Magtrol 5100 User manual

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Model 5100Model 5100
Model 5100Model 5100
Model 5100
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Single PhaseSingle Phase
Single Phase
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Power Analyzerower Analyzer
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UserUser
UserUser
User’s Manual’s Manual
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’s Manual

ii
While every precaution has been exercised in the compilation of
this document, Magtrol, Inc. assumes no responsibility for errors
or omissions. Additionally, no liability is assumed for any damages
that may result from the use of the information contained within
this 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.
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Sales and TSales and T
Sales and TSales and T
Sales and Technical Assistanceechnical Assistance
echnical Assistanceechnical Assistance
echnical Assistance
Manufacturers of:
Motor Test Equipment
!
Hysteresis Brakes and Clutches
70 Gardenville Parkway
Buffalo, New York 14224 USA
Tel: [phone] or 1-800-828-7844
Fax: [phone]
MAGTROL, INC.MAGTROL, INC.
MAGTROL, INC.MAGTROL, INC.
MAGTROL, INC.
Rev. B 02/01

iii
TT
TT
Table of Contentsable of Contents
able of Contentsable of Contents
able of Contents
SALES AND TECHNICAL ASSISTANCE .............................................................................................. ii
TABLE OF REVISIONS.......................................................................................................................... vi
1 - INTRODUCTION ................................................................................................................................ 1
Abbreviations ...................................................................................................................................................... 1
Unpacking ........................................................................................................................................................... 1
Power .................................................................................................................................................................. 1
Fuse Replacement ............................................................................................................................................... 1
Safety .................................................................................................................................................................. 1
Connectors .......................................................................................................................................................... 1
Maximum Ratings............................................................................................................................................... 1
Installation .......................................................................................................................................................... 2
ORIENTATION .................................................................................................................................................................... 2
ELECTRICAL LOAD ............................................................................................................................................................ 2
IEEE-488 (GPIB) ........................................................................................................................................................... 2
Initial Checkout................................................................................................................................................... 2
Transient Overloads ............................................................................................................................................ 2
Current Overload ................................................................................................................................................ 2
2 - SPECIFICATIONS .............................................................................................................................. 3
Voltage ................................................................................................................................................................ 3
Current ................................................................................................................................................................ 3
Meter Impedance ................................................................................................................................................ 3
Resolution ........................................................................................................................................................... 3
Isolation............................................................................................................................................................... 3
Display Auto Zero............................................................................................................................................... 3
Analog Outputs ................................................................................................................................................... 3
Data Acquisition ................................................................................................................................................. 3
ANALOG ........................................................................................................................................................................... 3
DIGITAL ............................................................................................................................................................................ 3
Measurement Accuracy ...................................................................................................................................... 4
Accuracy Certification ........................................................................................................................................ 4
3 - CONNECTING THE 5100 .................................................................................................................. 5
Surge Protection .................................................................................................................................................. 5
External Shunts ................................................................................................................................................... 5
Figure 1. External Shunt Connection ............................................................................................................ 5
Connectors .......................................................................................................................................................... 5
Single Phase AC or DC Connections.................................................................................................................. 6
Figure 2. Single Phase AC or DC with Remote Voltage Sense ..................................................................... 6
Three Phase, 3 Wire Delta Connections ............................................................................................................. 6
Figure 3. Three Phase, 3 Wire Delta, 2 Wattmeter with Remote Voltage Sense .......................................... 7
Three Phase, 3 Wire Wye, 2 Wattmeter Connections ........................................................................................ 7

iv
Figure 4. Three Phase, 3 Wire Wye, 2 Wattmeter with Remote Voltage Sense ............................................ 7
Three Phase, 4 Wire Wye, 3 Wattmeter Connections ........................................................................................ 7
Figure 5. Three Phase, 4 Wire Wye, 3 Wattmeter with Remote Voltage Sense ............................................ 7
Single Phase Current & Potential Transformer Connections ............................................................................. 8
Figure 6. Current & Potential Transformer - Single Phase .........................................................................8
Three Phase, 4 Wire Balanced Load, 1 Wattmeter Connections........................................................................ 8
Figure 7. Three Phase, 4 Wire Wye, Balanced Load, 1 Wattmeter............................................................... 8
Three Phase, 3 Wire Balanced Load, 1 Wattmeter Connections........................................................................ 8
Figure 8. Three Phase, 3 Wire, Balanced Load, 1 Wattmeter ......................................................................8
4 - OPERATION ...................................................................................................................................... 9
General ................................................................................................................................................................ 9
Amperes Display................................................................................................................................................. 9
Voltage Display .................................................................................................................................................. 9
Watts or Power Factor ........................................................................................................................................ 9
Mode Hold .......................................................................................................................................................... 9
Mode Avg ......................................................................................................................................................... 10
Analog Output Option....................................................................................................................................... 10
Figure 9. Analog Output Connections ........................................................................................................ 10
5 - GPIB COMMUNICATION................................................................................................................. 11
GPIB (IEEE-488) .............................................................................................................................................. 11
Hardware Installation ........................................................................................................................................ 11
Software Installation ......................................................................................................................................... 11
Primary Address ............................................................................................................................................... 11
Figure 10. GPIB Address Selection ............................................................................................................... 11
IBM® and Compatibles Instructions ................................................................................................................ 11
READ CYCLE .................................................................................................................................................................. 12
QuickBASIC® Example ................................................................................................................................... 12
GPIB Instruction Set ......................................................................................................................................... 12
Special Functions .............................................................................................................................................. 13
6 - OPERATING PRINCIPLES .............................................................................................................. 14
Amperes Transducing ....................................................................................................................................... 14
Voltage Sensing ................................................................................................................................................ 14
Figure 11. 5100 Input Circuits ...................................................................................................................... 14
Analog Processing ............................................................................................................................................ 14
Figure 12. Block Diagram ............................................................................................................................. 15
Digital Processing ............................................................................................................................................. 15
7 - CALIBRATION ................................................................................................................................. 16
General .............................................................................................................................................................. 16
Test Setup.......................................................................................................................................................... 16
Figure 13. Calibration Verification Test Setup ............................................................................................. 16
Calibration Verification .................................................................................................................................... 17
VOLTS CALIBRATION CHECK ............................................................................................................................................. 17
AMPERES CALIBRATION CHECK ........................................................................................................................................ 17
WATTS CALIBRATION CHECK ........................................................................................................................................... 18

v
MINOR ADJUSTMENT (IF NEEDED) ..................................................................................................................................... 18
VOLTS ZERO ................................................................................................................................................................... 18
AMPERES ZERO ............................................................................................................................................................... 18
VOLTS SCALE FACTOR ..................................................................................................................................................... 19
AMPERES SCALE FACTOR ................................................................................................................................................. 19
VOLTS BALANCE ............................................................................................................................................................. 19
CURRENT BALANCE ......................................................................................................................................................... 19
WATTS SCALE FACTOR .................................................................................................................................................... 19
APPENDIX A: SCHEMATICS .............................................................................................................. 20
Circuit 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

vi
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Table of Rable of R
able of Rable of R
able of Revisionsevisions
evisionsevisions
evisions
Date Change Page Number(s)
02/07/00 Added External Shunt Connection Drawing 5

1
1 - Introduction1 - Introduction
1 - Introduction1 - Introduction
1 - Introduction
ABBREVIATIONS
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UNPACKING
The Model 5100 is packed in reusable, shock resistant
packing material that will protect the instrument during
normal handling. In the event of shipping damage,
immediately notify the carrier and MAGTROL
Customer Service Dept.
Save all shipping materials for reuse when returning
the instrument for calibration or servicing.
POWER
The 5100 PA is factory wired for either 120 or 240
Vrms, 50/60 Hz, power at 40 volt amps, max. The line
cord is a detachable NEMA standard 3 wire which plugs
into the rear access power entry and filter module of the
5100 PA. The line cord must be detached from the PA
during servicing.
NOTE: The standard 5100 is factory
wired for 120 Vrms power.
Wiring for 240 Vrms is available
on special order.
FUSE REPLACEMENT
Remove the line cord and carefully pry up and remove
the fuse holder. Use a 1/2 Amp slow blow fuse for 120
Vrms or a 1/4 Amp slow blow fuse for 240 Vrms power.
SAFETY
SECURELY GROUND the 5100 PA case by
connecting a good earth ground at the ground stud that
is located on the rear panel. Use a number 12 AWG, or
larger 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 supplied
with your 5100 PA.
Use only the above connectors.
NOTE: GPIB (IEEE-488) - 24 Pin bus
standard. Not included, must be
ordered separately.
MAXIMUM RATINGS
LOAD voltage: line to line, or line to common is 600
Vrms.
LOAD current: 50 Amperes rms, continuous.
100 Amperes rms, 30 sec. max.
REMOTE VOLTAGE SENSE: Line to line is 600
Vrms. Also, do not exceed 600 Vrms differential
between the VOLTS INPUT and AMPS OUTPUT
terminals.

2
Magtrol Model 5100 Single Phase Power Analyzer
Chapter 1 - Introduction
INSTALLATION
ORIENTATION
The 5100 PA must be mounted within ± 20 degrees
from horizontal. This insures proper operation of the
mercury shunt bypass relay.
ELECTRICAL LOAD
Use wire rated for the maximum load current and voltage
expected.
Hint - use wire gauge large enough to insure good
connector set screw compression on the wire leads.
Soldering may be used instead of, or in addition to the
set screw.
IEEE-488 (GPIB)
Use only high quality shielded cable conforming to the
bus standards.
INITIAL CHECKOUT
Make sure the circuit is completely de-energized by
removing all voltage sources.
Plug the 5100 PA into the 50/60 Hz power mains.
Switch the POWER rocker switch (red) to ON and
observe that the digit readouts flash on-off-on and then
indicate zero or a small number. The VOLTS and
AMPERES range switch indicator lights will all
illuminate. The voltage ranges sequence down from 600
through 15 and current ranges sequence down from 50
through 2. The 15 Volt, 2 Amp and AUTO indicators
will remain illuminated. The MODE indicators do not
light during this power-on sequencing.
Your 5100 PA has passed the initial check.
TRANSIENT OVERLOADS
Connect an appropriate transient suppressor in parallel
with all inductive loads. Consult the suppressor vendors
application literature for proper selection and sizing.
Damage to the 5100 can result from
excessive voltage transients generated
by unsuppressed inductive loads.
This damage is not within the scope of
the normal instrument service and is not
covered by the MAGTROL WARRANTY.
CURRENT OVERLOAD
NO FUSES are in the 5100 PA measuring circuits.
Therefore, excessive current passed through the AMPS
terminals will cause excessive internal heating and
possible unit damage.
This overload abuse is not covered by
the MAGTROL WARRANTY.
Know your load conditions and double check all
connections. If an overload should occur, immediately
remove all power , locate and correct the problem before
re-energizing your circuit. If a circuit breaker is
installed, it must be installed on the LOAD side of the
5100 (downstream). This will keep the low impedance
of the input line connected to the 5100 PA for surge
suppression. If the line side must also contain a breaker,
it should be delayed in operation to open after the load
side breaker has opened.

3
2 - Specifications2 - Specifications
2 - Specifications2 - Specifications
2 - 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 terminal
to 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 and
20 Amp ranges.
•0.001 Ohm shunt resistance in the 50 Amp
range.
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 to
disable the AUTO ZERO function.
ANALOG OUTPUTS
This is an optional feature.
Analog AMPS, VOLTS and WATTS output signals
are a relative value of approximately 5 Volts DC for
full scale on each range selected. These outputs are
calibrated to 5.00 Volts DC ± 0.2% for full scale input
on 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 an
impedance of < 1 Ohm and current capacity of < 4 mA.
Each output signal and common is electrically isolated
from the measured circuit by 750 Volts continuous and
2500 Volts test breakdown. Leakage current is less than
0.3 µA at 240 Vrms, 60 Hz.
DATA ACQUISITION
ANALOG
The conversion of true rms to DC is expressed as:
Vrms ≡
()
12
0
Tvtdt
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 reading
Non-synchronized is 0.04 to 0.07 sec per
reading.