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PM4100APD Application Note: Energy Meter Evaluation Module PM4100APD
FEATURES + Compatible
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+ + + + + +
Current sensing via shunt or CT (on-board termination resistor). Counter and stepper counter connections by means of screw terminals. On-board precision calibration either by analog trimpot or digital Eeprom. Direct connection to micro-controller. Optically isolated output for connection to test equipment. Easy accessible test pins
with SA4102A / SA2002E / SA2002H /
SA2002P / SA2002D / SA2102D. All devices are PDIP20, except for the SA2002P which is PDIP16.
+ + +
Connection of external sensing elements, mains and power supply by means of screw terminals. Operation from either single +5V supply or dual rail supply (20mA). Direction and pulse output indication by means of on-board LEDs.
INTRODUCTION
The PM4100AD evaluation module is designed to demonstrate the functionality of the following devices SA4102A, SA2002E, SA2002H, SA2002P, SA2002D and SA2102D. The module is easily configured and setup for the various devices by means of on-board jumpers. The setup of the module is simplified with the help of the accompanying software that illustrates the jumper positions for each device. The measured energy is displayed on an on-board LED (PULSE), while a stepper motor counter or impulse counter can be connected to the screw terminals provided. A second LED (DIR) is used to indicate the energy direction. This application note should be used in conjunction with each device's specific datasheet for the individual device specifications and characteristics.
LIVE NEUTRAL
GND IIN IIP
DEVICE
PULSE 4N35
STEPPER
COUNTER
PULSE
MICRO
24C01A
DIR
PROGRAMER
VDD GND VSS
Figure 1: Functional Diagram
SPEC-1042 (REV. 3)
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PM4100APD
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The center position of P1 is used in the equation to ensure that calibration can be done by adjusting P1 to be higher or lower. Combining the two equations gives: (RA + RB)/220V = RB/14V
ANALOG INPUT
The most important external components for any SAMES integrated circuit are the current and voltage sense resistors, as well as the bias setting resistors. These resistors must be of the same type as specified in the parts list to ensure that temperature effects and noise susceptibility is minimized.
VOLTAGE INPUT IVP
The voltage input is driven with a current of 14ARMS (11ARMS to SA4102A) at the nominal rated mains voltage. Please note that this input will saturate with currents bigger than approximately 17ARMS, which translates into a 20% overdrive capability. This also ensures that the device will not saturate with a 10% variance in mains voltage. The main voltage is divided down via a resistor network (see Figure 2) to 14VRMS. This voltage is fed to a 1MW resistor (R8) to realize the 14ARMS. The resistor values are chosen in such a way that shorting jumper J2 leads to half the voltage on the voltage divider output. This feature makes the module compatible for both 220V and 110V supply networks. Ignoring jumper J2 results in the following equations: RA = R5 + R6 + R7 + R10 RB = R8 || (R9 + 0.5P1) Values for resistors R9 = 12kW, P1 = 20kW and R8 = 1MW is chosen. Substituting the values result in: RB = 26.29kW RA = RB x (220V/14V-1) RA = 386.84kW Choosing standard resistor values for R5, R6, R7, R10 and keeping in mind that J2 must half the output voltage leads to the following values: R5 = R7 = 82kW R6 = R10 = 100kW.
RA
J2
J26
NEUTRAL
R5
R6
R7
R10 R9
C1
R8
RB
P1 LIVE IN
Figure 2: Voltage divider circuit
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The capacitor C1 is inserted to compensate for the phase shift caused by the current transformer. The following equation shows how to calculate the capacitor value for a phase shift of 0.18 degrees. C = 1 / (2 x p x Mains frequency x R8 x tan(Phase shift angle)) C = 1 / (2 x p x 50 x 1M x tan(0.18 degrees)) C = 1.013F CTs with a low phase is recommended.
CURRENT SENSE INPUT
Resistors R2 and R3 (figure 3 and figure 4) define the current level into the current sense inputs of the device. The PM4100APD module can be configured to use any type of shunt or CT, but to ensure proper current sensing it is advisable to use a shunt or CT that will give a voltage drop of at least 20mV at maximum supply current. The resistor values are calculated for an input of 16ARMS on the current sense inputs at rated conditions. The design equation is as follows: R2 = R3 = (I / 16A) x RSH / 2
L
SHUNT Sensing
IL= Line current RSH = Shunt value
CON2 3 2 1 CURRENT R2 R3 IIN IIP GND
REFERENCE VOLTAGE
The on chip reference current is determined from a biasing resistor R4 connected between pin 3 of the device and VSS. This is 47kW for the SA2102D and SA4102A, and 24kW for the rest of the devices compatible with this module.
ANALOG GROUND (GND)
The GND pin of the device is connected to the analog ground plane, which is halfway between VDD and VSS.
Figure 3: Current sensing using a shunt
SENSING METHOD (CT OR SHUNT)
Provision is made for the use of either a Current Transformer (CT) or a Shunt on the application module. For use with a CT, the terminating resistor (R1) and phase compensation capacitor (C1), as well as jumper (J1) must be inserted. The jumper references one side of the CT to ground for sensing. When using a CT the current sensing resistors (R2 and R3) must be inserted according to the equation stated below. R2 = R3 = (IL/2500/16A) x R1/2 IL= Line current 1:2500 = CT ratio CT Sensing
CON2 3 2 1 CURRENT
GND
J1 CT
R1
CT ONLY
R2 R3
IIN IIP
Figure 4: Current sensing using a CT
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Jumper Selection The jumpers listed in table 2 is device independent and must be setup according to the users needs. Name J1 Option This jumper must be inserted when measurement is done using a CT, and left open when using a shunt. This jumper must be inserted when working from a 110V supply system, and left open when a 220V supply is used. This jumper must be closed for regular use Insert this jumper when using a shunt, and leave open when using a CT. Table 2: Device independent jumpers
SETUP OF THE PM4100APD AS AN ENERGY/POWER EVALUATION BOARD
The PM4100APD evaluation module comes with several jumper selections, which allows the user to setup the module to work for any of the devices mentioned. Tables 2 to 8 describe the various jumper options. These tables should be used in conjunction with figure 9, as well as the accompanying software on disk (PM4100.exe) which will make it easier to locate the jumper in question. External connectors The PM4100APD module connects directly to live and neutral by means of a screw terminal (SCK1), and the current sensing element is connected to CON2 as is shown in figures 5 and 6. Connection diagram for CON3 and CON6 is shown in figures 7 and 8. Programming the SA2002P must be done via an external programmer/opto-isolator that connects to CON 3. There is such a module available on request from SAMES, or a module can be build as per information supplied in Figure 7. Table 1 lists all the connectors available on the module. Name SK1 CON1 CON2 CON3 CON4 CON5 CON6 CON7 Description Mains Connection Power Supply Sensing element connector Programmer (SA2002P) Stepper Motor Counter Impulse Counter Micro Controller Opto-isolated Output Pulses Table 1: External connector descriptions
J2
J24 J26
LIVE IN Shunt
CON2 3 2 1 CURRENT
LIVE OUT
Figure 6: Current connection diagram for Shunt
CON3 PROGRAM
Figure 7: SA2002P Programming Connector
LIVE IN
CT
CON2 3 2 1 CURRENT
LIVE OUT
Figure 5: Current connection diagram for CT
CON6 MICRO
Figure 8: Micro Controller Connector
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5 4 3 2 1
7 6 5 4 3 2 1
SCL SDA LED RLOAD VSS
VDD
VDD FMO F_ OUT _ DIRO VSS
PM4100APD
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SA2002D State B B A B B B B A A A CLOSED A J11 J12 J13 J17, J18, J19 Name State J7 J8 J9 J10 A A A A: Setting to A and J20 to + enables the FAST output mode. Leaving J10 and J20 open disables FAST mode and enables standard mode. B B A Rated conditions select (J17 for R0, J18 for R1, J19 for R2). Please refer to the SA2002D datasheet for further information. For Fast mode, any combination except all to +. For different normal mode settings, refer to the SA2002D datasheet.
SA2002P Name J4 J5 J6 J7 J8 J9 J10 J11 J12 J15 J22 J25
Table 3: Jumper options for SA2002P SA2002H (J6, J13, J15 to be used with Micro-controller) Name J6 J11 J12 J13 J14 J15 J25 State B B B B A A A J23 J25 J20
Note: On module + = VDD and - = VSS "+" : FAST mode enabled. "-" or OPEN: Standard mode enabled. Also see J10. "-" A
Bi-Directional Energy Measurement J4 J5 Uni-Directional Energy Measurement A B
Table 4: Jumper options for SA2002H SA2002E Name J11 J14 J25 State B A A Forward J3 J4 J5 Reverse J3 J4 J5 A A + A A
Table 5: Jumper options for SA2002E
Table 6: Jumper options for SA2002D
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SA2102D Name J7 J8 J9 J10 State A A A A: Setting to A and J20 to + enables the FAST output mode. Leaving J10 and J20 open disables FAST mode and enables standard mode. J11 J12 J13 B B A SA4102A Name J7 J8 J9 J10 J11 J12 J13 J14, J15 State A A A A B B A
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Set to B to enable stepper motor or counter connectors (CON 4 and CON 5)
J14, J15 B. Connect if a stepper motor or counter is to be connected. J17, J18, J19 Rated conditions select (J17 for R0, J18 for R1, J19 for R2). Please refer to the SA2102D datasheet for further information. For Fast mode, any combination except all to +. For different normal mode settings, refer to the SA2102D datasheet. Note: On module + = VDD and - = VSS J20 "+" : FAST mode enabled. "-" or OPEN: Standard mode enabled. Also see J10. J21 CLOSED: Inserting the jumper enables the pulse stability circuitry. OPEN: Leaving it open disables the pulse stability circuitry. J23 J25 "-" A
J17, J18, Rated conditions select (J17 for R0, J18 for R1, J19, J21, J19 for R2, J21 for R3). Please refer to the SA4102 datasheet for further information. J20 Fms (see datasheet). Leave J20 open for fast pulse output. J23 Filter output select. Set to + for Averaging filter. Set to - for Filtered instantaneous output. J25 A
Bi-Directional Energy Measurement J4 J5 A B
Uni-Directional Energy Measurement Forward J3 A B J4 J5 Reverse + A A
Bi-Directional Energy Measurement J4 J5 Uni-Directional Energy Measurement Forward J3 J4 J5 Reverse J3 J4 J5 A A + A A
J3 J4 J5
A A
Table 8: Jumper options for SA4102A
Table 7: Jumper options for SA2102D
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PM4100APD
Module Calibration The output frequency can be adjusted and calibrated by means of the variable resistor P1 connected in the voltage divider as shown in figure 2. PCB Design Considerations There are numerous PCB design aspects to consider when designing a power/energy meter, but only a few crucial aspects will be discussed here. The sense resistors on the current input, R2 and R3 must be located as close to the SAMES device input pins as possible. This also holds true for the 1MW resistor (R8), and the biasing resistor R4. Also note that the supply bypass capacitors C2, C3 and C4 (insert C5 and C6 for the SA2002P) must be positioned as close as possible to the supply pins of the device, and connected to a solid ground plane.
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It is advisable to keep the ground plane surrounding the device clear of noise that may influence the sensing signals. The module is protected from high transients on the main voltage input by means of a Metal Oxide Varistor. These MOVs will clamp any high transients with a sufficiently long rise time to neutral, hence protecting the PCB. When designing a meter, a MOV of type S20 should be used, as the S10 type titled here will not withstand high surge tests.
Figure 9: Jumper positions
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PM4100APD
EVALUATION BOARD COMPONENT LIST
Designator C1 C10 C2 C3 C4 C5 C6 C7 C8 C9 CON1 CON2 CON3 CON4 CON5 CON6 CON7 J1 J10 J11 J12 J13 J14 J15 J16 J17 J18 J19 J2 J20 J21 J22 J23 J24 J25 J26 J3 J4 J5 J6 Part Type Non-Polar 10uF 220nF 220nF 1uF 220nF 220nF 100nF 100nF 10uF CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR CONNECTOR INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS INLINE PINS Description
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2.54mm, PITCH, NON-POLAR 16V, See page 3 for calculation of value 2.54mm, PITCH, TANTALUM. At least 10V 5.08mm, CERAMIC 5.08mm, CERAMIC 5.08mm, CERAMIC 0805 SMD CERAMIC, should be fitted for SA2002P 0805 SMD CERAMIC, should be fitted for SA2002P 5.08mm PITCH, CERAMIC 5.08mm PITCH, CERAMIC 2.54mm PITCH, TANTALUM. At least 10V 5.08mm PITCH, 3-WAY SCREW TERMINAL 5.08mm PITCH, 3-WAY SCREW TERMINAL 7 Single Inline Pins 5.08mm PITCH, 2-WAY SCREW TERMINAL 5.08mm PITCH, 2-WAY SCREW TERMINAL 5.08mm PITCH, 5-WAY SCREW TERMINAL 5.08mm PITCH, 2-WAY SCREW TERMINAL 2 Single Inline Pins 3 Single Inline Pins 3 Single Inline Pins 3 Single Inline Pins 3 Single Inline Pins 3 Single Inline Pins 3 Single Inline Pins 1 Single Inline Pins 3 Single Inline Pins 3 Single Inline Pins 3 Single Inline Pins 2 Single Inline Pins 3 Single Inline Pins 3 Single Inline Pins 2 Single Inline Pins 3 Single Inline Pins 2 Single Inline Pins 3 Single Inline Pins 2 Single Inline Pins 3 Single Inline Pins 3 Single Inline Pins 3 Single Inline Pins 3 Single Inline Pins
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EVALUATION BOARD COMPONENT LIST (Continued)
Designator J7 J8 J9 L1 L2 P1 R1 R10 R11 R12 R13 R14 R15 R16 R2 R3 R4 Part Type INLINE PINS INLINE PINS INLINE PINS LED LED 20k CT ONLY 100k 4k7 1k6 680R 680R 1k 1k RES (To be calculated) RES (To be calculated) RES 24kW Standard. 47kW for SA2102D / SA4102 A R5 R6 R7 R8 R9 S1 SK1 TP1 TP2 TP3 TP4 U1 U2 U2 U3 U3 Z1 4N35 MOV 24C01A 82k 100k 82k 1M 12k PB MAINS VDD VSS GND 14V DEVICE Description 3 Single Inline Pins 3 Single Inline Pins 3 Single Inline Pins 3mm, GREEN 3mm, RED Multiturn, Top Adjust
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1/4 WATT, 1% METAL FILM RESISTOR. See CT Datasheet 1/4 WATT 1% METAL FILM RESISTOR , 1/4 WATT 1% METAL FILM RESISTOR , 1/4 WATT 1% METAL FILM RESISTOR , 1/4 WATT 1% METAL FILM RESISTOR , 1/4 WATT 1% METAL FILM RESISTOR , 0805 SMD 1% 0805 SMD 1% 1/4 WATT, 1% METAL FILM RESISTOR. See page 3 1/4 WATT, 1% METAL FILM RESISTOR. See page 3 1/4 WATT 1% METAL FILM RESISTOR , (As default this position is left open, fit Resistor according to device used) 1/4 WATT 1% METAL FILM RESISTOR , 1/4 WATT 1% METAL FILM RESISTOR , 1/4 WATT 1% METAL FILM RESISTOR , 1/4 WATT 1% METAL FILM RESISTOR , 1/4 WATT 1% METAL FILM RESISTOR , Miniature Pushbutton, Push to make 5.08 PITCH, 3-WAY SCREW TERMINAL Testpin Testpin Testpin Testpin 20 PIN DIL, Tulip Type Socket 8 PIN DIL, Tulip Type Socket 1k 128x8 CMOS EEPROM - MICROCHIP 6 PIN DIL, Tulip Type Socket 4N35, 6 PIN DIP S10/K320; Use type S20 when designing a meter
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230V/110V J2 VDD R10 100k VSS J5 DIRI 14V J24 DIRO DIRO J4 J16 1uF/Non-Polar SCL J22 LED J12 GND J12 VDD J21 VSS LED J14 C10 C8 GND R16 DIRO J13 MON C9 C7 R15 JUMPS2 C6 VSS LED SDA J15 VDD FMO J6 DIRO J3 R5 82k J1 CT GND P1 20k R9 See notes J26 R8 1M C1 R1 R2 1 IIN IIP VREF 17 16 15 VSS VDD 12 11 SA2002E/H/P/D/ SA2102D/SA4102A VSS VSS J11 VDD MOP MOP VSS 13 14 18 IVP 19 GND 20 2 3 4 5 6 7 8 J9 J23 MON J10 FAST 10 FMO VDD 9 R3 RES R4 RES VSS VDD J8 GND C5 RES U1 CT ONLY 100k 82k R6 R7
1 2 3 4 CON3 VDD VDD VSS GND 14V 14V GND TP4 VDD FMO F_OUT DIRO VSS 1 2 3 4 5 MICRO CON6 VSS TP3 PROGRAM VDD TP2 TP1 DIRO
A0 VCC A1 TEST A2 SCL VSS SDA J25
8 7 6 5
SCL SDA
680R DIR L2 LED F_OUT OPTO/MICRO R14 680R 1 2 PULSE 1 2 U3 4N35
6
VSS
24C01A
6
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VDD R13 L1 CON7 5 4 5 4 1 2 PULSE SCL SDA LED RLOAD VSS 1 2 3 4 5 6 7
SK1
2 1
Z1
MAINS
GND
CON2
GND
CON1
VDD
3 2 1
GND
CURRENT
3 2 1 POWER SUPPLY
VSS
VDD
VDD
S1
J17
J18
J19
RLOAD J7
PB
R0
R1
R2
VSS
VDD
J20
FAST
2 CON4 1 STEPPER
CON5
Figure 10: Schematic Diagram
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VSS
VDD
U2
R11 4k7
R12
1k6
VSS
VDD
MON
MOP
C2 220nF
MOP
GND
C4 820nF/1uF
2 1 COUNTER
VSS
C3 220nF
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VSS
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Figure 11: Top Silkscreen
Figure 12: Bottom Silkscreen
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CT
Figure 13: Top PCB Layout
Figure 14: Bottom PCB Layout
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NOTES:
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CT
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PM4100APD PM9607AP
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DISCLAIMER:
The information contained in this document is confidential and proprietary to South African Micro-Electronic Systems (Pty) Ltd ("SAMES") and may not be copied or disclosed to a third party, in whole or in part, without the express written consent of SAMES. The information contained herein is current as of the date of publication; however, delivery of this document shall not under any circumstances create any implication that the information contained herein is correct as of any time subsequent to such date. SAMES does not undertake to inform any recipient of this document of any changes in the information contained herein, and SAMES expressly reserves the right to make changes in such information, without notification, even if such changes would render information contained herein inaccurate or incomplete. SAMES makes no representation or warranty that any circuit designed by reference to the information contained herein, will function without errors and as intended by the designer.
Any sales or technical questions may be posted to our e-mail address below: energy@sames.co.za
For the latest updates on datasheets, please visit our web site: http://www.sames.co.za. SOUTH AFRICAN MICRO-ELECTRONIC SYSTEMS (PTY) LTD Tel: (012) 333-6021 Tel: Int +27 12 333-6021 Fax: (012) 333-8071 Fax: Int +27 12 333-8071
P O BOX 15888 LYNN EAST 0039 REPUBLIC OF SOUTH AFRICA
33 ELAND STREET KOEDOESPOORT INDUSTRIAL AREA PRETORIA REPUBLIC OF SOUTH AFRICA
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