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JCOMM

Installation and Operation

Ctrl Nr: PM375100

Revision: 004

JCOMM Installation and Operation

2

Thank you for your recent purchase of a JCOMM from Power Distribution, Inc.

For safety reasons as well as to ensure optimal performance of your JCOMM, please carefully read the

instructions before trying to install, operate, service, or maintain the system.

For any questions regarding the installation, operation, service, or maintenance of your JCOMM, please

contact us:

Power Distribution, Inc. | 4200 Oakleys Court | Richmond, VA 23223

+1 804 737 9880 | +1.800.225.4838

pdicorp.com | [email protected]

JCOMM Installation and Operation Ctrl Nr: PM375100 Revision 004

© 2019 by Power Distribution, Inc. All rights reserved. Release Date: March 2019

Cover Photo: JCOMM

PDI, JCOMM, Quad-Wye, ToughRail Technology, and WaveStar are registered trademarks of Power Distribution Inc. All other trademarks are held by their respective owners.

About Power Distribution, Inc. (PDI)

Power Distribution, Inc. (PDI) is the pioneer of innovative power transformation, power distribution, and intelligent power

monitoring solutions for mission-critical operations. The company leverages its ISO standards-based manufacturing facilities in

Virginia and California, as well as partner and customer collaborations, to create the broadest range of award-winning solutions

in the industry. Through the PDI and ONYX brand names, these industry leading solutions are sought after by data center,

industrial and other mission-critical facilities and backed by continued global service and support. The net result: One company

to provide and to service the end-to-end power needs of a 24x7 connected world. For more information, please visit

www.pdicorp.com

mailto:[email protected]

http://www.pdicorp.com/

Contents _

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Contents

Safety ............................................................................................... 7

1 JCOMM Unit Description ........................................................... 8

1.1 JCOMM Summary ................................................................................... 8

1.2 JCOMM Specifications ............................................................................. 9

1.3 JCOMM Enclosure ................................................................................. 10

1.4 Optional WaveStar Color Monitor ............................................................ 11

1.5 BCMS Data Acquisition Boards ............................................................... 11

1.6 Power and Connections Panels ............................................................... 11

2 Planning a JCOMM Installation ............................................... 13

3 JCOMM Installation ................................................................ 15

3.1 Installation Kit ..................................................................................... 15

3.2 Install the JCOMM Enclosure .................................................................. 16

3.3 Connect Voltage Sources and Ground ..................................................... 17

3.4 Connect Main or Subdistribution CTs ....................................................... 19

3.5 Install Panelboard Branch Circuit CTs ...................................................... 21

3.5.1 Run Cable Harnesses to JCOMM ................................................... 22

3.5.2 Connect Cable Harnesses to JCOMM Connections Panel .................. 23

3.5.3 Connect CTs to Cable Harnesses .................................................. 23

3.5.4 Clip CTs to Circuit Wires ............................................................. 24

3.6 Alternate Panelboards ........................................................................... 27

4 Networking ............................................................................ 28

4.1 Modbus Network Setup ......................................................................... 28

4.2 Upstream Protocols Using a Monitor ....................................................... 29

4.3 Modbus Addresses ................................................................................ 29

4.4 Modbus Addressing with Monitor Installed ............................................... 30

4.5 Remapping Modbus Addresses with Monitors ........................................... 30

5 BCMS Software Setup ............................................................. 32

5.1 Initial Setup Steps ................................................................................ 32

5.1.1 Install CD Setup Software ........................................................... 32

5.1.2 Install FTDI USB Driver............................................................... 33

5.1.3 Start Setup for the First BCMS Board............................................ 33

5.2 Setup Screen ....................................................................................... 34

5.2.1 Determine Software Levels and Points List .................................... 34


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5.3 Modbus Network Parameters ................................................................. 36

5.3.1 Network Parity........................................................................... 36

5.3.2 Set Modbus Addresses ................................................................ 36

5.3.3 Modbus Commands .................................................................... 37

5.4 Set BCMS Options ................................................................................ 37

5.4.1 Password .................................................................................. 37

5.4.2 Voltage Options ......................................................................... 38

5.4.3 Current Options for Main and Subdistribution Feeds ....................... 39

5.4.4 No Main or Subdistribution CTs .................................................... 40

5.4.5 Miscellaneous Options ................................................................ 41

5.5 Set Branch Circuit Breaker Sizes ............................................................ 42

5.6 Set Warning and Alarm Thresholds ......................................................... 43

5.7 Set Warning and Alarm Time Delays ....................................................... 44

5.8 Setup Test Environment ........................................................................ 45

5.8.1 Current Monitoring During Setup ................................................. 45

5.8.2 Display Voltages and Current for Each Circuit ................................ 46

5.9 Panelboard Alarms ............................................................................... 47

5.9.1 Panelboard Full Load .................................................................. 47

5.9.2 Panelboard Current and Voltage Acceptable Ranges ....................... 47

5.10 Calibration .......................................................................................... 49

5.10.1 Voltage Calibration ................................................................... 49

5.10.2 Calibration for Main or Subdistribution Feeds ............................... 51

5.10.3 Calibrate Current for Individual Branch Circuits ............................ 52

5.10.4 Replicate a Branch Circuit Calibration ......................................... 53

5.11 BCMS Setup Command Summary ........................................................... 54

6 Troubleshooting Installation Problems .................................. 57

6.1 Communications Problems ..................................................................... 57

6.1.1 Check Modbus Network Setup for the BCMS board ......................... 57

6.1.2 Check Modbus Addresses ............................................................ 57

6.2 BCMS Board Power Problems ................................................................. 58

6.3 Data Problems ..................................................................................... 58

6.3.1 No Current Readings .................................................................. 58

6.3.2 No Voltage or Power Readings ..................................................... 59

7 Operation ............................................................................... 60

7.1 Points List Options ................................................................................ 60

Contents _______________________

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7.2 Panelboard Points Lists ......................................................................... 60

7.2.1 Panelboard Points Lists Content Summary .................................... 60

7.3 Reading and Writing Modbus Registers .................................................... 64

7.4 Alarm Handling .................................................................................... 65

8 Service ................................................................................... 66

8.1 Warranty ............................................................................................. 66

8.2 Maintenance ........................................................................................ 67

8.2.1 PDI Maintenance Contracts ......................................................... 67

8.2.2 Spare Parts ............................................................................... 68

Bibliography ................................................................................... 69

Glossary ......................................................................................... 70

Appendix A: PCB Connections ......................................................... 71

Index .............................................................................................. 74

Figures

Figure 1 JCOMM with WaveStar Color Monitor ................................................................ 8

Figure 2 JCOMM Enclosure ......................................................................................... 11

Figure 3 JCOMM Connection Panels and BCMS Boards ................................................... 12

Figure 4 Enclosure Knockouts and Hole Locations ......................................................... 17

Figure 5 JCOMM Power Panel ..................................................................................... 19

Figure 6 250A CT and Cable Harness for Main and Subdistribution Feeds ......................... 20

Figure 7 JCOMM Connections Panel ............................................................................. 21

Figure 8 Cable Harness Orientation ............................................................................. 22

Figure 9 Connect Cable Harness to JCOMM Connections Panel ........................................ 23

Figure 10 Connect Branch Circuit CTs to Cable Harness ................................................. 24

Figure 11 Clip Split-Core CT Over Circuit Wire .............................................................. 25

Figure 12 Wire Orientation on Panelboards .................................................................. 25

Figure 13 Completed Panelboard ................................................................................ 26

Figure 14 Modbus Connections ................................................................................... 28

Figure 15 Modbus Addresses Assigned to Points Lists .................................................... 29

Figure 16 BCMS Network Connections with and without a Monitor .................................. 30

Figure 17 Network Segmentation When a Monitor is Present .......................................... 31

Figure 18 Modbus Upstream Address Remapping with JCOMM Monitor ............................ 31


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Figure 19 BCMS Desktop Icon .................................................................................... 33

Figure 20 JCOMM USB Connections ............................................................................ 33

Figure 21 BCMS Setup Screen .................................................................................... 34

Figure 22 Determine BCMS Software and Points List ..................................................... 35

Figure 23 BCMS Acquisition Board Processors .............................................................. 35

Figure 24 BCMS Setup Password Entry ........................................................................ 38

Figure 25 Set BCMS Options - Voltage ........................................................................ 38

Figure 26 Set BCMS Options - Large Circuits ................................................................ 39

Figure 27 Specify How Large Circuits are Used ............................................................. 40

Figure 28 BCMS Options with No Main or Subdistribution Feed CTs ................................. 41

Figure 29 Set Branch Circuit Breaker Sizes .................................................................. 42

Figure 30 Set Branch Circuit Warning and Alarm Thresholds .......................................... 44

Figure 31 Setting Time Delays for Warnings and Alarms ................................................ 45

Figure 32 Min-Max Current Measuring During Setup ..................................................... 45

Figure 33 Zeroed Current Monitoring During Setup ....................................................... 46

Figure 34 Live Test Data Displays ............................................................................... 47

Figure 35 Measuring Voltage for Calibration ................................................................. 50

Figure 36 Voltage Source Calibration .......................................................................... 51

Figure 37 Branch Circuit Calibration ............................................................................ 52

Figure 38 WaveStar Color Monitor Backpanel ............................................................... 71

Figure 39 BCMS LV/HV Board .................................................................................... 73

Tables

Table 1 JCOMM Specifications .................................................................................... 10

Table 2 JCOMM Installation Kit Contents ..................................................................... 16

Table 3 BCMS Measurements: Normal and Power-KWH Points Lists ................................ 62

Table 4 BCMS Alarm and Warning Configuration: Normal and Power-KWH Points Lists ...... 63

Table 5 BCMS Alarms and Warnings: Normal and Power-KWH Points Lists ....................... 64

Table 6 Customer Replaceable Units ........................................................................... 68

Table 7 Service-Installed Onsite Spares ...................................................................... 68

Safety ________________________________________________________________

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Safety

Please pay special attention to the use of “Danger” symbols throughout this manual indicating electrical or

other safety hazards. Following these safety instructions is extremely important to avoid possible injury or

death.

DANGER!

This symbol is used throughout this manual to indicate the presence of high

voltages, representing a hazard for electric shock, burn or explosion. Follow the

instructions carefully to avoid serious or fatal injury.

Follow safe electrical work practices:

• Disconnect and lock-out all power supplying equipment before working on or installing

JCOMM components. Use a properly rated voltage sensing device to confirm power is OFF.

• Electrical equipment should be installed, operated, serviced, and maintained only by

qualified personnel and in accordance with all local safety codes. Power Distribution, Inc.

assumes no responsibility for any consequences arising out of the use of this manual. This

document should not be viewed as sufficient by otherwise non-qualified personnel to

operate, service, or maintain the equipment discussed.

• Read, understand, and follow the instructions before installing this product.

• Install device in an appropriate electrical enclosure per local regulations.

• ESD sensitive equipment. Ground yourself, discharge any static charge and ensure that the

device is effectively grounded before handling the unit.

http://upload.wikimedia.org/wikipedia/commons/a/a9/High_voltage_warning.svg


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1 JCOMM Unit Description

1.1 JCOMM Summary

The PDI JCOMM® provides an enclosure for one or two PDI Branch Circuit Monitoring Systems (BCMSs) and can be attached to monitored power distribution equipment or mounted on a nearby wall. JCOMMs can retrofit BCMSs to operational power distribution units (PDUs) or Remote Power Panels (RPPs), both for PDI and non-PDI equipment.

Each JCOMM (Figure 1) can monitor these configurations:

• Two separate 208/120VAC/60Hz 3-phase 4-wire voltage sources to panelboards

• Up to four 42-circuit panelboards or 168 branch circuits in total

• Up to four main feeds to panelboards or four subdistribution feeds to remote power distribution

equipment

Figure 1 JCOMM with WaveStar Color Monitor

Local Power Monitoring Station. A JCOMM can have an optional WaveStar® Color Monitor, a 7-inch color touchscreen display, capable of displaying information for up to 20 downstream BCMS devices, such as panelboards.

Alternatively, JCOMMs can be connected to a WaveStar® BCMS Hub, which can typically monitor up to 70 BCMS devices.

JCOMM BCMS uses the same BCMS software that PDI installs in factory-built power distribution equipment and can be networked with all other PDI BCMSs.


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1.2 JCOMM Specifications

JCOMM Specifications

Monitoring Capabilities

BCMS Data Acquisition Boards 1 or 2 BCMS boards

Points list (Modbus register map) options

Normal list (specialized for customized alarms) or Power-KWH list (specialized for power measurements) IEC points (specialized for IEC panelboards)

1-2 Voltage sources 208/120VAC/60Hz 3-phase 4-wire

42-168 Branch circuits Monitored with split-core 60A current transformers (CTs)

2-4 Main feeds or 2-4 subdistribution feeds (2 main or 2 subdistribution feeds per BCMS)

Monitored with -Split-core 5-250A CTs for ABCN -Split-core 5A CT for G

CT branch circuit cable harnesses 21 BC connectors; 5, 10, 15, 20 ft. lengths

CT main or subdistribution circuit cable harnesses

ABCNG connectors; 5, 15, 10, 20 ft. lengths

WaveStar® Color Monitor, a 7-inch color touchscreen display

Optional; display can monitor 20 downstream BCMS devices, such as panelboards

Setup connection USB 2.0 A-B high-speed cable

Enclosure

Weight (without cables) Approx. 11 lbs. or 5 kg.

Dimensions 20"W x 10"H x 6”D (51 cm x 25 cm x 15 cm)

Enclosure rating NEMA 1

Network Communications

Protocol Modbus RTU via RS422/485; 2-wire or 4-wire (jumper selected)

Protocol options upstream from monitor Modbus RTU, Modbus TCP/IP, SNMP

Modbus address range 1 to 247

Baud rate 9600

Parity Odd, even, or none

Communication format 8 data bits, 1 start bit, 1 stop bit

Electrical Characteristics

Input current rating 2.0A @ 115 VAC

Input voltage 120VAC +/- 10%, 3-phase +neutral + ground

Input frequency 60Hz +/-10%

Operating voltage 24VDC

Power usage 50W @ 24VDC

Modbus signals 3VDC


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JCOMM Specifications

Ground strip Computer grade single-point ground, compliant with FIPS Pub 94 and NEC requirements

Storage temperature -36°C to +70°C (-33°F to 158°F)

Environmental Requirements

Operating temperature 0°C to +60°C (32°F to 140°F).

Relative humidity ranges 0% to 95% non-condensing

Maximum operating altitude 3000 Meters

Standards Compliance

Unit standards compliance

NFPA70, NFPA 75, IEC/ANSI/UL60950-1, CSA-C22.2, FIPS Pub, OSHA standards; applicable portions of IEC/ANSI/UL60950-1,CSA-C22.2

Manufacturing testing NEMA, UL and CSA standards

Table 1 JCOMM Specifications

1.3 JCOMM Enclosure

JCOMM has a single enclosure type for all mounting situations (Figure 2).

The entire front of the enclosure swings open and the inside frame slides out for easy servicing of the BCMS boards, optional monitor, and cabling. Opening the JCOMM front gives access to the Connections Panel (on left) and the Power Panel (on right).

Knockouts and pre-drilled mounting holes facilitate mounting on walls or on top of PDUs or RPPs.

DANGER!

• Power must be turned off and locked out before removing the internal frame.

• Removing the internal frame should only be done by a licensed electrician or service technician.


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Figure 2 JCOMM Enclosure

1.4 Optional WaveStar Color Monitor

The front panel mounts an optional WaveStar Color Monitor, a 7-inch color touchscreen.

The WaveStar Color Monitor can display information from the points lists for 20 downstream

BCMS devices, such as panelboards. The monitor is part of the Modbus network and has its own

points list.

The Monitor can connect to upstream networks using Modbus RTU, Modbus TCP/IP, or SNMP.

1.5 BCMS Data Acquisition Boards

The frame can mount two BCMS Data Acquisition Boards, which are identical to PCBs used in

factory-installed BCMS and use the same software. Each BCMS is an independent monitoring

system.

Each BCMS board contains points lists (Modbus register maps) for two panelboards and their

associated main feeds. There are two points list options:

• The Normal list is specialized for alarm customization for branch circuits.

• The Power-KWH points list is specialized for power monitoring for branch circuits.

• The IEC points list is specialized for IEC panelboards.

BCMS software specific to the selected points list is loaded onto the board at the factory.

If subdistribution feeds are monitored, the BCMS also uses a small third points list for two

subdistribution feeds.

1.6 Power and Connections Panels

JCOMM has connection panels so that customers do not have to make direct connections to the BCMS PCBs (Figure 3).

Power Panel (right side). The Power Panel has connections for voltage measurement, power, and grounding:


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• Two (2) sets of terminal blocks for two voltage sources (208/120VAC/60Hz 3-phase 4-wire), allowing

separate voltages to each panelboard

• One (1) set of grounding terminals

• One (1) 24VDC power supply, fed from voltage source 1

• Two (2) power terminal blocks, providing 24VDC to the BCMS data acquisition boards and optional

monitor

Figure 3 JCOMM Connection Panels and BCMS Boards

Connections Panel (left side). The Connections Panel has connections for current monitoring and communications:

• Eight (8) cable harness connection for branch circuit CTs, two connections (odd/even numbered

sides) for each of the four (4) possible panelboards

• Four (4) cable harness connections for main feed CTs or subdistribution feeds

• Two (2) Modbus connections

Connections Panel - Branch circuit CT cable harnesses - Main/subdistribution feed cable harnesses - Modbus connections

Power Panel - Power/voltage sources - Ground strip - 24V power supply

BCMS Data Acquisition Boards

2 Planning a JCOMM Installation____________________________________________ ________

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2 Planning a JCOMM Installation

The following is a list of actions to review when planning a JCOMM installation.

JCOMM enclosure installation

1. Select power distribution equipment to be monitored by JCOMM BCMSs.

2. Based on (1), determine the number of JCOMMs required (specified on order).

3. Select the location of each JCOMM and determine mounting method, conduit, and mounting

hardware. The customer provides all conduit and mounting hardware. (See Section 3.2, “Install

the JCOMM Enclosure.”)

a. Typically a JCOMM will be attached directly to a PDU or RPP or to a nearby wall.

b. Plan conduit and CT cable harness lengths from JCOMM to circuits. If running cables

from under a monitored unit, make provision for cable bends to create correct branch

circuit addressing. (See Section 3.5, “Install Panelboard Branch Circuit CTs.”)

4. For power/voltage connections, the customer must provide

a. An approved electrical disconnecting means on each voltage source within sight of the

JCOMM in accordance with local codes and NEC standards. (See Section 3.3, “Connect

Voltage Sources and Ground.”)

b. A ground connection in accordance with FIPS Pub 64, NEC standards, and local codes.

Monitors: local power monitoring stations

5. Determine monitors to be used as local power monitoring stations:

a. Determine which JCOMMs will have a display.

b. Determine which BCMS devices will be monitored downstream of the display

(panelboards and subdistribution feeds).

c. Alternatively, determine if JCOMM BCMSs will be connected to a WaveStar BCMS Hub.

Communications

6. Determine protocols to be used between the JCOMM monitors and the building management

system (BMS). (See Section 4.2, “Upstream Protocols Using a Monitor.”)

7. Plan communications cables (type and length) and BCMS upstream links to the BMS. Customers

must provide all communications cables for connections upstream or downstream of a JCOMM.

(See Section 4.1, “Modbus Network Setup.”)

8. Create a Modbus address map. Incorrect network addressing is a common BCMS startup

problem. If using a JCOMM monitor or WaveStar BCMS Hub with a Modbus upstream protocol,

plan for downstream Modbus addresses to be remapped upstream from monitors. (See Section

4.5, “Remapping Modbus Addresses with Monitors.”)

Monitoring options

9. Select a points list. Points lists must be specified at time of order for loading into the BCMS

boards. (See Section 7.2, “Panelboard Points Lists.”)

10. Plan setup options, especially warning and alarm parameters. (Review all of Chapter 5, “BCMS

Software Configuration.”)

Building Management System

11. Create a Modbus address map for network addresses as seen from the BMS, including

remapped upstream Modbus addresses when a JCOMM monitor or WaveStar BCMS Hub is


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used as a local power monitoring station. (See Section 4.5, “Remapping Modbus Addresses with

Monitors.”)

12. Plan for efficient polling of warnings and alarms. (See Section 7.4, “Alarm Handling.”)

3 JCOMM Installation

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JCOMM installation is the responsibility of the customer.

A PDI-trained technician can provide on-site support for software setup and network connection for new JCOMM installations.

For planning questions, installation problems, or post-installation support:

• Call the PDI Technical Support (US or Canada): +1-804-304-8367.

• Or email [email protected].

3.1 Installation Kit

Upon receipt of your JCOMM shipment:

1. Open your JCOMM shipping package(s).

2. Check the packing list against the contents of the kit to make sure that all items in the packing list

have been included.

3. Check the enclosure, internal frame, boards, and connectors for damage.

4. Report any missing or damaged parts to PDI support at +1-804-304-8367 or

[email protected].

The contents of your JCOMM Installation Kit will include items from the following table:

Option Part Number Part Description

JCOMM Enclosure and Display Options

JCOMM with WaveStar Color Monitor

A JCOMM unit can have various part numbers depending on features.

JCOMM with no display

A JCOMM unit can have various part numbers depending on features.

JCOMM units must be installed by licensed electricians or by PDI-authorized technicians.




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Cable and CT Kits

Panelboard Kits (Branch Circuits): 1-4 Panelboard Kits

(1) Panelboard Kit, 42-circuit panelboard

(2) ICA14214-xx (xx=length) Cable harness for branch circuit split-core CTs: connectorized cable harness for 21 XMR14320 (60A) CTs in lengths of 5, 10, 15, or 20 ft.

(42) XMR14320 Branch circuit split-core CTs ≤ 60A

Main Circuit Cable Kits (Main or Subdistribution Feeds): 0-4 Main Circuit Cable Kits

(1) Main or subdistribution circuit cable kit

(1) CBL14321-xx (xx=length)

Main/subdistribution circuit CT cable harness: connectorized cable for (4) XMR14321 split-core CTs (ABCN) and (1) XMR14321-005 split-core CT (G), in lengths of 5, 10, 15, or 20 ft.

(4) XMR14321 Main/subdistribution feed CT: split-core CT, 5A - 250A (ABCN)

(1) XMR14321-005 Main/subdistribution feed CT: ground circuit, split-core CT, 5A (G)

Voltage/Power Cables: 0-2 Voltage/Power Cables

Optional PDI power/voltage cable

CBL14131-xx (xx=length) Power/voltage cable, with inline 1A 1000V cartridge fuses, in lengths of 5, 10, 15, or 20 ft.

Table 2 JCOMM Installation Kit Contents

3.2 Install the JCOMM Enclosure

The customer provides attachment hardware for mounting JCOMMs.

Parts used in this step:

JCOMM with WaveStar Color Monitor (various PNs depending on features)

JCOMM with no display (various PNs depending on features)

DANGER!

Severe or fatal injury can result from electrical shock during contact with high voltage conductors, monitoring PCBs, or similar equipment.

Disconnect power before drilling holes, attaching conduit, and attaching JCOMMs to walls, PDUs, RPPs, or other power distribution equipment.

Use Lock Out/Tag Out procedures.

Wear suitable personal protective clothing and use protective equipment for performing mechanical and electrical installations.

Leave ample space for attaching and routing wires.


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A JCOMM enclosure has four slots for mounting on a wall (Figure 4):

1. Mark (4) mounting holes on wall nearby equipment using the enclosed Mylar template. Place a

level against the top of the drilling marks to make sure the holes are level.

2. Drill ¼-inch bolt holes at the target location.

3. Hang the enclosure to make sure the enclosure will be level and securely mounted.

4. JCOMM has 1- and 2-inch knockouts on the top, bottom, and both sides of the unit for attaching

conduit.

When mounting a JCOMM to the top of an RPP or PDU, use conduit and other hardware to anchor the JCOMM to the unit.

Figure 4 Enclosure Knockouts and Hole Locations

3.3 Connect Voltage Sources and Ground

Parts used in this step:

CBL14131-xx (xx = length) Optional PDI power/voltage cable, with inline 1A 1000V cartridge fuses, in lengths of 5, 10, 15, or 20 ft.


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The customer is responsible for providing power/voltage cables. PDI can provide an optional power/voltage cable (CBL14131) in lengths of 5, 10, 15, or 20 ft. with inline 1A 1000V AC/DC cartridge fuses on ABC phases. The wire ends are 18AWG and should have ferrules if connected to a branch circuit breaker.

Connect ground and voltage sources to the Power Panel (Figure 5):

1. Make a ground connection to the grounding strip in accordance with FIPS Pub 94, NEC

requirements, and local codes.

2. Voltage Source 1:

a. Connect Voltage Source 1 ABCN from a panelboard circuit breaker or main feed to the

Source 1 terminal blocks, ABCN.

b. Connect Voltage Source 1 G to shared terminal block G.

3. Voltage Source 2, if used:

a. Connect Voltage Source 2 ABCN, from a panelboard circuit breaker or main feed to the

Source 2 terminal blocks, ABCN.

b. Connect Voltage Source 2 G to shared terminal block G.

IMPORTANT! The customer must provide an approved electrical disconnecting means for Voltage Source 1 and, if used, Voltage Source 2, such as a panelboard circuit breaker or a fuse, within sight of the JCOMM in conformance to NEC standards and local codes.



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Figure 5 JCOMM Power Panel

3.4 Connect Main or Subdistribution CTs

To measure current on main or subdistribution feeds, install split-core CTs rated at 250A on the wires (ABCNG) and connect to matching cable harnesses.

Different combinations of circuit phases can be monitored: ABCNG, ABC, N only, or G only. Specify in software setup which large circuit wires are monitored.

Power Terminal Block Connections

Grounding Strip

Voltage Source 2

Shared Ground

Voltage Source 1

Voltage Source 1 has two functions: 1. External power source for the 24VDC power supply 2. Panelboard voltage monitored by the BCMS Voltage Source 2 is monitored by the BCMS. It is only used if panelboards 1 & 2 use different voltages.

A B C N A B C N

Power Supply AC24VDC

24VDC (-) 24VDC (+) G

DANGER! Power must be disconnected and locked out before installing and connecting CTs.


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Parts used in this step (for each main or subdistribution feed):

(4) x XMR14321 Main/subdistribution feed CT: split-core CT, 5A - 250A (ABCN)

(1) x XMR14321-005 Main/subdistribution feed CT: ground circuit, split-core CT, 5A (G)

(1) x CBL14321-xx (xx = length)

Main/subdistribution circuit CT cable harness: connectorized cable for (4) XMR14321 split-core CTs (ABCN) and (1) XMR14321-005 split-core CT (G), in lengths of 5, 10, 15, or 20 ft.

Large-circuit split-core CTs (Figure 6):

1. Click a split-core 250A CT (XMR14213) over each main/subdistribution ABCN cable you are

monitoring on the line side of the associated breaker, except for the ground phase.

2. Click the 5A ground CT (XMR14213-005) over the ground line, if ground is being monitored.

Figure 6 250A CT and Cable Harness for Main and Subdistribution Feeds

Cable harnesses (Figure 6):

3. Run a cable harness (CBL14321-xx) through a left side JCOMM knockout leaving the five-

connector end near the main or subdistribution feed CTs.

4. Connect the cable harness to the 10-pin connector for the corresponding main feed or

subdistribution feed connector (1 or 2) for this BCMS at the bottom of the JCOMM Connections

Panel (Figure 7). (There are two main feed or subdistribution feed connections for each BCMS.)

5. Each cable harness has five labeled connectors (ABCNG). Connect split-core CTs ABCNG to the

connectors with matching labels on the cable harness for those phases being monitored.

ABCNG split-core connectors (labeled)

Connect this end to JCOMM Connections Panel

250A split-core CT

250A split-core CT cable harness


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Figure 7 JCOMM Connections Panel

3.5 Install Panelboard Branch Circuit CTs

Parts used in this step (for each panelboard):

(42) x XMR14320 Branch circuit split-core CT ≤ 60A with 2-pin connector

(2) x ICA14214-xx (xx=length) Cable harness for branch circuit split-core CTs: connectorized cable harness for 21 XMR14320 (60A) CTs in lengths of 5, 10, 15, or 20 ft.

BCMS 2 BCMS 1

Main/Subdistribution Feed CTs Cable Harness Connections

PB1/SD1 PB2/SD2 PB1/SD1 PB2/SD2

Reserved

BCMS 1

Branch Circuit CTs Cable Harness Connections

PB 2 Even Numbered Breakers (Right side)

PB 2 Odd Numbered Breakers (Left side)



BCMS 2 Branch Circuit CTs Cable Harness Connections





Modbus Out

Modbus In

Reserved

PB=panelboard SD=subdistribution


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To measure current on panelboard branch circuits, install split-core CTs rated at 60A and matching cable harnesses. CT installation has these steps:

1. Run cable harnesses in the correct orientation from panelboards to JCOMM.

2. Connect cable harnesses to JCOMM Connections Panel.

3. Connect split-core CTs to the cable harnesses.

4. Clip CTs over circuit wires in correct order.

3.5.1 Run Cable Harnesses to JCOMM

Figure 8 Cable Harness Orientation

Typically, JCOMM cable harnesses are run from a top-mounted JCOMM. Run the cable harness to the panelboard through a JCOMM a knockout so that cable harness CT connector #1 (J1) connects to the top of the panelboard and #21(J21) to the bottom. Put a U-bend in the harness to orient the harness so that it

The #1(J1) CT connector on the harness should

always be connected to the CT at the top of the

panelboard. See Section 3.5.2 Connect Cable

Harness to JCOMM Connections Panel.

If the JCOMM CT harness is

wired from above the

monitored unit, put a U-bend in

the cable harness so that the J1

connector is at top of the

panelboard.

If the JCOMM CT harness is wired from

under the monitored unit, the harness is

strung straight up from the bottom and

does not need a U-bend.

J1

J1 J1

J1 J1

PB1

PB2

PB1

PB2 J1

DANGER! Power must be disconnected and locked out before installing and connecting CTs.


23

correctly addresses the circuit (Figures 8 and 9). Use caution in creating the U-bend, allowing a gradual minimum bending radius.

If the CT harness is run into the monitored unit from the bottom, run the harness straight up from the bottom so that J1 is at the top. Do not add a U-bend in the harness.

Note: If you are using IEC panelboards, connections #19-21 are not used.

3.5.2 Connect Cable Harnesses to JCOMM Connections Panel

Connect the cable harness to the corresponding 22-pin socket on the JCOMM Connections Panel. Each panelboard has an odd-numbered and even-numbered side connector (e.g., PB1/odd, PB1/even) (Figure 9). Refer to the Connections Panel layout in Figure 7.

Figure 9 Connect Cable Harness to JCOMM Connections Panel

3.5.3 Connect CTs to Cable Harnesses

Connect a branch circuit CT (XMR14320) to each cable harness connector (Figure 10). Branch circuit cable harnesses (ICA14214-xx) each have 21 CT connectors, labeled 1-21, with #1 (J1) connector at the top.

a. Align the CT 2-pin connector as shown in Figure 10. b. Connect the 2-pin connectors together until they snap in place as illustrated.

#21 (labeled as J21)

High-numbered CT connections are at the bottom of the panelboard.

#1 (labelled as J1) is

connected to the top CT on

the panelboard.

The 22-pin connector attaches to JCOMM Connections Panel.


24

Figure 10 Connect Branch Circuit CTs to Cable Harness

3.5.4 Clip CTs to Circuit Wires

1. Clip a 60A split-core CT over each branch circuit wire where it leaves the panelboard breaker in sequence top to bottom. Branch circuit CT cable harness connectors are labeled 1-21, with #21 connection at the bottom of the panelboard. a. Open the CT and snap it over the circuit wire as shown in Figure 11. b. The split-core CT wire must always go to the right, regardless of whether the CT and

cable harness are on the left or right side of the panelboard. This is a standard connection procedure for all branch circuit CTs. BCMS automatically inverts the waveform for CTs on the right side of the panelboard to provide correct measurements. However, the appearance of the left and right sides of a panelboard will be different as shown in Figures 12 and 13.

Branch circuit CT cable harness connectors are labeled J21 (bottom end of panelboard) to J1 (top end).

Click each 2-pin CT connector into the matching connector in the cable harness.


25

Figure 11 Clip Split-Core CT Over Circuit Wire

Figure 12 Wire Orientation on Panelboards

Open a 60A split-core CT and place it over the branch circuit where the wire leaves its panelboard breaker.

The wire exiting the CT must face to the right on both sides of the panelboard.

Snap the CT shut over the circuit wire.

The clasp on the reverse side should click shut.

On the LEFT SIDE of the panelboard, the wire exits the CT to the right, but bends back to connect to the cable harness.

On the RIGHT SIDE of the panelboard, the wire exits the CT to the right and continues straight to connect to the cable harness.

The CT wire must ALWAYS exit the CT to the right on both sides of the panelboard.


26

Note: Always attach the CTs over the circuit wires as the last step if the panelboard will be energized at any time during installation. CT installation steps can be varied for convenience IF and ONLY IF the panelboard will not be energized at any time during installation.

Figure 13 Completed Panelboard

Warning!

Before applying power to the panelboard, make sure that all CTs are connected to their cable harness and that the cable harness is connected to the left-side JCOMM Connections Panel. The Connections Panel has burden resistors to prevent a voltage surge in the CTs.

If power is applied to a panelboard with CTs installed on circuit wires, but NOT connected through a cable harness to the connection panel, a voltage surge can be generated in the CTs that can damage electronics when all connections are completed.

Harnesses

JCOMM (door open) with CT harnesses and completed CT installation.



27

3.6 Alternate Panelboards

Panelboards are available in different configurations. JCOMM BCMS is designed for standard North American panelboards with 42 circuits distributed in two columns, 21 circuits per side.

There are also column-width panelboards with all circuits in a row in a single column, numbered sequentially, 1-42, which are addressed differently. For addressing column-width panelboards, contact PDI Service at 1-804-737-9880.

JCOMM Installation and Operation____________________________________________________________________

28

4 Networking

This chapter describes incorporation of JCOMMs and their BCMSs into a network. Networking problems are among the most common BCMS installation problems. Network addressing in particular should be carefully planned.

4.1 Modbus Network Setup

The networking protocol for JCOMM BCMS boards is Modbus RTU with the following characteristics:

• 9600 bps network speed

• Even (default), odd, or no parity (specified during BCMS software setup)

• 4-wire or 2-wire (2-wire selected by jumpers on the Connection Panel)

All customer Modbus network connections are made through two Modbus connectors on the Connections Panel (Figure 14). The customer provides Modbus cables for network connections.

Figure 14 Modbus Connections

All JCOMMs in a Modbus loop must be configured identically. 4-wire Modbus is the default. With a JCOMM monitor, 4-wire Modbus must be used downstream of the monitor.

2-wire Modbus can be used on JCOMM network connections when a monitor is not installed. For 2-wire Modbus loops, install jumpers connecting RX- to TX- and RX+ to TX+ on each JCOMM Modbus connector.

JCOMM Connections Panel

Modbus Out Connector

Modbus In Connector

To BMS or WaveStar® BCMS Hub or another Modbus connection

Networking JCOMMs

4-wire Modbus is the default.

When no JCOMM monitor is installed, to setup 2-wire Modbus, jumper Modbus connectors: RX- to TX- RX+ to TX+

With a monitor installed, keep the 4-wire default downstream of the monitor.

TX+ TX- RX+ RX- Common

4 Networking__________________________________________________________________________________________

29

4.2 Upstream Protocols Using a Monitor

BCMS boards use Modbus RTU protocol downstream from a JCOMM monitor.

Upstream from a JCOMM monitor, there are three protocol choices, which can be used simultaneously:

• Modbus RTU

• Modbus TCP/IP (high-speed protocol using an Ethernet link)

• SNMP (high-speed, event-driven protocol over an Ethernet link)

TCP/IP can also be used to display Color Monitor web pages. These protocols are specified in monitor setup. See the WaveStar Color Monitor, Installation and Operation manual (referenced in Bibliography) for setup information.

4.3 Modbus Addresses

Figure 15 Modbus Addresses Assigned to Points Lists

Each BCMS points list must be assigned a Modbus address (Figure 15):

• Modbus addresses are for points lists: 1 Modbus address = 1 Points List= 1 BCMS device.

• Each panelboard has a separate points list.

JCOMM Installation and Operation____________________________________________________________________

30

• There are no separate points lists for main feeds. Main feed current measurements are included in

each panelboard’s points list, whether BCMS measures main feeds with CTs or computes main feed

current from branch circuit measurements.

• If subdistribution feeds are monitored, there is a third small points list for storing data about two

subdistribution feeds. When main feeds are monitored with CTs, subdistribution feeds cannot be

monitored on that BCMS because the large circuit connections are used by the main feeds.

• Points list addresses within a BCMS must be sequential. Assign these addresses during BCMS

software setup.

4.4 Modbus Addressing with Monitor Installed

If there is no JCOMM monitor, each BCMS responds to the Modbus addresses assigned in BCMS setup. But if the JCOMM has a monitor, the monitor is connected between the BCMS boards and the Modbus network (Figure 16). The monitor intercepts and responds to Modbus addresses on behalf of the BCMSs, but it must remap these addresses as explained in the following sections.

Figure 16 BCMS Network Connections with and without a Monitor

4.5 Remapping Modbus Addresses with Monitors

In a Modbus network only the master device can poll a downstream device. There can be only one master, typically the BMS. However, a JCOMM monitor must also poll its downstream devices.

Because there cannot be two Modbus masters, when both a monitor and BMS are present, the network must be divided into segments at the monitor with one master per segment (Figure 17).

• Upstream segment: BMS is master to the monitor; monitor is slave to BMS.

• Downstream segment: monitor is master to its downstream BCMS devices.

The BMS cannot address BCMS devices downstream of the monitor because the monitor is the endpoint of that network segment.

Instead, the monitor remaps its downstream device addresses to upstream segment addresses. When the BMS requests data from a device downstream of a monitor, it addresses the downstream device

JCOMM Connections Panel (shown edge-on)

For networking, a JCOMM monitor is connected between BCMS boards and the Modbus network.

The monitor responds to Modbus network requests on behalf of the BCMSs.

With no monitor present, BCMS boards respond to Modbus network requests.

BCMS1 BCMS2

BCMS1 BCMS2

Monitor

Modbus: In Out In Out

4 Networking__________________________________________________________________________________________

31

indirectly through the monitor. Downstream devices are only visible to the BMS through these remapped addresses.

The monitor caches data from its downstream devices. It responds to BMS requests with cached data or retrieves fresh data from the downstream device.

Figure 17 Network Segmentation When a Monitor is Present

When planning BCMS with local JCOMM monitors, plan for remapping panelboard and subdistribution feed Modbus addresses to the monitor’s upstream side. These remapped addresses are what the BMS must use to address the downstream BCMS devices (Figure 18).

Figure 18 Modbus Upstream Address Remapping with JCOMM Monitor

If you use SNMP as the protocol upstream from the monitor, the monitor does not remap Modbus addresses, because there is only one Modbus network segment and only one master.

JCOMM Color Monitor


32

5 BCMS Software Setup

After a JCOMM has been physically installed with voltage, CT, and network connections, this physical

configuration must be described to the BCMS software for it to correctly monitor power distribution

equipment. Usually PDI service representatives perform BCMS software setup, but setup can be also

performed by a customer technician.

Each BCMS is set up separately. Setup includes the following tasks:

• Set Modbus addresses for points lists.

• Describe main feeds to the panelboards.

• Describe subdistribution feeds, if used, instead of main feeds.

• Describe the branch circuits on each panelboard.

• Specify warning, alarm, and alarm time delay parameters.

• Calibrate voltage and current measurements.

• Monitor the setup environment as a test environment with live data.

The following sections describe these tasks in detail.

5.1 Initial Setup Steps

5.1.1 Install CD Setup Software

Load PDI setup software (the latest version of BCMSII) on a portable PC using the startup CD from PDI:

1. Create a folder on C drive called BCMSII. 2. Load the startup CD. 3. Copy the file BCMSII.exe from the startup CD into C:\BCMSII. 4. For easy access, create a short-cut on the desktop to setup software: right-click on

C:\BCMSII\BCMSII.exe to create a short cut on the desktop to BCMSII.exe (Figure 19).

BCMS II software can also be downloaded from the PDI web site: http://www.pdicorp.com/index.php/service/downloads

DANGER!

• JCOMMs are powered from Voltage Source 1. The monitored power distribution equipment, such as an RPP or PDU, must be powered up for BCMS to function.

• Monitored equipment and JCOMMs should be powered up by an electrician or PDI-authorized technician for BCMS setup and test.

• Monitored power distribution equipment use high voltages. Exercise extreme caution, especially with newly installed equipment.

http://www.pdicorp.com/index.php/service/downloads

5 BCMS Software Configuration

33

5.1.2 Install FTDI USB Driver

Most computers already have a USB driver. Use the following instructions to install a new USB driver if, when you connect a USB cable from your PC to a JCOMM, Windows issues an error message requesting you to install a driver. The FTDI USB driver installed with these instructions is also more suitable for setup than generic USB drivers.

1. Load the D2XX folder from the Installation CD to the hard drive. For easy access, create a folder called BCMSII on the computer’s hard drive and save all BCMS files from the CD into this folder.

2. If an older device driver is installed, use FTDIUNIN.EXE from the BCMSII folder to uninstall the old driver.

3. Disconnect the PC from the Internet to prevent the PC searching for the driver on the web. 4. Connect a USB 2.0 A-B cable from your PC to the USB port on the JCOMM front panel for the

BCMS you are setting up. This will cause Windows to launch the ‘Found New Hardware’ Wizard. (Do NOT connect to the Internet—the USB driver search must be confined to files from the CD.) Select “Install from a list or specific location (Advanced)” and click the Next button.

5. Check the “Include this location in the search,” click the Browse button and find the file path (“C:\BCMSII\D2XX\” in this example). Once the file path has been entered into the box, click “Next” to proceed.

6. If Windows warns that unsigned drivers are about to be installed, click “Continue Anyway” to proceed with the installation.

7. After Windows has successfully completed installation of the driver, click “Finish”. The USB cable is now ready to use.

5.1.3 Start Setup for the First BCMS Board

1. If you have not already done so, connect a USB 2.0 A-B cable from a USB port on your PC to the

USB port for the BCMS board you are setting up (Figure 20). The JCOMM panel connectors are

male USB 2.0 connectors.

2. Click the desktop shortcut icon to load BCMSII setup software (Figure 19).

Figure 19 BCMS Desktop Icon Figure 20 JCOMM USB Connections

When the BCMSII software loads, the first screen to appear is the Setup Screen (Figure 21).

USB port for setting up BCMS board 2

USB port for setting up BCMS board 1


34

5.2 Setup Screen

Any of the USB setup commands can be entered on the command line. The results of the command you

enter are listed in the large main frame. The list of responses accumulates as you proceed and rolls off

the screen. You can clear the main screen display area by clicking the button Clear Display.

The available USB setup commands are given in the Setup Command Section.

However, there are many buttons and configuration tables that make most of BCMS setup much easier

than entering individual commands.

Figure 21 BCMS Setup Screen

5.2.1 Determine Software Levels and Points List

Software levels are specific to a points list and are loaded in manufacturing.

• 6.x levels are for the Normal points list.

• 13.x levels are for the Power - KWH points list.

Click See Current to display panelboard branch circuit currents during setup.

Click See Voltage to show panelboard voltages during setup.

Click See Sub Dis. to display main feed or subdistribution feed currents during setup.

Reset BCMS resets to zero all warnings and alarms, min-max measurements, and KWH accumulations.

Menu Line Command line: Enter commands here, then press Enter or click Write.

Quick links: Enter frequently used commands here for quick access. Quick Links are saved on disk and are available after a system restart.

Command results are displayed in this large space.

Command results are displayed in sequence and results are rolled off the screen.

Click the Clear Displays button to clear the screen.


35

Verify that the board has been initialized with the correct points list.

Click the Type button (Figure 22) to retrieve software version levels and points lists from the BCMS acquisition board. This is necessary for the setup software to know how to proceed with configuration. Some configuration screens vary according to the points list.

Alternatively, type the B command in the menu and then Enter or Write.

Figure 22 Determine BCMS Software and Points List

The acquisition board has seven processors, one main processor and six current processors (Figure 23).

• The first software level returned by the Type button (or the B command) is the main processor

software level.

• The next six numbers are the levels of the current processors (two sets of three processors for

each phase ABC). They should all be the same level.

Figure 23 BCMS Acquisition Board Processors

Click the Type button to determine the software levels and points lists, which are then displayed below the Type button. Setup software must have access to these to configure the BCMS correctly.

Current processors

Current processors

Main processor


36

5.3 Modbus Network Parameters

5.3.1 Network Parity

Almost all Modbus networks use even parity, but parity can be displayed and changed using the following commands:

p Displays Modbus parity used by BCMS (even is the default).

Pp Sets Modbus parity where p = e, o or n.

Example: Pe (sets parity to even)

Note: Setup commands to read data start with a lower-case letter. Setup commands to write data start with uppercase letters.

5.3.2 Set Modbus Addresses

Each panelboard must have a Modbus address, which is actually the address of its points list. Panelboard 2 must have an address one greater than panelboard 1.

Example:

A1 5 (sets Modbus address 5 for panelboard 1)

A2 6 (sets Modbus address 6 for panelboard 2)

For main or subdistribution feeds, there are three cases:

1. If subdistribution feeds to other units (as opposed to main feeds to panelboards) are being

measured with CTs, specify a Modbus address that will be monitored by the BMS or a local

monitor. Two subdistribution feeds can be monitored per BCMS acquisition board and these are

placed in a separate subdistribution points list, addressed by the specified Modbus address:

As 3

2. Main feeds to panelboards do not have separate points lists and they do not need an actual

Modbus address. CT measurements are placed in the panelboard points lists. But a Modbus

address must be specified for the setup system to recognize that there are CTs on the main

feeds.

Therefore, if main feeds are being measured with CTs, specify a separate Modbus address for

these feeds, but make it an address, beyond any you would use on this string, such as:

As 222


37

3. If there are no CTs on main feeds or subdistribution feeds, no Modbus address is needed. BCMS

computes total current to the panelboards from branch circuits and stores the data in the

panelboard points list. Set the subdistribution or main feed Modbus address to 0:

As 0

5.3.3 Modbus Commands

The only task that must be done during setup is setting the Modbus addresses of the points lists. All other setup tasks can be done outside of setup using Modbus commands to read or write values in the points lists. Modbus read and write commands can also be executed during setup with the following setup commands:

ms_nnn_yyy Reads Modbus points range (range of Modbus registers), where

s = 1 or 2 (address of points list for panelboard 1 or 2),

nnn is the start point or register, and

yyy is last point or register.

Ms_nnn_yyy_NNN Sets Modbus points list range values (range of Modbus registers), where

nnn is the start point or register,

yyy is last point or register, and

NNN is the value being written into the range.

5.4 Set BCMS Options

BCMS Options define the large circuit configuration and a selection of other points lists options. Click Set Options on the menu line to display the Set BCMS Options screen.

The following options are defined on the Set BCMS Options screen:

• Voltage sources to the panelboard

• Current sources for main feeds

• Current sources for subdistribution feeds

• Miscellaneous options and alarms

5.4.1 Password

A password is necessary to set options. Enter the password on the setup screen (Figure 24). If a PDI

representative is not performing the setup, contact your PDI representative for a password.


38

Figure 24 BCMS Setup Password Entry

5.4.2 Voltage Options

Figure 25 Set BCMS Options - Voltage

BCMS has four voltage options (Figure 25):

• Basic BCMS (No voltage). Voltage is not monitored. (Voltage monitoring is required for the

Power-KWH points list.)

• One voltage feeding both panels. Only one voltage—Voltage Source 1—is connected on the

JCOMM right-side panel. This is by far the most typical configuration.

• Two voltages, one feeding each panel. If both Source 1 and Source 2 voltages are connected

to the JCOMM right-side Power Panel, choose this option.

• Two switched voltages feeding both panels. This option is not available on JCOMM.

Other voltage options:

• THD. Check this box to have BCMS compute total harmonic distortion in the points list.

Enter password here.


39

JCOMM BCMS monitors only 208/120VAC/60Hz sources. Do not check these boxes:

• 50 Hz

• High-Voltage Board

5.4.3 Current Options for Main and Subdistribution Feeds

Each BCMS has two connections for large circuit CTs (250A) on the JCOMM left-side Connections Panel

that can be used for either main feeds to panelboards or subdistribution feeds to other power distribution

units. Specify the large circuit configuration as follows (Figure 26):

• In Sub Distribution Options, specify the phases (ABCNG) having CTs and whether one or two

feeds are monitored. (Note: Sub Distribution Options will not display if no Modbus address was

specified for subdistribution feeds.)

• In From Sub Distribution, specify how these monitored phases are used, such as for one feed

to each panelboard or for subdistribution feeds.

Sub Distribution Options describes the physical large circuit CT configuration, regardless of whether the

CTs are used for subdistribution or main feeds. Check the boxes reflecting the installed physical CT

configuration:

• Sub Feed 1 CTs. There are CTs on the large circuits for main feed or subdistribution feed 1.

• Sub Feed 2 CTs. There are CTs on the large circuits for main feed or subdistribution feed 2.

• Sub Feed Neutral CTs. The neutral wires on these circuits also have CTs.

• Sub Feed Ground CTs. The ground wires on these circuits also have CTs.

Figure 26 Set BCMS Options - Large Circuits

If there are boxes checked in Sub Distribution Options indicating that you have physically installed CTs

on large circuit feeds, then specify the use of those large circuits in Main Current Options: From Sub

Distribution (Figure 27).

Options checked in Sub Distribution Options determine the options displayed in the right-side panels.

1. In Sub Distribution Options, specify the physical CT configuration.

2. In From Sub Distribution, specify the use of the CTs.


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Figure 27 Specify How Large Circuits are Used

Neutral CT Configuration

If neutrals are monitored with CTs, then options are also displayed in From Sub Distribution. Check the appropriate box according to the installed configuration:

• Neutral CTs on Panel. Each panel has a neutral circuit with a CT (a main on each panelboard).

• Neutral CTs Total. There is one common neutral circuit with a CT (one main feeding both

panelboards).

• Ground CTs. There are CTs on the ground wires.

5.4.4 No Main or Subdistribution CTs

If there are no boxes checked under Sub Distribution Options, indicating that large circuits have no

CTs, then BCMS will calculate total current to the panelboards. These measurements are quite accurate

and very close to actual measurements with CTs.

= CT


41

There are two choices (Figure 28):

• Sum Branch. BCMS will calculate the total current for a panelboard using branch circuit

measurements. Due to differences in branch circuit power factors, this is a complex calculation

rather than a simple addition.

• Sum Branch and Total of Both Panels. BCMS will create a total for both panelboards and will

also sum the totals of both panelboards. If there is a separate voltage to each panelboard, this

option is not available.

Figure 28 BCMS Options with No Main or Subdistribution Feed CTs

5.4.5 Miscellaneous Options

Check the boxes for miscellaneous options on this screen as desired:

• Check for current loss. BCMS will raise an alarm when current falls to zero on an active circuit

that has measured at least 1.5A.

With the Power-KWH points list, there are also options displayed for KW and KWH precision:

• KW to Hundredth. KW values are recorded to 1/100 KW.

• KW to Tenth. KW values are recorded to 1/10 KW.

• KWH to Tenth. KWH values recorded to 1/10 KWH.

When finished setting options, click Send Options.

Click Exit to return to the main screen.

If no CT boxes are checked in Sub Distribution Options, as shown below, then BCMS will calculate (rather than measure) total main current using the panelboard branch circuits.

Sum Branch = BCMS will calculate total current on a panelboard from branch circuit measurements.

Sum Branch and Total of Both Panels = BCMS will create a total for both panelboards and will also sum the totals of both panelboards. (If there is a separate voltage to each panelboard, this option is not available.)


42

5.5 Set Branch Circuit Breaker Sizes

The final task in describing the power distribution environment to BCMS is to set individual branch circuit

breaker sizes. BCMS warnings and alarms are given as a percent of the breaker size, so this is also the

first step in creating a warning and alarm setup. Using BCMS default values, a warning is issued when

current to a circuit is measured at 70 percent of it breaker size and an alarm at 80 percent.

On the main screen, click USB on the menu line and choose Breakers. A screen will appear showing all

breakers in a 42-breaker panelboard (Figure 29).

Figure 29 Set Branch Circuit Breaker Sizes

Select Panelboard 1 in the panelboard box.

In the background, BCMS runs a scan of all circuits in the selected panelboard and current data during

setup. The scan can be started or stopped using the toggle button under Scan. When changing breaker

values, stop the scan, change the value, then start the scan.

Set breaker size for all breakers in the panelboard by entering a value here in Global Breaker Size.

The above boxes above show key registers from the points list: - Zero current registers - Warning registers - Alarm registers These registers and the branch circuit background scan provide active information about the panelboard during setup.

Start or stop the scan using this button to control the BCMS background scan.

This line shows the command being executed by the scan.


43

The default breaker size is 20A. If this value is not correct, set a new size for all breakers, then override

individual breaker sizes as necessary.

Set a global value for all 42 breakers as follows:

1. Stop the scan.

2. Set a different size for all 42 breakers by setting an integer value in the Global Breaker Size

field. Do not add an “A” after the number.

3. Start the scan.

4. The global breaker size should appear for all 42 branch circuits. Wait for an “A” to be added to

each number. That shows that the new value has been recognized by BCMS.

Override the Global Breaker Size or default value for individual breakers by entering an integer value in

the Breaker column for that breaker.

1. Stop the scan.

2. Enter an integer value (max 100 allowed).

3. Start the scan.

4. When the breaker size has been successfully set, an A appears after the number.

Repeat these steps for Panelboard 2.

5.6 Set Warning and Alarm Thresholds

Warning and alarm thresholds on a branch circuit are specified as a percent of the breaker size. These

thresholds are used to warn of an impending breaker trip, possibly causing a service outage for

equipment on that circuit.

The BCMS default values for thresholds are these:

• A warning for a branch circuit is given at 70 percent of its breaker’s size.

• An alarm for a branch circuit is given at 80 percent of its breaker’s size.

The Power – KWH points lists allows only global values for warnings and alarms. Branch circuits cannot

have individual values different than the global values. In the Normal points list values can be customized

for each circuit.

To set thresholds, Click Configuration on the menu line, and choose Thresholds.

To specify warning thresholds, set Global Warning percent as an integer value and, if desired, override the Global Warning value for individual circuits (Figure 30).

1. Select Panelboard 1 or 2.

2. Stop the scan.

3. To enter a warning value for all branch circuits for this panelboard, enter a number (such as 75) in

Global Warning.

4. Start the scan again.

5. When the global value has been propagated to all breakers in the Warn column, stop the scan.

6. Individual circuits can then be set to a different value. Specify a warning value in the circuit’s

Warning field.


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Figure 30 Set Branch Circuit Warning and Alarm Thresholds

To specify alarm thresholds:

1. Specify panelboard 1 or 2 in the Panelboard Box.

2. Stop the scan.

3. To enter an alarm value for all branch circuits, enter a percent value in Global Alarm.

4. To enter a value for an individual circuit, specify the value in the Alarm field for that circuit.

5.7 Set Warning and Alarm Time Delays

An alarm or warning can be further qualified to avoid giving an alarm for a transient current spike by

requiring a circuit to exceed its threshold for a minimum time interval.

In the Normal points list, Time Delay values have defaults that can be overridden globally for all circuits in the panelboard, or for individual circuits (Figure 31). For the KWH points list, you can specify global System Time Delays, but not Time Delays for individual circuits.

System Time Delay defaults are

• 0-second delay for warnings

• 10-second delay for alarms

(Image center removed to save space.)


45

Figure 31 Setting Time Delays for Warnings and Alarms

5.8 Setup Test Environment

Setup is not just a configuration environment but also a test environment for a new BCMS installation. Setup provides live circuit measurements to support the test environment both on branch circuit configuration screens and on the main setup screen.

5.8.1 Current Monitoring During Setup

Figure 32 Min-Max Current Measuring During Setup

Specify Global Warning and Alarm Time Delays by entering the number of seconds to be delayed in these boxes.

To override global or default time delay values for an individual circuit, specify an integer value in the Warn or Alarm column for that circuit.



Click Reset to reset Min-Max measurements

for a new test cycle.


46

During setup BCMS runs an active background scan on branch circuits that is shown on all configuration screens. In addition, there are other screens providing additional test environment data, including

• Minimum and maximum current measured for each branch circuit since the last reset.

• Zero current, showing whether a circuit has gone from at least 1.5A to 0, with color-coded values

for alarms.

To display minimum and maximum values, click View and choose Minimum-Maximum (Figure 32).

Click View, Zero Current, to show panelboard current readings during setup and whether an active

circuit that has read at least 1.5A has gone to zero current (Figure 33).

Figure 33 Zeroed Current Monitoring During Setup

5.8.2 Display Voltages and Current for Each Circuit

Click the appropriate button on the main setup screen to see these measurements (Figure 34):

• Voltage to panelboards

• Current to panelboard branch circuits

• Current to main feeds

Click Reset to reset zero current switches for

a new test cycle.



47

Figure 34 Live Test Data Displays

5.9 Panelboard Alarms

In additional to alarms for individual circuits, there are alarms for panelboards that are set from the Main Setup Screen.

5.9.1 Panelboard Full Load

The full load on the panelboard can be specified, using the following command:

Ms_F_NNN, where s=1 or 2 (panelboard number), and

NNN = value from 100A to 600A (the full load value)

Example: M1 F 400A (sets the full current load for panelboard 1 to 400A)

With the full load specified, BCMS will track the percentage of full load for each main circuit phase ABC in separate Modbus registers in the points list. There is no BCMS alarm relating to full load, but the BMS can monitor the percentages and set its own warnings or alarms, if desired.

5.9.2 Panelboard Current and Voltage Acceptable Ranges

Panelboard voltage and current measures can be bracketed with acceptable upper and lower limits. Outside of these acceptable ranges, BCMS sets “meter alarms” according to the threshold exceeded.

Display voltages to panelboards 1 and 2 for each phase.

Display current on main feeds to panelboards 1 and 2 or on subdistribution feeds 1 and 2.

Display current to individual circuits on panelboards 1 and 2.


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There are two Meter Alarm Modbus registers, flagging thresholds exceeded, such as “Over current panelboard” or “Under current panelboard.” One register provides “instantaneous” status from the latest reading, and the other is latching, staying on until reset.

Meter alarm values are set with the following commands:

Voltage overload or underload for a panelboard

Upper and lower thresholds for voltage can be specified for a panelboard. Outside this bracketed range, BCMS flags alarms for the panelboard.

Ms_VO_NNN Sets Voltage Overload Threshold of a panelboard where

s = 1 or 2, for panelboard 1 or 2, and

NNN = Threshold value, and Under Voltage Threshold < Voltage Overload Threshold < 300.

Ms_VU_NNN Sets Voltage Underload Threshold for a panelboard where


NNN is the Threshold value, where 60 < Voltage Underload Threshold < Over Voltage Threshold.

(Note: Switched voltages, and hence alternate voltage alarms, are not used with JCOMM.)

Current overload or underload for a panelboard

Upper and lower thresholds for current can be specified for a panelboard. Outside this bracketed range, BCMS flags alarms for the panelboard.

Ms_CO_NNN Sets the Current Overload Threshold of the panelboard where


NNN = overload threshold value in amperes (value must be greater than the Current Underload Threshold and less than 65535A)

Ms_CU_NNN Sets the Current Underload Threshold of the panelboard where


NN is the threshold value, ranging from > 0 to the value for Over Current Threshold.

Current overload or underload for panelboards totaled

The summed current of both panelboards can also be bracketed. Outside these values, BCMS flags an alarm.


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Ms_CTO_NNN Sets Total Current Overload Threshold for the summed current of both panelboards in total, providing an upper limit for the summed value of both panelboards, where

s=1 or 2 (using either panel board will create total for both sides), and

NNN is the Threshold value and 65535A > Total Current Overload Threshold >Total Under Current Threshold.

Ms_CTU_NNN Sets Total Current Underload Threshold, providing a lower limit for the summed value of both panelboards, where

S= 1 or 2 (either side is OK), and

NNN is the value for Total Current Underload Threshold, and 0 < Total Over Current Threshold < 65535A.

5.10 Calibration

All measured inputs—voltage to panelboards, main feed current, subdistribution feed current, and branch circuits—should be calibrated for optimal accuracy.

• Use a clamp-on power meter to provide independent measurements to calibrate BCMS readings.

• Calibration produces a scale factor, a correction factor applied to the raw data coming from a

current source (CT) or a voltage source.

• Scale factors are saved and can be applied to other circuits individually or to all circuits in the

panelboard.

5.10.1 Voltage Calibration

1. Load the main setup screen. If in a USB screen, click FileExit to return to the main setup

screen.

2. Set the voltage for one panelboard at a time.

a. If using only one source voltage (Source 1), both panelboards should be calibrated to the

same voltage.

b. If using two voltage sources, calibrate each panelboard individually.

3. Using a power meter, measure the voltage on a main feed to a panelboard from each phase to

neutral (Figure 35).

DANGER!

• Calibration measurements should be performed by a licensed electrician or other qualified technician.

• Calibration requires direct measurement of powered-on equipment with high voltages and currents.

• Take standard precautions for working with live high-voltage equipment.


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Figure 35 Measuring Voltage for Calibration

Voltage is the same for the entire panelboard, and so only one calibration for each input phase is necessary.

Set the measured voltage for each phase using the following commands (Figure 36):

Vs_p_nnn.n, where s=panelboard number (1 or 2), p=phase (A,B,C, or X for all phases), and nnn.n=voltage.

V1 A 121.0 sets the voltage for panelboard 1, phase A, to 121.0

V2 x 121.0 sets the voltage for all phases ABC on panelboard 2 to 121.0.

Note: Set the measured voltage for each panelboard; it is not automatically propagated to the second panelboard if there is only one voltage source.

Using a clamp-on power meter, measure the voltage at input to the panelboard for each phase (A-N shown).

Enter the measure into BCMS as a calibration, such as, V1 A 121.0


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Figure 36 Voltage Source Calibration

5.10.2 Calibration for Main or Subdistribution Feeds

Each main feed or subdistribution feed should be calibrated for current. Measure the current on the line

with a clamp-on power meter.

Enter calibration commands in the command line box. Measure each phase line individually and set its

calibration separately.

Zs_p_nnn.n, s=1, 2, T, S1, or S2, where

1 = panelboard 1, 2 = panelboard 2, or x = both panelboards,

T = one main feeding both panelboards,

S1 = main feed 1 or subdistribution feed 1,

S2 = main feed 2 or subdistribution feed 2,

p=phase (A, B, C, or X for all three phases), and

nnn.n=current (from 20.0 to 850.0A).

Examples:

Z1 B 58.5 sets phase B current to 58.5A on the main feed to panelboard 1 (each PB has a

separate main feed).

Click See Voltage button to display voltage for each phase of each panelboard.

V1 A 121.0

V1 B 121.0

V1 C 120.9

Enter voltage commands in the command line box.


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ZT A 80.0 sets phase A current to 80.0 on the main feed to both panelboards (there is only one

main circuit feeding both PBs).

ZS2 C 70.2 sets phase C current to 70.2A on subdistribution feed 2.

ZS1 X 102.5 sets current for on all phases to 102.5 subdistribution feed 1.

Rotate through the individual phases ABC on the main or subdistribution feeds, calibrating each phase

individually. NG cannot be calibrated.

5.10.3 Calibrate Current for Individual Branch Circuits

To calibrate individual branch circuits, use a clamp-on power meter to read the actual current in the circuit

where the wire leaves the panelboard breaker (Figure 37).

Enter the calibration measurement:

Cs_nn_NN.N Sets Input Current where

s = 1 or 2, for panelboard 1 or 2,

nn is the channel (circuit) number, 1 to 42 for individual circuit, or X for all circuits, and

NN.N is the measured current from the power mete (15 to 100 amps).

Examples:

C1 15 18.5 sets current for PB 1, circuit 15 to 18.5A.

C2 X 18.5 sets currents for all circuits on PB 1 to 18.5A.

Figure 37 Branch Circuit Calibration

As with all calibration commands, the C command returns

Measure branch circuit current with a clamp-on power meter.

Enter the measurement into BCMS as a calibration, such as

C1 3 10.8 (Calibrate PB1, circuit 3 to 10.8A)


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• A raw number, the measurement returned by the CT.

• A scale factor, the adjustment ratio that BCMS applies to all raw CT readings on this circuit.

View the current:

cs_nn Gets current and scale factors where s is the PB 1 or 2, where

nn is the channel from 1 to 42 or X for all current channels.

5.10.4 Replicate a Branch Circuit Calibration

The scale factor from a branch circuit calibration can be applied to all circuits on a branch circuit cable

harness, using the F (fill) command:

Fx_nnnn Fills a given scale factor on all channels (circuits) of a branch circuit cable harness, where

X = the PB section (1=PB1-odd, 2=PB1-even, 3=PB2-odd, 4=PB2-even) and

nnnn is the scale factor (usually taken from a calibration measurement).

Example: F3 1024 Fills CT Strip 3 which is on PB 2 with a scale factor of 1024.


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5.11 BCMS Setup Command Summary

Note: When entering one of the following setup commands, replace each underscore with a blank.

General Commands ? List all commands (available commands vary by points list). B List version numbers for main software and current processors. Resets ! Sets BCMS to its default setup. !H Sets the High Voltage Board to default setup. (Not applicable to JCOMM.) $ Resets all the BCMS Alarm Values. Ms_R Resets all Minimum and Maximum values on panelboard s where s is 1 or 2. Ms_K Resets KWH on all circuits of the panelboard where s is 1 or 2. (KWH points list only) Ms_KM Resets KWH on Main CT's where s is 1 or 2. (KWH points list only) Set BCMS acquisition board type MV_x Set the BCMS Board to High or Low Voltage where x = H for high voltage and L for low voltage.

Modbus Commands M Shows Modbus menu. Modbus network setup Pa Sets Modbus parity where a = e, o, or n. Example Pe sets parity to even. P Gets Modbus parity. As_nn Sets Modbus addresses to Panel 1, 2 or Sub to nn where s is 1, 2 or S and nn is a number from 1

to 255. Example: AS 3 sets the address for Sub Distribution to 3.

a Gets first Modbus address. Read or write a Modbus register range in the points list ms_nnn_yyy Returns a range of Modbus points or registers where

s = panelboard#, 1 or 2, and nnn is the start point (in the points list) from 1 to end number and yyy is the end point.

Ms_nnn_yyy_NNN Sets Modbus points where s = panelboard#, 1 or 2, nnn is the start point from 1 to end number, yyy is the end point from start to end number, and NNN is the value to be inserted into between the start and end points.

Calibration Commands Calibrate voltage to a panelboard Vs_p_nnn.n Sets Input Voltages where

s is the panelboard#, 1 or 2, p is the phase: A, B, C or X (for all), and nnn.n is the voltage from 100.0 to 300.0. Example: V1 A 121.5 sets voltage on PB 1 "A" Phase to Gnd. to 121.5 volts.

vs_p Gets voltage and scale factors where s is the panelboard#, 1 or 2, and p is the phase: A, B, C or X (for all).

Calibrate large circuits and panelboards for current Zs_p_NN.N Sets Total Phase Current where

s is 1,2, T, S1 or S2 for PB 1, PB 2, Main or Sub Dist (1 or 2),


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p is the Phase: A, B, C, (N, G Options) or X for all phases, and NN.N is the present current from 200 to 8500 amps. Example 1: Z1 B 58.5 sets current for PB 1 on phase 'B' to 58.5 Amps. Example 2: Z2 X 102.5 sets current for Sub Distribution Two on all phases to 102.5 Amps.

Calibrate branch circuits for current Cs_nn_NN.N Sets Input Current where s = 1 or 2 (PB number),

nn is the channel from 1 to 42 or X for all current channels, and NN.N is the present current from 15 to 100 amps. Example: C1 15 18.5 sets current for PB 1 on channel 15 to 18.5 Amps.

cs_nn Gets current and scale factors where s = PB 1 or PB 2, and nn is the channel from 1 to 42 or X for all current channels. Replicate a branch circuit calibration scale factor to other circuits Fx_nnnn Fills given Scale factor on all channels on a CT strip where x is the CT strip 1 to 4, and

nnnn is the Scale factor that you want to use. Example: F3 1024 Fills CT Strip 3 which is on PB 2 with the Scale factor of 1024.

Alarms and Warnings Breaker size (used as base for alarm and warning thresholds) Ms_B_NNN Sets all breaker sizes on panelboard s where

s = 1 or 2, and NNN is the breaker size in amps (15 to 100 allowed).

Set global warnings and alarms for branch circuits Ms_W_NNN Sets all Warning Thresholds on panelboard s where s = 1 or 2, and

NN is a percent value (from 40 to 100) of each breaker size to be set as Warning Threshold.

Ms_A_NNN Sets all Alarm Thresholds on panelboard s where s = 1 or 2, and NN = a percent value (from 50 to 100) of the breaker size that you want the Threshold.

Ms_WD_NNN Sets all Warning Time Delay on panelboard s where s = 1 or 2, and NN is the warning time delay value in seconds (0 to 10).

Ms_AD_NNN Sets all Alarm Time Delay values on panelboard s where s = 1 or 2 and NN is the time delay in seconds (0 to 10).

Set high and low panelboard thresholds Ms_CO_NNN Sets Current Over Load Threshold of the panelboard where

s = 1 or 2 (PB number), and NNN is the Threshold value > Under Current Threshold and < 65535A.

Ms_CU_NNN Sets Current Under Load Threshold of the panelboard where, s = 1 or 2 (PB number), and NNN is the Threshold value, > 0 and < Over Current Threshold.

Ms_CTO_NNN Sets Total Current Over Load Threshold of the panelboard where s = 1 or 2 (PB number) and NNN is the Threshold value > Under Current Threshold and < 65535A.

Ms_CTU_NNN Sets Total Current Under Load Threshold of the panelboard where s = 1 or 2 (PB number), and NNN is the Threshold value > 0 and < Over Current Threshold.

Ms_VO_NNN Sets Voltage Over Load Threshold of the panelboard where, s = 1 or 2 (PB number), and NNN is the Threshold value > 300 and < Under Voltage Threshold.

Ms_VU_NNN Sets Voltage Under Load Threshold of the panelboard where s = 1 or 2 (PB number).


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NNN is the Threshold value > 60 and < Over Voltage Threshold. Ms_VOA_NNN Sets Alt Voltage Over Load Threshold of the panelboard where

s = 1 or 2 (PB number), and NNN is the Threshold value from above 300 to Under Voltage Threshold.

Ms_VUA_NNN Sets Alt Voltage Under Load Threshold of the panelboard where s = 1 or 2 (PB number), and NNN is the Threshold value between 60 and Over Voltage Threshold.

Set panelboard “Full Load” value Ms_F_NNN Sets Full Load of Panelboard

where s = 1 or 2 (PB number), and NNN is full load value from 100A to 600A.

6 Troubleshooting Installation Problems

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The following troubleshooting tips cover the most common installation and setup problems. If problems continue after performing the following checks, call PDI Service at 804-304-8367 or email [email protected].

6.1 Communications Problems

The most common JCOMM and BCMS installation and setup problems are communications problems.

6.1.1 Check Modbus Network Setup for the BCMS board

• Verify that the BCMS board has correct has correct parity for the Modbus network:

o Use the p command to view parity during setup.

o Use the P command to set parity during setup.

• Verify that ModBus connectors have the correct pin-out. (See Error! Reference source not found..”)

• 4-wire Modbus is the default network configuration. If using 2-wire Modbus, check that Modbus connectors on the Connections Panel are jumpered TX+ to RX+ and TX- to RX-. (See Error! Reference source not found..”)

6.1.2 Check Modbus Addresses

Modbus addresses can only be set using BCMSII setup software. Modbus addresses are not stored in the points lists.

Verify that the Modbus addresses have been setup correctly in the BCMS board:

• Connect a USB cable from the setup PC to the front JCOMM USB port for this BCMS board.

• Access the BCMSII.exe by clicking the desktop icon created during setup.

• Verify BCMS Modbus addresses: List the Modbus addresses for the board using the a command.

o The first address is for panelboard 1 points list and the second address is for the panelboard 2 points list.

o There is also a third address for a subdistribution feeds points list, if subdistribution feeds are used and monitored.

o Verify that these addresses are correct downstream Modbus addresses as addressed either

in a direct Modbus chain from the BMS or downstream chain from a JCOMM monitor.

• If a JCOMM WaveStar Color Monitor is installed as a local power monitoring station:

o Check the monitor’s front panel to verify that there are no communication errors present.

o Verify that each panelboard can be displayed on the monitor.



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o Access the monitor setup page by pressing the ESC key and verify that the upstream addresses of the monitor are set correctly:

▪ The WaveStar Color Monitor remaps its downstream devices to upstream addresses

that can be accessed by the BMS. The number of devices monitored by the monitor

is shown on its setup page.

▪ For example, if the WaveStar display monitors four panelboards in a JCOMM and the

panelboard addresses are 1, 2, 3, and 4. If the monitor’s address is 20, it will respond

to addresses 21, 22, 23, 24 for panelboard addresses, when addressed by the BMS.

(See Section 4.5, “Remapping Modbus Addresses with Monitors.”)

• Verify that the BMS is addressing the correct addresses. A very common problem is that the BMS addresses the downstream addresses that were established in setup when a monitor or WaveStar BCMS Hub is present. The BMS should be addressing the addresses upstream of the monitor or Hub, as they have been remapped. (See Section 4.4, “Modbus Addressing with Monitor Installed.”)

• If the display does not resume communication with the BMS, verify that its upstream cable is undamaged and that communication wires are correctly connected.

6.2 BCMS Board Power Problems

• Check the LED’s on the BCMS board. LEDs should be blinking when the BCMS board has 24VDC power.

• If power LEDs are not blinking, check the connections from the 24VDC power supply (on the right side Power Panel) through the terminal blocks to the BCMS board. (See Figure 5, “JCOMM Power Panel.”)

6.3 Data Problems

6.3.1 No Current Readings

If the BCMS is not showing direct measurements of current for one or all circuits, perform the following checks:

1) Check connections for the branch circuit CTs and their cable harness:

a) Press the See Current button on the main setup screen to display current readings for each

branch circuit. This command will show you which circuits have no current.

b) Check that CTs for circuits with no current readings are snapped shut over their circuit wires.

c) Also check that these CTs are securely connected to the cable harness at the correct connector.

d) Check that the cable harness for these CTs is securely connected to the JCOMM Connections

Panel at the correct location. (See Figure 7, “JCOMM Connections Panel.”)

2) Check the orientation of branch circuit CTs:

a) Current measurements on a circuit depend on flow of current passing through the installed CT.

The green dot on the CT and the CT wire on branch circuit split-core CTs should be oriented to

the right as you face the panelboard to ensure correct directional flow of current through the CT.

CTs must be oriented this way on both the left and right sides of the panelboard.

b) Note: while current can be measured for the CT if its orientation is reversed, correct CT

orientation is necessary for determining related measurements, such as power factor.


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3) Check scale factors on circuits:

a) Display the scale factor for a circuit with no current reading using the c command (lower case

command), which displays calibration information. For example, type c1 13 (+ Enter) to display

the scale factor for circuit 13 on panelboard 1.

b) Most scale factors are near or around 1024.

c) Compare the scale factor reading to another channel (circuit) that is reading correctly.

d) If current readings still do not display (>0), reset the system to its default settings by entering the !

command on the main setup screen. Caution: using this reset command will set the BCMS to

factory defaults; you will lose all configuration information entered during setup.

6.3.2 No Voltage or Power Readings

If voltage or power readings are not displaying, perform these checks:

1) Using BCMSII setup software, check the options page. (Password is necessary.) Check that voltage

monitoring is enabled in the voltage options. (See Section 5.4.2, “Voltage Options.”)

2) Check that the voltage option listed is correct for your installation.

3) Check that branch circuit CTs are oriented correctly with the CT’s wire oriented to the right as you

face the panelboard. Incorrect CT orientation produces incorrect power factor measurements. (See

“Connect Branch Circuit CTs to Cable Harness,” and Figure 11, “Clip Split-Core CT Over Circuit

Wire.”)


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7 Operation

Each JCOMM BCMS functions independently and can monitor two panelboards and optionally two subdistribution feeds to remote power distribution equipment.

7.1 Points List Options

Each panelboard has a points list, or Modbus register map, where BCMS records data for that panelboard, including its main feeds. Customers can choose between two types of panelboard points lists, which are specialized for different power monitoring requirements:

• The Normal list provides warning and alarm customization for each branch circuit.

• The Power-KWH is specialized for power measurement, recording KW, KWH, KVA, KVAR, and

power factor for each branch circuit.

There is a small separate Subdistribution points list for subdistribution feeds, if these are present and monitored, providing current data and overcurrent alarms on these circuits.

7.2 Panelboard Points Lists

A panelboard points lists contains data on both the branch circuits in the panelboard and main feeds to the panelboard:

• Options and parameters from setup, such as voltage sources, main feed CT configuration, and

warning and alarm thresholds

• Direct (calibrated) measurements from CTs and voltage sources

o Current measurements for all 42 branch circuits in a panelboard

o Panelboard measurements, such as voltage, frequency, and current on main feeds (If

main feeds are not directly measured with CTs, BCMS computes panelboard current

totals from branch circuit measurements.)

• Data derived or accumulated from direct measurements, such as min-max current, power factor,

or KWH

• Warnings and alarms for branch circuits and panelboards

Configuration options and warning and alarm data are held in non-volatile storage on the board.

The points list documents indicate which registers can be read or written.

Points list documents are available as PDFs from the PDI service department at 1-804-304-8367 or [email protected].

7.2.1 Panelboard Points Lists Content Summary

The Normal and Power-KWH points lists have most points in common, but are specialized for specific tasks. Information unique to a points list is shown with a grey background in the following tables:

• BCMS Measurements (Table 3)

• BCMS Alarm and Warning Configuration (Table 4)

• BCMS Alarms and Warnings (Table 5)


7 Operation

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BCMS Measurements: Normal and Power-KWH Points Lists

BC = branch circuit PB = panelboard

Direct Measurements

Current, branch circuits 1-42 Direct measurement from branch circuit CTs

Current, main feeds ABCNG Specify which main circuit phases are monitored with CTs in setup. If there are no main feed CTs, BCMS computes main feed ABC values for each panelboard from branch circuit current totals. (Note: this computed value is not a simple sum of BC measurements.)

Voltage source 1 and voltage source 2

Voltage source 1 is required. JCOMM BCMS can monitor two voltage sources. Voltage is measured at one source per panelboard.

Frequency Frequency is measured from voltage source 1 or 2, phase A.

Accumulated and Derived Data—Branch Circuits

Minimum current (BC 1-42) The lowest current measured on each branch circuit

Maximum current (BC 1-42) The highest current measured on each branch circuit

KW (BC 1-42)

The Power-KWH points list provides detailed power measurements for each branch circuit as shown in this section (grey background).

These measurements are not available in the Normal points list.

KVA (BC 1-42)

KVAR (BC 1-42)

Power Factor (BC 1-42)

Accumulated and Derived Data—Panelboards

Current, ABC, each panelboard PB total current is measured from main feed CTs or computed by BCMS from branch circuit current measurements.

Current, ABC, panelboards summed Current for both PBs summed is measured from a single main feed to both PBs or a computed sum of the current to both PBs. (Not available if panelboards use separate voltages)

Percent total load on panelboard Full load on a panelboard is specified during setup. BCMS reports panelboard usage as a percentage of full load, but does not use this number as an alarm.

Real Power kW PB power measurement

Real Power phase A PB power measurement


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BCMS Measurements: Normal and Power-KWH Points Lists


Real Power phase B PB power measurement

Real Power phase C PB power measurement

Reactive Power kVAR PB power measurement

Apparent Power kVA PB power measurement

Total Power Factor phase A PB power measurement

Power Factor phase A PB power measurement

Power Factor phase B PB power measurement

Power Factor phase C PB power measurement

Energy Consumption, KWH PB power measurement

Total Harmonic Distortion, Voltage Source 1

PB power measurement; only provided if THD option was checked during “Set BCMS Options”

Total Harmonic Distortion, Voltage Source 2

PB power measurement; only provided if THD option was checked during “Set BCMS Options”

Table 3 BCMS Measurements: Normal and Power-KWH Points Lists

7 Operation

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BCMS Alarm and Warning Configuration: Normal and Power-KWH Points Lists


Global Settings for Branch Circuits

Note: Both Normal and Power-KWH points lists allow branch circuit breaker size and warning/alarm thresholds to be set globally (uniformly) for all branch circuits.

Breaker size, set uniformly for all branch circuits (BC 1-42)

Default BC breaker size is 20A. Branch circuit warnings and alarm thresholds are based on breaker size.

Warning threshold, set uniformly for all branch circuits (BC 1-42)

Percent breaker size, default = 70%

Alarm threshold, set uniformly for all branch circuits (BC 1-42)

Percent breaker size, default = 80%

Warning time delay, set uniformly for all branch circuits (BC 1-42)

Number seconds the warning threshold must be exceeded before a warning is issued, default = 0

Alarm time delay, set uniformly for all branch circuits (BC 1-42)

Number seconds the alarm threshold must be exceeded before a warning is issued, default = 0

Individual Settings for Branch Circuits

Breaker size for individual branch circuits 1-42

BC warning/alarm thresholds are given as a percent of breaker size. Both Normal and KWH points lists allow breaker size to be specified individually for each BC breaker (default = 20A).

The Normal points list allows customization of warnings and alarms for each branch circuit as shown in this section (grey background).

Not available in the Power-KHW points list.

Warning thresholds (BC 1-42) Percent breaker size, default = 70%

Alarm thresholds (BC 1-42) Percent breaker size, default = 80%

Warning time delays (BC 1-42) Number seconds the warning threshold must be exceeded before a warning is issued, default = 0

Alarm time delays (BC 1-42) Number seconds the alarm threshold must be exceeded before a warning is issued, default = 0

Table 4 BCMS Alarm and Warning Configuration: Normal and Power-KWH Points Lists


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BCMS Alarms and Warnings: Normal and Power-KWH Points Lists


Branch Circuit Alarms and Warnings

Zero current registers (3 registers, 1 bit for each branch circuit)

Alarms for active circuits that go to zero current, one bit set for each BC with zero current reading

Warning registers (3 registers, 1 bit for each BC)

Summary status, one bit set for each BC in warning

Alarm registers (3 registers, 1 bit for each BC)

Summary status, one bit set for each BC in alarm

Quick status alarm (1 register) Summary alarm for BCs: one bit set for each alarm/warning/zero current register that is in an alarm state

Panelboard Alarms

Note: All over/under panelboard alarms are based on thresholds specified in setup.

Over/under current panelboard Current to PBs is measured from main feed CTs or computed by BCMS from branch circuits and compared to specified thresholds

Over/under current both panelboards Current values are summed for both PBs and compared to specified thresholds.

Over/under voltage panelboard Voltage to PB is outside specified thresholds.

Table 5 BCMS Alarms and Warnings: Normal and Power-KWH Points Lists

7.3 Reading and Writing Modbus Registers

A BMS communicates with BCMS boards using Modbus commands directed at Modbus register locations in points lists. Points lists are addressed by their Modbus address.

BCMS responds to Modbus commands addressed to any Modbus register at one of its points list addresses. The points lists are directly addressed by the customer’s BMS, a JCOMM monitor, or a WaveStar Hub. (If the BCMS is downstream of a monitor or Hub, the BMS must address the points list using the remapped Modbus addresses in the monitor or Hub.)

Use standard Modbus read and write commands to retrieve or write registers in the points lists:

• Retrieve up to 200 bytes or 100 Modbus register values with a single read.

• Use write commands to alter set points, such as alarm and warning thresholds.

• Reset alarms and warnings by reading the warning or alarm register and writing it back with the

alarm and warning bits turned off.

• Separate Modbus requests to a BCMS by at least 400 ms.

7 Operation

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When SNMP is used upstream from a monitor, use the PDI SNMP MIB, available from PDI service. With SNMP, Modbus addresses upstream of a monitor are not remapped because there is no duplicate Modbus master on the network. See the WaveStar Monitor manual for information on using SNMP.

7.4 Alarm Handling

There are four contiguous Modbus registers in both points lists that summarize alarm status for individual branch circuits and panelboards. The BMS should read these registers regularly to be appraised of power conditions requiring immediate attention:

• Quick status alarm has a bit set for each of the branch circuit alarm or warning registers:

o Zero current registers

o Warning registers

o Alarm registers

• Over/under current panelboard

• Over/under current both panelboards

• Over/under voltage panelboard


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8 Service

8.1 Warranty

PDI’s Standard Warranty

PDI’s standard warranty covers a JCOMM for 18 months following shipment or 12 months after initial system start up, whichever comes first. After the end of the warranty period, service requests are handled on a time and material basis unless a preventative maintenance contract is in effect.

• U.S. – Full Coverage of Parts and Labor

• International – Parts Only Coverage Standard

Extended Warranty

Please contact a PDI service representative for detailed information about extended warranties.

Tel: +1-804-304-8367 | Email: [email protected]

Warranty Agreement

PDI warrants that its products will perform as specified in PDI publications, providing such products are properly installed, cared for, and properly operated under the specified environmental conditions.

Standard products manufactured by PDI are warranted to be free from defects in workmanship and material for a period of twelve (12) months from initial start up or eighteen (18) months from date of shipment, whichever comes first. Any products which are defective in workmanship or material will be repaired or replaced at the option of PDI. The obligation of PDI hereunder shall be limited solely to repair and replacement at its factory of products that fall within the foregoing limitations and shall be conditioned upon receipt by PDI of written notice within the warranty period of any alleged defects or deficiency. No products shall be returned to PDI without its prior consent.

Where it is impractical to return suspected faulty equipment to PDI for repair or replacement, PDI will provide on-site service upon request. Replacement parts and on-site labor necessary for fitting replacement parts and removal of faulty parts will be undertaken at no charge. Charges will, however, be made for travel to and from the installation site. Where an on-site warranty is in effect, the no-charge labor shall be between 8 a.m. and 6 p.m., Monday through Friday, excluding holidays. If the customer requests service outside the above hours, the customer agrees to pay the incremental difference between PDI's overtime and normal labor rates.

All warranties hereunder are contingent upon the initial start-up being done by PDI trained or other authorized personnel and upon proper use in the application for which the product was intended and do not cover products which have been modified or repaired without PDI approval or which have been subjected to neglect, accident, improper installation or application or on which the original identification marks have been removed or altered. These warranties will not apply if adjustment, repair or parts replacement is required because of accident, neglect, misuse, secondary transportation or other causes other than ordinary use.

PDI's liability under this warranty shall be in lieu of any warranty or condition implied by law as the quality or fitness for any particular use of the goods, and save as provided in this clause, PDI shall not be under


8 Service_________________________________________________________________________

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any liability, whether in contract, tort or otherwise for consequential damages resulting from defects in PDI products.

This warranty shall apply to all products manufactured by PDI unless this agreement is modified by addendum.

For questions, please contact the PDI service department at +1-804-304-8367 or email us at

[email protected].

8.2 Maintenance

8.2.1 PDI Maintenance Contracts

PDI offers maintenance contracts to help ensure the ongoing reliability of critical power systems.

Maintenance contracts are customizable to meet specific needs (number of PM visits per year, scope of coverage (e.g. parts not included), length of contract, etc.).

Maintenance contracts include:

1. Rapid Service Response

PDI Maintenance Service responds 24 hours a day, 7 days a week without additional costs for weekends, nights or holidays.

2. Two comprehensive Preventative Maintenance Visits Annually

• Infrared Scanners provide information that can determine impending failures on connections and

busing.

• Harmonic Analyzers provide real time information on the effects of harmonic currents on the

power distribution system.

Other services include:

• Thorough visual inspection of all parts (bulbs, displays, missing hardware and cleanliness)

• Verification of monitor calibration

• Inspection of load balance, KVA usage and building alarms

• Test and analysis report

3. Guaranteed Parts Availability

PDI guarantees parts availability to service customer equipment in timely fashion.

Please contact a PDI service representative for detailed information about Preventative Maintenance Contracts.

Tel: +1-804-304-8367 | Email: [email protected]




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8.2.2 Spare Parts

Customers can stock and replace the following JCOMM parts (Table 6):

JCOMM CRUs

Part Number Part Description

XMR14320 (1) Branch circuit CT: split-core CT ≤ 60A with 2-pin connector

CBL14214-xx (xx=length)

(1) Cable harness for branch circuit split-core CTs: connectorized cable harness for 21 XMR14320 (60A) CTs, in lengths of 5, 10, 15, or 20 ft.

XMR14321-250 (1) Main/subdistribution feed CT (ABC or N): split-core CT, 5 - 250A

XMR14321-005 (1) Main/subdistribution feed CT, ground circuit; split-core CT, 5A


(1) Main/subdistribution CT cable harness: connectorized cable for (4) XMR14321 split-core CTs (ABCN) and (1) XMR14321-005 split-core CT (G), in lengths of 5, 10, 15, or 20 ft.


(1) Optional PDI power/voltage cable, with inline 1A 1000V cartridge fuses, in lengths of 5, 10, 15, or 20 ft.

Table 6 Customer Replaceable Units

The following parts are also recommended for on-site spares. They should be replaced by a PDI service representative (Table 7 Service-Installed Onsite Spares).

Part Number Part Description

PCB11734 (1) BCMS low-voltage/high-voltage (LV/HV) acquisition board: 2-panelboard

PCB14024 (1) JCOMM Connections Panel (left side panel)

PCA16209 WaveStar Color Monitor 120V

Table 7 Service-Installed Onsite Spares

To order spare parts, contact PDI in one of the following ways:

• Telephone (800) 225-4838, Option 3

• Fax (804) 737-0973

• Email [email protected]

Specify part numbers and quantities from Tables 6 and 7 above. PDI can provide you a price

quotation and order form.


Bibliography

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Bibliography

Manuals for Related Products

JCOMMs can have an optional WaveStar Color Monitor or can be monitored from a WaveStar BCMS Hub.

• WaveStar® Color Monitor, Setup and Operation, PM375103

• WaveStar BCMS Hub Installation and Operation PM375108

Points Lists

Points lists can be downloaded from the PDI website. Go to Service Software Downloads:

https://www.pdicorp.com/services/service-software-downloads/

For BCMS points lists, download BCMS II Customer CD Info, a zip file. Unzip the file and open

the directory \Points List for BCMS Version to find the following points lists and use the latest

revision given:

o BCMS Normal panelboard points list is “BCMSII points list”.

o BCMS KWH panelboard points list is “BCMSII plus points list Power KWH”.

o BCMS IEC panelboard points list (for IEC format panelboards with 36 or 72 1P

circuits) is “72 BCMSII plus points list Europe KWH”.

https://www.pdicorp.com/services/service-software-downloads/

Glossary

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Glossary

acquisition board The central component of a BCMS; PCB containing BCMS software, including points list, that accumulates monitoring data from CTs, computes derived information, declares alarms, and presents power monitoring information to displays and to building management systems.

BCMS Branch Circuit Monitoring System.

BCMS device Power distribution elements monitored by a single points list (or Modbus register map) and addressed by a single Modbus address. Example: a panelboard is a BCMS device because it is monitored with one points list and has one Modbus address. An acquisition board can monitor three BCMS devices—two panelboards and one set of subdistribution feeds.

BMS Building management system.

CRU Customer-replaceable unit.

CT Current transformer.

Modbus RTU An industrial communications protocol.

Modbus TCP Modbus protocol with TCP, which allows higher transmission speeds.

PDU Power Distribution Unit.

points list Modbus register map.

RPP Remote Power Panel.

RTU Remote terminal unit; see Modbus RTU.

scale factor Ratio of current measured with a current transformer (or voltage by the acquisition board) and an independent measure given by a power meter; used in calibrating BCMS CT measurements.

SNMP Simple Network Management Protocol.

subdistribution A large circuit from a PDU that does not feed that PDU’s panelboards, but rather runs to another unit, typically an RPP.

THD Setup option for measuring total harmonic distortion.

Appendix A: PCB Connections

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JCOMM is designed so that customers do not have to make direct connections to PCBs. Connections

need only be made to the left-side Connections Panel and the right-side Power Panel. Connections to the

WaveStar Color Monitor backpanel and to the BCMS data acquisition board are shown here for

background information.

Figure 38 WaveStar Color Monitor Backpanel

WaveStar Color Monitor. The Color Monitor backpanel has these connections:

• Power connections: 120VAC, 230VAC, and 24VDC (230V is optional and requires a different

transformer.)

• Modbus connections:

• Downstream (to Monitor device chain) is always 4-wire Modbus

• Upstream is 4-wire or 2-wire, jumper selected

Summary alarm dry contact (NO)

RESET button

Modbus Upstream Connection

Modbus Down-stream Connection

J6: 24VDC

Input

J5: AC 120V/ 230V* Input

Fuse

Transformer (*Note: AC 230V is optional and requires a different transformer.)

Battery J11 Ethernet port


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• Summary Alarm: Dry contact (NO) signals when the Monitor has an alarm condition. Dry contact

specification: 0.5A at 120VAC or 30VDC.

The backpanel also has a RESET button; if the Monitor hangs, you reset it by pressing this button.

Replaceable parts:

• Fuse: 200 mA, 250V; replace fuse with a UL recognized, IEC compliant fuse of the same type.

• Battery: Lithium ion, Panasonic-BSG (CR2477), 3V, 1 AH (PDI Part Number 15174)

Caution: The battery used in this device may present a risk of fire or chemical burn hazard if mistreated. Do not recharge, disassemble, heat above 100°C (212°F) or incinerate. Replace battery with Panasonic-BSG (CR2477), 3V, 1 AH (PDI Part Number 15174) only. Use of another battery may present a risk of fire or explosion.

Dispose of used battery promptly. Keep away from children. Do not disassemble and do not depose of in fire.

BCMS Low Voltage/High Voltage (LV/HV) Board. Each BCMS is contained on a single PCB (Figure 39). The PCB has one main processor and six current processors. Current processors process CT readings.

Both main and current processors have software specific to the board type and points lists used on the board. PCB software is loaded in manufacturing using “Programming Connections.”

The PCB has connectors for:

• Two voltage sources

• Cable harnesses to CTs on two panelboards (odd/even side connections)

• Cable harnesses to two main or subdistribution feeds

• A Modbus network connection

• A USB connection for setup

• A power connection


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Figure 39 BCMS LV/HV Board

120V ANBNC

MP

CP

CP

CP

CP

CP

CP

BC CT Cable Harness Panelboard 2A ODD

BC CT Cable Harness Panelboard 2B EVEN

BC CT Cable Harness Panelboard 1B EVEN

BC CT Cable Harness Panelboard 1A ODD

VOLTAGE SOURCE #1

USB

Power Input

12VAC/12VAC/Ground

Modbus Connection

Main or SD CT Cable Harness 1

Main or SD CT Cable Harness 2

BC = branch circuit CP= current processor CT= current transformer MP= main processor SD = subdistribution

VOLTAGE SOURCE #2

Programming Connections

120V C Neutral 120V B Neutral 120V A


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Index

alarms and warnings

handling alarms, 65 points list, 63–64 see also BCMS software setup, 65

BCMS, 8

alarms and warnings, 14 Data Acquisition Board layout, 72–73 Data Acquisition Boards, 11 see also BCMS software setup, 61 see also points lists, 61

BCMS software setup, 32–56

calibration, 49–53 determine software and points list, 34 Modbus setup, 36–35 options, 37–41 panelboard alarms, 47 password, 37 replicate branch circuit calibration, 53 set alarm and warning thresholds, 43–44 set alarm and warning time delays, 45 set branch circuit breaker size, 42–43 setup command summary, 54–56 setup screen, 34 USB driver, 33

branch circuits

current transformer installation, 21

Color Monitor, 8, 11, 29, 57, 58, 71

downstream devices, 13

JCOMM

Connections Panel, 12, 20–21 enclosure, 9, 10–11 enclosure installation, 13, 16 features, 8 installation, 15–27 Power Panel, 11 specifications, 9

main feeds, 30, 36, 39–41, 60, 61

current transformer installation, 19–20

Modbus

2-wire setup, 28 address map, 13 addresses, 29 network segmentation, 30–31 network setup, 28 remapping addresses, 30–31

Modbus commands

in setup, 37

networking, 9, 28–31

protocols, 11, 13, 29

panelboards

inline, 27

parts, 16, 17, 20, 21

installation kits, 16 spare parts, 68

points lists, 11, 13, 29–30, 34

comparisons and summaries, 60 reading and writing Modbus registers, 64

safety warnings, 7, 10, 15, 16, 18, 19, 22, 32

service

maintenance, 67 spare parts, 68 warranty, 66–67

SNMP, 11, 29, 65

subdistribution feeds, 9, 11, 12, 20, 30, 39–41, 60

troubleshooting installation problems, 57–59

voltage connections, 13, 18

WaveStar BCMS Hub, 8, 13

Documents

Installation and Operation - pdicorp.com › wp-content › uploads › 2019 › 03 › ...The PDI JCOMM® provides an enclosure for one or two PDI Branch Circuit Monitoring Systems