Automation Solutions microAmper User manual

Amper Manual Version 2.01 Page 1 of 45
Amper, milliAmper
&
microAmper
by
Automation
Solutions

Amper Manual Version 2.01 Page 2 of 45
Automation Solutions LLC Terms and Conditions of Sale
Customer and Automation Solutions LLC ("AS LLC") agree that the purchase and sales of AS LLC hardware and software products ("the Products")
are made under these terms and conditions, and that AS LLC SHALL NOT BE BOUND BY CUSTOMER'S ADDITIONAL OR DIFFERENT TERMS.
Customer's order and purchase of the Products shall constitute acceptance of these terms and conditions.
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utilization of an improper hardware or software key or unauthorized maintenance or repair.
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11. WARNING: (1) AS LLC PRODUCTS ARE NOT DESIGNED WITH COMPONENTS AND TESTING FOR A LEVEL OF RELIABILITY

Amper Manual Version 2.01 Page 3 of 45
SUITABLE FOR USE IN OR IN CONNECTION WITH SURGICAL IMPLANTS OR AS CRITICAL COMPONENTS IN ANY LIFE SUPPORT
SYSTEMS WHOSE FAILURE TO PERFORM CAN REASONABLY BE EXPECTED TO CAUSE SIGNIFICANT INJURY TO A HUMAN.
(2) IN ANY APPLICATION, INCLUDING THE ABOVE, RELIABILITY OF OPERATION OF THE SOFTWARE PRODUCTS CAN BE
IMPAIRED BY ADVERSE FACTORS, INCLUDING BUT NOT LIMITED TO FLUCTUATIONS IN ELECTRICAL POWER SUPPLY,
COMPUTER HARDWARE MALFUNCTIONS, COMPUTER OPERATING SYSTEM SOFTWARE FITNESS, FITNESS OF COMPILERS
AND DEVELOPMENT SOFTWARE USED TO DEVELOP AN APPLICATION, INSTALLATION ERRORS, SOFTWARE AND HARDWARE
COMPATIBILITY PROBLEMS, MALFUNCTIONS OR FAILURES OF ELECTRONIC MONITORING OR CONTROL DEVICES,
TRANSIENT FAILURES OF ELECTRONIC SYSTEMS (HARDWARE AND/OR SOFTWARE), UNANTICIPATED USES OR MISUSES,
OR ERRORS ON THE PART OF THE USER OR APPLICATIONS DESIGNER (ADVERSE FACTORS SUCH AS THESE ARE
HEREAFTER COLLECTIVELY TERMED "SYSTEM FAILURES"). ANY APPLICATION WHERE A SYSTEM FAILURE WOULD CREATE
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LEVEL OF SUCH SYSTEM OR APPLICATION.
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of any excusable delay. In the event AS LLC is unable to perform in whole or in part because of any excusable failure to perform, AS LLC
may cancel orders without liability to Customer.
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Products to the extent that such litigation alleges that the Products or any part thereof infringes any United States patent, copyright, or
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and information AS LLC needs to defend or settle such claim, AS LLC shall pay any final award of damages in such suit and any expense
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to use the Products, (ii) replace the Products with others which do not constitute infringement, or (iii) remove the infringing Products and
refund the payment(s) made therefore by Customer. The foregoing states the Customer's sole remedy for, and AS LLC's entire liability
and responsibility for, infringement of any patent, trademark, or copyright relating to the Products provided hereunder. THIS LIMITED
INDEMNITY IS IN LIEU OF ANY OTHER STATUTORY OR IMPLIED WARRANTY AGAINST INFRINGEMENT.
14. ACKNOWLEDGMENT/GOVERNING LAW. Customer acknowledges reading these Terms and Conditions, under-stands them and agrees
to be bound by them. A waiver of any provision of this agreement shall not be construed as a waiver or modification of any other term
hereof. With respect to all orders accepted by AS LLC, disputes arising in connection with these Terms and Conditions of Sale shall be
governed by the laws of the State of Oklahoma without regard to principles of conflicts of laws.
15. APPLICATION LIABILITY. AS LLC assumes the buyer to be an expert in his intended application of AS LLC products. AS LLC claims no
special expertise in the application of its products into the buyer’s equipment. AS LLC accepts no responsibility for the buyer’s selection
and use of AS LLC products. Buyer’s interpretation and implementation of application suggestions and recommendations by AS LLC,
general or specific, transmitted verbally, electronically or in writing, published or unpublished, is strictly at the buyers own risk.

Amper Manual Version 2.01 Page 4 of 45
GENERAL SAFETY INSTRUCTIONS
Warnings in this manual appear in either of two ways:
1. Danger warnings – The danger warning symbol is an exclamation mark enclosed in a
triangle which precedes letters spelling the word “DANGER”. The Danger warning symbol is
used to indicate situations, locations and conditions that can cause serious injury or death:
2. Caution Warnings - The caution warning symbol is an exclamation mark enclosed in a
triangle which precedes letters spelling the word “CAUTION”. The Caution warning symbol
is used to indicate situations and conditions that can cause operator injury and/or equipment
damage:
Other warning symbols may appear along with the Danger and Caution symbol and are used to
specify special hazards. These warnings describe particular areas where special care and/or
procedures are required in order to prevent serious injury and possible death.
Electrical Warnings – The electrical warning symbol is a lightning bolt mark enclosed in a
triangle. The electrical warning symbol is used to indicate high voltage locations and
conditions that may cause serious injury or death if proper precautions are not observed:
For the purposes of this manual and product labels, a Qualified Person is one who is familiar with
the installation, construction, operation and maintenance of the equipment and the hazards
involved. This person must:
1. Carefully read and understand the entire manual.
2. Be trained and authorized to safely energize, de-energize, clear
faults, ground, lockout and tag circuits and equipment in
accordance with established safety practices.
3. Be trained in the proper care and use of protective equipment
such as safety shoes, rubber gloves, hard hats, safety glasses,
face shields etc. in accordance with established safety practices.
4. Be trained in rendering first aid.
CAUTION
DANGER

Amper Manual Version 2.01 Page 5 of 45
Table of Contents
Terms and conditions of sale. Page 2
General Safety Instructions Page 4
Manual Revisions Page 6
Introduction. Page 7
Specifications Page 10
Operation – Unpacking and Inspection Page 11
Operation – Configuration and Setup Page 13
Operation – Connecting the Amper to Electrical Signals Page 17
Operation – Starting Data logging Page 27
Operation – Retrieving Data and Using the ChartLogger Program Page 29
Operation - Scaling and Calibrating With ChartLogger Page 35
Advanced Features – Pulse Counting Page 37
Advanced Features – File Size Reduction Using Hysteresis Page 39
Reference - File formats and details used by the Amper Page 41
Reference – Card and Battery Notes Page 45

Amper Manual Version 2.01 Page 6 of 45
Manual Revisions
0.78 Oct 2007 Release
0.79 Dec 2007 Calibration explanation, add use of clamp on CT’s, load resistor examples corrected. Minor spec changes.
1.00 Dec 2007 ChartLogger re-calibration shown.
2.00 May 2008 Support for hysteresis and pulse counting capability.
2.01 Jun 2008 Cosmetic corrections.

Amper Manual Version 2.01 Page 7 of 45
Amper Datalogger Family
Introduction
Automation Solutions Amper, milliAmper and microAmper provide a new, modern way to
electronically collect current and voltage data. Each device may be connected to a signal of
interest and the device will automatically take readings at a preset rate, saving the data to a
standard low cost SD/MMC data card. The data may then be transferred to a PC for further
analysis, either with standard PC programs such as Microsoft’s Excel or with the provided
ChartLogger program, which is capable of manipulating and displaying huge amounts of data. This
manual covers operation of three similar models, the Amper, milliAmper and microAmper. The
Amper is typically connected in series with a standard 5A current transformer. The milliAmper is
typically connected in series in a 4-20mA current loop. The microAmper, along with a resistor, may
measure directly applied Voltages or currents and with a non-contact clamp on current probe it
may log currents to thousands of Amps. With the exception of the input signal rating the units are
identical and only differ by the internal load resistor. They may be referred to below simply as the
Amper. Features include:
Easy to operate. There are no switches, knobs or buttons. One blue LED occasionally flashes
to indicate successful writes to the card, another red LED flashes if there’s an error, such as the
data card full. Pulling out the card allows the operator to walk away with logged data in
seconds.
Easy to install. There are just two wires to connect, insensitive to polarity. The unit can be
connected and running in minutes. The extremely low impedance (0.05 Ohm for 5A CT’s and
15 Ohm 0.3 Volt drop for the millAmper) allows it to run in series with many other devices in the
current chain.
Easy to configure. All configuration settings are done via simple text files written on the memory
card. Use the Amper configuration program (provided) to make any changes, insert the card
and the configuration is automatically set and retained; the Amper then automatically deletes
the configuration files. The Amper configuration program easily lets the user change settings
such as site name, acquisition rate, time and date, CT and scaling factors.
No external power required. The unit typically operates for 5 years with the user replaceable
high capacity battery. Since events of interest often occur just before or after power loss being
independent of external power is a huge benefit. As well as maintaining the time and date the
unit automatically measures its own battery voltage, and will start to write warning messages to
the data card typically 3 months before the battery fails.
Accurate data logging. The Amper, designed for 5 Amp CT’s, measures current surges up to 30
Amps at full scale A to D resolution to accurately capture events such as motor startups,
overloads, heavy load changes, line sags and surges. If the input current is below 6 amps the
signal is automatically routed through a separate input signal path so it is still acquired at the
full scale A to D resolution. This gives a total resolution exceeding 14 bits. The other models
have similar input scaling circuits. True RMS (including dc offset) data acquisition is used, so
the data is accurate no matter what shape the signal waveform is. Measurements from any type
of VSD, switchboard or non sinusoidal source are all accurately recorded. All data is saved to
the card in raw text format, so may be calibrated or offset if required after acquisition without
any loss of accuracy.

Amper Manual Version 2.01 Page 8 of 45
Fast data logging. The user may set the data acquisition rate, from 20 readings per second to
about one per hour; in 50mS increments. Adjustable hysteresis lets the logger accurately catch
high speed impulses without creating giant files.
Lots of data logging. The amount of data collected using the Amper may be huge. At the fastest
data acquisition rate over 1.7 million readings are taken every day. At this rate in less than an
hour files are too big to load into Microsoft Excel. (No problem for the ChartLogger program,
included with the Amper) However, the large size and low cost of SD/MMC cards provide deep
data storage. Using a 2 GByte card and taking samples twice a second a year’s worth of data
fits on a single card. Use a sample rate of once a minute and you won’t live long enough to see
the card full.
Compatible data logging. Every single reading collected by the Amper is stored as a plain
ASCII string in a text file, along with the date and time stamp of each reading. Every day a new
data file is created. Open any day’s file with any text editor such as notepad. View, zoom, scroll,
pan, print, see statistics and inspect the data with ChartLogger. (Excel may be used for small
files).
Pulse Capability. Change a couple of configuration files on the data card and the Amper is
reconfigured to become a powerful pulse logger; useful for utility, traffic, flow and similar
measurements. Collect pulse data (up to 10 pulses per second) in buckets of minutes to an
hour allowing for easy analysis of totals that are simply impossible to collect with a typical
totalizer type counters. Even copy data from the card while running without loosing any pulse
counts.
Unattended data logging. Leave the Amper running all the time; if there’s a problem swap the
card and look at the data. Just pull the Amper data every year or so (unless you need it
sooner), replace the battery every 5 years or so; that’s it. Forget changing the circular charts,
the dried up pens and weekly wind ups.

Amper Manual Version 2.01 Page 9 of 45

Amper Manual Version 2.01 Page 10 of 45
Specifications:
Operating temperature -20ºC to 60 ºC non condensing
Storage temperature -30ºC to 70 ºC non condensing
Size 6.125” x 4.5” x 2.25”
Weight 1.5 lbs; 675 grams.
Power Required 3.6V 19Ah Lithium Battery Tadiran TL-5930S
Battery Life Depends on acquire rate; typically 3-8 years
Input Signal Range 0 - 6 Amp nominal, 0 – 30 Amp Surge (Amper)
0 - 100mA (milliAmper)
0 – 1.5V (microAmper)
Input Signal Load 0.05 Ohm (Amper)
15 Ohm (milliAmper)
10.0 KOhm (microAmper)
Input Surge Time Limit Amper 20 Amps 5 seconds Maximum
milliAmper 150mA maximum continuous
microAmper 0.2mA maximum continuous
Accuracy 0.15 % 0ºC to 50ºC
Conversion Resolution 14 Bit
Input Conversion Type True RMS for any waveform
Fastest Acquire Rate 50mS (20 samples / second)
Fastest Pulse Rate 10 Hertz / 20 edges.
Pulse Counting Bucket Size 1 to 60 minutes.
Data Storage Format ASCII text files
Data Storage Medium SD/MMC Flash Memory Cards, up to 2 GByte (FAT or FAT32)
Data Storage Capacity Depends on card size; approximately 60 Million analog samples
(Analog Mode) with a 2 GByte card.
Data Storage Capacity Greater than 50 years of data using a 2 GByte card.
(Pulse Mode)

Amper Manual Version 2.01 Page 11 of 45
Operation
Unpacking and Inspection:
The Amper datalogger uses a high capacity battery
containing Lithium. FAA regulations prohibit transporting
this battery via passenger aircraft. If the device has to be
shipped via passenger aircraft the battery must be
removed before shipment.
The date and time maintained by the Amper datalogger
will be lost if the battery is removed for more than
approximately 10 seconds. Do not remove the battery
unless the unit will not be used for extended periods of
time or the device needs to be shipped by passenger
aircraft.
Open the container and verify the following items are included.
1. Amper Datalogger
2. SD/MMC data card. The ChartLogger and Amper Setup software are on this card.
3. SD/MMC to USB Adapter
4. Manual
5. 2 Pin signal plug
6. Battery (this may already be installed in the Amper)
The microAmper may also be supplied with a resistor kit and BNC adapter.
If any are missing please contact the vendor for assistance.
NOTE
DANGER

Amper Manual Version 2.01 Page 12 of 45

Amper Manual Version 2.01 Page 13 of 45
Configuration and Setup
The Amper may need configuring before initial operation, to set suitable parameters such as
the site name, sample rate and the local time and date. The AmperSetup program provides a
quick and easy way to create these settings and write them to the card, then when the card is
inserted into the Amper all settings are automatically updated. Since these configuration files
are in a plain text format they may also be created with any plain text editor such as Microsoft
Notepad, details on the configuration files are explained further on in the manual. The following
chapters explain how to use the Amper Setup program to configure the Amper ready for
operation.
Using the Amper Setup Program
The Amper Setup program provides a quick and easy way to generate any configuration files
needed. The program itself is provided on the SD card that comes with the Amper. To install
the Amper Setup program insert the card in the PC (use the supplied SD/MMC to USB
converter if the PC does not have an SD/MMC slot). Navigate to the SD card directory on the
PC then double click on “Install Amper Setup”; this will install the setup program. The Setup
Program may now be started, and a screen similar to the following will appear:

Amper Manual Version 2.01 Page 14 of 45
The large control buttons initially appear grey such as the date and time in the screen above;
clicking on them will change color to indicate that they are operational. One or more may be
selected to create the required settings.
Set Sample Rate allows changing the sample rate for collected data. The sample rate may be
set from 50mS (20 samples a second) to approximately once an hour. An estimate of the data
file size will be shown in the box below. Use the up and down buttons to select the required
sample rate.
Set Site ID allows changing the ID of the site. This will be used as part of the name for the data
files. It may be up to 4 characters long without any special characters. Note that the Set Site ID
button must be enabled to allow changes to the scaling with the Scaling button; since the
scaling data written to a card needs to know the units ID it is to be associated with. Scaling data
from different sites may exist on the same card; these files are not actually read by the Amper.

Amper Manual Version 2.01 Page 15 of 45
Set Time Date. This will update the internal clock and calendar in the Amper. The time and
data will be taken from the PC’s clock, and may be seen in the window below the button.
Set Store Rate. For most applications this is never used. The Amper will only write to the card
when it needs to due to its internal data buffers being full. However, if acquiring at a slow rate it
may be a long time between card writes; for example if taking a reading every 5 minutes it will
be over 3 days before the card is written to. If data is needed before this wait a shorter time
may be set here; this will force a write to the card if new data exists within this time frame. It is
the longest time between writes (in minutes), so in the above example if the store rate was set
to 30 minutes then the most current readings stored on the card would never be more than 30
minutes old.
CT Ratio / Span & Offset. The Amper normally operates with a current transformer (CT). The
CT is an isolated pass through device (or hollow transformer) that senses a sample current and
provides an isolated output current typically in the range from 0 to 5 Amps RMS. This output
current is proportional to the sample current. Typical CT’s may be 50:5, 1000:5 etc rating,
meaning that they can measure currents up to 50 and 1000 Amps respectively with full scale
outputs of 5 Amps. When the CT ratio button is enabled a calibration factor is generated that
may be stored on the card. Note that this value is not used or even read by the Amper, but the
value is stored on the card so the ChartLogger program may use it. When the ChartLogger
imports the data from a site it also automatically reads these parameters if present, so the data
displayed in ChartLogger is in scaled units that relate to the site. The CT ratio may be entered
here, and is the nominal full scale reading for the current transformer. (The Amper will
accurately measure levels up to 5 times higher than this to accommodate overloads). Note that
setting the ratio 5:5 effectively scales the input as a 0 to 5 Amp ammeter, and it can be used as
such without the use of a CT. If the CT Ratio button is clicked again it displays span and offset
values typically used for the milliAmper; although they can be used by the Amper too.
For the milliAmper the nominal full scale value
corresponds to 20mA input. The span could be any
process variable, for example 10,000 PSI, 120 ft, 100
GPM. Note that most 4-20mA transducers provide 16mA
as the full scale ‘span’ and an offset of 4mA. Since the
milliAmper measures from 0 to 20mA the entered span is
typically 1.25 * the transducer span, and the offset will be
a value subtracted from the result by the ChartLogger
program as the data is displayed. For example, if a transducer measuring 0 -1000 generates a
4 to 20mA change, enter a span of 1250 and an offset of 250. This means that an input signal
of 0mA will result in -250 being displayed in the ChartLogger, a signal of 4mA would indicate 0,
and 20mA would indicate 1000. Generally the only signal sources that would require an offset
would be 4-20mA transducers.
To summarize, the nominal full scale range used for display in the ChartLogger program is
set by using either the ‘CT ratio’ or ‘Span’ button. They both have the same effect, generating
the ChartLogger ‘span’ value. If the ‘CT ratio’ button is used the ChartLogger ‘offset’ is set to
zero; if an offset is required use the Span / Offset button. Note that the span and offset may be
entered or changed later; they are not used by the Amper at all for datalogging but just by the
ChartLogger display program.
Write to Card. Once one or more settings have been selected this button will become enabled.
It will allow any settings to written to the card. Before clicking on it ensure that the drive letter,

Amper Manual Version 2.01 Page 16 of 45
such as D: or E: corresponds to the current card location, and that the card is not write
protected. The configuration files will always need to be in the top or root directory of the card.

Amper Manual Version 2.01 Page 17 of 45
Connecting the Amper to Electrical Signals
Only qualified persons may make electrical connections to
the Amper datalogger. Ensure all local safety codes and
procedures are followed.
First ensure any live circuits are disengaged and suitable lockout / tag out procedures are in
place.
Amper AC current measurement using a CT with 5 Amp secondary.
There is just a single 2 pin connector on the front of the Amper to connect. The two pins are
simply connected in series with the CT secondary. There is no electrical connection between
the Amper and the primary current being measured as the CT provides electrical isolation.
Since the electrical burden is so low the Amper may be connected in series with other
current measuring devices such as the Bristol Babcock ampchart without affecting the other
devices.
AMPER
0.05 Ohm
(inside Amper)
Current to be
m
easu
r
ed
Current
Transformer (CT)
Input to Amper
Example circuit where current
is to be measured using as CT
DANGER

Amper Manual Version 2.01 Page 18 of 45

Amper Manual Version 2.01 Page 19 of 45
Amper AC and/or DC current measurement without a CT.
The Amper is not intended for direct connection to high
voltage potentials. The electrical isolation between the 2
pin current sensing input and the grounded case is rated
at 40 Volts AC or less. Do not connect the input
connection directly to any Voltage exceeding 40 Volts with
respect to ground.
First ensure any live circuits are disengaged and suitable lockout / tag out procedures are in
place. There is just a single 2 pin connector on the front of the Amper to connect. The two pins
are simply connected in series with the current to be measured. Since the electrical burden is
very low (approximately 0.25 Volt drop for 5 Amps of current sensed) other devices may be in
the circuit without any affect.
The Amper is often used for low Voltage DC current measurements, for example to
determine the draw on a solar powered system. Since the Amper measures true RMS current
the polarity for connection is irrelevant, as the Amper does not indicate negative currents but
rather shows them as true RMS positive currents.
AMPER
0.05 Ohm
(inside Amper)
Current to be
m
easu
r
ed
Input connector
on Amper
12 Volt
Battery
Example circuit where current
is to be measured directly
DANGER

Amper Manual Version 2.01 Page 20 of 45
milliAmper AC and/or DC 0-20mA and similar current measurements.
The milliAmper is not intended for direct connection to
high voltage potentials. The electrical isolation between
the 2 pin current sensing input and the grounded case is
rated at 40 Volts AC or less. Do not connect the input
connection directly to any Voltage exceeding 40 Volts with
respect to ground.
First ensure any live circuits are disengaged and suitable lockout / tag out procedures are in
place. There is just a single 2 pin connector on the front of the milliAmper to connect. The two
pins are simply connected in series with the current to be measured. Since the electrical burden
is so low (approximately 0.30 Volt drop for 20mA of current sensed) other devices may be in
the current loop without any affect.
The milliAmper is often used for low Voltage DC milliamp current measurements, for
example connected to a suitable transducer it may log the level of a tank or pipeline flow. As
the milliAmper measures currents down to zero it also logs events such as power failing to the
4-20mA transducer. The milliAmper measures true RMS current, so the polarity for connection
is irrelevant as the milliAmper does not indicate negative currents but rather shows them as
true RMS positive currents.
Analog Input
on PLC
DC Power to
transducer
DC Power
to PLC
Control
power
su
pp
l
y
milliAmper
15 Ohm (inside
Amper)
Loop current to
be
m
easu
r
ed
Input connector
on milliAmper
Control
PLC
4-20mA Tank
Level Transducer
PLC I/O
Water /
Oil Tank
DANGER
Example circuit where 4-20mA
current is to be measured