How to Install a Verdigris System
Welcome! This manual will guide you on how to install your new system. If you need direct assistance, call our support line at 1-844-837-3447 or email
[email protected]. WARNING Installation of a Verdigris System should only be performed by a licensed electrician. You should consult your local inspector for compliance with electric codes.
Table of Contents Component List (what’s in the box) ……………………………………………….. 2 Tools Required……………………………………………………………………………….. 6 Data Transmitter Location……………………………………………………………… 7 Determine Panel Type……………………………………………………………………. 8 Select Voltage Tap Cable Type………………………………………………………… 9 Select Breakers For Voltage Tap……………………………………………………..10 Voltage Tap Installation For Three-Phase Panel…………………. 10 Voltage Tap Installation For Split-Phase Panel……………………. 11 Add Power Cable for High Voltage Panels (>250V)……………... 12 Select Appropriate CTs………………………………………………………………….. 13 Install CTs On Left Side Breakers…………………………………………………… 13 Install CTs On Right Side Breakers…………………………………………………. 15 About Large CTs and GIMs……………………………………………………………...16 Connect Multiple CT Chains…………………………………………………………… 20 Connect Multiple GIMs………………………………………………………………….. 20 Connect CTs to the Data Transmitter…………………………………………….. 21 For Installations Using Only CT Chains……………………………….. 22 For installations Using Only GIMs………………………………………. 23 For installations Using CTs and GIMs……………………….…………. 24 Power the Data Transmitter…………………………………………………………... 25 Connect Wifi or 4G / Connect Ethernet…………………………………………... 26 Mount the Data Transmitter Outside the Panel……………………………… 28 Check the CTs…………………………………………………………………………………. 29 Turn on The System & System Checks……………………………………………. 30 Troubleshooting…………………………………………………………………………….. 31 Clean Up and Close the Panel………………………………………………………… 34
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Component List (what’s in the box)
Data Transmitter 1x per system
CT Chain Up to 14x per system
Power Cable 1x per system for high voltage panels 2
Voltage Tap Cable 1x per system for high voltage panels
Combined Power and Voltage Tap Y-Cable 1x per system for low voltage panels
Male-to-Male Data Cable 2x per system
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Female-to-Male Data Cable 2x per system
Verizon 4G USB Modem Up to 1x per system
Wi-Fi USB Modem Up to 1x per system
USB Extension Cable 1x per system 4
Generic Interface Module (GIM) (Only for wire sizes greater than 4 AWG and/or ampacities greater than 100A) Up to 14x per system
Large CT (Only for wire sizes greater than 4 AWG and/or ampacities greater than 100A) Up to 42x per system
Mounting strips with adhesive backing 3x per system Male-to-Male Data Extension Cable Up to 14x per system, 1 per GIM 5
Tools Required For all installations, you will need the following tools in addition to Verdigris components:
Tools:
● Wire Stripper ● Screwdrivers, including PH-2, SL-2, S-2
(actual needs may vary based on size of panel screws) ● Impact drill (to open the panel) ● Power drill with hole cutter (1”) or Knockout punch set (1”) ● Hammer (used with screwdriver to punch prefabricated knockouts)
Parts: ● ● ● ●
Cable Ties (up to 25 per panel) Wire nuts (size dependent on size of panel breaker wires to be tapped) Colored Electric Tape (black, red, blue) Grommet or 2 screw connector (1”)
FOR SPECIFIC CONFIGURATIONS OPTION 1: Split phase 120/240V panels, YOU WILL ALSO NEED: ● 12 gauge wire in black and red
OPTION 2: 3 phase 120/208V panels, YOU WILL ALSO NEED: ● 12 gauge wire in black, red, and blue
OPTION 3: 3 phase 277/480V panels, YOU WILL ALSO NEED: ● 12 gauge wire in brown, orange, and yellow OR black wire with colored tape (brown, orange, and yellow) to label the wire phases appropriately
For panel configurations not listed above, use appropriately sized and colored wire as necessary.
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Data Transmitter Location Whenever possible mount the Data Transmitter inside of the panel. Space Requirements 1. Inside the panel: 9.5 in. x 8 in. x 2 in. (L x W x H). 2. Mount the Data Transmitter near the top or bottom of the panel box. If the panel size does not allow an inside mount, the Data Transmitter can be mounted outside the panel. If the Data Transmitter is mounted outside of the panel, then it should be housed in a NEMA rated enclosure. 1. Look for an existing 1” knockout in the panel or create a new 1” knockout, using the knockout punch or a power drill with a hole cutter. 2. Insert a grommet or 2-screw connector into the knockout hole. This will protect cables from sharp edges. 3. Mount the Data Transmitter on the wall near the knockout. 4. Feed the voltage tap cable through the knockout from outside to inside, with the 4-wire end going on the inside, and the larger connector end remaining outside the panel.
Left: a knockout through the side wall of a panel. Right: a 2 screw connector inside of a knockout with a cable running out.
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Determine Panel Type Follow instructions for your panel type: ● low voltage panels or high voltage panels Panels with a phase-to-neutral voltage ● less than or equal to 250V are low voltage panels ● greater than 250V are high voltage panels ● three-phase panels or split-phase panels ○ A, B, and C, typically marked by 3 different colors of wires going into the breakers, are three-phase panels ○ A and B, typically marked by 2 different colors of wires going into the breakers, are split-phase panels ● wye configuration panels or delta configuration panels ○ panels with 3 phases and 4 wires are wye configuration panels ○ panels with 3 phases and 3 wires (no neutral wire) are delta configuration panels
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Select Voltage Tap Cable Type For low voltage panels (250V) use the voltage tap cable.
Voltage Tap Cable WARNING DO NOT USE the Combined Power and Voltage Tap Y-Cable. The Verdigris system is not designed to be powered directly by panels with phase-to-neutral voltages greater than 250V. IMPORTANT: For all installations: You should not insert the voltage tap cable 4-wire leads in tandem with an existing branch circuit wire (“double lugging”), unless the breaker is identified for the termination of two conductors per NEC 110-14(a). You will need a range of wire nuts to connect the black wire of the Power Cable with a branch circuit wire into a breaker. 9
Select Breakers For Voltage Tap Install one voltage tap on each phase of the panel. The voltage tap can be performed without shutting off any breakers if there is at least 1 spare breaker per phase. If no spare breakers are present, but there are empty slots in the panel, spare breakers can be inserted and used for the voltage tap as well. NOTE: If you do not have one spare breaker on each voltage phase, you will need to briefly shut down the voltage tap breakers to complete this step. Please confirm with building operators that this will not interfere with operations or safety protocols. 1. Open the panel, and locate 1 spare breaker on each phase. 2. If the panel does not have any spare breakers, shut off 1 breaker on each phase. 3. Choose breakers as close to each other as possible to keep the wires organized.
Voltage Tap Installation For Three-Phase Panel If you are using spare breakers for the voltage tap: 1. Ensure the breakers are turned off 2. Insert the black voltage tap cable wire numbered “1” into the spare breaker on phase A 3. Insert the black voltage tap cable wire numbered “2” into the spare breaker on phase B 4. Insert the black voltage tap cable wire numbered “3” into the spare breaker on phase C 5. Turn the breakers on If you are using wired breakers for the voltage tap: 1. Ensure the breakers are turned off, with the client’s permission 2. Remove the wire from the wired breaker on phase A, this is the Phase A Circuit Wire 3. Using a wire nut, splice together the black voltage tap cable wire numbered “1” with the Phase A Circuit Wire and a third wire ○ The third wire should be of equal gauge as the Phase A Circuit Wire 4. Insert the third wire from the wire nut into the breaker on phase A 5. Repeat steps 2-4 for the Phase B voltage tap, with the black voltage tap cable wire numbered “2” 6. Repeat steps 2-4 for the Phase C voltage tap, with the black voltage tap cable wire numbered “3” 7. Turn the breakers on
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Voltage Tap Installation For Split-Phase Panel If you are using spare breakers for the voltage tap: 1. Ensure the breakers are turned off 2. Insert the black voltage tap cable wire numbered “1” into the spare breaker on phase A 3. Using a wire nut, splice together the black voltage tap cable wires numbered “2” and “3” with a third wire ○ The third wire should be 14 AWG in size or larger 4. Insert this third wire into the phase B breaker 5. Turn the breakers on If you are using wired breakers for the voltage tap: 1. Ensure the breakers are turned off, with the client’s permission 2. Remove the wire from the wired breaker on phase A, this is the Phase A Circuit Wire 3. Using a wire nut, splice together the black voltage tap cable wire numbered “1” with the Phase A Circuit Wire and a third wire ○ The third wire should be of equal gauge as the Phase A Circuit Wire 4. Insert the third wire into the phase A breaker 5. Repeat steps 2-4 for the Phase B voltage tap, combining the black voltage tap cable wires numbered “2” and “3” into one splice 6. Insert this third wire into the phase B breaker 7. Turn the breakers on
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Wire The Neutral If the panel has a neutral bar (is a wye configuration panel), attach the green-yellow striped wire from the voltage tap cable to the neutral bar. If the panel does not have a neutral bar (is a delta configuration panel): 1. Attach the green-yellow striped wire from the voltage tap cable to the ground bar 2. Make sure to report that this type of installation was done, such that the system can be configured appropriately
Add Power Cable for High Voltage Panels (>250V) NOTE: For low voltage panels (less than 250V), skip this section. If the Data Transmitter is inside of the panel: 1. Attach Power Cable to the Data Transmitter 2. Route the Power Cable through a knockout to the outside of the panel 3. Plug in the 3-prong male plug end into a nearby 120V outlet 4. Plug the voltage tap cable into the Data Transmitter If the Data Transmitter is outside of the panel: 1. Attach Power Cable to the Data Transmitter 2. Plug in the 3-prong male plug end into a nearby 120V outlet 3. Plug the voltage tap cable into the Data Transmitter WARNING: Use an extension cable as necessary to reach the outlet from the panel. Secure the cable as necessary to avoid creating a safety hazard.
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Select Appropriate CTs NOTE: Select the appropriate CTs for breaker ampacity. Larger amperage circuits may require the use of Large CTs in combination with GIMs. Verdigris offers the following CT sizes: ● CT chains (3 CTs per chain) ○ 30A - can monitor circuits up to 40A ○ 75A - can monitor circuits up to 90A ● Large CTs ○ 200A ○ 400A ○ 800A ○ Larger sizes available by custom order
If you are not sure which CTs are right for your breaker, call our support line at 1-844-837-3447 or email
[email protected].
Install CTs On Left Side Breakers 1. Position the CT Chain with the male end at the top, and the female end at the bottom
2. Starting at the top left of the panel (typically Circuit 1), begin the chain with “CT 1” on the CT chain 3. Open the CT loop. A flat screwdriver can help open the latch 4. Position the CT loop around the circuit breaker wire
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IMPORTANT: The CB arrow on the CT side must point towards the circuit breaker (CB).
5. Close the CT loop around the wire securely IMPORTANT: CTs must be securely closed for accurate data collection. 6. Continue to do the same with “CT 2” and “CT 3” on the CT chain IMPORTANT: DO NOT install out of order. Only install CTs in sequential order (1-2-3). Repeat the above steps with more CT chains on the following circuits until all circuit wires have a CT attached. Spare breakers with no wires installed can be skipped. NOTE: A maximum of 7 CT chains and/or GIMs may be installed in continuity. This means up to 21 CTs (in a chain or Large CTs) may be mounted on either side of a panel, which covers a standard 42 circuit panel. 14
Install CTs On Right Side Breakers 1. Position the CT Chain with the female end at the top, and the male end at the bottom. “CT 1” will be the bottom CT.
2. Starting with CT1 on the bottom right circuit breaker, attach the CTs from bottom to top IMPORTANT: The CB arrow must still point towards the circuit breaker (CB).
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About Large CTs and GIMs Large CTs can be opened for installation around a conductor: Large CTs have two parts, a ‘C’ shaped body and an ‘I’ section top, which is removable for installation. 1. Open the Large CT: ● Split-top CTs: Pull the ‘I’ section straight-out of the ‘C’ shaped body. A strong pull may be required.
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Screw-top CTs: remove the thumb-screws that secure the ‘I’ section
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Tilt-top CTs: Pull the end of the ‘I’ section farthest from the hinge until it rotates out.
IMPORTANT: Unless otherwise stated, Large CTs should be mounted with label towards source. This means the white label should face “upstream”, such as towards the circuit breaker (if monitoring a branch circuit), or towards the grid (if monitoring mains). 2. Put the ‘C’ body around the large circuit wire 3. Close the CT by reconnecting the ‘I’ section.
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The removable ‘I’ section only fits one way, so as it is removed, note how the steel core pieces fit together. There may be a silver marker line that indicates the proper direction for the ‘I’ section to attach to the ‘C’ section.
Be sure to match up the ends the same way. If the ‘I’ section appears to be stuck and does not close, the steel core pieces may not be aligned correctly Do not use excessive force when reattaching them. Instead, reposition or rock the removable portion until the CT closes without excessive force On screw-top models, reinstall the original screws and hand tighten. Do not use a screwdriver or other tool!
NOTE: For best accuracy, do not interchange the ‘C’ and ‘I’ parts among your Large CTs. 4. Insert the 2 wire leads from the Large CT into the matching color on the GIM terminal block
5. Orient the GIM terminal blocks on each side of the panel as shown below
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6. Attach Large CTs to the GIM in order of 3, 2, 1 as shown below
7. Using the magnet on the bottom of the GIM, mount it to any grounded metal surface in the panel, such as the side or back walls Note: CT chains and Large CTs/GIMs can be used interchangeably in terms of order. For example, on the left side of a panel, the installation could begin with 2 CT chains, followed by 3 Large CTs with a GIM, followed by another CT chain.
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Connect Multiple CT Chains Connect the male and female ends of the CT chains to each other, on each side of the panel Only a single male and female end should be “loose” on each side of the panel
Connect Multiple GIMs If your panel installation requires multiple GIMs: 1. Use a male-to-male data extension cable to connect the dark blue port of one GIM to the light blue port of another GIM 2. Connect all your GIMs until only one dark blue port is open at one end, and a light blue port is open at the other end
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Connect CTs to the Data Transmitter IMPORTANT: If the Data Transmitter is mounted outside of the panel, route data cables from CTs inside the panel through a knockout to the Data Transmitter. NOTE: For installations with CTs on only 1 side of the panel 1. Use a male-to-male data extension cable to connect the OUT socket to the IN socket on Port 0
2. Connect CTs and GIMs to Port 1 using the instructions below
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For Installations Using Only CT Chains Using the female-to-male and male-to-male data cables, connect Port 0 and Port 1 as shown below
IMPORTANT: ● ● ● ●
Port 0 OUT socket must connect to the TOP LEFT CT Port 0 IN socket must connect to the BOTTOM LEFT CT Port 1 OUT socket must connect to the BOTTOM RIGHT CT Port 1 IN socket must connect to the TOP Right CT
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For installations Using Only GIMs 1. Use the female-to-male data cables to connect the OUT socket of the Data Transmitter to the open light blue port on the GIM 2. Connect the IN socket of the Data Transmitter to the open dark blue part of the GIM
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For installations Using CTs and GIMs Using the female-to-male and male-to-male data cables, connect Port 0 and Port 1 as shown below
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Power the Data Transmitter 1. Connect the other large plug end of the Voltage Tap Cable or Combined Voltage Tap and Power Y-Cable to the Data Transmitter. Orient the connector the right way based on the notch in the middle
2. Connect the other end of the Power Cable (or the smaller, 3 prong socket connector on the Combined Voltage Tap and Power Y-Cable) to the Data Transmitter
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Connect Wifi or 4G If the Data Transmitter is inside of the panel: 1. Attach the male end of the USB extension cable into the Data Transmitter, and route the female end out of the panel, through the knockout 2. Attach the wifi or 4G modem into the female end of the USB extension cable
3. Use the provided adhesive strips to mount the wifi or 4G modem on a nearby flat, clean surface, pressing it in place against the wall for 30 seconds, which lets the adhesive set
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If the Data Transmitter is outside of the panel: 1. If there is room for the modem next to the Data Transmitter, insert the wifi or 4G modem directly into the Data Transmitter, and skip ahead to Mounting the Data Transmitter
2. If there is no room inside the panel, the wifi or 4G modem will need to be installed outside the panel. Follow the instructions above for If the Data Transmitter is inside the panel
Connect Ethernet If the Data Transmitter is inside of the panel: Route the ethernet cable from the client’s network into the panel, and insert the male end into the Data Transmitter If the Data Transmitter is outside of the panel: Route the ethernet cable from the client’s network to the Data Transmitter, and insert the male end into the Data Transmitter
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Mount the Data Transmitter Outside the Panel NOTE: If the Data Transmitter is to be housed inside of the panel, then skip this step. 1. Place two sets of the provided adhesive strips to the back of the Data Transmitter 2. Mount the Data Transmitter on a nearby flat, clean surface, pressing it in place against the wall for 30 seconds, which lets the adhesive set
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Check the CTs IMPORTANT: Recheck the installed CTs, as the physical movement of items inside of the panel from CT installation and data cable connection can cause CTs to become loose. 1. Check each CT to ensure that they are still closed properly
1. Check all GIMs to ensure the terminal blocks are snapped closed, and all Large CTs are snapped closed 2. Check all data cable connections to ensure they are properly seated
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Turn on The System & System Checks 1. Turn the power switch on the Data Transmitter to ON 2. The Data Transmitter LEDs should light up briefly with “Power” as green, and orange on the other four
3. If “Power”, “Port 0”, and “Port 1” are all green, then your system is correctly working
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Troubleshooting
If you need direct assistance, call our support line at 1-844-837-3447 or email
[email protected]. ●
“Port 0” and “Port 1” are flashing between blue and green or orange: the system has entered the chain testing mode. The system will continue to flash between blue and green/orange until both chains are properly connected, and have remained connected for 2 minutes.
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“Port 0” or “Port 1” LED is solid orange: there is a break between CT chains. This can mean a loose data port connection, or that there are too many CT chains (7 chains and/or GIMs maximum per port)
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When the CT chains are all connected correctly, (secured and not too many,) the LED will change from alternating blue/orange to blue/green
Above: Port 0 has a good connection, Port 1 still has a problem with its CT chains ○
Continue to check each data cable connection in each loop until both LEDs are flashing green and blue
Above: A fully connected, operational system ○
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If you are done testing data connectivity and both LEDs remain flashing green/blue, restart the system by turning the power switch on the Data Transmitter to the off position, wait 3 seconds, and turn it back on Check that the system has a solid green LED on both Port 0 and Port 1, as shown in the above photo
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“3 Phase” LED is blinking orange: the voltage tap is not reading correctly ○ This may mean the breakers for the voltage tap are not currently powered on, the taps were not installed correctly, or the voltage tap cable is not properly attached to the data transmitter ○ When the 3 Phase LED changes turns solid orange, then the voltage tap is properly connected 4G modem LED is flashing white/blue: the modem is updating its firmware remotely, this may take a few minutes, after which the modem LED should resume flashing green 4G: Connection is established when LED is flashing green
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NOTE: The modem’s indicator LED will be red during startup. Wait a few minutes for connection to be established
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Wifi: Connection is established when the modem’s LED is flashing green
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Ethernet: Connection is established when the green LED (left) is flashing, and the orange LED (right) is solid
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Clean Up and Close the Panel 1. Excessively long wires from Large CT, voltage tap cable, or Combined voltage tap and power y-cable can be cut 2. Other excessive cable lengths can be coiled to save space, and to keep the interior of the panel neat and tidy 3. Any wires external to the panel can be cable-tied to other objects to keep them organized; this is especially important for a separate Power Cable going to a nearby outlet
Congratulations! Your Verdigris system is now installed! Questions? Call Verdigris: 1.844.VERDIGRIS (1.844.837.3447) Email Verdigris:
[email protected]
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