attempts to join the attempts to join the OVERRIDE: A solid light indicates that the
: A solid light indicates that the local network of controllers. The READY indicator will remain solid, remain solid, indicating it has joined the local network network (or if the controller is a coordinator, indicate that this the controller is a coordinator, indicate that this controller is currently overriding the controller is currently overriding the attached loads control circuit and s control circuit and requesting that it curtail operation. requesting that it curtail operation. device is ready to accept connections from device is ready to accept connections from TROUBLESHOOTING other controllers). If the READY indicator does
. If the READY indicator does not appear within 10 seconds of completion of not appear within 10 seconds of completion of the configuration process, consult the the configuration process, consult the Troubleshooting section of this manual to ing section of this manual to determine corrective measures. Duty Cycle Adjustment The duty cycle of an EnviroGrid controller The duty cycle of an EnviroGrid controller represents the percentage of time the represents the percentage of time the controller must permit its attached load to must permit its attached load to function if it so desires. This setting computes is setting computes the number of 15 minute blocks within the number of 15 minute blocks within successive 3 hour periods when the controllers successive 3 hour periods when the controllers relays should enable the attached load to ttached load to operate. Display Panel To the left of the duty cycle display, there is a o the left of the duty cycle display, there is a vertical row of LED elements, provid providing the following information:
The following provide guidance to resolving The following provide guidance to resolving common issues encountered when configuring common issues encountered when configuring EnviroGrid controllers. 1. The controller does not display any The controller does not display any information upon power up information upon power up A. Wait at least 10 seconds after initially Wait at least 10 seconds after initially powering up the device powering up the device (to allow for the controller to complete its self controller to complete its self-test mode) B. If the display is still empty, turn off the If the display is still empty, turn off the device, and confirm that the power device, and confirm that the power leads are attached to the appropriate to the appropriate wires connected to the EnviroGrid wires connected to the EnviroGrid terminal block. C. If both power leads are leads are determined to be properly connected, use a volt meter be properly connected, use a volt meter to confirm that power is available (and to confirm that power is available (and in a range acceptable for an EnviroGrid in a range acceptable for an EnviroGrid controller). 2. The Sensor Test (Config Step 6) does not The Sensor Test (Config Step 6) does not READY: A solid light indicates that the ndicates that the show any non-zero power readings, yet the zero power readings, yet the controller has completed its start controller has completed its start-up and load is operating and obviousl load is operating and obviously drawing configuration cycle, and has joined a local configuration cycle, and has joined a local power. network. Does it blink during config?
Does it blink during config?
COORD: A blinking light indicates th light indicates that the device is a coordinator. A. Confirm that the CTs are securely Confirm that the CTs are securely closed, with the connection clips closed, with the connection clips fastened completely. B. Confirm that the leads from the leads from each of the CTs are securely attached to the are securely attached to the 2008 Copyright REGEN Energy Inc. opyright REGEN Energy Inc. Page 9 INSTALLATION, CONFIGURATION AND OPERATION AND OPERATION MANUAL appropriate wire connected to connected to the terminal block, as well as the correct terminal block, as well as the correct EnviroGrid terminal block. mounting points on the attached load. mounting points on the attached load. C. If the CTs have been confirmed to be been confirmed to be B. Confirm that the Relay Sense Confirm that the Relay Sense securely attached, and correctly securely attached, and correctly configuration setting (Step 003) is set configuration setting (Step 003) is set connected to the EnviroGrid connected to the EnviroGrid controller, properly (or toggle the value if set properly (or toggle the value if set use a clamp-on power meter to confirm power meter to confirm incorrectly). if the load is in fact drawing power. if the load is in fact drawing power. C. Detach the EnviroGrid re Detach the EnviroGrid relay control 3. The controller cannot connect to the local The controller cannot connect to the local wires and restore the attached loads wires and restore the attached loads network. Note that in Steps C-F below, F below, the control wires to their original state to control wires to their original state to controller should be powered off before controller should be powered off before determine if the load can operate determine if the load can operate using implementing the step, then powered on. implementing the step, then powered on. its native control circuitry. its native control circuitry. A. Confirm that at least one coordinator Confirm that at least one coordinator controller is currently operational. Note controller is currently operational. Note that the very first controller powered that the very first controller powered up should be a coordinator, and it up should be a coordinator, and it obviously will not connect to any other t connect to any other controllers. B. Confirm that the antenna (and antenna (and extension mounting cable, if use extension mounting cable, if used) is attached securely to the top of the attached securely to the top of the controller. Take care not to overtighten Take care not to overtighten the antenna (and extension wire if the antenna (and extension wire if used). C. Reposition the antenna to achiev Reposition the antenna to achieve a better line of sight angle to the to the coordinator D. Replace the antenna (and extension Replace the antenna (and extension mounting cable if used). E. Reconfigure a closer controller to be a Reconfigure a closer controller to be a Repeater, restart the Repeater, and restart the Repeater, and then restart the controller that could then restart the controller that could not connect to the network. not connect to the network. F. Reposition the controller further away osition the controller further away from the power source of the attached from the power source of the attached load (to minimize electrical load (to minimize electrical interference). 4. The attached load does not operate operate, despite setting the controller to a duty cycle of setting the controller to a duty cycle of 100%. A. Confirm that all EnviroGrid EnviroGrid relay control wires are securely fastened to the s are securely fastened to the 2008 Copyright REGEN Energy Inc. opyright REGEN Energy Inc. Page 10