IoT Pro Energy Module

Installation Guide

This installation must be performed by a qualified electrician or authorized technician only due to high voltage hazards

Before you begin

Before your first installation, complete the IoT Pro Quick Start in the office to familiarize yourself with the process

Safety First: If you are working on a switchgear or large distribution board where uncovered busbars are used, switch off the entire supply as contact with conductors is possible.

Installation Tips: Throughout this installation, refer to:

Cable Management - for proper cable routing techniques
Wire Extensions - if you need to extend any sensor cables

Turn off the main supply to the supply you are going to be monitoring and any supply close you may come in contact with before drilling any holes into electrical boxes

Parts Needed

1 x IoT Pro Energy Module
1 x Energy Meter
3 x Current Transducers (one for each phase) which converts high current to either 5A or 1A
2 x Terminal block for neutral
5 x 1A Quick blow fuses and holders
1 x 12VDC 1A Power supply
As Necessary x Single Core 0.75mm² cable in brown for L1, black for L2, grey for L3 and blue for neutral
As Necessary x 2 Core 0.75mm² cable for DC supply
1 x 12mm HSS drill bit
1 x 6mm Masonry drill bit
1 x M12 Grommet

Optional but Recommended

As Necessary x AD21.2 conduit or industrial wiring duct
1 x Bond and Seal (Wurth recommended)
M5 self drill A4 Stainless Steel screws

5 x L1 wire labels
8 x N wire labels
3 x L2 wire label
3 x L3 wire label
2 x +DC wire label
2 x -DC wire label
3 x S1 wire label
3 x S2 wire label
1 x TX+ wire label
1 x TX- Wire label
1 x 20mm HSS drill bit
6 x flexible conduit gland, we recommend this one, in AD21.2-M20
8x multi-hole cable glands, we recommend this one, in M12-3holes-2.7mm
Enclosure with 10 modules spaces of available din rail mounting, we recommend this one, with PG9 glands and size 210x110x100mm.
190mm of 35mm Din Rail

Installation

To start select the supply you would like to monitor and confirm that you have 10 modules of DIN Rail space available, separated into 4 module spaces for the energy meter, 1 module space for the 12v power supply and 5 module spaces for the fuse holders. 1 module is 18mm. If there is not enough space a separate enclosure would need to be installed

Option A: (Domestic Consumer Unit)

With enough space as explained above
1. place the energy meter, fuse and power supply modules on the din rail and connect wiring as explained below
With no space for extra modules
1. Locate a suitable place to install an enclosure, as close as possible to the unit you are going to measure
2. Attach the box to the wall using four M6x40 A4 stainless steel wall plugs
  1. If you use flexible conduit to cover any cables passing from the consumer unit to the enclosure
    1. Drill three 20mm holes at the bottom of the body of the box, not the cover
    2. Drill three 20mm holes at the bottom of the body of the consumer unit, not the cover
    3. Attach six flexible conduit glands in these holes
    4. Measure the correct length of flexible conduit needed and cut as necessary
    5. Measure the amount of supply cable needed and cut as necessary
    6. Measure the amount of CT signal cable needed and cut as necessary
    7. Measure the amount of data cable needed and cut as necessary
    8. Pass supply, CT and signal cable through separate conduits and connect to the glands
  2. If you decide not to use flexible conduit
    1. Drill four 12mm holes at the bottom of the body of the enclosure, not the cover
    2. Drill four 12mm holes at the bottom of the body of the consumer unit, not the cover
    3. Attach eight multi-hole cable glands in these holes
    4. Measure the amount of supply cable needed and cut as necessary
    5. Measure the amount of CT signal cable needed and cut as necessary
    6. Measure the amount of data cable needed and cut as necessary
    7. Pass each cable through the attached glands, only 1 cable per hole for adequate sealing (note: if you use the recommended glands there will be an extra hole in one of the glands, insert a piece of cable the length of the gland for a proper seal)
3. cut 190cm of DIN Rail and install it inside the enclosure using stainless steel M5 self tapping screws
4. place the energy meter, fuse and power supply modules on the din rail and connect wiring as explained below

Option B: (Switchgear)

With enough space on an existing DIN rail as explained above
1. place the energy meter, fuse and power supply modules on the din rail and connect wiring as explained below
With enough space inside the switchgear but not on an existing DIN Rail
1. cut a total of 180mm of DIN rail, you can split this as you prefer according to the sizes explained above
2. install it inside the switchgear using stainless steel M5 self tapping screws
3. place the energy meter, fuse and power supply modules on the din rail
4. Measure the amount of supply cable needed and cut as necessary
5. Measure the amount of CT signal cable needed and cut as necessary
6. Measure the amount of data cable needed and cut as necessary
7. if any cables are going to be left uncovered between connections we recommend using industrial wiring duct as necessary
8. connect wiring as explained below
With no space for extra modules inside the switchgear
1. Locate a suitable place to install an enclosure, as close as possible to the unit you are going to measure
2. Attach the box to the wall using four M6x40 A4 stainless steel wall plugs
  1. If you use flexible conduit to cover any cables passing from the switchgear to the enclosure
    1. Drill three 20mm holes at the bottom of the body of the enclosure, not the cover
    2. Drill three 20mm holes at the switchgear, not on top
    3. Attach six flexible conduit glands in these holes
    4. Measure the correct length of flexible conduit needed and cut as necessary
    5. Measure the amount of supply cable needed and cut as necessary
    6. Measure the amount of CT signal cable needed and cut as necessary
    7. Measure the amount of data cable needed and cut as necessary
    8. Pass supply, CT and signal cable through separate conduits and connect to the glands
  2. If you decide not to use flexible conduit
    1. Drill four 12mm holes at the bottom of the body of the box, not the cover
    2. Drill four 12mm holes at the switchgear, not on top
    3. Attach eight multi-hole cable glands in these holes
    4. Measure the amount of supply cable needed and cut as necessary
    5. Measure the amount of CT signal cable needed and cut as necessary
    6. Measure the amount of data cable needed and cut as necessary
    7. Pass each cable through the attached glands, only 1 cable per hole for adequate sealing (note: if you use the recommended glands there will be an extra hole in one of the glands, insert a piece of cable the length of the gland for a proper seal)
3. cut 190mm of DIN Rail and install it inside the enclosure using stainless steel M5 self tapping screws
4. place the energy meter, fuse and power supply modules on the din rail and connect wiring as explained below

Option C: (Machinery)

When it comes to machinery there will rarely be a suitable place to install separate modules, in this case we will be using an enclosure

Locate a suitable place to install an enclosure, as close as possible to the supply you are going to measure
Attach the box to the wall using four M6x40 A4 stainless steel wall plugs or to the metal of the machine using M5 self tapping screws (note: make sure that there is nothing behinf the metal plate you are going to screw into)
1. If you use flexible conduit to cover any cables passing from the switchgear to the enclosure
  1. Drill three 20mm holes at the bottom of the body of the box, not the cover
  2. Drill three 20mm holes at the machinery supply box, not on top
  3. Attach six flexible conduit glands in these holes
  4. Measure the correct length of flexible conduit needed and cut as necessary
  5. Measure the amount of supply cable needed and cut as necessary
  6. Measure the amount of CT signal cable needed and cut as necessary
  7. Measure the amount of data cable needed and cut as necessary
  8. Pass supply, CT and signal cable through separate conduits and connect to the glands
2. If you decide not to use flexible conduit
  1. Drill four 12mm holes at the bottom of the body of the box, not the cover
  2. Drill four 12mm holes at the machinery supply box, not on top
  3. Attach eight multi-hole cable glands in these holes
  4. Measure the amount of supply cable needed and cut as necessary
  5. Measure the amount of CT signal cable needed and cut as necessary
  6. Measure the amount of data cable needed and cut as necessary
  7. Pass each cable through the attached glands, only 1 cable per hole for adequate sealing (note: if you use the recommended glands there will be an extra hole in one of the glands, insert a piece of cable the length of the gland for a proper seal)

Electrical Connections

Turn off the main supply to the supply you are going to be monitoring and any supply close you may come in contact with before proceeding

Note: A complete wiring diagram is available at the end of this guide for reference

Fuse holders

Route the supply cable to the fuse holders and connect as follows:

L1: Brown wire from the first phase you want to measure
L2: Black wire from the second phase you want to measure
L3: Grey wire from the third phase you want to measure
N: Blue wire from the neutral of the phases you want to measure
LA: Brown wire from a separate place than the measured one
NA: Blue wire from the neutral of the phase chosen for LA

Energy Meter

Route the supply, CT and signal cable to the energy meter and connect as follows:

L1: Brown wire from the fuse holder
L2: Black wire from the fuse holder
L3: Grey wire from the fuse holder
N: Blue wire from the fuse holder
LA: Brown wire from the fuse holder
NA: Blue wire from the fuse holder
LA: Brown wire going to 12v power supply L
NA: Blue wire going to 12v power supply N
S1-1: The head end of the secondary winding (usually white) wire coming from CT on the first phase
S2-1: The tail end of the secondary winding (usually black) wire coming from CT on the first phase
S1-2: The head end of the secondary winding (usually white) wire coming from CT on the second phase
S2-2: The tail end of the secondary winding (usually black) wire coming from CT on the second phase
S1-3: The head end of the secondary winding (usually white) wire coming from CT on the third phase
S2-3: The tail end of the secondary winding (usually black) wire coming from CT on the third phase
TX+ A: Twisted pair brown & brown/white network cable going to the IoT Pro
TX- B: Twisted pair green & green/white network cable going to the IoT Pro

Power supply

Route the LA and NA cables from the energy meter to the 12v power supply and connect as follows:

L: Brown wire from LA
N: Blue wire from NA
+: one wire from a two Core 0.75mm² wire going to IoT Pro
-: one wire from a two Core 0.75mm² wire going to IoT Pro

IoT Pro

Route the 12v supply and signal cable to the IoT Pro and connect as follows:

A: Twisted pair brown & brown/white network cable coming from energy meter
B: Green network cable coming from energy meter
B*: Green/white network cable coming from energy meter
10-30VDC: wire from power supply +
GND: wire from power supply -

Testing and Commissioning

Initial Verification

Connect to the IoT Pro device using the mobile application
Confirm that Peripherals is OK
Verify the Application Data

Software Platform Configuration

Log In to your IoT Pro Software Platform
Navigate to Assets
Create a new asset whilst taking particular note of the following settings:
1. Choose the Device ID based on the label on the device
2. the current reading of the electricity meter