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INTRODUCTION
This chapter contains general information that will be useful to know before using the
MCP3905A/06A Energy Meter Reference Design. Items discussed in this chapter
include:
• Document Layout
• Conventions Used in this Guide
• Recommended Reading
• The Microchip Web Site
• Customer Support
• Document Revision History
DOCUMENT LAYOUT
This document describes how to use the MCP3905A/06A Energy Meter Reference
Design as a development tool to emulate and de b ug firm wa re on a target boar d. The
manual layout is as follows:
• Chapter 1. “Product Overview” – Important information about the
MCP3905A/06A Energy Meter Refere nc e Des i gn .
• Chapter 2. “Installation and Operation” – Provides a detailed description of
each block, as well as instructions on how to get started with this board.
• Appendix A. “Schematics and Layouts” – Shows the schematic and board
layout diagrams for the MCP3905A/06A Energy Meter Reference Design.
• Appendix B. “Bill Of Materials (BOM)” – Lists the parts used to build the
MCP3905A/06A Energy Meter Refere nc e Des i gn .
This user's guide describes how to use MCP3905A/06A Energy Meter Reference
Design. Other useful documents are listed below. The following Microchip documents
are available and recommended as supplemental reference resources.
• MCP3905 Data Sheet, “Energy Metering IC with Active Real Power Pulse
Output” (DS21948)
This data sheet provides detailed information regarding the MCP3905A device.
• AN994 Application Note “IEC Compliant Active Energy Meter Design Using
The MCP3905A/06A” (DS00994)
This application note documents the design decisions associated with this reference
design.
THE MICROCHIP WEB SITE
Microchip provides online support via our web site at www.microchip.com. This web
site is used as a means to make files and information easily available to customers.
Accessible by using your favorite Internet browser , the web site contains the following
information:
• Product Support – Data sheets and errata, application notes and sample
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distributors and factory representatives
Preface
CUSTOMER SUPPORT
Users of Microchip products can receive assistance through several channels:
• Distributor or Representative
• Local Sales Office
• Field Application Engineer (FAE)
• Technical Support
Customers should contact their distributor, representative or field application engineer
(FAE) for support. Lo cal sales offices are also available to help customers. A listing of
sales offices and locations is included in the back of this document.
Technical support is available through the web site at: http://support.microchip.com
This chapter provides an overview of the MCP3905A/06A Energy Meter Reference
Design and covers the following topics:
• What is the MCP3905A/06A Energy Meter Reference Design?
• What the MCP3905A/06A Energy Meter Reference Design Kit includes
1.2WHAT IS THE MCP3905A/06A ENERGY METER REFERENCE DESIGN
The MCP3905A/06A Energy Meter Reference Design device is an energy metering IC
that supplies average active power information via a pulse output with direct drive for
mechanical counters. It also includes a higher-frequency output that supplies
instantanous power information for calibration. The device contains function blocks
specific for IEC energy meter compliance, such as a no-load threshhold and startup
current.
The MCP3905A/06A Energy Meter Reference Design Printed Circuit Board (PCB) is
used as a reference design for single-phase, residential meter s. T he M CP3905 A/0 6A
Energy Meter Reference Design kit includes all necessary PCB circuits and layout tips
for IEC62053 and prior 1036/61036/687 active-energy meter standards compliance.
For more information regarding IEC compliance, refer to AN994, “IEC Compliant Active Energy Meter Design Using The MCP3905A/06A Energy Meter Reference Design”
(DS00994).
1.3WHAT THE MCP3905A/06A ENERGY METER REFERENCE DESIGN KIT
INCLUDES:
This MCP3905A/06A Energy Meter Reference Design kit includes:
• MCP3905A/06A Energy Meter Reference Design, 102-00037
POWER = 1432 KW
ENERGY = 43213 kWh
28/03/2004
15:23:23
Analog
Digital
PICmicro
®
REFERENCE DESIGN
MCP3905A Stand-Alone Mechanical Counter
Energy Meter
Microcontroller-based LCD Energy Meter
1000 imp/kWh
CLASS 1 METER
5(40)a
MCU
MCP3905A/06A
MCP3905A/06A
MCP3905A/06A
2.1INTRODUCTION
The MCP3905A/06A Energy Meter Reference Design is a stand-alone, single-phase
residential meter design for active-energy meter designs. For advanced
microcontroller-based meter products, this design also serves as the de sign of the
Analog Front-End (AFE). This design includes a low-cost DC power supply circuit and
the necessary protection for IEC62053 EMC compliance.
MCP3905A/06A ENERGY METER
REFERENCE DESIGN
2.2FEATURES
FIGURE 2-1: MCP3905A Stand-Alone Energy Meter and
Microcontroller-Based Energy Meter Using MCP3905A AFE Design.
For more detailed information regarding design decisions and an approach to
IEC62053 compliance using the circuitry in this board, refer to AN994 “IEC Compliant Active Energy Meter Design Using The MCP3905A/06A” (DS00994).
The MCP3905A/06A Energy Meter Reference Design PCB has the following features:
• Protection for IEC62053 Energy Meter EMC Immunity Tests
• On-Board DC power supply
• Resistor divider circuit for single-point meter calibration
• Connections for current-sensing shunt or other current sensing element
• Connection for voltage-sensing and power supply biasing
• Connections for mechanical counter and calibration output
• Low-noise PCB layout for small-signal conversion and IEC62053 accuracy
compliance for small shunt values
This meter can be manufactured by performing the following two steps detailed in this
document. For the external connections, the following terms are used: “phase” refers
to the hot (or line) side of the power supply lines. “Neutral” refers to the return wire
(or low-side) of the power supply lines.
2.3.1External Connections
Connections are made to the phase and neutral wire for voltag e-detection and AC/DC
power supply . The MCP3905A/06A Energy Me ter Reference De sign is designed to be
biased to the phase (or hot) side of a 2-wire power supply system.
1. Connect JP4 to the phase power supply line connection.
2. Connect JP3 to the neutral line.
3. Connect JP1 and JP2 across the shunt.
4. Connect JP5 and JP6 to the mechanical counter.
2.3.2Calibration of the Frequency Output using the Voltage Divider
Calibration Circuit
Each meter must be calibrated using the voltag e divider circuit going into Channel 1 of
the MCP3905A/06A. A known power is supplied to the meter (e.g., 1000W), and an
expected output frequency is the goal (1000 imp/kWh). Start with the highest value
resistor and short the resistor using it's respective shorting jumper. If the output
frequency is too high, remove the shunt. Continue testing each resistor short until all
jumpers are tested once. For more det ailed information regarding meter calibra tion and
the PCB design approach using the circuitry in this docume nt , ref er to AN99 4,
“IEC Compliant Active Energy Meter Design Using The MCP3905A/06A” (DS00994).
FIGURE 2-2:Photograph of Complete, Stand-Alone MCP3905A Energy Meter.
This reference design can be used as eit her a stand-a lone mechanical cou nter energy
meter, or as the analog front-end design in advanced microcontroller-base d meter
designs.
The AFE design limits the overall meter accuracy. A low noise, proven AFE circuit and
layout is still required for a high-accuracy meter. For both meter types, the current
sense input, voltage sense input, calibration scheme, jumper selection and power
supply design blocks described here should apply.
This reference design keeps all of the major compo nents on the back-side of the PCB.
This minimizes any ill effects from the environment in the situation that a meter case
experiences failure. Only the necessary components for calibration, jumper selection
and external connections are placed on the fro nt-side of the board. Keeping the lar ger
DC power supply components on the back-side of the board is also necessary for
installation in some meter cases with PCB standoffs.
The major components on the front-side of the MCP3905A/06A Energy Meter Reference Design are listed here and described in Section 2.5 “Front-Side Of PCB Detailed Description”.
1. Shunts for Gain, FC and HPF selection (J11-J15).
2. Calibration jumpers (J1-J10).
3. Output connections for mechanical counter and calibration (JP5-JP7).
4. Input connection from the current-sensing element (JP1,JP2).
5. Input connection from voltage or phase line and ground reference point
(JP3,JP4).
6. The analog ground plane, power supply ground plane, moat.
The major components on the back-side of the MCP3905A/06A Energy Meter
Reference Design are listed here and described in Section 2.6 “Back Side Of PCB Detailed Description”.
1. MCP3905A (U1).
2. DC Power Supply (C17, C16, U2, C18, etc.).
3. Metal Oxide Varistor (MOV1).
4. Optical isolator for PIC
These blocks, and their functionality, will be briefly described in the following two
sections. For more detailed information re garding design decisions and appr oaches to
IEC1036 compliance, refer to AN994, “IEC Compliant Active Energy Meter Design Using The MCP3905A/06A” (DS00994). For a more detailed circui t schematic, refer to
Appendix A. “Schematics and Layouts” and Appendix B. “Bill Of Materials
(BOM)”.
FIGURE 2-3:MCP3905A/06A Energy Meter Reference Des i gn Block Dia gr am .
2.5FRONT-SIDE OF PCB DETAILED DESCRIPTION
2.5.1Shunts for Gain and FC Selection (J11-J15)
Positions for both logic-high and logic-low are here for all gain and frequen cy const ant
selections. The logic-high positions are labeled “J1H” and the logic-low positions are
labeled “J1L” (Jumper 1 used here as an example). Do n ot short both the high and the
low positions for any one jumper.
2.5.2Calibration Jumpers (J1-J10)
Calibration resistors for each of these jumper locations are located directly beneath the
associated jumper. When a shorting resistor or jumper is in place, the associated
calibration resistor is shorted and bypassed.
2.5.3Output Connections for Mechanical Counter and Calibration
JP5 and JP6 are the differential output drive for the mechan ica l c ounter.
(JP5-JP7)
JP7 is the calibration or microcontroller output that is connected to HF
MCP3905A/06A devices. A LED is supplied to assist in any optical calibration
schemes.
2.5.4Connection to Current-Sensing Element (JP1,JP2)
These two connections lead directly through LRC filtering into Channel 0 of the
MCP3905A/06A. The schematic in Appendix A uses a low-cost shunt as the
current-sensing element. The shunt resistance should be placed in parallel with these
two connections, between JP1 and JP2.
2.5.5Connection to Voltage or Phase Line and Ground Reference
Point (JP3,JP4)
These two connections feed the DC power supply circuitry described in
Section 2.6.3 “Metal Oxide Varistor (MOV1)”. JP4 is connected to the ground of the
PCB, and JP3 to the high-side of the DC power supply circuitry. JP3 is also connected
to the resistor divider that feeds the analog input of Cha nnel 1 o f the MCP39 05A/06A.
This is the channel for measuring voltage and is conne cted to the dif ferential input in a
single-ended fashion. See Appendix A. “Schematics and Layouts” for further det ail.
2.6BACK SIDE OF PCB DETAILED DESCRIPTION
2.6.1MCP3905A (U1)
From the back side of the board, the MCP3905A/06A is located on the right ha nd side
where the analog ground plane exists. The MCP390 5 A/0 6A ha s ap pr o pr iate bypass
capacitors on V
its input logic pins connected to user-sel ectable jumpers, with the exception of the HPF
pin. For this system, the HPF is turned on with this pin connected to V
in AC mode only. The NEG connection is not connected in this reference design; this
pin should be left floating. The other three output pins (F
connected to nodes JP5, JP6 and JP7 described later in this section.
coming from the DC power supply circuitry . The MCP3905A/06A has
DD
OUT0
, F
OUT1
; the device is
DD
, HF
OUT
) are
2.6.2DC Power Supply (C17, C16, U2, C18, D2)
The DC power supply is created from a half-wave zener diode limited AC sig nal feeding
a 7805 +5V regulator . C1 7 and C16 divide the AC sig nal coming directly from the line
and designed in this document for 220V. The zener diode D2 limits the peak voltage to
15V.
2.6.3Metal Oxide Varistor (MOV1)
A MOV is included to suppress any high voltage transients co ming thro ug h the power
lines.
2.6.4Optical Isolator (U3)
An optical isolator is included in the reference design as an additional level of protection
for other circuitry used in advanced meter designs (PICmicro
otherwise). It is connected to the HF
Depending on the meter design, it may not be required. This design is a direct-connect
meter that has the entire PCB referenced to the phase or line -side of the power supply.
Therefore, any other circuitry would either need to be biased to the same point or
isolated using this scheme. A pull-up resistor is required on the output of the optical
isolator to allow the HF logic signal to appear.
frequency output of the MCP3905A.
OUT
®
microcontroller, DSP or
2.6.5The Analog Ground Plane, Power Supply Ground Plane, Moat.
The MCP3905A/06A Energy Meter Reference Design PCB is designed for low-noise
performance and immunity to external influences, as required by IEC61036. The DC
power supply and digital outputs are connected to the power supply ground plane
(right-side of the board when looking at it from the front). The lower noise analog
ground plane, including the MCP3905A/06A connections, is on the o pposite side of the
board, separated by a moat between the two ground planes. An inductive choke
connects the two grounds.