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| www..com Evaluation Board for the SA2005F Energy Metering IC PM2005FPD FEATURES + Designed to be used as a fully functional Watt-Hour meter. + Better than Class 1 operation + On-board power supply + 3 Phase 4 Wire configuration DESCRIPTION The SA2005F IC is an enhancement of the SA9105F. The PM2005FPD evaluation board provides energy data via an isolated pulse output for three-phase four-wire applications using the SA2005F. The mains voltages easily connect to the module by way of a Molex connector (SK1). The 3 on-board current transformers measure the current in each phase. A simple capacitive power supply supplies the energy metering IC with power. The LM431 regulators are used to generate 5V supply voltage for the IC on the board. sames + + On-board current transformers Can be used with external micro controller for calibration and different pulse rates .com DataShee SK1 VDD GND Power Supply GND VSS SA2005F CT1 Resistor Network 12 13 FOUT CT2 Resistor Network VDD VSS OPTO Module Setup Jumpers CT3 Resistor Network Figure 1: Block diagram SPEC-0889 .com(REV.2) 1/12 PRELIMINARY 01-10-02 .com DataSheet 4 U .com www..com PM2005FPD SETTING UP THE PM2005F MODULE JUMPER DESCRIPTION Power Supply Jumpers The power supply jumpers are used to disconnect the onboard power supply, allowing the metering section of the circuit to be powered from an external power supply if required. Jumper J4 J5 J6 J7 Description Connects VDD to the metering circuitry. Connects VSS to the metering circuitry. GND connection point. Connection point between the power supply GND (N) and the SA2005 GND sames Module Setup Jumpers The following jumpers (J8 and J9) are used to switch between the different dividing ratios. Mode 0 1 2 3 PGM1 VSS VSS VDD VDD PGM0 VSS VDD VSS VDD Frequency at Rated Conditions 64Hz 64Hz 64Hz 1160Hz CONNECTOR DESCRIPTION SK1 Connects the three phase 4 wire supply to the module. J11 Interface for external Processor. Number 1 2 3 Signal Name VDD Fout VSS SA2005F (U1) Pin 6 Pin 8 Pin 14 Voltage Selection Jumpers These jumpers are used to select between 115V and 230V operation. When closed the jumpers will half the series resistance in the voltage divider to the voltage sense inputs. Jumper J1 J2 J3 230V Open Open Open 115V Closed Closed Closed t4U.com .com DataShee J10 is used to take the output either to the opto couple or to J11, to be used with a micro. SK1 PH1 PH2 sames PM2005F PGM0 PGM1 MICRO VSS Fout VDD J11 U1 J3 J9 J8 J7 J6 GND J5 J2 PH3 N J1 OPTO/MICRO VSS J4 J10 VDD Figure 2: Jumper positions http://www.sames.co.za .com 2/12 PRELIMINARY .com DataSheet 4 U .com www..com PM2005FPD SETTING UP THE MODULE FOR ENERGY MEASUREMENT Figure 3 below shows a typical setup for the PM2005F evaluation module. The three phase voltages are connected directly to SK1 and each corresponding phase current is wired through the on-board CT's. Figure 3 also shows the default jumper settings. The PM2005F evaluation module is setup by default for 3x230V/60A sames operation. For 3x 115V operation jumpers J1, J2 and J3 need to be closed and capacitors C12, C13 and C14 values must be changed to 1F / 150VAC. A single red LED indicates when all three phases measures reverse energy. Individual direction information is available on the Fout pin. Load N PH1 PH2 PH3 SK1 t4U.com .com J3 J2 J1 DataShee J7 J6 GND J5 VSS J4 VDD J10 J11 J9 J8 Figure 3: PM2005FPD setup and connection http://www.sames.co.za .com 3/12 PRELIMINARY .com DataSheet 4 U .com www..com PM2005FPD CIRCUIT DESCRIPTION ANALOG SECTION The analog (metering) interface described in this section is designed for measuring 3x 230V/60A with precision better than Class 1. The most important external components for the SA2005F integrated circuit are the current sense resistors, the voltage sense resistors and the bias setting resistor. The resistors used in the metering section should be of the same type so that temperature effects are minimized. BIAS RESISTOR Pin VREF (SA2005F pin 15) is connected to VSS via R7 which determines the on chip bias current. With R7 = 24kW optimum conditions are set. VREF does not require any additional circuitry. CT TERMINATION RESISTOR The voltage drop across the CT termination resistor at rated current should be at least 16mV. The CT's used have low phase shift and a ratio of 1:2500. The CT is terminated with a 3.6W resistor giving a voltage drop across the termination resistor of 86.4mV at rated conditions (Imax for the meter). sames VOLTAGE DIVIDER Referring to figure 5 the connections for the voltage sense input for one phase is shown. The current into the A/D converter (IVP) is set 14ARMS at nominal mains voltage. This voltage sense input saturates at approximately 17ARMS. A nominal voltage current of 14A allows for 20% over driving. Each mains voltage is divided down by a voltage divider to 14V. The current into the voltage sense input is set at 14A via a 1MW resistor. The following equation is used to calculate the 14V voltage drop: RA = R22 + R23 + R24 + R25 RB = R8 || (R13 + P1) Combining the two equations gives: ( RA + RB ) / 230V = RB / 14V A 24kW resistor is chosen for R13 and P1 combined. A 1MW resistor is used for R8. t4U.com Substituting the values result in: RB = 23.44kW RA = RB x ( 230V / 14V - 1 ) .com RA = 361.6kW Resistor values of R22, R24 are chosen to be 82kW and resistors R23 and R25 is chosen to be 100kW each. The three voltage channels are identical so R14 = R16 = R18 = R20 = R22 = R24 = 82k and R15 = R17 = R19 = R21 = R23 = R25 = 100kW J3 R22 V1In 82k 100k 82k 100k R13 22k R23 R24 R25 C1 R8 1u 1M Pin 17 CURRENT SENSOR INPUT RESISTORS Referring to figure 4 the resistors R1 and R2 define the current levels into the SA2005's current sense inputs (phase on IIP1 and IIN1). The resistor values are selected for an input current of 16A into the current inputs at rated conditions. According to the equation described in the Current Sense inputs section of the datasheet: DataShee R1 = R2 = ( I / 16A ) x RSH / 2 = 60A / 2500 / 16A x 3.6W / 2 = 2.7kW I = Line current / CT Ratio The three current channels are identical so R1=R2=R3=R4= R5=R6. P1 10k Neutral GND I1 In CT1 R26 3.6R R1 2.7k Figure 5: Mains Voltage Divider Pin 19 Neutral R2 TZ76 GND 2.7k Pin 18 The capacitors C1, C2 and C3 is used to compensate for phase shifts between the SA2005 voltage sense inputs and current sense inputs. The on-board Ct's were characterized and found to have a constant phase shift of 0.18 degrees. The value of the phase shift compensation capacitors were calculated as follows: C = 1 / (2 x p x Mains frequency x R5 x tan (Phase shift angle)) C = 1 / (2 x p x 50 x 1MW x tan (0.18 degrees)) C = 1.013F Figure 4: Current Input Configuration http://www.sames.co.za .com 4/12 PRELIMINARY .com DataSheet 4 U .com www..com PM2005FPD sames Ground Plane The GND pin of the SA2005 is connected to the neutral phase, which is halfway between VDD and VSS. Note that supply bypass capacitors C4 and C5 are positioned as close as possible to the supply pins of the SA2005, and connected to a solid ground plane. Capacitor C6 is positioned as close as possible to the supply pins of the device for proper supply bypassing. Power Supply routing and de coupling The 5V supply is de-coupled and routed directly to the power pins of the IC by means of capacitor C5. Care is taken not to have current flowing in the node that connects the voltage reference resistor to VSS as it may introduce power supply noise on the voltage reference circuit. Signal Routing Most of the signal routing is done in such a manner that any signal coupling in to the measured signal will be a common mode noise signal and is rejected subsequently. Care should be taken that the signals to the SA2005 is not influenced by other sources such as transformers with electric fields coupling in to the signals. POWER SUPPLY Referring to figure 10, capacitor C10 is charged through D2 during the positive half of the sine wave from the R29, C12 mains voltage dropper. Identical charging circuitry exists for the other two phases. During the negative sine wave, C11 is charged through diode D1. The unregulated voltage charged on C10 and C11 is limited to 47 V by means of zener diode D7. Resistors R32 and R33 act as current limiting resistors that feed the unregulated voltage to the positive and negative voltage regulators U3 and U4. The voltage regulators need a load capacitance of around 10F (C8 and C9) to be in a stable operating region. C15 acts as a supply voltage storage capacitor. Jumpers J4, J5 and J7 allow the power supply to be completely disconnected form the metering section from the device. PCB DESIGN The module represents a Class 1 meter that is designed to demonstrate the functionality and performance of the SA2005F metering circuits. The SA2005F is a single chip solution for a three-phase meter with both fast and slow output. When the meter PCB is designed, it should be taken into account that the SA2005 is a mixed signal integrated.com circuit t4U.com DataShee and special care should to be taken with the power supply and CALIBRATION signal routing to the device. Calibration can be done by adjusting the trimpots (P1, P2, P3) Protection The SA2005 should be protected from its measuring environment. This is achieved by using resistor dividers to scale all the SA2005 input signals. MOV's Z1, Z2, Z3 together with resistors R29, R30, R31 protects the power supply capacitors. The current setting resistors on the current sense inputs of the device attenuates common mode and asymmetrical transients. Component placement All the resistors connecting to the SA2005's current sense inputs should be placed as close as possible to the SA2005. This eliminates the possibility of any stray signal coupling into the divided input signal. connected tot he three voltage inputs. http://www.sames.co.za .com 5/12 PRELIMINARY .com DataSheet 4 U .com www..com PM2005FPD COMPONENT LIST Part Type 1 / 100v / No Polarity 220n / 63v 1 / 63v 10 / 16v 470 / 25V 470n / 250VAC 470 / 25V 1N4007 47V LED 2.7k 24k 1M 22k 82k 100k 3R6 47R / 2 Watt 470R / 1 Watt 680R Pot 10k MAINS PGM1 S10 / 275 SA2005F TL431 TZ76 Micro Opto/Micro PGM0 sames Designator Description C1, C2, C3 Capacitor Electrolytic Radial C4, C5 Capacitor Monolithic Ceramic C6 Capacitor Monolithic Ceramic C8, C9 Capacitor Tantalum C11, C15 Capacitor Electrolytic Radial C12, C13, C14 Capacitor Polyester C10 Capacitor Electrolytic Radial D1, D2, D3, D4, D5, D6 Rectifier Diode D7 47V Zener Diode L2 LED 3mm Diameter, Red R1, R2, R3, R4, R5, R6 1/4 Watt, 1% Metal Film Resistor R7 1/4 Watt, 1% Metal Film Resistor R8, R9, R10 1/4 Watt, 1% Metal Film Resistor R11, R12, R13 1/4 Watt, 1% Metal Film Resistor R14, R16, R18, R20, R22, R24 1/4 Watt, 1% Metal Film Resistor R15, R17, R19, R21, R23, R25 1/4 Watt, 1% Metal Film Resistor R26, R27, R28 1/4 Watt, 1% Metal Film Resistor R29, R30, R31 2 Watt, 1% Wire Wound Resistor R32, R33 1 Watt, 1% Wire Wound Resistor R34, R37 1/4 Watt, .com 5%, Carbon Resistor P1, P2, P3 Multi turn trim pot, Top adjust SK1 7 Pin Molex, Canter square pin, Friction Lock J8 3 Pin Header Z1, Z2, Z3 Metal Oxide Varistor U1 24 Pin IC Socket, Tulip Type U3, U4 TO -92 Package CT1, CT2, CT3 1:2500, Current Transformer J11 3 Pin, Molex, Canter square pin, Friction Lock J10 3 Pin, Molex, Canter square pin, Friction Lock J9 3 Pin Header t4U.com DataShee http://www.sames.co.za .com 6/12 PRELIMINARY .com DataSheet 4 U .com www..com PM2005FPD PCB LAYOUT sames t4U.com .com Figure 6: PM2005F Top PCB layout DataShee Figure 7: PM2005F Bottom PCB layout http://www.sames.co.za .com 7/12 PRELIMINARY .com DataSheet 4 U .com www..com PM2005FPD sames t4U.com .com DataShee Figure 8: PM2005F Silkscreen PCB layout http://www.sames.co.za .com 8/12 PRELIMINARY .com DataSheet 4 U .com t4U.com http://www.sames.co.za .com DataSheet 4 U .com www..com PM2005FPD Neutral C2 C1 100k R11 P3 B4 10k R12 P2 A4 10k R13 P1 GND IVN1 R2 18 IIP1 IVN2 2 IIN2 1M IVN3 C3 1u 3 1M R10 20 C2 1u 2.7k GND R3 R27 3.6R R4 1 IIP2 DIR 9 2.7k 1M R9 1u 17 R8 C1 22k VDD 16 22k 680R 22k R37 VDD B2 B1 R19 B3 J3 100k JUMPS2 100k A2 A1 R23 A3 100k 100k R1 19 IIN1 GND R26 3.6R 2.7k 82k R24 R25 82k R20 R21 J2 82k 100k JUMPS2 10k R15 C3 C4 R16 R17 J1 JUMPS2 GND V3 In PH1 R14 82k V2 In PH2 R18 SK4 1 2 82k O1 4N35 Opto V1In PH3 R22 82k U1 J10 OPTO/MICRO CT1 J11 MICRO VSS TZ76 .com Figure 9: Schematic Diagram for Metering Section L2 LED 680R R34 VSS 2.7k GND R5 5 IIN3 FOUT 8 2.7k R28 3.6R C4 220n GND VDD VSS C5 220n 9/12 J8 R6 4 IIP3 PGM0 15 VREF TEST 14 VSS VDD 6 7 VDD VSS TCLK 10 12 VSS 2.7k GND R7 24k VSS PGM1 13 CT2 VDD TZ76 CT3 V3 Out PGM1 J9 C6 1u TZ76 PGM0 VSS J7 GND N N Node V2 Out V1 Out .com SA2005F PRELIMINARY sames DataShee t4U.com http://www.sames.co.za .com DataSheet 4 U .com www..com PM2005FPD VP R32 470/1W VD D1 PH1 L1 LL1 47 Z1 0.47uF/250VAC D3 S10/275 R30 L2 0.47uF/250VAC D7 47V N LL2 1N4007 1N4007 47 Z2 N S10/275 D5 C14 L3 0.47uF/250VAC VN N S10/275 LL3 1N4007 1N4007 R33 470/1W D6 R31 47 Z3 C13 D4 470/25V U3 TL431 J6 N PH2 R29 1N4007 1N4007 C12 D2 VDD J4 VDD + C10 + C8 10u SK1 4 3 2 1 PH1 PH2 PH3 N GND .com Figure 10: Schematic Diagram of Power Supply + C11 470/25v U4 TL431 10/12 PH3 MAINS + C9 10u + C15 470uF/25V VSS VS VSS J5 .com DataShee PRELIMINARY sames www..com PM2005FPD NOTES: sames t4U.com .com DataShee http://www.sames.co.za .com 11/12 PRELIMINARY .com DataSheet 4 U .com www..com PM2005FPD PM9607AP DISCLAIMER: sames 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. t4U.com Any sales or technical questions may be posted to our e-mail address below: energy@sames.co.za .com 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 http://www.sames.co.za .com 12/12 PRELIMINARY .com DataSheet 4 U .com |
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