Tyco 1540 User Manual

Installation and Operating Manual
Switchboard Integra 1540, 1000, 0640, 0440
0340 & 0240 Digital Metering Systems

http://energy.tycoelectronics.com

Energy Division

Tyco Electronics UK Limited
Crompton Instruments

Freebournes Road, Witham, Essex, CM8 3AH, UK
Tel: [phone]
Fax: [phone]

Crompton

Switchboard Integra

Multifunctional metering for

Three-phase Electrical Systems

Models 1540, 1000, 0640, 0440, 0340, 0240

Operating Instructions

Important safety information is contained in the seperate installation leaflet.

Installers must familarise themselves with this information before installation

Crompton Instruments

Freebournes Road

Witham

Essex

CM8 3AH

England

Tel: [phone]

Fax: [phone]

E-Mail: [e-mail]

Integra 1540, 1000, 0640, 0440, 0340, 0240 Issue 1 04/03

Contents Page

1 Introduction 5

1.1 Unit Characteristics 6

1.1.1 0240 6

1.1.2 0340 6

1.1.3 0440 and 0640 6

1.1.4 1000 7

1.1.5 1540 8

1.2 Maximum Power 9

1.3 Secondary Voltage 9

1.4 Demand Calculation 9

1.5 RS485 Serial Option 10

1.6 Pulse Output Option 10

1.7 Analogue Output Option 10

2 Display Screens 11

2.1 Layout 11

2.2 Start Up Screens 11

2.3 System Screen 12

2.4 System %THD Screen 13

2.5 Line to Neutral Voltages 13

2.6 Line to Neutral Voltage %THD 13

2.7 Line to Line Voltages 14

2.8 Line to Line Voltages %THD 14

2.9 Line Currents 14

2.10 Line Currents %THD 15

2.11 Neutral Current, Frequency and Power Factor 15

2.12 Power 15

2.13 Active Energy (kWh) 16

2.14 Reactive Energy (kVArh) 16

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Contents Page

2.15 Demand 17

2.16 Maximum Demand 17

2.17 Over Range 17

2.18 kWh and kVArh Display Range 18

2.19 Error Messages 18

3 Setting up 18

3.1 Introduction 18

3.2 Number Entry Procedure 19

3.3 Access 21

3.3.1 Access with No Password Protection 21

3.3.2 Access with Password Protection 21

3.4 Changing the Password 23

3.5 Full Scale Current 24

3.6 Potential Transformer Primary Voltage 24

3.7 Potential Transformer Secondary Value 26

3.8 Demand Integration Time 27

3.9 Resets 28

3.10 Pulsed Output, Pulse Duration 29

3.11 Pulse Rate 30

3.12 RS485 Baud Rate 31

3.13 RS485 Parity Selection 32

3.14 RS485 Modbus Address 33

3.15 Analogue Output Set Up 34

3.15.1 Introduction 34

3.15.2 Analogue Output Scaling Example 35

3.15.3 Power Factor 36

3.15.4 Phase Angle 39

3.15.5 Parameters available for analogue outputs 40

3.15.6 Reading (Parameter Selection) - A1r or A2r 41

3.15.7 Reading Top – A1rt or A2rt 42

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3.15.8 Reading Bottom - A1rb or A2rb 43

3.15.9 Output Top – A1ot or A2ot 43

3.15.10 Output Bottom – A1ob or A2ob 43

4 Specification 44

4.1 Display Only Versions 44

4.1.1 Input 44

4.1.2 Auxiliary Power Supply 44

4.1.3 EMC Standards 44

4.1.4 Safety 45

4.1.5 Insulation 45

4.1.6 Environmental 45

4.1.7 Enclosure 45

4.2 Display/Transducer Combined Versions 45

4.2.1 Inputs 45

4.2.2 Auxiliary Power Supply 46

4.2.3 Measuring Ranges 47

4.2.4 Accuracy 47

4.2.5 Reference conditions of influence quantities 47

4.2.6 EMC Standards 47

4.2.7 Safety 48

4.2.8 Insulation 48

4.2.9 Environmental 48

4.2.10 Enclosure 48

4.3 Display/Tranducer Combined 1000 and 1540 48

4.3.1 Inputs 48

4.3.2 Auxiliary Power Supply 49

4.3.3 Accuracy 49

4.3.4 Reference conditions 50

4.3.5 Reference conditions of influence quantities 50

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4.3.6 Nominal range of use of influence 51
quantities for measurands

4.3.7 Functional ranges 51

4.3.8 Screen 51

4.3.9 Standards 51

4.3.10 Safety 52

4.3.11 Insulation 52

4.3.12 Environmental 52

4.3.13 Enclosure 52

4.3.14 Serial Communications Option 52

4.3.15 Active Energy Pulsed Output Option 53

4.3.16 Integra 1540 Only 53

5 Basis of measurement and calculations 54

6 Serial Communications 56

6.1 RS485 Port - Modbus or JC N2 56

6.2 Modbus® Implementation 56

6.3 RS485 Implementation of Johnson Controls Metasys 60

7. Maintenance 63

8 Appendix A CE Declaration of Conformity 64

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Integra 1540, 1000, 0640, 0440, 0340, 0240 Issue 1 04/03

1 Introduction

This manual provides operating instructions for the Crompton Switchboard Integra series of
Digital Metering Systems. Some versions of the Integra incorporate the metering transducer
that provides the interface for the measurement of power supply parameters such as voltage,
current, power, frequency etc. In other versions, the display and transducer are separate,
interconnected units. The display allows the user to set up metering transducer parameters
and to monitor the measurements. Some Integra models can be supplied as either an integral
or display-only version, while others are only available in one format. This manual provides
user instructions.

A separate leaflet provides installation instructions.

Table1 lists the various models of Integra and shows their distinctive characteristics.

Table 1 Summary of Integra models

Model V A F PF kW kWh THD Analogue Serial Pulse Freq

0240 V F 45-65 Hz
0340 V A 45-65 Hz
0440 V A F

360-400 Hz
0640 V A F 45-65 Hz
1000 V A F PF kW kWh RS485 Pulse 45-65 Hz

option option

1540 V A F PF kW kWh THD Analogue RS485 Pulse

option* option option 45-65 Hz

* When used with an 1560/80 transducer that includes analogue options.

Voltage and current readings are true RMS, up to the 15th harmonic (31st for 1560/80
transducer).

The unit can be powered from an auxiliary a.c. or d.c. supply that is separate from the metered
supply. Versions of each model are available to suit 100-250V 45-65 Hz a.c./d.c. and 12-48V d.c
nominal supplies.

In this manual, the graphic

0240 0340 0440 0640 1000 1540

is used to show the models to which a screen applies. Boxes are greyed out to show models
that do not have that type of screen.

0240 0340 0440 0640 1000 1540

This example indicates that the screen only applies to Models 1000 and 1540.

0240 0340 0440 0640 1000 1540 Option

This indicates that the screen is an option on models 1000 and 1540.

Important safety information is contained in the accompanying installation instructions.

Installers must familarise themselves with this information before installation.

Integra 1540, 1000, 0640, 0440, 0340, 0240 Issue 1 04/03

5

1.1 Unit Characteristics

1.1.1 0240

The 0240 will display the following parameters:

• System voltage (average of all phases)

• System frequency (Hz)

• Voltage line to neutral for each phase (4-wire systems only)

• Voltage line to line for each phase (calculated in 4-wire)

The 0240 has Set-up screens for potential transformer primary
and secondary voltages.

1.1.2 0340

The 0340 will display the following parameters:

• System voltage (average of all phases)

• System current (average of all phases)

• Voltage line to neutral for each phase (4-wire systems only)

• Voltage line to line for each phase (calculated in 4-wire)

• Current in each line.

The 0340 has Set-up screens for:

• Full-scale current value

• Potential transformer primary and secondary voltages.

1.1.3 0440 and 0640

The 0440 operates on a mains frequency of 400 Hz nominal
and the 0640 at 45-65 Hz. The units can measure and display
the following parameters:

• System voltage (average of all phases)

• System current (average of all phases)

• System frequency (Hz)

• Voltage line to neutral for each phase (4-wire systems only)

• Voltage line to line for each phase (calculated in 4-wire)

• Current in each line

The 0440 and 0640 have Set-up screens for:

• Full-scale current value

• Potential transformer primary and secondary voltages.

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Default display

Default display

Default display

1.1.4 1000

The 1000 will display the following parameters:

• System voltage (average of all phases)

• System current (average of all phases)

• System frequency (Hz)

• Voltage line to neutral for each phase (4-wire systems only)

• Voltage line to line for each phase (calculated in 4-wire)

• Current in each line

• Neutral current

1

• Power Factor

• Active Power (kW)

• Reactive Power (kVAr)

• Apparent Power (kVA)

• Active Energy (kWh)

2

• Reactive Energy (kVArh)

2

• Total System Current Demand (AD)

2

• Total System Active Power Demand (kWD)

2

• Maximum Total System Current Demand (AD)

2

• Maximum Total System Active Power Demand (kWD)

2

The 1000 has Set-up screens for:

• Full-scale current value

• Potential transformer - primary voltages.

• Demand integration time and energy/demand resets

• Pulse output duration and rate divisor (option)

• RS485 serial Modbus parameters (option)

A pulsed relay output, indicating kWh, and an RS485 Modbus

TM

output are available as optional extras. The Modbus output
option allows remote monitoring from a Modbus master.

1

Neutral referenced parameters are only available when used with 4-wire and single phase

configured transducers.

2

All energy and demand measurements are importing only unless connected as exporting unit.

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Default display

1.1.5 1540

The1540 is available either as a display unit operating in
conjunction with a 15xx measurement transducer or as a
self-contained unit incorporating a transducer. The unit can
measure and display the following:

• System voltage (average of all phases)

• System current (average of all phases)

• System frequency (Hz)

• Voltage line to neutral for each phase (4-wire systems only)

• Voltage line to line for each phase (calculated in 4-wire)

• Current in each line.

• Neutral current

1

• Power Factor

• Active Power (kW)

2

• Reactive Power (kVAr)

2

• Apparent Power (kVA)

• Active Energy (kWh)

2

• Reactive Energy (kVArh)

2

• Total System Current Demand (Admd)

2

• Total System Active Power Demand (kWD)

2

• Maximum Total System Current Demand (AD)

2

• Maximum Total System Active Power Demand (kWD)

2

The 1540 has Set-up screens for:

• Full-scale current value

• Potential transformer - primary and secondary voltages
(Dis 1540 and Integra 15xx)

• Potential transformer - primary voltages (self contained)

• Demand integration time and energy/demand resets

• Pulse output duration and rate divisor (option)

• RS485 serial Modbus parameters (option)

• Analogue current output (option, with separate
transducer only)

A pulsed relay output, indicating kWhr (and Kvarh on the two
part Dis 1540 and Integra 15xx combination), and an RS485
Modbus

TM

output are available as optional extras. The Modbus
output option allows remote monitoring from another display
(not self contained) or a Modbus master.

The Analogue current output option provides a current output
that indicates the value of a chosen parameter.

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Default display

1

Neutral referenced parameters are only

available when used with 4-wire and

single phase configured transducers.

2

All energy and demand measurements

are importing only unless connected as

exporting unit.

1.2 Maximum Power

Products covered in this manual are limited to a maximum power of 360 MW. During set-up,
primary voltage and current setting are checked and the unit will not accept entries that breach
the 360 MW limit. This is covered in more detail in the sections that show primary voltage and
current set-up. The Maximum Power restriction of 360 MW refer to 120% of nominal current and
120% of nominal voltage, i.e. 250 MW nominal system power.

1.3 Secondary Voltage

0240 0340 0440 0640 1000 1540

Most of the products described in this manual allow the user to specify, within a range, the
secondary voltage of the potential transformer (PT) with which it is to be used. The exception is
the Integra 1000 and self contained Integra 1540, which has the PT secondary factory set. On the
Integra 1000/1540, the user cannot change this value.

1.4 Demand Calculation

0240 0340 0440 0640 1000 1540

The maximum power consumption of an installation is an important measurement, as most
power utilities base their charges on it. Many utilities use a thermal maximum demand indicator
(MDI) to measure this peak power consumption. An MDI averages the power consumed over a
number of minutes, reflecting the thermal load that the demand places on the supply system.

The Integra uses a sliding window algorithm to simulate the characteristics of a thermal MDI
instrument, with the demand being calculated once per minute.

The demand period can be reset, which allows synchronisation to other equipment. When it is
reset, the values in the Demand and Maximum Demand registers are set to zero.

Demand Integration Times can be set to 8, 15, 20 or 30 minutes.

The number of sub-intervals, i.e. the demand time in minutes, can be altered either by using the
Demand Integration Time set-up screen (see Section 3.8) or via the RS485 port, where available,
using the Modbus

TM

protocol.

During the initial period, when the elapsed time since the demands were last reset or since the
Integra was switched on is less than one minute, the maximum demands (current MaxAD and
power MaxkWD) will remain at zero and not follow the instantaneous demands.

Maximum Demand is the maximum power or current demand that has occurred since the unit
was last reset as detailed in Section 3.9 Resets.

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1.5 RS485 Serial Option

0240 0340 0440 0640 1000 1540 Option

This option is available on two-part (separate transducer and display) units
and on 1000 and self-contained 1540 units.

This option uses an RS485 serial port with Modbus or JC NII protocol to provide a means of
remotely monitoring and controlling the Integra unit. Both protocols are supplied in the same
unit. Communications automatically configure according to the protocol that is recognized when
the master sends a message.

Where the installation comprises separate display and transducer units, the display
communicates with the transducer using a modified Modbus protocol via the RS485 port. Such
a transducer may have two such ports, either or both of which can be used for connection to a
display. Where a port is available, it can be connected to a PC for control and monitoring
purposes.

Set-up screens are provided for setting up the Modbus port. See Sections 3.12 to 3.14. These
screens are not applicable for setting up a port connected to a display unit, as the characteristics
of such a port are preset. On a two-port unit, communications settings made from an Integra
display affect the other communications port, unless the second port is also connected to a
display, in which case the changes have no effect.

1.6 Pulse Output Option

0240 0340 0440 0640 1000 1540 Option

This option provides a relay pulse output indication of measured active energy (kWh). The unit
can produce one pulse for every 1, 10 or 100kW of energy consumed. Two-part 1540 display
units operating with 1560 or 1580 transducers can also produce a pulse for every 1000 kW of
energy consumed. The pulse divisor can be set from the Set-up screen as detailed in Section

3.11 Pulse Rate. The pulse width (duration) can be set as detailed in Section 3.10 Pulsed Output,
Pulse Duration. On two part units, two pulsed outputs are available with common pulse rate
divisions and pulse widths.

1.7 Analogue Output Option

0240 0340 0440 0640 1000 1540 Option

This option is available on two-part (separate transducer and display) units and provides an
analogue current output that indicates the value of a chosen parameter. The parameter can be
chosen and set up via the set-up screen as described in Section 3.15 Analogue Output Set Up.

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2 Display Screens

2.1 Layout

The screen is used in two main modes: display of measured
values and parameter setup.

In display mode, three measured values can be shown, one on
each row. For each row, the LED indicators show the parameter
being measured and the units.

The >> button moves between display screens.

In Set up mode, the top row shows an abbreviation of the
parameter name, the middle row shows the parameter value
being set and the bottom row is used for confirmation of the
entered value. In general, the key changes a parameter value
and the >> key confirms a value and moves on to the next
screen.

This example is the potential transformer primary voltage
confirmation screen.

The example screens shown in this manual are those relating to the 1540 models – the most
complex. The screens for simpler models are similar except that some of the parameters and
values are omitted. Section 1.1 shows the default display screens for the various models.

2.2 Start Up Screens

Initially, when power is applied to the Integra Display, two
screens will appear. The first screen lights the LED’s and can be
used as a display LED check.

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Voltage display

Setup confirmation screen

The second screen indicates the firmware installed in the
display unit. This example states that the version is 0.008. The
version on a particular unit will differ in line with ongoing
development and improvements.

After a short delay, the default Display screen will appear.

Use the >> (Next) key to move from one screen to the next in the sequence. The sequence
depends on the supply configuration (single phase 2 or 3 wire, 3 phase 3 or 4 wire).

2.3 System Screen

0240 0340 0440 0640 1000 1540

The following sections show 3 and 4 wire systems.

Single phase 2 and 3 wire systems have similar display screens.

The system screen is the default display. It appears when the unit is energised after the start up
screens. Section 1.1 shows the default system screens for the various models.

System Average Voltage (Volts)*

System Average Line Current (Amps).

System Total Active Power (kW).

Pressing key >> moves to the next screen

* Line to Line for 3 wire systems, Line to Neutral for 4 wire and
single phase 3 wire systems.

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2.4 System %THD Screen

Average % Total Harmonic Distortion for System Voltages.

Average % Total Harmonic Distortion for System Currents.

Key >> moves to next screen.

2.5 Line to Neutral Voltages

Three phase, four wire systems only.

Voltage Line 1 to Neutral (Volts).

Voltage Line 2 to Neutral (Volts).

Voltage Line 3 to Neutral (Volts).

Key >> moves to next screen.

2.6 Line to Neutral Voltage %THD

Three-phase, four wire systems only.

%THD of Line 1 Voltage to Neutral.

%THD of Line 2 Voltage to Neutral.

%THD of Line 3 Voltage to Neutral.

Key >> moves to next screen.

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0240 0340 0440 0640 1000 1540

0240 0340 0440 0640 1000 1540

0240 0340 0440 0640 1000 1540

2.7 Line to Line Voltages

Voltage Line 1 to Line 2 (Volts).

Voltage Line 2 to Line 3 (Volts).

Voltage Line 3 to Line 1 (Volts).

Key >> moves to next screen.

2.8 Line to Line Voltages %THD

Three-phase, three wire systems only.

Line 1 to Line 2 Voltage %THD.

Line 2 to Line 3 Voltage %THD.

Line 3 to Line 1 Voltage %THD.

Key >> moves to next screen.

2.9 Line Currents

Line 1 Current (Amps).

Line 2 Current (Amps).

Line 3 Current (Amps).

Key >> moves to next screen.

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0240 0340 0440 0640 1000 1540

0240 0340 0440 0640 1000 1540

0240 0340 0440 0640 1000 1540

2.10 Line Currents %THD

Line 1 Current %THD.

Line 2 Current %THD.

Line 3 Current %THD.

Key >> moves to next screen.

2.11 Neutral Current, Frequency and Power Factor

Neutral Current (Amps).
(4-wire and single phase 3 wire system only).

Frequency (Hz).

Power Factor (0 to 1, on 1000 and combined 1540; sign (-)
prefix, on 1540 two part: prefix C indicates Capacitive load and
L = Inductive).

Key >> moves to next screen.

2.12 Power

Reactive Power (kVAr).

Apparent Power (kVA).

Active Power (kW).

Key >> moves to next screen.

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0240 0340 0440 0640 1000 1540

0240 0340 0440 0640 1000 1540

0240 0340 0440 0640 1000 1540

2.13 Active Energy (kWh)

This is the energy that has been consumed since the unit was last reset (see Section 3.9 Resets).

Active Energy (kWh)

7 digit reading i.e. 0001243.

Key >> moves to next screen.

2.14 Reactive Energy (kVArh)

This is the reactive energy that has been consumed since the unit was last reset (see Section 3.9
Resets). The reading shows the energy (kVArh) in the reactive component of the supply.

Reactive Energy (kVArh)

7 digit reading i.e. 0000102

Key >> moves to next screen.

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0240 0340 0440 0640 1000 1540

0240 0340 0440 0640 1000 1540

2.15 Demand

This screen displays the present demand, i.e. the maximum power and the maximum current
demanded during the defined integration window period. See Section 3.8 Demand Integration
Time.

System Total Active Power Demand (kWD)

System Total Current Demand (AD)

Key >> moves to the next screen.

2.16 Maximum Demand

This screen displays the maximum power and the maximum current that has been demanded
since the unit was last reset (see Section 3.9 Resets).

Maximum System Total Active Power Demand (kWD)

Maximum System Total current Demand (AD)

Key >> returns to the start of the sequence with the System
Screen

2.17 Over Range

The displayed values must be in the range –999 x 1000 to 9999 x 1000. Any parameter value
outside this range will cause the display to show overrange.

This situation will be indicated by displaying four bars in the
appropriate line:

The value on the middle line is over range.

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0240 0340 0440 0640 1000 1540

0240 0340 0440 0640 1000 1540

2.18 kWh and kVArh Display Range

The kWh and kVArh display range is limited to 9999999. If the unit is allowed to increment
beyond this value the count will either wrap back to zero (if the 1560/1580 transducer is set to 7
digit mode) or continue to be updated in the 1560/1580 transducer but the display will change to
seven bars. The value will continue to be available via the Modbus output.

2.19 Error Messages

The display repeatedly requests new values from the measurement processor. If there is a
problem obtaining these values, the display will continue to retry but will alert the user by
displaying the message Err1. This message may be seen briefly during conditions of extreme
electromagnetic interference with the normal display returning once the interference has ceased.

If the Err1 message persists, try interrupting, for ten seconds, the auxiliary supply (or supplies)
to the Integra (display and transducer). This may restore normal operation. Also check that
auxiliary power is reaching the transducer and is within specification. Check that there are no
problems with the communications cable between the display and transducer, where applicable.

3 Setting up

3.1 Introduction

The following sections give step by step procedures for configuring the Integra transducer for a
particular installation using an attached display.

To access the Set-up screens, press and hold the (Adjust) key and the >> (Next) keys
simultaneously for five seconds. This brings up the password entry stage. (See Section 3.3
Access).

On completion of the last Set-up screen, the program exits Set-up mode and returns to the last
selected Display screen. To return to the Display screens at any time during the set up
procedures, press the and the >> keys simultaneously for five seconds.

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0240 0340 0440 0640 1000 1540

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3.2 Number Entry Procedure

When setting up the unit, many screens require the setting up of a number, usually on the
middle row of digits. In particular, on entry to the setting up section, a password must be
entered. The procedure is as follows:

In general, press the (adjust) key to change something on the current screen. Pressing the >>
(next) key normally leaves the current screen unchanged and brings up the next screen.

The example below shows how the number 0000 can be changed to 1234.

The digits are set one at a time, from left to right. The decimal
point to the right of the digit (* in the picture) flashes to
indicate which digit can currently be changed. It thus acts as a
cursor. Where the cursor coincides with a genuine decimal
point on the display, the decimal point will flash.

Press the key to scroll the value of the first digit from 0
through to 9, the value will wrap from 9 round to 0. For this
example, set it to ‘1’.

Press the >> key to confirm your setting and advance to the
next digit.

Use the key to set the second digit to the required value.

Press the >> key to confirm your selection and advance to the
next digit.

Use the key to set the third digit to the required value.

Press the >> key to confirm your selection and advance to the
next digit.

First digit

Second digit

Third digit