Download Op5511 User Manual - Opal-RT

OP5000 Signal Conditioning & I/O Products
for RT-LAB Engineering Simulators
OP5511 High-current and high-voltage input conditioning module
User Manual
Published by
Opal-RT Technologies, Inc.
1751 Richardson, suite 2525
Montréal (Québec) Canada
H3K 1G6
www.opal-rt.com
© 2004 Opal-RT Technologies, Inc.
All rights reserved
Printed in Canada
OP5511_user_manual-E_4V4I.doc
Rev. E
Page 2
Preliminary Information
High-current and high-voltage input conditioning module
1 INTRODUCTION
The high-current and high-voltage input conditioning module allows the conversion of 4
current and 4 voltage signals to ±10V voltage level. The current inputs are factory
configurable for up to 50A continuous. The measured voltage range is configurable for up
to 600 volts by jumpers.
2 DESCRIPTION
The high current and high voltage input conditioning module allows the conversion of
current and voltage to +- 10 volts signals. Such modules are typically used for monitoring
current and voltage on DC/AC motors.
The front panel has activity and out-of-range LEDs for each channel. For currentmeasurement channels, the activity LED (green) turns on when a current above 200mA is
detected, while the out-of-range LED (red) turns on when the upper current limit of the
selected sensor has been reached. For voltage-measurement inputs, the activity LED
(green) turns on at 2V, while the out-of-range LED turns on when the upper voltage limit of
the selected range has been reached.
2.1 CHASSIS LAYOUT
Figure 1: High-current and high-voltage input conditioning module (Front)
Page 1
Figure 2: High-current and high-voltage input conditioning module (Back)
2.2 FEATURES
•
•
4 current-measurement inputs, factory configurable for up to 50 Amps continuous.
4 voltage-measurement inputs, jumper configurable from 50 volts to 600 volts
range.
Rugged screw terminal connections
Compatible with Opal-RT OP5340 analog input module
Activity and Out-of-range LEDs for each channel
•
•
•
2.3 BOARD SETTINGS
2.3.1
VOLTAGE RANGE
The input voltage range is configured using a jumper on the circuit board. Each channel
(Ch. A to Ch. D) can have a different range.
Available Voltage Range
50 V (no jumper)
100 V
200 V
400 V
600 V (default)
Table 1: Available voltage ranges
Page 2
Figure 3: Jumper for voltage
configuration
Preliminary Information
High-current and high-voltage input conditioning module
2.3.2
PIN ASSIGNMENTS
Figure 4 shows the front panel of the module where I/O-level signal outputs and power
input are located. Connector J1 (DB25) would generally be connected to an analog-todigital converter, such as the OP5340. The conditioning module requires a regulated ±15
volts power supply to be used. In order to reduce noise, a linear power supply is preferred.
Power is connected to the J2 connector. Table 2 and Table 3 present the pin assignments
for both J1 and J2 connector.
See Appendix B for mating connector part numbers.
FRONT PANEL
Analog Output
Signals connector
(J1)
Minimum Voltage & Out of
Range Indicators
Connector
+-15 VDC
(J2)
Indicators
+-15 VDC
Minimum Current & Out of
Range Indicators
Figure 4: Front panel connectors
Pin#
1
2
3
4
5
6
7
8
9
10
11
12
13
Description
Ch A Current Sensor Output
Ch B Current Sensor Output
Ch C Current Sensor Output
Ch D Current Sensor Output
Ch A Voltage Sensor Output
Ch B Voltage Sensor Output
Ch C Voltage Sensor Output
Ch D Voltage Sensor Output
ID0
ID2
N/C
- 15 volts (reference)
+ 15 volts (reference)
Pin#
14
15
16
17
18
19
20
21
22
23
24
25
Description
GND
GND
GND
GND
GND
GND
GND
GND
ID1
N/C
GND
GND
Table 2: J1 Connector
Pin#
1
2
3
4
Description
-15 volts
GND
+15 volts
GND
Table 3: J2 Connector
ID2
ID1
ID0
Value
0
0
0
Invalide-Default
0
1
0
4CH @ 5A
1
0
0
4CH @ 15A
1
1
0
4CH @ 25A
0
0
1
4CH @ 50A
0
1
1
Mixed channel
1 = 3.3V on pin
Table 4 : ID configuration
Page 3
The back panel includes screw terminals to connect the current (J3) and voltage (J4)
inputs. To minimize connection resistance, it is highly recommended to connect only 1 wire
per screw for the current input pins. If the same pin is needed to provide both current and
voltage measurement, the J5 connector shall be used. See description below for details.
AUXILIARY CONNECTOR (J5)
Figure 5: Back panel connectors
•
Current connector (J3)
Pin #
1
2
3
Part number:
Nominal current:
Nominal voltage:
AWG conductor:
Page 4
4
5
6
7
8
PC 16/8-STF-10,16
55 A
300 V
min. 18
max. 6
1
2
3
4
5
6
7
8
Description
+ Channel A
- Channel A
+ Channel B
- Channel B
+ Channel C
- Channel C
+ Channel D
- Channel D
Preliminary Information
High-current and high-voltage input conditioning module
•
Voltage connector (J4)
Pin #
1
2
3
4
Part number:
Nominal current:
Nominal voltage:
AWG conductor:
•
5
6
7
8
BLZ 5.08/8F SN SW
10 A
300 V
min. 26
max. 12
Description
1
+ Channel A
2
- Channel A
3
+ Channel B
4
- Channel B
5
+ Channel C
6
- Channel C
7
+ Channel D
8
- Channel D
Auxiliary connector (J5)
Pin #
1
2
3
4
Part number:
Nominal current:
Nominal voltage:
AWG conductor:
5
6
7
8
9 10
MC 1,5/10-STF-3,81
8A
300 V
min. 28
max. 16
Description
TP
1
Ch. A – Current Connector
J12
2
Ch. B – Current Connector
J22
3
Ch. C – Current Connector
J32
4
Ch. D – Current Connector
J42
5
Ch. A – Voltage Common
J11
6
Ch. B – Voltage Common
J21
7
Ch. C – Voltage Common
J31
8
Ch. D – Voltage Common
J41
9
GND – Internal ground
J1
10
GND – Internal ground
J2
The first four (4) outputs, dedicated to the voltage measure, are connected to their
respective channels of the current connector. Because of the unique structure of the
current sensor component, the impedance between positive and negative input of each
current channel is very small so the potential difference between them is almost inexistent.
For this reason, only one output per channel is available on the auxiliary connector (J5).
The next four (4) outputs are connected to the common points of the voltage sensor inputs.
The common point is connected to the middle of the resistor ladder between the positive
and negative inputs. The voltage inputs are composed of differential amplifiers thus the
common points can be connected to the internal ground of the circuitry that is available on
the auxiliary connector (J5), pin 9 and 10.
See Appendix C for connection example.
Page 5
3 BOARD CALIBRATION
Each high-current and high-voltage input conditioning board is calibrated after
manufacturing. Two modes of calibration are available. The board can be calibrated using
the reference voltages generated on the board or external source of current/voltage
connected directly to the bloc terminals. The calibration of each channel is done
separately. The offset and the gain are fine-tuned using multiturn potentiometers.
3.1 REFERENCE VOLTAGE SETTING.
There are two reference voltages on the board to be set: at +2.5 volts and –2.5 volts. They are used
for calibration and minimum input signal (activity) and out-of-range indicators.
-2.5V Ref
+2.5V Ref
RV2
RV1
Figure 5: Voltage reference section
o
o
o
o
Locate RV1 and RV2 potentiometers on the board (see APPENDIX E to locate them).
Connect a precision voltmeter between ground and the point +2.5V on the board (see
Figure 5 above)
With RV1 potentiometer, adjust exactly the reference voltage to + 2.5 volts. More
precise adjustment will be, the better results can be reach with the board.
Do the same tuning for –2.5 volts using RV2 potentiometer.
3.2 CALIBRATING THE BOARD WITH REFERENCE VOLTAGES.
This is the first step of calibration, which permits to ensure the accurate functioning of the output
section. See APPENDIX E for more details to locate the four Current Channels. See APPPENDIX F
for more details to locate the four Voltage Channels.
ƒ
Locate first voltage channel on the board. The calibration section is composed of two
multiturn potentiometers (RV11A, RV12A), headers with shunt (W12A, W13A) and
rotary selector switch (S13A).
Page 6
Preliminary Information
High-current and high-voltage input conditioning module
CH A
C25A
Cap
W12A
RV12A
Offset
600V
Gain
SIG
calibration
W13A
400V
RV11A
GND
-2.5V
100V
200V
+2.5V
measure
50V
5
Filter
7
S13A
Figure 6: Calibration section
ƒ
Choose filter value by setting the appropriate rotary switch. Refer to the drawing below
for existing filter values. Refer to APPENDIX D for a more detailed location.
5
5
2
1
7
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
1
OFF (no filter)
2
200 HZ
3
2 KHZ
4
20 KHZ
5
4
7
Filter
7
5
3
Position
7
Connect a precision voltmeter to the first voltage channel output of the connector J1.
Refer to the section 2.3.2 to know the channel output position on the connector.
Remove the shunt from the header W12A and put it on GND position of the header
W13A.
Adjust RV12A potentiometer to read 0.000 volts on the output.
Next, change the shunt to +2.5V position of the header.
Adjust RV11A potentiometer to read –10.000 volts with the tolerance of +/- 0.005 volts.
Change the shunt to –2.5V position. The voltmeter should show the same value as for
the previous measure but with reverse sign if the reference voltage was properly
adjusted precisely.
After the calibration replace the shunt on the header W12A.
Repeat these steps for the other channels. The part reference change with channels.
For the voltage channels, the Gain potentiometers go from RV11A to RV11D, the Offset
potentiometers go from RV12A to RV12D, the header go from W13A to W13D and the
rotary switch from S13A to S13D.
For the current channels, the Gain potentiometers go from RV51A to RV51D, the
Offset potentiometers go from RV52A to RV52D, the header go from W53A to
W53D and the rotary switch from S53A to S53D.
Page 7
3.3
CALIBRATING THE BOARD WITH EXTERNAL SOURCES.
The first method of calibration (previous section 3.2) with the reference voltage is adequate if the lack
of input section adjustment is compensated in the Simulink model. This situation can take place if the
frequent changes of input range are considered. It can occur as well in the manufacturing process
when the customer needs are not known.
The second method of calibration requires additional current and voltage sources, which cover whole
range of the input channels. The calibration procedure is similar to the first method but the reference
voltage is replaced by the external sources.
Locate first voltage channels on the board. The calibration section is composed of two
multiturn potentiometers (RV11A, RV12A), headers with shunt (W12A, W13A) and
rotary selector switch (S13A).
CH A
W12A
C25A
Cap
RV12A
Offset
RV11A
600V
Gain
calibration
W13A
400V
SIG
-2.5V
100V
200V
GND
measure
50V
+2.5V
ƒ
5
Filter
7
S13A
Figure 6-1: Calibration section
ƒ
Choose filter value by setting the appropriate rotary switch. Refer to the drawing below
for existing filter cut-off frequency. Refer to APPENDIX D for a more detailed location.
5
5
2
1
7
Page 8
1
OFF (no filter)
2
200 HZ
3
2 KHZ
4
20 KHZ
5
4
7
Filter
7
5
3
Position
7
Preliminary Information
High-current and high-voltage input conditioning module
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
3.4
Choose voltage range. Section 2.3.1 describe the voltage range setting.
Connect a precision voltmeter to the first voltage channel output of the connector J1.
Refer to the section 2.3.2 to know the channel output position in the connector.
Make sure the shunt is on the header W12A.
Connect the voltage source to the first voltage input channel. Set it to 0 volts
Adjust RV12A potentiometer to read 0.000 volts on the output.
Next, change the voltage source to the range maximum value. For example, set the
source to 100 volts if 100V range was chosen.
Adjust RV11A potentiometer to read 10.000 volts with the tolerance of +/- 0.005 volts.
Make some measure e.g. at 25%, 50%, and 75% of the range and ensure the accuracy
of readings.
Repeat these steps for the other channels. The parts references change with channels.
The same procedure will be followed, as explained in the previous section for adjusting
the Gain and Offset potentiometers.
OPTIMIZING THE STEP-RESPONSE.
This adjustment to optimize the step-response for each channel.
APPENDIX G shows the location of the variable capacitors for the four Current channels and for the
four Voltage channels.
1.Select the proper SENSOR (5A, 15A, 25A, 50A) with the appropriate jumper for each channel or
select the proper range of operation (50v, 100v, 200v, 400v, 600v) with the appropriate jumper for
each channel
2. Connect a Function Generator G at the corresponding channel input.
3. Adjust the corresponding variable capacitor Cap X to get the best step response at the Outputs
COx and VOx on an oscilloscope.
Page 9
APPENDIX A - SPECIFICATIONS
CURRENT SENSOR CHANNEL
ƒ
Input range: factory setting (available in 5, 15, 25 and 50 amps)
ƒ
Signal output range: ± 10 volts
ƒ
Isolation: galvanic, 2.5 kV
ƒ
Bandwidth: DC to 100 kHz
ƒ
Linearity: < 0.2%
ƒ
Accuracy: < 0.5%
ƒ
Rise time: < 2 microseconds
ƒ
Power supplies: ±15 volts
VOLTAGE SENSOR CHANNEL
ƒ
Input range: jumper-selectable (50, 100, 200, 400, and 600 volts)
ƒ
Signal output range: ± 10 volts
ƒ
Common mode: greater than 200 volts after the resistive divider
ƒ
Bandwidth: DC to 100 kHz
ƒ
Linearity: < 0.2 %
ƒ
Accuracy: < 0.5 %
ƒ
Rise time: < 2 microseconds
ƒ
Power supplies: ±15 volts
CASING
ƒ
Page 10
Physical dimensions: 6.3" x 6.3" x 2.0"
Preliminary Information
High-current and high-voltage input conditioning module
APPENDIX B – MATING CONNECTORS
J1 Output Signals Connector
Figure 6: J1 connector (Front view)
Part number for cable
Qty
1
1
1
Manufacturer
Belden
NorComp
NorComp
Man. Part#
Description
9734
171-025-103L001
970-025-030R121
12-pair, individually shielded, cable
DB-25 plug, male contacts
DB-25 metal back-shell
J2 Power Connector
3
1
4
2
Figure 7: J2 connector (Front view)
Part number for cable
Qty
1
1
Manufacturer
Switchcraft
Alpha Wire
Man. Part#
TA4FL
1174C
Description
Q-G series cord plug
4-wire cable
Page 11
APPENDIX C – CONNECTION EXAMPLE
Interconnection for measurement
Only one channel CURRENT and one channel VOLTAGE represented
INPUT VOLTAGE J4
connector
+
+
+
+
VOLTAGE DIVIDER
AUXILIARY J5
connector
Ch.D
Ch.C
Ch.B
Ch.A
GND Internal Ground
GND Internal Ground
cD
Ch.D-Voltage
cC
Ch.C-Voltage
cB
Ch.B-Voltage
cA
Ch.A-Voltage
Id
Ch.D-Current
Ic
Ch.C-Current
Ib
Ch.B-Current
Ia
Ch.A-Current
V+
INPUT CURRENT J3
connector
+
+
ISOLATION
CURRENT SENSOR
+
+
-
Ch.D
MOTOR
Ch.C
VCh.B
Ch.A
High Current Wire
Low Current Wire
MODULE SIDE
USER SIDE
To measure the Current, the cable has to pass through the Ch. A Input Current removable
terminal screw connector (contact Ch. A+ and contact Ch. A.- )
To measure the Voltage, only one wire from the motor to be connected to the Ch. A- Input
Voltage removable terminal screw connector, the other part of the voltage Ch. A+ is
already available on the Auxiliary connector (internal connection). Make an external wire
connection between Auxiliary Ia and Voltage Ch. A+
If the reference Motor Voltage has the same ground as the Simulator, connect on the
Auxiliary connector the common point Ch. A Voltage to the Simulator Ground with an
external wire.
Page 12
Preliminary Information
High-current and high-voltage input conditioning module
APPENDIX D. FILTER FREQUENCY SELECTION
Detail for each frequency selector, same for both Current and Voltage Channels.
5
NONE
7
5
200 HZ
7
5
VOLTAGE
CHANNEL
CURRENT
CHANNEL
A
B
C
D
A
B
C
D
S13A
S13B
S13C
S13D
S53A
S53B
S53C
S53D
2 KHZ
7
5
20 KHZ
7
Page 13
APPENDIX E. CURRENT SENSOR GAIN-OFFSET ADJUSTMENT
1. LAY-OUT FOR CURRENT CHANNEL POTENTIOMETERS
-2.5V Ref
+2.5V Ref
RV2
C63A
Cap
Offset
W53A
SIG
GND
-2.5V
calibration
RV51A
Gain
25 A
50 A
RV52A
measure
5A
15 A
5
Filter
7
S53A
W51A
Offset
W53B
RV51B
SIG
measure
GND
5A
15 A
25 A
50 A
RV52B
W52B
-2.5V
CH B
C63B
Cap
+2.5V
CURRENT
SENSORS
W52A
+2.5V
CH A
RV1
calibration
Gain
5
Filter
7
S53B
W51B
Offset
W53C
SIG
GND
-2.5V
measure
5A
15 A
calibration
RV51C
Gain
25 A
50 A
RV52C
W52C
+2.5V
CH C
C63C
Cap
5
Filter
7
S53C
W51C
RV52D
Offset
Gain
calibration
SIG
W53D
RV51D
GND
measure
-2.5V
5A
15 A
25 A
50 A
5
Filter
7
S53D
W51D
Page 14
W52D
+2.5V
CH D
C63D
Cap
Preliminary Information
High-current and high-voltage input conditioning module
2. CALIBRATION CURRENT CHANNEL PROCEDURE:
1.Select the proper SENSOR (5A, 15A, 25A, 50A) with the appropriate
jumper for each channel
2. Put current I to zero by disconnecting the inputs and cancel out the
output Offset Voltage with the appropriate potentiometers Offset A, Offset
B, Offset C, Offset D
3. Put current I to a known value between in the range and adjust the Gain
with the appropriate potentiometers Gain A, Gain B, Gain C, Gain D
4. If the channels don't have the same SENSOR, they must be calibrated
individually at the step 3
R
I
+
Ch A
Gain A
+
V
+
+
I
-
Offset A
Gain B
Offset B
Ch B
Gain C
Offset C
Ch C
Gain D
1
14
CO1 (Channel A)
2
15
CO2 (Channel B)
3
16
CO3 (Channel C)
4
17
CO4 (Channel D)
Offset D
Ch D
Page 15
APPENDIX F. VOLTAGE SENSORS GAIN-OFFSET ADJUSTMENT
1. LAY-OUT FOR VOLTAGE CHANNEL POTENTIOMETERS.
CH A
C25A
Cap
W12A
Gain
CH B
SIG
GND
calibration
W12B
Offset
W13B
SIG
GND
-2.5V
+2.5V
calibration
RV11B
400V
Gain
600V
CH C
Offset
W13C
SIG
GND
-2.5V
+2.5V
calibration
RV11C
400V
Gain
-2.5V
100V
RV11D
Gain
W12D
RV12D
measure
Offset
calibration
W13D
C25D
Cap
50V
Filter
7
SIG
CH D
5
S13C
GND
600V
Filter
7
RV12C
W12C
measure
100V
200V
5
S13B
C25C
Cap
50V
Filter
7
RV12B
measure
100V
200V
5
S13A
C25B
Cap
50V
Page 16
W13A
600V
+2.5V
-2.5V
400V
RV11A
+2.5V
VOLTAGE
SENSORS
200V
600V
Offset
measure
50V
100V
200V
400V
RV12A
5
Filter
7
S13D
Preliminary Information
High-current and high-voltage input conditioning module
2. CALIBRATION VOLTAGE CHANNEL PROCEDURE:
1.Select the proper range of operation (50v, 100v, 200v, 400v, 600v) with
the appropriate jumper for each channel
2. Put V to zero by shorting the inputs. Measure at Vox and cancel out the
Offset Voltage with the appropriate potentiometers Offset A, Offset B, Offset
C, Offset D
3. Put V to a known voltage between 0 and the maximum of the range.
Measure at VOx and adjust the Gain with the appropriate potentiometers
Gain A, Gain B, Gain C, Gain D
4. If the channels don't have the same range of operation, they must be
calibrated individually at the step 3
+
+
+
+
Gain A
-
Offset A
5
18
VO1 (Channel A)
6
19
VO2 (Channel B)
7
20
VO3 (Channel C)
8
21
VO4 (Channel D)
Gain B
+
+
+
+
-
Offset B
Ch A
Ch B
Gain C
Offset C
Ch C
Ch D
Gain D
Offset D
V
Page 17
APPENDIX G. STEP-RESPONSE ADJUSTMENT
+
Cap A
Ch A
+
Ch B
+
Ch C
-
Cap B
Offset B
Gain B
Cap C
Offset C
Gain C
Cap D
Offset D
Gain D
+
Cap A
Ch D
-
Offset A
Gain A
+
+
+
+
-
Ch A
Ch B
Ch C
Ch D
VOLTAGE
CHANNELS
Cap B
G
Offset A
Gain A
CURRENT
CHANNELS
G
Offset B
Gain B
Cap C
1
14
CO1 (Channel A)
2
15
CO2 (Channel B)
3
16
CO3 (Channel C)
4
17
CO4 (Channel D)
5
18
VO1 (Channel A)
6
19
VO2 (Channel B)
7
20
VO3 (Channel C)
8
21
VO4 (Channel D)
Offset C
Gain C
Cap D
Offset D
Gain D
CALIBRATION FOR OPTIMAL STEP-RESPONSE:
1.Select the proper SENSOR (5A, 15A, 25A, 50A) with the appropriate jumper for
each channel or select the proper range of operation (50v, 100v, 200v, 400v, 600v)
with the appropriate jumper for each channel
2. Put a Function Generator G at the corresponding channel inputs.
3. Adjust the corresponding variable capacitor Cap X to get the best step response
at the Outputs COx and VOx.
Page 18