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Evaluation Board for the SA9904B Energy Metering IC PM9904BPD
FEATURES + Designed to
+ + + + be used together with accompanying software as fully functional three phase trivector meter. Better than class 1 operation. On board power supply. Two on-board LED's for active and reactive pulse output. 3 Phase 4 wire configuration. + + + + +
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On-board LCD display. On-board current transformers. Isolated connection to PC parallel port. Easy accessible test pins. Micro-controller plug-in support
DESCRIPTION
This application note describes the PM9904BPD evaluation board and together with the SA9904B data sheet provides a complete evaluation platform. The SA9904B is an accurate bidirectional power / energy measurement IC with serial (SPI) interface measuring active as well as reactive power / energy, RMS voltage and frequency. More detailed information specific to the of SA9904B can be found in its datasheet. The PM9904BPD module is designed for a three-phase fourwire applications, referenced to neutral. The mains voltages easily connect to module by way of a Molex connector (SK1). The 3 on-board current transformers measures the current in each phase. A simple capacitive power supply supplies the energy metering IC with power. The LM431 regulators are used to generate a 5 V supply voltage for the on-board optocouplers. Provision has been made to connect an external 5V power supply to drive the isolated opto-coupler. The SA9904B forms the energy/power metering front-end of the module and connects to the SPI bus. Sharing the SPI bus is the SA8807A LCD driver which is capable of driving 96 segments on a 4 back plane LCD. The PM9904BPD evaluation board is configured and calibrated via the parallel port of a PC. The data interface between the evaluation board and the PC is fully isolated. The PM9904BPD module can easily be connected to a microcontroller. The SAMES micro-controller board connects to the evaluation module by means of JP1 thereby creating a complete power meter without the PC interface. Physically the micro-controller board plugs into the evaluation module with its opto-coupler facing the mains connector (SK1). It shares the SPI bus with the SA8807A onboard LCD controller.
SK1 VDD GND Power Supply GND VSS LCD DISPLAY
PCVSS PCVDD
JP4
SK3
VDD
PCVDD
PCVSS
CT1
Resistor Network JP1
SA8807A JP2
CT2
Resistor Network
SA9904A J12 F50 JP3
CT3
PCVSS
Resistor Network Test Pins VDD VSS PCVSS Test Pins
Figure 1: Block diagram
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PM9904BPD JUMPER SETTINGS
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. Default closed Connects VSS to the metering circuitry. Default closed GND connection point. Connection point between the power supply GND (N) and the SA9904 GND. Default closed
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with the PM9904BPD module the jumpers must be closed, and can be left closed in the case of the SAMES micro-controller board. This board is capable of driving the SPI bus in this state. Default Closed. An additional output from the module is made available to the parallel port of the PC. The output can be selected to be the SA9904B's F50 output or it can be selected to be the modules push button output. Jumper Description PB (left connection) - Connects the push button output through a opto-coupler to pin 13 of the parallel port F50 (right connection) - Connects pin 7 of the SA9904 through a opto-coupler to pin 13 of the parallel port
Voltage selection jumpers
The following jumpers are used to select between 115V and 230V operation. When closed the series resistance in the voltage divider circuits to the voltage sense inputs are halved. Default Open. Jumper J1 J2 J3 230V OPEN OPEN OPEN 115V Closed Closed Closed Jumper J12
Parallel power supply jumper
Jumper JP4 is used to select the power source for the optocoupler U7. Power can be taken from the PC's parallel port or from an external 5 volt supply via SK3. Description Left connection - Power for U7 is taken from the PC's parallel port (pins 1, 14,16,17) Right connection - Connects U7 to SK3. An external power supply can be connected to SK3 to power U7.
SK1
Communication jumpers
Jumpers J8 to J11 connect pull up resistors to the SPI inputs of the SA9904. The pull up resistors are required by the open drain outputs of the HCPL2631 opto-couplers. If a PC is used
JP4
PH1
PH2
SK3
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PM9904AP JP4
JP2
Micro board PB JP3 J8 J9 J3 J10 J11 J7 SK2 Push button J6 GND J5 VSS J4 VDD J2 J1 J12 F50* JP1
*On some pcb's this may be labled as PB / F150, however f50 and f150 is the same connection.
Figure 2: Jumper positions
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PH3
N
PM9904BPD CONNECTOR DESCRIPTION
Jumper SK1 Description Connects the three phase 4 wire supply to the module. Female BD25pin connects the evaluation board to the PC parallel port by a 1 to 1 cable. The module is isolated from the PC by the opto-couplers. 5V supply to U7 opto coupler This header strip can be used for measuring the I/O pins of the SA9904B and SA8807. Note that this connector is on the same potential as the SA9904B. Provision is made for VDD and VSS so that a board with a micro controller can be easily fitted without any additional wiring. Signals available on this connector are: Pin number Signal SA9904 (U1) SA8807 (U2) 1 2 3 4 5 6 7 8 VDD VSS F50 SCK CS MISO MOSI CE Pin 6 Pin 14 Pin 7 Pin 8 Pin 13 Pin 9 Pin 12 NC Pin 13 Pin 26 NC Pin 18 NC Pin 20 Pin 19 Pin 21
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SETTING UP THE PM9904AP MODULE
Figure 3 below shows a typical setup for the PM9904BPD evaluation module. The three phase voltages are connected directly to SK1 and each corresponding phase current is wired through the on-board CT's. An external power supply can be connected to SK3 should the PC's parallel port not be able to source enough current for the module's opto-couplers. Figure 3 also shows the default jumper settings. The PM9904BPD evaluation module is setup by default for 3x 230V/80A operation. For 3x 115V operation jumpers J1, J2 and J3 need to be closed. Also capacitors C12, C13, and C14 values must be changed to 1uF / 150 VAC. When these hardware settings have been verified the user has the choice of using the micro-controller board or a PC to evaluate the SA9904B further. Please note when using the PC the micro-controller board should be unplugged to prevent a bus contention on the SPI bus, since the PC and microcontroller would be attempting to drive the bus simultaneously. Micro-controller board Once the board has been plugged into the evaluation module no further action is required, just apply power. PC After removing the micro-controller board the evaluation board can connected to the PC's parallel port using a 1 to 1 parallel cable (not supplied). Once the evaluation board has been connected to the PC and powered up, the supplied software can be launched. Refer to the next section for the software installation and setup details.
N PH1 PH2 PH3
SK2 SK3 JP1
MISO - Master In Slave Out MOSI - Master Out Slave In
Load
SK1
5V
JP4 Supp Sel
CT3
CT2
CT1
J3 J2 J1
JP2
J12 PB/F150 JP1 J8 J9 SPI Port
J7 J6 GND J5 VSS J4 VDD
To PC Parallel port
JP3
J10 J11 OUT
SK2
Figure 3: PM9904AP setup and connection
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PM9904BPD PM9904BPD EVALUATION SOFTWARE
Software for the SA9904AP module is supplied on one 3.5" 1.44MB floppy disk and is designed to communicate with the SA9904AP module via the PC's parallel port. The supplied software is written for DOS. Additional Windows software will be posted to the SAMES web site for downloading when available. The source code, written in Turbo C, is also included.
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Getting the SA9904 to generate pulses proportional to the energy measured.
Figure 4 is a flow diagram showing how to generate pulses proportional to energy measured by the SA9904A. The speed of execution is not critical, although it will influence the resolution of the pulses that is generated. It is recommended that the flow diagram be implemented together with a timer interrupt used for the creep timing. The same flow diagram is applicable for the SA9604A, but reading of the register values should be synchronized with changes in bit D19 of its frequency register.
File description
The following files are included on the floppy disk: 9904mtr.c This file contains the source for the functions that read the SA9904 registers, store these values in integration registers, check for any overflow and generate the corresponding energy pulse for the PM9904BPD on-board LED's. It makes provision to measure unbalanced energy per phase or sum the energy for each phase. The software does not make use of timers and relies on counting the software loops to generate reasonable delays for the LED outputs. pc_spi.c This file contains the source for all the SPI interface routines which are used to communicate between the PM9904BPD module and th e PC's parallel port. pc_lcd.c This file contains the source for all the functions relating to the SA8807 LCD driver IC, as well as other functions to switch on the LCD display icons. 9904mtr.exe This is the executable file.
Read Active Register
Subtract previous value
Check and fix register value wrapping
Add to active energy integrator
If integrator > threshold
No Wait for next measurement cycle Do other functions on the meter
Yes Subtract threshold from integrator
Load creep timer
Running the software
The program is executed by running the 9904mtr.exe file with the following arguments: 9904mtr.exe 1 10 The first parameter specifies the LPT port address to use where 1= 0x378 (LPT1) and 2 = 0x278 (LPT2). The second parameter is a loop delay. Larger values will slow down the SPI communication speed to the PM9904BPD module.
Generate pulse
Figure 4: Pulse flow diagram
Threshold and pulse rates
The active and reactive registers on the SA9904B increment at a rate of 320 000 counts per second at rated metering conditions for a sine wave. A single count of the active register corresponds to an amount of energy expressed in Watt seconds (Ws). Energy per count is (Ws): Epc = Vnom x Imax / 320 000
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PM9904BPD
where: Vnom is the mains voltage and correspond to 14A in the voltage inputs of the SA9904B. Imax is the maximum mains current to be measured and correspond to 16A on the current inputs of the SA9904B. The pulse rate required for a meter is usually expressed in pulses/kWh. A single pulse on the LED is mostly a fraction of a kWh and is converted to energy in Ws/pulse Energy per LED pulse is (Ws/pulse): Epp energy = 1000 x 3600 / Mpr where: Epp is energy per LED pulse Mpr is the meter pulse rate or meter constant in pulses/kWh The threshold is calculated by dividing the energy represented by a LED pulse by the energy per register count. Active energy threshold = Epp / Epc The threshold is thus the amount of energy to be measured (accumulated / integrated) by the meter before a LED pulse is generated.
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The simplest way to implement the creep threshold is to relate it to the time between meter pulses. If the time between pulses is more than the limit, the energy accumulator is cleared. Pulse rate of meter at rated conditions (Hz): Rf = ( Vnom x Imax / 1000 ) x ( Mpr / 3600 ) where: Vnom is the mains voltage and correspond to 14A in the voltage inputs. Imax is the maximum mains current to be measured and correspond to 16A on the current inputs of the device. Mpr is the meter pulse rate in pulses/kWh. Creep threshold time (s): Ct = 1/(Cc / Imax) x Rf where: Cc is the specified creep current; energy below this value is discarded. Imax is the maximum mains current to be measured and correspond to 16A on the current inputs of the device. Rf is the rated current frequency. The flow diagram (figure 6) for the timer interrupt shows how the time between pulses is measured, if the time since the last pulse is more than the time measured, the integrator is reset and a new count down is started.
Start Timer Interrupt
Pulse threshold Integrator Amplitude Threshold value subtracted from integrator
Integrator zero
No If LED On
Pulse LED
Yes Decrement LED ON timer
Pulse Generated Reg 8 add to Integrator Reg 4 add to Integrator Reg 0 add to Integrator
Yes If LED ON Timer = 0 Switch LED off
Figure 5: Implementation of an overflow integrator
No If creep timer > 0 Yes Decrement creep timer
Meter creep current
For the SA9904B meter creep must be taken care of in software. From the explanation above on how to generate pulses, the meter must also be prevented from pulsing in cases where the energy measured is less than the creep threshold as per the meter specification. The creep current is defined as the limit for measured energy, any energy less than the creep threshold is discarded, and energy above the creep threshold is measured.
Yes If creep timer = 0 No Exit Interrupt Reset integrator Load creep timer
Figure 6: Interrupt flow diagram
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PM9904BPD THE MICRO-CONTROLLER BOARD
OVERVIEW
This section describes the plug-in micro-controller board and should be read in conjunction with the evaluation software section, where basic metering software is described. The micro-controller's software was developed according to this section. The board plugs into the evaluation module as described earlier in this application note.
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Keys Four keys are provided of which one is connected to the microcontroller's reset pin. The other three are available to implement an HMI (Human Machine Interface) in the firmware; they're labelled Up/Down and Enter on the printed circuit board. Rate outputs Two LEDs are provided for active and re-active energy respectively. These pulse outputs can be coupled to an optocoupler via JP3/4 providing an output for external usage. This output-pulse selection is accomplished with a jumper on JP3/4 as follows: + Jumper on board's outside edge = a ctive + Jumper on board's centre pins = re -active + Jumper on board's inside edge = not used Miscellaneous Connectors JP1 and JP2 are provided to ease debugging during code development, all relevant signals are available. J1 in conjunction with SK2 are the two plug-in points to the evaluation module, where SK2 is the SPI connector and J1 merely a stabilising holder. The micro-controller is programmed via SK1 using the controller's ICSP (in circuit serial programming) capability, as described in the relevant MICROCHIP datasheet. If the intention is to program the board from MICROCHIP's PICSTART-programmer a buffer needs to be inserted in the VDD line to boost the programmer's output capability. An example of such a buffer is shown in Figure 8.
>5V
1
Figure 7: Micro-controller board Hardware The schematic is presented in Figure 18. As can be seen the major elements are: + micro-controller, + eeprom, + keys, + rate LEDs / opto-isolated rate pulse output + and miscellaneous connectors. Micro-controller A PIC 16F876-20/so is used to generate the rate pulses, in this application the micro uses a 20 MHz crystal (X1). This device has 8kB Flash ROM (program memory) and 368 Byte RAM (data memory). Detail information on the device can be obtained in the appropriate MICROCHIP datasheet. EEPROM A 93C46 EEPROM provides storage for non-volatile data, such as calibration factors. This device has 1 kB space available or stated differently 128 x 8bit words.
820K R1
100R R3
2N3906
I/P
2N3819 O/P
1.2M R5
820K R2
0V
Figure 8: Typical buffer circuit
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PM9904BPD
Firmware The micro-controller's code was created according to the guidelines set out in the evaluation software section. It is presented as a kick-start to experimentation with the microcontroller module and as such shouldn't be seen as the best (or only) possible implementation. The code was generated using Hi-Tech PIC C (v7.86PL4); the demo version on their www site (www.htsoft.com) is sufficient for experimentation. The program flow is presented in Figure 9. SPI Bit-banging SPI is used to aid portability to other micros, i.e. three port pins under direct software control creates SPI_CLOCK, MOSI and reads MISO. The SPI access of the SA9904B is divided into two tasks namely, fast and slow changing data. This is accomplished via an interrupt driven time-slicing architecture, with a basic timer tick of 10ms. Rate LEDs / opto-outputs The 10ms pulse widths on these outputs are derived from the basic timer tick. Creep The creep algorithm is simply: - if the time between two successive pulses is greater than a predefined maximum, the respective energy accumulator is cleared. The simplest
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method of deciding what the predefined value should be is to measure the time between two pulses at the lowest permissible load current, this is then expressed i.t.o basic timer ticks. User Interface A simple interface has been implemented using two of the three available keys. The Enter Key toggles display of consumed kWh and kVARh units. The Down Key displays per phase voltage and frequency data, each press shows the next phase's data. Memory Usage ROM: 4070 words or 50% of the total capacity RAM: Bank0 Bank1 Bank2 Bank3
86% 26% 83% ---
or 50% of the total capacity
Please refer to the readme. 1st file for any updated information not contained in this application note. The mentioned file is part of the source code that accompanies this module.
/* Switch Power on */ START
Setup Ctrler's ports and interrupts
init()
Displays the start-up screens on LCD Read voltage and frequency registers. User Interface interrupt service routine: 10ms ticks ctrl fast & slow tasks ctrl pulsing of rate LEDs Manage interrupt on keypress
boot_scrn() Read energy registers isr()
process_a_data() process_r_data()
END
/*Power off*/
Figure 9: Program flow
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PM9904BPD CIRCUIT DESCRIPTION
ANALOG SECTION
The analog (metering) interface described in this section is designed for measuring 3 x 230V/80A with precision better than Class 1. The most important external components for the SA9904B integrated circuit are the current sense resistors, the voltage sense resistors and the bias setting resistor. The resistors used in the metering section are of the same type to minimize any temperature effects.
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Voltage Divider
Referring to figure 11 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 phase 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 Combining the two equations gives: (RA + RB) / 230V = RB / 14V A 24kW resistor is chosen for R13 and a 1MW resistor is used for R8. Substituting these values result in: RB = 23.44kW RA = RB x (230V / 14V - 1) RA = 361.6kW Resistor values of R22, R24 are chosen to be 82kW and resistors R23 and R25 is chosen to be 120kW each. The three voltage channels are identical so R14= R16 =R17 = R18 = R20 = R22 = R24 = 82kW and R15= R17 =R19 = R21 = R23 = R25 = 120kW The capacitors C3, C4 and C5 is used to compensate for phase shifts between the SA9904's 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 50Hz x 1MW tan (0.18 degrees )) C = 1.013F
Bias Resistor
Pin VREF (SA9904B pin 15) is connected to Vss via R7 which determines the on chip bias current. With R7=47kW optimum conditions are set. VREF does not require any additional circuitry.
CT Termination Resistor
The voltage drop across the CT termination resistors should be at least 16mV at rated current (Imax). The on-board CT's have low phase shifts and have a ratio of 1:2500. Each CT is terminated with a 2.7W resistor resulting in a voltage drop of 86.4mV across each resistor at rated conditions.
Current Sense Resistors
Referring to figure 10 the resistors R1 and R2 define the current level into the SA9904B's current sense inputs (phase one IIP1 and IIN1). The resistor values are selected for an input current of 16A into the current inputs at rated conditions. According to equation described in the Current Sense inputs section of the datasheet: R1 = R2 = (I / 16A) x RSH / 2 = 80A /2500 / 16A x 2.7W / 2 = 2.7kW where: I = Line current / CT Ratio The three current channels are identical so R1 = R2 = R3 = R4= R5 = R6.
V1In
CT1 R26 2.7R
R1 2.7k
J3
Pin 19
V1In L1 R22 82k R23 120k R24 82k R25 120k
C5 R13 1u 24k
R8 1M
Pin 17
V1 Out
R2 TZ76 GND 2.7k
Pin 18
GND
Figure 10: Current input configuration
Figure 11: Mains voltage divider
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PM9904BPD
Power Supply
Referring to figure 15, 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.
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Power Supply routing and de-coupling
The 5V supply is de-coupled and routed directly to the power pins of the SA9904B by means of capacitor C15. Care was 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
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 subsequently rejected. Care should be taken that the signals to the SA9904B not be influenced by other sources such as electric fields from transformers etc.
THE SA8807A LCD DRIVER
OVERVIEW
The SAMES SA8807A Liquid Crystal Display (LCD) driver is capable of driving up to 96 LCD segments and is designed for displays having 3 or 4 track multiplexed back planes. The SA8807A includes an on-chip oscillator and needs only a single external capacitor. Communication to the SA8807A is via the Serial Peripheral Interface (SPI) which is shared with the SA9904B. This LCD driver is ideal for any micro-controller based system requiring a liquid crystal display of up to 12 seven-segment digits.
PCB DESIGN
The PM9904AP evaluation module represents a Class 1 meter and is designed to demonstrate the functionality and performance of the SA9904B metering integrated circuits. The SA9904B is mainly the analog front end of a meter. The SA9904B measures the energy, voltage and frequency which are made available to an external micro-controller, by way of JP1, or to a PC. When the meter 's PCB is designed, it should be remembered that the SA9904B inputs are analog and special care need to be taken with the power supply and signal routing to the SA9904B.
Protection
The SA9904B should be protected from the measuring environment. This is achieved by using resistor dividers to scale all the SA9904B's input signals. MOV's Z1, Z2, Z3 together with resistors R29, R30, R31 protect the power supply capacitors as well as the voltage sense inputs. The current setting resistors on the current sense inputs attenuates any common mode and asymmetrical transients.
USING THE SA8807A Oscillator
The SA8807A includes an on-chip oscillator that is controlled by a single external capacitor. Adjusting the capacitor value will change operating frequency of the SA8807A. The back plane multiplexing is a function of the SA8807A operating frequency. It is thus important to select the frequency high enough that the multiplexing of the display is not noticeable, but still within limits of the LCD display reaction time. f =7F x 0.1Hz / C f = Required oscillator frequency f / 8 = back plane multiplex rate for a 4 back plane display
Component placement
All the resistors on the SA9904B's current sense inputs should be placed as close as possible to the SA9904B. This eliminates the possibility of any stray signals coupling into the input signals.
SPI Interface
The SA8807A shares the SPI interface with the SA9904B and connects directly to the opto-couplers on the PM9904BPD evaluation board. The CE signal enables the SPI interface for the display driver and the CS signal enables the SPI interface for the SA9904B.
Ground Plane
The GND pin of the SA9904B is connected to the neutral phase, which is halfway between VDD and VSS. Note that supply bypass capacitors C1 and C2 are positioned as close as possible to the supply pins of the SA9904B, and is connected to a solid ground plane. Capacitor C6 is also positioned as close as possible to the supply pins of the SA9904B for proper supply bypassing.
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PM9904BPD
Commands
The demonstration software uses a buffer in memory on the PC to generate the complete display. The buffer is dumped to the LCD driver device in one go. The data passed to the driver IC is formatted with a starting address followed by the data for all segments. The first 8 bits is interpreted as address byte and the rest of the data is sequentially passed as data bytes. The address counter on the driver IC is incremented every 8 clocks. The procedure is repeated until all of the LCD memory is filled up.
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To write to the device the following address is passed: 1 0 A5 A4 A3 A2 A1 A0 Data
Data to the device is passed with MSB first D7 D6 D5 D4 D3 D2 D1 D0 Were D7 and D3 map to pin VR[3] of driver and COM4 of LCD Were D6 and D2 map to pin VR[2] of driver and COM3 of LCD Were D5 and D1 map to pin VR[1] of driver and COM2 of LCD Were D4 and D0 map to pin VR[0] of driver and COM1 of LCD See SA8807A datasheet for more information.
Address
The address of the data is set up in the following manner
Pin36 Pin35
Pin32
a
COM1
f
b
f
b
T2 T3 T4
DR-01255
Total Com
1
g
4
g
COM2
e
c d h
e d
c h
COM3
Cost
COM4
Pin1
Pin2
Pin5
COLUMNS
Figure 12: Mapping of a single character Address LCD Pin COM1, 17 COM2, 18 COM3, 19 COM4, 20 30 5f 5g 5e 5d 5 7 5a 5b 5c 5h 32 4f 4g 4e 4d 4 5 4a 4b 4c 4h 33 3f 3g 3e 3d 3 4 3a 3b 3c 3h 34 2f 2g 2e 2d 2 3 2a 2b 2c 2h 35 1f 1g 1e 1d 1 2 1a 1b 1c 1h 36 Cosi Total Com Cost 0 1 T1 T2 T3 T4
Table 1: LCD display memory map Address LCD Pin COM1, 17 COM2, 18 COM3, 19 COM4, 20 Blank Blank Blank T1, T2, T3, T4 23 Blank Blank Blank Total 11 21 k1 Hz ~1 ~2 10 16 k2 W s h 22 % Error imp/KWh Wh/imp ~3 9 15 V A r h 24 8f 8g 8e 8d 8 13 8a 8b 8c 8h 26 7f 7g 7e 7d 7 11 7a 7b 7c 7h 28 6f 6g 6e 6d 6 9 6a 6b 6c 6h
Table 2: LCD display memory map (continued)
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BACKPLANES
T1
Cosf
a

PM9904BPD THE LIQUID CRYSTAL DISPLAY
4-R1.0 1.0 2 3 . 0 0
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8.41
imp/kWh
8
.
321 Hz ~ ~ ~ k1 kWrh kWsh 8h k2 Wh/imp
%Error
5.0
1.5
b
.
0.8
.
6
a
1
g
c
1.5
.
f
17 x 2.54 = 43.180.1
27.6
.
10.02.0
.
e
d
0.5
0.
2
DETAIL OF DIGIT (1 ~ 8)
.
T4 TOTAL
.
FRONT POLARIZER
7
FRONT GLASS
0.250.05
4.0
5
REAR POLARIZER(Reflective)
T3
60.0 0.8
2.540.05
58.0
.
1.10.1
12.3
.
2.540.05
T2
.
REAR GLASS
3
.
T1
4.6
.
2
.
4.6
.
b
a
3.4
1
g
c
d
1h
.
8.41
t1
t2
t3
3.5
t4
T1Coso T2Total T3Com T4Cost
7.18
16.45
f
.
Figure 13: All the Icons and Dimensions of LCD
Pin COM1 COM2 COM3 COM4
DR-00902
4.0
1.0 Max.
Max.
1.0
36 cosf Total Com Cost
35 1f 1g 1e 1d
34 2f 2g 2e 2d
33 3f 3g 3e 3d
32 4f 4g 4e 4d
31
T1
Pin COM1 COM2 COM3 COM4
1 T1 T2 T3 T4
2 1a 1b 1c 1h
3 2a 2b 2c 2h
4 3a 3b 3c 3h
5 4a 4b 4c
6
4h
Table 4 : Mapping of display (continued)
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4.5
7.5
4.3
14.0 Min. Viewing Area
4.27
e
30 5f 5g 5e 5d
29
28 6f 6g 6e
27
26 7f 7g 7e
25
24 8f 8g 8e
23
22 %Error imp/KWh Wh/imp
21 k1 Hz ~1 ~2
23
COM3 COM4
T2
6d
T3
7d
T4
8d
Total ~ 3
Table 3 : Mapping of display 7 5a 5b 5c 5h 8 9 6a 6b 6c 6h 10 11 7a 7b 7c 7h 12 13 8a 8b 8c 8h 14 15 V A r h 16 k2 W s h 17 COM1 COM2 18
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Max.
2.8 2 . 5 0 . 2 0 . 6 0 . 6 . 2 16.8 0 . 6 0 . 6 2 . 5 0 . 2
4
0.65
.
7.8
3.1
1.6
8.3 8.0 Max.
2.13
1.95 2.4 1.4 1.9 7.5 4.5
23
PM9904BPD SCHEMATIC
C2 V3 In PH3 R14 82k C1 R15 120k B2 V2 In PH2 R18 82k B1 R19 120k A2 V1In PH1 R22 82k CT1 R26 2.7R A1 R23 120k R1 2.7k IVP1 R2 TZ76 GND CT2 R27 2.7R 2.7k R3 2.7k F50 SCK CS DI DO 7 8 13 12 9 2 18 IIP1 IVP2 IIN2 IVP3 17 20 3 19 R24 82k U1 IIN1 GND 16 GND R8 1M R9 1M R10 1M F50 SCK CS MOSI MISO SCK CS DI DO R20 82k J3 A3 R16 82k J2 B3 J1 C3 JUMPS2 R17 120k JUMPS2 R21 120k JUMPS2 R25 120k R13 24k C5 1u C4 1u C3 1u A4 B4 R12 24k C4 R11 24k
sames
JP1 F50 VDD VSS F50 SCK CS MISO MOSI CE VDD 1 2 3 4 5 6 7 8 SPI Port
R4 TZ76 GND CT3 R28 2.7R 2.7k R5 2.7k
1
IIP2
5
IIN3
R6 TZ76 GND V3 Out J7 V2 Out V1 Out GND N N Node VSS 2.7k R7 47k
4
IIP3
OSC1
10 X1 3.5795MHz
C2 220n
15 14
VREF VSS SA9904B
OSC2 VDD
11 GND 6 VDD VSS C1 220n C6 1u
Figure 14 : Schematic diagram of metering section
VP D1 R29 47 Z1 SK1 4 3 2 1 MAINS PH1 PH2 PH3 N N PH2 S10/275 R30 47 Z2 N PH3 C13 LL2 1N4007 1N4007 D7 47V N C12 LL1 1N4007 D2 1N4007
J4 VDD R32 470/1W VD VDD
PH1
+ C10
470/250VAC D3 D4 470/25V U3 TL431
+ C8
10u
J6 GND
470/250VAC D6 1N4007
+ C11
S10/275 R31 47 Z3 N C14 LL3 470/250VAC VN S10/275 D5 1N4007 470/25v U4 TL431 R33 470/1W
+ C9
10u
+ C15
470 VS VSS J5 VSS
Figure 15: Schematic diagram of power supply
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12/22
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SK3 1 2 PC 5V 5V PCVSS
PM9904BPD
O1 O2 O3 O4
R51 4.7R R50 4.7R R48 4.7R R49 4.7R
PC_OUT PCVDD C16 100n PCVSS C17 100n VSS VDD C18 100n
D6
R34 680R
U5 1 2 VCC 8 7
VDD
JUMPS2
J8
R44 4.7k
VDD
MOSI JUMPS2 J9 R45 4.7k SCK D3 VSS VDD D2
Figure 16: Schematic diagram of Isolated interface
R42 1k
L1 LED
PCVSS
JP4
3 5V PCVDD PC_OUT 6 D5 R35 680R 4 HCPL2631 GND 5
R43 1k
Supp Sel
L2 LED
PCVSS
SK2 1 14 2 15 3 16 4 17 5 18 6 19 7 20 8 21 9 22 10 23 11 24 12 25 13 PC O1 O2 D0 I0 D1 O3 D2 O4 D3 D4 D5 D7 D4
R36 680R
U6 1 2 3 6 VCC 8 7
VDD
JUMPS2
J10
R46 4.7k
13/22
CE JUMPS2 J11 R47 4.7k CS I0 I1 I2 I3 I4 PCVSS
JP2 1 2 3 4 5 6 IN JP3 D0 D1 D2 D3 D4 D5 D6 D7 O1 O2 O3 O4 PCVSS
R37 680R PCVSS PCVDD
4 HCPL2631
GND
5 VSS
D6 D7 I3 I4 I2 I1 PCVSS I1 I2 R40 4.7k 6 5 GND HCPL2631 PCVSS VSS 4 R39 680R SW-PB F150 R41 4.7k U7 8 7 2 3 VCC 1 R38 680R J12 PB/F50 PB1 VDD MISO
1 2 3 4 5 6 7 8 9 10 11 12 13 OUT
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VDD U2 13 22 28 25 C7 39n 26 23 27 VSS SCK MOSI MISO CS_D COM3 COM2 COM1 COM0 18 19 20 21 33 32 31 30 SCK MOSI MISO CE VR[3] VR[2] VR[1] VR[0] SA8807AF GND END M3 VDD RES V1 CLK VS[23] VS[22] VS[21] VS[20] VS[19] VS[18] VS[17] VS[16] VS[15] VS[14] VS[13] VS[12] VS[11] VS[10] VS[9] VS[8] VS[7] VS[6] VS[5] VS[4] VS[3] VS[2] VS[1] VS[0] 17 16 15 14 11 10 9 8 7 6 5 4 3 2 1 43 42 41 40 39 38 37 36 35 LNC LP23 LP21 LP16 LP22 LP15 LP24 LP13 LP26 LP11 LP28 LP9 LP30 LP7 LP32 LP5 LP33 LP4 LP34 LP3 LP35 LP2 LP36 LP1
PM9904BPD
Figure 17: Schematic diagram of LCD and Driver
LCD1 LP1 LP2 LP3 LP4 LP5 LP7 LP9 LP11 LP13 LP15 LP16 COM0 COM1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 LP36 LP35 LP34 LP33 LP32 LNC LP30 LNC LP28 LNC LP26 LNC LP24 LP23 LP22 LP21 COM2 COM3
OEL-7678
14/22
HR-LCD
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PM9904BPD
sames
Figure 18: Silkscreen PCB layout
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15/22
PM9904BPD PCB LAYOUT
sames
Figure 19: Top PCB layout
Figure 20: Bottom PCB layout
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16/22
PM9904BPD COMPONENT LIST (PM9904BPD BOARD)
Items 1 2 1 2 4 3 5 6 5 6 7 9 16 17 18 20 20 21 22 25 27 26 27 29 30 31 33 35 37 36 37 38 39 40 41 43 Part Type 100n 10 / 16V 1 / 16V / No Polarity 1 / 63V 220n / 63V 22n / 63V 470n / 250VAC 470 / 16V 470 / 25V Tz76 1N4007 47V LED SW-PB 2.7k 47k 1M 24k 4.7R 120k 1k 2.7R 4.7k 470R / 1 Watt 47R / 2 Watt 680R 82k MAINS PC PC 5V TL431 HCPL2631 3.5795 MHz S10 / 275 SA9904B SA8807AF Designator C16, C17, C18 C8, C9 C3, C4, C5 C6 C1, C2 C7 C12, C13, C14 C15 C10, C11 CT1, CT2, CT3 D1, D2, D3, D4, D5, D6 D7 L1, L2 PB1 R1, R2, R3, R4, R5, R6 R7 R8, R9, R10 R11, R12, R13 R48, R49, R50, R51 R15, R17, R19, R21, R23, R25 R42, R43 R26, R27, R28 R40, R41, R44, R45, R46, R47 R32, R33 R29, R30, R31 R34, R35, R36, R37, R38, R39 R14, R16, R18, R20, R22, R24 Sk1 Sk2 Sk3 U3, U4 U5, U6, U7 X1 Z1, Z2, Z3 U1 U2 Rectifier Diode Zener Diode LED 3mm Diameter Micro switch Description Capacitor Monolithic Ceramic Capacitor Tantalum Capacitor Electrolytic Radial Capacitor Monolithic Ceramic Capacitor Monolithic Ceramic Capacitor Monolithic Ceramic Capacitor Polyester Capacitor Electrolytic Radial Capacitor Electrolytic Radial
sames
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, 5%, Carbon Resistor 1/4 Watt, 1%, Metal Film Resistor 1/4 Watt, 5%, Carbon Resistor 1/4 Watt, 1%, Metal Film Resistor 1/4 Watt, 5%, Carbon Resistor 1 Watt, 1%, Wire Wound Resistor 2 Watt, 1%, Wire Wound Resistor 1/4 Watt, 5%, Carbon Resistor 1/4 Watt, 1%, Metal Film Resistor 7 Pin Molex, Center square pin, Friction Lock Db25, PCB Mount, Female 2 Pin Molex, Center square pin, Friction Lock TO -92 Package DIP 8 Package Crystal Metal Oxide Varistor 20 Pin IC Socket, Tulip Type 44 Pin PLCC IC Socket
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17/22
VDD R1 33k D1 1N4148 R2 640R C4 100n VSS D2 RST 1N4148 MCLR RA0 RA1 RA2 RA3 RA4 RA5 F50 RB1 RB2 RB3 RB4
VDD 20
OSCO
OSCI
OSC1/CLKIN OSC2/CLKOUT MCLR/VPP RC0/T1OSO/T1CKI RA0/AN0 RC1/T1OSI RA1/AN1 RC2/CCP1 RA2/AN2 RC3/SCK/SCL RA3/AN3/VREF RC4/SDI/SDA RA4/T0CKI RC5/SDO RA5/AN4/SS RC6 RB0/INT RC7 RB1 RB5 RB2 RB6 RB3 RB7 RB4 VSS VSS 8 19
VDD
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SK1 1 2 3 4 5 6 ISP MCLR VDD VSS RB3 RB6 RB7 J1 8 7 6 5 4 3 2 1 Holder N1 N2 N3 N4 N5 N6 N7 N8 JP1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 L 10 11 12 13 14 15 16 17 18 26 27 28 CS_D CS_A CS_M SCK MISO MOSI RC6 RC7 RB5 RB6 RB7 MCLR RA0 RA1 RA2 RA3 RA4 RA5 VSS OSCI OSCO CS_D CS_A CS_M SCK R JP2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 RB7 RB6 RB5 RB4 RB3 RB2 RB1 F50 VDD VSS RC7 RC6 MOSI MISO VSS C1 33p X1 20MHz VSS C2 33p
PM9904BPD
Figure 21: Micro-Controller Board Schematic
C3 100n
U1 9 1 2 3 4 5 6 7 21 22 23 24 25
VDD SK2 C5 1u RST VSS VDD VSS F50 SCK CS_A MISO MOSI CS_D 1 2 3 4 5 6 7 8 SPI Port S1 UP S2 DOWN S3 ENTER S4 RESET
18/22
L1 R3 VDD 1k Active L2 R4 VDD 1k Reactive RA1 RA0
PIC16F876-20/SO
VSS VSS
U2 CS_M SCK MOSI MISO 1 2 3 4 CS SCK DI DO 93C46 VCC NC ORG VSS
VDD 8 7 6 5 VSS
VDD JP3 RA0 RA1 RA2 1 2 3 Out Select R5 VSS1k U3 4N35 JP4 1 2 3 R6 10k SK3 1 2 Opto Out Q1 PNP
sames sames
PM9904BPD MICRO-CONTROLLER BOARD
ISP
sames
P A9904B2
sames
D1 R2 C4 R1 RB7 Q1 RB6 RB5 D2 U1 RB4 RB3 RB2 C1 RB1 F50 VDD VSS RC7 C2 C3 U2 MISO ENTER S3 RC6 MOSI R4 Reactive DOWN S2 R3 Active C5 UP S1 R5 RESET S4 R6 Opto Out
MCLR RA0 RA0 RA2 RA3 RA4 RA5 VSS OSCI OSCO CS_D CS_A
P A9904B2
CS_M SCK
Figure 22: Top PCB layout
Figure 23: Bottom PCB layout
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19/22
PM9904BPD
sames
ISP D1 R2 C4 R1 MCLR RA0 RA0 RA2 RA3 RA4 RA5 VSS OSCI OSCO CS_D CS_A C2 C3 U2 MISO ENTER S3 C1 RB1 F50 VDD VSS RC7 RC6 MOSI R4 Reactive DOWN S2 R3 Active D2 U1
sames
RB7 Q1 RB6 RB5 RB4 RB3 RB2 C5 UP S1 JP3/4 R5 RESET S4 R6 Opto Out
P A9904B2
CS_M SCK
Figure 24: Silkscreen PCB layout (Micro-controller board)
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20/22
PM9904BPD COMPONENT LIST (Micro-controller board)
Designator D1 D2 R5 R4 R3 C5 U3 R6 X1 R1 C2 C1 U2 C3 C4 R2 L1 S2 S3 JP4 J1 SK1 JP1 SK3 JP3 U1 Q1 JP2 S4 L2 SK2 S1 Part Type 1N4148 1N4148 1k 1k 1k 1u 4N35 10k 20MHz 33k 33p 33p 93C46 100n 100n 100R....1kW Active DOWN ENTER HEADER 3 Holder ISP L Opto Out Out Select PIC 16F876-20/SO PNP R RESET Reactive SPI Port UP Footprint MELF-MINI-D MELF-MINI-D 805 805 805 3528 DIP6 805 XTAL3 805 805 805 SO-8 805 805 805 LED3MM SW_PB_SMALL SW_PB_SMALL SIP3 SIP8 SIP6 SIP14 2PIN_MOLEX SIP3 SOL-28 SOT-23 SIP14 SW_PB_SMALL LED3MM SIP8 SW_PB_SMALL Description Si signal diode Si signal diode Resistor, 1% Resistor, 1% Resistor, 1% Capacitor, tantalum/10V Opto-coupler, medium speed Resistor, 1% Crystal Resistor, 1% Capacitor, ceramic Capacitor, ceramic e2prom, 1kB Capacitor, ceramic Capacitor, ceramic Resistor, 1% 3mm green Micro switch, push to make Micro switch, push to make 3 pin SIP pins 8 pin SIP socket 6 pin SIP pins 14 pin SIP pins
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2 Pin Molex, Centre square pin, Friction lock 3 pin SIP pins Micro-controller Any Si PNP, e.g. SMBT3906 14 pin SIP pins Micro switch, push to make 3mm red 8 pin SIP socket Micro switch, push to make
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21/22
PM9904BPD 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.
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 33 ELAND STREET LYNN EAST 0039 REPUBLIC OF SOUTH AFRICA
33 ELAND STREET KOEDOESPOORT INDUSTRIAL AREA PRETORIA REPUBLIC OF SOUTH AFRICA
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22/22

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