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EG4xxx Owner’s Manual 2 INSTALLATION
1 Introduction
Thank you and congratulations to your purchase of an Onset EG4xxx device!
Properly installed, the device will be able to record and report energy usage and
production for years to come.
The first and second section of this manual describes installation and commis-
sioning of the product. The third section provides operating instructions and is
followed by a section on equipment maintenance. The appendices provide the
device specifications and a reference to troubleshooting information.
2 Installation
Installation must be performed by a licensed electrician according to all applicable
local, national, and international codes.
CAUTION: The EG4xxx power connector carries high voltage. For safety,
the device must be installed in a suitably rated enclosure for the installation en-
vironment. The enclosure must have a screw-on or locking cover that prevents
accidental touch of the power connector.
2.1 What’s included in the box
•1×EG4xxx device
•1×AC Power plug (5-position plug)
•1×DC Power plug (2-position plug)
•0–30×Current transformers (CTs) w/ 8ft wires & plug (as ordered)
•1×HomePlug AV wall-outlet adapter w/5ft Ethernet cable (if ordered)
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2.2 Materials required for installation
•Per phase: Use of proper smallest available breakers or rated fuse taps for
the install per local NEC rules. Usually 15A circuit breaker or single multi-
pole breaker depending on phases used.
•Black, red, and white stranded AWG 12 wire; length depending on instal-
lation location. Thermal resistance to at least 75◦C. Blue wire is needed in
addition for 3-phase installations. Use wire that has insulation rating greater
than the max voltage inside the panel. Note: wire colors may vary based on
country and electrical service.
•Electrical tape
•Conduit and couplings as needed
•Mounting and wire organization hardware as needed
•If installed outside, appropriately rated enclosure (e.g. IPX4/NEMA4)
2.3 Tools required for installation
•#0 slotted screw driver (needed if length of CT-wires needs to be adjusted)
•Circuit-breaker finder (if using HomePlug power-line communication)
•Voltage meter
Additionally, for device commissioning and installation verification:
•Clamp-on AC current meter
•Laptop with Ethernet cable
2.4 Nomenclature and Symbols
In the US, residences typically receive power through split-phase power distribu-
tion which is provided through two hot legs, a neutral, and a protective ground.
Most commercial and industrial buildings receive power through 3-phase power
distribution provided through 3 hot phases, a neutral and protective ground.
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EG4xxx Owner’s Manual 2 INSTALLATION
Throughout the rest of this document, we use the term “phase” to refer both to the
phases of 3-phase power distribution as well as the two legs used in split-phase
power distribution.
The following table describes the symbols used on the device:
Symbol: Description:
Caution, risk of danger.
2.4.1 Measurement Category
Measurement Category III is for measurements performed in the building installa-
tion. Examples are measurements on distribution boards, circuit-breakers, wiring,
including cables, bus-bars, junction boxes, switches, socket-outlets in the fixed
installation, and equipment for industrial use and some other equipment, for ex-
ample, stationary motors with permanent connection to the fixed installation.
2.5 Safety Warnings
Please follow the installation instructions in this manual for wiring diagram and
proper selection of CTs.
To reduce the risk of electric shock:
•Do not connect device to a circuit operating at >277 Vrms to neutral.
•Always open or disconnect circuits from Power Distribution System of
building before installing or servicing the unit or attached current trans-
formers.
2.6 Installation Location
The EG4xxx is usually installed near the power-distribution panel of a building,
where there is easy access to the power circuits to be measured.
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The EG4xxx is permanently connected equipment. A 15A circuit-breaker shall be
included (one per phase) in close proximity of the device and within easy reach
of the operator. The breakers shall be marked as the disconnecting device for
EG4xxx. The breakers shall be wired to the device in compliance with the NFPA 8
National Electrical Code using a conductor size of at least AWG12 and tightened
to 10 ft·lb.
The EG4xxx is a listed device and must be installed inside a suitable enclosure.
The enclosure the EG4xxx is installed in must be rated according to the environ-
ment it is used in. For example, outdoor installations require an outdoor-rated
enclosure (e.g., IPX4/NEMA4).
Select an installation location that is not exposed to direct sunlight or the elements.
Otherwise, the warranty may be voided.
Do not install the device in a way that would make it difficult to operate the dis-
connecting device (circuit breakers).
2.7 Device Overview
Figure 1: EG4xxx inputs and outputs
As shown in Figure 1, the EG4xxx has three input connectors: the AC Mains is a
5-pin connector used to wire the device to the building supply. The DC Connector
is a 2-pin connector for monitoring or powering from a DC voltage. The CT
Connector is used to connect current transformers (CTs) or other sensors. The
LCD and multi-switch provide some user interface.
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EG4xxx Owner’s Manual 2 INSTALLATION
The unit also has an Ethernet port (RJ45 connector) which can be used to hard-
wire the device to a Local Area Network (LAN). It also has two USB ports (Type-
A Female) to interface to various other IT devices.
An LCD shows a basic user interface with readouts from the set variable registers.
It may be controlled through the multi-switch for basic control and configuration.
2.7.1 LCD
The LCD is an installation aid shown in Figure 2. When powered on, the LCD
will show a logo as the device boots. During this time the backlight will flicker
showing boot activity. Once the LCD shows the first register screen, the device is
automatically recording data if configured to do so.
Figure 2: EG4xxx LCD
2.7.2 AC Mains Connector
This connector is shown in Figure 3 and the pin-out is as follows:
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Figure 3: AC Mains Connector
Pin: Name: Description:
1L1 Wire to phase 1 of building supply.
2NWire to building’s Neutral.
3L2 Wire to phase 2 of building supply for split- and three-phase
installs.
4 Unused. Leave unconnected.
5L3 Wire to phase 3 of building supply for three-phase installs.
The AC Mains Connector is CAT III rated (for measurements performed in the
building installation, such as circuit breakers). Pin L1 serves three purposes: it
powers the device (2W typical, 12W maximum), the voltage on the line is mea-
sured to calculate power used/generated on phase L1, and it carries the power-
line signal for communicating with the HomePlug AV wall-plug adapter. The pin
must be wired to the building’s power supply with a voltage in the range from 85–
277Vrms (to neutral). In contrast, pins L2 and L3 are used purely as voltage-taps
so power used/generated on phases L2 and L3 can be calculated. Wiring these pins
is necessary only if there are CTs measuring current(s) on L2/L3. The voltage on
these lines can be 0–277Vrms (Vac or Vdc).
To measure any signal on the AC Mains Connector L1 and N must be powered
with at least 85Vrms. If no voltage is supplied to this port, then the unit will
not measure any signal from L1, L2, or L3. The unit can continue to operate if
powered by the DC port.
2.7.3 DC Connector
This connector is shown in Figure 4 and the pin-out is as follows:
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Figure 4: DC Connector
Pin: Name: Description:
1+Wire to DC signal.
2-Wire to ground.
The DC Connector CAT III rated for use from -60 – 60Vdc. It can measure the
voltage across that full range but if powered by the DC port, there must be at
least 9Vdc. If an installation utilizes both the AC Mains Connector as well as
DC Connector, and DC power is used to power the unit, there must be more than
12Vdc to ensure unit pulls power from the DC port.
2.7.4 CT Connector
This connector is shown in Figure 5. It provides 15 or 30 positions for the CT
plugs illustrated in Figure 9. The silk-screened numbers indicate which CT should
be connected to which pair of pins. Pins that are to receive the black wire of the
CTs are marked with a circle with black interior, pins for the white wires are
marked with a circle with white interior.
Figure 5: CT Connector
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The CT Connector is rated for wiring one to thirty units of the CTs listed in Sec-
tion B.6. The input voltage rating is 0.333Vrms at the rated current.
NOTE: There is no risk of damage if a CT plug is accidentally inserted such
that it straddles the pins for two different CTs. If this happens, the EG4xxx will
not be able to measure power properly but otherwise there are no ill effects. To
correct the problem, simply remove and re-insert the plug at the right position.
2.7.5 Ethernet (LAN) and USB Connector
This connector is shown in Figure 6. It provides hard-wired Ethernet connectivity
via an RJ45 plug and two USB host ports via Type-A Female plugs.
Figure 6: Ethernet Connector
The green LED in the top-left corner of the connector turns on (green) when an
Ethernet cable is plugged in and a valid Ethernet carrier signal has been detected.
The LED goes dark briefly whenever data is being exchanged over the cable. The
yellow LED in the top-right corner of the connectors is a speed indicator. It turns
on (yellow) operating at 100Mbps and is off (dark) when operating at 10Mbps.
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The USB ports are USB2.0 compatible and can supply up to 1A at 5V. They may
be used with various supported IT devices such as RS485-to-USB converters or
WiFi adapters.
2.7.6 Multi-switch
Figure 7 is a close-up of the multi-switch. The user can slide the switch Left or
Right for navigation and push the switch into the unit to select.
Figure 7: Multi-Switch
The multi-switch can be used to navigate the LCD menu system. By default, any
action seen from the multi-switch will wake the backlight to ensure a viewable
interface.
2.7.7 Time Reference
During normal operation, the EG4xxx maintains accurate time by synchronizing
with an NTP server, such as one of the public servers available at ntp.org. Since
NTP provides atomic-clock accuracy, there is usually no need to set the time man-
ually.
When the NTP server is not accessible, either temporarily (e.g., after a power fail-
ure) or permanently (e.g., at a remote site), the EG4xxx relies on a Super Capacitor
backed real-time clock to maintain proper time.
The backup is designed only to cover relatively short power outages. The Super
Capacitor takes about 5 minutes to fully charge, and will keep correct time for
approximately 8 hours without power.
When power is restored after such an event, the EG4xxx will attempt to restore
proper time via the NTP server. If unavailable, and the Super Capacitor is de-
pleted, the device will fall back to using the time that was in effect when the last
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