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Page 1: 5100 User's Manual · 1. 1 - Introduction. ABBREVIATIONS P. A Model 5100 Power Analyze. r GPI. B IEEE-488 Instrument Bus Standar. d LE. D front panel indicator ligh. t A,V, W, P

Model 5100Model 5100Model 5100Model 5100Model 5100

Single PhaseSingle PhaseSingle PhaseSingle PhaseSingle PhasePPPPPower Analyzerower Analyzerower Analyzerower Analyzerower Analyzer

UserUserUserUserUser’s Manual’s Manual’s Manual’s Manual’s Manual

revision
This manual was last revised 02/07/01
Page 2: 5100 User's Manual · 1. 1 - Introduction. ABBREVIATIONS P. A Model 5100 Power Analyze. r GPI. B IEEE-488 Instrument Bus Standar. d LE. D front panel indicator ligh. t A,V, W, P

ii

While every precaution has been exercised in the compilation ofthis document, Magtrol, Inc. assumes no responsibility for errorsor omissions. Additionally, no liability is assumed for any damagesthat may result from the use of the information contained withinthis publication.

Trademark Acknowledgments

GPIB-PC is a trademark of National Instruments Corporation.

IBM is a registered trademark International Business Machines Corporation.

QuickBASIC is a registered trademark of Microsoft Corporation.

GE-MOV is a registered trademark of the General Electric Corporation.

FLUKE is a registered trademark of the John Fluke Mfg. Company.

Microsoft is a registered trademark of the Microsoft Corporation.

Supercon is a registered trademark of the Superior Electric Company.

wwwwwwwwwww.w.w.w.w.mmmmmagtragtragtragtragtroooool.cl.cl.cl.cl.cooooommmmm

Sales and TSales and TSales and TSales and TSales and Technical Assistanceechnical Assistanceechnical Assistanceechnical Assistanceechnical Assistance

Manufacturers of:

Motor Test Equipment!

Hysteresis Brakes and Clutches

70 Gardenville ParkwayBuffalo, New York 14224 USA

Tel: (716) 668-5555 or 1-800-828-7844Fax: (716) 668-8705

MAGTROL, INC.MAGTROL, INC.MAGTROL, INC.MAGTROL, INC.MAGTROL, INC.

Rev. B 02/01

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TTTTTable of Contentsable of Contentsable of Contentsable of Contentsable of Contents

SALES AND TECHNICAL ASSISTANCE .............................................................................................. ii

TABLE OF REVISIONS.......................................................................................................................... vi

1 - INTRODUCTION ................................................................................................................................ 1Abbreviations ...................................................................................................................................................... 1

Unpacking ........................................................................................................................................................... 1

Power .................................................................................................................................................................. 1

Fuse Replacement ............................................................................................................................................... 1

Safety .................................................................................................................................................................. 1

Connectors .......................................................................................................................................................... 1

Maximum Ratings ............................................................................................................................................... 1

Installation .......................................................................................................................................................... 2ORIENTATION .................................................................................................................................................................... 2ELECTRICAL LOAD ............................................................................................................................................................ 2IEEE-488 (GPIB) ........................................................................................................................................................... 2

Initial Checkout ................................................................................................................................................... 2

Transient Overloads ............................................................................................................................................ 2

Current Overload ................................................................................................................................................ 2

2 - SPECIFICATIONS .............................................................................................................................. 3Voltage ................................................................................................................................................................ 3

Current ................................................................................................................................................................ 3

Meter Impedance ................................................................................................................................................ 3

Resolution ........................................................................................................................................................... 3Isolation............................................................................................................................................................... 3

Display Auto Zero ............................................................................................................................................... 3

Analog Outputs ................................................................................................................................................... 3

Data Acquisition ................................................................................................................................................. 3ANALOG ........................................................................................................................................................................... 3DIGITAL ............................................................................................................................................................................ 3

Measurement Accuracy ...................................................................................................................................... 4

Accuracy Certification ........................................................................................................................................ 4

3 - CONNECTING THE 5100 .................................................................................................................. 5Surge Protection .................................................................................................................................................. 5

External Shunts ................................................................................................................................................... 5Figure 1. External Shunt Connection ............................................................................................................ 5

Connectors .......................................................................................................................................................... 5

Single Phase AC or DC Connections.................................................................................................................. 6Figure 2. Single Phase AC or DC with Remote Voltage Sense ..................................................................... 6

Three Phase, 3 Wire Delta Connections ............................................................................................................. 6Figure 3. Three Phase, 3 Wire Delta, 2 Wattmeter with Remote Voltage Sense .......................................... 7

Three Phase, 3 Wire Wye, 2 Wattmeter Connections ........................................................................................ 7

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iv

Figure 4. Three Phase, 3 Wire Wye, 2 Wattmeter with Remote Voltage Sense ............................................ 7

Three Phase, 4 Wire Wye, 3 Wattmeter Connections ........................................................................................ 7Figure 5. Three Phase, 4 Wire Wye, 3 Wattmeter with Remote Voltage Sense ............................................ 7

Single Phase Current & Potential Transformer Connections ............................................................................. 8Figure 6. Current & Potential Transformer - Single Phase ......................................................................... 8

Three Phase, 4 Wire Balanced Load, 1 Wattmeter Connections ........................................................................ 8Figure 7. Three Phase, 4 Wire Wye, Balanced Load, 1 Wattmeter............................................................... 8

Three Phase, 3 Wire Balanced Load, 1 Wattmeter Connections ........................................................................ 8Figure 8. Three Phase, 3 Wire, Balanced Load, 1 Wattmeter ...................................................................... 8

4 - OPERATION ...................................................................................................................................... 9General ................................................................................................................................................................ 9

Amperes Display ................................................................................................................................................. 9

Voltage Display .................................................................................................................................................. 9

Watts or Power Factor ........................................................................................................................................ 9

Mode Hold .......................................................................................................................................................... 9

Mode Avg ......................................................................................................................................................... 10

Analog Output Option ....................................................................................................................................... 10Figure 9. Analog Output Connections ........................................................................................................ 10

5 - GPIB COMMUNICATION................................................................................................................. 11GPIB (IEEE-488) .............................................................................................................................................. 11Hardware Installation ........................................................................................................................................ 11

Software Installation ......................................................................................................................................... 11

Primary Address ............................................................................................................................................... 11Figure 10. GPIB Address Selection ............................................................................................................... 11

IBM® and Compatibles Instructions ................................................................................................................ 11READ CYCLE .................................................................................................................................................................. 12

QuickBASIC® Example ................................................................................................................................... 12

GPIB Instruction Set ......................................................................................................................................... 12

Special Functions .............................................................................................................................................. 13

6 - OPERATING PRINCIPLES .............................................................................................................. 14Amperes Transducing ....................................................................................................................................... 14

Voltage Sensing ................................................................................................................................................ 14Figure 11. 5100 Input Circuits ...................................................................................................................... 14

Analog Processing ............................................................................................................................................ 14Figure 12. Block Diagram ............................................................................................................................. 15

Digital Processing ............................................................................................................................................. 15

7 - CALIBRATION ................................................................................................................................. 16General .............................................................................................................................................................. 16

Test Setup .......................................................................................................................................................... 16Figure 13. Calibration Verification Test Setup ............................................................................................. 16

Calibration Verification .................................................................................................................................... 17VOLTS CALIBRATION CHECK ............................................................................................................................................. 17AMPERES CALIBRATION CHECK ........................................................................................................................................ 17WATTS CALIBRATION CHECK ........................................................................................................................................... 18

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v

MINOR ADJUSTMENT (IF NEEDED) ..................................................................................................................................... 18VOLTS ZERO ................................................................................................................................................................... 18AMPERES ZERO ............................................................................................................................................................... 18VOLTS SCALE FACTOR ..................................................................................................................................................... 19AMPERES SCALE FACTOR ................................................................................................................................................. 19VOLTS BALANCE ............................................................................................................................................................. 19CURRENT BALANCE ......................................................................................................................................................... 19WATTS SCALE FACTOR .................................................................................................................................................... 19

APPENDIX A: SCHEMATICS .............................................................................................................. 20Circuit Board 78B128 - LED display ............................................................................................................... 20

Circuit Board 78B141 ....................................................................................................................................... 21

Circuit Board 78B142 ....................................................................................................................................... 22

Circuit Board 78B175 ....................................................................................................................................... 22

Circuit Board 78B143 ....................................................................................................................................... 23

Circuit Board 78B144 ....................................................................................................................................... 24

Circuit Board 78B145 - Digital Readout & MPU ............................................................................................ 25

Parts Location for Circuit Board 78B143 ......................................................................................................... 26

MAGTROL LIMITED WARRANTY ....................................................................................................... 27

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vi

TTTTTable of Rable of Rable of Rable of Rable of RevisionsevisionsevisionsevisionsevisionsDate Change Page Number(s)

02/07/00 Added External Shunt Connection Drawing 5

Page 7: 5100 User's Manual · 1. 1 - Introduction. ABBREVIATIONS P. A Model 5100 Power Analyze. r GPI. B IEEE-488 Instrument Bus Standar. d LE. D front panel indicator ligh. t A,V, W, P

1

1 - Introduction1 - Introduction1 - Introduction1 - Introduction1 - Introduction

ABBREVIATIONS

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FP,W,V,AAVdna

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UNPACKING

The Model 5100 is packed in reusable, shock resistantpacking material that will protect the instrument duringnormal handling. In the event of shipping damage,immediately notify the carrier and MAGTROLCustomer Service Dept.

Save all shipping materials for reuse when returningthe instrument for calibration or servicing.

POWER

The 5100 PA is factory wired for either 120 or 240Vrms, 50/60 Hz, power at 40 volt amps, max. The linecord is a detachable NEMA standard 3 wire which plugsinto the rear access power entry and filter module of the5100 PA. The line cord must be detached from the PAduring servicing.

NOTE: The standard 5100 is factorywired for 120 Vrms power.Wiring for 240 Vrms is availableon special order.

FUSE REPLACEMENT

Remove the line cord and carefully pry up and removethe fuse holder. Use a 1/2 Amp slow blow fuse for 120Vrms or a 1/4 Amp slow blow fuse for 240 Vrms power.

SAFETY

SECURELY GROUND the 5100 PA case byconnecting a good earth ground at the ground stud thatis located on the rear panel. Use a number 12 AWG, orlarger wire.

CONNECTORS

Plugs that mate with 5100 PA connectors:

Superior Electric Supercon®

INPUT (plug, white, female) - PS50GWT

OUTPUT (plug, white, male) - PP50GWT

VOLTS HIGH (plug, black, female) - PS25GB

VOLTS LOW (plug, white, female) - PS25GWT

For your convenience, the above connectors are suppliedwith your 5100 PA.

Use only the above connectors.

NOTE: GPIB (IEEE-488) - 24 Pin busstandard. Not included, must beordered separately.

MAXIMUM RATINGS

LOAD voltage: line to line, or line to common is 600Vrms.

LOAD current: 50 Amperes rms, continuous.100 Amperes rms, 30 sec. max.

REMOTE VOLTAGE SENSE: Line to line is 600Vrms. Also, do not exceed 600 Vrms differentialbetween the VOLTS INPUT and AMPS OUTPUTterminals.

Page 8: 5100 User's Manual · 1. 1 - Introduction. ABBREVIATIONS P. A Model 5100 Power Analyze. r GPI. B IEEE-488 Instrument Bus Standar. d LE. D front panel indicator ligh. t A,V, W, P

2

Magtrol Model 5100 Single Phase Power AnalyzerChapter 1 - Introduction

INSTALLATION

ORIENTATION

The 5100 PA must be mounted within ± 20 degreesfrom horizontal. This insures proper operation of themercury shunt bypass relay.

ELECTRICAL LOAD

Use wire rated for the maximum load current and voltageexpected.

Hint - use wire gauge large enough to insure goodconnector set screw compression on the wire leads.Soldering may be used instead of, or in addition to theset screw.

IEEE-488 (GPIB)

Use only high quality shielded cable conforming to thebus standards.

INITIAL CHECKOUT

Make sure the circuit is completely de-energized byremoving all voltage sources.

Plug the 5100 PA into the 50/60 Hz power mains.Switch the POWER rocker switch (red) to ON andobserve that the digit readouts flash on-off-on and thenindicate zero or a small number. The VOLTS andAMPERES range switch indicator lights will allilluminate. The voltage ranges sequence down from 600through 15 and current ranges sequence down from 50through 2. The 15 Volt, 2 Amp and AUTO indicatorswill remain illuminated. The MODE indicators do notlight during this power-on sequencing.

Your 5100 PA has passed the initial check.

TRANSIENT OVERLOADS

Connect an appropriate transient suppressor in parallelwith all inductive loads. Consult the suppressor vendorsapplication literature for proper selection and sizing.

Damage to the 5100 can result fromexcessive voltage transients generatedby unsuppressed inductive loads.

This damage is not within the scope ofthe normal instrument service and is notcovered by the MAGTROL WARRANTY.

CURRENT OVERLOAD

NO FUSES are in the 5100 PA measuring circuits.Therefore, excessive current passed through the AMPSterminals will cause excessive internal heating andpossible unit damage.

This overload abuse is not covered bythe MAGTROL WARRANTY.

Know your load conditions and double check allconnections. If an overload should occur, immediatelyremove all power , locate and correct the problem beforere-energizing your circuit. If a circuit breaker isinstalled, it must be installed on the LOAD side of the5100 (downstream). This will keep the low impedanceof the input line connected to the 5100 PA for surgesuppression. If the line side must also contain a breaker,it should be delayed in operation to open after the loadside breaker has opened.

Page 9: 5100 User's Manual · 1. 1 - Introduction. ABBREVIATIONS P. A Model 5100 Power Analyze. r GPI. B IEEE-488 Instrument Bus Standar. d LE. D front panel indicator ligh. t A,V, W, P

3

2 - Specifications2 - Specifications2 - Specifications2 - Specifications2 - Specifications

VOLTAGE

Five DC and AC Ranges:

• 15, 30, 150, 300 & 600 Volts DC & Volts rms.

Remote Voltage Sensing:

• Differential input - 110 dB CMRR.

• Maximum of 30 Volts peak, volts low terminalto amps output terminal.

CURRENT

Five DC and AC Ranges:

• 2, 5, 10, 20 and 50 Amps DC and Amps rms.

METER IMPEDANCE

Voltage, DC or AC:

• 3 Megohm load on each voltage range.

Current, DC or AC Ranges:

• 0.011 Ohm shunt resistance in the 2, 5, 10 and20 Amp ranges.

• 0.001 Ohm shunt resistance in the 50 Amprange.

RESOLUTION

Processing resolution is 16 binary bits.

Voltage Display:

• All ranges ≤ 9.999 V is ± 0.001 Volt.

• Ranges ≥10 V and ≤ 99.9 V is ± 0.01 Volt.

• Ranges ≥ 100 V is ± 0.1 Volt.

Current Display:• All ranges ≤ 9.999 A is ± 0.001 Amp.

• Ranges ≥ 10 A and ≤ 50 A is ± 0.01 Amp.

Power Display:

• ± 0.01% of active Volts and Amps range

• GPIB - Amps, Volts and Watts

Same as display resolution.

ISOLATION

1500 Vrms break down from input circuit to chassis(ground).

DISPLAY AUTO ZERO

When the A and V, display indication is less than 0.5 %of range, the displayed value is set to ZERO.Refer to SECTION 5 - SPECIAL FUNCTIONS todisable the AUTO ZERO function.

ANALOG OUTPUTS

This is an optional feature.

Analog AMPS, VOLTS and WATTS output signalsare a relative value of approximately 5 Volts DC forfull scale on each range selected. These outputs arecalibrated to 5.00 Volts DC ± 0.2% for full scale inputon the 10 Amp current range and 150 Volt voltage range(1500 Watt range). Ripple is less than 5 mV.

The outputs are operational amplifiers with animpedance of < 1 Ohm and current capacity of < 4 mA.Each output signal and common is electrically isolatedfrom the measured circuit by 750 Volts continuous and2500 Volts test breakdown. Leakage current is less than0.3 µA at 240 Vrms, 60 Hz.

DATA ACQUISITION

ANALOG

The conversion of true rms to DC is expressed as:

Vrms

≡ ( )1 2

0Tv t dt

T

∫• Rms to DC conversion averaging time constant:

Volts and Amps time constant TC ≅ 60 msec.

Watts time constant TC ≅ 120 msec.

Watts = V × I × cos θ (instantaneous)

DIGITAL

• Processing:

Integration period = 0.10 second.

Display update time = 2 readings per second.

• IEEE-488 (GPIB):

Synchronized = 0.1 sec. per readingNon-synchronized is 0.04 to 0.07 sec perreading.

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4

Magtrol Model 5100 Single Phase Power AnalyzerChapter 2 - Specifications

MEASUREMENT ACCURACY

Specified test conditions: Ambient temperature of 72°± 10°F and power factor of 0.1 to 1.0, lead or lag.

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ACCURACY CERTIFICATION

All instruments are shipped with a CERTIFICATE ofCALIBRATION from MAGTROL Inc. Magtrolpolicies and procedures comply with MIL-STD-45662A. Measurement standards are traceable to theNational Institute of Standards and Technology (NIST).

Instrument calibration every six calendar months isnecessary to maintain full compliance with allspecifications.

If a one year calibration cycle is used, all accuracyspecifications are reduced by 0.1%. After one calendaryear, the instrument is considered to be out ofcalibration.

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5

5100 BACK PANEL

SOURCE

High

Low

LOAD

High

Low

Black

White

WhiteBlack

Ext. Shunt

Input OutputAMPS

High

Low

VOLTS

Black

White

Black

White

External Shunt

3 - Connecting the 51003 - Connecting the 51003 - Connecting the 51003 - Connecting the 51003 - Connecting the 5100

Always install a properly rated circuitbreaker or fuse between the 5100analyzer and the load. Also, make surethat your power source has it's owndisconnect and overload protection thathas an operating time lag that insuresthe load breaker always operates first.

Wire according to all applicable wiringcodes, making sure the wire gauge andinsulation ratings are adequate for yourapplication.

SURGE PROTECTION

Use Metal Oxide Varistors (MOV) or otherPROTECTION:equivalent transient suppressorsconnected between lines at the load (across the load).These suppressors are an absolute necessity wheninductive loads are used. In three phase systems, eachload must have a suppressor.

EXTERNAL SHUNTS

Figure 1. External Shunt Connection

100 All watts

150 EXT-600V-KW

200 EXT-600-KW

250 EXT-300 & 600-KW

400 EXT-300 & 600

750 EXT-150, 300 & 600-KW

1000A EXT-150, 300 & 600

• EXT Shunt must be plugged in (even if not inuse) or 5100 will display “HELP.”

• EXT Shunt is calibrated with one 5100. Calibrationwill be off if used with a different 5100.

• Sense leads to shunt should not be disconnectedor calibration will be off.

• Shunt must be sent back with 5100 forrecalibration.

CONNECTORS

Use the supplied Supercon® connectors.

AMPS:

INPUT - PLUG, WHITE, FEMALE-(PS50GWT)

OUTPUT - PLUG, WHITE, MALE-(PP50GWT)

VOLTS:

HIGH - PLUG, BLACK, FEMALE-(PS25GB)

LOW - PLUG, WHITE, FEMALE-(PS25GWT)

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6

Magtrol Model 5100 Single Phase Power AnalyzerChapter 3 - Connecting the 5100

(WHITE)LOW GND

INPUT

AMPS

5100 PA

OUTPUT

LOW

VOLTS

HIGH

MOV

HIGH (BLACK)EARTH

CB

LOA

DLINE

Figure 2. Single Phase AC or DC withRemote Voltage Sense

THREE PHASE, 3 WIRE DELTA CONNECTIONS

Load true power is the algebraic sum of the two wattmeter readings ( W = W1 × W2 ) regardless of load powerfactor or balance. The general discussion from Figure 2 applies.

NOTE: For load power factor = 0.5, one wattmeter reads zero, as the power factor goes less than 0.5it's power is negative and is subtracted in the algebraic watts summation. The 5100 PA willnot display a minus sign for this condition. If your 5100 has the Analog Output Option, thewatts (relative) polarity is available by measuring both analog watts outputs. For powerfactors greater than 0.5, the polarity of both wattmeters will be the same therefore, true powerin watts is simply the unsigned sum of the wattmeter readings.

SINGLE PHASE AC OR DC CONNECTIONS

This circuit utilizes the 5100 PA REMOTE VOLTAGE SENSE feature by measuring the voltage at the load. Thisincreases measurement accuracy by eliminating line voltage drop from the power measurement. For safety, anoverload circuit breaker (CB) removes all load voltage during an over current condition. Make sure that connectionsfrom the remote voltage sense lines are connected very close to the circuit breaker and the lines from the breaker toload are as short as possible.

If a circuit breaker is used in the input line to the 5100 PA, a circuit should be used that preventsthe breaker from opening until after the load side breaker has operated. Otherwise, potentiallydamaging inductive transients will be applied to the 5100 PA. Damage caused by thesetransients are outside the scope of the MAGTROL WARRANTY.

For voltage sense lines less than 25 feet in length, a twisted pair of #20 gauge (or larger) wire can be used. For lineslonger than 25 feet or lines grouped with other AC conductors, shielded cable should be used. Connect the shield atthe 5100 PA GND terminal. If the wires connecting the load to the 5100 PA OUTPUT are short and the resultingvoltage drop is insignificant, the voltage sense connections can be made at the rear panel of the 5100 PA.

Connect the chassis ground terminal to a good earth ground. Use at least #12 gaugeinsulated copper wire.

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7

Magtrol Model 5100 Single Phase Power Analyzer Chapter 3 - Connecting the 5100

GND

INPUT

AMPS

5100 PA

EARTH

CB

LINE

EARTH

LOAD

LOAD

LOAD

MOV

Ø1

Ø2

Ø3

MOV

MOV

OUTPUT

LOW

VOLTSHIGH

GND

INPUT

AMPS

5100 PA

OUTPUT

LOW

VOLTSHIGH

Figure 3. Three Phase, 3Wire Delta, 2Wattmeter withRemoteVoltage Sense

THREE PHASE, 4 WIRE WYE, 3 WATTMETER CONNECTIONS

Three wattmeters are required for unbalanced loads. Total power is the algebraic sum of the three wattmeter readings.The general discussion from Figure 2 and the power factor discussion of Figure 3 applies.

CBLINE

EARTH

Ø1

Ø2

Ø3

NEUTRAL

GND

INPUT

AMPS

5100 PA

EARTH

OUTPUT

LOW

VOLTSHIGH

GND

INPUT

AMPS

5100 PA

EARTH

OUTPUT

LOW

VOLTSHIGH

GND

INPUT

AMPS

5100 PA

OUTPUT

LOW

VOLTSHIGH

MOV

MOV

MOV

LOA

D

LOADLOAD

W1

W2

W3

Figure 5. Three Phase, 4Wire Wye, 3Wattmeter withRemoteVoltage Sense

THREE PHASE, 3 WIRE WYE, 2 WATTMETER CONNECTIONS

True power is the algebraic sum of the two wattmeter readings regardless of power factor and degree of load balance- see NOTE for Figure 3, concerning power factors less than 0.5. Also, the general discussion from Figure 2 applies.

GND

INPUT

AMPS

5100 PA

EARTH

CB

LINE

EARTH

Ø1

Ø2

Ø3

OUTPUT

LOW

VOLTSHIGH

GND

INPUT

AMPS

5100 PA

OUTPUT

LOW

VOLTSHIGH

MOV

MOV

MOV

LOA

D

LOADLOAD

Figure 4. Three Phase, 3Wire Wye, 2Wattmeter withRemoteVoltage Sense

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8

Magtrol Model 5100 Single Phase Power AnalyzerChapter 3 - Connecting the 5100

THREE PHASE, 4 WIRE BALANCED LOAD, 1 WATTMETER CONNECTIONS

With a balanced load, one wattmeter connected in one phase reads 1/3 of the total power consumed.

WATTSTOTAL = 3 × WATTMETER READING

The general discussion from Figure 2 applies. The three load impedances are equal for balanced loads.

GND

INPUT

AMPS

5100 PA

OUTPUT

LOW

VOLTSHIGH

EARTH

CB

LINE

LOA

D

MOV

01

LOAD LOAD

02

03

NEUTRALMOV

MOV

Figure 7. Three Phase, 4Wire Wye,Balanced Load,1 Wattmeter

THREE PHASE, 3 WIRE BALANCED LOAD, 1 WATTMETER CONNECTIONS

WATTSTOTAL = 3 × WATTMETER READING

An artificial neutral is formed by a star connection of three identical resistors (R). The value of these resistors shouldbe high enough to avoid loading the lines and affecting the power measurement. The general discussion from Figure2 applies. The three load impedances are equal for a balanced load.

GND

INPUT

AMPS

5100 PA

OUTPUT

LOW

VOLTSHIGH

EARTH

CB

LINE

LOA

D

MOV

Ø1

LOAD LOAD

Ø2

Ø3

R

RRMOV

MOV

Figure 8. Three Phase, 3Wire, BalancedLoad, 1Wattmeter

SINGLE PHASE CURRENT & POTENTIAL TRANSFORMER CONNECTIONS

Voltage and current measurement ranges can be extended by using current and potential transformers. Frequencyresponse will be determined by the characteristics of the transformers used. The general discussion from Figure 2applies. Three phase lines can be measured by using the two or three wattmeter techniques previously illustrated.

GND

INPUT

AMPS

5100 PA

OUTPUT

LOW

VOLTSHIGH

MOV 1

EARTH

CB

LOA

D

CT PT

MOV 3MOV 2

LOW (WHITE)

HIGH (BLACK)

LINE

Figure 6. Current & Potential Transformer -Single Phase

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9

4 - Operation4 - Operation4 - Operation4 - Operation4 - Operation

GENERAL

Using Sections 1 and 3 as a guide, connect the 5100.Before connecting the power mains, double check allconnections using an Ohmmeter.

Verify that the overcurrent circuit breaker is open andconnect the power mains.

Observing the 5100 front panel indicators. Turn the 5100power switch ON and confirm proper operation - referto “Initial Checkout” under Chapter 1 - Introduction.

Energize the power mains and apply power to the loadby closing circuit breaker CB. If improper operationoccurs, immediately disconnect power mains, locate andcorrect the problem.

The 5100 has three MODES - HOLD; PF (power factor)and AVG (averaging); five AMPS ranges plus AUTO(autoranging); and five VOLTS ranges plus AUTO. Allhave adjacent red LED's indicating the active mode andmeasurement range.

AMPERES DISPLAY

The AMPS display is a four digit, floating point displayof true AC rms or DC current flowing into the AMPSINPUT connector (white) on the rear panel. For detailedspecifications refer to Chapter 2 - Specifications.

The 5100 defaults to AUTO (auto ranging) at turn on.AUTO up-ranging occurs if the rms current exceedsthe top of the range value plus about 5% or, if a peakvalue exceeds full range rms value × 1.414 plusapproximately 5%.

AUTO down ranging occurs when the current is justless than full range value of the next lower range.

Selection of any amps range pushbutton activates theselected range by overriding the AUTO- range selection- AUTO LED goes off and selected AMPS LEDilluminates. However, the AUTO up-range function isalways silently monitoring the current and is ready toup-range the instrument if the current increases abovethe range full scale. If the current falls below the valueof the originally selected range, that range will then re-activate. The instrument will automatically up-range

from the measured current but will down-range only tothe selected range. The display will show "HELP" whenthe 5100 PA maximum current is exceeded.

VOLTAGE DISPLAY

The VOLTS display is a four digit, unsigned floatingpoint display of AC rms or DC voltage between therear panel HIGH (black) and LOW (white) terminals.

The voltage input is differential (neither terminal tiedto common) allowing connection at a remotely locatedload. This remote connection removes the voltage dropin the load connection wires from the powermeasurement. The VOLTS - LOW terminal (WHITE)must be connected to the AMPS - OUTPUT line at theload - see Figure 1.

The AUTO and manual VOLTS range selection isidentical in operation to the AMPS as described above.

WATTS OR POWER FACTOR

The WATTS display is five digit, unsigned floatingpoint display of power in WATTS or POWER FACTORas a decimal number.

WATTS is the power ON default MODE, press theMODE - PF button for POWER FACTOR MODE.Watts measurements are from milliwatts through 30kilowatts, and Power Factors from 0.0001 through0.9999.

WATTS = V × I × cos θ = TRUE POWER

The WATTS range is set by the AMPS and VOLTSactive ranges.

Power FactorTrue Power

V I≡

×

MODE HOLD

The HOLD pushbutton may be depressed at any time.When depressed, all internal machine functions arehalted except auto ranging. If the AVG (averaging)function is active when the HOLD button is depressed,the last running average value of AMPS, VOLTS andWATTS will be latched on the display.

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10

Magtrol Model 5100 Single Phase Power AnalyzerChapter 4 - Operation

The HOLD and AVG functions can be combined. Seethe MODE AVG paragraph, below.

MODE AVG

AVG is an integration or averaging function on VOLTS, AMPS and WATTS.

Averaging remains active across manual or auto rangechanges.

The averaging function is useful in stabilizing the displaywhen digits are changing because of slowly varyingvalues. Integration periods from seconds to minutes maybe needed.

The HOLD and AVG functions work together. Whenentering AVG with HOLD off, the averaging registersare cleared and integration starts from the current value.With the HOLD function active first, pressing AVGstarts the integration point from the last stored valuesof AMPS, VOLTS or WATTS. When AVG is turnedoff, non-averaged values are displayed and the valuesat that instant are stored in non-volatile RAM and uponreentering the AVG mode will be returned as the newaveraging starting points. Also, when the Analyzerpower is turned off, the last averaged values stored willbe held and returned when the AVG function isreactivated.

The HOLD - AVG function permits truly integratedpower measurements where power is appliedintermittently or, where a combination of devices requireintegrated measurements with interruptions betweenmeasurements.

NOTE: WATTHOURS can bedetermined by using the AVGfunction and a timing clock.

Watthours = (watts avg × time inhours)

Power Factor (PF) is notaveraged.

ANALOG OUTPUT OPTION

This option provides analog output signals for AMPS,VOLTS and WATTS. These three analog outputs withtheir common are isolated from the measured circuitsby 750 Volts continuous and 2500 Volts test breakdown.

The outputs are provided through a standard 5 pin DINstyle connector that is located on the rear panel of the5100 - see figure 9 for connections.

The analog output voltage is calibrated to 5.00 VoltsDC for full scale input on the 10 Amp current rangeand the 150 Volt voltage range (1500 Watt range). Theactual output on other ranges will be a relative valueclose to 5 Volts due to tolerances in gain resistors andinstrumentation amplifiers. For example: Full scaleoutput on the 15 Volt range may be 4.95 Volts DC.The analog output at 12 Volts input would be FS / Rng× Rdg or 4.95 / 15 × 12 = 3.96 Volts DC.

NOTE: Analog output of POWERFACTOR is not provided

See Chapter 2 - Specifications.

Figure 9. Analog Output Connections

N/C 5 1 COM

WATTS 4 2 AMPS3

VOLTS

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11

5 - GPIB Communication5 - GPIB Communication5 - GPIB Communication5 - GPIB Communication5 - GPIB Communication

GPIB (IEEE-488)

The IEEE-488 or GPIB (General Purpose Interface Bus)provides direct connection and control of the 5100 fromany appropriately equipped computer for the purposeof data acquisition and display. MAGTROL factoryassistance is available.

HARDWARE INSTALLATION

A GPIB interface requires installation of an interfacecard in the host computer and driver software residenton the PC's hard disk. MAGTROL can supply theNational Instruments Corp. GPIB-PC2A® interface, forIBM® or compatible PC's.

SOFTWARE INSTALLATION

Formatting and initialization assistance is available fromMAGTROL Customer Service.

All GPIB data acquisition systems require the use oftermination characters to signal the conclusion of a dataexchange. The 5100 uses the Hewlett Packard - HPIB™standard ASCII termination characters "Carriage Return(CR) and Line Feed (LF)", in that order. On a writecycle, the 5100 looks for the CR-LF to signal completionof an instruction and transmits these characters uponconclusion of a data read cycle.

PRIMARY ADDRESS

All instruments serviced on the bus have a separateprimary address code. The factory setting for the 5100is twelve (12). This code can be changed by changingthe DIP switch settings that are located on the rear paneland above the GPIB connector. Change this addressonly if there is an addressing conflict with otherinstrumentation on the bus. Refer to the table in Figure10 to set the DIP switch pattern.

SWITCH SEGMENT

1 2 3 4 5LSB MSB

ADDRESS

01010101010101010101010101010101

00110011001100110011001100110011

00001111000011110000111100001111

00000000111111110000000011111111

00000000000000001111111111111111

012345678910111213141516171819202122232425262728293031

1 2 4 8 16

10

1 2 3 4 5 6 7 8

Not Used

Figure 10. GPIB Address Selection

(Address 12 shown)

IBM® AND COMPATIBLESINSTRUCTIONS

The 5100 PA is configured for the Hewlett Packardstandard termination characters of CARRIAGERETURN (CR hex OD) and LINE FEED (LF hex OA).On a read cycle (5100 to PC), the 5100 expects thestandard IEEE-488 read protocols and primary address.It responds with a data string followed by a CR and LF.This signals the end of a transmission. Upon receipt ofthese characters, the PC must be configured to terminateGPIB communications and proceed with its ownprogram execution. On a write cycle (PC to 5100), the5100 expects to receive: (1) the PRIMARY ADDRESS;(2) INSTRUCTIONAL DATA STRING (3); theTERMINATION CHARACTERS of CR and LF. If

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Magtrol Model 5100 Single Phase Power AnalyzerChapter 5 - GPIB Communication

these characters are not forthcoming, the 5100 has noway of knowing when to terminate handshaking, resetthe GPIB and continue with its program loop. If omitted,the only way to restore operation is to cycle power OFF-ON or, force a GPIB interface reset - if available.

READ CYCLE

In read (5100 to PC) command mode, the 5100 willoutput a data string containing the information on theAMPS, VOLTS and WATTS display.

The ASCII output format is:

A= aa.aaV=vvv.vW=ww.www<CR><LF>

aa.aa is the CURRENT value as displayed on the AMPSdisplay.

vvv.v is the VOLTAGE value as displayed on theVOLTS display.

ww.www is the WATTS value as displayed on theWATTS display.

The string length is always 24 characters. Most PC'swill require that the input string length be dimensioned.

If the 5100 is in PF (power factor) MODE instead ofWATTS, the "W" changes to "P".

QUICKBASIC® EXAMPLE

The following QuickBASIC ® program provides buscontrol and data transfer.

'$INCLUDE: 'c:\gpib-pc\qbasic\qbdecl.bas'

rd$ = SPACE$(24)

eos$ = CHR$(13) + CHR$(10)

CALL IBFIND("gpib0", gpib0%)

CALL IBFIND("dev12", dev12%)

CALL IBSIC(gpib0%)

start:

CLS

LOCATE 23, 1: PRINT "Press any key ..."

LOCATE 1, 1: INPUT "Enter the functioncharacter(s)"; f$

f$ = UCASE$(f$)

wrt$ = f$ + eos$

CALL IBWRT(dev12%, wrt$)

DO

CALL IBRD(dev12%, rd$)

LOCATE 12, 29: PRINT rd$

LOOP WHILE INKEY$ = ""

GOTO start

GPIB INSTRUCTION SET

AA Sets AMPS AUTO ranging on.

A2 Sets AMPS range to 2, AUTO o

A5 Sets AMPS range to 5, AUTO o

A10 Sets AMPS range to 10, AUTO o

A20 Sets AMPS range to 20, AUTO o

A50 Sets AMPS range to 50, AUTO o

AZ Sets AUTO zero oCycle POWER off/on to set AUTO zero on.

CAL Uncalibrated data

CALC Calibrated data

DEV Shifts GPIB operation to DEBUG.

DEVC Shifts from DEBUG to standard GPIB.

H Sets HOLD function on.

HC Sets HOLD function off.

I Sets the AVG function on.

IC Sets the AVG function off.

L Locks out all front panel controls

LC Clears front panel lockout.

OPEN Allows GPIB data access at random.

P Sets WATTS display to show PF.

SYNC Sync's data access to 0.1 sec

VA Sets VOLTS AUTOranging on.

V15 Sets VOLTS range to 15, AUTOzero o

V30 Sets VOLTS range to 30, AUTOzero o

V150 Sets VOLTS range to 150, AUTOzero o

V300 Sets VOLTS range to 300, AUTOzero o

V600 Sets VOLTS range to 600, AUTOzero o

W Switches from PF display to WATTS.

ZNV Sets all nonvolatile memory to zero.

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13

Magtrol Model 5100 Single Phase Power Analyzer Chapter 5 - GPIB Communication

SPECIAL FUNCTIONS

Three special functions are available at power turn on:

(1) To disable autozero display function:

Turn 5100 power off; depress and simultaneouslyhold the MODE-HOLD and the 2 AMPS rangebuttons as POWER is switched ON. All leastsignificant digit (LSD) changes around zero willdisplay. Normal operation suppresses ± severalcounts around zero.

(2) To remove the factory set calibration factors:

Turn the 5100 power off, depress andsimultaneously hold the MODE-PF and the 2AMPS range buttons as POWER is switched ON.Uncalibrated values (without factory programmedcalibration factors) are displayed.

(3) To remove all programmed calibration factors anddisplay the basic input binary word (integer BCDformat):

Turn the 5100 power off, depress andsimultaneously hold the MODE-AVG and the 2AMPS range buttons as POWER switch ON.

NOTE: These functions are provided forthe 5100 PA performanceevaluation and are not of use tothe average user.

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14

6 - Operating P6 - Operating P6 - Operating P6 - Operating P6 - Operating Principlesrinciplesrinciplesrinciplesrinciples

AMPERES TRANSDUCING

Current measuring is accomplished using two calibratedmanganin meter shunts. For the 2 ,5, 10 and 20 Ampranges, 0.011 Ohms resistance from two seriesconnected metering shunts provide a voltage to adifferential input calibration amplifier. In the 50 Amprange, the low current section of the shunt is bypassedby a low resistance mercury relay leaving 0.001 Ohmof active shunt. See Figure 10.

This autorange activated shunt bypass relay protects themetering shunts from overheating for overloads up to100 amps for about 30 seconds.

VOLTAGE SENSING

The VOLTS input terminal connects a 1.5 megohmresistive voltage divider to a differential input amplifierto provide scaled voltage for measurements.

See Figure 11.

CR

(WHT)

(BLK)

LOW

HIGH

RS1.01

S2R

2, 5, 10, 20A

50A

AMP

AMP

5100

(COM) LOW

HIGH

VOLTS

(WHT)LINE, LOW

(WHT)

U1, U2, U7

VI

LINE, HIGH

(BLK)

VE

U3

(COM)

AMPS, OUTPUT(COM)

5100 BURDEN

VOLTS = 3M OHMCURRENT: 2, 5, 10, 20 AMP. = 0.011OHM 50 AMP = 0.001 OHM

1.5M

1.5M

Ω .001Ω

LOA

D

ANALOG PROCESSING

Input signals proportional to AMPS and VOLTS areamplified and scaled for each range. These scaledsignals pass through a true rms to DC converter, avoltage to frequency converter and an optical isolationcoupler. The resulting signals represent true rms currentand voltage as a function of frequency (AF0 and VF0,respectively).

Also, scaled AMPS and VOLTS signals are input to aprecision four quadrant X-Y multiplier, averaged bypassing through an active two pole Butterworth filter,converted to frequency in a voltage to frequencyconverter and isolated through an optical coupler. Theresulting signal, WF0, represents true power - (V × I ×Cos θ) in WATTS as a function of frequency.

There is 2500 volts isolation between the measuredcircuit and the AF0, VF0 and WF0 frequency signals.

See Figure 12 for a block diagram.

Figure 11. 5100 Input Circuits

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15

Magtrol Model 5100 Single Phase Power Analyzer Chapter 6 - Operating Principles

IAMP Vrms- 1T

V2dt 20.2

=100KhzV/F

Adc Avf

OPTOISO

0.22

Wvf

=100KhzV/F OPTO

ISO

Vdc

Vrms- 1T 0.2

Vvf

ISOOPTO2dt2V =100Khz

V/F

Vo= XYCos10 U12

+

-

-VAMP+

AMPSINPUT

INPUTVOLTS

U1, U2, U7

ACTIVEFILTER

Abal/Gai

Vbal/Gai

Wbal Wcal

U11

U3

U8

U23

U9

U14

U24

U10

U35

U25

AFo

WFo

VFo

VI

VE

Q

t

0

t

0

DIGITAL PROCESSING

Frequency proportional signals of AMPS, VOLTS andWATTS (AF0, VF0 and WF0, respectively) areintegrated for a precise period of 0.1 seconds for digitalconversion and processing via an eight bitmicrocomputer. The MPU controls functions of rangecontrol, auto-zero, calibration, BCD conversion,parameter display and GPIB transmission.

The MPU acquisition and conversion rate is 100milliseconds (10 readings per second) and the displayupdates at 500 milliseconds (2 updates per second).The MPU scans all front panel pushbutton control inputs25 times per second. When a pushbutton is depressed,the appropriate program loop is entered and the functionis executed on the next program cycle. No damagewill result to the 5100 PA from any combination ofpushbutton selections.

In the AVG MODE (averaging), the 5100 PA integratesthe 10 data readings per second (AMPS, VOLTS andWATTS) and then samples the averaged value fordisplay. As the sampled readings accumulate, thechanging display digits will steady down to provide astable measurement of true power (computed fromaverage VOLTS and AMPS). This technique workswell when the displayed digits are changing too fast tobe recognized resulting from changing powerconsumption.

Figure 12. Block Diagram

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16

7 - Calibration7 - Calibration7 - Calibration7 - Calibration7 - Calibration

GENERAL

Complete calibration of the 5100 PA is beyond thecapabilities of most users. MAGTROL Inc.recommends that the 5100 PA should be returned tothe factory for calibration certifying the instrument tofull specifications.

NOTE: breaking the factory CAL VOIDsticker voids the MAGTROLWARRANTY - Please call theMAGTROL Service Departmentbefore you break this seal.

However, this section includes CALIBRATIONACCURACY VERIFICATION procedures and stepsto make minor trim-ups of calibration.

NOTE: Performing these steps VOIDSthe factory CALIBRATIONCERTIFICATION that comeswith the 5100 PA., the factoryseal will be broken.

TEST SETUP

The recommended test setup is shown by Figure 13.

The accuracy of the voltage and currentstandards used for calibration shouldbe at least four times the accuracy ofthe 5100 PA specifications. Theequipment shown in this test setupmeets this requirement.

To accurately measure AC power it isimportant that the current source havea phase shifting control. With such aphase adjustment, phase shift causedby incidental circuit inductances canbe compensated for by adjusting thephase of the current wave form to beexactly in phase (zero phase shift) withthe voltage wave form.

Sources of incidental circuit inductance include thecurrent shunts within the 5100, output impedance ofthe calibrators, impedance of the load and wiringinductance.

Since the current calibrator output is usually a lowimpedance with low compliance voltage, the 5100'scurrent measuring shunts are the circuits majorresistance. Let's take a representative example andcompute the resulting phase shift:

Let L = 10 µhenries (total of shunt, wiring, etc.)Let RSHUNT = 0.011 Ohm; RWIRING = 0.01 OhmR = 0.011 + 0.01 = 0.021 OhmsLet F = 60 Hz ∴ 2π F L ≈ 0.004θ = Arctan (2π FL / R) = Arctan (0.004 / 0.021)θ ≈ 11 degrees, or about 1.8 % measurement error.

This error can be eliminated by adjusting the calibratorsvariable phase shift control. This demonstrates the needfor care in making power analyzer calibrationmeasurements.

OPTIONAL-FOR AMPS >2TRANSCONDUCTANCE AMP.

FLUKE 5725A;5205AGUIDELINE 7620A, OR

EQUIVALENT

GND

INPUT

AMPS

5100 PA

OUTPUT

LOW

VOLTSHIGH

EARTH

VOLTAGE CALIBRATORFLUKE 5700A ORFLUKE 5100A OR

EQUIVALENT

VOLTAGE CALIBRATORFLUKE 5700A OR

EQUIVALENT

VOLTS VOLTS, HIGH LOW

VARIABLEPHASEOUTPUT

PHASELOCK

IN

LOW CURRENTHIGH

UUT

(REF)

Figure 13. Calibration Verification Test Setup

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Magtrol Model 5100 Single Phase Power Analyzer Chapter 7 - Calibration

CALIBRATION VERIFICATION

Refer to Figure 13, for the recommended test setup.

If other test equipment is used, appropriately modifythe test steps for your equipment.

Potentially lethal voltages are used inthe following test steps.- avoidelectrical shock. Refer to yourcalibrator operator manual foroperating instructions - thesecalibrators generate lethal voltages,extreme care is necessary.

The three steps of the calibration verification are asfollows:

1. Volts Calibration Check

2. Amperes Calibration Check

3. Watts Calibration

Set both the VOLTS and AMPERES calibrators tostandby mode.

VOLTS CALIBRATION CHECK

DC:

1. On the 5100 PA, depress the 15 volts rangepushbutton.

2. Set the volts calibrator for zero volts DC and operatemode.

The 5100 VOLTS display should read zero +0.0001% max of volts full scale range.

3. Set volts calibrator for + 15 volts DC.

The 5100 VOLTS display should read 15.00 volts.

4. Record the VOLTS readings.

5. Set the calibrator for -15 volts DC and repeat theabove step.

6. Record the VOLTS readings.

7. Repeat the above 6 steps for the 30, 150, 300 and600 volts ranges.

Lethal Voltages are Used!

8. Compare the above readings to the 5100 PAACCURACY SPECIFICATIONS in Chapter 2 ofthis manual.

The (+) and (-) readings should be within ± 2 leastsignificant digit (LSD) of each other.

AC:

1. Set the volts calibrator for 60 Hz and repeat thevolts checks as outlined in the DC test above.

NOTE: If a beat frequency effect isexperienced between thecalibrator output and the 60 Hzpower line frequency, try settingthe calibrator for 80 Hz instead of60 Hz.

2. Set the volts calibrator to standby mode.

AMPERES CALIBRATION CHECK

DC:

1. On the 5100, depress the 2 AMPERES rangepushbutton.

2. Set the current calibrator for zero amperes andoperate mode.

The AMPERES display should read zero + 0.0001%max of range full scale.

3. Set the current calibrator for + 2 Amperes DC.

The AMPERES display should read 2.000 Amps.

4. Record the current readings.

5. Set the current calibrator for -2 Amperes.

The AMPERES display should read 2.000.

6. Repeat the above 5 steps for the 5, 10, 20 and 50Amp ranges.

7. Compare the above readings to the 5100 PAACCURACY SPECIFICATIONS in Chapter 2 ofthis manual.

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Magtrol Model 5100 Single Phase Power AnalyzerChapter 7 - Calibration

The (+) and (-) readings should be within ± 2 LSDof each other.

AC:

1. Set the current calibrator for 60 Hz and repeat thecurrent checks outlined above.

NOTE: If a beat frequency effect isexperienced between thecalibrator output and the 60 Hzpower line frequency, try settingthe calibrator for 80 Hz instead of60 Hz.

2. Set the current calibrator to standby mode.

WATTS CALIBRATION CHECK

This step calls for the simultaneous application ofvoltage and current to the 5100 PA.

DC:

1. On the 5100, select a VOLTS and AMPERESrange.

2. Set the volts and current calibrators for a voltageand current near the center of each selected range.

3. Switch the CALIBRATORS to operate mode.

The WATTS readout should show a power that isthe product of the VOLTS and AMPS indications( POWER = V × I ).

4. Compare the 5100 PA WATTS readout to theproduct of VOLTS and AMPS from theCALIBRATORS output. This difference is theWATTS error.

AC:

POWER = V × I × Cos θwhere θ = phase angle between volts and amps.

NOTE: maximum true power is deliveredonly when θ = zero degrees (cosθ = 1). Therefore, the voltscalibrator variable phaseadjustment is set for zero phasebetween the volts and amps at theinput to the 5100 PA. Refer tothe calibrator instruction manualsfor this adjustment procedure.

1. The phase shift control should be carefully set toprovide a peak 5100 PA WATTS indication, thiscorresponds to zero volts to amps phase angle.

2. Repeat the procedure as used for the DC powerverification and record readings.

3. Compare the recorded reading to the 5100 PA.ACCURACY SPECIFICATIONS in Chapter 2 ofthis manual.

MINOR ADJUSTMENT (IF NEEDED)

NOTE: All trim pot adjustments arelocated on the 78B143 circuitboard of the 5100 - see Chapter 8- Schematics.

Lethal Voltages are Used!

VOLTS ZERO

1. Disable the autozero function, refer to “SpecialFunctions” under Chapter 5 - GPIBCommunication.

2. Go to the 5100 VOLTS range that needs zeroadjustment.

3. Set the volts calibrator for zero volt DC output.

4. Adjust trim pot R16 for zero (+ 0.0001% max)VOLTS display reading. This sets all voltage ranges- all ranges should be zero + 0.0001% of range fullscale.

AMPERES ZERO

1. Disable the autozero function, refer to “SpecialFunctions” in Chapter 5 - GPIB Communication.

2. Go to the 5100 AMPERES range(s) that needadjustment.

3. Set the current calibrator for zero amp DC output.

4. For the 2, 5, 10, and 20 amp ranges, adjust trim potR9, for zero AMPERES display indication.

For the 50 amp range, adjust trim pot R13 for zeroAMPERES display indication.

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Magtrol Model 5100 Single Phase Power Analyzer Chapter 7 - Calibration

VOLTS SCALE FACTOR

1. Go to the 5100 VOLTS range(s) that needadjustment.

2. Set the volts calibrator for an output equal to therange maximum voltage.

3. Adjust the trim pot(s) so the VOLTS display readsthe full scale voltage as shown below:

For the 15 volt range, adjust R17

For the 30 volt range, adjust R19

For the 150 volt range, adjust R21

For the 300 volt range, adjust R23

For the 600 volt range, adjust R25

AMPERES SCALE FACTOR

1. Go to the AMPERES range(s) that need adjustment.

2. Set the current calibrator DC output to the rangemaximum current and adjust trim pot(s) so theAMPERES display reads the full scale current:

For the 2 Amp. range, adjust R27

For the 5 Amp. range, adjust R29

For the 10 Amp. range, adjust R31

For the 20 Amp. range, adjust R33

For the 50 Amp. range, adjust R35

Note: Calibration on the 20 and 50Amps ranges may have to bedone at less than full range scale,depending on your calibrationequipment.

VOLTS BALANCE

1. Go to the 5100 PA 150 VOLTS range.

2. Set the voltage calibrator for + 150 volts DC. output.

3. Note the VOLTS display reading.

4. Reverse the calibrator polarity to -150 volts DC.

If the plus to minus display readings differ by morethan ± 2 LSD, connect a digital voltmeter atamplifier U23 pin 14 and adjust trim pot R67, forzero ± 0.1 millivolt DC.

CURRENT BALANCE

1. Go to the 5100 PA 2 Amp. range.

2. Set the current calibrator for + 2 Amps DC output.

3. Note the AMPERES display reading.

4. Reverse the calibrator polarity to - 2 Amps DC.

If the plus and minus display readings differ by morethan ± 2 LSD, connect digital voltmeter at amplifierU8 pin 14 and adjust trim pot R41, for zero ± 0.1millivolt.

WATTS SCALE FACTOR

1. Set the volts and current calibrators for 150 VDCand 2 Amp DC output.

2. Adjust trim pot R48, for 300.00 WATTS displayreading.

3. Confirm AC measurement accuracy by setting thecalibrators for 150 VRMS and 2 Amps RMS at 60Hz. The WATTS display should read close to300.00 watts and be within the specificationaccuracy.

See “Accuracy Specifications” in Chapter 2 -Specifications.

NOTE: Adjust current calibrator's phaseshift control for zero phase anglebetween volts and amps (peak thewatts indication) - see“Calibration Verification” step 3for AC.

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20

Appendix AAppendix AAppendix AAppendix AAppendix A: Schematics: Schematics: Schematics: Schematics: Schematics

CIRCUIT BOARD 78B128 - LED DISPLAY

ab

gf

cdp

ed

ab

gf

cdp

ed

HP

HD

SP

-550

1C

omm

on A

node

LED

Dis

play

s

ab

gf

cdp

ed

ab

gf

cdp

ed

ab

gf

cdp

ed

ab

gf

cdp

ed

ab

gf

cdp

ed

ab

gf

cdp

ed

ab

gf

cdp

ed

ab

gf

cdp

ed

ab

gf

cdp

ed

ab

gf

cdp

ed

ab

gf

cdp

ed

+ 1C

1

d7d8

Com

+5

ad

bdp

c

J7

ad

c

eg

f

d6

dp

d5

d3d4

d2

b

d1d3

d5d4

ef

g

d2d1

WA

TT

SLS

DM

SD

LSD

digi

t 8di

git 3

digi

t 4di

git 2

digi

t 1di

git 5

LSD

MS

D

AM

PS

MS

D

VO

LTS

digi

t 4di

git 5

digi

t 3di

git 1

digi

t 2di

git 6

digi

t 7

Page 27: 5100 User's Manual · 1. 1 - Introduction. ABBREVIATIONS P. A Model 5100 Power Analyze. r GPI. B IEEE-488 Instrument Bus Standar. d LE. D front panel indicator ligh. t A,V, W, P

21

Magtrol Model 5100 Single Phase Power Analyzer Appendix A: Schematics

CIRCUIT BOARD 78B141

12Y3Y4

14

9

74C244Y1Y2

1816

68

11A4A3

A12

A24

Y7A8 Y8

2G

3

A5Y6Y5

75

17

191

1G

1315

A6A7

12Y3Y4

14

9

74C244Y1Y2

1816

68

11A4A3

A12

A24

Y7A8 Y8

2G

3

A5Y6Y5

75

17

191

1G

1315

A6A7

12Y3Y4

14

9

74C244Y1Y2

1816

68

11A4A3

A12

A24

Y7A8 Y8

2G

3

A5Y6Y5

75

17

191

1G

1315

A6A7

CB

3

74F138A

12

13Y1Y2

1514

Y0

Y4

Y6Y5

Y7

Y3 G16

97

12

1011

12Y3Y4

14

9

74C244Y1Y2

1816

68

11A4A3

A12

A24

Y7A8 Y8

2G

3

A5Y6Y5

75

17

191

1G

1315

A6A7

CD4518

EN10

Q314

RST15

CD4518

EN2

Q36

RST7

CD4518

2CK

1

Q3RST

67

EN

CD4518

EN2

Q36

RST7

11CD4518

Q0

RST

10EN

15

CD4518

EN10

Q314

RST15

CD4518

EN2

Q36

RST7

CD4518

EN10

Q314

RST15

11CD4518

Q0

RST

10EN

15

Q012

CD452011

Q110

EN

1413

RSTQ3

15Q2

Q04

CD45203

2EN Q1

1CK

65

RST Q2Q3

7

CD4518

EN10

Q314

RST15

CD4518

EN2

Q36

RST7

Q012

CD452011

Q110

EN

1413

RSTQ3

15Q2

Q04

CD45203

2EN Q1

1CK

65

RST Q2Q3

7

FUNCTION C1 C2HOLD 0 1

AVG 1 1PF 1 0

8,9

U +5 COM4,5,8

10

1516

16

2-89,11,13

12016

3,11 1,8,9

1,8,9

8,15719

2014

16

10,12,1416,17

1618

12Y3Y4

14

9

74C244Y1Y2

1816

68

11A4A3

A12

A24

Y7A8 Y8

2G

3

A5Y6Y5

75

17

191

1G

1315

A6A7

12Y3Y4

14

9

74C244Y1Y2

1816

68

11A4A3

A12

A24

Y7A8 Y8

2G

3

A5Y6Y5

75

17

191

1G

1315

A6A7

10 1 1 0 x x x

RANGE SWITCH

5 0 1 0 x x x

a b c d e f2 1 0 0 x x x

x=don't care

150 x x x 1 1 0300 x x x 0 0 1600 x x x 1 1 1

15 x x x 1 0 030 x x x 0 1 0

20 0 0 1 x x x50 1 1 1 x x x

A23

1CD4724

A02

6A1Q1

Q2

4Q0

5

Q4

Q6

EQ5

Q7

13DQ3

14

12111097

Q04

CD45203

2EN Q1

1CK

65

RST Q2Q3

712

Y3Y4

14

9

74C244Y1Y2

1816

68

11A4A3

A12

A24

Y7A8 Y8

2G

3

A5Y6Y5

75

17

191

1G

1315

A6A7

Note: All capacitors in uF

Unless otherwise notedAll resistors in OHMS

Q012

CD452011

Q110

EN

1413

RSTQ3

15Q2

U3

U4

COM

E

PA7

PA3PA5

PA4PA6

PA1

PA2PA0

U1

PA6

PA5PA7

PA0

PA1

PA2PA4

PA7PA6

PA5

PA0

PA4

PA7PA6

PA5PA3

U2

PA0

PA1PA2PA3

J1PA2 PA0

PB6

PA5PA4

PA6

+5

PA4

PA3PA1

PA2

PA7PB0

PB2PB1

U16

U17

U17

RSTQ3U10

U11

U11

1015

12EN Q1

Q2

6

43

RSTU12

5

Q3Q2

27

CD4520Q0Q1EN

2CKEN

1CD4518

U15

U16

Q3RSTU15

67

U9

3CD4520

U9

11

456

RST

CD4520

Q2U10 Q3

Q0

2Q0

EN Q17

13

10

8 d

11

f

9

e

2

12

1a

PA3PA1

U8

U7

PA6PA4PA2PA0

PA7PA5

U18

PA1PA0

PA2PA3

12

PA4PA6

PA2

PA7PA5

PA3PA1

PA0

U5

PA5PA7

PA4PA6

PA3PA1

U6

PA3PA1

PA2PA0

+5C2C1

COM

A

J5

WV

AVERAGING

COM

POWER FACTORHOLD

+5

COM

J4

12K+5

b3

5

12Kx8

7406U19

200

6200

c

2004

Vol

Wpol dc

ef

Aol

ab

CD4520

Q1

34

Q0

CD452011

Q0Q1

U13

U13

EN2

1015

EN

U12RST

Q0Q1Q2

1211

1314

Q3Q2

CD4520

56

EN15

U14RST

Q3

RST7

U14

10

Page 28: 5100 User's Manual · 1. 1 - Introduction. ABBREVIATIONS P. A Model 5100 Power Analyze. r GPI. B IEEE-488 Instrument Bus Standar. d LE. D front panel indicator ligh. t A,V, W, P

22

Magtrol Model 5100 Single Phase Power AnalyzerAppendix A: Schematics

CIRCUIT BOARD 78B142

HOLDPF

SW2 SW1

CR1

SW3

AVG

J4

CR2

CIRCUIT BOARD 78B175

BR1

PD05

T1

14A-20-10

94

6 7

12

10

1

3C4.1uF

C31uF

C14700uF

C21uF

OI

+5V7805

Line

120

Com

C

Neu

(Heatsinkto chassis)

25V120

240

Page 29: 5100 User's Manual · 1. 1 - Introduction. ABBREVIATIONS P. A Model 5100 Power Analyze. r GPI. B IEEE-488 Instrument Bus Standar. d LE. D front panel indicator ligh. t A,V, W, P

23

Magtrol Model 5100 Single Phase Power Analyzer Appendix A: Schematics

13 11

+IN

14

Vo

CO

M

1-I

N

C Fo

Cm

p

U14

106 75

13 11

+IN

14

CO

M

Vo

1-I

N Fo

Cm

p

U13

C10

75 6

U35

6832

7 5

+5

U4

U7

6- +

U5

13 11

+IN

14

Vo

CO

M

1-I

N

C Fo

Cm

p

U9

106 75+

15-1

5R

42

Avf

U8

Vin

12 1114B

Fo

133

CO

M41 2

BF

i

RM

So

Cav

9 8

+V -V

10

7D

EN

idB

o

5 6

OF

FS

CS

R44

-15

C66

R40

R43

-15

+15

R41 R

115

C50

+ C10

C49

C9

6832

7 5

+5

+15

U21

Y2

13 12

Y0

Y1

15 143 6

B G1

C

1A

2

Y7

79

Y3

11 105

G2A

Y5

Y6

4Y

4G

2A

Vhi

U16

4521

6

U15

4521

6

U22

Y2

13 12

Y0

Y1

15 143 6

B G1

C

1A

2

Y7

79

Y3

11 105

G2A

Y5

Y6

4Y

4G

2A

U18

4521

6

U19

4521

6

U17

4521

6

A20

A50

Aco

m

+5

Vlo

R9

R8

R11

4 R12

14 12

3

+15

134,

5,6

CO

M+

5-1

5

54

1

0

1

10

A1

1

0

20A

8,23

Ac 1

0

0

5ARN

GA

b0

1

1

2AU

Aa

33 11

9,10

411 8

14

9,13

,14,

24

12,2

6

21,2

2

47

4

816

1

1

0

300

V1

1

1

6

00V

1

0

1

150

V

Vc 0

1

1

1

5V

1

1

1

50

A

Va

1

0

0

30VRN

GV

b

U29

4521

6

U28

4521

6

U23

Vin

12 11

BF

o14 13

2 3C

OM

41B

Fi

RM

So

Cav

9 8

+V -V

106 7

DE

Ni

dBo

5O

FF

SC

S

+15

- +

U25

6832

7 5

13 11

+IN

14

Vo

CO

M

1-I

N

C Fo

Cm

p

U24

106 75

+5

BR

1

- +

-15

U20

4521

6

+15

-15

+15

-15

+15

- +3

24

1

- +

2 3C

146

-U

12

R49

C15

R54

R48

X2

OU

T12

2V

Bal

1R

47

X1

C67 +

-15

R66

Vvf

+

Vrm

s B

al

R51

+15

51 -1

5

Wba

l

-15

R67 R

116

6 7Y

2

Z1

1011

Z2

U11

Y1

R62

+5

R57

+15

C17

C19

Wpo

l

R56

R64

C20

R65

+15

R68

C21

CR

18

R63

CR

17

R33

R34

10a

20a

R27

15

R29

R31

2a

R30

R28

5a

R32

+7

69

238

A20

Bal

9 6C

2

14

101116

+15

7

231 1

R39

R36

R35

50a

R37

A50

Bal

+

C6

96

+

C4

96

C12

+15

C11

C8

3+

154

-15

12

+

Arm

s B

al

R38

C7

8

Aba

l

R59

+15

R58

C18

R61

C13

Wvf

+-1

5

R53

Wca

lR

50

-15

+15

Wvf

-C

16

-15

R46

U10

R52

R11

7R3

Aa

Ab

R10

3

R110R109R108

R10

6V

b

R10

4A

c

Va

R10

5

R18

R20

R16

15v

14

-15

30v

3 1

10U

3 15-

14 1116

R17

R19

15 10

R15

-15 C

R15

CR

16

15R

25

U6

300v

600v

R26

R21

R24

R23

U5

150v

R22

1

14

69 387 2

CR

9

CR

6C

R7

CR

10

CR

4C

R5 C

76

R7

R10

CR

3+

15

R6

-15

CR

11

R14

CR

13

+15

CR

12

+15

C77

R10

2J7

R2

RV

1

-15

CR

8 R1

R11

+

C3

C1

+-15

1415

U1 7

x100

10

-15

+15

118

-

8

+2 3

12

C5

-15

+15

+

x100

-15

7157

U2

x200

R13

14

10

CR

14 C78

8

2+ +

122

-16

3

- +U34 R

8484

-15

-15

5

R83

C28

3 2

CR

19C

48-1

5+

15

R82

C36

C

C37

OU

T

+15

IN

VR

3

+5

C29

OU

T

VR

2

C-1

5

C34

C35

OU

T

VR

1

C+

15

+

C65

+15

C60

C62

C55

C63

C64

C56

AolJ5

Vol

C59

C61

R86

+15

67

1

R81

R85

C73

C74

C72 (U6)

(U5)

(U4)

CH

AS

SIS

PO

WE

R

-15 SIG

NA

L

C69

C68

(U14)

(U24)

(U9)C71

(U13)C70

+15

8

C51

+15

R80

5

+-15

C75

R75

R76

R77

C25

3 2

C27

14

R79

7-

6

+U27

C24

U26

R78

47

2 3R

74C

266

R72

R73

+15

C22

C52R

69

+15

R70

C47

WV

CO

M

C23

+5

+5

A+

+5

12

3

24

9

710

C40

8R

101

R97

U12

PIN

6IN C

OM

U32

17

R99

CA

L15

WA

TT

S A

NA

LOG

R10

016

+15

1210

-01

ANAL

OG

OU

TPU

T O

PTIO

N

14A

-2.5

R-3

6T

2

BR

2-

18 97

-15

+15

-15

AC

LIN

E

612

0v

120v 24

0v

1

43

1214

A-1

0R-3

6C

32C

30

-+

9

10

IN ++

76

U33

56

120v24

0v4

C45

C46

OU

T

+15

-15

C31

AC

LIN

EC

33+

IN

+

+

C42

C44

VR

5

CIN

+

+ C41

+O

UT

VR

4

CIN

C43

+

16

U30

IN15

10

+15

R112R111

R113

CA

LA

MP

S A

NA

LOG

R87

U8

PIN

6

R90

R89

R10

7V

c

R88BA

L

CO

M

IN U31

18-1

5

12

CO

M

18

+15

16

12 10-15

U23

PIN

6

R98BA

L

R92

17

R93BA

L

R95

R94

VO

LTS

AN

ALO

GC

AL

17 15

14A

U33

+15

W

16

V

8R

911213

3

2

7

C38

120v

71

T1

3

C39

2

CO

NN

EC

TO

RB

AC

K P

AN

EL

13

U33

-15

9

38 +

1524

-15

7

+15

94

R96

CIRCUIT BOARD 78B143

Page 30: 5100 User's Manual · 1. 1 - Introduction. ABBREVIATIONS P. A Model 5100 Power Analyze. r GPI. B IEEE-488 Instrument Bus Standar. d LE. D front panel indicator ligh. t A,V, W, P

24

Magtrol Model 5100 Single Phase Power AnalyzerAppendix A: Schematics

CIRCUIT BOARD 78B144

U1b

U1c

U1a

921

8

1016

81

CT

L

C9

3Q4Q

1617

15

191Q

182Q

53D

4

4D6

31D

2

2D

7Q7D8Q

OC

12

5D6Q5Q

1413

118DLE

1

6D789

3Q4Q

1617

15

191Q

182Q

53D

4

4D6

31D

2

2D

7Q7D8Q

OC

12

5D6Q5Q

1413

118DLE

1

6D789

U +5 COM7

10202,3,41 14

01

10

SW d c b a

01

11

020A50A

10

02A

10A5A

000

00

00 1

0

11

1 00

11150V300V

1600V

0100

1

00

15V30V

11

10

3Q4Q 16

17

15

191Q182Q

53D4

4D6

31D2

2D

7Q7D8Q

OC

12

5D6Q5Q

1413

118DLE

1

6D789

SW7AAR

SW8

SW615V

36

54

SW11

+5SW122A

RELAY

50A

20ASW9

10A

5A

SW10

J5

+

C7

+5

cba

def

C5

PB5

PB3PB4 R13

U2R15

R9

R11

PA3PA2

J1PA0PA1

PA5PA4

R22

U5

R20

R17

R18

R1

R7

R12

R10R

3R

5

R21

Bypass with .1uF

R14

R16

R19

SW4

SW3

SW5

SW1

SW2

101113

12

U4C3

VAR

AaAb

J7

R2

VaVb

Ac

Vc

C1U3

150V

30V

R8

R6

600V

300V

R4

Page 31: 5100 User's Manual · 1. 1 - Introduction. ABBREVIATIONS P. A Model 5100 Power Analyze. r GPI. B IEEE-488 Instrument Bus Standar. d LE. D front panel indicator ligh. t A,V, W, P

25

Magtrol Model 5100 Single Phase Power Analyzer Appendix A: Schematics

CIRCUIT BOARD 78B145 - DIGITAL READOUT & MPU

U6

4Q3Q6 92

74H

C37

3

1Q5

87

4D3D

41D

3

2Q2D

6Q 8Q7Q16 19

5Q5D

1512

18 118D7D LE

13 17146D

35P

32

P35

P34

P36

P33

34 33 313240

SC

1E

P30

373839 36

8 1110

P31

P20

RS

T

P23

P22

P21

932 5

EX

2MC

6803

4

X1

NM

IS

C2

6IR

Q

P43

P45

P44

22P

47P

46

25 24 23

P37

P41

P40

26P

42272930 28

17 1918 20

P15

P13

P14

P17

P16

1312 14 1615

P10

P24

P12

P11

7P

A4

PA

5P

A6

CA

1P

A7

8 40932

PA

1P

A0

PA

3P

A2

4 65

27 2628 36

D4

D5

RS

0

D6

D7

3233 30 2931

MC

6821

D1

D0

D3

D2

15P

B5

14 1716

CB

118 191211

PB

1

10 13P

B3

PB

2

39

38 37IR

QB

34P

B6

PB

4IR

QA

W

CB

2

PB

7R

ES

2335 2125

PB

0C

A2

CS

2

RS

1

R/

E

13

DQ

4D

Q3

14 1510D

Q0

11D

Q2

DQ

1

9

5 4A

3A

2

A4

36

DS

1220

A0

8

A1

7

18C

E

WE

OE

20 2116D

Q5

DQ

7D

Q6

17

22 19

A8

A9

A10

23

A5

2A

6A

71

Seg

d

DIG

IT 6

DIG

IT 3

24 2223

Vss

2728 2526

5 6 7

Seg

fD

A0

D.P

.

DP

inD

A1

21

Seg

b43

ICM

7218

C

Seg

c

Seg

gS

eg e

Seg

a

DIG

IT 8

1718 16 15

DIG

IT 7

DIG

IT 4

2021 19

D0

12 13 14

DIG

IT 5

D2

DIG

IT 2

DIG

IT 1

D3

98 1110

WR

ITE

MO

DE

Vdd

D1

DA

2

Seg

d

DIG

IT 6

DIG

IT 3

24 2223

Vss

2728 2526

5 6 7

Seg

fD

A0

D.P

.

DP

inD

A1

21

Seg

b43

ICM

7218

C

Seg

c

Seg

gS

eg e

Seg

a

DIG

IT 8

1718 16 15

DIG

IT 7

DIG

IT 4

2021 19

D0

12 13 14

DIG

IT 5

D2

DIG

IT 2

DIG

IT 1

D3

98 1110

WR

ITE

MO

DE

Vdd

D1

DA

2

P10

TO

P13

= C

OD

E B

DA

TA

P15

TO

P17

= D

IGIT

AD

DR

ES

SP

14 =

D.P

.

000

0 00

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Page 32: 5100 User's Manual · 1. 1 - Introduction. ABBREVIATIONS P. A Model 5100 Power Analyze. r GPI. B IEEE-488 Instrument Bus Standar. d LE. D front panel indicator ligh. t A,V, W, P

26

Magtrol Model 5100 Single Phase Power AnalyzerAppendix A: Schematics

PARTS LOCATION FOR CIRCUIT BOARD 78B143

Page 33: 5100 User's Manual · 1. 1 - Introduction. ABBREVIATIONS P. A Model 5100 Power Analyze. r GPI. B IEEE-488 Instrument Bus Standar. d LE. D front panel indicator ligh. t A,V, W, P

Magtrol, Inc. warrants its products to be free from defects in material and workmanship under normal use andservice for a period of one (1) year from the date of shipment. Software is warranted to operate in accordance withits programmed instructions on appropriate Magtrol instruments. This warranty extends only to the original purchaserand shall not apply to fuses, computer media, or any other product which, in Magtrol’s sole opinion, has beensubject to misuse, alteration, abuse or abnormal conditions of operation or shipping.

Magtrol’s obligation under this warranty is limited to repair or replacement of a product which is returned to thefactory within the warranty period and is determined, upon examination by Magtrol, to be defective. If Magtroldetermines that the defect or malfunction has been caused by misuse, alteration, abuse or abnormal conditions ofoperation or shipping, Magtrol will repair the product and bill the purchaser for the reasonable cost of repair. If theproduct is not covered by this warranty, Magtrol will, if requested by purchaser, submit an estimate of the repaircosts before work is started.

To obtain repair service under this warranty, purchaser must forward the product (transportation prepaid) and adescription of the malfunction to the factory. The instrument shall be repaired at the factory and returned to purchaser,transportation prepaid. MAGTROL ASSUMES NO RISK FOR IN-TRANSIT DAMAGE.

THE FOREGOING WARRANTY IS PURCHASER’S SOLE AND EXCLUSIVE REMEDY AND IS IN LIEU OFALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIEDWARRANTY OF MERCHANTABILITY, OR FITNESS FOR ANY PARTICULAR PURPOSE OR USE.MAGTROL SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIALDAMAGES OR LOSS WHETHER IN CONTRACT, TORT, OR OTHERWISE.

CLAIMSImmediately upon arrival, purchaser shall check the packing container against the enclosed packing list and shall,within thirty (30) days of arrival, give Magtrol notice of shortages or any nonconformity with the terms of the order.If purchaser fails to give notice, the delivery shall be deemed to conform with the terms of the order.

The purchaser assumes all risk of loss or damage to products upon delivery by Magtrol to the carrier. If a product isdamaged in transit, PURCHASER MUST FILE ALL CLAIMS FOR DAMAGE WITH THE CARRIER to obtaincompensation. Upon request by purchaser, Magtrol will submit an estimate of the cost to repair shipment damage.

Magtrol Limited WMagtrol Limited WMagtrol Limited WMagtrol Limited WMagtrol Limited Warrantyarrantyarrantyarrantyarranty