63230-511-200A2

Instruction Sheet 09/2015

PowerLogicTM IONTM Meter Demo Case

with ION7650, PM8240, PM5560 meters

Safety Information
Read these instructions carefully and look at the equipment to
become familiar with the device before trying to install, operate,
service or maintain it. The following special messages may
appear throughout this bulletin or on the equipment to warn of
potential hazards or to call attention to information that
clarifies or simplifies a procedure.
The addition of either symbol to a “Danger” or “Warning” safety label
indicates that an electrical hazard exists which will result in personal
injury if the instructions are not followed.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

DANGER
DANGER indicates a hazardous situation which, if not avoided,
will result in death or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.

CAUTION
CAUTION indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.

NOTICE
NOTICE is used to address practices not related to physical injury.

Please Note Electrical equipment should be installed, operated, serviced and

maintained only by qualified personnel. No responsibility is assumed
by Schneider Electric for any consequences arising out of the use of
this material.
A qualified person is one who has skills and knowledge related to
the construction, installation, and operation of electrical equipment
and has received safety training to recognize and avoid the hazards
involved.
 PowerLogic ION Meter Demo Case 63230-511-200A2
Safety Precautions 09/2015

Safety Precautions
Installation, wiring, testing and service must be performed in
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accordance with all local and national electrical codes.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC
FLASH
• Apply appropriate personal protective equipment (PPE) and
follow safe electrical work practices. See NFPA 70E in the USA,
CSA Z462 or applicable local standards.
• This equipment must only be installed and serviced by qualified
electrical personnel.
• Turn off all power supplying this equipment before working on or
inside equipment.
• Always use a properly rated voltage sensing device to confirm
that all power is off.
• Replace all devices, doors and covers before turning on power
to this equipment.
• Treat communications and I/O wiring connected to multiple
devices as hazardous live until determined otherwise.
• Power unit only from sockets equipped with earth contact.
Failure to follow these instructions will result in death or
serious injury.

NOTE: See IEC 60950-1:2005, Annex W for more information on

communications and I/O wiring connected to multiple devices.

Introduction
This document is for internal use only. It describes the functionality
of the demo case and explains the communications and wiring
setup.

2 © 2015 Schneider Electric All Rights Reserved

63230-511-200A2 PowerLogic ION Meter Demo Case
09/2015 Case Contents

Case Contents
The Demo Case is made up of these items:

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• Carrying case
• Power cable
• Two Phoenix communications connectors (installed)
• This instruction sheet

Figure 1: Demo Case and Carrying Case

© 2015 Schneider Electric All Rights Reserved 3

 PowerLogic ION Meter Demo Case 63230-511-200A2
Front Panel Orientation 09/2015

Front Panel Orientation

This standard Demo Case consists of an ION7650, PM8240,
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PM5560, and a power simulator control board. The output of the

power simulator is connected to the ION7650 and PM8240 meters.
Figure 2: Front Panel

D1 R1 D1

PM8240
ION7650

S1 S2

PM5560
S1 S2

Sag/Swell
Power Simulator Control Sag/Swell Sag/Swell
Trigger Magnitude Sag/Swell Duration Switch Current Load
Adjust Adjust
Board Swell Duration Adjust Long

Sag Min Max Min Max Short Min Max

ION7650
Serial Number__ ____________________
Order Number__M7650B1C0B5E0A0A__
Inputs: S1 switch connected to digital input 1
S2 switch connected to digital input 2
Outputs: D1 light connected to digital output 1
R1 light connected to relay output 1

PM8240 (typical)
Serial Number__ ____________________
Order Number__METSEPM8240__
Inputs: S1 switch connected to digital input 1
S2 switch connected to digital input 2
Outputs: D1 light connected to digital output 1

PM5560 (typical)
Serial Number__ ____________________
Order Number__METSEPM5560__
Inputs: N/A
Outputs: N/A

4 © 2015 Schneider Electric All Rights Reserved

63230-511-200A2 PowerLogic ION Meter Demo Case
09/2015 Power Simulator Controls

Power Simulator Controls

The ION7650 and the PM8240 voltage inputs are connected to the

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power simulator outputs. The power simulator outputs
approximately 33 Vac when powered by 120 Vac, and 60 Vac when
powered by 220 Vac. The current load adjust dial ranges from
0-50 mA. Depending on the input voltage, use the settings in
Table 1 to display realistic PT values.
The PM5560 voltage input is connected to the input voltage of the
Demo Case. Therefore, the sag/swell features of the power
simulator controls do not affect the PM5560.
Table 1: Suggested PT and CT Settings

Demo Case Figure 3: Power Simulator Control Panel

120 Vac 220 Vac
Input Voltage
PT Primary 436 807 6 7
PT Secondary 120 120 1 2 3 4 5
CT Primary 2500 2500
S1 S2
CT Secondary 5 5

Sag/Swell Sag/Swell Sag/Swell

Trigger Magnitude Sag/Swell Duration Switch Current Load
Swell Adjust Duration Adjust Long Adjust

Sag Min Max Min Max Short Min Max

Table 2: Power Simulator Control Panel Operation

1 Sag/Swell Trigger To generate a swell, push the switch up. To generate a sag, push the
switch down. NOTE: The sag or swell duration is NOT controlled by how
long the switch is held in the up or down position.

2 Sag/Swell Magnitude Adjust Turn this dial to adjust the size of the power quality event. When the dial is
set to the maximum (Max), the generated sag or swell is at its largest
deviation from nominal. A swell is above nominal and a sag below nominal.

3 Sag/Swell Trigger Duration Adjust Turn this dial to adjust the timed length of the power quality event.

Switch Position Adjust Position PQ Duration – Approx.

Short Min. 0.0004 secs. (0.4 ms)
Short Max. 0.150 secs (150 ms)
Long Min. 0.010 secs (10 ms)
Long Max 0.400 secs (400 ms)

4 Sag/Swell Trigger Duration Switch Use this switch to increase the duration of the power quality disturbance.

5 Current Load Adjust Turn this dial to change the load current applied to the meters.
NOTE: When the load is connected to the monitored load receptacle, the
current load adjust dial has little effect on the load reading.

6,7 ION7650 S1 and S2 S1 switch connected to digital input 1

S2 switch connected to digital input 2

© 2015 Schneider Electric All Rights Reserved 5

 PowerLogic ION Meter Demo Case 63230-511-200A2
Monitored Load 09/2015

Monitored Load
Figure 4 shows the monitored load receptacle, which is located on
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the right side of the Demo Case.

Figure 4: Monitored Load Receptacle

Monitored Load
Max. 5 A

The meters in the case monitor the load from a device that is
plugged into this receptacle. The measured current values of the
meters are affected.
To avoid blowing the internal power input fuse, only connect
equipment that is rated under 150 W to the monitored load
receptacle.

NOTE: When the load is connected to the monitored load

receptacle, the current load adjust dial has little effect on the load
reading.

6 © 2015 Schneider Electric All Rights Reserved

63230-511-200A2 PowerLogic ION Meter Demo Case
09/2015 Communications and Expansion

Communications and Expansion

The left side of the Demo Case contains connections for:

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• Communications to the meters
• Support of additional meters to be added to the system
• Input (for power cord)
• Auxiliary power
Figure 5: Left Side of Demo Case

COM1 DAISY COM2 DAISY

CHAIN CHAIN

1 SH – + SH – +

ETHERNET ETHERNET
PORT 1 PORT 2

UPLINK PORT
2 AUTO DETECT

INT.
ONLY

EXT.
METER
3
AUX POWER
OUTLET

4 6

The sections that follow provide detailed information about the

numbered items in Figure 5.

© 2015 Schneider Electric All Rights Reserved 7

 PowerLogic ION Meter Demo Case 63230-511-200A2
Communications and Expansion 09/2015

[1] COM1 and COM2 Daisy Chain The green Phoenix connectors installed on COM1 or COM2 are
used to connect the serial daisy chain of the ION7650 (see 1 in
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Figure 5).
For more about serial connections, see “Serial Communications” on
page 10.

[2] Ethernet Connections All meters in the Demo Case are connected to an Ethernet switch
built into the case. You can use the remaining ports of the Ethernet
switch to connect to another meter or computer (see 2 Figure 5).

NOTE: All ports on the Ethernet switch have cross-over auto-

detection. You can use straight or cross-over cables.

[3] Internal or External Meter Switch This switch allows an external meter to be connected to the power
simulator in the Demo Case (see 3 in Figure 5). Plug the external
meter into the receptacle directly under it and set the switch to
external meter (EXT METER). For the wiring diagram, see
“Connecting an External Meter to the Power Simulator” on page 12.

[4] Power Switch The ON/OFF switch on the Demo Case turns off all power to the
Demo Case including the meters, Ethernet switch, and power
simulator (see 4 in Figure 5).

8 © 2015 Schneider Electric All Rights Reserved

63230-511-200A2 PowerLogic ION Meter Demo Case
09/2015 Communications and Expansion

[5] Input Power and Fuse The Demo Case can accept voltage input ranging from 100–230
Vac (50–60 Hz) (see 5 in Figure 5). The 5 A fuse is also located

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here.

Replacing a Blown Fuse

Before replacing the fuse, determine why the fuse was blown.
Eliminate the cause of the overload.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC
FLASH
• Apply appropriate personal protective equipment (PPE) and
follow safe electrical work practices. See NFPA 70E in the USA,
CSA Z462 or applicable local standards.
• This equipment must only be installed and serviced by qualified
electrical personnel.
• Turn off all power supplying this equipment before working on or
inside equipment.
• Always use a properly rated voltage sensing device to confirm
that all power is off.
• Replace all devices, doors and covers before turning on power
to this equipment.
• Unplug the power cord from the power source and remove any
loads on the outlets before replacing the fuse.
• Do not attempt to service the Demo Case except for replacing
the fuse.
• Treat communications and I/O wiring connected to multiple
devices as hazardous live until determined otherwise.
• Power unit only from sockets equipped with earth contact.

Failure to follow these instructions will result in death or

serious injury.

To replace the fuse, unplug the input power cord from the Demo
Case and pry open the fuse holder with a screwdriver. Replace the
fuse only with 250 V, 5 A, Type 5 mm x 20 mm, fast-acting fuse.

© 2015 Schneider Electric All Rights Reserved 9

 PowerLogic ION Meter Demo Case 63230-511-200A2
Serial Communications 09/2015

[6] Auxiliary Power Receptacle The AUX POWER OUTLET can be used to power additional
meters, portable computers, or other electronic devices (see 6 in
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Figure 5). This power receptacle is not monitored by the meters and
does not affect the power simulator load current. To avoid blowing
the fuse, do not exceed 3 A to power additional devices through the
AUX POWER OUTLET.
The voltage on the auxiliary power outlet and the input power
receptacle is the same.

NOTICE
MISMATCHED VOLTAGE
Ensure that any load connected to the auxiliary outlet has the
same voltage rating as the input power.
Failure to follow these instructions can result in equipment
damage.

Serial Communications
The ION7650 has two serial ports. The ION7650 COM2 is
connected to the PM5560 and then to the external Phoenix
connector. The ION7650 COM1 is connected to the serial port of the
PM8240 and then to the external Phoenix connector.
Figure 6: Serial Connections

PM5560 PM8240

COM2 COM1

NOTE: The Phoenix connector manufacturer’s part # is

MSTB2.5/3-ST-5.08

10 © 2015 Schneider Electric All Rights Reserved

63230-511-200A2 PowerLogic ION Meter Demo Case
09/2015 Ethernet Communications

Ethernet Communications
The Demo Case is equipped with an internal 5-port Ethernet switch.

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The ION7650 and PM8240 are connected to the switch. The
PM5560 is connected to the PM8240 with Ethernet. The remaining
Ethernet ports are available on the side panel (see 2 in Figure 5).
Figure 7: Ethernet Communications Layout

ION 7650

PM 8240 PM 5560

Ethernet
5 4 3 2 1 Sw itch

Port 1

Port 2

U plink Port

NOTE: All the ports on the Ethernet switch have cross-over auto-
detection. Either straight or cross-over cables work.

© 2015 Schneider Electric All Rights Reserved 11

 PowerLogic ION Meter Demo Case 63230-511-200A2
Connecting an External Meter to the Power Simulator 09/2015

Connecting an External Meter to the Power Simulator

You can add an external meter to the Demo Case system by using
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one of the serial or Ethernet connections on the left side of the

Demo Case. In addition to communications, the meter can also be
connected to the internal power simulator. The following diagrams
show how the external power simulator connector is wired to
accommodate an additional meter.

Table 3: External Power Simulator Connection

Location Name Connection to External Meter
I Out I 11 and V REF
I Return I 12
Voltage Point V1

Figure 8: Current Flow and Voltage Connection

Current flows through the connection Voltage measurements connection

12 © 2015 Schneider Electric All Rights Reserved

63230-511-200A2 PowerLogic ION Meter Demo Case
09/2015 Connecting an External Meter to the Power Simulator

Use a power cable extender to connect to the external meter

connection point.

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Figure 9: Power Cable Extender

Table 4: Power Cable Extender Connections

Connection Standard Color

I Out White colored wire
I Return Green colored wire
Voltage Point Black colored wire

NOTE: Always check the color code with an ohmmeter before

completing the connections.

Figure 10: External Meter Wiring Example

After the external meter is connected and the switch is set to EXT
METER, all the meters in the system are connected to the power
simulator at the same time. Any sag/swell event is sent to all meters.
Any current adjustments are seen by all the meters.

NOTE: To activate the connector, use a small screwdriver to slide

the switch towards Ext Meter.

© 2015 Schneider Electric All Rights Reserved 13

 PowerLogic ION Meter Demo Case 63230-511-200A2
Instruction Sheet 09/2015

Troubleshooting
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Symptom Possible Solution

Demo Case has no power • Ensure that the power cable is tightly connected.
• Check that the power switch is in the ON position (located on the left side of the
case).
• Check that the power input fuse (located underneath the input power connector) is in
place and not blown.
Meters measure no current Ensure the slider switch is in “Int. Only” mode. If “Ext. Meter” mode is being used,
check the wiring on the external meter.
Current Load Adjust dial does not Check to see if external load is connected. The internal load is quite small. If an
change current load external load is applied, the current adjust has little impact.
Meter measures no V-LL voltage This is normal operation due to the single phase power simulator. Please look for V-
LN values instead.
Unable to contact an Ethernet device • Check that the IP address of meter is configured correctly.
• Check that the subnet mask setting is configured correctly.
Unable to contact a serial device • Verify the protocol setting on all devices in the daisy chain.
• Check the unit ID setting on all devices in the daisy chain.
• Check the baud rate setting on all devices in the daisy chain.

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63230-511-200A2 © 2015 Schneider Electric All Rights Reserved