CRD5463PM - CRD5463PM Power Monitor

CRD5463PM
CRD5463PM Power Monitor
Reference Design and Software
Features
General Description
 Easy Plug-and-play Design
 USB Communication with PC
 Real-time Measurements:
The CRD5463PM demonstrates the CS5463 power
measurement IC. It has an integrated AC-DC power supply,
voltage and current sensors, and isolated UART/USB
interface. Working with the GUI software, it provides accurate
real-time measurements of line voltage, load current, line
frequency, active power, reactive power, apparent power,
power factor, and temperature.
–
–
–
–
–
–
–
–
Line Voltage
Load Current
Active Power
Reactive Power
Apparent Power
Power Factor
Line Frequency
Temperature
 Operational Voltage: 90 ~ 260 VAC
 Maximum Load Current: 15 A RMS
 Active Power Measurement Accuracy:
– 0.2%, 3 ~ 3900 W
 Lab Windows™/CVI™ GUI Software
 Factory Calibrated, Re-calibration Capable
The CRD5463PM includes two power cords, a USB cable, and
a plug adaptor. When used with a PC, the CRD5463PM
immediately becomes a high-precision power meter. The
UART interface communication protocol, GUI, and MCU
software source codes are also available from Cirrus Logic.
The CRD5463PM is a useful design reference and evaluation
tool for customers to develop power metering/monitoring
systems that use the CS5463 IC.
ORDERING INFORMATION
CRD5463PM Power Monitor Reference Design
AC Line
Input/Switch
USB Port
Actual Size:
120mm x 120mm x 60mm
www.cirrus.com
AC Load
Copyright  Cirrus Logic, Inc. 2010
(All Rights Reserved)
OCT ‘10
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CRD5463PM
1. CHARACTERISTICS AND SPECIFICATIONS
1.1 Recommended Operating Conditions
Parameter
Symbol
Min
Typ
Max
Unit
VAC
90
-
260
V
RMS Current
Irms
-
-
15
A
Peak Current
Ipeak
-
-
22
A
Freq
5
2000
Hz
TA
-40
-
+85
ºC
Symbol
Min
Typ
Max
Unit
Current Consumption
IAC
-
79
-
mA
Power Consumption
PAC
-
2.3
-
W
RMS Voltage Measurement (90 ~ 260 VAC)
Vaccu
-
±0.1
-
%
RMS Current Measurement (30 mA ~ 15 A)
Iaccu
-
±0.2
-
%
Active Power Measurement (3 W ~ 3900 W)
Paccu
-
±0.2
-
%
BW
-
-
2
kHz
Voltage Range
Current Range
Frequency Range
Operating Tempereture
1.2 Electrical Characteristics
Parameter
Power Consumption
Accuracy
(Note 1)
(Note 2)
Measurement Bandwidth
NOTES:
1.
2.
Measured at VAC = 240 V and TA = 25º C.
Measured at TA = 25º C and PF=1.
WARNING
High Voltage Hazard
When the CRD5463PM is connected to AC lines, high voltage is present inside the box.
DO NOT REMOVE THE PROTECTIVE COVER FROM THE CRD5463PM WHEN POWER IS CONNECTED.
GUI
USB
AC
SOURCE
CRD5463PM
Reference
Meter
(V, A)
AC
Load
Figure 1. Calibration and Test Connection Diagram
NOTES:
1.
Voltage drop and power loss in the cable connecting the CRD5463PM and the reference meter may introduce
additional error.
2. The measurement bandwidth of the CS5463 is 2 kHz. At low power factor, the CRD5463PM may measure lower
current and higher power factor than the reference meter if the reference meter has a measurement bandwidth
greater than 2 kHz.
3. When testing at low power factor, the peak load current shall never exceed 22 A.
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2. SYSTEM OVERVIEW
As illustrated in Figure 1, the CRD5463PM is composed of voltage and current sensors, a CS5463 power
measurement device, an ATtiny2313 microcontroller, opto-coupler isolation, and UART-USB converter.
AC/DC
I
Voltage & Current
Sensors
CS5463
Power
Measurement
Isolation
V
MCU
SPI
Reset
Interrupt
UART
UART USB
U
S
B
UART
Figure 2. CRD5463PM Simplified Block Diagram
2.1 DC Power Supplies
There are two isolated +5V DC power domains in the CRD. One is converted from AC power lines through
capacitor-dropper AC/DC power supply and provides +5VDC supply to the CS5463 and MCU. The other
is directly from PC through USB interface and provides +5VDC to the UART-USB converter.
This capacitor type of DC power supply is very low-cost but not efficient. Total power consumption drew
from the AC line is 2.3 Watt and 79mA (tested with 240 VAC input).
2.2 Voltage Sensor
The high AC line voltage must be converted to small voltage signal before being applied onto the CS5463
voltage channel inputs (VIN±). The CRD5463PM uses resistor voltage divider as the voltage sensor.
Vin
R1
Vout
Vout = Vin ×
R2
R2
R1 + R 2
Figure 3. CRD5463PM Resistive Divider Voltage Sensor
The divider ratio is determined by the maximum Vin and the maximum input range of the CS5463 voltage
channel. The maximum input range of the CS5463 voltage channel is 176 mV RMS. The division ratio
shall be chosen to satisfy the equation:
Vin max×
R2
< 176mVrms
R1 + R 2
To leave some margin, the Vout is normally set around 150 mVrms with the maximum Vin. In the
CRD5463PM, R2 is 1 kΩ. R1 is composed of four 422 kΩ resistors to increase the total voltage rating of
the voltage sensor.
When Vin = 260 V RMS, Vout = 260 V × 1 / [1 + (4 × 422)] = 154 mV RMS.
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2.3 Current Sensor
The AC load current must be converted into a low-level voltage signal before being applied to the CS5463.
A shunt resistor is a very common choice for current sensing in power monitoring applications because it
is inexpensive, small, linear, and normally doesn't introduce phase shift.
R Shunt
Vout
Vout = I × Rshunt
I
Figure 4. CRD5463PM Shunt Resistor Current Sensor
Benefiting from its 50x gain amplifier and the low noise level on the current channel, the CS5463 can accommodate the ultra low-value shunt to achieve both low power dissipation at high current and high accuracy at low current.
The shunt resistance is determined by the maximum peak load current (Ipeak) and the CS5463 current
channel’s maximum input range. With the 50x PGA setting, the maximum input range of the CS5463’s
current channel is 50 mVp. Therefore, the Rshunt is chosen to satisfy the equation:
Ipeak × Rshunt < 50 mVp
The power rating of the shunt should be at least twice the actual power dissipation of the shunt with the
maximum continuous load current.
To measure the maximum of 15 A RMS and 23 A peak load current, the CRD5463PM uses a 2 mΩ, 1.5 W
shunt resistor as the current sensor.
2.4 CS5463 Power Measurement IC
The power measurement device CS5463 is on the daughter board. The CS5463 is an integrated power
measurement device which combines two ΔΣ analog-to-digital converter, power calculation engine and a
serial interface on a single chip. The sensed line voltage and load current are first converted into 24-bit
instantaneous values. The powerful on-chip DSP calculates voltage and current RMS values, active power, reactive power, apparent power, power factor, etc.
All these measurement values are available in specifically addressed 24-bit registers which can be accessed through SPI interface.
For more detailed information of the CS5463, please refer to the CS5463 datasheet.
http://www.cirrus.com/en/pubs/proDatasheet/CS5463_F2.pdf
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CRD5463PM
2.5 ATtiny2313 Microcontroller
In addition to the CS5463 on the daughter board, an Atmel™ ATtiny2313 microcontroller is used to initialize the CS5463, convert the SPI into UART, and provide nonvolatile memory for the calibrations.
The ATtiny2313 is an MCU with SPI and UART interfaces, 2 kB Flash program memory and 128 bytes
EEPROM data memory. The MCU acts as a communication bridge between the CS5463’s SPI interface
and the UART of the UART-to-USB converter. The EEPROM data memory is used to store calibration
information.
The hardware connections between the ATtiny2313 and the CS5463 are RESET, SCLK, CS, SDI, SDO,
INT (interrupt), and connection-configurable clock signals. Through the population of the 0 ohms resistor
R15 or R16, the clock source can be shared between the CS5463 and the ATtimy2313. In the current
version of the CRD5463PM, the CS5463 and ATtiny2313 are configured to use their own clock sources.
The CS5463 uses a 4.096 MHz crystal and the ATtiny2313 uses its internal 8 MHz R-C oscillator.
On the daughter board, connector J4 is provided for programming and debugging the ATtiny2313 MCU.
WARNING
High Voltage Hazard
The signal ground for the daughter board is the power line.
DO NOT CONNECT ANY DEBUGGING OR PROGRAMMING TOOLS TO THE J4 CONNECTOR WHEN
AC LINE POWER IS CONNECTED.
Please consult with Cirrus Logic engineering if re-programming the MCU is desired.
For more detailed information of ATtiny 2313, please refer to the ATtiny2313 datasheet.
2.6 Isolated UART
Because the CRD5463PM uses non-isolated components as the current and voltage sensors, the signal
ground of the CS5463 and MCU is the live connection to the main power. However, the signal ground of
the PC USB port is normally chassis ground or earth ground. The electrical isolation must be fulfilled on
the UART communication interface to allow the CRD5463PM to be connected to a PC through a USB
cable without short-circuit and safety problems. The CRD5463PM uses 2 opto-couplers to isolate the
UART interface. The isolation rating is 5300 V RMS.
2.7 UART-USB Interface- FT232R
A USB-to-UART interface IC, FT232R, is used on the main board to interface the CRD to a PC as a virtual
COM port through the USB connection.
3. SOFTWARE CONTROL
The CRD5463PM comes with GUI software and a USB cable to link the CRD to a PC. The GUI was developed with Lab Windows™/CVI™, a software development package from National Instruments Corporation. The GUI software is available for download on the Cirrus Logic web site at:
http://www.cirrus.com/industrialsoftware
The software was designed to run under Windows 2000™ or Windows XP® operating system.
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4. INSTALLATION PROCEDURE
4.1 Software Installation Procedure
FTDI drivers must be installed before the GUI software is launched. Please refer to the following document
for details of how to install the drivers.
4.1.1
GUI Installation
1) Go to Cirrus Industrial Software download website (http://www.cirrus.com/industrialsoftware).
2) Click the link for the GUI desired.
3) Download the file onto the PC and unzip it. A new folder will be created.
4) Open the new folder and run the setup.exe file.
5) Follow the instructions presented by the installation wizard.
6) To Run the GUI, navigate to:
Start > All Programs >Cirrus Power Monitoring Reference (CRD5463PM) > CRD5463PM
4.1.2
Driver Installation
Important: FTDI drivers must be installed before the GUI software is launched. Please refer to the following document for details of how to install the drivers.
http://www.ftdichip.com/Documents/AppNotes/AN_104_FTDI_Drivers_Installation_Guide_for_WindowsXP(FT_000093).pdf
4.2 Using the Software
Before launching the software, connect the CRD to an open USB port on the PC using the provided cable.
Connect the CRD to the main power and the load using provided power cord and plug adaptor. Once the
power has been switched on, the software program can be launched.
4.3 Main Window
When the software is launched, the Main window will appear. This window contains information concerning the software's title, revision number, copyright date, etc.
Figure 5. CRD5463PM GUI Main Window
At the top of the screen is a menu bar which displays user options. The menu bar has three items: System,
Connect, and Help.
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CRD5463PM
4.3.1
Connect Menu
The Connect menu allows user to establish a serial communication connection with CRD5463PM.
Figure 6. CRD5463PM GUI Connect Menu
4.3.2
System Menu
The System menu allows user to operate the power monitoring and re-calibrate the CRD when necessary.
Figure 7. CRD5463PM GUI System Menu
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CRD5463PM
Quit allows the user to exit the evaluation software. Upon selecting Quit, a message windows appears
and queries if exiting the evaluation software is desired.
Figure 8. CRD5463PM GUI Quit Dialog
4.4 Connect
After Connect to the CRD is selected under this menu, a sub-window will appear.
Figure 9. CRD5463PM GUI Connect to CRD5463PM Window
Follow the instructions on the Connect to CRD5463PM window and the The CRD is connected. message
will pop up if the connection has been established correctly.
Figure 10. CRD5463PM GUI Successful Connection Message
Otherwise a error message will appear, indicating that the initial communication has failed.
Figure 11. CRD5463PM GUI Connection Error Message
Check to verify that the USB cable and power cord are connected properly and the power switch is at the
ON position.
8
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CRD5463PM
4.5 Power Monitoring Window
After Monitor is selected under the System menu, the Power Monitoring window will appear. The Power
Monitoring window provides the real time measurements.
Figure 12. CRD5463PM GUI Power Monitoring Window
4.5.1
START and STOP Buttons
To start power monitoring, click the green START button in the window. The CRD will start continuous
analog-to-digital conversion, compute the power parameters every N samples, and send calculation results to the GUI. The GUI software receives the data block from the CRD through the connected USB port
(virtual COM port), convert the raw register values into true power values based on the calibration information read from the MCU internal EEPROM, and display the final measurement results in the window.
Figure 13. Power Monitoring Window, Results Displayed
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CRD5463PM
4.5.2
Define Fundamental Frequency
During initialization, the CS5463 is configured to measure the fundamental frequency automatically – the
AFC bit of the Mode register is set by the MCU. The Define Fundamental Frequency selection box enables the user to disable the automatic frequency calculation function and define the specific line frequency by changing the Epsilon register value..
Figure 14. Power Monitoring Window, Define Fundamental Frequecy Menu
4.5.3
Change Measurement Period
The power measurement period or register refreshing rate depends on the CS5463 sample rate and the
configuration of the CS5463 CycleCount (N) register. By default, N is 4000 and the measurement period
is 1 second. The Measurement Period selection box is used to change the CS5463 CycleCount register
value (N) and therefore, change the measurement period.
Cycle Count (N)
Measurement Period (Seconds)
Refresh Rate (Hz)
8000
2
0.5
4000
1
1
2000
0.5
2
800
0.2
5
400
0.1
10
Figure 15. Power Monitoring Window, Measurement Period Menu
10
DS805RD2
CRD5463PM
4.6 Calibration Window
When Calibration is selected from the System menu in the main widow, the Calibration window will appear. The Calibration window is used to re-calibrate the CRD.
Figure 16. System Calibration Window
4.6.1
Calibration Connections
A stable AC source, an accurate reference power meter, and a stable AC load are needed for calibration.
Follow the connection diagram in the System Calibration window to connect the equipment and CRD. To
minimize calibration error introduced by the voltage drop on the connection wires, the power cable between the CRD and the reference meter should be as short and as large guage as possible.
4.6.2
Irms Offset Calibration
The CRD5463PM Irms offset calibration is to detect and save the residual value in the Irms register when
the load is zero. This value represents the current channel noise level of the CRD. In normal power monitoring operation, this offset will be removed from the Irms register readings. The GUI also forces all the
power measurements to be zero if the Irms register value is smaller than the offset. Follow the procedure
below to operate the Irms offset calibration.
1) Turn on the power source and adjust the voltage to the nominal operation voltage.
2) Switch on the CRD5463PM.
3) Launch the GUI.
4) Open the System Calibration window
5) Turn off or remove the AC load.
6) Click the Irms Offset CAL button, the GUI will prompt the following message to confirm the load
has been removed from the system.
Figure 17. Calibration Process Confirmation Dialog
DS805RD2
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CRD5463PM
7) Click the Yes button to proceed with the calibration process.
8) Wait for the completion of the process. The Irms Offset calibration takes about 4 seconds.
Figure 18. Calibration Completed Dialog
4.6.3
Gain Calibration
The CRD5463PM gain calibration process is to detect and save the Vrms and Irms register values and
associated true voltage and current values. In normal power monitoring operation, the GUI will use these
values to convert the raw register data into true measurement results. The CRD needs gain calibration
under one voltage and load condition only. Follow the procedure below to operate the gain calibration.
1) Turn on the AC source and adjust the voltage to the nominal operation voltage.
2) Switch on the CRD5463PM.
3) Launch the GUI.
4) Open the System Calibration window.
5) Turn on the load. The power factor of the load should be 1 and the load level should be in the range
of your accuracy interest.
6) Enter the calibration condition, AC volatge and AC current with the voltage and current measurements from the reference meter.
7) Click the GAIN CAL button. The following message will pop up.
Figure 19. Calibration Process Confirmation Dialog
8) Wait for the completion of the process. The gain calibration takes about 5 seconds.
Figure 20. Calibration Completed Dialog
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Figure 21. Schematic (Page 1 of 2)
CRD5463PM
5. SCHEMATIC
DS805RD2
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Figure 22. Schematic (Page 2 of 2)
CRD5463PM
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6. BILL OF MATERIALS
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Figure 23. Component Placement ( Top Silkscreen)
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7. BOARD LAYOUT
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Figure 24. Top Routing
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Figure 25. Bottom Routing
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8. REVISION HISTORY
Revision
Date
Changes
RD1
JUL 2010
Initial Release.
RD2
OCT 2010
Updated BOM, schematic, and layer plots to rev B.
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Contacting Cirrus Logic Support
For all product questions and inquiries contact a Cirrus Logic Sales Representative. To find the one nearest to you
go to www.cirrus.com
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Cirrus Logic, Cirrus, and the Cirrus Logic logo designs are trademarks of Cirrus Logic, Inc. All other brand and product names in this document may be trademarks
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Atmel is a registered trademark or trademark of Atmel Corporation or its subsidiaries.
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