three-phase rogowski coil based e-meter solution

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TI Designs Three Phase Rogowski Coil Based E-Meter Solution TI Designs Design Features TI Designs provide the foundation that you need The board can be configured to: including methodology, testing and design files to 3-phase 0.2% energy metering solution quickly evaluate and customize the system. TI Designs Software di/dt integration and energy help you accelerate your time to market. calculation library provides for easy code development Design Resources Software integrator solution – minimal TIDM-3PHMETER- hardware changes to migrate from existing Tool Folder Containing Design Files ROGOWSKI C- based solutions MSP430F67791A Product Folder No effect of DC components of current TPS54060 Product Folder Current sensing immune to EMI No phase shift in current measurement ASK Our E2E Experts Featured Applications WEBENCH® Calculator Tools The applications are as follows: E-meter with Rogowski coil current sensors Utility metering Power quality meters Grid infrastructure meters An IMPORTANT NOTICE at the end of this TI reference design addresses authorized use, intellectual property matters and other important disclaimers and information. All trademarks are the property of their respective owners. 1 TIDU474 – September 2014 Three Phase Rogowski Coil Based E-Meter Solution Submit Documentation Feedback Copyright © 2014, Texas Instruments Incorporated

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Page 1: Three-Phase Rogowski Coil Based E-Meter Solution

TI DesignsThree Phase Rogowski Coil Based E-Meter Solution

TI Designs Design FeaturesTI Designs provide the foundation that you need The board can be configured to:including methodology, testing and design files to • 3-phase 0.2% energy metering solutionquickly evaluate and customize the system. TI Designs

• Software di/dt integration and energyhelp you accelerate your time to market.calculation library provides for easy codedevelopmentDesign Resources

• Software integrator solution – minimalTIDM-3PHMETER- hardware changes to migrate from existingTool Folder Containing Design FilesROGOWSKI C- based solutionsMSP430F67791A Product Folder • No effect of DC components of currentTPS54060 Product Folder

• Current sensing immune to EMI• No phase shift in current measurement

ASK Our E2E ExpertsFeatured ApplicationsWEBENCH® Calculator Tools

The applications are as follows:• E-meter with Rogowski coil current sensors• Utility metering• Power quality meters• Grid infrastructure meters

An IMPORTANT NOTICE at the end of this TI reference design addresses authorized use, intellectual property matters and otherimportant disclaimers and information.

All trademarks are the property of their respective owners.

1TIDU474–September 2014 Three Phase Rogowski Coil Based E-Meter SolutionSubmit Documentation Feedback

Copyright © 2014, Texas Instruments Incorporated

Page 2: Three-Phase Rogowski Coil Based E-Meter Solution

System Description www.ti.com

1 System DescriptionThis design, featuring the MSP430F67791A microcontroller, implements a highly integrated single chipelectricity metering solution with support for Rogowski Coil current sensors. Hardware and software designfiles are provided to enable calculation of various parameters for multi-phase energy measurement suchas RMS current and voltage, active and reactive power and energies, power factor, and frequency. Theadded hardware and software support for Rogowski coils make it easy to interface with Rogowski coilswith minimal hardware changes when migrating from traditional current transformers. The Rogowski coilcurrent sense library implements an efficient software integration of the Rogowski output, enabling this tobe a single chip solution for three-phase e-metering. The software package also includes a dummyapplication for quick and easy evaluation of the hardware and software.

2 Design FeaturesThis design is modelled after the EVM430-F6779 metering EVM, and has the same feature set as thatboard, except for the current measurement front-end, which has been modified to support Rogowski coils.Keeping a similar design as the CT based EVM enables easy migration from CT based solutions to aRogowski coil based current measurement solution. The software library has been developed to performintegration of the Rogowski coil output and calculate active, reactive and apparent powers, along withfrequency and optionally, RMS voltage and current. The library functions are easily accessible through anAPI, making it easy to develop host applications to run the library and run auxiliary functions like display,communications and calibration. A dummy application is also packaged with the software, featuring aUART based interface to interact with the meter. The RS232 port on the meter can be connected to a PCand the user can log the metering data, and read and write each phase's calibration data to the flashmemory using any serial port monitor (such as HyperTerminal).

3 Block DiagramFigure 1 shows the basic block diagram of the EVM. The phase voltages are fed to the microcontroller’sSigma-Delta ADC inputs after passing through a resistor divider. The di/dt output of the Rogowski coils arepassed through passive anti-aliasing filters before feeding into the controller’s sigma delta inputs. Noanalog integration or gain stage is needed for the Rogowski coil outputs, since the software takes care ofintegration, and each of the controller’s sigma delta blocks features a built in programmable gain amplifierwith a gain of up to 128.

The built in LCD controller of the MCU is used to interface with a 160 segment LCD for displaying themetering results, and an isolated RS-232 interface is used to communicate with a PC using the dummyapplication.

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Page 3: Three-Phase Rogowski Coil Based E-Meter Solution

www.ti.com Circuit Design and Component Selection

Figure 1. Block Diagram of Rogowski Coil EVM

4 Circuit Design and Component Selection

4.1 Power SupplyPower supply to the board can either be provided by the MSP430 FET programmer during debugging, orusing the switching power supply module on board. The switching power supply provides a single outputvoltage of 3.3 V directly from the ac mains at 100 V to 230 V RMS. In the configuration shown, the meteris powered as long as there is AC voltage on Phase C, corresponding to pad LINE 3 on the hardware andP3+1 on the schematic. The internal circuitry of a switching power supply is omitted from this applicationreport. For the drive of the power supply, refer to the documentation of the power supply module.

4.2 Analog InputsThe MSP430 analog front end, which consists of the ΣΔ ADC, is differential and requires that the inputvoltages at the pins do not exceed ±930 mV (gain = 1). To meet this specification, the current and voltageinputs must be divided down. In addition, the ΣΔ24 allows a maximum negative voltage of -1 V. Therefore,AC signals from mains can be directly interfaced without the need for level shifters. This section describesthe analog front end used for voltage and di/dt channels.

4.2.1 Voltage InputsThe voltage from the mains is usually 230 V or 120 V and must be brought down to a range of 930 mV.The analog front end for voltage consists of spike protection varistors followed by a simple voltage dividerand a RC low-pass filter that acts like an anti-alias filter. Figure 2 shows the voltage divider and anti-aliascircuit implemented on the board.

3TIDU474–September 2014 Three Phase Rogowski Coil Based E-Meter SolutionSubmit Documentation Feedback

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Page 4: Three-Phase Rogowski Coil Based E-Meter Solution

SM

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Software Description www.ti.com

Figure 2. Voltage Input Circuit

4.2.2 4.2.2 di/dt InputThe di/dt inputs from the Rogowski coils must be passed through a passive 2-pole RC filter in order toreject any high frequencies that may cause aliasing in the ADC, especially since the coils have a very highbandwidth. di/dt Input Front End illustrates the passive anti-alias filter used in the design. A TVS diode isprovided at the input in order to prevent the input to the sigma delta from going beyond the specifiedlimits.

di/dt Input Front End

5 Software DescriptionThis section describes the Softdidt Rogowski Coil metering library and the dummy application used to testand calibrate the EVM. The software is developed in the IAR Embedded Workbench for MSP430microcontrollers.

The software for the three-phase metrology using Rogowski coils is discussed in this section. Theapplication programmer’s interface (API) functions are described together with their function parametersand their return values. The software itself is supplied as a library, which exposes a clearly defined APIwith C prototyped function entry points, and which can be linked against application code, makingsoftware development easy. The following functionality is accessible using these API calls:• Configuration for run time adapting the library (calibration constants to include gain, phase, and zero

offset trim, other run time options such as choice of test pulse output)• Event capture for easy application interfacing (low line voltage, over current, reverse current)• Signal processing chain hooks for advanced users (intermediate calculation values)

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Page 5: Three-Phase Rogowski Coil Based E-Meter Solution

Energy Accumulation (x3 phases)

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www.ti.com Software Description

5.1 High-Level Architecture of the SoftwareSoftware Signal Flow describes the basic signal flow through the software. Voltage samples acquired bythe SD24 are passing through two high-pass filters before being corrected for the signal path delay.Current samples pass through a single high-pass filter for DC-removal before being integrated and passedon through an additional high-pass filter, which compensates for the cancellation of the pole of the firsthigh-pass filter in the integrator. After that, the filtered voltage and current samples are used to calculatethe active and reactive energy. They also can be accessed by the API calls. For the calculation of thereactive energy, the voltage samples are shifted by 90° before being multiplied with the current samples.For both paths, the calibration values for offset and gain are applied and the results are finally scaled tothe units published in the API documentation below.

Software Signal Flow

5.2 Energy Meter SoftwareThis section details the contents of the package and the available API calls. Note that only minoradjustments for the sensor are necessary and that all other functions can be used as-is.

5.2.1 Contents of the Library PackageThe package for the library contains the following files:• The file softdidt.h in the directory Library\include. This is the file containing the export definitions for the

API functions and their return codes and the setup definitions for the phases. The contents will bedetailed later in this guide.

• The file Library.r43 in the directory Library\Release. This is the Rogowski-coil software library againstwhich the application code needs to be linked.

• An example project in the directory Dummyapp is detailed later in this document.

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Page 6: Three-Phase Rogowski Coil Based E-Meter Solution

Software Description www.ti.com

5.2.2 API Functions

5.2.2.1 Initialization FunctionsThe following list the initialization functions.

DiDtInitLibrary()Prototype uint16_t DiDtInitLibrary(void)Parameters NoneReturn Value uint16_t version - library version number in the form 0xHHLLDescription Performs any required software initialization of the library.Comments 0xHH is the major version number and 0xLL is the minor version number;

changes to the major version number represent incompatible feature setchanges.

DiDtInitHardware()Prototype status_t DiDtInitHardware(const sensor_routing_t *adcchannels)Parameters sensor_routing_t * adcchannels - filled with the mapping between ADC

channel and sensor input, one for each phaseReturn Value status_t result – result codeDescription Informs the library of the hardware set up.Comments The library expects that the processor clock is already running at its high rate,

and this function call will configure the ADC channels and one timer needed torun.

DiDtInitSensors()Prototype status_t DiDtInitSensors(const sensor_setups_t *sensors)Parameters sensor_ setups_t * sensors - array of setup structures, one for each phaseReturn Value status_t result – result codeDescription Sets up any sensor to sensor variations for the attached Rogowski coils.Comments None

DiDtInitAccumulators()Prototype status_t DiDtInitAccumulators(const sensor_accumulators_t *sensors)Parameters sensor_accumulators_t * sensors - accumulator structure to updateReturn Value status_t result – result codeDescription Initialise the accumulator setComments This function is required to set the continuation point for the accumulators

after a power cycle, for example having retrieved them from non-volatilememory.

5.2.2.2 Obtaining Running ResultsThe following functions are used to obtain running results.

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www.ti.com Software Description

DiDtReadSnapshot()Prototype status_t DiDtReadSnapshot(sensor_results_t *sensors)Parameters sensor_results_t * sensors - result structure to updateReturn Value status_t result – result codeDescription Collects the last second snapshot of the sensor readings.Comments Calling this function at a rate faster than the accumulation period will merely

return the last snapshot multiple times. Callers can check if the data has beenupdated since the last poll by inspecting the sequence number, which isincremented once per accumulation period.

DiDTReadAccumulators()Prototype status_t DiDtReadAccumulators(sensor_accumulators_t *sensors)Parameters sensor_accumulators_t * sensors - accumulator structure to updateReturn Value status_t result – result codeDescription Reads the current accumulator set.Comments Calling this function at a rate faster than the accumulation period has no

effect, the accumulators are read only.

5.2.2.3 Runtime ChangesThe following functions are for runtime changes.

DiDtAdjustTestPulse()Prototype status_t DiDtAdjustTestPulse(const test_pulse_t *setting)Parameters Test_pulse_t setting - pointer to test pulse settingsReturn Value status_t result – result codeDescription Updates the test pulse settingsComments A setting change also clears out the internal pulse accumulator since it would

be in the wrong scale; this is therefore also the case at startup when callingthis function for the first time.

5.2.2.4 Registering Callout FunctionsThe following functions are for registering callout functions.

DiDtRegisterMetrologyCallout()Prototype status_t DiDtRegisterMetrologyCallout(metrocallout_t function, void *param)Parameters status_t DiDtRegisterMetrologyCallout(metrocallout_t function, void *param)

void * param - An opaque parameter to pass to the function when it is calledReturn Value status_t result – result codeDescription Registers a single function with the library that will be called when a metrology

event occursComments None

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Software Description www.ti.com

DiDtRegisterSampleCallout()Prototype status_t DiDtRegisterSampleCallout(samplecallout_t function, void *param)Parameters samplecallout_t function - Function to register, or NULL to deregister void *

param - An opaque parameter to pass to the function when it is calledReturn Value status_t result – result codeDescription Registers a single function with the library that will be called when raw sample

data is available for each phase.Comments None

5.2.3 Data TypesThe following data types are used in addition to those in <stdint.h> per ISO9899:1999.

Table 1. Data Types

Data Type Descriptionbool_t A boolean taking the values TRUE (!FALSE) or FALSE (0) onlystatus_t An alias of uint16_t for returning success or error codesadcchannel_t An alias of uint16_t for specifying an ADC channel numberadcgain_t An alias of uint16_t for specifying the ADC gain valuemetro_reason_t An alias of type uint16_t containing reason codes which may be passed to callout

functions to inform the application code that some interesting event has occurred withinthe metrology. The codes are detailed in Section 4.2.5.

metrocallout_t A function pointer called when the library has interesting events to report, called with asubreason code indicating the event of interest, and the opaque handle that wassupplied when the function pointer was registered

samplecallout_t A function pointer called when the library has interesting events to report, called withthe filtered voltage and current sample, and the opaque handle that was supplied whenthe function pointer was registered

phasemask_t A bitmap of active phases when passing multiple structures around

5.2.4 Data StructuresThe data structures used in the library and the API functions can be found in the header file softdidt.h. Inthis header file, the scaling of the different results is also explained. The two main structures usedthroughout the software, sensor_results_t and sensor_accumulators_t, contain the measurement resultsthat are detailed in Section 5.2.4.1 and Section 5.2.4.2. The structures used during calibration of thesystem are outlined in their respective sections.

5.2.4.1 sensor_results_tTable 2 describe the fields in sensor_results_t.

Table 2. Fields in sensor_results_t

Variable Type Scaling RemarkVrms Uint16_t V*2-7 RMS VoltageIrms Uint16_t V*2-8 RMS Currentwh Uint16_t Wh/s*2-8 Active Energyvarh Uint16_t VARh/s*2-8 Rwatts Uint16_t W Instantanous Active Powerline_frequency Uint16_t Hz*2-10 Frequencywh_forward Uint8_t - Direction of Wh (Fwd=1)

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Page 9: Three-Phase Rogowski Coil Based E-Meter Solution

www.ti.com Meter Demo

Table 2. Fields in sensor_results_t (continued)Variable Type Scaling Remarkvarh_forward Uint8_t - Direction of VARh (Fwd=1)sequence Uint8_t - Free running sequence number

5.2.4.2 sensor_accumulators_tThis structure contains the current results for each phase in a sub-structure “phases” of the typesensor_accumulator_t and the phasemask defining the phase(s) used.

Table 3. Fields in sensor_accumulators_t

Variable Type Scaling Remarknet_wh int64_t Wh *2-8 Net Wh (active)net_varh int64_t VARh *2-8 Net VARh (reactive)

5.2.5 Callout ReasonsThe following reason codes may be passed to the callout functions to inform the application code thatsome interesting event has occurred within the metrology.

Table 4. Metrology Callout Reasons

Definition DescriptionSUBREASON_VOLTAGE_SAG Voltage sag in progressSUBREASON_OVER_CURRENT Gross over-current detectedSUBREASON_REVERSE_CURRENT Reverse current detectedSUBREASON_SUSPECT_FREQUENCY Suspect mains frequencySUBREASON_ACCURACY_LOST Calculation accuracy error detected.

NOTE: The library manages the intermediate accuracyinternally; therefore, this code is not currently used.

SUBREASON_NEW_SNAPSHOT New summation results are available

6 Meter Demo

6.1 EVM Overview

6.1.1 Loading the Example CodeOpening the ProjectThe source code is developed in the IAR™ IDE using IAR compiler version 6.x. The project files cannotbe opened in earlier versions of IAR. If the project is loaded in a version later than 6.x, a prompt to createa backup is displayed, and you can click YES to proceed. For the first time it is recommended tocompletely rebuild the project.

Open IAR Embedded Workbench, find and load the project Dummyapp.ewp, and rebuild all. (Refer toRebuilding the Project).

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Meter Demo www.ti.com

Rebuilding the Project

Load the project onto the EVM by clicking “Debug and Download” from the Project drop down menu. Thiswill launch the application.

Calibrating Over Rs232Calibration is best performed using a meter test station and test pulse, but a rough calibration can beperformed using a known current and voltage source via the serial terminal. Connect to the display PCBvia the isolated serial port using 9600bps 8N1 and no handshaking. The description here describes a zerooffset calibration of just one phase, but in a production situation all three phases could be zero offsetcalibrated in parallel, with the addition of more complex software.

To start calibration:

Select the phase to operate on, here, using phase Aphase=0and read back the active settings using read

If the flash memory has been erased the values will all be 0xFFFF, a sensible initial set of values to startwith would be to enter the following assignments:

wh_gain=16384

wh_offset=0

varh_gain=16384

varh_offset=0

delay=0

creep_threshold=0

write

Zero OffsetApply a known current of 15A and 240V and 0, this is convenient because it is 3600W per phase (which ininternal units corresponds to 256 × 2-8Wh/s). The actual current should merely be selected to be wellaway from zero.

Turn logging on and observe the output values over a couple of seconds. Sum the values for each phaseand divide by 256, this coarse correction should then be applied to the default of 16384 set earlier. Forexample

log=1A, +230, -2, 3234B, +260, +1, 3656C, +255, -3, 3585A, +233, -2, 3235B, +260, +1, 3656C, +256, -3, 3600wh_gain=18118

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www.ti.com Test Results and Calibration

Rebuilding the Project (continued)calculated as (16384 × 2 × 256) / (230 + 233) = 18118

Apply zero current to the meter and accumulate energy over a reasonable period of time, in this example30 seconds is selected

zero offset=30

the meter will calculate the correction factor and update the local RAM copy.

Delay trimSet the test load to 15A and 240V and 60, adjust the delay register in the range 0-255 to achieve anoutput of 128 × 2-8Wh/s.

Gain trimApply a known current of 15A and 240V and 0, check the gain having set the phase and zero offset.Having applied the new calibration values, the results can be committed to flash using the write command.In the event of a mistake, the modified values can be discarded by either selecting another phase with the‘phase’ command or reading back the stored settings with ‘read’.

7 Test Results and Calibration

Metrology ResultsThe metrology results obtained by using a metrology test setup are shown in Error (%) vs. Input Current(A), at 230V, 50Hz. The meter was tested from 0.05A to 100A (Dynamic range of 2000:1) at 230V, and 0⁰,+60⁰ and -60⁰ current. The test pulse generated by the meter was fed into the test setup which comparedthe test pulse frequency against the actual power to generate the error percentage.

Error (%) vs. Input Current (A), at 230V, 50Hz

8 Design FilesThis section provides the schematics and layout images used for this design.

8.1 SchematicsThe schematics are presented in the following order:

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Page 12: Three-Phase Rogowski Coil Based E-Meter Solution

Clock Headers

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S8/P10.0 79S7/P10.1 80S6/P10.2 81S5/P10.3 82S4/P10.4 83S3/P10.5 84S2/P10.6 85S1/P10.7 86S0/P11.0 87

CB3/TA3.1/P11.1 88TA1.1/P11.2 89TA2.1/P11.3 90

CBOUT/P11.4 91TRCCLK/TACLK/P11.592

BSL_TX/PM_TA0.0/P2.093BSL_RX/PM_TA0.1/P2.194

PM_TA0.2/P2.2 95PM_TA1.0/P2.3 96SBWTCK/TEST 97

TDO/PJ.0 98TCLK/TDI/PJ.1 99

TMS/PJ.2 100TCK/PJ.3 101

SBWTDIO/NMI/RST102

SD

0P

0103

SD

PN

0104

SD

1P

0105

SD

1N

0106

SD

2P

0107

SD

2N

0108

SD

3P

0109

SD

3N

0110

VA

SY

S2

111

AV

SS

2112

VR

EF

113

SD

4P

0114

SD

4N

0115

SD

5P

0116

SD

5N

0117

SD

6P

0118

SD

6N

0119

AV

SS

1120

AV

CC

121

VA

SY

S1

122

AU

XV

CC

2123

AU

XV

CC

1124

VD

SY

S125

DV

CC

126

DV

SS

1127

VC

OR

E128

123456789

10111213141516171819202122

44434241403938373635343332313029COM0COM1COM2COM32423

LCD1

C35

C29

C26 C24 C44 C34

C32

C38

C22 C30C31 C28 C23

C36C33

R36

12

SV1

34

R5

9

R6

0

R6

1

R5

8

12345

SV2

R4

9

R5

2

R4

2R

43

R4

6

R4

5R

44

R4

0

R4

1

123

JP4

123

JP5 123

JP6 123

JP7 123

JP8 123

JP9

R48

C27 C25 C43

1JP2

2

LE

D_

AC

T

LE

D1

LE

D2

LE

D3

LE

D_

RE

AC

T

LE

D4

LE

D5

LE

D6

1234

DGND

1234

DVCC

C49

12

BT

N4

12

BT

N2

12

BT

N1

12

BT

N3

12

RE

SE

T

1JP13

C63

R4

R99

R100

R101

R102

R103

123

AU

XV

CC

3

12

HD1D44

TDO

TDO

TDO

TDI

TDI

TMS

TMS

TCK

TCK

TCK

S4

S4

S5

S5

S6

S6

S7

S7

S10

S10

S11

S11

S12

S12

S13

S13

S14

S14

S15

S15

S16

S16

S17

S17

S18

S18

S19

S19

S20

S20

S21S

21

COM0

COM0

COM1

COM1

COM2

COM2

COM3

COM3

S8

S8

S9

S9

R13

R13

R23

R23

R33

R33

S22

S2

2S23

S2

3

S1

S1

VR

EF

VR

EF

S0

S0

S2

S2

S3

S3

AV

CC

AGND AGND

DGND

DGND DGND

DV

CC

DVCC

DV

CC

V1

+V

1-

I1+

I1-

I2+

I2-

V2

+V

2-

V3

+V

3-

I3+

I3-

IN+

IN-

INTEXT

S39

S3

9S38

S3

8S37

S3

7S36

S3

6S35

S3

5S34

S3

4S33

S3

3S32

S3

2S31

S3

1S30

S3

0S29

S2

9S28

S2

8S27

S2

7S26

S2

6S25

S2

5S24

S2

4

RESET

RESET

BTN1

BTN1

BTN2

BTN2

LE

D1

LED1

LE

D2

LED2

LE

D3

LED3

LE

D4

LE

D4

VA

SY

S1

/2

VA

SY

S1

/2

VA

SY

S1

/2

VA

SY

S1

/2

VC

OR

E

VC

OR

E

AU

XV

CC

1

AU

XV

CC

1

AUXVCC1

AU

XV

CC

2

AU

XV

CC

2

AUXVCC2

AU

XV

CC

3

AUXVCC3

AUXVCC3

DVSYS_VDSYS

DV

SY

S_

VD

SY

S

DV

SY

S_

VD

SY

S

DVSYS_VDSYS

RS232_RXDRS232_TXD

EZ-RF_RXDEZ-RF_TXD

SDA

SDA

SCL

SCL

AC

T

ACT

RE

AC

T

RE

AC

T

LE

D6

LED6

LE

D5

LED5

SMCLK

SMCLK

MCLK

MCLK

ACLK

ACLK

IR_TXDIR_RXD

IR_SD

BTN3

BTN3

BTN4

BTN4

XOUT

XOUT

XIN

XIN

DRESET

DRESET

DTCK

DTCK

DTMS

DTMS

DTDI

DTDI

DTDO

DTDO

TEST/SBWTCK

TEST/SBWTCK

TEST/SBWTCK

RF

_S

OM

IR

F_

SIM

OR

F_

CL

K

RF_VREG_ENRF_RESETCCRF_CCA

RF_SFD

RF_GPIO1RF_GPIO2RF_CS

RF

_F

IFO

PR

F_

FIF

O

CBOUT

CBOUT

VMON

RTCCLK

RTCCLK

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

L

K

I

H

G

F

E

D

C

B

A

16151413121110987654321

A

B

C

D

E

F

G

H

I

K

L

MSP430F67791

MSP430F6779IPEU

+

Design Files www.ti.com

Figure 3. Schematics Page 1

12 Three Phase Rogowski Coil Based E-Meter Solution TIDU474–September 2014Submit Documentation Feedback

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Page 13: Three-Phase Rogowski Coil Based E-Meter Solution

Analog Front-End (Voltage)Analog Front-End (Current)

47p

47p

47p

47p

15n

15n

AGND

AGND

AGND

AGND

330k 330k 330k

2.3

7K

1k

330k 330k 330k

2.3

7K

1k

1k

1k

S2

0K

27

5S

20

K2

75

EXCML20A

EXCML20A

SM

AJ5

.0C

AS

MA

J5

.0C

AS

MA

J5

.0C

A

47p

47p

15n

AGND

AGND

330k 330k 330k

2.3

7K

1k

1k

S2

0K

27

5

EXCML20A

EXCML20A

SM

AJ5

.0C

A

AGND

AGND

AGNDAGND

12

k

4.3k

4.3k

12

k

4.3k

4.3k

47n47n

47n 47n

1n

AGND

12

k

4.3k

4.3k

12

k

4.3k

4.3k

47n47n

47n 47n

1n

AGND

12

k

4.3k

4.3k

12

k

4.3k

4.3k

47n47n

47n 47n

1n

AGND

12

k

4.3k

4.3k

12

k

4.3k

4.3k

47n47n

47n 47n

1n

C2

C11

C1

C9

C8

C10

R5 R6 R7

R1

5

R14

R8 R9 R10

R1

7

R16

R32

R33

R1

R2

L1

L3

TV

S2

TV

S3

TV

S4

C3

C13

C12

R11 R12 R13

R1

9

R18

R34

R3

L5

L6

TV

S1

LINE1

LINE2

LINE3

NEUTRAL

I1+

I1-

I2+

I2-

I3+

I3-

IN+

IN-

R2

2

R21

R23R2

6

R27

R28

C7C18

C19 C20

C7

6

R2

9

R30

R31R1

04

R105

R106

C5C16

C17 C64

C6

5

R1

22

R123

R124R1

25

R126

R127

C77C78

C79 C80

C8

1

R1

28

R129

R130R1

31

R132

R133

C82C83

C84 C85

C8

6

V1+P1+1

I1+

I1-

V1-

V2+

V2-

P2+1

AGND

AGND

V3+

V3-

P3+1

IN-

NEUTRAL

NEUTRAL

NEUTRAL

LINE1

LINE2

LINE3

CUR1+CUR1+

CUR1-CUR1-

CURN-

CURN+ IN+

I3-

I3+

CUR3-

CUR3+

CUR2+

CUR2-

I2+

I2-

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

L

K

I

H

G

F

E

D

C

B

A

16151413121110987654321

A

B

C

D

E

F

G

H

I

K

L

V2

V1

V3

www.ti.com Design Files

Figure 4. Schematics Page 2

13TIDU474–September 2014 Three Phase Rogowski Coil Based E-Meter SolutionSubmit Documentation Feedback

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Page 14: Three-Phase Rogowski Coil Based E-Meter Solution

DVCC

2.2uF10

0u

F/1

00

V

0.22uF/305VAC

0.22uF/305VAC

Vsupply

1N4007

1N4007

1N4757A

1N4757A

0

0.22uF/305VAC1N4007

1N4757A1

50

uF

0.1

uF

SMAJ5.0ABCT

4.7u/400V

TPS54060_DGQ_10

1M

33

.2K 1M

0.01uF

0.1

uF

100

100

100

22

.1k

.056uF 100pF

NEUTRAL

NEUTRAL

NEUTRAL

B1

60

1mH

47uF

NEUTRAL

51

.13

1.6

k1

0k

NEUTRAL

C48

C1

02

C46

C50

D20

D22D21

D19

R39

C39D18

D17

LL

NN

NCNC

26 26

22 22

VO+ VO+

VO- VO-

C1

01

C4

2

ZD

3

C100

123

JP

3

BOOT1

VIN2

EN3

SS/TR4

RT/CLK5 PWRGD 6VSENSE 7

COMP 8GND 9

PH 10

U3

R3

5R

37

R3

8

C45

C4

7

R92

R93

R94

R9

5

C60 C61

D2

3

L7

C62

R9

6R

97

R9

8

VCC_PL

VCC_PL

DGND

DGND

NEUTRAL

NEUTRAL

VCC_ISO

VCC_ISO

P1+1

P2+1

P3+1

P3+1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

L

K

I

H

G

F

E

D

C

B

A

16151413121110987654321

A

B

C

D

E

F

G

H

I

K

L

+

+

VCC Select

Un-isolated VCC from AC Mains

Isolated VCC from AC Mains

Design Files www.ti.com

Figure 5. Schematics Page 3

14 Three Phase Rogowski Coil Based E-Meter Solution TIDU474–September 2014Submit Documentation Feedback

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Page 15: Three-Phase Rogowski Coil Based E-Meter Solution

RF Daughter Card

IR Pulse In/OutIsolated RS232 Communication

EZ-RF Connect

Act / React

EEPROM

DGND

DGND

DGND

PS8802

PS8802

SL127L6TH

1kTIL191

VCC

10

uF

0.1

uF

DGND

1kTIL191

VCC

DGND

DVCC

0000

00000000

0

00

DVCC

DVCC

47

DGND

0.1uF

4.7uF

DGND DGND

2.2k

68

DVCC

DNP

1.5k

1k1

0k

22

0

BC857BSMD

BC857BSMD

0.1

uF

LL103A

10uF

10uF

LL103A

LL103A

LL

10

3A

1k

2.2k

DN

P

0.1uF

DGNDDGND

24C02CSN

0.1

uF

DVCC

DGND

DGND

DGND

000

162738495

RS-232

G1

G2

2

3

78

5

6

U1

2

3

78

5

6

U2

1

RX

_E

N

21

TX

_E

N

2

1 23 45 67 89 10

11 1213 1415 1617 1819 20

RF2RF2

1 23 45 67 89 10

11 1213 1415 1617 1819 20

RF1RF1

EZ-RF

21

43

56

R68

1

2 3

4OPTO1

C5

8

C5

9

1JP11

2

R72

1

2 3

4OPTO2

1JP12

2

R74R76R80R82

R75R81R83R84R85R86R88R91

R87

R90R89

VCC2TXDRXDSDVCC1GND

R4

7

C52

C51

R69

R65R66

R67

R62R

63

R6

4Q2

Q1

C5

4D24

C56

C55

D26

D25

D2

7R

78

R71

R7

0

C57

84

SCL6

SDA 5

A01A12A23

WP7VCC

GND

IC1

C4

1

R79R77R73

1

ACT

2

1

REACT

2

RF_FIFORF_FIFO

RF_FIFOPRF_FIFOP

RF_SFDRF_CCA

RF_SOMIRF_SIMORF_CLKRF_CS

UART_TX

DVCC

DVCC

DVCC

DGND

RF_GPIO2

ACTIR_SD

IR_RXDIR_TXD

REACT

DB9_-12V

DB9_GND

DB9_+12V

UART_RXRS232_RXD

RS232_TXD

EZ-RF_TXD

EZ-RF_RXD

SCL

SDA

RF_RESETCC

RF_RESETCC

RF_VREG_EN

RF_GPIO1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

L

K

I

H

G

F

E

D

C

B

A

16151413121110987654321

A

B

C

D

E

F

G

H

I

K

L

IRDA

Arr

ay

EE

PR

OM

www.ti.com Design Files

Figure 6. Schematics Page 4

Bill of Materials

15TIDU474–September 2014 Three Phase Rogowski Coil Based E-Meter SolutionSubmit Documentation Feedback

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Design Files www.ti.com

Table 5. BOM

Qty Value Digikey # Description Eagle Library Package Board Designator1 24C02CSN 24LC02B-I/SN-ND IC EEPROM 2KBIT 400KHZ 24C02CSN IC1

8S1 32.768 KHZ 300-8341-1-ND CRYSTAL 32.768 KHZ 6PF LF Crystal XT1

SM2 12pF 311-1059-1-ND CAP CER 12PF 50V 5% NPO C-EUC0603 C37 C404 1n 399-1136-1-ND CAP CER 0.001UF 50V 10% C-EUC0805 C65 C76 C81 C86

X3 15n 311-1143-1-ND CAP CER 0.015UF 50V 10% C-EUC0805 C8 C10 C12

X16 47nF 399-8092-1-ND CAP CER 0.047UF 25V Y5V C-EUC0805 C17 C19 C5 C7 C16 C18

060 C20 C64 C77 C78 C79 C80C82 C83 C84 C85

9 100nF 311-1343-1-ND CAP CER 0.1UF 50V Y5V C-EUC0603 C23 C25 C27 C28 C30 C31060 C33 C36 C43

7 0.1uF 311-1343-1-ND CAP CER 0.1UF 50V Y5V C-EUC0603 C41 C42 C52 C53 C54 C57060 C59

2 0.47uF 311-1428-1-ND CAP CER 0.47UF 16V 10% C-EUC0603 C38 C44X7

9 4.7uF 311-1455-1-ND CAP CER 4.7UF 10V 10% C-EUC0603 C22 C24 C26 C29 C32 C34X5R C35 C51 C49

6 47p 311-1484-1-ND CAP CER 47PF 500V 5% C-EUC0805 C1 C2 C3 C9 C11 C13NPO

1 10uF 399-3685-1-ND CAP TANT 10UF 6.3V 20% CPOL-USCT3216 C55 C56 C5812

1 4.7u/400V 399-6097-ND CAP ALUM 4.7UF 400V 20% CPOL-USE5-10.5 C100R

8 - 3M9447-ND CONN HEADER VERT SGL JP1E ACT JP2 JP11 JP12 REACT2P RX_EN TX_EN HD1

8 - 3M9448-ND CONN HEADER VERT SGL JP2E JP3 JP4 JP5 JP6 JP7 JP83P JP9 JP10 AUXVCC3

8 - 961105-6404-AR CONN HEADER VERT SGL MA05-1 SV25P

3 - 3M9449-ND CONN HEADER VERT SGL MA04-1 DGND DVCCs4P

1 - A106735-ND CONN HEADER VERT DUAL JP2Q SV14 S20K275 495-1417-ND VARISTOR 275V RMS 20MM R S20K275 R1 R2 R32 Orange 511-1245-ND LED 3.1MM 610NM ORANGE LED3MM LED_3 LED_42 Green 511-1247-ND LED 3.1MM 563NM GREEN R LED3MM LED_1 LED_6

T

16 Three Phase Rogowski Coil Based E-Meter Solution TIDU474–September 2014Submit Documentation Feedback

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Table 5. BOM (continued)Qty Value Digikey # Description Eagle Library Package Board Designator2 Red 511-1249-ND LED 3.1MM 650NM RED LED3MM LED_ACT LED_REACT

TRAN2 Yellow 511-1251-ND LED 3.1MM 585NM YELLOW LED3MM LED_2 LED_5

T2 BC857BSMD 568-6094-1-ND TRANSISTOR PNP 45V BC857BSMD Q1 Q2

100M1 TFBS4711-TT1 751-1068-1-ND TXRX IRDA 115.2KBIT TFBS4711-TT1 IRDA

1.9MM1 - A32036-ND CONN D-SUB RCPT STR F09VP RS1

9PO4 LL103A LLSD103ADICT-ND DIODE SCHOTTKY 40v D-SOD-80 D24 D25 D26 D27

350M1 - MHC14K-ND CONN HEADER 14 POS ML14 JTAG

STR6 EXCML20A P10191CT-ND BEAD CORE 4A 100 MHZ EXCELSA390805 L1 L3 L5 L6

0801 150uF P14374-ND CAP ALUM 150UF 10V 20% CPOL-EUE2-5 C101

R4 - P8079SCT-ND SWITCH TACTILE SPST-NO PB BTN1 BTN2 BTN3 BTN4

0 RESET2 TIL191 PS2501-1A-ND OPTOCOUPLER 1CH TIL191 OPTO1 OPTO2

TRANS2 PS8802 PS8802-1-F3-AXCT-ND OPTOISOLATOR ANALOG PS8802 U1 U2

HS1 68 RMCF0603FT68R0CT-ND RES TF 68 OHM 1% 0.1W R-EU_R0603 R65

0608 100 RMCF0603JT100RCT-ND RES 100 OHM 1/10W 5% R-EU_R0603 R54 R55 R56 R57 R58 R59

0603 R60 R612 1k RMCF0603JT1K00CT-ND RES 1K OHM 1/10W 5% R-EU_R0603 R62 R68 R72 R78

06031 1.5k RMCF0603JT1K50CT-ND RES 1.5K OHM 1/10W 5% R-EU_R0603 R67

0601 220 RMCF0603JT220RCT-ND RES 220 OHM 1/10W 5% R-EU_R0603 R64

06032 2.2k RMCF0603JT2K20CT-ND RES 2.2K OHM 1/10W 5% R-EU_R0603 R69 R71

0601 330 RMCF0603JT330RCT-ND RES 330 OHM 1/10W 5% R-EU_R0603 R48

06031 47K RMCF0603JT47K0CT-ND RES 47K OHM 1/10W 5% R-EU_R0603 R51

0603

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Table 5. BOM (continued)Qty Value Digikey # Description Eagle Library Package Board Designator1 47 RMCF0603JT47R0CT-ND RES 47 OHM 1/10W 5% R-EU_R0603 R47

060318 0 RMCF0603ZT0R00CT-ND RES 0.0 OHM 1/10W 0603 R-EU_R0603 R73 R74 R75 R76 R77 R79

SM R80 R81 R82 R83 R84 R85R86 R87 R88 R89 R90 R91

5 560k RMCF0603FT560KCT-ND RES TF 560K OHM 1% 0.125 R-EU_R0603 R42 R43 R464 100K RMCF0603JT100KCT-ND RES 100K OHM 0.1W 5% R-EU_R0603 R49 R50 R52 R53

08053 10k RMCF0603JT10K0CT-ND RES 10K OHM 0.1W 5% R-EU_R0603 R40 R41 R63

08051 10R RMCF0805JT10R0CT-ND RES 10 OHM 1/8W 5% 0805 RES0805 R36

S8 12k 311-12.0KCRCT-ND RES 12k OHM 1/8W 5% RES0805 R22 R26 R29 R104 R122

0805 S R125 R128 R13116 4.3k 311-4.3KARCT-ND RES 4.3k OHM 1/8W 5% RES0805 R21 R23 R27 R28 R30 R31

0805 S R105 R106 R123 R124 R126R127 R129 R130 R132 R133

6 1k RMCF0805JT1K00CT-ND RES 1.0K OHM 1/8W 5% RES0805 R14 R16 R18 R32 R33 R340805

3 2K37 RMCF0805FT2K37CT-ND RES 2.37K OHM 1/8W 1% RES0805 R15 R17 R19080

9 330k RMCF0805JT330KCT-ND RES 330K OHM 1/8W 5% RES0805 R5 R6 R7 R8 R9 R10 R110805 R12 R13

7 0 RMCF0805ZT0R00CT-ND RES 0.0 OHM 1/8W 0805 RES0805 R4 R39 R99 R100 R101SMD R102 R103

2 - Must Order From Samtec CONN HEADER 20POS TFM-110-02-SM-D-A-K RF1 RF21.27M

1 SMAJ5.0ABCT SMAJ5.0ABCT-ND DIODE TVS 5.0V 400W UNI DIODE-DO214AC ZD35

4 SMAJ5.0CA SMAJ5.0CABCT-ND DIODE TVS 5.0V 400W BI SMAJ5.0CA TVS1 TVS2 TVS3 TVS45%

1 SL127L6TH Mill-Max 850-10-006-20- SL127L6TH EZ-RF001000

1 TI_160SEG_LCD Custom-made TI_160SEG_LCD LCD1DNP R-EU_R0603 R44 R45DNP DNP C63

1 DNP R-EU_R0603 R661 DNP R-EU_R0603 R70

18 Three Phase Rogowski Coil Based E-Meter Solution TIDU474–September 2014Submit Documentation Feedback

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Table 5. BOM (continued)Qty Value Digikey # Description Eagle Library Package Board Designator1 CUI_XR 102-1801-ND Isolated Power Supply, 3.3 V, CUI_XR U$1

700mA1 MSP430F67791AIPEU MSP430F67791AIPEUR-ND1 100uF 1189-1020-ND CAP Electrolytic 100uF 100V 10 mm x 20 mm, 5 mm leads C102

23 0.22uF 495-2320-ND CAP poly 0.22uF 18 mm x 7 mm, 15 mm leads C39 C46 C50

305VAC/630V1 2.2uF 445-4497-2-ND CAP Ceramic 2.2uF 100V 1210 C48

X7R1 0.01uF 445-5100-1-ND CAP CER 10000PF 25V 10% 603 C45

X1 47uF 587-1383-1-ND CAP Ceramic 47uF 10V X5R 1210 C62

11 0.1uF 399-1095-1-ND CAP Ceramic 0.1uF 10V X5R 603 C47

01 .056uF 490-6433-1-ND CAP Ceramic .056uF 25V 603 C60

X7R1 100pF 399-6841-1-ND CAP Ceramic 100pF 25V 603 C61

NPO,1 B160 641-1107-1-ND Diode Schottky 1A 60V B160 SMB D23

S3 48V 1N4757ADICT-ND Diode Zener 51V 1W DO-41 D17 D19 D21

1N4757A3 1N4007 1N4007FSCT-ND DIODE GEN PURPOSE DO-41 D18 D20 D22

1000V1 1mH Must order from CoilCraft (M Inductor, SMT, MSS1038-105 0.402 x 0.394 inch L7

(1 1M A102234CT-ND RES 1M OHM 1/16W 0.1% 603 R35,R38

06031 33.2k RNCS0603BKE33K2CT-ND RES 33.2K OHM 1/16W .1% 603 R37

061 22.1k A102241CT-ND RES 22.1K OHM 1/16W 1% 603 R95

061 51.1 A102292TR-ND RES 51.1 OHM 1/16W 1% 603 R96

0601 31.6k A102261DKR-ND RES 31.6K OHM 1/16W 1% 603 R97

061 10.0k A102331CT-ND RES 10.0K OHM 1/16W 0.1% 603 R98

03 100 P100W-2BK-ND RES 100 OHM 2W 5% AXIAL 12 mm length, 4 mm diameter R92 R93 R94

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Table 5. BOM (continued)Qty Value Digikey # Description Eagle Library Package Board Designator1 TPS54060ADGQ 296-30339-5-ND IC REG BUCK ADJ 0.5A MSOP-10 U3

10MS

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PBC Layout PrintsThe layout implemented is a 2-layer design. This section illustrates the PCB layout prints.

Figure 7. Top Layer Plot 1

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Figure 8. Bottom Layer Plot 2

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Figure 9. Ldi/dt Input Front End

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8.2 CAD ProjectTo download the CAD project files, see the design files at TIDM-3PHMETER-ROGOWSKI .

8.3 Gerber FilesTo download the Gerber files, see the design files at TIDM-3PHMETER-ROGOWSKI

9 Software FilesTo download the software files, see the design files at TIDM-3PHMETER-ROGOWSKI

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www.ti.com About the Author

10 About the AuthorANIRBAN GHOSHworks at TI as an Applications Engineer in the Smart Grid Business Unit, for electricitymetering and metrology related projects.

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