Installation & User Manuals
- PowerGuard commercial system installation instructions
- PowerGuard DPM20-2 installation instructions & diagram
- POWERGUARD DPM20-8 installation instructions & diagram
- PowerOptimal PowerGuard Commercial Range User Manual v1.5
PowerGuard commercial system installation instructions
PowerGuard CPM30-1W
Installation
Remove the lid of the unit and securely fit upright against a panel or wall with Fischer or
normal 4mM screws. The 4,5mM mounting holes are accessible through the rectangular
apertures on the four corners of the enclosure. Drill or punch 20mM holes at the bottom of
the enclosure to accommodate glands as required for wiring.
Set Up Instructions
After powering up the system, SW1 active will inhibit its load when overall demand falls
within the backlash range selected on the shed controller. This feature falls away when the
backlash transgression restores and only activates again after a power interruption. This
feature is essential for customers with a compromised electrical supply.
SW2 active responds to phase conscious shed requests, again essential for customers with a
compromised supply. Customers with adequate supply will realise an improved random
shed pattern with SW2 off.
SW3, 4 & 5 set the minimum shed period following a shed request. With these switches off,
the period is 1 minute and increases by 2,5 minutes for each additional binary bit added.
Total shed period is as follows: SW3=3,5; SW4=6; SW3+4=8,5; SW5=11; SW3+5=13,5;
SW4+5=16 and SW3+4+5=18,5 minutes.
SW6, 7 & 8 control the minimum time between accepting shed requests. These switches
together with switches 3,4&5 are essential for air conditioner control to ensure that the
occupant’s comfort levels are not compromised. With SW6,7&8 off, there is no lock-out
interval. SW6=15; SW7=30; SW6+7=45; SW8=60; SW6+8=75; SW7+8= 90 and SW6+7+8=105
minutes.
SW9 & 10 decide on how many CPM30-1W receivers, on average, should respond to a shed
request. For example, if 100 receivers are installed, all set to odds = 50, then approximately
2 units will shed for each shed request. With a total of 10 units, all set to odds = 10,
approximately 1 unit will shed for each shed request. Odds are manipulated such that a
recently shed unit will revert to maximum odds to allow other units to shed before it
responds to the next shed request. With both SW9&10 off, odds= 5; SW9= 10; SW10= 25
and SW9&10= 50. Odds can be decreased within a control grid to favour higher priority
loads or can be increased to protect lower priority loads.
PowerGuard DPM20-2 installation instructions & diagram
Powerguard Dpm20-2
Installation Instructions
1) Isolate power to the distribution panel by opening the main incoming breaker associated with the
relevant existing power meter and verify that the power is indeed switched off.
2) Retract the incoming feeder line to the distribution panel from the main breaker/isolator and
reconnect after feeding the wire through the large hole in the enclosed current transformer.
3) Position the DPM20-2 controller so that the control wires to the two relay outputs can be routed
conveniently.
4) If required, the Din-rail mounting clip can be removed by splitting the unit and sliding the
assembly out. No tools are required for this operation as gentle hand pressure is sufficient.
5) Cut the white wire loop from the current transformer to a convenient length and connect to the ‘CT
100:1’ terminal. It is important that no current flows through the transformer before these wires are
terminated as high voltages can be generated across the un-terminated output wires.
6) Referring to the enclosed ‘DPM20-2 INSTALLATION’ diagram, up to two 20 Amp loads not
exceeding 4,4KW resistive or 1 HP inductive and can now be connected according to the diagram
allowing CH2 to control the lowest priority (first to shed) load and CH1 to serve the highest priority
load. Use wire with 2,5mM cross sectional area minimum for the controlled loads. Care should be
taken when connecting neutral wires to pair them with the relevant earth leakage or non-earth
leakage buss when connecting to the relevant controlled loads. Both relay contacts are
completely isolated.
7) A maximum total current of up to 99 Amps can now be programmed on the two rotary switches
marked ‘SET MAX. CURRENT’. This setting would typically be the value of the main incoming
isolator or circuit breaker.
8) 230 Vac can now be connected to the terminals marked ‘230 VAC INPUT’, observing the line and
neutral designation. This supply must be protected by an independent 5 Amp circuit breaker and
taken from the non-earth leakage supply bus. A flashing blue LED light indicates power as well as
main processor activity.
9) After four to six minutes, provided that there is sufficient power available (approximately 15
Amps), CH1 will switch on and if current reserve allows, CH2 will follow in approximately 1.5
seconds. Closed contacts are indicated by their respective green LED’s.
10) As soon as the total current drawn by the distribution board exceeds the value programmed in
step no 7, CH2 relay contact will open for a minimum of 15 minutes and then only restore power
to its load as supply becomes available again. Should demand continue to increase during this
period, CH1 will also shed, again only to restore after 15 minutes if power is available.
POWERGUARD DPM20-8 installation instructions & diagram
PowerGuard DPM20-8
Installation Instructions
Rev. 1.1
E info@poweroptimal.com
W www.poweroptimal.com
1. Isolate power to the distribution panel by opening the main incoming breaker associated with the relevant
existing power meter and verifying that the power is indeed switched off.
2. Retract the incoming feeder line to the distribution panel from the main breaker/isolator and reconnect
after feeding the wire through the large hole in the enclosed current transformer.
3. Position the DPM 20-8 controller so that the control wires to the RL1 relays can be routed conveniently.
4. Cut the white wire loop from the current transformer to a convenient length and connect to the ‘CT 100:1’
terminals. It is important that no current flows through the transformer before these wires are terminated.
5. Referring to the enclosed ‘DPM20-8 INSTALLATION’ diagram, up to eight RL20-1 relays can be controlled
from one DPM20-8. The RL20-1 relays in turn can control 8 x 230 Vac line loads not exceeding 4kW resistive
or 1 HP inductive and can now be connected according to the diagram allowing no. 8 to control the lowest
priority (first to shed) load and no. 1 to serve the highest priority load. Use wire with at least 2.5mm² cross
sectional area for the controlled loads. Care should be taken when connecting neutral wires to pair them
with the relevant earth leakage or non-earth leakage buss when connecting to the RL20-1 relays.
6. A maximum total current for the board can be programmed on the two rotary switches marked ‘SET MAIN
MAX. CURRENT’. This setting would typically be the value of the main incoming circuit breaker or isolator.
Also set the ‘SET S/BY MAX. CURRENT’ switches to a value that the standby generator can deliver
continuously, de-rating for high altitude installations. These settings can be verified on the LCD display.
7. The two contacts marked ‘S/BY’ can be short circuited by potential-free contacts to switch from main to
standby load control setting.
8. 230 Vac can now be connected to the terminals marked ‘230 VAC INPUT’, observing the line and neutral
designation. This supply must be protected by an independent 5-amp circuit breaker and taken from the
non-earth leakage supply busses. A flashing blue led light indicates power as well as main processor activity.
9. After four to six minutes, provided that there is enough power available (approximately 15 Amps at 230Vac),
CH1 will switch on. Again, if current reserve allows, CH2 to CH8 will switch on in approximately 1.5 second
steps.
10. The LCD display indicates active outputs as well as the total current consumption.
11. As soon as the total current drawn by the distribution board exceeds the maximum current value
programmed in step no. 6, CH8 contact will open for a minimum of 15 minutes and then restore power to
its load as supply becomes available again. Should demand continue to increase during this period, CH7 to
CH1 will also shed and after 15 minutes restore the lowest numbers, again depending on availability of
power.
12. Blue LED lights on the RL1 relays indicate power while green LED lights indicates active output to the
relevant load.
Directors: RA Fearon, FS Moolman, JJ Theron, DM Weber (Independent), IR Jandrell (Independent)
Company registration number: 2012/099947/07 PO Box 39521, Capricorn Square, Cape Town, 7948
PowerOptimal PowerGuard Commercial Range User Manual v1.5
PowerGuard Commercial Range User Manual
Version number: 1.5
Mr. Johan Theron
General contact: sean.moolman@poweroptimal.com
082 788 1615
Technical contact: johan.theron@poweroptimal.com
083 600 1827
Address: PO Box 39521
Capricorn Square
7948
Cape Town
Table of Contents
1. PowerGuard unit operation 3
1.3 Settings on the PowerGuard Controller 5
1.4 Settings on PowerGuard Receivers 7
1.5 LED light codes / meanings 7
2.3 How to view & interpret graphs 11
2.4 How to view & interpret the dashboard 12
2.5 Estimated monthly savings 14
Appendix A. Front face of PowerGuard CPM30-1W Single Channel Receiver 17
Appendix B. Front face of CPM16-30 16-Channel Receiver 18
1. PowerGuard unit operation
The PowerGuard system is fully automated and has been designed to require no user intervention.
1.1 System operation
The below simplified diagram shows how the PowerGuard system is connected to a facility’s electrical system.
The PowerGuard Controller measures the total incoming current using current transformers installed on the incoming power line(s) (either single phase or 3 phase). It also measures the average voltage on the incoming power line(s).
Based on the measured current and voltage values, the Controller calculates the power demand (in kVA) for the facility. This value (total power demand of the facility) is displayed on the LCD screen.
a. Normal operation
Based on the preset control level, the PowerGuard Controller will start sending out shed requests to all the Receivers (PG R in the diagram). Each Receiver has its own pre-set settings that determine how it will respond to the controller – specifically, how regularly it should switch off (probability of responding), for how long it should switch off, and for how long after a previous switch-off it should not switch off again (see Section 1.4).
The Controller will continue to send shed requests until the power demand stabilises at a level below the control level.
This simple configuration allows a lot of flexibility in how the facility can be managed, and effectively distributes switch-off of loads across the facility in a balanced manner. (However, it is not necessary to change ANY settings once the system has been commissioned and configured by PowerOptimal. The overall control level can be changed if there are substantial changes to occupancy or circumstances, but no other settings need to be changed.)
The facility can be controlled either at a maximum current value (A) or a maximum demand value (kVA). This setting is found on the Controller (see Section 1.3). Whether it is controlled at maximum current value or maximum demand value is determined by the main purpose of the system – i.e. is it to (i) alleviate power supply constraints, or (ii) reduce demand charges. Note: this setting is typically only configured once (during installation) by PowerOptimal, and there is no need to change it.
(i) Power supply constraints – control at maximum current (A)
If the facility has power supply constraints (e.g. experiencing power trips), control at a maximum current value is more suitable, since loads will then only be shed on the phase that requires reduction in current to avoid power trips. The online monitoring system can be used to determine whether load balancing across the phases can be improved – e.g. if one notes that a specific phase is the main or only cause of shedding, loads can be moved from that phase to another phase.
(ii) Reducing demand charges – control at maximum demand (kVA)
When demand charge (electricity cost) reduction is the main purpose of the system, then it is better to control the facility’s power use on a maximum demand (kVA) basis, since this is what demand charges are calculated on by the utility / municipality.
b. Time of use settings
The system can be configured to manage at three different control levels based on input from timers: ‘normal’, and two time of use settings. It can also be configured to completely switch off all loads at certain times. Please speak to a PowerOptimal representative if you wish to implement any of these settings. It will require installation of one or more timers.
c. Backup power setting
The system can be configured to automatically detect when there is a switch to backup power, and to manage at a different control level on backup power. Please speak to a PowerOptimal representative if you wish to configure the system for backup power management.
d. Power failures
When power returns after a power failure, the system will wait four minutes for the power to stabilise, and then it will systematically switch on the loads in a staggered manner, in order to avoid the cold pick-up power demand spike.
All controlled loads are protected against under- and overvoltage, and will be switched off should such an event occur.
1.2 LCD screen readout
Current – White line (A)
Total demand (kVA)
Current – Red line (A)
Current – Blue line (A)
Average voltage (V)
1.3 Settings on the PowerGuard Controller
On the next page is the front face of the PowerGuard Controller.
The only setting that should be changed by the user under normal circumstances is the Shed Level (circled in red). Just turn the dials with a screwdriver to select the control level. The numbers read as one would a normal number (e.g. dial settings 0 – 1 – 0 – 5 would be 105 kVA or amps).
The other settings are configured during installation & commissioning and should not be altered.
1.4 Settings on PowerGuard Receivers
See Annexure A for the front face of the CPM30-1W receiver and Annexure B for the front face of the CPM16-30 receiver. No settings should be or need to be changed by the user.
1.5 LED light codes / meanings
Controller
The following LED lights are present on the PowerGuard Controller for monitoring and diagnostic purposes:
The LED lights have the following meanings:
Name | Colour | Meaning | ||
On | Flashing | Off | ||
Processor Heart Beat | Green | NA | Processor operational | Processor not operational / no power |
Shedding on Red Phase | Red | NA | 1 sec – in backlash range 2 sec – shed 4 sec – shed all | No shed signal being sent at specific point in time |
Shedding on White Phase | Yellow | NA | 1 sec – in backlash range 2 sec – shed 4 sec – shed all | No shed signal being sent at specific point in time |
Shedding on Blue Phase | Blue | NA | 1 sec – in backlash range 2 sec – shed 4 sec – shed all | No shed signal being sent at specific point in time |
Shed Signal Quality (only indicates whilst shed signal is being sent) | Red-Green bi-colour | If both colours are visible – good signal | NA | Off or only one colour visible – poor signal / faulty condition |
Shed All Request | Orange | Shed all request active | NA | NA |
Receiver
The PowerGuard Single Channel Receiver (CPM30-1W) has a single small light window on the front of the cover for diagnostic purposes. The light position is indicated below.
Indicator light window
The indicator light window indicates the following:
Colour & mode | Meaning |
No light | No power |
Red and blue lights | (a) Alternating – processor active / power on (b) Slow-down / temporary stop in speed or rhythm of alternating – receiving shed instruction |
Green light | Power available to load |
2. Online monitoring
The PowerGuard system has a built-in modem and sends measurements to the PowerOptimal database every half hour. The database is accessible via Energy Cybernetics’ Powerwatch front-end.
2.1 How to log in
- Go to: www.cpowerwatch.com
- Click on the “Sign In” button at the top right of the screen.
- Enter your username and password as provided during installation.
2.2 Landing page
Upon login, you should see a screen similar to the below:
The blue band on the left-hand side contains the functionality for your site. If you hover over the symbols, text will appear indicating the function for that button.
Click on the “Graph Page” button to view near-real time graphs of your system.
Click on the “Personalised Dashboard – PowerOptimal” button to view a dashboard of system performance.
2.3 How to view & interpret graphs
Below is a screenshot of the graph page:
1. Select site
3. Select what data to display
2. Select date range
- Select your site from the drop-down list;
- Select the date range that you want to view;
- Select the data that you want to display on the graph;
- You can navigate the graph in several ways. For example, you can hover over a data point to see the values at that time. You can select a date range on the graph itself by clicking anywhere on the graph and keeping the mouse button pressed whilst moving the mouse horizontally across the graph. You can also drag the bottom date selection left and right to view other / different dates.
2.4 How to view & interpret the dashboard
Below is a screenshot of the dashboard page:
2. Select date range
5. Summary data on maximum demand
4. Graph of peak demand and shed requests
3. 24-hour (daily) demand profiles
1. Select site
- Select your site from the drop-down list;
- Select the date range that you want to view;
- You can see a set of 24-hour demand profiles and shed requests on the right-hand side.
- Bottom left is the graph for the selected date range, showing the highest number of sheds in a 30-minute period for the day, as well as the highest demand (in kVA) for the day.
- The boxes in the middle indicate the maximum kVA and estimated savings for the selected date range. (Note: maximum demand charge is applied once per billing period, so to see the estimated savings for a specific billing period, use the start and end date of that billing period as the date range.)
Below is a close-up of the above graph:
The orange columns indicate the highest number of shed requests in any 30 minute period on the specific date (with values on the right vertical axis), whilst the lines indicate the highest actual (blue) and estimated (dark red) kVA values for the specific date. The grey horizontal line indicates the control level of the PowerGuard unit.
You can hover over the graph to see specific values.
This graph and the small daily graphs on the right makes it easy to see the functioning of the PowerGuard system and provides a ready overview of the total demand of your facility. As the total demand approaches the peak demand level, the system starts to shed in order to maintain overall demand below the peak level.
The difference between the “Actual kVA” and “Estimated kVA” lines is the estimated kVA reduction achieved by the PowerGuard system on that day.
2.5 Estimated monthly savings
You can use the PowerOptimal Dashboard (discussed in Section 2.3) to obtain an estimate of the monthly savings achieved through the use of PowerGuard.
4. Estimated kVA & financial savings for the month / billing period
3. Select date range
2. Estimated kVA reduction per shed
1. Site setup
- Click on the gear icon and check that the data is correctly configured for your site:
The demand charge tariff that you are being charged by Eskom or your municipality
The maximum demand level that the PowerGuard system is controlling your site at
- Check the estimated kVA reduction per shed request for your site. Note: This value is configured by PowerOptimal during the initial commissioning and calibration of the system. You don’t need to change this number.
- Set the date range that you wish to look at (you should preferably set the date range to coincide with the billing date range on your electricity bill).
- Now you can read off the estimated savings in kVA and rands for the specific date range (billing period)!
3. Basic troubleshooting
Below is a table with basic troubleshooting tips. If you cannot resolve the problem using the below table, please contact your electrician or give us a call!
Issue | Possible causes | What to do |
Water from the hot water tap is cold. | a. Geyser problem b. PowerGuard control level is set too low. | a. Call electrician to fix the geyser b. Increase PowerGuard control level on the Controller (see Section 1.3) |
Air conditioner does not switch on again after a shed | The air conditioner has not been configured to switch on after a shed, or someone has changed the air conditioner settings. | See your air conditioner manual on how to change the settings to switch on automatically when power is returned. |
I cannot log in on the PowerWatch online monitoring site. | Incorrect username and password. | Please check your username and password, or contact PowerOptimal for assistance. |
We have unusually high activity at our facility, and I want to increase the maximum demand level. | Increase PowerGuard control level on the Controller (see Section 1.3) | |
Demand peak has increased – shed instructions seem not to have effect on peak demand level (loss of control) | Possible communication problem between controller and receivers | At a quiet time, reduce the PowerGuard control level on the controller to a very low level, and confirm reception of shed signal on each receiver as indicated by blue-red LED on the receiver slowing down its speed of flashing. |
Troubleshooting the online monitoring graphs
Issue | Possible causes | What to do |
System is not on air | 1. Hardware disconnected (no power to PowerGuard controller) 2. SIM card off air 3. Modem faulty 4. Software problem (database / online monitoring software) | Wait for two hours and log in again. If problem persists: 1. Check if power is on at controller, and if the controller is functioning (see Section 1.5). 2. Call PowerOptimal to remotely test the modem, check if sim card is loaded and check the back-end software. |
Gaps in data | 1. Cell phone network problems 2. SIM card problems | If the gaps occur repeatedly, contact PowerOptimal to check SIM card. |
Strange patterns / behaviour (e.g. very high shed activity for a long period; no shed activity over a few weeks / month; demand exceeds control level) | 1. Change in electricity use (e.g. change in occupancy, behaviour, expansion of the facility, etc.) 2. Someone has changed the peak demand level control setting on the controller. 3. Communication problems between controller and receivers. 4. Faulty controller / receiver. | 1. First check whether the controller is functioning (see Section 1.5), and whether it is still set at the correct peak demand control level (see Section 1.3). 2. Check communication between controller and receivers by (at a quiet time) reducing the PowerGuard control level on the controller to a very low level, and confirming reception of shed signal on each receiver as indicated by blue-red LED on the receiver slowing down its speed of flashing. |
Appendix A. Front face of PowerGuard CPM30-1W Single Channel Receiver
Appendix B. Front face of CPM16-30 16-Channel Receiver
