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Product Specifications

PowerOptimal PowerGuard CPM-3PC Mk2 specification
INTRODUCING THE
	PowerGuard® CPM-3PC Mk 2
 
The PowerGuard CPM-3PC MK2 is a maximum demand controller designed to control loads where either not enough power is available or where peak demand (kVA) needs to be reduced in order to save on electricity bills.
This single enclosure houses power supplies, communication modem, display, control selection as well as all the required external connector terminals.
SPECIFICATIONS
INPUT
Load information is accessed from standard current transformer outputs covering the point of entry serving the area to be controlled.
CONTROL
Current or kVA-based control can be selected to regulate demand. For customers with insufficient supply, current based phase selective sheds ensure that only the transgressing overloaded phase responds to shed signals. The number of shed signals per half hour are recorded to assist with fine-tuning shed levels while line current graphs aid with phase balancing.
PROGRAMMING
All the variables associated with creating a shed instruction can be set up either on rotary numerical switches or slide selector switches. This enables all shed criteria to be viewed without the need for laptops or specialised software.
DISPLAY
An on board LCD unit displays the real time line currents and total kVA. Light emitting diodes indicate processor heartbeat; phase conscious shed requests, line quality of shed signals and total shed demand.
SPECIFICATIONS
Current transformer ratio adjustable from 1 to 9 999 Amps. Secondary output is 1 Amp into 1 Ohm burden for full scale
Star, delta LV and MV catered for
Supply from standard 3-phase 230 Volt, < 20 Watts
Shed level is adjustable from 1 to 9 999 Amps or kVA
Two closing contact inputs are available to reduce ‘time of use’ sensitive accounts from 1 to 99% of selected shed level
Single contact closure for total progressive shed/restoration of all loads, e.g. air conditioners after hours
Shed interval delay adjustable from 4 seconds to 99 minutes
Switch selectable shed criteria for Amps or kVA
Two user specific selections for custom software
1 to 31 kVA backlash adjustment
Screwdriver adjustable current simulation with phase selection for testing
Remote control via cellular networks
Clear cover to observe load, total kVA, shed activity and shed criteria
Housing dimensions are 380H x 280W x 135H mm, Weight is 3.8 Kg.
On board GPRS modem for remote internet based monitoring of phase currents, kVA, shed request profile, shed active report and average phase voltage
Conforms to IEC/SANS 60669

PowerOptimal PowerGuard CPM-SDB specification
INTRODUCING THE
	PowerGuard® CPM-SDB
 
PowerGuard CPM-SDB doubles as a shed control signal amplifier or shed signal restorer when coupled to a PowerGuard CPM-XC10 transceiver.
As an amplifier, the unit can enhance coverage of a PowerGuard load management installation by up to a further 400 receiver points per amplifier.
Connected to the PowerGuard CPM-XC10 transceiver, the unit will restore and echo the original shed signal to drive up to 400 PowerGuard shed receivers.
SPECIFICATIONS
SPECIFICATIONS
Power: 230Volts AC
Consumption: < 30 Watts
Dimensions: 200 x 120 x 75 mm less aerial
Weight: 1 kg

PowerOptimal PowerGuard CPM-XC10 specification
INTRODUCING THE
	PowerGuard® CPM-XC10
 
The PowerGuard CPM-XC10 is a dedicated transceiver designed to facilitate wireless communication between PowerGuard CPM-3PC MK2 and any PowerGuard receiver network.
Together with PowerGuard CPM-SDB, the CPM-XC10 can provide communication between the standard PowerGuard control signal from point of entry across roads, paving or between buildings where cabling is not feasible.
The unit can be used as a transmitter, repeater or receiver. Careful design ensures avoidance of RF signal collision. Up to four channels on each of the four selectable frequencies allows for multiple systems in close proximity to operate independently.
SPECIFICATIONS
SPECIFICATIONS
Power: 230Volts AC
Consumption: < 3 Watts
Transmission frequency: 866 MHz
Output power: 10 milliwatt (mW)
Range: Up to 200 m line of sight
Dimensions: 200 x 120 x 75 mm less aerial
Weight: < 1 kg

PowerOptimal PowerGuard CPM16-30 specification
INTRODUCING THE
	PowerGuard® CPM16-30
 
The PowerGuard CPM16-30 is a 16-channel demand regulator with 30 Amp switching capacity per channel designed to work with the PowerGuard CPM-3PC or CPM-3PC Mk2 controllers. The unit was developed primarily to reduce costs on demand sensitive electricity bills but can also be installed for customers who do not have enough power.
This certified unit is designed and manufactured in South Africa. 
SPECIFICATIONS
INPUT
Shed requests are received via a polarity insensitive low voltage short circuit proof signal generated by the PowerGuard CPM-3PC or CPM-3PC Mk 2.
CONTROL & PROGRAMMING
Various algorithms can be selected to optimise the control of air conditioners, geysers and boiler elements thereby making intervention seamless in most installations.
Progressive load restoration assists with ‘’cold pick up’’ situations following supply interruptions. All control criteria are switch programmable in order to avoid the need for laptops or specialised software.
DISPLAY
LEDs indicate shed status as well as processor heartbeat, control signal presence, over-voltage and supply activity. 
SPECIFICATIONS
An over-voltage feature protects all affected loads by disconnecting them during damaging high voltage situations. 
Current transformer ratio adjustable from 1 to 9 999 Amps. Secondary output is 1 Amp into 1 Ohm burden for full scale
Standard single phase 230 Volt AC supply, <20 Watts
Control input is opto-coupled to eliminate ground loops and elevated neutral spreads during faults
Clear cover to observe shed status, control activity and programmed shed criteria
Output is potential-free 30 Amp relay contacts
Housing dimensions are 380L x 280W x 135H mm
Weight is 3.5 kg
Conforms to SANS/IEC 60669

PowerOptimal PowerGuard CPM20-1W specification
INTRODUCING THE
	PowerGuard® CPM20-1W
 
PowerGuard’s CPM20-1 was developed as a modular cost effective 20 Amp load shed receiver to implement savings on demand sensitive bills as well as for installations that do not have enough power. The unit is particularly suited to control individual geysers in complexes, hotels and lodges.
This certified unit is designed and manufactured in South Africa.
SPECIFICATIONS
INPUT
Shed requests are received via a polarity insensitive low voltage short circuit proof signal generated by the PowerGuard CPM-3PC or CPM-3PC Mk 2.
CONTROL & PROGRAMMING
Progressive load restoration assists with ‘’cold pick up’’ situations following supply interruptions. Control criteria are switch programmable in order to avoid the need for laptops or specialised software.
DISPLAY
LEDs indicate shed status as well as processor heart-beat, control signal presence and condition of incoming supply for easy monitoring.
SPECIFICATIONS
An over- and under voltage feature protects all affected loads by disconnecting them during potentially harmful voltage situations.
Standard single phase 230 Volt AC supply, <5 Watts
Control input is opto-coupled to eliminate ground loops and elevated neutral spreads during faults
Port hole in cover to observe shed status as well as control activity.
Output is potential-free 20 Amp relay contact
Housing dimensions are 160L x 80W x 55H mm
Weight 0.6 Kg
Conforms to SANS/IEC 60669

PowerOptimal PowerGuard CPM30-1W specification
INTRODUCING THE
	PowerGuard® CPM30-1W
 
The PowerGuard CPM30-1W is the result of on-going development with experience gained from our popular CPM20-1W unit which was developed primarily to reduce costs on demand sensitive electricity bills as well as for customers who do not have enough power. This unit features extended functionality and switching capacity as well as upgraded software algorithms to realise the maximum benefits associated with air conditioner load control.
This certified unit is designed and manufactured in South Africa.
SPECIFICATIONS
INPUT
Shed requests are received via a polarity insensitive low voltage short circuit proof signal generated by the PowerGuard CPM-3PC or CPM-3PC Mk 2.
CONTROL & PROGRAMMING
Various criteria can be selected to optimise the control of air conditioners, geyser and boiler elements thereby making intervention seamless in most installations. Progressive load restoration assists with ‘’cold pick up’’ situations following supply interruptions. All control criteria are switch programmable in order to avoid the need for laptops or specialised software.
DISPLAY
LEDs indicate shed status as well as processor heart-beat, control signal presence and condition of incoming supply.
SPECIFICATIONS
An over- or under voltage feature protects all affected loads by disconnecting them during potentially harmful voltage situations.
Standard single phase 230 Volt AC supply, <5 Watts
Control input is opto-coupled to eliminate ground loops and elevated neutral spreads during faults
Port hole in cover to observe shed status as well as control activity.
Output is potential-free 30 Amp relay change-over contacts
Housing dimensions are 200L x 120W x 76H mm
Weight 0.8 Kg
Conforms to SANS/IEC 60669

PowerOptimal PowerGuard DPM20-2 specification
INTRODUCING THE
	PowerGuard® DPM20-2
 
The two channel PowerGuard DPM20-2 demand manager caters for the average middle-class underpowered home with one or two geysers, pool pump and one or two air conditioners.
This installation is typically powered from a single phase 230 Volt AC @ 63 Amp supply.
This unit is designed and manufactured in South Africa.
SPECIFICATIONS
INPUT
Power usage is measured by a current transformer (included) on the main incoming line.
CONTROL & PROGRAMMING
PowerGuard will manage two independent loads according to a fixed hierarchy in order to avoid over-current trips during high electrical usage. External utility override input.
DISPLAY
LCD display shows total current drawn as well as active switching elements.
SPECIFICATIONS
2 x 20 Amp control contacts
Operating voltage: 230Volts AC
Power consumption: <3Watt
Operating range: 180 to 280 Volts ac
Maximum input voltage: 420 Volt ac indefinitely
6 kV impulse test
Conforms to SANS 10142
Controlled loads will be disconnected outside operating voltage range for protection
DIN rail mounted
Screwdriver current setting from 1 to 99 Amps

PowerOptimal PowerGuard DPM20-8 specification
INTRODUCING THE
	PowerGuard® DPM20-8
 
The eight channel PowerGuard DPM20-8 caters for larger homes, single or three phase, that suffer electrical trips because of marginal supply. Dual maximum current settings allow demand control of utility as well as standby (generator or UPS) power.
This unit is designed and manufactured in South Africa.
SPECIFICATIONS
INPUT
Power usage is measured by a current transformer (included) on the main incoming line.
CONTROL & PROGRAMMING
The eight switch elements (PowerGuard RL20-1) are modular and are controlled from the control unit (DPM20-8) via low voltage signals. Various hierarchies are available for loads with different requirements such as geysers and air conditioners. External input for utility override.
DISPLAY
LCD display shows total current drawn as well as active switching elements.
SPECIFICATIONS
One to eight x 20 Amp control contacts
Operating voltage: 230 Volts AC
Power consumption: <5 Watt to < 15 Watt, depending on number of channels
Operating range: 180 to 280 Volts AC
Maximum input voltage: 420 Volt AC, indefinitely
6 kV impulse test
Conforms to SANS 10142
Controlled loads will be disconnected outside operating voltage range for protection
DIN rail mounted
Screwdriver current setting from 1 to 99 Amps

PowerOptimal PowerGuard RL20-1 specification
INTRODUCING THE
	PowerGuard® RL20-1
 
PowerGuard RL20-1 is a DIN-rail mount relay primarily designed for use in conjunction with the PowerGuard DPM20-8 demand control unit. Contacts are activated by a DC voltage which is opto-isolated from the control circuit. The contact configuration switches the mains live circuit to the output when energised.
This unit is designed and manufactured in South Africa.
SPECIFICATIONS
SPECIFICATIONS
Input power: 230Vac
Control voltage: 5 – 48 Volt DC
Size: DIN standard, 48mm wide

Installation & User Manuals

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
			Author(s):		Dr. Sean Moolman
						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
Table of Contents	2
1. PowerGuard unit operation	3
1.1 System operation	3
1.2 LCD screen readout	5
1.3 Settings on the PowerGuard Controller	5
1.4 Settings on PowerGuard Receivers	7
1.5 LED light codes / meanings	7
2. Online monitoring	9
2.1 How to log in	9
2.2 Landing page	9
2.3 How to view & interpret graphs	11
2.4 How to view & interpret the dashboard	12
2.5 Estimated monthly savings	14
3. Basic troubleshooting	15
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

Troubleshooting Guides