I received a few request to describe the installation of my Brultech GreenEye Monitor (GEM for short). My house has an old main panel, and I recently added a sub panel as part of a major house rewiring. My intent was to monitor both panels using the Brultech GreenEye Monitor.
I plan to cover this in a few installments: main panel wiring, sub panel wiring, Brultech wiring, Brultech config, software setup.
This is the main panel. It has two 2-phase groups (for the sub panel and the dryer), and several 15A and 20A circuits. Two of the circuits are currently not used.
The CT installation in the old main panel. You can see I used the (much cheaper) "donut" CTs for everything, including the main service. This is not a trivial operation, and you have to be very comfortable with electrical systems before you attempt this yourself. When in doubt, get an electrician to do it. It takes about 30 minutes. Don't even think about doing this with the power on the panel. You can kill yourself.
All CT connections are zip-tied together, and exit the panel through a nippel on the left. The nippel is critical to avoid chafe on the CT cables. The nippel is connected to a square box.
The CT splices in progress. Since I have two panels, and the monitoring unit is about 20 feet away, I decided to simply use CAT5 cables for the signals. CAT5 is typically 24 AWG, which is the same as the leads of the CT themselves. As you can see I used multiple CAT5 cables, each named A-F (one spare). The CAT5 and the CT leads are spliced using 3M telecom crimp connectors. It's still a little messy, but the cables will later be grouped together by CAT5 cable and bundled with two zip ties. Every CT lead is labeled with the circuit number to reduce time-consuming troubleshooting later on.
The finished splice box. The 6 CAT5 cables go up to the joists, and run inside ceiling bays to the monitoring panel. The Square box received an extension ring to avoid having to jam the bundles into the box. Cover plate and straigforward labeling finishes the job.
Part 2 will cover the sub panel installation.