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Evaluation Board for the SA2005M and SA2005P Energy Metering IC's PM2005M/P
FEATURES + Designed to be used as fully functional Watt-Hour meter. + Better than Class 1 operation + On-board power supply + 3 Phase 4 Wire configuration + On-board current transformers + Measured energy pulse output LED + Individual phase direction indication + Individual phase fail and error condition indication DESCRIPTION
The SA2005M IC is a single-chip solution with pin programmable features. The SA2005P IC is also a single-chip solution and retrieves its configuration and calibration information from an external EEPROM. More detailed information specific to the SA2005M or SA2005P can be found in the applicable Datasheets. The PM2005M/P evaluation board has been designed to be a fully functional watt-hour meter for three-phase four-wire applications using either the SA2005M or SA2005P. 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.
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SA2005M specific: + Selectable dividing ratios for different rated conditions + Selectable calibration LED resolution and assuming mode SA2005P specific: + Calibration and setup data stored on an external EEPROM + Flexible programmable features
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SK1 VDD GND Power Supply GND VSS SA2005M SA2005P CT1 Resistor Network 7 8 9 LED PH3 PH2 PH1 PH/DIR CT3 Resistor Network MOP MON
VDD
VSS
VDD LED
Module Setup Jumpers / EEPROM
CT2
Resistor Network
VFAIL1 DIR1
VFAIL2 DIR2
VFAIL3 DIR3
0 0 0 0 0 0 Stepper motor
Figure 1: Block diagram
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PM2005M/P SETTING UP THE PM2005M/P 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
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Jumpers S4 to S6 set the calibration LED resolution (dividing ratio) as well as the summing mode (pin RE of the SA2005M). Please note that only one jumper should be closed at any one time. Closing more than one jumper may short circuit the power supply. Summing State Mode Only S4 closed Absolute sum Only S5 closed Total sum Only S6 closed Total sum S4, S5 and S6 open Absolute sum LED dividing ratio 4 1 4 1 Voltage Level on pin 8 of the SA2005 VDD VSS PH/DIR=100Hz Floating
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
Jumpers S7 to S9 sets the dividing ratio (counter resolution, pin IM of the SA2005M) for the SA2005M's motor drive output. Please note that only one jumper should be closed at any one time. Closing more than one jumper may short circuit the power supply. Dividing ratio (counter resolution) Voltage Level on Pin 9 of the SA2005 VDD VSS PH/DIR=100Hz Floating
State
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Only S7 closed 1 (100 pulse/kWh) Only S8 closed 100 (1 pulse/kWh) Only S9 closed 10 (10 pulse/kWh) S7, S8 and S9 open Test Mode
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Module Setup Jumpers The following jumpers (S1 and S9) are used to set the various dividing ratios, resolution and summing modes. Setup for use with the SA2005M Jumpers S1 to S3 set the rated conditions dividing ratio (pin RA of the SA2005M). Please note that only one jumper should be closed at any one time. Closing more than one jumper may short circuit the power supply. Voltage Level on Pin 7 of the SA2005 VDD VSS PH/DIR=100Hz Floating
Set-up for use with the SA2005P
Jumpers S1 to S9 must be removed (open), so as not to influence the functionality of the IIC bus operation. Jumper S10 may be used on certain IIC EEPROMS to protect the data written to the EEPROM. This jumper must be opened when programming the EEPROM.
State
Description of 3/3
Only S1 closed Select a multiplying ratio Only S2 closed Select a multiplying ratio of 1/3 Only S3 closed Select a multiplying ratio S1, S2 and S3 open of 2/3 Select a 1252Hz pulse rate at rated input conditions
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PM2005M/P CONNECTOR DESCRIPTION
SK1
Connects the three phase 4 wire supply to the module. J8 (SA2005P only) Programming interface for the IIC EEPROM.
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Note that the usual pull up resistors associated with devices on a IIC bus is integrated in the SA2005P IC. The SA2005P's CL input is a weak driver and can be overdriven by any external signal. Loading of this pin with external circuitry may influence the SA2005P's ability to reload its registers from the EEPROM.
Number 1 2 3 4 5
Signal Name VDD VSS SCL SDA RLOAD
SA2005P (U1) Pin 6 Pin 14 Pin 8 Pin 9 Pin 7
24C01 (U2) Pin 8 Pin 1, 2, 3, 4 Pin 6 Pin 5 NC
SK1
PH1
PH2
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PH3
N
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U1
PM2005M/P
J8 VDD VSS SCL SDA RLOAD U2 S10 VDD RA S1 RE S4 IM S7 VSS PH/DIR RA S3 RE S5 S6 IM S8 S9 S2
J3
J2
J1
J7 J6 GND J5 VSS J4 VDD
Figure 2: Jumper positions
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PM2005M/P
SETTING UP THE MODULE FOR ENERGY MEASUREMENT
Figure 3 below shows a typical setup for the PM2005M/P 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 PM2005M/P evaluation module is setup by default for
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3x230V/60A 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. As soon as a load is applied, the pulse LED L7 will start flashing and the energy counter will increment proportional to the energy measured.
Load
N PH1 PH2 PH3
SK1
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S10
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J3 J2 J1
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J7 S1 S4 S7 S2 S5 S8 S3 S6 S9 VSS J4 VDD J6 GND J5
Figure 3: PM2005M/P setup and connection
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PM2005M/P
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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.
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 SA2005M and SA2005P 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 (SA2005M or P pin 19) 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.
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.
CT TERMINATION RESISTOR The voltage drop across the CT termination resistor at rated Substituting the values result in: current should be at least 16mV. The CT's used have low RB = 23.44kW phase shift and a ratio of 1:2500. The CT is terminated with a RA = RB x ( 230V / 14V - 1 ) 3.6W resistor giving a voltage drop across the termination RA = 361.6kW t4U.com resistor 86.4mV at rated conditions (Imax for the meter)..com 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 the equation described in the Current Sense inputs section of the datasheet:
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Resistor values of R22, R24 are chosen to be 82kW and resistors R23 and R25 is chosen to be100kW each. The three voltage channels are identical so R14 = R16 = R18 = R20 = R22 = R24 = 82k and R15 = R17 = R19 = R21 = R23 = R25 = 100kW
J3
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.
R22 V1In 82k
R23 100k
R24 82k
R25 100k R13 22k
C1 R8 1u 1M
Pin 21
P1 10k
Neutral GND
I1 In
CT1 R26 3.6R
R1 2.7k
Figure 5: Mains Voltage Divider
Pin 23
R2 Neutral TZ76 GND 2.7k
Pin 22
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
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PM2005M/P
POWER SUPPLY
Referring to figure 9, 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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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.
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.
PCB DESIGN
The module represents a Class 1 meter that is designed to demonstrate the functionality and performance of the SA2005M or SA2005P metering circuits. The SA2005M/P is single chip solution for a three-phase meter that drives a Signal Routing mechanical counter. When the meter PCB is designed, it Most of the signal routing is done in such a manner that any should be taken into account that the SA2005 is a mixed signal signal coupling in to the measured signal will be a common .com mode noise signal and is rejected subsequently. Care should DataShee t4U.comintegrated circuit and special care should to be taken with the power supply and signal routing to the device. be taken that the signals to the SA2005 is not influenced by
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
other sources such as transformers with electric fields coupling in to the signals.
Calibration Calibration can be done by adjusting the trimpots (P1, P2, P3) connected to the three voltage inputs.
Imax 10 20 30 40 60 80
Vmax 230 230 230 230 230 230
RA PH/DIR PH/DIR VDD PH/DIR VDD PH/DIR
RE PH/DIR or VDD PH/DIR or VDD PH/DIR or VDD VSS or Open VSS or Open VSS or Open
IM VDD VDD VDD VDD VDD VDD
LED Pulse rate (Pulses/kWh) 3200 1600 1600 3200 3200 1600
Motor Pulse Rate (Pulses/kWh) 800 400 400 200 200 100
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PM2005M/P COMPONENT LIST
Items 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Part Type 1 / 16v / No Polarity 220n / 63v 1 / 63v 100n 10 / 16v 470 / 25V 470n / 250VAC 470 / 16V 1N4007 47V LED LED LED MOTOR OPTO Prog 2.7k 24k 1M 22k 82k 100k 3R6 47R / 2 Watt 470R / 1 Watt 680R Pot 10k MAINS Prog S10 / 275 SA2005M or SA2005P 24C01A TL431 TZ76
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Description Designator Capacitor Electrolytic Radial C1, C2, C3 Capacitor Monolithic Ceramic C4, C5 Capacitor Monolithic Ceramic C6 Capacitor Monolithic Ceramic C7 Capacitor Tantalum C8, C9 Capacitor Electrolytic Radial C10, C11 Capacitor Polyester C12, C13, C14 Capacitor Electrolytic Radial C15 Rectifier Diode D1, D2, D3, D4, D5, D6 47V Zener Diode D7 LED 3mm Diameter, Red L1, L2, L7 LED 3mm Diameter, Yellow L3, L4 LEC 3mm Diameter, Green L5, L6 2 Pin Molex, Canter Square pin, Friction Lock SK2 2 Pin Molex, Canter Square pin, Friction Lock SK4 5 Pin Molex, Canter Square pin, Friction Lock SK3 1/4 Watt, 1% Metal Film Resistor 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 .com 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 2 Watt, 1% Wire Wound Resistor R29, R30, R31 1 Watt, 1% Wire Wound Resistor R32, R33 1/4 Watt, 5%, Carbon Resistor R34, R35, R36, R37 Multi turn trim pot, Top adjust P1, P2, P3 7 Pin Molex, Canter square pin, Friction Lock SK1 5 Pin Header J8 Metal Oxide Varistor Z1, Z2, Z3 24 Pin IC Socket, Tulip Type U1 1k IIC EEPROM / Not fitted. For use with SA2005P U2 TO -92 Package U3, U4 1:2500, Current Transformer CT1, CT2, CT3
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PM2005M/P PCB LAYOUT
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Figure 6: PM2005M Top PCB layout
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Figure 7: PM2005M Bottom PCB layout
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PM2005M/P
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SK1 PH1
CT3
CT2
CT1
PH2
PH3
PM2005M/P.PCB
R29
R30
Z1
Z2
R31
N
R22
Phase 3 Calibrate R11 C3 P3 P2 R12 Phase 1 Calibrate Phase 2 Calibrate R4 U1 R27 R3 R10 SA2005P C7 SK3 VDD VSS SCL SDA RLOAD Prog IIC K07.8/s R37 RE S4 IM S7 LSD Energy Per kWh SK2 SK4 O1 L7 LED Pulses/kWh L6 DIR3 L4 DIR2 L2 DIR1 J4 VDD S8 S9 L5 VFAIL3 v S5 S6 IM Energy Direction per Phase J5 VSS RA SA2005M VDD D S1 VSS SS S2 PH/DIR RA S3 RE GND J6 J8 R28 U2 C4 R34 R35 S10 + R6 R5 C2
R18
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PM2005M/P
R9 R26 R1 R2 R8 C5 C7 C6 R36 C1
P1
R23
R20
R19
R24 R13
J3
R16
R15
R14
D4
D2
C9
R33
D3
CNT1
Motor
Opto
U3
C8
C15
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Figure 8: PM2005M Silkscreen PCB layout
D7
L3 VFAIL2
L1 VFAIL1
U4
R32
D6
D1
D5
Finish Start
c e
Finish Start
Finish Start
J7 C12
Z3
C13
C14
J2
J1
R25
R21
R17
C11
C10
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PM2005M/P
Neutral C2 R14 C1 100k R11 P3 B4 10k R12 P2 A4 10k R13 P1 GND R8 1u C2 1u C3 1u 1M R9 1M R10 1M C1 22k VDD 16 22k 680R 22k R37 VDD B2 R18 B3 J3 100k JUMPS2 82k A2 R22 A3 100k 82k R1 19 IIN1 IVN1 R2 18 IIP1 IVN2 2 IIN2 IVN3 3 20 2.7k GND R3 R27 3.6R R4 1 IIP2 DIR 9 2.7k 17 GND R26 3.6R 2.7k 100k 82k A1 R23 R24 R25 100k 82k B1 R19 R20 R21 J2 82k 100k JUMPS2 10k C3 C4 82k R15 R16 R17 J1 JUMPS2
GND
V3 In
PH1
SK4
1 2
V2 In
PH2
O1 4N35
Opto
V1In
PH3
U1 J10 OPTO/MICRO
CT1
J11 MICRO
VSS
TZ76
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Figure 9: Schematic Diagram for Metering Section
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L2 LED 680R R34
VSS 2.7k GND R5 5 IIN3 FOUT 8 2.7k R28 3.6R
CT2
VDD
TZ76
C4 220n GND VDD VSS C5 220n C6 1u
CT3
J8
R6 4 IIP3 PGM0 15 VREF TEST 14 VSS VDD 6 7 VDD VSS TCLK 10 12 VSS 2.7k PGM1 13
V3 Out GND R7 24k VSS
PGM1 J9
TZ76
PGM0
VSS J7 GND N N Node
V2 Out
V1 Out
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SA2005F
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PM2005M/P
VP R32 470/1W D1 PH1 L1 LL1 R29 1N4007 1N4007 C12 D2
VDD VD VDD J4
+ C10
470nF/250VAC 470/25V U3 TL431 D3 D4 1N4007 D7 47V N
47 Z1 N S10/275 R30 L2 470nF/250VAC LL2 1N4007 47 Z2 N S10/275 D5 C14 L3 470nF/250VAC VN N S10/275 LL3 1N4007 1N4007 R33 470/1W D6 R31 47 Z3 C13 PH2
+ C8
10u
SK1
J6 GND
4 3 2 1
PH1 PH2 PH3 N
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Figure 10: Schematic Diagram of Power Supply
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+ C11
470/25v PH3
MAINS
+ C9
10u
+ C15
470 VSS VS VSS J5
U4 TL431
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PM2005M/P PM9607AP DISCLAIMER:
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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.
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Any sales or technical questions may be posted to our e-mail address below: energy@sames.co.za
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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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