BRAYDEN WPG-1 Metering Pulse Generator Instruction Manual

INSTALLATION INSTRUCTION SHEET
WPG-1 Metering Pulse Generator
Instruction Manual

WPG-1 Metering Pulse Generator

MOUNTING POSITION – The WPG-1 can be mounted in any position. Two mounting holes are provided. The WPG-1 must be mounted in a non-metallic enclosure or somewhere where it can receive the wireless information from the meter without interference. The WPG-1 must be mounted within about 50 feet of your meter. Distances vary with building construction and proximity to the meter. For best results, mount as close to the meter as possible. The pulse output lines from the WPG-1 may be run longer distances, but the WPG-1 should have uninterrupted line-of-sight access to the greatest extent possible for best results. Choose a mounting location that will not have any metallic parts — moving or stationary — that can affect the RF communications.
POWER INPUT – The WPG-1 is powered by an AC voltage of between 120 and 277 volts. Connect the AC supply’s “hot” wire to the L1 terminal. Connect the NEU terminal to the AC supply’s “neutral” wire. Connect GND to electrical system Ground. CAUTION: Wire Phase to Neutral only, NOT Phase to Phase. The power supply is auto-ranging from 120 to 277VAC. No configuration or settings are necessary. Ground must be connected. If no true neutral exists at the mounting location, connect both the NEU and GND terminals to ground.
METER DATA INPUT – The WPG-1 receives data from a WiFi-enabled AMI electric meter that has been paired with the WPG-1’s WiFi receiver module. The meter must be paired with the WiFi receiver module before the WPG-1 can be used. Once paired, the WPG-1 starts receiving kWh, kVARh, or kVAh information from the meter. (See Page 3.)
OUTPUTS – Two 3-wire isolated dry-contact outputs are provided on the WPG-1, with output terminals K1, Y1 & Z1 and K2, Y2, & Z2. Transient suppression for the contacts of the solid-state relays is provided internally. The output loads should be limited to 100 mA at 120 VAC/VDC. Maximum power dissipation of each output is 800mW. The outputs are protected by fuses F1& F2. One-tenth (1/10) Amp fuses (the maximum size) are supplied standard.
OPERATION – See the following pages for a full explanation of the operation of the WPG-1.

SOLID STATE INSTRUMENTS
a division of Brayden Automation Corp.
6230 Aviation Circle, Loveland, Colorado 80538
Phone: (970)461-9600
E-mail: support@brayden.com

WPG-1 Wiring Diagram

WPG-1WiringDiagram.vsd

WPG-1 Wireless Pulse Generator
Wiring Diagram| REVISIONS
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NO| DATE| DESCRIPTION
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DATE ORIGINAL
07/1/22| SCALE
N/A| | |
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LATEST REVISION| JCS NO.| CHECKED| DRAWN
WHB

Brayden Automation Corp./Solid State Instruments div.
6230 Aviation Circle
Loveland, CO 80538
(970)461-9600
support@brayden.com
www.solidstateinstruments.com

WPG-1 Wireless Meter Pulse Generator

Pairing the WiFi Radio Receiver
The WPG-1 contains a Wifi module that acts as a Wifi Access Point. This is called the WPG_AP. The AMI electric meter must be paired with this access point. This may be accomplished by the utility or on their website if they have the process automated. The pairing process, generally known as “provisioning”, varies from utility to utility, and not all utilities provide WiFi radio availability in their meters. Contact your electric utility to find out how their provisioning process is accomplished. The WPG-1 must be powered for the WPG_AP module to be paired with the meter and must be within range of the meter, usually within 50-100 feet. The WPG-1 and its carton are labeled with the SSID and Long Format Device Identifier (“LFDI”). These are necessary to provision the meter with the WPG-1.
The WPG-1’s Wifi Module’s SSID and LFDI are programmed into the meter or sent to the meter by the utility over the AMI mesh radio network. By being “paired”, the meter and the WPG-AP module have created a dedicated 2-node wifi “network”. No other wifi-enabled devices can join this network. The AP module (acting as the Client) knows that it can only ask for and receive meter data from that particular electric meter(acting as the Server).
Before powering the WPG-1, install the WiFi module in the WPG-1’s host slot if not already mounted. Secure with 4-40 x 1/ 4″ mounting screw.
Power up the WPG-1 (This assumes that the utility has already sent the SSID and LFID to the meter.) Apply power to the WPG-1. The RED LED on the WiFi module will flash once per three seconds looking for the meter. Once the joining process has been completed, the RED LED will remain on continuously to indicate that the meter is joined with the WiFi Module in a wifi network. Once the RED LED is lit continuously, the WPG-1 can receive information from the meter. The Green LED on the Wifi module will flash 7 times every 8 seconds to indicate that data is being received from the meter. If no valid communication is received from the meter in the programmed reset period, the WPG-_AP WiFi module will revert back to looking for the meter, and the LED will flash once per three seconds. If it is not continuously lit, then it is not provisioned correctly with the utility meter, the utility meter is not powered or not available by WiFi, or another problem pre-empting the provisioning. Do not proceed until this step is successfully completed.

WiFi Module Communication Status LEDs
Upon power-up, the YELLOW Comm LED should light indicating that the WiFi receiver module is correctly inserted, initialized and communicating with the WPG-1’s processor. After the successful completion of the pairing, the GREEN Comm LED should begin to blink once every 8 to 9 seconds. This indicates that a valid transmission has been received by the receiver module and has been successfully relayed to the WPG-1’s processor. The Green Comm LED will continue to blink once every 8-9 seconds continuously as long as the meter is connected to the WPG-1. If the Green Comm LED does not blink, that is an indication that the data transmissions from the meter are not being received, may be corrupted, or in some manner are not valid transmissions. If the Green Comm LED has been blinking reliably every 8-9 seconds for some time, then stops for a while and then restarts again, this indicates that transmissions are intermittent and sporadic, or generally means there is a problem in the WiFi receiver module’s ability to receive data reliably from the meter. To correct this, change the proximity of the WPG-1 to the meter, move it closer to the meter if possible and eliminate any metallic obstructions between the meter and the WPG-1. Also check to make sure that any walls or barriers between the WPG-1 and the meter have as little metal in them as possible. In some applications the WPG-1 may need line-of-sight with the meter.

Pulse Outputs
Outputs can be configured to be in the Toggle (Form C) 3-Wire mode or the Fixed (Form A) 2-Wire mode. Generally speaking, the Form C mode can be used with either 2-Wire or 3-Wire pulse receiving devices, while the Form A mode uses only a 2-Wire interface to the downstream pulse (receiving) device. The choice would depend on the application and the desired pulse format that the receiving device prefers to see.
The WPG-1 will “spread out” the pulses over the next 10 second period if a high enough watt-hour value is received in a transmission to require that more than one pulse is generated. For example, suppose you have the Output Pulse Value of 10 wh selected. The next 8 second data transmission indicates that 24 wh have been consumed. Since 24 watt-hours exceeds the 10 watt-hour pulse value setting, two pulses must be generated. The first 10wh pulse will be generated immediately. About 4-5 seconds later the second 10wh pulse will be generated. The remainder of four watt-hours stays in the accumulated energy register (AER) awaiting the next transmission and the energy value of that transmission to be added to the contents of the AER. Another example: Assume 25 wh/p Output Pulse Value. Let’s say the next transmission is for 130 watt- hours. 130 is greater than 25, so 5 pulses will be outputted over the next 7 seconds, approximately one each 1.4 seconds (7 seconds / 5 = 1.4 seconds). The remainder of 5 wh will stay in the AER awaiting the next transmission. Some trial and error may have to be done for any particular building since pulse rates will change depending on maximum load.
WPG-1 Metering Pulse Generator.vsd
If the receiver module is reliably receiving data from the meter and passing it on to the WPG-1’s processor, then you should see the Red (and Green in the Form C output mode) output LED’s toggle each time the selected pulse value is reached, and the processor generates a pulse. If the pulse output value is too high and pulses are too slow, enter a lower pulse value. If pulses are being generated too rapidly, enter a larger pulse output value. The maximum number of pulses per second in the toggle mode is approximately 10, which means that the output’s open and closed times are about 50mS each in toggle mode. If the calculation by the WPG-1’s processor is for pulse output timing that exceeds 15 pulses per second, the WPG-1 will light the RED Comm LED, indicating an overflow error, and that the pulse value is too small. It is “latched” on so that the next time you look at the WPG-1, the RED Comm LED will be lit. In this way, you can quickly determine if a pulse output value is too small. In the optimum application, pulses would not exceed more than one pulse per second at full scale demand. This allows a very even and “normal” pulse rate that as closely as possible resembles an actual KYZ pulse output from the meter.
The WPG-1 has two independent Form C (3-wire) outputs. These are labeled as K1, Y1, Z1 for output #1 and K2, Y2, Z2 for output #2. Each output can be operated as FORM C(3-Wire) output or FORM A(2-Wire). If an output is operated in the Form A mode, the K-Y output is used.

Pulse Types
There are six pulse types: Wh, VARh or VAh pulses, each either as Delivered or Received quantities. The WPG-1 has the capability to output two of these at a time on the two independent pulse outputs. This manual refers to watt-hour pulses, but all references to watt-hour pulses are generally applicable to the other two pulse types as well, unless otherwise noted.
Wh Pulses: Wh pulses are the real power component of the power triangle. Wh pulses are used to derive kW. Since Wh pulses are directly available from the WiFi-enabled meter, the Wh value of a pulse is added to the AER each time a pulse is received. When the pre-determined output pulse value is reached, a Wh pulse is outputted on the output assigned.
VARh Pulses: VARh pulses are the reactive power component of the power triangle. VARh pulses are used to derive VAR’s. Since VARh pulses are directly available from the WiFi-enabled meter, the VARh value of a pulse is added to the AER each time a pulse is received. When the pre-determined output pulse value is reached, a VARh pulse is outputted on the output assigned.
VAh Pulses: VAh pulses are the apparent power component of the power triangle. VAh pulses are used to derive VA’s. Since VAh pulses are directly available from the WiFi-enabled meter, the VAh value of a pulse is added to the AER each time a pulse is received. When the pre-determined output pulse value is reached, a kVAh pulse is outputted on the output assigned.
It is important that you select the correct type of pulse output. The correct type of pulse output will depend on your billing structure from the utility and what you want to use pulses for. If you are doing demand control and your demand is billed in kW’s then you want to use Wh pulses. Conversely, if you are billed for demand in kVA, then you want to select VAh pulses. If you are doing power factor control, you will likely need Wh pulses on one output and VARh pulses on the other output. Contact your utility or Solid State Instruments for technical support.

Overranging the Output
As previously mentioned, if there are too many pulses calculated to be outputted in a 6-7 second interval than the WPG-1 can generate given the timing constraints, the WPG-1 will light the RED Comm LED. In this situation, simply increase the output pulse value by entering a higher number in the Pulse Value box, then click . This LED is intended to notify the user that some pulses have been lost and a larger pulse value is needed. As load is added to a building over time, there is a greater likelihood that this may occur, especially if the pulse value is small. Be sure to consider this if/when you add load to the building. If an error condition occurs, set the Output Pulse Value for a Wh value that is double the current pulse value. Remember to change the pulse constant of your receiving device as well, since pulses will now be worth twice the value. Cycle power to the WPG-1 to reset the RED Comm LED after increasing the pulse value.
WPG-1 Metering Pulse Generator.vsd

WORKING WITH THE WPG-1 RELAY
OPERATING MODES: The WPG-1 Meter Pulse Generator allows the outputs to be configured in either the “Toggle” or “Fixed” pulse output mode. In the Toggle mode, the outputs alternate or toggle back and forth between K-Y and K-Z continuity each time a pulse is generated. This is synonymous with the classic 3-Wire Pulse metering and emulates the SPDT switch model. Figure 1 below shows the timing diagram for the “Toggle” output mode. K-Y and K-Z closures or continuity are always opposite of each other. In other words, when the K-Y terminals are closed (on), the K-Z terminals are open(off). This mode is best for timing pulses to derive demand whether 2 or 3 physical wires are being used to the downstream (pulse receiving) device or system.

In the Fixed output mode, shown in Figure 2 below, an output pulse (K-Y closure only) is a fixed width (T1) each time the output is triggered. The pulse width (closure time) is determined by the setting of the Pulse Width (W) command. This mode is best for energy (kWh) counting systems but may not be the best for systems doing demand control where pulses are timed to derive instantaneous kW demand. The K-Z output is not used in the normal/fixed mode.

*If the output is configured for Form A pulses the K-Z output is is not used. In Figure 2 above, the K-Z output is disabled, thus showing no pulses.
Contact the factory for technical support at (970)461-9600.

WPG-1 Programming

Setting the WPG-1’s Settings
Set the WPG-1’s output pulse value, the meter multiplier, the pulse output mode, pulse type and pulse timing by using the USB [Type B] Programming Port on the WPG-1 board. All system settings are configured using the USB Programming Port. Download the SSI Universal Programmer software available as a free download from the SSI website. Alternately, the WPG-1 can be programmed using a terminal program such as TeraTerm. See “Setting up the Serial Port” on Page 9.

Programmer Startup
Before starting the program connect the USB cable between your computer and the WPG-1. Make sure that the WPG-1 is powered up. Click on the SSI Universal Programmer icon on your desktop to start the program. In the upper left corner you will observe two Green simulated LEDs, one indicating that the USB cable is connected and the other that the WPG-1 is connected to the programmer. Make sure both LED’s are “lit” .

USB Cable Connected:|
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Serial Connected:|

Meter Multiplier
If the building on which you are installing the WPG-1 has an “Instrument- Rated” electric meter, you must enter the Meter Multiplier to the WPG-1’s program. If the meter is a “Self-Contained” electric meter, the Meter Multiplier is 1.
If the facility’s electric metering configuration is Instrument-Rated, determine the Multiplier of the meter. In an instrumentrated metering configuration, the meter multiplier is normally the Current Transformer (“CT”) ratio, but will also include the Potential Transformer (“PT”) Ratio, if PT’s are used, usually only on larger applications. An 800 Amp to 5 Amp current transformer, for example, has a ratio of 160. Therefore, the meter multiplier on a building with 800:5A CT’s would be 160. The Meter Multiplier is normally printed on the customer’s monthly utility bill. If you cannot find it, call your utility and ask what the meter or billing multiplier is. To program the Multiplier in the WPG-1, enter the correct Multiplier in the Meter Multiplier box and click . See the main program screen on Page 10.

Pulse Type
The Pulse Type for the Output 1 Output 2 are set individually. Output pulse types are Watt-hours (real power), VAR-hours (reactive power) or VA-hours (apparent power), each as either Delivered or Received. Select the correct selection in the drop down menu for Output 1 Type and Output 2 Type and click