Power Max Digital Meter
Contents
1. 444 4400 ann nn nennen 2 1 1 CUSTOMER SERVICE AND SUPPORT 2 1 2 PRODUCT WARRANTY 2 1 3 LIMITATION OF WARRANTY 2 1 4 STATEMENT OF CALIBRATION 2 1 5 DISCLAIMER 2 2 OVERVIEW 2220 2222 nn nn nn 6 2 1 PHYSICAL DESCRIPTION 7 PRO FRONT PANEL 7 2 2 1 The Indicators 8 2 2 2 The Keys 8 2 2 3 Here s an example to try 10 2 POWER MAX EM 6400 TECHNICAL SPECS 10 2 3 1 Standard Measurements2. 11 1 1 1 1 Accuracy 12 2 3 2 Auxiliary Power Supply 12 2 3 3 Front Panel Display 12 2 3 4 Installation and Input Ratings 13 2 3 5 Environmental Conditions 13 2 3 6 Dimensions and Shipping 13 3 QUICK START GUIDE 444mm mm nn nn 14 3 1 KEYPAD OPERATION 14 3 1 1 Auto Scroll 18 1 1 1 FAVOURITE FAV key 18 A SETUP PROGRAM 18 3 2 1 Editing the Setup 19 3 2 2 Energy Integrator 24 3 2
3. CON ZERV 3 1 1 Auto Scroll Auto Scroll allows you to monitor a group of Display Pages seguentially every 5 seconds without constant key pressing This is convenient for viewing from a distance Since the Power Max EM 6400 displays the Parameter Name 1sec followed by the Value 4 sec on the same large displays both are egually readable from a distance No more sguinting at a clutter of parameter indicators To enter auto scroll go to the desired display page and keep the Up Aor Down Y key pressed for minimum 3 seconds then release key The display flashes AUTO and then automatically scrolls through other pages at the same level column in the above table Press any key to revert to Manual Scrolling e The Up A key enters Limited Auto scroll within the same Group e g only RMS or only INTG e The Down Y key enters Full Auto scroll down the entire column of pages 1 1 1 FAVOURITE FAV key The FAV key scrolls through the following pages VLL A F VLN A F VA W VAR W VAR PF PF1 PF2 PF3 V9p1 V 2 V0g3 A091 A002 A 3 VA d R d tr MD HR VAb Wh R VAh R Wh ft VAh t Wh This gives simple one touch access to the most commonly used parameters even for unskilled operators One touch does not operate in the Setup Program Mode Optional parameters are with bold characters e If you re lost the FAV key is a quick way to ge
4. CLR e INTG y gt PASS A GE INTG n FAL gt ED LORA Boe x EIER Le g e n d A DM w FAIL _ lt gt Use or keys Name Value Use a or keys SET sys STAR Y PR Mo Use key only A V SEC V PRI 415 0 V SEC 415 0 A PRI 0100 Regia A 415 0 PASS SAVE N a 100 0 S starts with SYS E T oor 5 000 wi et 4 Edit New value 4 lt gt Blinking Steady 0100 Digit display A PRI FAIL SAVE l 5 000 i i n gt SEC 193 LABL N A Sec 5 000 LABL 123 VA Fn d LABL 123 VA Fn 3d hand 9600 VA Fn 3D baud 9600 PRTY Evn l Baud 9600 PRIY Evn 1 PRTY Evn l ID 1 000 ID 1 000 Figure 3 2c The complete Setup Program menu Power Max EM 6400 User Manual v02 04 01 21 CON ZERV Table 3 2 Editing the Setup Values First you must enter the Main Menu and reach SET using the previous Table This example illustrates changing System Mode SYS from STAR to DELTA Action Display Remarks SET You rein the Main Menu Press W Enter Setting SyS Wiring System V PRI Voltage primary V SEC Voltage secondary We have now reached SyS top STAR Wiring System Star 3E 4V3A row for editing 415 0 Voltage primary 415V Press W to view Value 415 0 Voltage secondary 415V Press W to edit SYS value STAR Blinks Only Top Row is edited The value blinks 415 0 Ignore 415
5. CON ZERV Smart Energy Management Power Max EM6400 DIGITAL MULTIFUNCTION METER 1 Measure Conzerv Systems Pvt Ltd formerly Enercon Sytems Pvt Ltd 44P Electronic City Phase ll East Hosur Road Bangalore 560 100 INDIA T491 80 51189700 F 91 80 51189729 E contact conzerv com Customer Help Desk 1600 425 0555 Toll Free All India from BSNL MTNL Or Call 080 2852 0604 Standard Charges Apply ISO 9001 2000 Certified www conzerv com CON ZERV 1 GENERAL 1 1 Customer Service and Support Customer service and support is available via email at support 2conzerv com Please include the model serial number and a description with which we can re create the problem at our Support Centre You can shorten this time by also including necessary settings the wiring diagram and the particular readings which uniquely identify the problem Toll free phone support is available in some countries For the latest phone number list please visit www conzerv com 1 2 Product Warranty CONZER V warrants all products to be free from defects in material workmanship and title and will be of the kind and quality specified in CONZERV s written description in the manual The foregoing shall apply only to failures to meet said warranties which appear within one year from the date of shipping During the warranty period CONZERV will at its option either repair or replace any product that proves to be defective Please see the LlMITED WARRANTY
6. e Continuous pressing for 3 seconds initiates Auto scrolling through the above FAV pages e During the power up if the FAV key is pressed meter will go in to set up mode This is the simplest way to enter in to the setup The parameter name is displayed every 9 second for 2 seconds as well as the first time you press a key At this point press the next key immediately to scroll to the next page you want to see If you are not sure which page you re watching one press of any key will immediately identify the name On pressing the key again immediately takes you to the next page The Meter Menus and Displays are organized as below Navigating with the Power Max EM6400 is very easy and intuitive For full details see the Keypad Operations Table and the Meter Function Map The left most column RUN CLR SET constitutes the Main Menu Press the key in the direction you want to go Display shows where you re headed Power Max EM 6400 User Manual v02 04 01 9 CON ZERV Press the key that takes you in the desired direction You can t cross the thick boundary Table 2 4 Menu and Display Map 2 2 3 Here s an example to try When you switch on a factory fresh meter 1t starts at the RMS page circled 1 in the diagram below This will be our Home Page From here to now go to the VAh Energy Page circled 3 in the diagram below 1 Start at RMS 2 Go Down Y to IntG and 3
7. 6 ELECTRICAL INSTALLATION 2 32 6 1 AUXILIARY CONTROL POWER SUPPLY 33 6 2 PTS AND CTS 33 6 2 1 PT CT Wiring 33 6 3 VOLTAGE SIGNAL CONNECTIONS 34 6 3 1 PT Connections 34 6 3 2 Selecting the Voltage Fuses 34 6 4 CURRENT SIGNAL CONNECTIONS 34 Power Max EM 6400 User Manual v02 04 01 3 6 4 1 CT Connections 35 6 4 2 CT Polarity 35 6 4 3 CT Connection Reversal 36 6 5 SETUP SYSTEM TYPE 36 6 6 PHASE LABELS 44444444444 36 6 7
8. CONNECTION DIAGRAMS 36 6 7 1 Power Max EM 6400 Rear Panel 36 6 7 2 Three Phase 3 Wire Delta 37 6 7 3 Three Phase 4 Wire Star Wye 38 7 COMMUNICATION INSTALLATION 39 FAR RS 485 39 Tel REPEATERS 40 12 FACTORY SETTINGS 41 7 4 MODBUS REGISTERS 41 1 1 2 PHASE LABELS 42 7 4 1 Parameters not available on Display 42 Power Max EM 6400 User Manual v02 04 01 4 Blank pages for notes Power Max EM 6400 User Manual v02 04 01 CON ZERV CON ZERV 2 OVERVIEW The Power Max EM 6400 series of smart instruments offer comprehensive T
9. CT could get over burdened and give large errors Choosing a 1A CT secondary can reduce this error The CT Secondary value must be user programmed into the meter The Power Max EM 6400 should be conveniently located for easy connections of voltage PT and Current CT signals the auxiliary control supply Power Max EM 6400 User Manual v02 04 01 33 CON ZERV NOTE 1 The Power Max EM 6400 s Field Programmable PT and CT Primary or secondary Settings may be utilized to Calibrate out the PT and CT amplitude error for improved accuracy 6 3 Voltage Signal Connections For proper meter operation the voltage connection must be maintained The voltage must correspond to the correct terminal The cable reguired to terminate the voltage sense circuit should have an insulation rating greater than 600V ac and a current rating greater than 0 1A There are 4 Voltage input terminals marked V1 V2 V3 and Vn See the wiring diagrams that follow for details For Delta connection the Vn terminal should be left un connected 6 3 1 PT Connections The EM 6000 directly accepts LT voltage inputs of up to 500 V ac rms Line to Line Voltages greater than this typically HT systems must be connected through Potential Transformers PTs The Power Max EM 6400 allows Field Programming of both PT Primary and Secondary voltages See the voltage input overload graph for more detail Field Programmable PT Primary range 0 1 to 999 kV ac rms L L Fiel
10. lt DEVICE Repeater Fig 7 4 Two Wire RS 485 Communication Installation Connection with Repeaters 7 3 Factory Settings e Communication Protocol Modbus RTU o Baud Rate 9600 bps o Data bits 8 o Stop bits 1 o Parity Even e Data type 32 bit Float Real for all parameters unless otherwise specified o Except for parameter INTR Number of interruptions Outages in RMS parameter blocks unsigned 32 bit integer data type RunSec Run Seconds in Integrated block unsigned 32 bit integer data type e Data Format Direct reading from the meter no scaling is required e Modbus Function code 03 Read 7 4 Modbus Registers e Before integrating the Meters into your SCADA network your SCADA software must be configured for Modbus RTU communication for the Address Blocks below by a qualified technician who understands your SCADA software Typically the Device Address Block Start Address Number of Registers 20 registers per Power Max EM 6400 Data block of 10 x 32 bit values must be configured to suit the meter Additionally related SCADA settings for polling priority logging and viewing the Data must also be made Refer your SCADA software instructions on how to do this e Serial data from the Meter is available via the Modbus RTU protocol on the Serial RS485 port The Unit ID which is unique to each meter is programmed via the Set Up Menu through the Front Panel keys e All addresses are in Decimal How
11. CERTIFICATE provided with the product for further details 1 3 Limitation of Warranty This warranty does not apply to defects resulting from unauthorized modification misuse or use for any reason other than electrical power monitoring OUR PRODUCTS ARE NOT TO BE USED FOR PRIMARY OVER CURRENT PROTECTION ANY PROTECTION FEATURE IN OUR PRODUCTS IS TO BE USED FOR ALARM OR SECONDARY PROTECTION ONLY THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANABILITY OR FITNESS FOR A PARTICULAR PURPOSE CONZERV SHALL NOT BE LIABLE FOR ANY PENAL INDIRECT SPECIAL OR CONSEOUENTIAL DAMAGES ARISING FROM ANY AUTHORIZED OR UNAUTHORIZED USE OF ANY CONZERV PRODUCT LIABILITY SHALL BE LIMITED TO THE ORIGINAL COST OF THE PRODUCT SOLD 1 4 Statement of Calibration Our instruments are inspected and tested in accordance with specifications published by an independent testing facility The accuracy and calibration of our instruments are traceable to the National Institute of Standards and Technology through eguipment that is calibrated at planned intervals by comparison to certified standards 1 5 Disclaimer The information presented in this publication has been carefully checked for reliability however no responsibility is assumed for inaccuracies The information contained in this document is subject to change without notice Power Max EM 6400 User Manual v02 04 01 2 CONTENTS 1 GENERAL
12. that the reading is negative Per IEEE 100 and industry standard practice by meter men the following are Negative With Forward Flow of Watts Capacitive Leading VARs and PF With Reverse Flow of Watts Inductive Lagging VARs and PF and Watts Kilo When lit indicates that the reading is in Kilo 10 3 10 000 is displayed as 10 00 K 1 0 K is shown as 1000 Table 2 2 Giga Mega M Kilo K and Decimal Point Scaling Above 9990 k M ON K OFF Above 9999 M Giga K M indicators ON Above 9999G Display shows H1 for positive numbers and Lo for negative numbers RMS readings are four digits Energy readings have eight digits including four additional fractional digits The maximum number the Meter handles is 9 999 G for RMS and Energy values This means that the Energy readings of the meter will overflow at 3 values of kWh or kV Ah selectable through set up depending upon the PT and CT ratios programmed See Table 3 4 Integrator Overflow Value 2 2 2 The Keys Operating the meter is easy using the five smart keys to navigate through the Keypad Operations Table The Display Pages expand as you go right much like the directory or Explorer tree displayed on any computer The display shows where you re headed Power Max EM 6400 User Manual v02 04 01 8 CON ZERV Table 2 3 The Key pad operation table Right Key e Go forward into sub parameter pages e During Edit Setup values select
13. the meter rating Potential Transformers usually have a full scale output of 110V ac rms line line and Current Transformers a full scale output of 5A or sometimes 1A The PTs Potential Transformers and CTs Current Transformers must be planned installed and tested by a gualified electrical contractor before wiring the meter The accuracy of the measurement also depends on the accuracy and phase angle error of the PTs and CTs Instrument Class 1 or better PTs and CTs are recommended Do not use Protection Class 10P10 etc CTs to feed the Power Max EM 6400 they have poor accuracy and phase characteristics Ensure that the CT Primary rating has been selected so that your normal load variation lies between 40 and 80 of its full scale If your CT is over rated say if the load is always less than 10 of the CT Primary rating accuracy suffers On the other hand if the CT is under rated then you may exceed its full scale and burn out both the CT and the Power Max EM 6400 6 2 1 PT CT Wiring The PTs and CTs must have adeguate VA rating to support the burden loading on the secondaries You may want to support the Auxiliary supply burden from one of the PTs CT wiring can mpose additional burden loading on the CT For example if the CT has a SA secondary and the wire resistance is 1 0 Q then the CT has to support an additional burden of 5VA If the wiring distance from the CT secondary is greater than stated in Table 6 1 then the
14. the rear panel 14 terminals are provided 7 terminals on each side e Six terminals for current one in and one out per phase e Four terminals for voltage for three phases and neutral e Two terminals for meter Auxiliary Power Supply and e Two terminals for the RS 485 communications port Power Max EM 6400 User Manual v02 04 01 36 Figure 6 1 Meter Rear panel 6 7 2 Three Phase 3 Wire Delta With 2 CTs Direct Voltage Connections if Voltages are less than 601V ac L L Otherwise 3 PTs for Closed Delta or 2 PTs for Open Delta LINE S2 S1 L1 LOAD amp LZ s2s1 let L3 AN x a PT PT Optional S1 2 Amps LO vi s2 lA S2 S1 b s2 4 Other Meters Te Aux supply S2 Control power ds Bl CONZERV d i Other Meters wi 7 Communication In Series Figure 6 2 The Delta Connection Diagram Note Remember to make sure Delta is programmed in the meter Setup Leave the Vn terminal un connected Power Max EM 6400 User Manual v02 04 01 37 CON ZERV 6 7 3 Three Phase 4 Wire Star Wye 3 CTs Direct Voltage Connections if Voltages are less than 601V ac L L Otherwise 3 PTs For Single Phase the same diagram is used except that only Phase 1 connections exist and Phase 2 and Phase 3 are unused The unused current terminals must be shorted together to reduce noise picked up in the meter LINE S2 S1 L1 LOAD Ge o i 2 s2S1 ICT L3 5 I N
15. time as explained above All values are Direct Reading and have a high resolution This is necessary for accurate energy analysis over short intervals of time It also means that the readings max out and reset sooner or later as given below Since the Integrator contains counters for several parameters VAh Wh VARh VARh Run Hours On Hours Interruptions they all reset together whenever any one of them usually VAh overflows This makes energy management calculations such as Average PF very easy The maximum number that the Meter handles is 9 999 Giga for RMS and Energy values The value at which the meter overflows is given below See Table 3 4 Integrator Overflow Period The Overflow Period depends on the Product of the PT Ratio and CT Ratio that you ve programmed for your application Vpri Apri PT Ratio CT Ratio y X sec Asec Table 3 4 Integrator Overflow Period PT Ratio x CT Ratio Max Reading Overflow Period Months Max Min 1 to 1 999 9 999x10 2 to 10 999 9 999x10 19 29 3 3 Summary We have now learnt 1 To operate the Power Max EM 6400 Series products 2 To configure its Setup and 3 To Clear its Integrator Power Max EM 6400 User Manual v02 04 01 24 CON ZERV 4 AC POWER MEASUREMENT This Chapter describes the following 1 Fundamentals of Three Phase Measurements 4 1 Three Phase Systems A three phase system delivers higher levels of power for industrial and commercial applic
16. 0 Ignore Press W to change to Delta 2E ID PN Blinks Note To discard the change 415 0 e Press 4 415 0 e Restores the previous value Press W to accept the value DLTA Steady Sys is now set to Delta 415 0 Press Y to scroll down and W to change 415 0 other values We re done Press 4 to head j i back Blinks Press lt again SAVE NOTE To discard present changes press V to Ml show SAVE Press lt 4 to accept MW yes save PASS PASS flashes and Stores the Setup changes SET Now you re back in the Main Menu and can go A to RUN and gt to RMS Table 3 3a Clearing the Energy Integrator and Max Demand W h VA h VAR h VAR h etc Aton Display Romane Use Table 3 1 to enter the Main Menu Press V to reach CLR CLR You re in the Main Menu Press W to enter CLR mode INT Gp Press BW to proceed with CLR INTG ff EEE INTG Yes i NOTE lt escapes back to Main Menu Press W to Clear PASS PASS flashes INTG and Max demand INTG Cleared To head back press lt CLR Now you re back in the Main Menu and can go A to RUN and gt to RMS Power Max EM 6400 User Manual v02 04 01 22 CON ZERV Table 3 3b Clearing only the Maximum Demand Use Table 3 1 to enter the CLR You re in the Main Menu Main Menu Press V to reach CLR Press to enter CLR mode MD Select the parameter V or A INTG or Se
17. 2 1 Integrator Overflow 24 Os Je SUMMARY de aiu 24 4 AC POWER MEASUREMENT 2220 0 0 2202000000 220 25 4 1 THREE PHASE SYSTEMS 25 4 2 CONSUMPTION AND POOR PF 26 4 3 3D KVA MEASUREMENT 26 5 MECHANICAL INSTALLATION 22 2220 022220 02 27 5 1 INSTALLATION PROCEDURE m nn 30 5 1 1 Panel Mounting for New Installations 30 5 1 1 1 Location and Mounting considerations 30 5 1 1 2 Usage 30 5 1 1 3 Panel Considerations and Environment 30 5 1 1 4 Viewing 31 5 1 1 5 Mounting 31
18. 400 reading occupies TWO consecutive Modbus Registers e Most advanced SCADA packages will provide these capabilities 1 1 2 Phase Labels Table 7 1 Phase Labels Programmable through Setup Factory Default 1 2 3 7 4 1 Parameters not available on Display Voltage phase angle parameters are not available on the Front Panel Display but available on the RS485 communication port S No Parameters not available on Front Panel Display Voltage Phase Angle Phase 1 Voltage Phase Angle phase 2 Voltage Phase Angle Phase 3 END OF DOCUMENT Power Max EM 6400 User Manual v02 04 01 42
19. 6400 should never be dismantled or opened There are no user serviceable parts inside The Power Max EM 6400 contains high precision components which require special handling available only at authorized CONZERV service locations High voltages are likely to be present inside even after the Power Max EM 6400 has been switched off Opening the covers of the Power Max EM 6400 and or any attempts to dismantle service repair or modify the unit by unauthorized persons may cause severe injury will damage the unit and will also render CONZERV s warranty void 5 1 1 2 Usage First decide on how the Power Max EM 6400 is going to be used If you do not already have an Energy Management programme in operation then your Energy Consultant should be able to help you dentify which load s offer max mum savings potential This will help you decide Which point is to be monitored where the readings will be viewed from who must have access to the instrument and how often For best performance choose a location which provides all the required signals with minimum wiring lengths 5 1 1 3 Panel Considerations and Environment The Power Max EM 6400 is a high precision measuring instrument and its operating environment is of utmost importance For maximum performance the instrument should be mounted in a dry dust free location away from the heat sources and strong electromagnetic fields To operate reliably the following conditions must be met Sto
20. E 7 S E Current thd Phase 1 Total Harmonic distortion Phase 1 Current thd Phase 2 Total Harmonic distortion Phase 2 Current thd Phase 3 Total Harmonic distortion Phase 3 VA demand W d W demand selectable through setup gt c o Ww NeJU N THD Voltage thd Phase 1 Total Harmonic distortion Phase 1 Voltage thd Phase 2 Total Harmonic distortion Phase 2 REV R d Rising demand t r Time remaining MD Maximum demand HR On hour at which the Maximum demand has occurred VA h _ Volt ampere hours was Iyahous If watts is negative VA h W h VAR h VAR h do not Integrate VARh VAR hours Inductive VARh Negative VAR hours Capacitive munns Kun hours Total hours the Load was On Accumulates when current is present R VAh Volt ampere hours export Voltage thd Phase 3 Total Harmonic distortion Phase 3 INTG VA h VAR h h E DD mm I DD e od lt zo a p Ah Power Max EM 6400 User Manual v02 04 01 15 CON ZERV R Wh _ R Wh IWatt hours export R VAR SS R VAR VAR hours Inductive export RVAR R VAR Negative VAR hours Capacitive export R Pin R Run Run hours Total hours the meter was run with reverse energy flow export TOT VAh Wh EVAR AVAR Total Run hours Total hours the meter was run with current t Run t Run input signals ON hours Total hours the meter was ON Accumulates if On h On h se
21. Go Right to VAh There are no complicated key sequences since the grouping of parameters 1s intuitive The keys always do what they say under all modes Figure 2 3 Getting Around an Example A complete Keypad Operations Map appears in the next chapter RUN constitutes the Main Menu along with CLR and SET not shown above but evident in the left most Main Menu RUN CLR SET column To get into the Main Menu you first need to enter a code 2 3 Power Max EM 6400 Technical Specs The Power Max EM 6400 Series is a high accuracy low cost ultra compact power and energy meter that offers ISO 9000 quality accuracy and functional flexibility and MODBUS RTU communications capability The standard unit flush mounts in a DIN 96 cutout The Power Max EM 6400 Series is designed for retrofit application such as replacement of existing analog meters and is also usable as a stand alone meter in custom panels PDUs switchboards switchgear UPS s generator sets MCCs systems etc The Power Max EM 6400 Series except EM 6459 provides easy communication to PLCs DCS BMS and other systems through the use of Modbus RTU communications on RS 485 isolated to 2kV for 1 minute from other circuits Power Max EM 6400 User Manual v02 04 01 10 CON ZERV The Power Max EM 6400 Series of products are configurable and programmable through the front panel Measures true rms electrical parameters I Seco
22. Manual v02 04 01 32 CON ZERV 6 1 Auxiliary Control Power Supply The Power Max EM 6400 reguires a Single phase ac dc Auxiliary Control Power Supply to supply power to its internal electronic circuitry The Setup procedure Section 3 2 must first be completed with only the Auxiliary Supply connected External surge suppressors are necessary in the Auxiliary Supply Circuit for proper operation during extreme surge conditions where the voltage surges exceed the Auxiliary Supply limits E g Rural areas and outlying areas prone to lightning strikes Auxiliary Supply Range e 80 to 270V ac 100 to 270V dc e Burden load lt 3VA Auxiliary NOTE I The Auxiliary Power Supply may be derived from the voltage signals NOTE 2 If you have a 440 v Three Wire Delta system and a reliable Neutral is not available a 440v 240v Supply transformer should be used to provide the standard 240v Auxiliary Supply DANGER 6 Do not feed the Power Max EM 6400 s auxiliary power supply terminals with a voltage greater than the rating marked on the label The Power Max EM 6400 will be permanently damaged and CONZERV s Warrantv shall be void 6 2 PTs and CTs Large electrical installations have high voltages and currents which may exceed the direct connection rating of the meter In this case Potential Transformers PTs and Current Transformers CTs are used to precisely step down or reduce the voltage and current level to suit
23. N i 4 EIR HE xl xl xl PT Optional S1 2 Amps S2 e S1 V3 u S2 S1 Other Meters Aux supply S2 Control power Other Meters q In Series Communication Figure 6 3 The Star Wye 3phase 4wire Mode Connection Power Max EM 6400 User Manual v02 04 01 38 CON ERV 7 COMMUNICATION INSTALLATION 7 1 RS 485 Each Power Max EM 6400 series instruments have a unigue address up to three digits long The range of the instrument address is 1 to 247 This allows the user to communicate with up to 247 instruments on one COM port of the PC The Power Max EM 6400 series works on the Modbus RTU protocol Under Modbus each port supports up to 247 instruments However each RS485 segment allows only 32 nodes instruments Therefore Data Repeaters are necessary to amplify the signal between segments Available standard baud rates are 1200 2400 4800 9600 and 19200 To select the proper baud rate apply the following rules e For best results under normal conditions leave the meter factory set at 9600 baud e For a smaller number of instruments over a long distance use a low baud rate 4800 2400 1200 e In noisy EMI RFI conditions try 4800 or 2400 baud e With short cable runs lt 300 meters or 975 feet 19200 baud speeds up data transfers The connection diagrams show one Termination Resistor RT across the cable pair at each end of the cable This is a IW resistor 590 or better Its value should
24. approximately egual the Impedance of the Data Cable as specified by the cable manufacturer If you re not sure a value of 1209 might Just work fine The termination resistors help absorb the data signal reflections off the ends of the cable reducing data packet defects and the corresponding data packet re transmissions In cable runs longer than say 200 meters 650 feet and with baud rates higher than 9600 baud these benefits become more apparent Power Max EM 6400 Instruments RS 485 Hookup Diagram 2 wire Half Duplex IM Inn Figure 7 1 2 Wire Half Duplex Communication Connection Power Max EM 6400 User Manual v02 04 01 39 CON ERV RS 485 Communication Port f EM 6400 Instruments rear view im mm amp 3 og RS 485 Data Converter 2 Figure 7 2 Closed Loop 2 Wire Half Duplex RS485 Communication Connection RS 485 RS 485 Communications Communications ort Port ED f D RS 485 Data Converter Figure 7 3 Detail of Closed Loop 2 Wire Half Duplex 7 2 Repeaters RS 485 Transceivers Repeaters of the Half Duplex variety are required for large networks of instruments e In atwo wire connection a maximum of 247 instruments on one COM port of the PC can be included in the same network e One RS 485 Segment can accommodate only 32 Devices Power Max EM 6400 User Manual v02 04 01 40 DEVICE DEVICE 32 COMPUTER Repeaters 32 UNITS DEVICE
25. ations The three phases correspond to three potential lines A 120 phase shift exists between the three potential lines A typical configuration has either a Delta connection or a Wye Star connection see Figure 4 1 below In a three phase system the voltage levels between the phases and the neutral are ideally defined by V1 V2 V3 V12 V3 V23 V3 V31 V3 In practice there will be some unbalance difference Figure 4 1 Three Phase System 1 Delta 2 Star Wye Voltages between the phases vary depending on loading factors and the quality of distribution transformers Power measurement in a poly phase system is governed by Blondel s Theorem Blondel s Theorem states that in a power distribution network which has N conductors the number of measurement elements required to determine power is N 1 A typical configuration of poly phase system has either a Delta connection or a Star Wye connection see Figure 4 2 below Figure 4 2 Poly Phase System 1 Delta 2 Star Wye Power Max EM 6400 User Manual v02 04 01 25 CON ZERV 4 2 Consumption and Poor PF CONSUMPTION Wh W x T where W instantaneous power T time in hours The total electric energy usage over a time period is the consumption of Wh Typically the unit in which consumption is specified is the kilowatt hour kWh one thousand watts consumed over one hour Utilities use the Wh eguation to determine the overall consumption in a bi
26. d Programmable PT Secondary range 100 to 500v ac rms L L Power Max EM 6400 Voltage Input burden 0 2 VA per input See Section 3 2 Setup Field Programming section for programming details IMPORTANT The PT Primary and Secondary values must be User Programmed before using the Meter Otherwise the readings will be wrong CAUTION Before wiring de energize the PT secondary by opening the circuit or removing the fuse Do not short the PT secondary 6 3 2 Selecting the Voltage Fuses We strongly recommend using fuses on each of the sense voltages and the control auxiliary power although connection diagrams often do not show them Use a 1A fuse on each voltage input 6 4 Current Signal Connections The meter accepts up to 6A ac rms per channel directly Above that a Current Transformer must be interposed to scale down the current There are three pairs of Current Input terminals marked A1 A2 and A3 Each pair of input terminal is labelled as S1 S2 and has an arrow indicating the direction of current flow For proper measurements the phase identification as well as the polarity of the current signals must be correct The Forward flow Import by consumer current direction must be into the S1 terminal and the exit from the S2 terminal Please maintain the correct sequence and polarity to avoid wrong readings Any unused current input terminals e g A2 S1 S2 for Delta must be shorted together The shorted terminal
27. e 1000 is required o To enter the code edit the blinking digit value up or Down to get 1000 o Keep going Left o Without entering the code you may view the settings but you can t change them Within the SET page options the Factory settings are shown Bold Text in the right side column above Power Max EM 6400 User Manual v02 04 01 16 Code y oc i RUN P a gt v RMS A F V A F VA W VAR W VA See Y z a ap gt V 1 mm v A o 1 rW n DM 4 w Zus t e 9 MD HR pt eee ee ee RER y me u MR r A 9 a A v Wh VARh VARh run h THD with THD option only DIAG CON ZERV Legend lt q gt Use or keys 4 Use f or v keys v Use v key only R VAh R Wh R VAR RS 485 mme Status Evn 1 a 6400 Factory 02 04 QA only 01 00 vi Figure 3 1 The Run Mode Flow chart Power Max EM 6400 User Manual v02 04 01 17
28. ered but masks it with 0000 so someone watching doesn t steal the password After changing the desired Setup values Step 4 the sequence to get back to the RMS page is 5 6 7 8 e Exiting Setup requires you to Save the settings Step 6 SAVE Y press lt To Discard the changes toggle Up A or Down to get SAVE N before pressing lt Power Max EM 6400 User Manual v02 04 01 19 CON ZERV Going forward from 7 RUN to 8 PROG does not require any Code You go Pr straight through Legend lt gt Use gg or gt keys an Use O or y y Use v key only To PROG Code Entry Enter the New Value Figure 3 2a Entering and Exiting Setup Legend lt q Use or gt keys To program via code entry T _ a j v seys y Use v key only Figure 3 2b Code entry for Entering Setup Power Max EM 6400 User Manual v02 04 01 20 CON ZERV RUN vies 2000 CODE PROG View ey E Ser only o program via code entry lt l PASS 9 00 Bu 4 FAL Pe view E copE q i a
29. ever check your SCADA Program s Modbus driver specs such as an offset of 40 001 In this case of Power Max EM 6400 Address 3000 must be treated as Modbus Register Address 43 001 e The Power Max EM 6400 supports the transfer of whole block and also of individual Data values 2 Registers are used for storing single Data value o In transfer of whole block it basically treats each block as an object with the starting address e g 3000 considered as the object name This enables fast block transfers since Power Max EM 6400 User Manual v02 04 01 A CON ERV Energy Management usually reguires a block of related readings as of the same point of time This method also eliminates time skew within readings of that Block o In transfer of individual data values it basically treats 2 registers as an object with the starting address e g 3900 considered as the object name This enables to transfer required data values for energy management e Most of the data are in 32bit format IEEE Single Precision Float 2 registers are used for storing a single data value A float or real setting on your SCADA Driver will usually suffice for automatic conversion A few values are in Unsigned Long 32 bits e Your SCADA software must support Register Blocks consisting of different Data Types Integers and Floats to transfer of Whole Block e Each Modbus register size is 16 bits All Power Max EM 6400 readings are 32 bits Therefore each Power Max EM 6
30. g Clamp Screws Slotted 2 nos Combination Phillips and Slotted head The cut out should be punched with the proper tool and should be free from burrs Before Wiring insert the Power Max EM 6400 into the cutout from the front Then fasten the two side clamps from the rear While supporting the Power Max EM 6400 from the front tighten both side clamp screws in a criss cross pattern till all slack is taken up and then apply one full turn Do not over tighten Power Max EM 6400 User Manual v02 04 01 31 CON ZERV 6 ELECTRICAL INSTALLATION DANGER All Installation wiring and periodic maintenance of the Power Max EM 6400 as well as its associated circuits involve high voltages and currents While this manual suggests several safety and reliability steps it must be used in conjunction with the safety codes in force at your location Failure to practice safe working procedures is likely to cause damage to the installation severe injury and or death All work including handling of electrical circuits during Installation wiring periodic maintenance must be done only by qualified personnel Neither CONZERV nor its agents may be held responsible for damage or death arising out of the wiring and or PT CT or other external circuits The covers of the Power Max EM 6400 should never be dismantled or opened There are no user serviceable parts inside The Power Max EM 6400 contains high precision components which require special ha
31. he range thereafter without re programming the Power Max EM 6400 the Power Max EM 6400 will read erroneous values 6 4 2 CT Polarity When the meter is connected using the CTs you must maintain the correct CT polarities CT polarities are dependent upon correct connections of CT leads and upon the direction the CTs are facing when clamped around conductors The dot on the CT must face the line side the corresponding secondary connection must connect to the appropriate input on the meter Failure to connect CTs properly results in inaccurate power readings If your meter is not reading power properly it is more than likely that the CT is incorrectly wired If one or two CTs are reversed then Energy parameters accumulate only one phase value If two or all the phases of the CT are reversed Energy will not accumulate Energy Export will not be measured Power Max EM 6400 User Manual v02 04 01 35 CON ZERV 6 4 3 CT Connection Reversal To check the polarity of the CT after the meter has been installed simply look at the phase wise W Watt readings to see that each of the readings are positive assuming you are consuming power If one of the W readings is negative that particular phase CT is reversed and must be corrected On the other hand if you are exporting power all three phase wise W readings must be negative 6 5 Setup System Type The Power Max EM 6400 needs to know what type of 3 phase system it is connected to T
32. his is programmed in the Setup procedure Section 3 2 before using the meter The meter does allow you to change this setting while it is running however this capability is meant for correcting a gross error or for training or educational purposes not to be changed regularly The options are e Star Wye For 3 phase 4 wire Three Watt meter or Three Element circuits Here all three voltage Phase signals the Neutral voltage connection and all three current input signals need to be wired in means all the 4 voltage terminals and 6 current terminals described in the following section need to be wired This setting is also used for Single Phase Circuits Here the V1 and VN terminals as well as the A1 S1 and S2 terminals will be used to sense a single voltage and a single current e Delta For Three Phase Three Wire Two Watt meter or Two Element circuits 6 6 Phase Labels The Phase Labels shown on the display are programmable via the Power Max EM 6400 Front Panel Set up menu The choices available are 123 factory set RYB RST POR ABC 6 7 Connection Diagrams Choose the diagram below that best describes your application You must ensure that the CT phase and corresponding PT phase are identical and that the CT polarity is correct as explained in CT Polarity above Follow the outlined procedure to verify correct connection 6 7 1 Power Max EM 6400 Rear Panel The meter terminals are located on
33. hree Phase Electrical Instrumentation and load management facilities in a compact and rugged package To get the best out of your investment we suggest that you take a few moments to review this Manual This Chapter contains the main operating instructions The remaining Chapters explain the Installation and Setup steps before the Meter 1s ready for use The Power Max EM 6400 is a universal meter Before use please program the SYS measurement system configuration PT and CT ratios through the front panel keys Otherwise it will read your system incorrectly Other settings such as communication parameters must also be programmed as needed CONZERV stands behind your Power Max EM 6400 products with complete User Support and Service If the need arises please do not hesitate to contact us at support conzerv com Figure 2 1 The Power Max EM 6400 Multi function Load Manager Power Max EM 6400 User Manual v02 04 01 6 CON ZERV 2 1 Physical Description FRONT The front panel has 3 rows of 4 digits characters each with auto scaling K kilo M Mega and minus indications The kilo and Mega indications lit together show Giga readings Five smart keys make navigating the parameters very guick and intuitive for viewing data and configuring Setup the Power Max EM 6400 REAR The voltage and current terminals and the communication port are located on the back of the meter CAUTION These contain hazardous v
34. lect which parameter to be deleted MD Press W to proceed with CLR MD fj Clear MD Yes NOTE lt 4 escapes back to Main Menu Press W to Clear PASS PASS flashes and MD cleared and MD MD displayed To head back press lt CLR Now you re back in the Main Menu and can go A to RUN and to RMS To program via code entry Legend lt gt Use Mo RUN CODE y RMS Figure 3 2d Clearing the Integrator and Demand Power Max EM 6400 User Manual v02 04 01 23 CON ZERV 3 2 2 Energy Integrator Your Power Max EM 6400 meter is eguipped with Energy Integrator function which provides several parameters for Energy Management VAh Wh VARh VARh run h run hours on h on hours Intr Interruptions outages A few of these need explanation run h Indicates the period the Load is ON and has run This counter accumulates as long as any one Amps phase has more than 10mA through the meter terminal on h The period for which the meter supply is ON INTR Number of Supply Outages means the number of Auxiliary Supply interruptions If the meter Auxiliary Supply is from a UPS then the Intr number of interruptions will be zero as long as the UPS stays ON even 1f the Voltage Signals did die out from time to time 3 2 2 1 Integrator Overflow Your Power Max EM 6400 meter contains a comprehensive Integrator to support Energy Management It accumulates several parameters over
35. lling period POOR POWER FACTOR Results in reactive power consumption Transferring reactive power over a distribution network causes energy loss To force consumers to correct their Power Factor utilities monitor reactive power consumption and penalize the user for Poor Power Factor 4 3 3D kVA Measurement The Power Max EM 6400 is equipped with 3D Measurement of KVA This advanced method provides the most accurate and predictable measurement under unbalanced as well as distorted waveform conditions However in case the Power Max EM 6400 needs to match the reading of older or simpler meters which use the Arithmetic KVA definition this too is available as a Set up option Table 4 1 VA Function Set up Options kVA KVA Function KVAFunction Formula Other Names Other Names Names Which Which one Ew VaR yn 2 2 a Factory KVA3D z JEW E VAR yn Wr yp VAR yp D a Best all around setting Where D Distortion Power per IEEE 100 ector Good under Low Arithmetic unbalance to au Scalar KVA match simpler meters without 3D capability Power Max EM 6400 User Manual v02 04 01 26 CON ZERV 5 MECHANICAL INSTALLATION The Power Max EM 6400 is panel mounted and has reliable rear mounted terminal strips rated at 500v The 92 x 92 mm cut out and 96 x 96 mm bezel dimensions adhere to DIN 43700 Depth reguired behind the Bezel is 80 mm plus space for wiring Two side clamps are provided for fir
36. m mounting CAUTION All Installation wiring and maintenance instructions to be carried out by qualified personnel only Please read this and the following chapter completely before proceeding These diagrams display the var ous dimensions of mechanical installations SIDE VIEW 5 00 96 00 REAR VIEW Power Max EM 6400 User Manual v02 04 01 FRONT VIEW EM 6400 TOP VIEW Power Max EM 6400 User Manual v02 04 01 28 RECOMMENDED CUTOUT 92 x 92 mm Power Max EM 6400 User Manual v02 04 01 gaits CON ZERV HS a Not to scale 29 CON ZERV 5 1 Installation Procedure 5 1 1 Panel Mounting for New Installations 5 1 1 1 Location and Mounting considerations DANGER All Installation wiring and periodic maintenance of the Power Max EM 6400 as well as its associated circuits involve high voltages and currents While this manual suggests several safety and reliability steps it must be used in conjunction with the safety codes in force at your location Failure to practice safe working procedures is likely to cause damage to the installation severe injury and or death All work including handling of electrical circuits during Installation only qualified personnel must do wiring and periodic maintenance Neither CONZERV nor its agents may be held responsible for damage or death arising out of the wiring and or PT CT or other external circuits The covers of the Power Max EM
37. n i i l i auxiliary supply is present irrespective of input signals ae Intr Auxiliary interruption Accumulates the auxiliary interrupt DIAG For factory testing only 5 DIA2 For factory testing only CLR INTG SET Choice of values SYS Power system s configuration Star 3E 4V3A Delta 3E 3V2A Stas V PRI Voltage primary winding PT Line to Line 100 yin V to 999 kV 415 0 V SEC Voltage secondary winding PT Line to Line 80 to 600 V 415 0 A PRI Current primary winding CT I A to 99 KA 5000 0 A SEC Current secondary winding CT I to 6 5 A 5 000 LABL Phase labelling formats 123 RYB RST PQR ABC VA Fn VA function selection 3d Arth d SEL Demand selection auto user d PAR Demand parameter VA W d PRd Demand period 5 10 75 20 25 30 baud Baud rate 1200 2400 4800 9600 19200 Prty Parity and Stop bit settings EVn I EVn 2 Odd 1 Odd 2 no 1 no 2 ID RS485 Device ID number 007 to 247 Evn 1 Even 1 stop bit changing these values while the device in use is not recommended Default set up values are given in bold and italics KEY FUNCTION MAP NOTES 1 To Clear Integrated values or Set meter settings you must first enter the Main Menu 2 Go Up to PROG then Left to enter the Main Menu See Map or Table 3 1 e You must now enter the Factory Set code of 1000 to proceed o CODE y followed by the entry of the Cod
38. nd update Wh accuracy Class 1 0 as per IEC 62052 11 and 62053 23 class 0 5 is optional as per IEC 62052 11 and 62053 22 and ANSI C12 20 Impulse 6 kV IEC 60060 1 2 uS 50 us Fast Transient gt 2kV IEC 61000 4 4 Level 3 ESD IEC 61000 4 2 Emission meets CISPR 22 Power 4 Quadrant Energy 2 Quadrant Provides 3D power computation for kVA 2 3 1 Standard Measurements The Power Max EM 6400 can measure locally display and remotely transfer over MODBUS RTU the following electrical parameters over the input range with an accuracy of Class 1 0 or better for Volts and Amps Power and Energy functions Class 0 5 is optional True rms voltage phase to neutral and 3 phase average True rms voltage phase to phase and 3 phase average True rms current per phase and 3 phase average Real Power and Energy Reactive Power and Energy Power Factor Freguency The Power Max EM 6400 provides all single phase per phase Real Apparent Reactive Power and Power Factor values Positive Inductive and Negative Capacitive Reactive Energy 1s separately accumulated for Lead Lag analysis Power Max EM 6400 User Manual v02 04 01 11 CON ZERV 1 1 1 1 Accuracy Table 2 5 Accuracy Table Class 1 0 standard and Class 0 5 ordering option Measurement eee Class 1 0 Class 0 5 BRS fe Votage LL perp SY Barr SY hym SY Ampere je ame TEE ener m Rel Power kW Per Prema an 10 _Reaive Power VAR Per Phase nd Tw 20 g
39. ndling available only at authorized CONZERV service locations High voltages are likely to be present inside even after the Power Max EM 6400 has been switched off Opening the covers of the Power Max EM 6400 and or any attempts to dismantle service repair or modify the unit by unauthorized persons may cause severe injury will damage the unit and will also render CONZERV s warranty void This Chapter describes the following e The Need and selection of Potential Transformers PTs and Current Transformers CTs e Auxiliary Supply PT and CT Connections NOTE For best wiring results with the new Terminal cover please ensure the following specs Improper wire man ship will damage the Terminals and require Factory Replacement This does not indicate defective manufacture and is not covered by product warranties e Power Driver preferred Hand Screw Driver OK e TIP Phillips preferred DO NOT USE POZIDRIV TIPS Flat OK D Screw Head Diameter 3 5mm TIP Shaft Diameter lt 5mm IMPORTANT Driver Shafts inserted angularly or of Diameter 5mm or more WILL GET STUCK in the Safety Cover Tightening Torque 25 to 60 N cm Loosening Torque 55 to 60 N cm Screw Travel 6 mm less wire thickness Torque greater than 60 N cm may strip the screw or break the Safety Cover Worn out bits and insufficient hold down pressure while tightening will cause the bit to ride on the screw head thus stripping and damaging it Power Max EM 6400 User
40. needs to digit Three times totally be changed from 2 to 1 Press Y to decrement 1000 Now the Code of 1000 is almost in 0 Press 4 to enter the Main 0000 Notice that a 0 quickly hides each code digit Menu you enter PASS RUN indicates a successful entry into the RUN Main Menu Congratulations Or If you were not successful don t despair you FAIL can have another go from the top of this Table Briefly switching off the Meter will easily return Ko ee to the RMS page the starting point Again press V SET Press W to get into setup SYS Go bais EEE to see other Settings V PRI Go to see and change their values V SEC Once you re done re trace RUN You re now at the top of the Main Menu Go your path lt and A gt You ll see RMS You can now go gt or V Remember Save Y to view all the display pages 3 2 1 Editing the Setup First take a look at the Table 2 3 Keypad Operations Table Locate the Shaded Bold display pages below To enter SET and change a Setting value the sequence shown below is 1 2 3 and 4 along the way the following must be observed e The Password Code must be entered to change the Setup The code offered will read 0000 Edit A V the blinking Digit to achieve 1000 Press 4 when done with each digit to keep moving towards the Run page The Meter accepts each digit ent
41. next right side digit Left Key e The Opposite of the Right key e Go Back towards to the Main Parameter Pages Going Left past PROG reguires Code entry to enter Main Menu Setup and Clear e During Edit Setup selects previous left side digit e Exits from Edit mode back to the Main Menu Up Key Scroll Up through Display Pages at the same level within the same Function Continuous pressing for 3 seconds initiates limited Auto scroll within the same Function Press any key to return to manual scrolling While editing increases the value of the blinking digit during Edit Typically while changing the Meter Setup settings Down Key e The Opposite of the Up key Scroll Down through other Display Pages at the same level through all functions Continuous pressing for 3 seconds initiates the Full Auto scroll mode through all functions Press any key to return to manual scrolling While editing decreases the value of the blinking digit during Edit Favourite FAV Key e The FAV key scrolls through the following pages RMS Home page VLL A F VLN A F VA W VAR W VAR PF PFI PF2 PF3 V9o1 V992 V903 A9ol A992 A003 VA d R d tr MD HR VAh Wh R VAh R Wh t VAh t Wh This gives simple one touch access to the most commonly used parameters even for unskilled operators One Touch does not operate in the Setup Program Mode e If you re lost the FAV key is a quick way to get back to the RMS home page
42. nt Three current measurements phase wise 1 2 3 one average current of all three phases and three current phase angles A A A with respect to the corresponding Voltage Line Neutral vector e Frequency Measured from whichever phase is active e Power VA W and VAR Per phase and Total PF per phase and 3phase Per Phase W readings provide a quick CT Polarity Check A negated W phase reading indicates CT reversal e Energy VAh Wh VARh Ind VARh Cap Run Hrs On Hrs Supply Interruptions outage e Kilo Mega Giga indication for the above parameters 3 1 Keypad Operation Table 3 1 shows a complete Map of all the Key Functions Next Figure 3 1 shows a flowchart of Key Operations Look at the shaded left half titled Name Then follow these simple steps e First take a quick look at what the Keys do Try the simple example e Now try getting around to other parameters by moving Up Down Right and Left The readings are organized as Display Pages to the Right of RMS and INTG o The Kilo Mega and Negative Indicators are automatic Kilo and Mega light up together to show Giga e You cannot To go Left into the Main Menu RUN unless you enter an entry Code See Table 3 1 Note 1 e Once in the Main Menu RUN you can go Down to CLR or SET Going right though the CLR page allows you to clear the Integrator Similarly keep going right thro
43. oltages during operation and must be operated only by gualified and authorized technicians 2 2 Front Panel The front panel contains the following indicators and controls e Three rows of display 4 digits each that display three rms parameters simultaneously or one Energy Parameter The displayed readings update every second e For each row Kilo Mega Kilo Mega Giga indicator and a Negative indicator e Five keys to scroll through the display page The Power Max EM 6400 solves the problem of tiny cluttered indicators by prominently displaying the parameter name right on the large readouts For the first time in a Panel Meter the Parameter Name is as clearly readable as the value The name will be displayed for 2 seconds as well as each time you press a key and then the Value for 8 seconds This method also allows programmable Phase Labels in the Power Max EM 6400 products You can choose from 123 Factory setting ABC RYB PQR or RST EM 6400 ENERCON Figure 2 2 The P ower Max EM 6400 front panel with display and keypad Power Max EM 6400 User Manual v02 04 01 7 CON ZERV 2 2 1 The Indicators Table 2 1 Kilo Mega and Negative Indicators Mega When lit indicates that the reading is in Mega 10 6 10 000 K is shown as 10 00 M 1 0 M is displayed as 1000 K When Kilo and Mega are both glowing the reading is in Giga 10 9 10 000 M is shown as 10 00 G 1 0 Gis shown as 1000 M Neg When lit indicates
44. rage Temperature 25 to 70 C 13 to 158 F Operating Temperature 10 to 60 C 14 to 140 F Relative Humidity 5 to 95 non condensing The Power Max EM 6400 should be separated from other equipment and sufficient space must be provided all around for cooling air to rise vertically past the instrument The cooling air temperature must be below the specified operating temperature The panel or housing in which the Power Max EM 6400 is mounted should protect it from dust moisture oil corrosive vapours etc Power Max EM 6400 User Manual v02 04 01 30 CON ZERV The panel doors must be easily opened to provide easy access to the Power Max EM 6400 wiring for trouble shooting Allow clearance 1f the unit is going to swing out as well as adeguate slack in the wiring Allow space for terminal blocks CT shorting blocks fuses auxiliary contractors and other necessary components 5 1 1 4 Viewing For ease of operation in the location should be preferably at or slightly above eye level For viewing comfort minimize glare and reflections from strong light sources 5 1 1 5 Mounting Before Mounting and Wiring the Setup procedure see section 3 2 should have been completed The Power Max EM 6400 is panel mountable 9205 0 w x 92 0 5 0 mm h DIN 43700 Panel Thickness 0 5 to 4 0mm Instrumental Bezel dimension 96 x 96mm Depth behind Bezel 80 mm Leave clearance for wires 82 mm with Terminal Cover Mountin
45. rations and single phase via Star Wye Phase 1 e 3 phase voltage and current inputs o Volts 80 to 500 Phase Phase Amps 50 mA to 6 A Overload 10 A continuous 50 A for 3 seconds Field configurable for 5 A or 1 A secondary CTs Burden Load Less than 0 2 VA per Volt Ampere input Frequency 50 60 Hz 45 to 65 Hz O O 0 bob 2 3 5 Environmental Conditions e Sealed dust proof construction Meets IP51 for the front panel e Temperature Operating 10 to 60 C 14 to 140 F Storage 25 to 70 C 13 to 158 F e Humidity Below 5 to 95 non condensing 2 3 6 Dimensions and Shipping e Basic unit installed depth 80 mm behind bezel with 92x92 mm panel cutout flush mount The Protection cover affixed over the rear Terminal Block extends the depth to 82 mm e Bezel dimension 96 x 96 mm Panel Cutout 92 x 92 mm e Weight 400 gms approx Unpacked 500 gms approx Shipping See Chapter 5 Mechanical Installation Power Max EM 6400 User Manual v02 04 01 13 CON ZERV 3 QUICK START GUIDE This Chapter shows at a glance how to view the following pages e Viewing Three Phase Total values Viewing Per phase Values Viewing Energy Values INTG Clearing Resetting Energy Values Setting up Program the meter before use The Power Max EM 6400 displays e Voltage Three voltage measurements Line to Line 1 2 2 3 3 1 and Average Three voltage measurements Line to Neutral 1 4 2 4 3 4 and Average e Curre
46. s do not need to be grounded Power Max EM 6400 User Manual v02 04 01 34 CON ZERV Install the wiring for the current circuit at 500V ac insulation as a minimum The cable connection should be rated for 7 5A or greater and have a cross sectional area of 16AWG minimum CAUTION 9 Before wiring de energize the CT secondary by shorting it via a shorting block Under no circumstances must the CT secondary be left open circuited even momentarily when primary current is flowing This causes high voltages that will overheat and explode the secondary of the CT and damage the instruments as well 6 4 1 CT Connections Mount the current transformers CTs as close as possible to the meter for best accuracy The following table illustrates the maximum recommended distances for various CT sizes assuming the connection is via 16AWG cable Table 6 1 CT Size and Maximum Distance 100 VA 15 0 VA 30 0 VA 120 Feet Field Programmable CT Primary range 1A to 999kA ac CT Secondary 1A or 5A ac programmable Other values are also programmable to compensate CT errors 1f desired EM 6000 CT burden 0 2VA maximum per input See the Setup Field Programming section for programming details IMPORTANT The CT Primary and Secondary values must be User Programmed before using the Meter Otherwise the readings will be wrong NOTE 1 With Dual Range CTs select the best range for programming the Power Max EM 6400 Do not change t
47. t Apparent Poster VA Per Phase and Tan 10 freskerne 10 _ ao BEU To e Active Energy kWh Import Export e Reactive Energy kVARh Ind Cap e Apparent Energy kV Ah e Note 1 Additional error of 0 05 of full scale for meter input current below 200 mA e Note 2 PF error limit is same as W error limit in 2 3 2 Auxiliary Power Supply The meter needs a single phase ac or dc Control supply to power its internal electronics Auxiliary supply voltage 80 to 270 V ac or 100 to 270V dc Burden load lt 3 VA auxiliary supply 2 3 3 Front Panel Display e Brilliant 3 lines 4 digit digit height 14 2 mm per line LED display with auto scaling capability for Kilo Mega and Giga e The display provides the user access to all phase Voltages phase to neutral and phase to phase Currents per phase and total Watts VARs VA Power Factor Frequency and kWh kVAh and kVARh e The Power Max EM 6400 displays total volts amps and frequency simultaneously e Easy set up through keys located on the faceplate for common configuration parameters e Password protection on setup parameters Power Max EM 6400 User Manual v02 04 01 12 CON ZERV 2 3 4 Installation and Input Ratings e Auto ranging voltage inputs should allow direct connection up to 500 VLL ac systems no PTs required up to 500 VIL phase to phase e Supports field configurable direct 4 Wire Star Wye 3 Wire Star Wye 3 Wire Delta configu
48. t back to the RMS home page e Continuous pressing for 3 seconds initiates Auto scrolling through the above FAV pages 3 2 Setup Program The meter must be set programmed configured to match the application settings before use Otherwise the readings will be wrong All the Setup values can be re programmed at any time upon entering SET However the settings SYS Star wye or Delta Vpri Vsec Apri Asec critically determine the scaling of measured readings While the scaling may be used to tune out Instrument Transformer errors wrong settings will upset the readings of running systems It is the user s responsibility to ensure that only qualified personnel correctly Set up the Meter Power Max EM 6400 User Manual v02 04 01 18 CON ERV Table 3 1a Entering in to setup Display From the RMS or INTG The meter 1s about to enter the Main Menu page go Up A a blinks To proceed with Code Entry we need to enter Then go Left the Main Menu e Go Left lt Code vi is displayed NN blinks Or to abort and re enter RMS e Press Or to only view setup no edit e Press A or Fto toggle W to an e Press lt to enter Main Menu Fail is flashed then RUN is displayed To proceed with Code Entry 000 The MEMS digit indicates the cursor The code is Factory Set to 2 We have now entered the Units Tens and 1000 Press lt 4 to enter each Hundreds digits The Thousands digit
49. ugh SET to program the meter settings When done o Go Left all the way back to the Main Menu o Go Up to RUN o Go Right into RMS to view the Display Pages again Power Max EM 6400 User Manual v02 04 01 14 CON ERV Table 3 1 Meter Function Map lt Code Name Description Note 1 RMS V LL V 12 VLL Voltage phase to phase Avg A Start Here A 23 V 12 Voltage rms phase 1 to phase 2 F 31 V 23 Voltage rms phase 2 to phase 3 V 31 Voltage rms phase 3 to phase 1 A Current Average F Frequency Vi Voltage rms phase to Neutral 2 Voltage rms phase 2 to Neutral 3 Voltage rms phase 3 to Neutral VLN Voltage phase to Neutral Average A 2 A Current phase wise Average F 3 A 1 Current rms phase 1 2 Current rms phase 2 3 Current rms phase 3 F Frequency in Hertz N Current Phase Angle of phase 1 in degrees 2 Current Phase Angle of phase 2 in degrees 3 Current Phase Angle of phase 3 in degrees y VA 1 VA Volt amperes Total 2 VA 1 Volt amperes phase 1 3 VA 2 Volt amperes phase 2 VA 3 Volt amperes phase 3 W Watt Total VAR VAR Total W 1 W Watt Total Note Watts reverse current 2 W 1 Watts phase 1 3 W 2 Watts phase 2 W 3 Watts phase 3 VAR VAR Total PF Power factor Average Power factor phase 1 Power factor phase 2 Power factor phase 3 Note Indicates Lead Capacitive Power factor A Vv lt Z v l B lt sz lt SBS 7 F
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