PowerLogic™ ION8600 Metering and Control Device Installation Guide

Introduction

This guide provides comprehensive instructions for the installation and setup of the PowerLogic™ ION8600 Metering and Control Device. It is intended for qualified personnel with experience in high voltage and current devices. Ensure all installations comply with local and national electrical codes.

Safety Precautions

DANGER indicates a hazard that, if not avoided, will result in death or serious injury.

CAUTION indicates a hazard that, if not avoided, could result in minor or moderate injury or damage to the device.

Note provides important installation, operating, and maintenance instructions.

During normal operation, hazardous voltages are present. Always follow standard safety precautions, such as removing PT fuses and shorting CT secondaries when performing installation or service work.

Do not use ION8600 outputs for primary protection functions. Do not use the device in situations where failure could cause injury, death, or fire. The meter can be used for secondary protection functions.

Do not HIPOT/Dielectric test digital inputs, digital outputs, or communications terminals.

Ensure the meter's chassis ground is properly connected to earth ground for safety and optimal performance. Failure to do so voids the warranty and poses an electric shock risk.

Installation Considerations

Form Factors

The PowerLogic™ ION8600 is available in two form factors:

• Socket Meter: Designed to fit into S-Base meter sockets and A-to-S Base adapters (9S, 35S, 36S, 39S, 76S).
• Switchboard Meter: Eliminates the need for shorting blocks by incorporating them into the drawout case. Connections are made via rear terminals. An optional breakout panel is available for easier on-board I/O and communications connections.

RMICAN Model

A socket or switchboard meter certified by Industry Canada for revenue metering in Canada. It may feature security options, including a factory-sealed version.

Meter Overview

The ION8600 meter features several controls and indicators on its front panel:

• Demand Reset Switch: Resets peak demand values.
• ALT/Enter Button: Toggles display modes and accesses the Setup menu (hold for 3 seconds).
• TEST Mode Button: Places the meter into TEST mode, ceasing billable quantity accumulation.
• Master Reset Pinhole: Located under the front label for resetting the device.
• Navigation Buttons (Up/Down): Highlight menu items or adjust numerical values.

Meter Labels

Refer to the meter's serial number label for equipped options and model information. Key labels include:

• Test Amps
• Class Accuracy
• Test Constant (LED pulse rate)
• Class Designation
• Form Factor
• Voltage Input Rating
• Wiring Configuration
• Model Number
• Voltage Transformer Ratio
• Current Transformer Ratio
• Primary Watthour Constant
• Transformer Factor (VTR x CTR)
• Serial Number and ANSI Bar Code Area

Before You Begin

Recommended Tools

• #1 and #2 Phillips screwdrivers
• Precision flat-head screwdriver
• Wire cutters/stripper

Dimensions

Refer to the diagrams for Socket Meter and Switchboard Meter dimensions.

Step 1: Mount the Meter

Environmental Considerations

Socket Meter Mounting

1. If required, attach an anti-tamper seal to the outer cover.
2. Align the meter so the chassis ground strap contacts the ground source on the socket.
3. Feed communications wiring through the socket opening.
4. Attach the socket-sealing ring and seal the Demand Reset switch if needed.

Switchboard Meter Mounting

1. Prepare a mounting hole for the switchboard case according to the provided dimensions.
2. Place the switchboard case into the mounting hole and secure with washers and nuts.
3. Position the case cover and tighten the thumbscrew. Apply anti-tamper sealing if required.

Step 2: Wire the Ground Terminal

DANGER: Ensure the meter is grounded BEFORE connecting the power supply. Failure to properly connect the chassis ground voids the warranty.

Refer to diagrams for specific ground connection details for socket and switchboard meters.

Step 3: Wire the Onboard I/O

The ION8600 may have onboard I/O with a 16-pin connector. A supplied cable has a female connector for the meter and 16 bare-ended wires for connecting to digital input/output devices.

Form C Digital Outputs (Ordering Option)

Type: Form C solid state outputs (C1, C2, C3, C4).

• Max Load Voltage: 200 VAC/VDC
• Max Load Current: 100 mA
• ON Resistance: 30 Ω typical
• OFF Resistance: 400 MΩ minimum
• Isolation: 3250 V rms (to meter), 1000 V rms (between outputs)
• Update Rate: 20 ms
• Signal Type: Continuous or pulse
• Precautions: Use clamping diode for DC, MOV for AC, and a 250 mA fuse.
• Max Output Transition: 50 per second
• Lifetime: 10,000,000 operations (no load), 100,000 operations (rated voltage/load).

Form A Digital Inputs (Ordering Option)

Internal Digital Input Excitation:

• Type: Form A inputs (S1, S2, S3, SCOM)
• Wire: Use appropriate wiring.
• Min. Pulse Width: 20 ms
• Max. Input Transition Rate: 50 per second
• Scan Time: 20 ms
• Timing Resolution: 1 ms (with 2 ms accuracy)
• Inputs: ON for ≤ 2 kΩ, OFF for ≥ 4 MΩ.

External Digital Input Excitation:

• Voltage Range: 24 to 130 Vdc (external)
• Min. Pulse Width: 20 ms
• Max. Input Transition Rate: 50 per second
• Scan Time: 20 ms
• Timing Resolution: 1 ms (with 2 ms accuracy)
• Inputs: ON for ≤ 2 kΩ, OFF for ≥ 20 MΩ.

Setting Jumper for External Digital Input Excitation: Follow the steps to disable internal excitation and enable external supply.

Precautions: State change latency is 20 ms (digital output) and 40 ms (digital input). For critical control schemes, use intermediate mechanisms for relay control.

Step 4: Wire the Voltage and Current Inputs

Wiring diagrams are provided for various configurations:

• Form 9 and 9S (3 element)
• Form 9 and 9S, 4-Wire Wye, no PTs, 3 CTs
• Form 9 and 9S, 4-Wire Wye, 3 PTs, 3 CTs
• Form 9 and 9S, 3-Wire Wye, 3 PTs, 2 CTs
• Form 9 and 9S, 4-Wire Delta, no PTs, 3 CTs (Red/High Leg Delta)
• Form 35 and 35S (2-element)
• Form 35 and 35S 3-Wire Delta, 2 PTs, 2 CTs
• Form 35 and 35S, 4-Wire Wye, 2 PTs, 3 CTs*
• Form 35 and 35S, 3-Wire Delta, No PTs, 2 CTs
• Form 36 and 36S (2½-element)
• Form 36 and 36S, 4-Wire Wye, no PTs, 3CTs
• Form 36 and 36S 4-Wire Wye, 2 PTs, 3 CTs
• Form 39S (3 element; 14 optional)
• Form 395 4-Wire Wye, no PTs, 4 CTs
• Form 395 4-Wire Wye, 3 PTs, 4 CTs
• Form 76S
• Form 76S 4-Wire Wye, 2 PTs, 4 CTs

CAUTION: For Form 9 or 9S, 4-Wire Delta wiring, consult the Red/High Leg Delta technical note.

Voltage Inputs: Specifications for various forms (9S/39S, 35S, 36S/76S) including input types, connector, wire size, steady state, overload, dielectric withstand, surge withstand, and input impedance are detailed.

Current Inputs: Specifications for Low Current (1A) and Standard (5A) options are provided, covering inputs, connector type, wire, starting current, input rating, overload, dielectric withstand, max voltage, surge withstand, and burden.

Using Potential Transformers: A table indicates when PTs are required based on System Mode (Wye, Single Phase, Delta) and Voltage Range.

Step 5: Wire the Communications

The ION8600 supports various communication options:

• Socket or Switchboard meter connections: RJ11/RJ31, RJ45 (10Base-T), DB9 Serial Assignments, and IRIG-B Option.
• COM1: RS-232 or RS-485 (user selectable).
• COM2: Internal Modem RJ11 or RJ31.
• COM3: Optical Port (ANSI Type II).
• COM4: RS-485.
• Network: Ethernet RJ45 (10Base-T) or Ethernet Fiber (10Base-FL) (socket-style meters only).

Switchboard Meter Wire Cluster: Diagrams illustrate connections for various ports including Aux Power, RJ31, RJ11, RJ45, and Molex connectors.

Molex Pin Assignments: A detailed table lists pin numbers, wire colors, and functions for COM1 and COM4.

Communications Options Table: Lists available options for each port (COM1-COM4, Network, I/O expansion, IRIG-B, Auxiliary Power) with connector types and notes.

Optional Switchboard Breakout Panel: Diagrams show I/O Connections, Communication Connections, Auxiliary Power Supply Connections, and Voltage and Current Inputs. Instructions for captured-wire connections are provided.

RS-232 Connections: Diagrams illustrate various RS-232 cable configurations for connecting to computers, modems, and I/O expanders.

Step 6: Wire the Power Supply

Power is applied when voltage inputs are energized or via an external power cord.

Power Supply Specifications

Tables detail specifications for meters powered from voltage inputs (Standard Power Supply, Standard Low Voltage Power Supply) and externally-powered meters (Auxiliary Low Voltage Power Supply, Auxiliary High Voltage Power Supply). Specifications include Rated Inputs, Surge Withstand, Burden, and Minimum Ride-through.

Step 7: Power Up the Meter

DANGER: Ensure ground is securely connected and the supply voltage is within the allowed range before applying power.

1. Close the PT fuses (or direct voltage input fuses).
2. Open the CT shorting blocks.
3. Apply power to the meter.

Step 8: Set Up Meter Using the Front Panel

Access Basic Setup by pressing and holding the Alt/Enter button for three seconds.

Basic Setup

Configure the following parameters:

• Volts Mode: Power system configuration (e.g., 9S 4W-WYE/DELTA, 35S 3 Wire, 36S 4 W-WYE).
• PT Primary/Secondary: Potential Transformer voltage ratings.
• CT Primary/Secondary: Current Transformer current ratings.
• 14 CT Primary/Secondary: Ratings for the 14 current transformer (if available).
• Polarity (VA, VB, VC, IA, IB, IC, 14): Polarity of transformers.
• Phase Rotation: Power system's phase rotation (ABC, ACB).

Demand Setup

Configure parameters related to Sliding Window Demand (SWD) values:

• SWD Subinterval
• SWD # Subintervals
• SWD Pred Resp
• TD Interval
• TD time const

COM1, COM2, COM3, COM4 Setup

Configure serial communication parameters for each port:

• Protocol: Active communications protocol (ION, Modbus RTU, etc.).
• Baud Rate: COM port baud rate.
• Transmit Delay: Meter's transmit delay setting.
• Unit ID: Meter identifier.
• Serial Port: Parity and stop bits.
• RTS/CTS Handshake: Hardware flow control for RS-232.

Network Setup

Configure network parameters:

• IP Address
• Subnet Mask
• Gateway
• SMTP Server
• SMTP Timeout
• MAC Address

Format Setup

Configure display formatting:

• Phase Labels
• PF Symbol
• Digit Group
• Date Format
• Show DST
• Volts Decimal
• Current Decimal
• Power Decimal
• Update Rate
• Contrast
• Backlight TO

Display Setup

Configure display behavior:

• DMD Lock TO
• Test Mode TO
• Display Scale
• Scaling Mode
• Delta Vectors

Security

Configure security settings:

• Modify Passwd
• Disable Security
• Web Config

Step 9: Verify Meter Operation

LEDs

The LEDs on the side of the meter indicate communication status:

• TXD/RXD: Flash indicates signals being transmitted/received.
• RI: Ring Indicator (flashes when modem rings).
• CD: Carrier Detect (on for active modem connection).
• LINK: On for active connection to 10 Base-T Ethernet port.
• ACTIVITY: Flash indicates signals being transmitted/received for Ethernet 10 Base-T.

Phasor Diagrams

View real-time phasor diagrams using the Phasor Viewer in ION Setup (downloadable from the website) to verify meter wiring.

Diagrams are provided for WYE - ABC Rotation, WYE - ACB Rotation, 3 Wire Delta - ABC Rotation, 3 Wire Delta - ACB Rotation, and 4 Wire Delta (High/Red Leg Delta).

Step 10: View Meter Data

NORM Mode

Use Up/Down buttons to scroll through NORM mode screens:

• NORM Screen: kWh, kVARh, kVAh, Peak Demand Delivered/Received, Peak Demand Reset, Q Metering, Disk Simulator, All Segments.
• ALT Screen: Name Plate 1 & 2, Event Log, Vector Diagram, Instantaneous Voltage/Current/Power/Demand, Voltage/Current Harmonics, Instantaneous Demand.

TOU Display Screens

View Time-of-Use data:

• TOU Energy by Rate
• kW Peak Demand
• Previous Billing Energy/Peak Demand
• Previous Season Energy/Peak Demand
• Prev Billing/Season Energy/Pk Dem
• Active TOU Rate/Season
• Flicker
• Frequency

TEST Mode

Enter TEST mode to view specific test data (kWh Test, kVARh/KVAh Test, Instantaneous Demand Test). Access TEST mode via ION software or by removing the outer cover and pressing the TEST mode button.

Contact Information

For further assistance, contact Schneider Electric:

• Power Monitoring and Control: 2195 Keating Cross Road, Saanichton, BC, Canada V8M 2A5, Tel: 1-250-652-7100
• USA: 295 Tech Park Drive, Suite 100, Lavergne, TN 37086, Tel: 1-615-287-3400
• France: Electropole (38 EQI), 31, rue Pierre Mendès France, F - 38050 Grenoble Cédex 9, Tel: +33 (0) 4 76 57 60 60

For technical support, contact your local Schneider Electric sales representative or visit www.global.powerlogic.com.