TOPACC Zero-flux (tm) measuring system user manual. Hitec Power Protection bv reserves the right to change the contents of this user manual without prior notice. Reproduction in any form whatsoever, in whole or in part is not permitted without written permission of Hitec Power Protection bv.
TOPACC Zero-flux (tm) measuring system user manual. Hitec Power Protection bv reserves the right to change the contents of this user manual without prior notice. Reproduction in any form whatsoever, in whole or in part is not permitted without written permission of Hitec Power Protection bv.
TOPACC Zero-flux (tm) measuring system user manual. Hitec Power Protection bv reserves the right to change the contents of this user manual without prior notice. Reproduction in any form whatsoever, in whole or in part is not permitted without written permission of Hitec Power Protection bv.
Document number : TOPACC Revision : 2, October 2003
Due to a policy of continuous development and improvement Hitec Power Protection bv reserves the right to change the contents of this user manual without prior notice.
Reproduction in any form whatsoever, in whole or in part is not permitted without written permission of Hitec Power Protection bv.
Hitec Power Protection bv Phone : +31 546 589 500 Div. Special Measuring Systems Facsimile : +31 546 589 489 PO Box 65 E-mail : sales@hitecsms.com 7600 AB Almelo, The Netherlands Internet : http://www.hitecsms.com
1. GENERAL DESCRIPTION OF THE SYSTEM TOPACC 1.0 ............................................................. 3 1.1 Technical Specifications ....................................................................................................... 3 1.2 Available types ..................................................................................................................... 4 1.3 Available versions ............................................................................................................... 4 1.4 Applied measuring heads .................................................................................................... 5
2. INSTALLATION ................................................................................................................................... 5 2.1 Rating plates ........................................................................................................................ 5 2.2 General instructions ............................................................................................................. 6 2.2.1 Electronics module ................................................................................................ 6 2.2.2 Measuring head ..................................................................................................... 6 2.3 Mounting ............................................................................................................................... 6 2.3.1 Printed Circuit Boards and Eurocassette .............................................................. 6 2.3.2 19" rack-mount chassis ......................................................................................... 7 2.3.3 The measuring head ............................................................................................. 7 2.4 Electrical connections .......................................................................................................... 7 2.4.1 Printed Circuit Boards and Eurocassette .............................................................. 7 2.4.2 19" rack-mount chassis ......................................................................................... 8 2.4.3 Cable for the measuring head .............................................................................. 10
3. VISUAL INDICATIONS ...................................................................................................................... 10 3.1 Power on ............................................................................................................................ 10 3.2 Output Valid ......................................................................................................................... 10 3.3 Zero current ......................................................................................................................... 10
4. WORKING PRINCIPLE ..................................................................................................................... 11 4.1 General ................................................................................................................................ 11 4.2 Block diagram analysis ....................................................................................................... 14
5. MAINTENANCE ................................................................................................................................. 16 5.1 Trouble shooting .................................................................................................................. 16 5.1.1 Disassembly ......................................................................................................... 16 5.1.2 Visual inspection .................................................................................................. 16 5.1.3 Power Supply ....................................................................................................... 16 5.1.4 Test signals connector X2 (Chassis for 19" rack mounting) ................................ 16 5.1.5 Flux Compensator Board ..................................................................................... 17 5.1.5.a Insulation test ........................................................................................ 17 5.1.5.b Voltage Stabilizers ................................................................................. 17 5.1.5.c Zero Current Detector ........................................................................... 17 5.1.5.d Oscillator and induced voltage .............................................................. 17 5.1.5.e Peak Detector ........................................................................................ 18 5.1.5.f Excitation Control .................................................................................. 18 5.1.5.g AC-Loop ................................................................................................ 19 5.1.5.h Power Amplifier ..................................................................................... 19 5.1.5.i AC-loop/Amplifier dummy load test....................................................... 19 5.1.6 Voltage Output Board ........................................................................................... 20 5.2 Accuracy check ................................................................................................................... 20 5.2.1 With standard resistor .......................................................................................... 20 5.2.2 With reference DCCT ........................................................................................... 21 5.3 Calibration ........................................................................................................................... 21 5.3.1 Procedure for adjusting offset .............................................................................. 21 5.3.2 Procedure for gain and CMR ............................................................................... 22
6. OPTIONS FOR THE SYSTEM TOPACC 1.0 .................................................................................... 22 6.1 For all models ...................................................................................................................... 22 6.2 Special for 19" rack-mount chassis ..................................................................................... 22
7. APPENDIX I DRAWINGS AND PARTS LISTS ................................................................................. 23 7.1 General ................................................................................................................................ 23
7.2 Printed Circuit Board and Eurocassette additions .............................................................. 23 7.3 Chassis for 19" rack mounting additions ............................................................................ 23
1. GENERAL DESCRIPTION OF THE SYSTEM TOPACC 1.0
The bipolar Zero-flux current transformer System TOPACC 1.0, developed by HOLEC for scientific research, epitomize the concept of a galvanically separated system for measurement of direct and alternating currents up to 6000 Amp with exceptionally high accuracy and stability.
The conductor that carries the current to be measured forms the primary winding. The magnetic circuit is constituted by a set of ferromagnetic toroidal cores fitted with a common secondary winding and separate auxiliary windings, all integrated in the measuring head. The design of the measuring head, whether or not provided with a bus-bar section, is governed by the application. Depending on the type of Zero-flux current transformer ordered, the electronics module can be supplied on printed circuit board(s), in an euro cassette with or without built-in power supply or as fully self-supporting 19" rack-mount chassis. 1.1 Technical Specifications
Primary Circuit: rated current up to 6000 A permissible over current 115% of rated current (*) short-circuit current 10 times rated current for 0.1s current slew rate unlimited
Output Circuit: rated voltage 10V maximum load current 5 mA output impedance 10 m output slew rate 1.5 V/s small signal-bandwidth (signals < 5% of rated primary current) 0...500 kHz (**) rms value of output noise related to rated output voltage, 0... 10Hz < 0.1 ppm 0... 100Hz < 0.3 ppm 0... 10kHz < 1.5 ppm
DC accuracy: offset error related to rated output voltage, (adjustable) initial (at 25C) < 2.5 or 0 ppm (***) versus temperature < 0.5 or 0.25 ppm/K (***) versus time < 5 ppm/year ratio error related to actual output voltage, initial (at 25C) < 25 ppm versus temperature < 1 or 0.25 ppm/K (***)
versus time < 5 ppm/year linearity error related to actual output voltage < 2.5 ppm
Ambient Temperature, measuring head 0... 55 C electronics module 10...40 C
Notes *) Up to the rated primary current a perfect ampere-turns balance is maintained. At some value above 1.15 Irated the cores become saturated, which will result in a non-defined output voltage. An internal relay indicates this status. Proper operation will be restored as soon as the primary current has returned to I rated. An other internal relay will be activated when the primary current is below about 0.1% of the nominal value. **) Above 100 Khz the position of the primary conductor becomes important. ***) The initial offset error can be adjusted to 0. By using specially selected and perfectly matching components it is possible to offer, as an option, a System TOPACC 1.0 with a ratio -and offset error of less than 0.25 ppm/K.
1.2 Available types A standard bipolar TOPACC Zero-flux current measuring system consists of an electronics module, a measuring head and an interconnection cable (standard length 3 m).
Types : T20-* T25-* T40-* T50-* T60-* I.max. : 2000 A 2500 A 4000A 5000A 6000A
* = No. 1 ... 8 (see available versions below)
1.3 Available versions
T** -1 2 (Euro card) printed circuit boards for 3U sub-rack mounting. Dimensions front plates: 128.5 x 50.5 x 160 mm (3U, 10HP) 128.5 x 20.3 x 160 mm (3U,4HP) Supply voltages: T20, T25, T 40 = 24 V DC T50 = 32 V DC T60 = 40 V DC
T**-2 2 (Euro card) printed circuit boards for 6U sub-rack mounting. Dimensions front plate: 257 x 50.5 x 160 mm (6U, 10HP) Supply voltages: T20,T25,T40 = 24 V DC T50 = 32 V DC T60 = 40 V DC
T**-3 Euro cassette with 2 printed circuit boards for 3U sub-rack mounting Dimensions front plate: 128.5 x 106.3 x 160 mm (3U, 21HP). Supply voltages: T20,T25,T40 = 24 V DC T50 = 32 V DC T60 = 40 V DC
T**-4 Euro cassette with 2 printed circuit boards for 6U sub-rack mounting Dimensions front plate: 257 x 70.5 x 160 mm (6U, 14HP). Supply voltages: T20,T25,T40 = 24 V DC T50 = 32 V DC T60 = 40 V DC
T**-5 3 (Euro card ) printed circuit boards for 3U sub-rack mounting. Dimensions 128.5 x 50.5 x 160 mm (3U, 10HP) front plates 128.5 x 50.5 x 160 mm (3U,10HP) 128.5 x 20.3 x 160 mm (3U,4HP) Supply voltage: 115 or 230 V ac (state at ordering)
T**-6 Euro cassette with 3 printed circuit boards for 3U sub-rack mounting Dimensions front plate: 128.5 x 141 x 160 mm (3U, 28HP). Supply voltage: 115 or 230 V ac (state at ordering)
T**-7 Euro cassette with 3 printed circuit boards for 6U sub-rack mounting Dimensions front plate: 257 x 106.3 x 160 mm (6U, 21HP). Supply voltage: 115 or 230 V ac (state at ordering)
T**-8 Chassis for 19" rack mounting. Dimensions: 44 x 483 x 250 mm (1U, 19") Supply voltage: 115 or 230 V ac (state at ordering)
** = T20, T25, T40 etc.
1.4 Applied measuring heads All measuring heads are built according to customers specification. Please state, at ordering, the rated current for 10V output.
TOPACC type : T20 T25 T40 T50 T60 Model measuring head : B/20 E/25 E/40 E/50 E/60
Model B Model E Dimensions : Standard 120 h=60mm Dimensions : Standard 220 h=110mm Optional 145x125x150mm Optional 225x225x180mm Bore : 45 mm Bore : 60 mm Weight : 2-3 kg Weight : 10 - 15 kg Test voltage : Standard 2.5 kV (1 min) Test voltage : Standard 2.5 kV (1 min) Optional 5 kV (1 min) Optional 5 kV (1 min)
2. INSTALLATION 2.1 Rating plates Both electronics module as measuring head have a unique rating plate for easy identification. As electronics module and measuring head together form a measuring system the serial numbers on both components are the same but have an additional code.
The electronics module Version: This indicates the version of the module. The first number indicates the maximum current of the system. This can be 20-25-40 and 60. A choice of eight different versions is available. System: This indicates the basic system. The TOPACC 1.0 system has a secondary current of 1A at rated primary current. Serial number: The serial number contains much information. It can be divided in four parts: 1. Letter code "M" indicating - (Electronics) Module. 2. Year of manufacturing 3. Letter code indicating the size of the measuring head 4. Manufacturing number Note: In case printed circuit boards are supplied an extra letter is added to the serial number. F for Flux compensator - V for Voltage output board - P for Power supply board.
The measuring head The rating plate on the measuring head has much in common with the one on the electronics module. This is because they both belong together. System: Indicating the basic system I sec. : Indicating the secondary current at rated primary current I prim. : Indicating the rated primary current. As the measuring heads are build to customer specifications this could show a value up to 6000 A. Serial number: Same as for the electronics module however it starts with the letter code H.
Arrow: Indicating the direction of the main current for a positive output voltage. As the TOPACC 1.0 is a bipolar system there is no objection in choosing the opposite direction however the voltage output will indicate a negative voltage. P1 and P2 are the IEC markings for the primary circuit.
2.2 General instructions The measuring head and the electronics module must have the same indication - TOPACC 1.0 - on their rating plates. The serial numbers preferably should also be the same, however a mix up of measuring heads is possible supposing the letter code (=size) -in the serial numbers- is the same and Iprim is <4000A. For adjustments to be made with alternative measuring head see chapter 5.1.5.d. Do not expose the electronics module and measuring head to heavy shocks or rough handling. Keep them in the original packing as long as possible.
2.2.1 Electronics module Place the TOPACC 1.0 in a dry, and dust-free position with good ventilation. Air inlets and outlets must not be blocked by anything. Heat accumulation inside the electronics module will reduce the accuracy. Sources of heat below the electronics module should also be avoided for the same reason.
Relative humidity should be kept within 80% (10-40C) for the electronics module. Condensation moisture should be avoided as it can strongly degrade the specifications.
WARNING! Incorrect supply voltage will damage the electronics. Check if the indicated supply voltage on the electronics module corresponds to your power supply voltage.
2.2.2 Measuring head For thermal reasons the specified permissible over current can last up to 5 minutes per 15 minutes.
External magnetic fields, from any origin, of more than 5 mT around the measuring head should be avoided to ensure proper operation of the Zero-flux current transformer. For the same reason pay attention to the specified "radius of bus-bar free volume " (R) for the returning bus current or adjacent high current circuits.
Radius of bus bar free volume TOPACC version Radius T20-.. 200 mm T25-.. 200 mm T40-.. 250 mm T50-.. 300 mm T60-.. 300 mm
WARNING! If primary currents are expected in case of a disconnected measuring head, short-circuit all connections of it, otherwise high voltages could be induced in the secondary and auxiliary windings of the measuring head and cause damage.
2.3 Mounting 2.3.1 Printed Circuit Boards and Euro cassette These models have a height of 3U or 6U and can be plugged into a sub-rack system DIN 41494, part 5 and IEC 297, section 3. Preferably mount the printed circuit boards - from left to right as seen at the front - as follows: 1. The Power Supply board (if supplied) 2. The Flux Compensator board 3. The Voltage Output board The printed circuit boards are fitted with a male F-type connector with the rows "d" and "z" ( DIN 41612). The female F-type connector counterpart for the Flux Compensator is factory connected to the interconnection cable and can be
screwed directly onto the connector-mounting rail of a 3U or 6U sub-rack system. A female F-type connector for the Voltage Output board and for the optional Power Supply board is supplied by HOLEC
2.3.2 19" rack-mount chassis This model comes as an integrated measuring system where Power Supply, Flux Compensator and Voltage Output are built in. It is only 44 mm high and 260 mm deep. There are no special demands for mounting the chassis. It can be used as free standing desktop system or can be mounted in a cabinet. It is advisable to support the chassis with L-brackets when mounted in a cabinet. For the standard version the interconnection cable at both ends has 15-pole male sub-D connectors. Both connectors are wired in the same manner.
2.3.3 The measuring head Depending on the maximum current to be measured, two models are available. 1. Model B for rated primary currents up to 2000 Amp. See for the dimensions Appendix I - drawing ZF 06.266.02 This model can optionally be equipped with a halogen free, fire retardant polyester housing 2. Model E for rated primary currents from 2000 to 6000 Amp. See for the dimensions Appendix I - drawing ZF 06.267.02
Figure 3 Cross-section of wound toroidal core assembly
2.4 Electrical connections 2.4.1 Printed Circuit Boards and Euro cassette See Appendix I - Drawing ZF 06.170.04 , External connections. This drawing shows the set-up seen from the rear side for the 3U version with the optional HOLEC dual power supply. The drawing can also be used for the other 3U/6U versions. The female F-type connectors have solder lugs and can be wired with 0.2-1.0 mm 2 or AWG 24-18 wire.
Power Supply
WARNING! Incorrect supply voltage will damage the electronics. Check if the indicated supply voltage on the electronics corresponds to your power supply voltage.
An optional dual power supply can be operated with 50 .. 60 Hz. Depending on what is ordered, the input voltage is 115 V or 230 V (or any other voltage). The output voltage (+Vb, -Vb) depends on the version ordered. An IEC-fuse (5x20mm) protects the supply transformer. A spare fuse is also located on the circuit board. The "power supply common" (indicated with "o") and the earth terminal are galvanically isolated but H.F. coupled with a high voltage ceramic capacitor C5 , mounted on the circuit board. Connect the output of the power supply with the flux compensator as indicated on the diagram. In case a local or central D.C. power source is used connect it to the appropriate points of the flux compensator (+Vb, 0V, -Vb).
Status signals "Output Valid" and "Zero Current" inform about the operational conditions of the TOPACC system. For both a potential free change-over contact is available. Furthermore "Output Valid" and "Zero Current" have additional normally open (N.O.) contacts (z10 and z16 resp.) on the flux compensator. Both additional contacts are connected to common and can be used for extra indication, for example a remote LED.
Measuring head The cable going to the measuring head is factory connected to the female F-type connector counterpart of the flux compensator. To prevent for EMI problems, connect d22 or z22 in the shortest way to the earth connection to ensure a low impedance path for capacitive currents produced by the primary circuit. It is important that the power supply common has the same earth potential. If for some reason these earth connections are not preferred connect d22 with d20. Note: For adjustments to be made with alternative measuring heads, see chapter 5.1.5.d
Output Signal The output signal is available at the voltage output connector. System TOPACC 1.0 is equipped with a 4-wire voltage output to compensate for voltage loss in the cabling and connectors. Following methods for connecting the output cable are advisable. The "power supply common" is indicated with "o".
a. To improve the Electro Magnetic Compatibility (E.M.C.) use a cable with two twisted pairs of conductors and a tightly-woven screen for carrying the output signal. Connect both ends of the screen to an earthing point with short wires. Preferably use one twisted pair for the Hi and Lo wire and the other pair for the sense wires.
Figure 4 4-wire connection with a dual twisted pair screened cable
b. For short-distance (within the sub-rack) also non-screened dual twisted pairs can be used for signal transport. c. Also a 2-wire connection (screened or non-screened) is possible. To do so connect d24 and z24 for High and connect d22 and z22 for Low. Using a 2-wire connection, voltage losses due to the load current will not be compensated. This leads to an additional ratio error. Furthermore this additional ratio error is very temperature dependent ( T.C. copper = 0.38 % per C). It is up to the user to determine whether this is acceptable or not with respect to the demanded accuracy.
WARNING! Do not connect anything to the points d/z10 and d/z12 of the voltage output board because this will influence the accuracy dramatically, for these points are the voltage connections of the high precision burden resistor.
2.4.2 19" rack-mount chassis See Appendix I - Drawing ZF 06.265.03 , Wiring diagram Drawing ZF 06.265.04 , External connections
Mains supply connector X1: The electronics module operates with 50 ... 60 Hz without changing anything. Depending on what is ordered the supply voltage is 115V or 230V (or any other voltage).
WARNING! Incorrect supply voltage will damage the electronics. Check if the indicated supply voltage on the electronics module corresponds to your power supply voltage.
Check the mains rating plate on the rear of the module for the correct mains voltage. The 3-pole IEC mains inlet filter has a built-in fuse (5x20mm) to protect the supply transformer and contains a spare fuse. Earthing the system is advisable for personal protection reasons. If the mains supply is not provided with an earth lead (as in some countries) use the fast-on connection on the rear of the module to earth it separately. Follow the instructions from the local power company for safeguarding against electrical shocks.
Status signals connector X2: At this 9-pole female sub-D connector the contacts of two status-relays are available. They signal the status "Output Valid" and "Zero Current". To ensure a maximum EMI-screening use a metallized or metal connector hood and a screened multi-core cable. Furthermore two test signals (via series-resistor 10K) and a common are provided.(See chapter Maintenance)
WARNING! Do not use the test signals at pins 4,5 and 9 at normal working conditions. See chapter Maintenance.
Figure 5 Status signals connector X2
Measuring head connector X3: The measuring head cable must be connected to the 15-pole female sub-D connector X3, situated on the electronics module. Tighten the screws of the connector housing firmly to ensure a good electrical contact and screening. Note: For adjustments to be made with alternative measuring heads, see chapter 5.1.5.d
Voltage output connector X4: The output signal is available at the 9-pole female sub-D connector X4. System TOPACC 1.0 is equipped with a 4- wire voltage output to compensate for voltage loss in the cabling and connectors. Following methods for connecting the output cable are advisable. The "power supply common" (indicated with "o") and the metal chassis are galvanically isolated but H.F.-coupled with a high voltage ceramic capacitor C1 inside the module.
a. To improve the Electro Magnetic Compatibility (E.M.C.) use a cable with two twisted pairs of conductors and a tightly-woven screen for carrying the output signal. One end of the cable screen is connected to the shell of the counterpart of X4 and to pin 5. The other end of the cable screen should be connected in a similar way. The screen must be connected directly to the chassis at the user side. For safety reasons the chassis of the TOPACC must also be connected to earth. See mains supply connector X1. For a maximum EMI-screening use a metallized or metal connector hoods. Preferably use one twisted pair for the Hi and Lo wire and the other pair for the sense wires. Note: If a connection between the power supply common and the chassis of the TOPACC (Pin 2 to 5) is preferred the user side must have a differential input.
b. Also a 2-wire connection with a single twisted-pair screened cable is possible. To do so connect Pin 1 and Pin 3 for High and connect Pin 2 and Pin 4 for Low. Connect the screen in the same way as in above figure. Using a 2- wire connection, voltage losses due to the load current will not be compensated. This leads to an additional ratio error. Further more this additional ratio error is very temperature dependent ( T.C. copper = 0.38 % per C). It is up to the user to determine whether this is acceptable or not with respect to the demanded accuracy.
Figure 6 4-wire connection with dual pair screened cable
2.4.3 Cable for the measuring head The cable has to be plugged into the 15-pole female sub-D connector situated on the measuring head. Tighten the screws of the connector housing firmly, because the static screen of the measuring head has to find electrical continuity with the cable screen via the connector shells. The hood of the sub-D connector is metallized. The cable is a 10-core P.V.C insulated with an overall braided tinned copper screen. The core cross section is 0.34 mm 2 . (AWG 22)
Note: See Appendix I for the wiring of the cable. PCB and Eurocassette versions - Drawing ZF 06.170.04, external connections. Chassis version - Drawing ZF 06.266.04, connecting cable 19" chassis.
3. VISUAL INDICATIONS The System TOPACC 1.0 is equipped with several LED indicators for quick survey. They are located in the front panel of the electronics module. All LED's indicate a "true" situation.
3.1 Power on This LED indicates the presence of the DC voltage on the printed circuit boards. It has only a simple series resistor so an under -or over voltage situation is not signalled. The colour of the "Power on" LED is red. The optional dual output power supply for the Printed Circuit Board and Euro cassette version is equipped with 2 red LED's marked with "+" and "-".
3.2 Output Valid It can happen that the primary current reaches such a high level that the secondary current required to maintain the ampere-turns balance cannot be produced by the power amplifier. The zero-flux condition will be preserved for primary currents up to about 115% of the rated value. However, if over currents last for too long, the toroids become saturated and the output voltage no longer bears any relation to the primary current. A detection circuit is therefore provided which signals this operating condition via a relay and a green LED indicator. At the same time a reset circuit is activated which enables the TOPACC to restart normal operation as soon as the over current ends.
3.3 Zero current The bipolar TOPACC is supplied with a zero current detector which is activated when the primary current drops below 0.1% of the rated value. This condition is signalled via a green LED indicator in the front panel.
The indications "Output Valid" and " Zero-Current" are also available on potential free contacts. See chapter Electrical Connections and the Block Diagram Analysis.
4. WORKING PRINCIPLE 4.1 General The principle of measurement is based on obtaining a perfect balance between the magnetic flux generated by the current in the primary current carrier and that generated by the current in the secondary winding situated in the measuring head. This balance is known as the condition of zero flux. Find below the basic diagram of the magnetic integrator. The toroidal core T is placed around the primary current carrier Np. The toroid is provided with the secondary winding Ns and the auxiliary winding Na. The auxiliary winding is connected to the input of a high-gain power amplifier which feeds the secondary winding and a burden resistor. Any change of current in the primary current carrier causes a change of flux through the toroid, which in turn induces a voltage in the auxiliary winding. This voltage is fed to the power amplifier and the resulting current enters the secondary winding, where an equal but opposing flux is produced to counteract the original change of flux. Assuming the amplifier has infinite gain and zero offset, the flux balance effected in the toroid is maintained. The secondary current is then directly related to the primary current by the turns ratio of the primary winding to the secondary winding. It is, therefore, a true measure of the primary current.
Figure 7 Basic diagram of magnetic integrator
The magnetic modulator The magnetic integrator provides the TOPACC Zero-flux current transformer with the necessary bandwidth for current measurements over an extensive frequency range. On the other hand, in practice, the gain of the power amplifier cannot be infinite. Thus, due to a change in the primary ampere-turns, it is possible that a voltage will be induced in the auxiliary winding of the magnetic integrator which the power amplifier cannot completely compensate. This, in combination with the unavoidable offset of the power amplifier, would lead to an increasing disturbance of the flux balance (drift). The result is that saturation of the toroid occurs and the measuring system becomes unstable. To minimize the effect of drift the TOPACC Zero-flux current transformer is furnished with a magnetic modulator. Part of this is an extra toroid (T2, additional to T1, see figure below) which is fitted in the measuring head. The auxiliary winding Na2 wound around toroid T2 is excited by an oscillator with a fixed frequency. The frequency is between 50 an 100 Hz. Higher frequencies would reduce the accuracy of the measurements due to core losses. On top of that the induction voltages caused by the auxiliary winding Na2 would be unacceptably high.
Figure 8 Simplified circuit diagram of the TOPACC zero-flux current transformer
To compensate for the voltages induced in the primary current carrier and the secondary winding, a third toroid, T3 is included in the measuring head. The auxiliary winding Na3 around this toroid is wound in the same direction as that around toroid T2, but it is connected to the oscillator in the opposite way. The magnetic modulator continuously checks whether the secondary ampere-turns are in balance with the primary. Through regulation of the secondary current Is the power amplifier prevents imbalance occurring. At the condition of zero flux the magnetizing current in the auxiliary winding Na2 exhibits half-wave symmetry.
HOLEC uses in the System TOPACC 1.0 a peak detection method to control this symmetry and hence preserve the ampere-turns balance. This method is to check if the positive and negative peak values of the magnetizing current are equal. (U.S. patent 4,912,396; European patent applied for). To prevent any hysteresis occurring due to rema- nent magnetism the magnetizing current in auxiliary winding Na2 is adjusted to saturate toroid T2. This means that the symmetry of this current can relatively simply be determined. To do this the peak values are compared with each other using diode rectifiers. When there is symmetry, the positive and negative peak values are equal. The average value of the output voltage of the peak detector is then zero. High sensitivity and great stability is achieved by selecting well- matched diode pairs and high-quality toroidal-core material. To improve these characteristics even further and, in addition, to obtain optimum bandwidth, a double peak detector is applied. Toroid T3 is then used along with toroid T2 for detection. Due to theoretical considerations, the bandwidth of the various detection circuits is limited to an amount which corresponds with the frequency of the excitation voltage fed to the auxiliary windings Na2 and Na3. The TOPACC current transformer combines the wide bandwidth of the magnetic integrator with the high sensitivity and the great stability of the magnetic modulator. Because the voltages induced by the auxiliary windings Na2 and Na3 counteract each other, the output voltage of the power amplifier is wholly available for overcoming the voltage losses of the secondary circuit and for feeding the burden resistor.
The burden resistor Extremely high requirements hold for the burden resistor into which the secondary current is fed. After amplification in the output circuit of the TOPACC Zero-flux current transformer the voltage across this resistor must be suitable to allow very accurate readings to be made, whether they are ultimately produced in analogue or digital form. In view of the required measurement precision a four-wire resistor is the best. The power dissipation should be kept very low, so the voltage drop across the resistor must remain limited. Considering the characteristics of operational amplifiers that are now available for the output circuit, a voltage drop of 0.5 V is acceptable. Despite the fact that high-quality resistors can be purchased on the industrial market, for technical reasons, HOLEC much prefers to make its own for the TOPACC. This type resistor is mounted on the Voltage Output board of the TOPACC 1.0, and has a nominal value of 0.5 ; so with a nominal current of 1A, the power dissipation is only 0.5 W. The alloy of the resistance wire has a low temperature coefficient which, by means of addi- tional treatment, is reduced to virtually zero at room temperature. A special coating contributes to the long-term stability. The resistor is loosely mounted in a groove of a heat sink and then bedded in a heat-conducting paste. Prevention of the conductor being under mechanical strain avoids unexpected temperature drift. The inductive voltage loss across the burden resistor is compensated for by magnetic coupling of the resistance wire and the branched-off voltage conductors.
Figure 9 Characteristics of the magnetic mo- dulator
Figure 10 Construction of burden resistor
This coupling is effected by placing the current and voltage conductors close together in a special way. These measures enable a bandwidth of 1 MHz to be achieved. To reduce any thermocouple effects which might arise between the alloy of the resistance wire and the copper of the voltage conductors good thermal coupling is made between the two voltage pick-offs. The thermal stability of the burden resistor under nominal load conditions is, even over the long term, ensured without the need of resorting to heating elements, Peltier elements or constant temperature chambers.
The precision amplifier The precision amplifier is a very stable differential amplifier which delivers a highly accurate output voltage of 10V when the secondary current through the burden resistor meets the specified value. To ensure that the amplification factor remains constant, the most important point is that the temperature coefficients of the four amplifier resistors are matched (TCR tracking). The offset error is minimized by careful choice of the operational amplifier. The precision amplifier is fitted with sensing outputs to compensate for voltage losses in the externally connected conductors upgrading the measurement precision of the TOPACC Zero-flux current transformer. Furthermore, sensitivity to HF interference is much reduced by capacitive coupling of these outputs.
Particularly with a view to countering thermocouple effects, the burden resistor and precision amplifier are very carefully arranged on the Voltage Output board of the TOPACC.
4.2 Block diagram analysis Figure 11 Block diagram Zero-flux current transformer System TOPACC 1.0
The electronics of the TOPACC 1.0 system consists of two printed circuit boards; the Flux Compensator and the Voltage Output Board. The primary rated current is determinated by the number of turns of the secondary winding Ns, which is connected to the flux compensator. The secondary rated current is always 1 amp. in the TOPACC 1.0 system. Internal "voltage stabilizers" are feeding the integrated circuits for both printed circuit boards. The "oscillator" generates a triangular-shaped voltage which has a frequency of 72 Hz. The amplitude can be adjusted with potentiometer R3, depending on the size of the measuring head. The auxiliary windings Na2 and Na3 are magnetized in such a way that the cores become saturated. A possible DC-component on the output of the oscillator is blocked by a series capacitor. With potentiometer R2 the differences in magnetic characteristics can be balanced, resulting in minimum of induced voltage in both secondary and primary winding. The signal of the integrator core Na1 and the output signal of the "peak detector" are combined in the "AC-loop". With potentiometer R1 (on the front panel of the PCB version) the small offset, caused by several electronic components, can be adjusted. Further more the small remanency of Na2 and Na3, expressing itself as offset, can be adjusted with potentiometer R1. The "power amplifier" behaves like a voltage-controlled current source. The current of the power transistors is limited at approx. 1.3A. The heat sink is coated with aluminium oxide which takes care of the isolation between the power transistors and the heat sink. Using this method ensures a very effective heat transfer. The heat sink is electrically connected to "common". The output current is directed, via jumper W1, to the secondary winding Ns in order to, very precisely, compensate the primary ampere-turns. The current than goes, via the paralleled diodes, through the "burden resistor" on the voltage output board. On this board we find, besides the HOLEC made burden resistor, a "precision amplifier" which takes care of the rated output voltage of 10V. The high-precision resistor/amplifier assembly is factory calibrated for gain, CMR (Common Mode Rejection) and offset. The rough adjustments, if necessary, were factory made with standard metal film resistors (1%, TC 50 ppm/C). For the gain; the resistors R11 and R12 (in parallel). For the CMR; the resistors R23 and R24 (in parallel). For the offset; the resistor R 26. The fine adjustments were made respectively with potentiometers R1, R2 and R3. Their trimming range is less than 100 ppm.
The above described blocks form the control-loop of the measuring system TOPACC 1.0. More functions are classified in the above block diagram. They all have supporting functions. The "Excitation Control" detects malfunction of the oscillator and the saturation of the measuring head. The input signal of the power amplifier V1 stays normally within certain limits. It can happen that these limits are exceeded at following situations: measuring head not connected, wire cut, saturation of the measuring head, current limit of the power transistors exceeded or break down of the power transistors. This status is being detected by the "Window Detector". The two above mentioned functions come together in the block "Output Valid". In the table below the functions are summarized.
Excitation O.K. ? V1 within window ? LED, relay K1 Output Valid ? Yes Yes On Yes Yes No Off No No Yes Off No No No Off No
So, when the output is said to be valid the relay K1 is energized or "On". Not included in the table is the loss of +Vb or -Vb or both. The relay will then be de-energized or "Off".
The block "Zero Current Detector" has a window detector. At a current value below 0.1% of the rated current - at a frequency between 0 and 0.5 Hz- the relay K2 is activated. The LED indicator lights up. Above a frequency of approximately 8 Hz, independent from the amplitude of the primary current, the relay stays de-energized. The "Zero Current Detector" is interlocked with the "Output Valid" relay K1. This is necessary because in the case of a disconnected measuring head it is impossible to detect whether the primary current is zero or not. This is summarized in the table below.
Current <0.1%? Output Valid?
LED, relay K2 Zero Current? Yes Yes On Yes Yes No Off No No Yes Off No No No Off No
Saturation of the measuring head can occur at a power on or at an over current situation. This causes a lack of information to and from the "Peak Detector". This saturation is detected by the "Excitation Control" and activates the "Loop Finder". This results in a sweeping of the output current of the power amplifier. At a certain moment there will occur an ampere-turns encounter between primary and secondary side which enables the "Peak Detector" to become active again and thereby producing a correct control signal. Shortly after that this situation is monitored by the "Excitation Control" which de-activates the "Loop Finder". This means that proper operation has been restored which is signalled via the output valid relay and a LED. Proper operation will be possible as soon as the primary current has returned to the rated value. This will also be the case when the TOPACC 1.0 is switched on while the rated primary current is already flowing.
5. MAINTENANCE 5.1 Trouble shooting 5.1.1 Disassembly To gain access to the printed circuit boards remove the cover of the electronics module (only chassis version) or slide out the printed circuit boards.
5.1.2 Visual inspection Troubles sometimes can be located by means of a visual inspection. This may be accomplished by observing the following symptoms: a. The accumulation of dirt, dust or moisture. Remove this contamination with low-pressure, clean dry air or with a soft brush. b. Scorched or burned parts. Damages of this type are usually caused by other defective components. Determine the cause of damage before replacing components.
5.1.3 Power Supply If the LED's are not signalling as expected or when the output signals are conflicting with the input conditions start to check the power supply. If a Topacc version was supplied with an integrated or optional power supply, check this circuit first. (Mains cable, fuse, internal connections, bridge rectifier etc.) For the DC-value of the power supply see chapter 1. This DC-value is also indicated on the printed circuit boards. If a fuse is blown, try to find an explanation for this event first. The fuse and the spare fuse where specially selected for protecting the toroidal mains transformer. The current rating and the I 2 t-value of the fuse is indicated on the electronics. The fuse can also be replaced by a "slow" type fuse, with the indicated current rating.
5.1.4 Test signals connector X2 (Chassis for 19" rack mounting) At this 9-pole sub-D connector two test signals are available with respect to pin 9 (Common). At pin 5 the magnetizing current can be measured and at pin 4 the "induced voltage" can be observed. For description and waveforms see 5.1.5 point d. Note: Pins 4 and 5 have a series resistor of 10 k.
5.1.5 Flux Compensator Board For the following tests the use of an extender board is advised, in order to have all connector pins available for measuring purposes. (F-type connector with the rows d and z.) If not possible leave the board installed and connect the test leads to the indicated components on the board as described.
* Some signals are available at provided test points : X1 ... X6 * Measure with respect to common: d/z20 or W2 (see drawing ZF 00.639.02) * Use measuring equipment with an input impedance of at least 1 M. * If not stated otherwise the Flux Compensator Board, the Voltage Output Board and the Measuring Head are interconnected and the primary current is Zero. * Connect a dual power supply with a voltage level as indicated on the label of the printed circuit board: d/z6 = +Vb, d/z28 = -Vb and d/z20 = common. * For easy access to the measuring points and components remove the heat sink by unscrewing two M2.5 screws.
5.1.5.a Insulation test If a strong heating up of the heat sink is noticed even at zero primary current, it is possible that there is a short-circuit between the collectors of the power transistors and the heat sink support (=0V). To check this, desolder jumper W2, short circuit all connector pins and perform an insulation test with 100 Vdc between the soldering points of W2. The insulation resistance should be more than 10 M. If needed replace the heat sink support or apply a silicone or mica washer with silicone paste. Solder jumper W2 again.
5.1.5.b Voltage Stabilizers The "Voltage Stabilizers" should produce +14 0.5V on z8 and -14 0.5V on d8. This can also be measured at the left side of respectively resistor R78 and R77.
5.1.5.c Zero Current Detector Putting a small DC-current trough the measuring head can test the Zero Current Detector. Relay K2 will switch over at a voltage level of approx. -7V at point X5. Be aware of the interlocks of relay K1 and K2 as described under chapter 4.2.: Block diagram analysis.
5.1.5.d Oscillator and induced voltage The "oscillator" should generate a triangular-shaped voltage with a frequency of 73 7 Hz. Measure this at point X6. By adjusting the amplitude of the oscillator with potentiometer R3, the magnetizing current must be set to 1.5 0.2V peak value. Measure at point z32 or at the cathode of V2.
A: Oscillator output 5V/div.
B: Magnetizing current 1V/div.
TB: 5ms/div.
Figure 12 Normal excitation
With potentiometer R2 the "induced voltage" must be adjusted to its minimum peak-value < 0.5 mV * Nsec. (Nsec = Iprim Isec). The wave-shape depends on the measuring head that is connected and is unpredictable. However it should be synchronous with the oscillator frequency. Measure at point d/z4 or at the cathode of V7.
When the secondary and primary ampere-turns are not cancelling out (cut wires, defective amplifier etc.) the magnetizing current will show a different shape. (see figure below). When lifting jumper W1 from the output amplifier, it is possible that the magnetizing current restores to the shape in the above figure.
A: Oscillator output 5V/div.
B: Magnetizing current 1V/div.
TB: 5ms/div. Figure 13 Excitation due to saturation
5.1.5.e Peak Detector The output signal of the "Peak Detector" is shown in the figure below. The output signal is measured in closed-loop situation (Jumper W1 fitted). The wave-shape depends a lot of the adjustment made for induced voltage, but will be synchronous with the magnetizing current. Measure at point X2.
A: Magnetizing current 1V/div.
B: Output peak detector 0.1V/div.
TB: 5 ms/div. Figure 14 Peak detector signals
To check proper operation of the peak detector lift jumper W1 and measure the output voltage at point X2 with a voltmeter at zero primary current. Requirement: 0 0.1V. Then have a current flow of 50 mA in the direction of the arrow trough the measuring head. Now the output voltage at point X2 will change about +1V.
5.1.5.f Excitation Control The "Excitation Control" produces, under normal conditions, an average output signal lower than -9V. Measure this at point X4 with jumper W1 fitted.
RA: Oscillator output 5V/div.
RB: Zero level for B-trace
B: Excitation control output 5V/div.
TB: 5ms/div.
Figure 15 Excitation control
In case the magnetizing current has a shape like trace B of fig.13, the voltage at point X4 will drop to about zero.
5.1.5.g AC-Loop The output signal of the "AC-Loop", under normal conditions, is within 0.1V. Measure this at point X3. With potentiometer R1 the loop-offset must be adjusted within 100 V. Measure the loop-offset between the points d/z24 and d/z26 or across the parallel connection of resistor R81 (221), V23 and V24.
5.1.5.h Power Amplifier For the normal output signal of the "Power Amplifier" see the description of the induced voltage at the "Oscillator" section of this chapter. The average level of the output signal should be zero at zero primary current. The quiescent current of the power transistors can be measured across resistors R48 and R52. This value should be between 2 and 20 mV.
5.1.5.i AC-loop/Amplifier dummy load test There is a possibility to test the "AC-Loop" in combination with the "Power Amplifier". At the same time other functions could be tested. To perform this test do following: a. Disconnect the measuring head b. If wanted disconnect the Voltage Output Board (Not necessarily needed) c. Connect a resistor decade box between the points X1 and X3 and adjust to 10 K d. Connect the oscillator to the input of the AC-Loop: z30 to z2 or the left side of resistor R45 to the top side of resistor R11. (See drawing ZF 00.639.02) e. Load the power amplifier with a resistor of 10 (approx. 25W). Connect the resistor between the points d/z4 and d/z20 or between the cathode of V7 and jumper W2. In case the Voltage Output Board is installed and should also be tested, connect the 10 resistor between the points d/z4 and d/z26 or between the cathode of V7 and the anode of V24.
In this way a unity-gain amplifier is made from the AC-Loop which is driven by a resistive loaded power amplifier. With resistor R3 the triangle-shaped input voltage can be adjusted between 5 and 12V peak value. When the heat sink has been removed the power amplifier can be loaded only a short period of time (approx. 1 min.)
RA: Oscillator output at point z30 or left side of resistor R45, 5V/div.
RB: Output power amplifier at point d/z4 or the cathode of V7 with a resistor decade box at 10 K, 10V/div.
B: Same as RB, but with decade box at 2 K
TB: 5ms/div.
Figure 16 Test of the power amplifier
Trace RB has flat peaks because of the current limit action of the power amplifier. (Approx. 1.25A) Trace B is recorded with a 2K resistor between the points X1 and X3 that gives an amplification of 0.2 for the AC- Loop. The output signal of the power amplifier is inverted because of the AC-Loop. The distortion of the output signal of trace B is caused by the non-linear transfer-characteristic of the power amplifier. The amplitude of the output signal depends from the current gain of the power transistors. Because of the current- source characteristics of the power amplifier, the output voltage will rise - within the limits of the supply voltage - when the load resistor is increased. The voltage output board, if connected as described above, will show the same output voltage between Hi and Lo as trace B and RB but with inverted polarity.
The following tests should be performed without a load connected. Disconnect the load or lift jumper W1. The "Output Valid" relay K1 with its LED will be de-energized by the "Window Detector" when the peak value of the triangle voltage on point X3 rises to approx. 10V. The peak value can be adjusted with potentiometer R3 or with the resistor decade box between the points X1 and X3.
A part of the "Loop Finder" could also be tested with the same triangle voltage. The voltage at the bottom side of resistor R23 will become a square wave when the peak value of the triangle voltage on point X3 rises to approx. 7V. Below this level the signal at resistor R23 will either be +14V or -14V. There is also a possibility to test the "Loop-Finder" as it will function in action, i.e. in an over current situation. To do so, remove the connections described at point c. and d. in the last page. Instead of that connect point z30 to point d/z20 or the left of resistor R45 to jumper W2. Furthermore connect point z2 to point d/z20 or the topside of resistor R11 to jumper W2. This will result in a sweeping action of the AC-Loop. Measure this at point X3. The frequency is not so important but will be around 2Hz.
A: Output of AC-Loop at point X3, 5V/div.
TB: 0.2 s/div.
Figure 17 Test of the Loop-Finder
5.1.6 Voltage Output Board With the method described under point 5.1.5.i the output of the "Precision Amplifier" can be tested roughly. For calibration of the Voltage Output Board see chapter 5.3
5.2 Accuracy check Due to the very good long-term stability of the TOPACC 1.0 it is not necessary to check the accuracy periodically. Under normal operating conditions the ratio drift and offset drift versus temperature and time will be within specifications. Nevertheless, if an accuracy check is needed, the following circuits could be used. (For adjustments see chapter 5.3)
5.2.1 With standard resistor
Figure 18 Accuracy check with a standard resistor
The secondary winding of the measuring head is indicated with Ns. For the primary winding a multicore cable could be used with connectors at both ends. When putting together these connectors all cores are series connected. The turns made with this cable should be well divided around the measuring head. The standard 4-wire resistor must have a proven value and temperature stability. Assuming the TOPACC has a rated current of 1200A, Np must have 120 turns when the standard resistor is 1 . The maximum output voltage (Vout=Vref) depends on the maximum dissipation allowed for the standard resistor. For lowest thermal voltages the connections from Vref and Vout to the DC Null-Voltmeter should be made with copper wire.
To measure the offset error, open the primary circuit (Ip=0). To measure the total error produce a current of 1A in the primary circuit. In the suggested set-up every micro-volt on the DC Null-Voltmeter equals 1 ppm. The ratio error can be found by subtracting the offset error from the total error.
5.2.2 With reference DCCT The following figure demonstrates the use of a reference DCCT for an on-site accuracy check. The main current is applied to one or more turns of both DCCT's. If a DC Null-Voltmeter is used, select the number of turns for Np1 and Np2 in such a way that Vref and Vout are equal. It is also possible to compare Vref and Vout by means of a high precision digital ratio meter. In that case there will be more freedom in choosing the number of turns for Np1 and Np2. Using following circuit (the numbers are only an example) it is possible to easy check the accuracy at rated current level. When the test is done in a climate chamber it is also possible to check the ratio and offset error versus temperature. When making a recording of the test it is very useful to make a calibration step of about 10ppm to indicate the sensitivity on the paper. Figure 19 Accuracy check with reference DCCT
5.3 Calibration If calibration of the DCCT is desired, one of the test circuits suggested in the accuracy check description can be employed. However a special test set-up will be needed for both the Flux Compensator Board and the Voltage Output Board.
This test set-up must be wired according to drawing ZF 06.170.04, external connections, in Appendix I. For adjusting the CRM also, modify the external connections of the Voltage Output Board according to the following figure. Use normal silicon rectifier diodes for general purposes with a current rating of 1A. This circuit produces a common mode voltage for the Precision Amplifier when jumper W is opened while there is flowing a secondary current.
Figure 20 Modification of external connections
5.3.1 Procedure for adjusting offset - Remove the protection labels on the shielding-box of the precision amplifier to get access to Potentiometers R1,R2 and R3. See drawing ZF 00.641.02 in Appendix I. Do not remove the shielding-box itself. - Open the primary circuit to make sure the primary current is zero. - Connect a DC null-voltmeter directly across the output of the TOPACC 1.0 - Minimize the offset with potentiometer R3. Reverse connections to the null-voltmeter to identify thermal voltages
Note: Adjusting potentiometer R1 on the Flux Compensator Board for loop offset is described under chapter 5.1.5 "AC-Loop"
5.3.2 Procedure for gain and CMR - Connect the DC null-voltmeter as indicated in the suggested test circuits of the accuracy check description. - Produce a primary current resulting in an output voltage of 1V or 10V depending on the used test circuit. - Minimize the reading on the DC null-voltmeter with potentiometer R1 (gain) - Open jumper W (see fig.20) and minimize again the reading by turning potentiometer R2 (CMR). - Close jumper W and repeat the adjustment with potentiometers R1 and R2 . - Check, after the calibration has been completed, if jumper W is firmly placed ! - Stick protecting labels on the holes of the shielding-box
Note: When adjusting gain and CMR take into account both the offset of the unit you are calibrating and the reference
6. OPTIONS FOR THE SYSTEM TOPACC 1.0 6.1 For all models - Increased thermal stability
- Longer cable between electronics module and measuring head
- Primary bus bar for the measuring head
- Current output ( 1A rated current) instead of a voltage output. The maximum value of the external burden resistor is in that case 1.
- Partially magnified reading or a so called "lens type". As an example: 60 A gives an output voltage of 10V, but the primary current can rise up to 3000A
without saturation of the measuring head taking place.
- Multiple output a: 2 outputs simultaneously available, for example 4000A/10V and 100A/10V b: One normal output and one low-pass output (i.e. 10h) for example 2000A/10V and one filtered output of 50A/10V with a bandwidth of 10Hz. This is sometimes used for static-VAR applications to detect DC-currents in AC-lines. - Multiple measuring range by means of taps on the secondary winding of the measuring head. Up to 5 taps selectable with a local or remote switch.
6.2 Special for 19" rack-mount chassis - The taps for a multiple measurement range can be selected jumper settings at the rear side of the electronics module or with an optional rotary switch in the front panel. - LCD panel display with an accuracy of 0.1% in the front panel of the electronics module for monitoring the output signal. - Test points on the front panel for several internal signals - 4-terminal output at the front panel for workbench use
7. APPENDIX I DRAWINGS AND PARTS LISTS
7.1 General Document number Lay-out flux compensator ZF 639 ZF 00.639.02 Lay-out voltage output ZF 641 ZF 00.641.02 Dimensions measuring head model B. 0...2000A ZF 06.718.02 Dimensions measuring head model E. 2000...6000A ZF 06.267.02
7.2 Printed Circuit Board and Euro cassette additions