Service Manual for TOD meter(PK15) 2018 0116 PDF

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Description

Service Manual (TOD meter)

1 General Introduction 1.1

Overview

The three phase TOD meter ( Model:HXE3415) is a new generation of high-precision energy metering instrument researched and developed in advanced Ultralow Power LSI Technology and SMT processing technology, which has power quality monitoring, optical communication and other main functions. Meter meets the international standards IEC 62052-11, IEC62053-22, IEC62053-23 and DDS60:2007 etc, and its main functions include:  Accurate measurement of positive and negative active power, accuracy class 1.0  Accurate measurement of positive and negative reactive power, accuracy class 2.0  Real-time power quality monitoring (active power, apparent power, voltage, current, power factor and frequency etc.)  Record and save 12 months of historical power data.  Support optical communication

1.2

Function

1.2.1 Basic parameter Item

Technical requirement

Meter type

Three phase electronic meter

Reference voltage (Ub)

3×230/400V

Reference current (Ib)

10(100)A

Measuring range

Active power, Reactive power

Electrical standard

IEC standard

Wiring method

3 phase 4 wire

Accuracy class

Active 1.0, Reactive 2.0

Frequency range

50Hz±2%

Pulse constant Operating temperature

1000imp/kWh 1000imp/kvah -25℃～+70℃

1.2.2 Communication mode Mode: optical communication; Optical is 300 bps standby, 4800bps handshake communication, comply with IEC62056－21standard.

1.2.3 Electricity Active absolute value mode: +A=|+A1|+|+A2|+|+A3|+|-A1|+|-A2|+|-A3| -A=|-A1|+|-A2|+|-A3| Reactive: +R=I+III,

-R=II+IV

1.2.4 Display function The meter has the LCD display with following size and layout:

Drawing3. 7.1.1 Dimension of displayed digit

 

Meter has clear visibility with a range of view angle of 45°right down the LCD within one meter. The display is provided with background lighting for easy reading

Order of display item： ：

Means the sequence of current display item in all display item, such as 1 to 32

Current tariff no.

If Tariff 1 is the current tariff, the display will be Communication indicator

If the meter is using optical communication, the communication indicator will display. Voltage indicator These indicators show the status of voltage and stands for Phase A, Phase B and Phase C respectively. When voltage is normal, these indicators are displayed normally. When the voltage is unusual, such as under voltage or overvoltage, these indicators will flash. Battery condition The indicator will flash with 1Hz frequency when the voltage of battery is low or battery life is almost over. The flash will disappear after the battery is replaced. Data:

Unit field Different units can be shown: kWh, Hz, etc.

Quadrant indicator

This indicator indicates the work quadrant of three-phase. The work quadrant is judged according to the active algebraic sum and reactive algebraic sum of

L1 L2 L3 will be blink at follow condition 1. When energy reverse, the relate phase will blink 2 .when over voltage, the relate phase will blink 3 .when phase disconnect, the relate phase will blink (the voltage more than 20V) 4 .when meter polarity reverse, then L1 L2 L3 all blink 5. When meter phase sequence reverse, then L1 L2 L3 all blink Triangle: The Triangle of every feature: S1: reserve S2: Meter cover detection feature enable S3: the lock of display at the factory model S4: the indicator of the MD reset manual at the factory model ,if the triangle permanently on mean reset manual successfully; if the triangle blink mean MD reset manual feature unable; S5: reserve S6: It represents the current of A phase, if the triangle blink mean A phase add the load, if static, it mean no load; S7: It represents the current of B phase, if the triangle blink mean B phase add the load, it mean no load; S8: It represents the current of C phase, if the triangle blink mean C phase add the load, it mean no load; REV: reverse energy TOTAL: it means total energy PREV: history data MD: MD indicator CONT: the times of the event CUM MD: accumulate MD DATETIME: data and time EOI: It is an indicator of the MD window, when the left the time of MD interval less than 10s, it will display EOI.

1.2.5 Button function 1

The meter supports for three display modes: automatic rotated display, ALT display,

2 3 4 5

6

7

8

1.3

test display. Rotated time and rotated item of automatic rotated display table and button display items of button display table could be configured. Up to 32 display items could be set in rotated display table and button display table. Display item and format see chapter 3.7.3. The full display will last 3 seconds, then go into the automatically rotated display. Automatic rotated display is the default display mode and it could be switched to ALT display mode through push button in 3s. The meter will display from the first ALT display item and these ALT display items also could be switched through pressing button in 3s. The ALT display mode will be switched to rotated display mode automatically if the button is not operated over 20s. And the meter will display from the first rotated display item. In the case of button display mode, press the button 3 seconds and enter into test display mode, the meter will display from the first the rotated display item, the LCD will have a TEST sign in the test display mode. The test display mode will be switched to rotated display mode automatically if the button is not operated over 20s. And the meter will display from the first rotated display item.

Wiring

2 Hardware Interface 2.1

Voltage sampling circuit

2.2

Current sampling circuit

6

2.3

LCD Circuit

2.4

Button Circuit

3 Hardware physical diagram

7

MCU 71M654 3G-IGT

Current sampling circuit

Resistance capacitance power supply circuit

4 Underlying software interface instruction Meter HXE3415 adopts local optical communication, IEC62056-21 protocol, Handshake baud rate 300bps, communication baud rate 4800bps, and initial communication password (meter password) is 00000000. Generally, it is no need to choose meter no. during communication test. If the meter no. is required, please tick and then fill in the correct meter no.

8

5 Common problems in hardware 5.1

Typical fault one: no electricity

5.1.1 Reason analysis Check the resistance capacitance RC power supply circuit Tool: Multi meter Steps: (1) Check whether upper PCB voltage +3V3S is normal;

Difficulty: primary

Hit the multi meter gear to DC 20V, add red meter pen to 3V3S test point and black pen to GND point, checking whether the voltage value is normal or not. (2) Check whether VHH input voltage is normal;

Difficulty: primary

a) If 3V3S test point voltage is abnormal, then test whether the VHH input voltage is normal or not. (The test method is the same as that of +3V3s) b) If VHH input voltage is abnormal, please check whether there is poor welding on resistance capacitance and whether there is bridging between the pins of MCU. (3) Check whether the power supply is normal; Difficulty: primary

a) If above tests are all ok, then check whether the input voltage is normal or not. 9

5.2

Typical fault two: optical communication failure

5.2.1 Reason analysis Before analysis, first to observe the basic phenomenon of meter by using normal data request frame communication three-phase meter, checking whether there is communication symbol on the LCD screen, if yes, it just a transmission link failure. (1) The receiving tube or transmitting tube is inserted reversed or damaged; (2) The corresponding component is damaged, poor soldering or Solder Pad Off. Tools: Test bench, multi meter, and computer Steps: (1) Check whether the communication symbols are normal; Difficulty: primary Electrify the meter, use IEC62056-21 single software to communicate, and check whether there is any communication symbol on the LCD. If communication symbol appears, it indicates the communication receiving part has no problem. (2) Check whether the transmission circuit is normal;

Difficulty: primary

If there is communication symbol on the LCD screen but cannot communicate, it is only the failure of transmission circuit. Check whether there are wrong parts or reversed insert. Note: the transmitting tube and pulse lamp are easily confused, and comparing the inner crystals of transmitting tube and pulse lamp, it is found the inner crystal of transmitting tube is higher than that of pulse lamp. Check whether there is poor soldering or bridging on R91. (3) Check whether the receiving circuit is normal; Difficulty: primary Check whether there is reversed insert, poor soldering, damage on D51, if not, then check whether there is poor soldering, wrong or bridging on R93 and Q6.

5.3

Typical fault three: error out-of –tolerance

5.3.1 Reason analysis Sampling circuit fault

Difficulty: medium

Tools: Multi meter, test bench Steps: (1) First to check whether the pulse lamp flickers, whether the common mode inductor is poor welding or there are impact parts; 10

(2) Measure and judge whether the internal resistance of manganin is bad, whether the isolated sensor or pulse transformer is welded well. (3) Install meter to test bench, add IB point current, and just check whether the error of 3 points (100%Ib 1.0/0.5L 10%Ib 0.5L) are qualified or not.

5.4

Half Digit PCB’s ---------------------- (30)

Analysis point: ① LCD pin appears Weld or short solder? ② MCU control LCD pin I / O port appears Weld or short solder Repair point: ① Use the Electric iron welding the LCD pin again; carefully check whether there is a problem soldering the LCD pin.

② MCU LCD pin with iron Luo drag, see the following figure:

11

5.5

Power up but Communication fail-------------- (10)

①

②

12

③

5.6

Power up (Error) show---------------------- (02)

Repair point: The first power-up may have this phenomenon, only need to carry out the clear all.

5.7

Power off PCB’s--------------------- (05)

Analysis point: 13

Clamp clip power on the map will appear poor contact, please confirm whether the power? Repair point:

Test the meter +3V3SY--GND

3.3V

+3V3D—GND

3.3V

Other General Issues Issues

Quantity

1

No Power Up

2

LCD Off

5

3

LCD Digits Missing

2

4

5 6 7

16

KWH and Kvarh LEDS not Blinking KWH & Kvarh LEDS not Blinking at L1 KWH & Kvarh LEDS not Blinking at L2 KWH & Kvarh LEDS not Blinking at L3

8

11 10 6

8

KWH LED OFF

4

9

Power LED OFF

3 13

Problem Analysis 1. Voltage or zero lines bad welded; 2. Crystal oscillator bad welded or damaged; 3. Main chip damaged or bridging. 1.LCD pin bad welded or damaged 1. LED indicator welded reversed or damaged; 2. 3 pulse transformers damaged simultaneously. 1. L1 voltage line bad welded; 2.L1 pulse transformer damaged. 1. L2 voltage line bad welded; 2.L2 pulse transformer damaged. 1. L3 voltage line bad welded; 2.L3 pulse transformer damaged. 1. LED is welded reversed or damaged. 1. LED is welded reversed or damaged. 1. Parameter setting problem; 2.Button or switch welded reversed. 1. Parameter setting problem; 2.Button welding error or damaged.

10

ERR on LCD Display

11

Scrolling Button not Working

1

12

Voltage less than 3.0 at +3V3F Test Point

14

1.Main chip damaged or bridging

13

Communication Failed

12

1.Main chip damaged or bridging

14

No Calibrate

24

1. Main chip damaged or bridging; 2.Reversed sampling wire welding.

15

Opened Button Damage

7

1.Impact parts

16

LEDs Broken

7

1.Impact parts

17

Microcontroller Pins

6

1. Poor welding or bridging

Short

14

6 Common command Command ID

Operation mode

Data

CA08

W/R

F001

C396

R

Reading TDK program space check code

CA00

E

Reset(meter)

When the LCD displays "-CLEAR-" during the reset period, it is not allowed to power down. After completing reset, the LCD automatically returns to normal display, and then it can be powered down.

C01E

Write password set

Write**C01E**00000000**

C07E

Read password set

Write**C07E**00000000**

Description Enter factory mode

15

Remark Need to short S1, F001means to enter factory mode, 0000 means to exit factory mode. When the same batch of programming is completed, the check code must be the same....