PRELIMINARY MANUAL. DC8-50-V3 Current measurement system

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1 PRELIMINARY MANUAL DC8-50-V3 Current measurement system Firmware: v4 Last update: Table of contents Purpose of DC8-50 measurement board...3 DC8-50 advantages:...3 Connecting the power...4 Power connector (P5), top connector...4 Communications port connector (P4), bottom connector...4 Current inputs...4 Voltage measurement on sensor board...4 Power measurement...5 Digital inputs...5 LED indicators on CPU board...5 LED indicators on sensor board...5 Dimensions and mounting holes drawing...6 DC8-50 photo...7 Mounting bracket...8 Specifications...9 Reading the data...10 Measurement modes...10 Supported data formats...10 Average current (A),...10 Maximum current values (A),...11 Minimum current values (A),...11 Average power (kw),...12 Voltage measurement (V),...12 Current average (A), x Maximum current values (A), x Minimum current values (A), x Average power values (W),...14 Voltage measurements (V), x Digital inputs,...15 DI counters,...15 Setup and calibration...16 Serial port configuration...16 Calibration...16 Sensor Offset Calibration...16 Configuration...17 Product data...17 Commands...17 DI Counter Roll Values...17 strana 1/22

2 DI Counter Mode...18 DI setup...18 Current sensor sensitivity...18 Current sensor offset values...18 Voltage sensor offset values...19 Voltage source mappings for power calculations...19 Current calculation factors...19 Voltage calculation factors...20 Current calibration registers...20 Voltage calibration registers...20 DC12 config program...21 Quick start...21 Packaging...22 strana 2/22

3 Purpose of DC8-50 measurement board DC8-50 is designed to measure AC and DC current on its 8 current inputs. In addition it measures power supply voltage up to 60 VDC and DC voltage to 1000 VDC on one isolated high voltage channel. To provide additional monitoring capabilities, the board has two self-powered digital inputs used to monitor voltage free contacts in combiner box. The DCxx boards are produced in several modifications which share the same controller and software. These boards can be used to measure DC current from 10A to 800A. The measurements are presented on galvanically isolated, two wire, RS485 port with Modbus RTU protocol. DC8-50 can be used in many applications: telecom DC power distribution -48VDC solar power stations inside junction or combiner boxes. in power utilities to monitor 110 VDC a 220 VDC control power distribution. DC8-50 advantages: High measurement density. Bi-directional current measurement. Fast response on serial port: 1 ms response time, 5 modbus transactions per second with default port speed (depends on number of registers read). Wide input power voltage 10 VDC do 68 VDC (needed power option needs to be specified on order). Low power 1,5W. Built-in signal processing. Short voltage and current fluctuations can be detected using min and max values. Decaying avarage digital filter for Iavg values. Isolated serial port better reliablitily. Isolated current sensors can measure on high voltage circuits up to 1000 VDC. Both floating point and integer values on MODBUS for compatibility with PLCs. strana 3/22

4 Connecting the power Power supply is connected to the four-pin connector on the controller board. Plus is connected to pin 1 and minus to pin 3. Pins 2 and 4 are used to measure the power supply voltage or 48VDC power in telecom installations. When used on solar electric plants, we recommend to leave these pins unconnected. The 4-pin power connector is marked P5 on the PCB. Power connector (P5), top connector P i n F u n c t i o n 1 Power DC+ 2 Measured voltage +(0..120V) DC 3 Power DC- 4 Measured voltage -(0..120V) DC For both power and measured voltage inputs in P5 connector, we recommend to use a 0,5 A fuse. There is an overvoltage protection device on the board and an external fuse is needed for its proper function. There is no fuse on the board. Communications port connector (P4), bottom connector P i n F u n c t i o n 1 RS 485 A (+) 2 RS 485 B (-) 3 RS 485 ground All three pins are galvanicaly isolated from all other controller circuits. Pin 3 is called RS485 Ground, this is the common ground for RS485 signals, but it is also fully isolated. Please check RS485 connection rules for correct communuications port connection. Current inputs The board contains 4 groups of power connectors. Each group has 2 current inputs and outputs. Each sensor is a separate isolated circuit, but sensors in each group are located closer together, so voltage between these circuits should not be higher than 250VDC. Groups are isolated from each other to 1000VDC. There are four power connectors, one for each group, that are marked on the board as P5, P6, P7 and P8. Power connectors are no-screw type for easy connection. Voltage measurement on sensor board There is one isolated voltage sensor on the board between screw terminals marked strana 4/22

5 and. Measured voltage can be in the range of 0 to 1000 VDC. Voltage sensor is well protected and will not be damaged if reverse polarity voltage is permanently applied. It is recommended that measured voltage should be fused with a 0,5A external fuse with voltage rating corresponding to measured voltage range. Power measurement When voltage inputs are used to measure voltage, power calculations are available on MODBUS map. For flexibility, the three voltage data sources can be mapped to each current data source for power calculations. Please check the MODBUS map description. Digital inputs There are two digital inputs provided on sensor board P$6 connector. The primary use for these inputs is to monitor the status of voltage free contacts. There are two LEDs to display the status. When contact is closed, its respective LED is lit. The digital inputs are scanned at high speed, pulses longer then 100 us can be reliably detected. On the data interface, pulses can be read as zero or one values. At the same time, writeable counters are provided for each input. Counters can be used to detect fast pulse trains. In configuration parameters, users can set de-bounce time and roll values for counters. LED indicators on CPU board There are four LEDs on CPU board: ISO3V3 COM port isolated power (green) 3V3 CPU power (green) TXD Transmit LED (red) RDX Receive LED (green) LED indicators on sensor board LED1, LED2 Two LEDs indicating the status of digital inputs LED3 Isolated power for voltage sensor strana 5/22

6 Dimensions and mounting holes drawing Connectors and sensors strana 6/22

7 DC8-50 photo strana 7/22

8 Mounting bracket The DC12-10R board can be supplied with optional mounting bracket. Mounting bracket simplifies installation to electric switchboard back panel. strana 8/22

9 Specifications P o w e r s u p p l y Input voltage options 12V: 9-20 VDC 24V: VDC 48V: VDC Power consumption 1.5W Overvoltage protection Built-in transil diode Recommended fuse 0.5A (standard fuse, is not supplied with the board) EMI Built-in LC filter C u r r e n t m e a s u r e m e n t Number of channels 8 Measurement range A Nominal current 32 A (this is recommended fuse/breaker rating) Max overload 50A for 1 minute with no damage to sensors Input conductor 16 mm2 hard wire, 10 mm2 stranded wire with ferrule Non-linearity <0,5% of measured value in range of -45A..+45A Accuracy 0.5% of range Series resistance <2 mω V o l t a g e m e a s u r e m e n t o n s e n s o r b o a r d Channels 1 Range VDC Accuracy 0.2 % of range Permanent overload VDC VDC Isolation 2500 VDC from each current input, power supply and data port Impedance 1440 kohm V o l t a g e m e a s u r e m e n t Channels 1 Range VDC Accuracy 0.2% range Impedance 99 kohm D i g i t a l o n p o w e r s u p p l y i n p u t i n p u t s Number of inputs 2 Input voltage -30 VDC VDC C o m m u n i c a t i o n s p o r t Interface Isolated two wire RS485 Speed 9600, 19200, or bps Default settings bps, 1 start bit, 8 bit data, even parity, 1 stop bit Protocol Modbus RTU to published standard V strana 9/22

10 Reading the data IMPORTANT NOTE: DC8-50 shares the same controller and the same firmware with other products with 12 current channels. This board has only 8 channels, but data for unused channels are still available in the modbus map, but the values are invalid and should be disregarded. To read the data the board uses Modbus RTU protocol over two wire RS485 serial link. Default port settings are c, which is the recommended default in Modbus specification. Modbus RTU is open standard published on For reliable Modbus operation it is important to use correct cable and observe the RS485 wiring rules. The rules are also available on Modbus web site. For installations with long cabling, it is essential to use proper over-voltage protection devices for data lines. According to RS485 wiring rules, we recommend to ground the cable shield in one point of the bus. Important: the third pin on communications port is marked COM ground. This pin is internal common ground of the com port and is isolated from all other circuits. Do not use this pin for cable shield grounding. Measurement modes There is measurement mode parameter in configuration settings. When set to DC, current values are average, min and max calculated directly from samples. When set to AC, RMS currents are calculated first, then average min and max values are calculated from RMS. All currents in AC mode are positive. The AC mode is only functional for current measurement. Voltage measuremet is always DC. Power measuremens are not available in AC mode. Supported data formats DC8-50 supports the following data formats:,, UINT32, SINT32 and. The floating point format is not standard for Modbus and many versions of floating point numbers are in use. We support the that is called Float Inverse in Modbus Poll program and IEEEFloat in Schneider Electric ION Enterprise. For those who can not use our, we have the same data available in simple a formats. Average current (A), I1 avg I2 avg I3 avg strana 10/22

11 40007 I4 avg I5 avg I6 avg I7 avg I8 avg I9 avg I10 avg I11 avg I12 avg Maximum current values (A), Maximum values are automatically reset after reading I1 max I2 max I3 max I4 max I5 max I6 max I7 max I8 max I9 max I10 max I11 max I12 max Minimum current values (A), Minimum values are automatically reset after reading I1 min I2 min I3 min I4 min I5 min I6 min I7 min I8 min strana 11/22

12 40065 I9 min I10 min I11 min I12 min Average power (kw), P1 avg P2 avg P3 avg P4 avg P5 avg P6 avg P7 avg P8 avg P9 avg P10 avg P11 avg P12 avg Voltage measurement (V), V1 avg V2 avg V3 avg V1 max V2 max V3 max V1 min V2 min V3 min Current average (A), x I1 avg I2 avg I3 avg strana 12/22

13 40204 I4 avg I5 avg I6 avg I7 avg I8 avg I9 avg I10 avg I11 avg I12 avg Maximum current values (A), x10 Max currents are reset after reading I1 max I2 max I3 max I4 max I5 max I6 max I7 max I8 max I9 max I10 max I11 max I12 max Minimum current values (A), x10 Minimum current values are reset after reading I1 min I2 min I3 min I4 min I5 min I6 min I7 min I8 min strana 13/22

14 40233 I9 min I10 min I11 min I12 min Average power values (W), P1 avg P2 avg P3 avg P4 avg P5 avg P6 avg P7 avg P8 avg P9 avg P10 avg P11 avg P12 avg Voltage measurements (V), x V1 avg V2 avg V3 avg V1 max V2 max V3 max V1 min V2 min V3 min strana 14/22

15 Digital inputs, DI DI DI3 (not used) DI4 (not used) DI counters, CNT CNT CNT3 (not used) CNT4 (not used) strana 15/22

16 Setup and calibration Serial port configuration When power is applied to the control board, the processor always starts with default port parameters. After 10 seconds it will switch over to user configuration saved in flash memory. If you ever loose communications to the board, connect it so that it is the only device on the bus and use the 10 seconds to set the parameters of comm port to correct values. Calibration Calibration is done in manufacturing process of DC8-50. Calibration allows to correct the sensor offsets and sensitivity. Voltage sensors are also calibrated in factory. Calibration process is supported by on-board processor, so the boards can be re-calibrated in the field, provided the calibration voltage and current sources are available. Current calibration is done in two steps: With power supply connected and zero current on sensors, the magic number is written to specified address. The processor will then calculate and save the sensor offset values. Current source is connected to one or all sensors. Measured current value is written to specified address. Processor will calculate sensor sensitivity correction factor and save it to flash. Resulting calibration constants are available for reading only. Sensor Offset Calibration DC8-50 comes pre-calibrated, no additional calibration is needed. However, current sensors may change their zero offset over time because of aging or extreme ambient temperature. This may require additional zero offset calibration in future. Please bear in mind that calibration steps may be different for different versions of firmware. We keep manual versions for each firmare revision, so please check if your manual version corresponds to firmware revision. Here are the steps: 1. Write calibration passcode to This will open calibration mode. 2. Write magic number 7294 to Controller will save current readings as new zero values. This step should be performed when all measured currents are zero. 3. Write 1 to This will close calibration mode, write new values to permanent memory and restart the controller with new constants. strana 16/22

17 Configuration Unit ID: In manufacturing the unit ID is set to last three digits of serial number Port speed: 9600, (default), or Parity: 0 no, 1 odd, 2 even (default) Stop bits: 1 (default) nebo Mode: 0 DC (default), 1 AC Delay 1: TX before delay (usec) (default 1800) Delay 2: TX after delay (usec) (default 1800) Configuration status: 0 user cfg, 1 default cfg AVG time, time aggregation period (sec): 1 default UINT32 Serial number (YYMMDDXXX) UINT32 Firmware version (YYMMDDXXX) UINT32 Configuration code (XXXXXXXXX) I Offset cal Magic number V1 Offset cal Magic number V2 Offset cal Magic number V3 Offset cal Magic number Factory reset Magic number 1278 (reset to Default) Configuration address (related to factory calibration) Product data Commands DI Counter Roll Values CNT1 rval - RollValue for counter DI1 ( ) CNT2 rval CNT3 rval CNT4 rval strana 17/22

18 DI Counter Mode Counter mode: 0= incremented on leading edge (default), 1= incremented on trailing edge, 2= incremented on leading and trailing edges CNT1 mode CNT2 mode CNT3 mode CNT4 mode Debounce period period length [msec] for the recognition of a valid DI ( ) DI setup Current sensor sensitivity Sensor sensitivity. Allowed range [mv/a] Sensor I Sensor I Sensor I Sensor I Sensor I Sensor I Sensor I Sensor I Sensor I Sensor I Sensor I Sensor I12 Current sensor offset values Offset I Offset I Offset I Offset I Offset I5 strana 18/22

19 40957 Offset I Offset I Offset I Offset I Offset I Offset I Offset I12 Voltage sensor offset values Offset V Offset V Offset V3 Voltage source mappings for power calculations Voltage sources: 0=no voltage source specified, 1: V1, 2: V2, 3: V Vsrc Vsrc Vsrc Vsrc Vsrc Vsrc Vsrc Vsrc Vsrc Vsrc Vsrc Vsrc 12 Current calculation factors K I K I K I K I K I5 strana 19/22

20 40989 K I K I K I K I K I K I K I12 Voltage calculation factors K V K V K V3 Current calibration registers Actual measured current is written to these registers in calibration process I1 cal I2 cal I3 cal I4 cal I5 cal I6 cal I7 cal I8 cal I9 cal I10 cal I11 cal I12 cal Voltage calibration registers Measured voltage values are written to these registers in calibration process Measured voltage for calibration V1 cal V2 cal V3 cal strana 20/22

21 DC12 config program Important: use correct version of this program that matches the board firmware! DC12config is designed to change parameters and verify the board performance without the need to study the manual. Quick start Start the program, connect the board to computer using RS485 converter hardware. Press the Connect Board button. Communication status on the bottom status line will show if connection was successful. If board does not respond, set the program to default communication parameters and cycle the power for the board. Use the 10 seconds before the board switches to saved parameters to change the port settings to known values. On measurement tab the measured values are displayed. DC12config is free software and is available on this address: strana 21/22

22 Packaging DC8-50 is delivered in box containing: Assembled DC12-10R with CPU board, M4 mounting spacers and transparent top cover. Three detachable connectors are packed separately in plastic bag. Optional steel mounting bracket if ordered User manual strana 22/22

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