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SY8125 Serials Single Phase Energy Meter Test Bench

User Manual

HONG KONG SONG YANG INDUSTRIAL LTD.

Operation Manual

SY8125D Operation Manual

CONTENTS
1 2 3 4 4.1 4.2 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 6. 7. 8. 9. INTRODUCTION.................................................................................................... 1 FUNCTION ............................................................................................................ 1 TECHNICAL SPECIFICATION ................................................................................ 1 WORKING PRINCIPLE ......................................................................................... 3 Working principle frame------------------------------------------------------------------------- 3 Working principle--------------------------------------------------------------------------------- 4 KEYBOARD FUNCTION ......................................................................................... 4 Model Selection----------------------------------------------------------------------------------- 5 Setting Parameters of tested meter---------------------------------------------------------- 6 Output Parameter-------------------------------------------------------------------------------- 6 F1 Function---------------------------------------------------------------------------------------- 7 Device Parameters------------------------------------------------------------------------------ 7 System Parameters----------------------------------------------------------------------------- 8 F2 Function Key Setting----------------------------------------------------------------------- 9 Test-------------------------------------------------------------------------------------------------- 9 TURN OFF .......................................................................................................... 11 TROUBLE SHOOTING ......................................................................................... 12 MAINTENANCE ................................................................................................... 12 EQUIPMENT PACKAGE ....................................................................................... 12

10. SOFTWARE APPLICATION ................................................................................. 12 This manual is for reference only; any modification will not be notified individually. Please use the manual that comes with the equipment.

SY8125D Operation Manual

INTRODUCTION
SY8125 single phase energy meter test bench is a new generation, high precision, energy meter calibration equipment. It uses the internationals most advanced technology and components available in 90 decade. The equipment works under the control of keyboard or remote computer.

2
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13

FUNCTION
Warm up Basic error test Standard deviation (S) in error test Repeatable error test Latent test (no load test)/automatic/manual operation with seek mark automatically Initial test (starting test)/automatic/manual operation with seek mark automatically Voltage influence test Frequency influence test Deviation test for 24 hours Harmonic test Phase circuit testing with close link Neutral circuit testing with close link Neutral missing testing

3
3.1

TECHNICAL SPECIFICATION
Accuracy class: 0.05 / 0.1 / 0.2 Accuracy 1.0 Cos= 0.5 (lag) 0.8(lead) 0.5 (lead) 0.05 0.05 0.07 0.10 0.1 0.10 0.15 0.20 0.2 0.20 0.30 0.40

3.2

3.3

3.4

3.5

Standard equipment: SY3803: Wide current reference standard energy meter, Accuracy: Class 0.05 / 0.1 Multi secondary voltage transformer (MSVT): Primary & Secondary Voltage Ratio: 1:1 No of secondary outputs: 48 Range of secondary burden: 15VA per winding Error: < + 0.01%, + 0.3 min, when each secondary load is the same Insulation performance: AC voltage 2kV for 1 minute (between primary and secondary) Output voltage: Voltage range: 30V ~ 300V (Phase Neutral) Measurement error: 0.1%RG Drift per year: 0.05% Output current:: Page 1

SY8125D Operation Manual Current range: 10mA ~ 120A (Option 20mA ~ 200A) Measurement error: 0.1%RD (50mA~120A) 0.1%RG (10mA~50mA) Drift per year: 0.05% 3.6 Power factor: Power factor range: -1.000 - 0 - 1.000 Measurement error: 0.1%RG, PF 0.5-1 Drift per year: 0.05% 3.7 Frequency range: Frequency range: 45 ~ 65Hz Measurement error: 0.02% Drift per year: 0.005% 3.8 Stability of the Equipment with respect to time: Power: 0.05% (Base 5S) Voltage: 0.03% (Base 5S) Current: 0.03% (Base 5S) 3.8 Distortion factor: Sinusoidal voltage & current 0.5% (linear load) 3.9 Harmonic wave output 2-21 harmonic wave, Contents of Harmonic Wave (Voltage &Current< 40%) 3.10 Control mode: 3.10.1 Keyboard control: LCD menu, fully automatic, manual calibration. 3.10.2 Software control: Under Windows 98/2000/XP system, fully automatic, self-definition calibration. 3.11 Number of meters calibrated: 6~48 positions 3.12 Mains supply voltage : 220V/240V15% (option 120V), 50/60Hz The maximum power consumption: 3000VA 3.13 Ambient temperature: Storage range: -200C ~ 550C Operating range: 50C ~ 400C Specified range: 100C ~ 300C Temperature co-efficient: 0.01% / 0C Relative Humidity: 85% 3.14 Dimension: Type of bench Meters 6 12 24 32 40 48 24 32 40 48 Number 1 1 1 2 2 2 1 2 2 2 Number of row Single Double Double Double Double Double Double Double Double Double Size 16007501600 mm 16007501920 mm 22007501920 mm 18007501920 mm 20007501920 mm 22007501920 mm 22007001920 mm 18007001920 mm 20007001920 mm 22007001920 mm

Integration

Fission

Console: 6008001920 mm Page 2

SY8125D Operation Manual

4
4.1

WORKING PRINCIPLE
Working principle frame

Errors calculate and display unit

Digital signal

CPU

Computer

Control / Interface port

Voltage

Reference Standard Meter

Voltage Amplifier Voltage Transformer

Current Amplifier Current Transformer

Range Switch

Keyboard

Current

CT

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SY8125D Operation Manual

4.2 4.2.1 4.2.2

4.2.3

Working principle When the CPU receives orders from the operating keyboard or computer, it will control the digital signal source and range switch to work. Digital signal source Signal source uses the most advanced technology of digital frequency modulation, amplitude modulation and phase modulation to synthesize a sine wave. These waves will be the input signal source for single phase voltage and single phase current. These signal sources will be amplified by the power amplifiers. Power amplifier Power amplifier uses the most advanced integrate power operation amplifier. It has designed a perfect protection system for overloading voltage short circuit and overloading current open circuit. It has speedy limit current protection system and keeps the power amplifier in steady working.

KEYBOARD FUNCTION
Definition of Keyboard and Symbol of Display Unit

F4 0 1.0 5 100% . 100%

F5 1 0.5L 6 100% 50%

F6 2 0.8L 7 100% 20%

F7 3 0.5C 8 100% 10%

M-Test

St-Test

Auto

Start

4 0.8C 9 100% 5%

ADJ

F1

Set

F2

ESC

F3

Symbol of Function Key M-Test: Creep Testing (no load test) 5% ~ 600% Imax, 0.5Imax: Load Range 0 ~9: Factor . : Numeric Figures St-Test: Initial testing (start testing ) Start: Error testing 0.5L, 0.8L, 1.0, 0.8C, 0.5C: Power

Decimal Point

: Increase/decrease selected current/voltage value Leading/logging selected current/voltage/phase angle : Enter Page 4

SY8125D Operation Manual Main Measuring Menu After power On, system will proceed auto calibrating and data-initializing. After 3 seconds, the LCD will display as below:

U 0.000

I 0.000

W 0.000

1P2W W STD Forward I Sine Wave T =01

Un=220.0V F =50.00Hz C1=01800.00

Ib =10.00A Imax=100.00A I =100%Ib C2=01800.00 Start To Test

Set To Set Parameter

Parameters Setting of Tested Meter


5.1

Model Selection: Press set key to set Tested Meters parameter:

= = = = = Output model = = = = = * [ 1 ] 1P2W W STD [ 2 ] 1P2W var STD

to set parameter 1-2 to select

to set others ESC to quit

Use numeric key to select, * mark to be on the left side of selected model. Press to set parameters of tested meter, press key to set other parameters (Output Parameter). Press ESC to confirm and quit.

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SY8125D Operation Manual

5.2

Setting Parameters of tested meter

=== == Electrical Energy Meters Parameter =====


[ * ] Un = 220.0V [ ] Ib = 10.00A [ ] F=50.00Hz [ ] T=01 [ ] Tmax =01 [ ] Tmin =01 [ [ [ [ ] C1=01800.00r/kWh ] C2=01800.00r/kWh ] Imax = 100.00A ] Class = 1.0

Use to move * mark to select corresponding setting item, press numeric figure key or decimal point to proceed setting. Press ESC key to confirm and return to previous menu. Press F1 key to select r/kWh or p/kWh. (Any vacant position shall be set the constant as 0.) The frequency range is 45.00Hz 65.00Hz. C1 is the constant of front half tested meters, and C2 is the other. Press F1 key to select the constant unit p/kWh or r/kWh. p/kWh means electrical meter; r/kWh means mechanical meter. 5.3 Output Parameter

= = = = = Output Parameter = = = = =

[ * ] Forward I [ ] Sine wave ESC to quit Enter to select

Use key to move * mark to select corresponding setting item. Use key to select forward current/reverse current; Waveform (sine wave, harmonic wave, phase angle control). Press numeric figure key to set the phase time and content of harmonic. Use or back key to confirm and return to previous menu operation. Harmonic phase is 0-3590. The effective range of harmonic is 2-21. The content of harmonic is 0-50%. When setting the synthetic harmonic, the total content shall be less than 50%. Notice: At Single Phase Energy Meter Test Bench the Output and phase order is not be used. Harmonic content = harmonic component virtual value / radix wave component virtual value x 100%
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SY8125D Operation Manual

5.4

F1 Function Press F1, it will appear the following menu:

Parameter select [ * ] device parameter [ ] system parameter ENTER to select ESC to back

Use key to move * mark to select corresponding setting item. Then press ENTER to set device parameter / system parameter. 5.5 Device Parameters

[ * ] Number = 03 [ ] Search mark: on [ ] angle modify: off [ ] range modify: on 09 to set ESC to back

Use d. e.

key to move * mark to select corresponding setting item. Number: setting meter positions of the test bench. Search mark: when processing initial test and creep test, enable this function means that when process initial test or creep test, the software will search mark at first. Use key to enable or disable this function.

f.

Angle modify: when testing meters, if this function is enabled. Software will adjust phase output automatically every time. (Note: If the output waveform is sine wave, software adjusts output phase; if output waveform is harmonic wave, Software adjust output amplitude.) Use key to enable or disable this function. Range modify: when testing meters, if this function is enabled, Software will adjust amplitude output automatically every time. Use key to enable or disable this function.

g.

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SY8125D Operation Manual

5.6

System Parameters LCD monitor show password: the password of equipment is 6103 or 6100. Input password 6103, then press key to set output system parameter.

System
[ * ] U =X.XXX [ ] I =X.XXX [ ] =XXX.X [ ] Iqa =X.X

parameters

09 to set

ESC to back

a. b. c. d.

U is amplitude coefficient of voltage. I is amplitude coefficient of current. is phase coefficient. Iq is excursion coefficient of current.

When change coefficient, output will be changed. Input password 6100, then press key to set other system parameter.

[*] [ [ [ [ ] ] ] ]

RSM-3P/1P-A/D First step=20 % Company name: on/off Language: English/Chinese Imax=120A ENTER to select ESC to back

a. b. c. d. e.

RSM: choose the reference standard energy meter (change is option also must change reference standard energy meter) First step: content becomes bigger and the output will rise faster, but it maybe causes equipment protection, the suggested value is 20-30%. Company name: display or hide the company name on the LCD. Language: select language. Imax is the maximal current permits when the system working.

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SY8125D Operation Manual 5.7 F2 Function Key Setting When under main measuring menu, Press F2, it will appear the following menu:

Setup of initial test and latent test [ * ] latent U : 110% Un [ ] latent I : 021.0 mA [ ] latent T: 00 Min [ ] initial I: 004.0 mA [ ] initial T: 10 Min

Enter to select

ESC to back

Use key to move * mark to select corresponding setting item, 09 to set. When * mark lies to creep T: 10 Min and initial I: 5.0 mA , Press key to select initial test and creep test mode of operation. When processing initial test and creep test, they operate according to rules or current setting. Use key to move * mark to select corresponding setting item, 0 - 9 to set.

5.8

Test

5.8.1 Error Test 5.8.1.1 Manual operation a. After all parameter set , press Start key to output current/voltage, LCD display will show the message Please Wait!. b. Press Start to decrease current, then press Start key or Status key to output current again. c. Press ABC, A, B, C key to select output current. d. Press power factor key to change phase angle between current/voltage. e. Press Load burden key to change current load. 5.8.1.2 Voltage/Current/Phase Angle adjustment During manual operation, press ADJ key to enter this function.

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SY8125D Operation Manual

0.000

0.000

0.000

[ * ] *U [ ] 10%

I 1%

*0.1% 0.01%

F3
a. b. c.

Enter to select

to adjust

Press F3 key to select setting item. Press key to select U ,I, ; press key to select 10% 1% 0.1% 0.01%, or 201010.1 After select adjust item. Please press or to adjust current/voltage to be increased or decreased, or adjust the phase angle to be leading or logging.

5.8.2 Starting Test (press M-Test key) 5.8.2.1 Search mark in start test If testing equipment has function of searching mark, press F5 key to enter auto. Mark tracing function, after find mark, press key to enter start test. Press ESC key to return previous menu. 5.8.2.2 Start test setting (press M-Test key)

0.000

0.000

0.000

Initial I: 5.0 mA Initial T: 03 min [0102] Initial T: 03 min [0304] ESC to back
When time get, output will be decreased to zero. Press ESC key to return previous menu operation.

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SY8125D Operation Manual

5.8.3 Creep Test (no load test) (press St-Test key) 5.8.3.1 Search mark in creep test If testing equipment has function of searching mark, press F4 key to enter auto. Mark tracing function, after finding mark, press enter key to enter creep test, press ESC key to return previous menu. 5.8.3.2 Creep test setting (press St-Test key)

0.000

0.000

0.000

Latent U: 242.1V Latent T: 10 min Latent T: 10 min

I: 20.0 mA [0102] [0303]

ESC to back
When time get, output will be decreased to zero. Press ESC key to return previous menu operation.

NOTICE!
During testing meters, signal source checks whether power amplifier is out of order continuously. If power amplifier is out of order, then voltage or current will be decreased to zero, LED monitor will show protection message. After malfunction of the equipment are repaired, process operation of testing meters again.

6. TURN OFF
6.1 6.2 6.3 6.4 Lower down the output voltage and current to zero. Push the stop button. Push the power switch turn of f the power supply. Push the stop button immediately if there is any unclear situation happened during operation.

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SY8125D Operation Manual

7. TROUBLE SHOOTING
7.1 7.2 During operation, any occurrence of abnormal situation, please check as follows: Check whether the rated voltage, current and loading power is correct. Inspect whether the cables connect correctly. Inspect whether the loading is normal. Error test is abnormal. Check whether the preset parameter for the meter calibrated and the standard meter are correct. Check whether the infrared collector works correctly. Check whether the ground for the equipment and the PC are normal. HS-6000 doesnt work correctly If HS-6000 doesnt work correctly, In the process of calibrating the meter, push the button of RST to re-calculate.

7.3

8.
8.1 8.2

MAINTENANCE
Periodically inspect (quarterly) and tight the wire connection, especially inspect whether the ground is okay (including PC computer). If the equipment cant start normally, please check whether the three-phase power source is normal. The equipment is equipped with protection system for missing phase power source. If the three-phase four-wire power source is abnormal or the fuse is off, the equipment will not start. Should take action to prevent any virus from infecting the PC computer, malfunctioning the software and doing unexpected damage to the equipment. Suggest to do virus check monthly Any wrong execution of equipments procedure caused by unexpected condition can be fixed by turning off the power and restarting the equipment. Please contact us if there is any occurrence of malfunction of the equipment.

8.3

8.4 8.5

9.
9.1 9.2 9.3

EQUIPMENT PACKAGE
Full set: equipment one set. Accessory RS-232 serial cable Data Quality approval certificate Test report Users operation manual Software operation manual Installing & service manual

1 piece 1 copy 1 copy 1 copy 1 copy 1 copy

10. SOFTWARE APPLICATION


Please refer to the software manual.

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Software Manual

Energy Meter Auto-calibration System Software Operation Manual

Contents
1 OVERVIEW OF SYSTEM FUNCTIONS......................................................................................... - 13 1.1 1.2 Basic Functions ..................................................................................- 13 Special Functions ...............................................................................- 13 -

SYSTEM CONFIGURATION ............................................................................................................ - 13 2.1 2.2 2.3 Operating Environments......................................................................- 13 System Installation ............................................................................- 13 Systems Main Interface ......................................................................- 13 -

3 4

WATT-HOUR METER PREPARATION BEFORE CALIBRATION ....................................... - 14 3.1 Basic Data Input ................................................................................- 14 -

AUTOMATIC CALIBRATION OF WATT-HOUR METER ....................................................... - 16 4.1 Configuration of Calibration Scheme .....................................................4.1.1 Configuration of Warm-up Parameters...........................................4.1.2 Configuration of Startup Parameters .............................................4.1.3 Configuration of Creep Parameters ...............................................4.1.4 Configuration of Basic Error Calibration Points ................................4.1.5 Calibration Constants .................................................................4.1.6 Configuration of Special Calibrations ................................................4.2 Automatic Calibration of Watt-Hour Meter ..............................................4.2.1 Warm-up, Creep, and Startup Tests ..............................................4.2.2 Calibration of Basic Errors ...........................................................4.2.3 Calibration Constants .................................................................4.2.4 Other Special Functions ..............................................................4.3 Data Saving ......................................................................................16 16 17 17 17 18 18 19 20 21 22 24 24 -

DATA MANAGEMENT ....................................................................................................................... - 25 5.1 5.2 5.3 Comprehensive Inquiry .......................................................................- 25 Report Printing ..................................................................................- 26 Records Backup .................................................................................- 26 -

SYSTEM TOOLS .................................................................................................................................. - 27 6.1 System Configuration .........................................................................6.1.1 System Common Data ................................................................6.1.2 Configuration of Device Parameter................................................6.2 Custom Report Generator ....................................................................27 27 29 30 -

Energy Auto-calibration System Software Operation Manual

Overview of System Functions

1.1 Basic Functions Simple and fast watt-hour meter parameter input; Warm-up; Startup; Creep; Calibration of basic errors Calibration of ordinary electronic / inductive watt-hour meters basic errors; Calibration of forward errors; Calibration of reverse errors; Calibration of standard deviation estimates; Calibration constants.

1.2 Special Functions Simultaneous calibration of different-constant watt-hour meters; Real-time reading of various calibration data; Voluntary configuration of calibration current load; automatic or manual configuration of sampling cycles; Custom configuration; Records and report customization, voluntary selection of print items; Real-time protection of calibration data, protection against power cut and data restoration.

System Configuration

2.1 Operating Environments This system can be run on Win95/98/me or Win2000/XP with requested screen resolution to be 800600 or over. Acceptable communication ports are RS232.

2.2 System Installation Place the installation disk for watt-hour meter calibration device (hereinafter referred to as SONGYANG calibration device) into the hard disk driver and the disk will start up and automatic installation begins immediately. Proceed with the next installation step per installation guides. Please backup the original data before re-installation!

2.3 Systems Main Interface After being installed successfully, double-click the SONGYANG calibration system icon on desktop to enter the calibration system. The interface after system being run is shown as Figure 1.

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Energy Auto-calibration System Software Operation Manual

Figure 1 3

Main interface of SONGYANG energy meter calibration & test system

Watt-Hour Meter Preparation before Calibration

3.1 Basic Data Input Click the shortcut button [Para.] below the window menu in Figure 1 to access the basic parameter input interface. Configure watt-hour meters basic parameters on Meter Selection Parameter Input interface as shown in Figure 2. Configuration of watt-hour meter parameters is described as below: If Same Information is selected, the same watt-hour meter parameters as this meter will be shown for other meters. If watt-hour meter parameters are to be modified for other meters, please cancel this selection. If meter no. is to be used as asset number, select Asset No = Meter No. Such parameters as voltage, current and so on should be configured before calibration and selection can be conducted in the corresponding positions as shown in Figure 2. If such parameters as current, constant, model and so on can not be found in pull-down menu, please select the [Add] in this pull-down menu to add new items to the common data list; when returning to this interface, new items will appear in this pull-down menu for future selection.

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Energy Auto-calibration System Software Operation Manual

Figure 2

Meter Selection-Parameter Input interface

The Start No. in Figure 2 is to configure the prefixes of each watt-hour meters asset number or meter no.. After the digit of meter no. and the start no. are determined, click the [AutoFill] button to code the watt-hour meters automatically. If the device has error pulse sampling switch channels, please select the number of sampling switch channels. Just select the same number of sampling switch channels as that of sampled pulses received. Continued Test is to draw watt-hour meters calibration data saved in data base to allow user to continue its calibration. This function is used for next days re-calibration on watt-hour meters that are saved but not completely calibrated on previous day. If any watt-hour meter does not need calibration, click the red v before corresponding watt-hour meter as shown in Figure 2 to delete this watt-hour meters data and another click will re-select another meter. If Enter key is pressed directly on asset number column, meter can also be selected. After the meter parameters have been configured, click [Test] and the system will send initialization information to calibration device for it to get to PC control mode. After successfully connected, the system will come to default calibration interface. Page - 15 -

Energy Auto-calibration System Software Operation Manual 4 4.1 Automatic Calibration of Watt-Hour Meter Configuration of Calibration Scheme Click the small shortcut button [Pro.] on top of the window body or corresponding menu as shown in Figure 1 or right-click the test point and test item area as shown in Figure 6 to come to the calibration scheme configuration interface as shown in Figure 3. Voluntary change of selected calibration schemes can be made, including test points and their sequence, upper and lower limits, sampling cycles, modified values, startup currents, and so on. If modified values have not been saved, just click [Restore] to cancel modified items. Please save modified scheme in a timely manner!

Figure 3

Calibration scheme configuration interface

The configuration of test points is processed in image. When having chosen a test point, whether double-clicking the mouse or pressing the Space or Enter button may select or cancel the selection of that test point. If there exist no current load point or power factor point needed in the table, click [Point Grid] button to add new points and load current can be added voluntarily.

4.1.1 Configuration of Warm-up Parameters Tick the Warm-up check box in Figure 3 to configure the warm-up time with its unit to be minutes. Warm-up test uses Lb as warm-up current. During the period of warm-up test, the photoelectric probe should be aligned. Page - 16 -

Energy Auto-calibration System Software Operation Manual

In the watt-hour meter calibration interface (Figure 6), choose the Warm-up test box and double-click test time and error limit display area to modify warm-up test time. This modification will only affect present test and not be saved by system and the configured values in this scheme will still prevail in the next calibration. See Figure 4.

Figure 4

Warm-up time modification interface

4.1.2 Configuration of Startup Parameters Tick the Startup check box in Figure 3 to configure the startup current parameters. Similarly, choose the Startup test box in the watt-hour meter calibration interface (Figure 6) and double-click test time display area to modify startup test time. This modification will affect present test and also be saved by system. 4.1.3 Configuration of Creep Parameters Choose the Creep test box in Figure 3. Creep voltage range will be 80%~115% and multiple selections are allowed. Each test can be imposed with startup current of any value. Similarly, choose the Creep test box in the watt-hour meter calibration interface (Figure 6) and double-click test time display area to modify creep test time. This modification will affect present test and also be saved by system.

4.1.4 Configuration of Basic Error Calibration Points As shown in Figure 3, select required calibration points in the imaged calibration point selection area. Double-clicking the mouse or pressing the Space or Enter key can select that point and the same operation may cancel the selection of that point. If any calibration points are added or canceled, the selected points on right-sided table must also be added or canceled accordingly. If new calibration points are added but the sampling cycle have been set to 1.0 Ib, the sampling cycles of all other calibration points will be calculated automatically based on this setting. The sequence of calibration points is determined on the basis of sequence of selections and can be adjusted voluntarily by means of the Move-up and Move-down buttons below the table. If Automatic Sequencing button is pressed, the system will sequence the calibration points based on power factors and calibration current loads. Page - 17 -

Energy Auto-calibration System Software Operation Manual

If the Standard Deviation check box is ticked, the system will test the standard deviation automatically when calibrating specific load point; standard deviations upper and lower limits may be configured simultaneously. Ib 1.0 and 0.5L are standard deviations test points. Save the settings in a timely manner after calibration points have been configured. In the watt-hour meter calibration interface (Figure 6), choose any one of the error calibration points and double-click test time and error limit display area to modify the sampling cycles. This modification will only affect present calibration and not be saved by system and the configured values in this scheme will still prevail in the next calibration.

4.1.5 Calibration Constants The calibration constant will be standard meters constants. So the configuration of standard meter is a decisive factor. In [System Setup] -[Device Parameter] menu, the manufacturer and model of standard meter should be configured per actual device. Wrong configuration of standard meter may lead to wrong calibration result.

4.1.6 Configuration of Special Calibrations Open the [More] button menu as shown in Figure 6 and an interface as Figure 5 will appear.

Figure 5

Special calibration configuration interface

Voltage Load: If watt-hour meters with special voltages are to be calibrated and voltage changes are to be tested, the voltage loads here must be modified with its range to be 0~120%Un. After confirmed, it will affect the load points selected afterwards. If not resetting that value, the values here will return to 100% after the system has re-selected a new meter for connection. Frequency Value: If watt-hour meters with special frequencies are to be calibrated and frequency changes are to be tested, the frequencies here must be modified with its range Page - 18 -

Energy Auto-calibration System Software Operation Manual to be 45 ~ 65Hz. After confirmed, it will affect the load points selected afterwards. Stop if error is out of range: If non-conformant errors are found during automatic continued calibration, the systems running may be stopped or continued, but the Excessive Error Stop should be changed for correct control. Stop when captured the color-mark: If you want to suspend the calibration after automatic color mark searching ended during creep and startup, please tick the Suspend check box in the prompt box after the black mark has been captured, as shown in Figure 5. Enter the meter No. If meter number has not been input during meter selection, now the meter number may be input during this calibration process to save time.

4.2 Automatic Calibration of Watt-Hour Meter

Figure 6

Watt-hour meter calibration interface

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Energy Auto-calibration System Software Operation Manual After the device has been successfully initialized and connected, the watt-hour meter calibration module can be accessible and a calibration interface as Figure 6 will appear. After corresponding Test box in Figure 6 has been chosen, click [Auto] or [Step] and the system will carry out corresponding test automatically per configured conditions. If any calibration item in test point and test item area is chosen in Continuous or Single Step states, the system will switch automatically to the test of that item.

Figure 7

Warm-up, creep, and startup test interface

4.2.1

Warm-up, Creep, and Startup Tests When coming to warm-up, creep, and startup tests during automatic calibration, Present Test Point prompt strip will move to corresponding test item and each meters test time will be displayed on yellow message bar. See Figure 7. As shown in Figure 7, the status bar in the lower part of the window body will display relevant test information; the creep and startup tests will judge the test results automatically when they ended and a P will be displayed for conformance and F be displayed for non-conformance.

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Energy Auto-calibration System Software Operation Manual

Figure 8

Color mark capturing configuration interface

If automatic color mark alignment is needed during creep and startup tests, tick the Capture.. check box, and then a prompt message will appear which reminds you to determine the color mark capturing current. See the interface in Figure 8. Click [OK] to save that value. After the color mark is found, the system will indicate this by displaying a sign ^ in corresponding test column.

4.2.2

Calibration of Basic Errors When coming to the calibration of errors during automatic calibration, the interface will be the one in Figure 6. The yellow row is the error receiving window which is synchronous with the error display window of the device. After the configured numbers of sampling errors are received, the average errors of calibration points will be displayed in the error value area. If received errors and average errors exceed standard errors, the scripts will be red as warning and the speaker will emit Tick sound. When coming to Ib 1.0 and 0.5L during calibration and if standard deviation test has been configured, the system will test the standard deviations automatically. The lower right corner in Figure 6 will display the power direction of present calibration. Clicking [State] will enable you to switch the power direction. As shown in Figure 9, the monitor will display such parameters as present voltage, current, phase angle, active/reactive/apparent powers.

Figure 9

Watt-hour meter monitor interface Page - 21 -

Energy Auto-calibration System Software Operation Manual After the calibration ended or during calibration, in addition to displaying watt-hour meters average errors in main window body, you may click the button #1 in Figure 6 to display the error reading interface as Figure 10. That figure is displaying each watt-hour meters detailed errors in every calibration point, including original, average, and round-off errors.

Figure 10 4.2.3

Present meter error reading interface

Calibration Constants Click the [More..] button as in Figure 6, select Const Test to enter the calibration constant module. See interface in Figure 14. Calibration constants may be quantitative or timing, while quantitative constants use standard meters as reference objects. If timing calibration is chosen, the calibration time will be configured and calibration values be neglected and made inactive; if quantitative calibration is chosen, calibration time will be neglected. When calibration begins, different button has to be clicked for different way of calibration. Please configure carefully the calibration load points and upper and lower control limits before calibration begins. If start and end values are referenced for final calculation, please input watt-hour meters start value as shown in Figure 14. After calibration ended, the device will return to the pulse numbers of standard meters and calibrated meters and corresponding currents be calculated. If start and end values are referenced for final calculation, please input watt-hour meters end value in this table. Then click [Result] button to calculate the calibration results automatically and determine if watt-hour meters are qualified or not. After exit, calibration results and errors will be saved together. Page - 22 -

Energy Auto-calibration System Software Operation Manual

Figure 14

Calibration constant interface

Figure 15

Random point calibration interface

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Energy Auto-calibration System Software Operation Manual 4.2.4 Other Special Functions Click the [More..] button as in Figure 6, select Select Random Point Test to enter the random point calibration module. See interface in Figure 15. In random point calibration interface, you can select commonly used calibration points very quickly; after clicking the Current Load button, calibration points begin to change. For special current load points, special values such as 30 can be input in the text input box on top of the Current Load button; click the [%] below text input box and the calibration point will be adjusted to 30%. Present points error limits and sampling cycles may be configured on the lower right corner of Figure 15.

4.3 Data Saving After automatic calibration ended or during calibration, click the [Save] button as shown in Figure 6 to save the calibration data. After clicking, an interface as Figure 16 will appear.

Figure 16

Calibration data saving interface

Meter numbers not to be saved may be deleted from meter number column. For unqualified meters, a prompt message will appear for you to confirm if they need to be saved or not. After Page - 24 -

Energy Auto-calibration System Software Operation Manual corresponding information has been input in the middle of the table, please click [Exit with save] button to save the calibration data in its data base. To return to the calibration interface, just click [Return] button; while [Exit without Saving] will warn you again if you need return to systems main interface before saving. If you exited before saving, a prompt message Found temporary data of last calibration, do you need to restore them? will appear when you begin calibration next time. You may click [Yes] to draw temporarily saved calibration data for continued calibration. See Figure 17. This function will also appear when sudden power cut happens during calibration, which may protect calibration data effectively and prevent repeated and valueless works.

Figure 17

Calibration data restoration interface Data Management

4.4 Comprehensive Inquiry Click the shortcut button [Que.] below the window menu as in Figure 1 to come to the calibration data management module where you may browse, print, backup or export any records that conform to inquiry conditions. See interface in Figure 1. Click the [Query] button in calibration data.

Figure 18

Inquiry condition interface

Management window as shown in Figure 1 to open the inquiry condition dialog as in Figure 18. Inquiries may be made by asset number, date, model, calibrator, manufacturer, phase line, or type Page - 25 -

Energy Auto-calibration System Software Operation Manual or combination of any two or more of these conditions and integrated inquiries can be made by combining the final results. The records found can be printed, backed up, or exported. If 0 was chosen in the status bar at lower right corner, the system will give you a prompt message before performing relevant operation; if you are to continue the operation, all records will be inquired, or only chosen records are inquired.

4.5 Report Printing Click [Print] button in calibration data management window as shown in Figure 1 to open the report printing dialog as in Figure 19; select report format, click [OK] to start print pre-view.

Figure 19

Report printing selection interface

Before printing the report, additional items may be selected such as the error of power direction. Please select the report format you need before customizing your printing. When printing report, please select an appropriate report format for your company. 4.6 Records Backup Click [Bac.] button in calibration data management window as shown in Figure 1 to open the backup dialog as in Figure 20; select a backup directory, click [OK] to start backup; after backup is finished, a prompt message will appear to remind you of a successful backup and show you the backup directory. Please note that only the directory is double-clicked, can it be selected when choosing a backup directory. The selected directory will be displayed on the top. In order to inquire the backup data, please go to the calibration data management window and click [Backup Query] button.

Page - 26 -

Energy Auto-calibration System Software Operation Manual

Figure 20

Backup directory selection interface

The shortcut button [Bac.] in Figure 1 is to quick-backup all the data recorded in live database.

System Tools

5.1 System Configuration Click the [Set.] shortcut button below window menu as in Figure 1 to enter system configuration module.

5.1.1

System Common Data After entering the system configuration module, interface as Figure 21 will appear and the first page will be the common data management page. Select data type in data type list and on its right side, corresponding data contents will appear. Below the list, prompt messages will be available for such data content operations as deleting, adding, or inserting. When you are switching the data type or closing the window, data contents will be saved automatically. Data contents will be found in pull-down menus of such interfaces as meter selection, inquiry, saving, and so on. It is very convenient for users selection and input.

Page - 27 -

Energy Auto-calibration System Software Operation Manual

Figure 21

System common data configuration interface

Figure 22

Device parameter configuration interface Page - 28 -

Energy Auto-calibration System Software Operation Manual

5.1.2

Configuration of Device Parameter Click [Device Parameter] page as in Figure 21, an interface as Figure 22 will appear. Configure the device, standard meter, communication port, and unit of use; among them, the configuration of the unit of use will also affect the report output. Configuration of Calibration Control Click Calibration Configuration page as in Figure 21, an interface as Figure 23 will appear.

Figure 23

Calibration control configuration interface

Sampling Times: The number of error sampling during error calibration; the average error will be calculated when this number is reached. Standard Deviation Sampling Times: The number of error sampling during standard deviation calibration; the standard deviation value will be calculated when this number is reached. System Stabilization Time: When the adjustment of load point ended during calibration, the device will only begin its pulse sampling and error calculation after the stabilization time has passed, which will make the error more stable. Page - 29 -

Energy Auto-calibration System Software Operation Manual Replacement of the-same-day record: If this option is selected, only one calibration record will be saved for the same watt-hour meter on the same day. 5.2 Custom Report Generator Select custom records printing format in the report printing selection interface as in Figure 19, a custom printing format pull-down menu (1p2w was shown in Figure 19) and configuration button will appear. Enter the configuration interface as Figure 24 to perform the configuration of custom report.

Figure 24

Custom records printing report generator configuration interface

The use of [], [], {Up}, or {Down} buttons as shown in Figure 24 will make it possible to perform such print item operations as adding, deleting, moving up and down. The Header, Body, and Footer in the lower part of Figure 24 are to configure report print items width and values can be input manually or buttons be pulled directly. On the upper right corner in Figure 24 are the buttons for the configuration of page format and print items such as fonts, lines, and so on. The four buttons in report format (Single-Phase Report was shown in Figure 24) pull-down menu are for adding, deleting, and saving report format and exit respectively. The new format may be named voluntarily by yourself. Page - 30 -

Energy Auto-calibration System Software Operation Manual

Figure 25

Report preview interface

During report format configuration, a real-time report preview is possible. In Figure 25 you will find the previewed report in which partition instruction was implemented.

Page - 31 -

Service Manual

SY8125 Service Manual

Catalogue

1. MEASURING PRINCIPLE ...................................................................................................... 32 1.1 The work principle and frame of the test bench.................................................................. 32 1.2 Main parts of the test bench ............................................................................................... 32 1.2.1 Structure frame of the test bench.................................................................................. 32 1.2.2 Signal source ................................................................................................................ 33 1.2.3 Power amplifier ............................................................................................................. 33 1.2.4 Voltage switch case ...................................................................................................... 34 1.2.5 Keyboard ...................................................................................................................... 34 1.2.6 Error processor ............................................................................................................. 34 1.2.7 Simultaneous overturn system...................................................................................... 36 1.2.8 Emergency stop button ................................................................................................. 36 1.2.9 RS-232 ..36 1.3 Reference standard meter.................................................................................................. 36

2 INSTALLATION AND SERVICE............................................................................................... 37 2.1 Installing the test bench...................................................................................................... 37 2.1.1 Placement of the test bench ......................................................................................... 37 2.1.2 Preparation and installation .......................................................................................... 37 2.1.3 Power on the test bench ............................................................................................... 38 2.1.4 Simple function test ...................................................................................................... 38 2.1.5 Hanging meter for trial operation .................................................................................. 39 2.1.6 Computer operation ...................................................................................................... 39 2.2 Daily maintenance and points for attention ........................................................................ 39
3 4 Trouble shooting................................................................................................................ 41 List of spares...................................................................................................................... 43

5 Connection diagram of the test bench............................................................................. 44 5.1 Wiring diagram of three phase signal source ..................................................................... 44 5.2 Wiring diagram of three phase amplifier............................................................................. 44 5.3 Wiring diagram of HS-6000 error processor....................................................................... 45 5.4 Wiring diagram of three phase power supply: .................................................................... 46 5.5 Wiring diagram of search black mark circuit:...................................................................... 47

SY8125 Service Manual


1. Measuring principle Introducing the principle of the test bench, the composing and the connecting of the parts, frame and standard parts of an apparatus of definition help you understand, use and maintenance the equipment. The work principle and frame of the test bench This installation is made up of digital signal source, power amplifier, error processor and meter hanging rack and so on. Each unit controlled by the microcomputer individually, and works together forms a body. 1.1

Keyboard

Signal source

Power

amplifier

Voltage switch

Tested meter

Current

Standard

Error calculator

Computer PC

From the frame, MCU receive information from keyboard, then it operates the frequency modulation, amplitude modulation and phase modulation and so on, at the same time it can communicates with the outer setting. The deferent signal by signal source provide to the voltage amplifier and current amplifier Below is the structure frame of the test bench. 1.2 Main parts of the test bench 1.2.1 Structure frame of the test bench.

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SY8125 Service Manual

1.2.2 Signal source It is controlled by a single chip microcomputer, outputs both small voltage and current signals, meanwhile, receives orders from any button (or personal computer), perform such operations as frequency modulation, amplitude modulation, and phase modulation on output signals, and conducts controls on relays based on current values and orders transmitted and also on various error calculators of meter hangers. Also, on signal sources front board there exist one keyboard and one LED display which are the windows for man-machine dialogue, and it is this keyboard through which we send out orders to let the equipment work. LEDs function is to display signals, information on watt-hour meter to be calibrated, and calibration status. Moreover, on signal sources panel there exist one DIP switches and six small red lights; DIP switch is to configure keyboard operation/computer connection and small red lights are to display power amplifiers protection status (if any signal fails, the corresponding small red light will give out light, accompanied by a buzz sound). The following figures are signal sources schematic diagrams of its front and rear views.

Schematic diagram of three-phase signal sources front board

Signal Source
RS232 Signal

U Sw.

I Sw.1

I Sw.2

RSM

PC

Ua

Ub

Uc

RS485

Signal

Power

Ia

Ib

Ic

Layout of three-phase signal sources rear board 1.2.3 Power amplifier Three-phase power source contains voltage-current-power amplifier, current amplifier, feedback CT, voltage amplifier, feedback PT, and voltage-current measurement range switch. Input signals include voltage signals, current signals, voltage-current measurement range switching signals, auxiliary power supply, 24V switch power and so on; output signals include 0 ~ 120A current signals, 0~300V voltage signal, etc. Page -33-

SY8125 Service Manual


0 ~ 120A current signals are output in three terminals 1/10/100 (or 200A) respectively. Current measurement range switchboard is phase sequence dependent and can not be changed arbitrarily. If switchboard is replaced, jumper setting (EN) must be identical with actual situation. Panel schematic diagram as below:

I Signal

U Signal

Voltage

Current

Voltage

Current

24V

0V

Output

1.2.4 Voltage switch case Because three phase meter has many voltage standards, we divide the voltage into four(57.7/100/220/380), so we should switch when meter in different voltage, signal source sends the switch signal, control the relay board in the switch case to achieve the circuit of the switch rising depressor. The voltage to each meter and to the standard meter is the same voltage.

1.2.5 Keyboard How to dispose keyboard please consult SY8125 operation manual. 1.2.6 Error processor Each position has the error calculator, which is fixed behind the error display window of the meter mount rack. Connect PC by RS485 and main control SCM. There are some technical parameters about the HS-6000 type error processor. a Error display range: four bits efficient digits, decimal fraction display error. b Error range: + 99.99% c Checkout method: high frequency pulse figure set up in advance Page -34-

SY8125 Service Manual


d e f g h i j k Photoelectric pulse passage: < 100Hz Standard pulse passage: < 500kHz Pulse signal electricity plane: TTL or OC(open collector) The tested meters circles range: 1-99 Check meter number: 1 The range of the standard number setting up in advance: 1-9,999,999; Exterior communication connection: RS-485 joined connection can communicate with PC computer, calibrating meter automatically. Uncertainty: + 1 theoretics pulse number

SY8125 equipment calculates comparative error with high frequency pulse setting up in advance (%). The high frequency pulse of standard electricity energy meter send to the error calculator, after the tested meter turns one circle , the error calculator numerate the high frequency number added up as the actual test high frequency pulse number m, compared with preset high frequency impulse figure m0.According to the formula(1)it calculate the comparative error of the tested meter %

m0 m 100% + 0 m

. (1)

Among them: 0: When the system error of standard meter or test bench do not need corrected0=0 m: The actual test high frequency pulse figure m0; Preset high frequency pulse figure that is the standard preset figure. Calculate standard preset figure in according to formula 2:

m0 =

C HO N C L K I KU J N

.. (2)

Among them: CHO: The high frequency pulse constant of the standard meter (PH/kWh); N: The low frequency pulse figure of the tested meter, that is checkout circles; The low frequency pulse constant of the tested meter, (PL/kWh); CL: The current transformers change and compare, for wide loading standard KI: meter; KI=1 The isolated proportion of the voltage isolated transformers twice terminal KU: and standard terminal, for the wide quantity limited standard electric power meter: KU=1 JN; The connection modulus, single-phase JN=1
The low frequency pulses of watt-hour meter to be calibrated N, measurement range of transformer connected to standard meter or the shift of standard meters override switch should be selected properly so that the calculated (or pre-configured) pulses and actually measured pulses meet the following stipulations.

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SY8125 Service Manual

Accumulated value of different-grade watt-hour meters Accuracy grade of watt-hour meters Minimum accumulated value Class 0.02 50000 Class 0.05 20000 Class 0.1 10000 Class 0.2 5000

HS-6000

Error calculator panel 1.2.7 Simultaneous overturn system

If photoelectric samplers are used, for the convenience of meter hanging, you can press this button to overturn all the photoelectric samplers upwards simultaneously, thus making it easier to hang the meters. After meter hanging is finished, photoelectric samplers can again be put down. 1.2.8 Emergency stop button

If equipment outputs can not meet the requirements of watt-hour meter to be calibrated, which may cause damage to the watt-hour meter to be calibrated or equipment fails suddenly with unknown reasons, you may press this button immediately to cut off the power supply. Counterclockwise turning will reset this button (after trouble has bee shot). 1.2.9 RS-232 RS-232 connector is communication port for the bench to outside (pc), when connecting, please turn off the bench and the pc computer, make the RS-232 communication wire connect correctly, then turn on the bench and computer.

Reference standard meter SY3803 series multifunctional standard meter is the high precision electric power measure meter using international newest figure electron technique and on the basis of the DSP high speedy processor.
1.3

SY3803 may test and show systemic voltage (V), current (A), active power (W), reactive power (VAR), frequency(Hz), power factor (PF), phase angle( ),apparent power(s), the electricity quantity and the output energy impulse. The show is using
Page -36-

SY8125 Service Manual


character gather LCD menu, which is clear, operate easily, function set is convenient, it is the brainpower electric power test instrument. SY3803 standard meter is the main standard equipment of the facility. Compare all the tested meters to the standard impulse, account the error of the tested meter. Please consult installation setting to install the standard meter.
2 Installation and service 2.1 Installing the test bench 2.1.1 Placement of the test bench Move the test bench horizontally to designated location of installation, then turn the four supporting legs in test benchs four corners downwards until the supporting legs contacted the ground. If the ground is not level enough, adjust the supporting legs until the bench top is level (Leveling Instrument may be used). Notes: Test benchs installation environment should meet the requirements of watt-hour meters inspection standards and reliable grounding conductors be available in the room! 2.1.2 Preparation and installation As vibration may happen to the test bench during its long-distance transportation which may cause some connections of test benchs internal components to come loose and affect test benchs future use and performance, you have to conduct some necessary inspections before install the test bench. 2.1.2.1 Remove test benchs front and rear covers, dismantle the signal source and power amplifier boxes and so on, and clean up the foreign bodies and dust within the test bench. Fasten all components connections within the test bench. 2.1.2.2 Open the power source and signal source, check and fasten all the screws and ICs that may come loose. Observe carefully for any foreign bodies on PCBs, especially small metals and iron chips. If any foreign bodies are found, just clear them. 2.1.2.3 Remove the meter hangers rear cover, check and fasten all the screws, connectors, ICs, etc. that may come loose. 2.1.2.4 Remove the quick connector devices cover and check if any current and voltage line connections have loosened. 2.1.2.5 Fasten the terminals and electrical components on distribution board, adjust the time delay relay to 1~2S. 2.1.2.6 Reference standard meter installation: Reference standard meter was packed in a special paper box. Open the carton, take out the standard meter, remove standard meters cover, check and fasten all the screws and ICs that may come loose, Observe carefully for any foreign bodies on PCBs, especially small metals and iron chips. If any foreign bodies are found, just clear them. Install the standard meter to its correct location per accompanying drawings, get the Page -37-

SY8125 Service Manual


lines of standard meters rear board and test bench well connected. Be careful of the connection of both voltage and current lines. Pulse lines should be connected to FH terminal, i.e. high-frequency output terminals; if they are wrongly connected, reference standard meter will not work normally. Connect the unit to a power supply, and make the switch in open status. 2.1.2.7 After components are fastened, re-connect the power source and signal source and so on. When connecting, pay attention to the identity of markings between plugs and sockets. If any nonidentity exists, please refer to relevant instructions and drawings. Attention: Do not connect to any auxiliary power supply first.

2.1.3 Power on the test bench 2.1.3.1 Check and make sure that no obvious abnormalities exist with other components of the test bench. Make sure that the power switch is in its OFF position. Verify the requirements of test benchs power input; make sure that the power supplies of signal source, reference standard meter, and power source have been disconnected. Power on the test bench; use a voltage meter to check if the power input of power distribution board is normal; if abnormal, check the input power. Turn the power switch of test bench to its ON position; measure with voltage meter for the normality of power source, signal source, and standard meters power inputs. 120V power supply; measurement: 220V 15%; built-in voltage amplifying equipment 220V~240V power supply; measurement: 220V~240V15% Attention: The input power must be strictly verified to be identical with the power requirements indicated on nameplate; phase line can not be connected to a neutral line wrongly, otherwise equipment might be damaged. 2.1.3.2 Test bench grounding Find test benchs grounding lines and connect the other ends of them to the grounding terminals in the room. 2.1.3.3 Turn off the power by switching to its OFF position; re-connect the auxiliary power supplies of power source, signal source, and reference standard meter; turn on the power by switching to its ON position. Test benchs signal source should display normally and without unrecognizable characters but with 1~2 seconds delay; power amplifier is activated, emits both sound and light alarms, and delays for about 2 seconds. If the signal source displays any unrecognizable characters, please open the signal source to check if any components have come loose; if yes, this problem can be solved by fastening the loose components. 2.1.4 Simple function test After the test bench is started up normally, short-circuit the short-circuit plate in meter hangers current loop but do not hang the meter on meter hanger at this moment. Parameters Page -38-

SY8125 Service Manual


of the meter to be calibrated are to be configured to three phase, four line (three-phase test bench), and 220V/5A; press the Start button, observe if the voltage, current, power, and phase can be output normally (Keyboard Configuration and Calibration Examples in instruction manual must be read for specific operation procedures). 2.1.5 Hanging meter for trial operation Hang the energy meter to each meter position on the test bench; install the scanning head, the scanning head must be connected to the socket in each meter position; then setup the parameters of energy meter to be calibrated. See operation manual for details. Test items include basic error test, startup test, and creep test. 2.1.6 Computer operation Install the accompanying software in a computer; connect the test bench to a personal computer with accompanying bridge cable (nine-pin serial cable); switch the PC/KEY on test bench to PC position, then the signal source will display messages about computer connection and relevant operations; after the serial ports have been configured, calibration by means of computer can be performed. Please see software operation manual for detailed computer connection and calibration operation. Attention: Please install computers bridge cables when both computer and equipment are in shutdown status, or device may be led to work abnormally or the components of personal computers I/O ports be damaged. 2.2 Daily maintenance and points for attention 2.2.1 Every time when the device is powered on, the load rate is 100%Ib and power factor is 1.0L; such parameters of watt-hour meter to be calibrated as constant, rated current, rated voltage, and maximum current are defaulted to be the parameters set in last calibration. These parameters can be re-configured according to the watt-hour meter to be calibrated. 2.2.2 Every time when the device is started up, the power amplifier will be activated after a few minutes delay. When the power amplifier is activated, it will be reset and emit both sound and light alarms for both voltage and current. This is a normal startup phenomenon. Before the power amplifier has been powered up, its Start key is not allowed to be pressed; otherwise the power up of power amplifier will have an impact on the power amplifier. There exist too many voltage parameters for three-phase watt-hour meter. So every time when a meter is hanged, attention should be paid to watt-hour meters voltage parameters. Wrong configuration of voltage may damage the watt-hour meter. Do not turn off the power switch when voltage and current are starting up. Power switch can only be turned off when no voltage or current are being output. Every time when the device is being cold-started, it should be warmed up for about ten minutes and then be put into use. Page -39-

2.2.3

2.2.4

2.2.5

SY8125 Service Manual


2.2.6 When installing the watt-hour meter, voltage loop short-circuit and current loop open-circuit should be avoided as far as possible. If voltage loop is short-circuited or overloaded or current loop is open-circuited or overloaded, the device will detect and protect itself automatically, send out a message, and close the signal output automatically. Before the equipment left the manufacturers factory, configuration of all parameters was finished and generally speaking, users do not need to configure the equipment if no special situation arises. Any arbitrary change of system parameters may cause the system to work abnormally. If system parameters are lost, please re-configure them by referring to the accompanying manual. Clean up the interiors of the device irregularly; fasten all terminals that may come loose. When hanging the meter for trial operation, any loosening of the current loop may cause abnormal errors or current protection.

2.2.7

2.2.8

2.2.9

2.2.10 Mark Search function will only be active during creep and startup.

Page -40-

SY8125 Service Manual


3 Ser.

Trouble shooting
Malfunction Possible Reason No power input 1 Startup failure *Phase missing of three-phase power supply Puncturing of the power tube of power amplifier Wrong configuration of signal sources internal parameters 2 Wrong initialization display or no display of signal source Loosening of interior connectors and ICs connections *Loosening of display driver board (at the back of the LED) Wrong output factor of signal source (including the correction factor of indication instruments) Wrong signal source output port or wrong signal switching Open-circuited output Bad contacts in the loop Alarm is output when current is increasing Puncturing of the power tube of power amplifier Abnormal current measurement ranges switch board *Wrongly exchange of three-phase power amplifier Wrong output factor of signal source (including the correction factor of indication instruments) Wrong signal source output port or wrong signal switching 6 Alarm is output when voltage is increasing Open-circuited output Solution Re-connect the power input Check the three-phase auxiliary power supply Replace the HS07000 PCB Re-configure parameters (per Outgoing Inspection Reports attached documents) Re-fasten it

Fasten the display driver board Check the output factor of signal source, or re-configure it (per Outgoing Inspection Reports attached documents) Check if signal source and power amplifier signal are correctly connected Check and fasten cablings of current loop Check and fasten cablings of current loop Replace the HS07000 PCB Replace switch board HS07029 or high-current switch relay SMAT-124DM2 Relocation of power amplifier box Check the output factor of signal source, or re-configure it (per Outgoing Inspection Reports attached documents) Check if signal source and power amplifier signal are correctly connected Check cable connections of voltage loop

No output and no alarm when current is increasing

No output and no alarm when voltage is increasing

Page -41-

SY8125 Service Manual


Puncturing of the power tube of power amplifier Ser. Malfunction Possible Reason Bad contacts in current loop 7 High error or jumping when in 0.5L Bad contacts in current feedback loop Bad grounding of test bench Replace the HS07000 PCB Solution Check and fasten cable connections Check and fasten cable connections Re-ground If the power switch of standard meter is turned on; if voltage input and current signal are correct; if the cable connection to transmit pulse to HS6000 is broken or in bad contact If bridge cable is connected and reliably grounded Re-configure standard meter constant Re-configure the constant of meter to be calibrated Check the communication cable Replace the HS6000 Check if cables are 2-3, 3-2, 5-5 Re-configure serial port to conform to actual uses Switch to on-line status Check the interior communication board, maybe by using the substitution method Replace with a good serial port or another computer

Standard meter does not work or wrong pulse output cabling of standard meter

Calibration error 99.99%

Wrong work status of standard meter (not connected to computer) Wrong configuration of standard meter constant Wrong constant configuration of meter to be calibrated

Abnormal communication with HS600 (off-line)

Bad contact of communication cable Abnormal HS6000 Bad serial cable Wrong serial port configuration in personal computers software

10

Communication error with personal computer

Signal source not switched to on-line status Bad contact of signal sources interior communication board

Bad computer serial port

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SY8125 Service Manual


4 (1) (2) (3) (4) (5) (6) (7) (8) (9)

List of spares Scanning head Pulse cable Voltage test cable Communication cable (RS232) Tools Current short circuit wire Fuse HS-6000 Software CD

Page -43-

SY8125 Service Manual


5 5.1

Connection diagram of the test bench Wiring diagram of three phase signal source
To voltage & current switch signal socket of amplifier

To RS-232 socket of RSM

To RS-232 socket of the test bench

Signal Source
RS232 Signal

U Sw.

I Sw.1

I Sw.2

RSM

PC

Ua

Ub

Uc

RS485

Signal

Power

Ia

Ib

Ic

To "N","L"&"E" terminal of signal source in the power supply PCB

To RS-485 socket of HS07020.PCB

To voltage & current signal socket of amplifier

5.2

Wiring diagram of three phase amplifier


To current switch To voltage & current signal socket of signal socket of signal source signal source To terminal "L" of mounting rack To PCB for search To current black mark terminal of RSM

To voltage switch signal socket of signal source

Voltage & Current

I Signal

U Signal

Voltage

Current

Voltage

Current

24V

0V

Output

To output terminal of 24V switch power

To "0V" & "150V" terminal of MSVT

To "N","L"&"E" terminal of Phase A,,B,C in the power supply PCB

Page -44-

SY8125 Service Manual

5.3

Wiring diagram of HS-6000 error processor

connecting with No. 1 position

To 485 socket of meter position

To J1 of HS07028.PCB To J2 of HS07016.PCB

To Scanning head socket of meter position

Page -45-

SY8125 Service Manual


5.4 Wiring diagram of three phase power supply:

Page -46-

SY8125 Service Manual


5.5 Wiring diagram of search black mark circuit:

Page -47-

SY3803 Single Phase High Precision Energy Reference Meter

Operation Manual

SY3803 Operation Manual

CONTENTS

1. 2. 3.
3.1 3.2

Introduction ...................................................................................... 48 Technical specification.................................................................. 48 Outlook .............................................................................................. 50


Front panel .............................................................................................. 50 Back panel............................................................................................... 50

4.
4.1 4.2 4.3 4.4 4.5 4.6

Embed software user manual ...................................................... 50


Definition of Keyboard and Symbol of Display Unit ................................. 50 Turn On ................................................................................................... 51 Test mode select...................................................................................... 51 Voltage range select ................................................................................ 52 Current range select ................................................................................ 52 Alarm information .................................................................................... 52

5.
5.1 5.2 5.3

Communication protocol .............................................................. 53


Communication settings: 9600, n, 8, 1 .................................................... 53 Pin definition of RS232 Port .................................................................... 53 Communication Command list................................................................. 53

6.

Package List ..................................................................................... 55

SY3803 Operation Manual


1. Introduction SY-3803 single phase energy reference meter is a high precious single phase energy reference meter; it uses the advanced technology and latest electronic components available in the world, and use high speed DSP as the main processor to ensure the accuracy and long time stability. Features and main function 1) Voltage input: 40V480V. 2) Current input: 0.01A120A. 3) CT work scope: 50%-120% 4) Test Mode: 1p2w watt 1p2w Var 5) Communication: RS232C Communication port 2. Technical specification 1) Voltage: Specified voltage range: Measurement error: Drift per year: 2) Current: Specified current range:
Measurement error: Drift per year:

40V - 312V 0.05%RG 0.025% 10mA 120A

(100/50/25/10/5/2.5/1/0.5/0.25/0.1/0.05/0.025) 0.05%RD (50mA-120A), 0.05%RG (10mA-50mA) 0.025%


-1.000 - 0 - 1.000 0.05%RG, PF 0.5-1 0.025%

3)

Power factor: Specified power factor/phase angle range: Measurement error: Drift per year: Frequency: Specified frequency range: 45Hz - 65Hz Measurement error: 0.02% Drift per year: 0.005% Test Mode:

4)

5) 6) 7)

1p2w watt 1p2w Var Communication: RS232C Communication port (Hz) Fout: fH=CH . p/3600 (Hz)

fL=fH/10000 Output mode: TTL 8) Meter constant table: Table 1: CH (P/kwh) 100A 480V 240V 120V 60V 8 10
5

50A 1.6 10
6

25A 3.2 10
6

10A 8 10
6

5A 1.6 10
7

2.5A 3.2 107 6.4 107 1.28 108 2.56 108

1.6 106 3.2 106 6.4 106

3.2 106 6.4 106 1.28 107

6.4 106 1.28 107 3.2 107

1.6 107 3.2 107 6.4 107

3.2 107 6.4 107 1.28 108

Page - 48 -

SY3803 Operation Manual

1A 480V 240V 120V 60V 8 10


7

0.5A 1.6 10
8

0.25A 3.2 10
8

0.1A 8 10
8

0.05A 1.6 10
9

0.025A 3.2 109 6.4 109 1.28 1010 2.56 1010

1.6 108 3.2 108 6.4 108 CL=CH/10000 9)

3.2 108 6.4 108 1.28 108

6.4 108 1.28 108 3.2 109

1.6 109 3.2 109 6.4 109

3.2 109 6.4 109 1.28 1010

Accuracy: Class 0.05 Class 0.1


0.1% 0.2% 0.1% 0.2% 0.1% 0.2% 0.1% 0.2% 50mA - 120A 10mA - 50mA 100mA - 120A 10mA - 100mA 100mA - 120A 10mA - 100mA 100mA - 120A 10mA - 100mA

Active power (energy)


cos =1 cos =0.5lag cos =0.5lead cos =0.8lead Drift per year 0.05% 0.1% 0.05% 0.1% 0.05% 0.1% 0.05% 0.1% 50mA - 120A 10mA - 50mA 100mA - 120A 10mA - 100mA 100mA - 120A 10mA - 100mA 100mA - 120A 10mA - 100mA

0.025%
0.1% 0.2% 0.1% 0.2% 0.1% 0.2% 0.1% 0.2% 50mA - 120A 10mA - 50mA 100mA - 120A 10mA - 100mA 100mA - 120A 10mA - 100mA 100mA - 120A 10mA - 100mA 0.2% 0.3% 0.2% 0.3% 0.2% 0.3% 0.2% 0.3%

0.05%
50mA - 120A 10mA - 50mA 100mA - 120A 10mA - 100mA 100mA - 120A 10mA - 100mA 100mA - 120A 10mA - 100mA

Reactive power (energy)


sin =1 sin =0.5lag sin =0.5lead sin =0.8lead Drift per year Apparent power (energy) Accuracy Drift per year 0.05% 0.1% 50mA - 120A 10mA - 50mA 0.1% 0.2% 50mA - 120A 10mA - 50mA

0.025%

0.05%

0.025%

0.05%

10) Display Display parameters: U(V) / I(A) / P(Watt) / S(VA) / Q(var) / Pf (-1.00001.0000) / (0o360 o)/F(HZ) 11) Power supply: 220V/240V, 50Hz/60 Hz 12) Power Consumption: 15VA 13) Stability of the Equipment with respect to time: < 30min 14) Influence of supply voltage on the measuring results: 0.004% (power supply variation +-10%) 15) Ambient temperature: Page - 49 -

SY3803 Operation Manual


Storage range: Operating range: Specified range: 0'C ~ 55'C 5'C 40'C 10'C - 30'C

Temperature co-efficient: 0.003% / 0.01%

16) 17)

Humidity: 85% Size: 482mm 420mm 140mm Weight: 7kg

3. Outlook 3.1 Front panel

Figure 1: 3.2 Back panel Power SW FH_Out FL_Out

Front panel

V Input

I Input (0.1A-100A)

GND

Power Supply

RS232 Communication Port Back panel

Figure 2: Mention:

Before turn on power supply for reference meter, user should connect Voltage input/Current Input/RS232 Communication cable correctly.

4. Embed software user manual 4.1 Definition of Keyboard and Symbol of Display Unit Irng : Current range select.

Page - 50 -

SY3803 Operation Manual


Urng : Voltage range select. Test Mode. Confirm. ESC.

Mmode : Enter :

Escape :

U: I: P: S: Q: Pf: : F: 4.2

Voltage Current Active Power Apparent Power (VA) Reactive Power Power factor Angle between U & I Frequency (Hz)

Turn On Turn on power for reference meter, After 15 seconds, meters main cover will display as below:

Figure 3: 4.3

Main cover

Test mode select Press key mode will enter mode select function, cover will display as below:

Figure 4:

Test mode select cover

Use to select test mode, P means active power, Q means reactive power.

Page - 51 -

SY3803 Operation Manual


4.4 Voltage range select Press key Urng will enter voltage range select function, cover will display as below:

Figure 5:

Voltage range select cover

Use to select voltage range, Enter will confirm and return. 4.5 Current range select Press key Irng will enter current range select function, cover will display as below:

Figure 6:

Current range select cover

Use to select current range, Enter will confirm and return. 4.6 Alarm information When input voltage is over the selected voltage range, meter will display alarm information as below:

Figure 7:

Voltage alarm

When input current is over the selected current range, meter will display alarm information as below: Page - 52 -

SY3803 Operation Manual

Figure 8:

Current alarm

5. Communication protocol 5.1 Communication settings: 9600, n, 8, 1 5.2 Pin definition of RS232 Port Pin No 1 2 3 4 5 6 7 8 9 5.3 Communication Command list 5.3.1 Voltage range select Send: Order Code UB X=0, 480V X=1, 240V X=2, 120V X=3, 60V Answer: Answer Code UBACK Para EOF 3B(HEX) Para X EOF 0D(HEX) Mean Null RXD TXD Null GND Null Null Null Null

5.3.2

Current range select Send:

Page - 53 -

SY3803 Operation Manual


Order Code IB X=0, 100A X=1, 50A X=2, 25A X=3, 10A X=4, 5A X=5, 2.5A X=6, 1A X=7, 0.5A X=8, 0.25A Answer: Answer Code IBACK 5.3.3 Test mode select Send: Order Code MS X=0, active power. X=1, reactive power. Answer: Answer Code MSACK 5.3.4 Test result readout Send: Order Code DT Answer: Answer Code MSACK Para Test result(below) EOF 3B(HEX) Para 0 EOF 0D(Hex) Para EOF 3B(HEX) Para X EOF 0D(Hex) Para EOF 3B(Hex) Para 0,X EOF 0D(Hex)

Test result format is described as below: Test result include 15 parameters, every parameter is combined with identify code and Page - 54 -

SY3803 Operation Manual


real data. Identify code A B C D E F G H I J K L M N O Data(ASC) XXXXXXXXXX 0000000000 0000000000 XXXXXXXXXX 0000000000 0000000000 XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX X X X
o

Unit V

Mean Voltage

Comment Voltage resverd resverd

current

Current resverd resverd

W VA VA

Active Power Apparent ReactivePower PF Angle U&I Frequency V range I range Test Mode

Active Power Apparent ReactivePower PF Angle U&I Frequency V range I range Test Mode

HZ

Every real datas data length is 10 asc code. If data is positive number, then the previous 6 number is integer, and the last 4 number is decimal. Voltage real data: 0002208888 Means: Voltage = 220.8888 (V) If data is negative number, then the asc code n means minus. Previous 6 number is integer, and the last 4 number is decimal. For example: Active Power real data: 00n2208888 Means: Active Power = -220.8888 (Watt) For example:

6. 6.1 6.2 6.3 6.4 6.5

Package List SY-3803 Single phase energy reference meter ----- 1 pc User manual ----- 1 pc Power wire ----- 1 pc Fuse (1A) ----- 1 pc BNC Connector ----- 2 pc

Page - 55 -

HONGKONG SONGYANG INDUSTRIAL LIMITED


HONGKONG OFFICE: Add: Room 1507, 15/F., Emperor Group Centre, 288 Hennessy Road, Wanchai, Hong Kong. Tel: 00852 - 21218691 Fax: 00852 - 21218692 CHINA OFFICE: Add: 8F, SUNSHINE PLAZA, No.186 HUSHU NAN ROAD, HANGZHOU, CHINA Tel: 0086 - 571 - 85394178, 85393435, 85391965, 85301329 Fax: 0086 - 571 - 85301324 MANUFACTURE: HANGZHOU SONGYANG ELECTRONIC TECHNOLOGY CO., LTD. Add: Building 4, 6 Xiyuan 8th Road, Sandun Xihu Technology and Economic Park, Hangzhou, China India Market & Service: M/s Abacus Technologies Add: C-6 CEL Apartments Vasundhara Enclave, Delhi, 110096, India Tel: 0091-9810363260 Website: http://www.energymeter.biz E-mail: sales@energymeter.biz