Wireless Overcurrent Sensor

Relay
Design Review
September 27, 2010
ECE 445 Fall 2010

Team 18
Ray Zumbahlen
Tsvetan Rusev
TA: Xiangyu Ding

Wireless Overcurrent Sensor Relay

Team 18 Zumbahlen, Rusev

Wireless Overcurrent Sensor Relay

I.

Objectives and Goals

The title of our project is Wireless Overcurrent Sensory Relay. We will
be working with S&C Electric Company (hereinafter S&C) in a collaborative
effort to bring this system into industry to be used on their circuit switching
line of products. This is part of the reason why we chose this project. It has
a practical real-world application that has high chances of being
implemented in an existing system to make the overall device more reliable
and efficient, which is what engineering is about.
The goals of our system are to accurately measuring current on a
transmission line, and to relay this information wirelessly by sending a trip
signal to a circuit breaker. Right now, S&Cs line of circuit switching devices
does not monitor the current on a transmission line between a circuit
switcher and a transformer. So the goal is to get this current measurement
without making a physical connection to the transmission line and sending
the current magnitude wirelessly to flag a trip signal at the circuit switcher
depending on the value of the line current.
Also, our system will be self-powered in the sense that it will use the
current in the transmission line to power itself. It will need no source of
external power. The device will have the ability to store power in order to
successfully shut down after a trip signal is sent since then there would be
no line current to harvest energy from. The high level goal is to have a
functioning product at the end of the semester that S&C can use to
implement this for a full three phase device.
Device Features

Wireless radio allows versatile placement of sensor

Quick overcurrent signaling
Stores energy to power down itself after a fault
Real-time current monitoring

Device Benefits

II.

Overcurrent protection between circuit switcher and transformer

Energy efficient via self-powering from the lines
Low to no maintenance design
Design
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Team 18 Zumbahlen, Rusev

A. MSP430 Software Flow Chart

Figure 1 Software Flow Chart

B. Schematics, Simulations, and Descriptions

1. Crowbar Circuit
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Team 18 Zumbahlen, Rusev

The purpose of the crowbar circuit is to protect the storage

capacitor and the DC-Link from overvoltage conditions. During a
fault, the voltage induced in the secondary of the CT may exceed the
rated voltages of the capacitor and the DC-Link. Two reverse parallel
SCRs are used to short the secondary of the CT when such a condition
occurs. When the supply voltage exceeds the breakdown voltage of
the Zener Diodes (D13 and D14) the SCRs are triggered reducing the
voltage across load.
Figure 2 - Crowbar Simulation Schematic

The circuit operation is evident from the simulation plots below

in Figure 2. Figure 2 represents the voltage across the load and the
current through the SCRs. In this simulation, the input voltage is
below the Zener breakdown and the crowbar remains inactive; that is
no current flows through the SCRs. The load sees input sinusoidal
voltage equal to the input voltage. Under these conditions the
storage capacitor will be charged to the input voltage (secondary of
the CT).
Figure 3 is a simulation of the same schematic. The input
voltage however is now increased to above the Zener reverse
breakdown. Every time the breakdown voltage is exceeded the SCRs
are triggered and the CT is shorted. Thus the voltage across the load
decreases to about 2-4V. Once triggered the SCRs remain active until
a zero crossing of the current waveform. This allows the capacitor to
charge even if the overvoltage condition continues indefinitely (which
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Wireless Overcurrent Sensor Relay

Team 18 Zumbahlen, Rusev

can only occur in case of communication malfunction and the circuit

switcher remains closed).
Figure 3 - Crowbar Inactive Simulation Output

Figure 4 - Crowbar Active Simulation Output

Wireless Overcurrent Sensor Relay

Team 18 Zumbahlen, Rusev

2. Crowbar and Storage

Figure 5 - Crowbar & Storage Simulation Schematic

Energy storage is needed to allow the device to remain powered

during crowbar operation. A storage capacitor will provide smooth
power to the electronics and allow the device to remain operational
for a short amount of time after the circuit switcher has been
triggered. Figure 4 describes how the storage capacitor is connected
to the crowbar. A bridge rectifier is used to convert the AC input
voltage. In this configuration the capacitor also provides filtering for
the rectified AC signal.
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Team 18 Zumbahlen, Rusev

Below is a simulation plot describing how the overall power

supply operates. It can be seen that the capacitor reaches rated
voltage within 2 cycles. The red and purple traces represent the how
the Zener breakdown operation and SCR triggering.
Figure 6 - Crowbar Active & Storage

3. DC-Link
The DC-Link draws power directly from the storage capacitor
and converts it to adequate voltage to power the MSP430
microcontroller, XBee communications, and the Rogowski coil signal
conditioning circuitry. It is based on the Supertex HV9961 LED driver
and is a modified switching power supply. According to the
manufacturer, the HV9961 is capable of operating in the range of 8450V rectified AC and is capable of saucing 165mA. Given the
voltage and current specifications, the DC-Link from Figure 5 should
be able to handle power demands.
Figure 6 - DC-Link Schematic

Wireless Overcurrent Sensor Relay

Team 18 Zumbahlen, Rusev

4. Op-Amps & MSP430

The WOSR (Wireless Overcurrent Sensor Relay) shall have the
capability to measure line current with 5% accuracy. In order to
achieve that for the range currents specified (5-600A), two channel
parallel signal amplification and filtering will be used. Channel one or
the low current channel (as we will refer to it) will measure 5-60A and
the channel 2 or the high channel will measure 60-600A. The gains
for the two channels will be chosen according to the Rogowski coil
specifications.
The MSP430 is interfaced to the sensor circuit via two A/D
channels. It will analyze the signals and make a decision to send or
not to send a trip signal over the XBee radio. It will also measure and
display in real time the current on the line.
XBee transmitter receives serial data from the MSP430 and
broadcasts it wirelessly. When a trip signal is sent, the XBee receiver
will set a flag (light an LED for example) as an indication of the
tripping.
Figure 7 - Signal Conditioning & MSP430 Schematic

Wireless Overcurrent Sensor Relay

Team 18 Zumbahlen, Rusev

Below is a pSpice simulation schematic and output waveform of

the op-amp circuit. The Rogowski coil is modeled as a transformer
and its output is offset by 1.5V. This is necessary because it will allow
the A/D converters to see the entire waveform (not just the positive
half- cycle). The output waveform is what the MSP430 will see on its
A/D channels. The gains and Rogowski coil output voltage for this
simulation were chosen arbitrarily and will be adjusted to actual
sensor output from testing.
Figure 8 - Op-Amp Simulation Schematic

Wireless Overcurrent Sensor Relay

Team 18 Zumbahlen, Rusev

Figure 9 - Op-Amp Simulation Output

III.

Verification
A. Performance Requirement
The current sensing device shall be located on the Sensing Module
and should be capable of sensing current from 5A through 600A
symmetrical. The current sensing device should be able to withstand
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Wireless Overcurrent Sensor Relay

Team 18 Zumbahlen, Rusev

10A of continuous load and a 600A fault current for 0.5 seconds.
Magnitude accuracies of 5% or better will be implemented for the
current sensing device. The maximum internal diameter of the current
sensing device will be 2 and the total weight will be less than 10lbs.

The power supply shall also be located on the Sensing Module. This
device shall be able to harvest energy from currents greater than 5A
in order to power up the processor. At 600A, the Sensing Module shall
be able to measure current against a TCC curve and send a trip signal
to the receiver module in less than 15 cycles. The self-powering
supply shall provide power to all portions of the Sensing Module and
keep supply voltage at 3.3V. The self-powering supply shall also
provide enough energy to keep the Sensing Module fully functional
after the fault occurs until proper shut down is completed. This
however will not be utilized to power the Receiver Module.

The Sensing Module shall utilize a low-power processor that is

responsible for coordinating all of the signals and operations of the
Sensing Module. For this, we have chosen to use the MSP430
FG4618.

The Sensing Module shall include a means to communicate the trip

command to the Receiver Module. Wireless communication shall be
used, and the transmitter must be able to securely transmit the trip
signal for a distance of 50 feet and operate at less than 150 mW. For
this operation, we have chosen to implement the XBee radio since it
gives us secure transmission that meets the above requirements seen
in [1].

Once installed on the power line the device shall require no

maintenance or calibration
B. Testing Procedures
Many of the requirements in our project were directed to us by S&C
Electric. Although we are trying to implement the same general
requirements, our system is much less involved than the overall
system they intend to implement. Therefore, we modified some
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Wireless Overcurrent Sensor Relay

Team 18 Zumbahlen, Rusev

requirements stated in their internal company proposal [2] which we

are not to disclose. However, we are referencing that document for
many requirements listed below.
1. Sensing
We will first test the sensor (Rogowski Coil) by putting current
through it and recording the output voltage. We will be using the
Grainger Power Lab in the basement of Everitt Lab. Since we are not
able to provide 600A in the lab, we plan to use 12 gauge wire and
push 15 A through it. To emulate the 600A we need to test, we will
feed the wire back through the coil 40 times. We will investigate the
current vs. voltage relationship and calculate the voltage per ampere
ratio of the sensor. Then we will have to test the sensor with the
amplifiers as well. This is because we have a large range of current
we need to sense and, the amplifiers will have different gains to put
the sensor output signal in a preferred range. We also must carefully
test the noise in the signal from the coming from the power supply.
We do not have the Rogowski coil yet, so it is impossible to say what
the gains of our amplifier need to be. However, according to the
TAEHWATRANS INC Rogowski Coil data sheet, the output voltage will be

between 16.72mV and 17.22uV as stated in [3].

2. Power Supply
To begin this testing, we are running simulations to get an idea
of what our power supply will be doing. Then, the next step will be
similar to the Rogowski coil testing. We need to test our CT at various
currents (0A to 15A) to ensure the CT core does not saturate. Again,
using 15A and 40 turns on the primary, we can assume it will operate
as if there were 600A on one primary turn. We will also test that the
voltage supplied to the ICs remains 3.3V. Also, we will make sure
that the power supply can charge up the energy storage capacitor to
its max charge quickly.
3. Wireless Capability
For the wireless capabilities, we will use the XBee devices. The
requirement for this module is that it must transmit at least a
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Team 18 Zumbahlen, Rusev

distance of 50 ft. line of sight. However, we will ensure that the

device can transmit at distances greater than this. How we will test
this functionality is self-explanatory. We will also test that the noise
coming from the transmission line will not prevent successful XBee
transmission. For this, we will simply place the XBee transmitter as
close to the power supply as possible with high current on the line
and perform a transmission. As far as modular testing goes, we will
use the processor to simulate sensor readings ranging from 5A to
greater than 600A and ensuring that the XBee will transmit, receive,
and relay the trip signal. The XBee should be a viable source for this
module as the data sheet states it has the ability to transmit 100 ft.
outdoors (line of sight) which is more than enough distance for our
system. It also uses less than 150 mW of power also stated in [1].
4. Measurement Accuracy
We require that the measurement accuracy be within plus or
minus 5% at all times. For this, we will take the reading from the LCD
display on the Experimenters Board and compare it to a measured
value on the line using a multi-meter.
5. Successful Flagging
Each time we put more than 600A on our line, we will ensure
that we successfully transmit and visually display (on an LED) a trip
signal flag.
6. System
Upon completing testing on the modular components, we will
test the system at a higher level as a whole. To do this, we will test
the system at various levels of line current. We will check a variety of
currents under 600 A (actually 15 A) and measure the accuracy of our
sensing system. Also, we will put very close to 600 A through the line
to ensure the system does not send the trip signal prematurely.
Finally, we will test at greater than 600 A to be sure the trip signal will
indeed be sent wirelessly to the receive unit and light up our LED.
C. Tolerance Analysis
The most important component that will determine the
performance of our project is the Rogowski coil current sensor. Although
it is wound in a way to minimize EM interference it will still be affected
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Team 18 Zumbahlen, Rusev

by noise. Identifying noises and providing adequate shielding and

filtering of the signal is a key to the success of this project. Minimizing
noise picked up by the current sensor will allow for higher measurement
precession and faster operation. Precision of 5% or less of the actual
current will suffice. Temperature will also be a factor as it might affect
IV.

the sensors electrical properties.

Ethical Considerations

IEEE item number 7 in the IEEE Code of Ethics [4] says we shall seek,

accept, and offer honest criticism of technical work, to acknowledge and correct
errors, and to credit properly the contributions of others. Since w e are

developing this product in a collaborative effort with S&C Electric, it will be

important for us to give appropriate credit for the aid and direction we
receive from S&C Electric. Also, at the beginning of the project, we signed a
non-disclosure agreement with the company. This is so that we do not use
this idea and/or technology for our own personal financial gain. That is, we
are not to sell this idea or any ideas presented by S&C Electric to any other
organizations. The idea is property of S&C Electric so it is not ours to do
whatever we please. So, the largest ethical consideration we have to make
is when it is regarding disclosing too much or the wrong information to
anyone that could use it for their personal gain. Other than this, there are
not too many ethical issues regarding the actual use or functionality of the
device.

V.

Cost and Schedule

A. Cost Analysis
Parts in Possession
Part Name

Purpose

Price

Current
Transformer
MSP 430 FG4618

Harvest energy from line

Take, process, and
output data
Wireless

XBee Radio

14

$90.00

Quanti
ty
1

Total
$90.00

$9.67

$9.67

$19.00

$38.00

Wireless Overcurrent Sensor Relay

LED

Team 18 Zumbahlen, Rusev

Communications
Trip Signal Flag

$0.15

1
Subtotal =

$0.15
$38.15

Parts on Hand in Everitt Lab

Part Name

Purpose

Price

10 AWG Wire

Simulate transmission
line
Boost sensor output
voltage
Voltage Regulator

$0.20
$0.10
$0.20
$4.04

Op Amps
.1 uF cap
1 uF cap
10 uF cap
100 uF cap
500 uF cap
diode (1N4004)
Zener diode
(1N4730A)
MUR160 diode
1k resistor
3 M resistor
IRFU320 regulator

$0.50/ft

Quanti
ty
20

$10.00

$0.61

$2.44

$0.15
$0.15
$0.20
$0.20
$0.20
$0.10
$0.15

1
4
1
1
1
9
3

$0.15
$0.60
$0.20
$0.20
$0.20
$0.90
$0.45

1
12
1
1
Subtotal =

Total

$0.20
$1.20
$0.20
$4.04
$22.58

Parts Ordered
Part Name

Purpose

Price

Quanti
ty
1
2
1

Rogowski Coil
SCR (30TPS08)
HV9961 LED
driver

Sensor current on line

Crowbar
may use ICM7215IPG

$150.00
$3.01
$2.24

$150.00
$12.04
$2.24

Subtotal =

$164.28

Parts Total
Description
Parts in Possession
Parts on hand in Everitt
Lab
Parts Ordered
Grand Total =

B. Schedule
15

Sub-Totals
$38.15
$22.58
$164.28
$225.01

Total

Wireless Overcurrent Sensor Relay

Team 18 Zumbahlen, Rusev

Detailed Schedule for Remaining Weeks

Week #

Ray
- Meet with S&C to discuss
project
- Research parts
2 (Sept
- Develop project proposal
13)
- Choose processor, transceiver,
sensor
3
- Order Rogowski Coil
(Sept20)
- Prep for Design Review
- Determine MSP430/XBee
connections
4 (Sept
- Conduct personal and peer
27)
review
- Test wireless functionality
- Begin programming processor
5 (Oct 4)
- XBee limitation tests
(distance/noise)
- Help Steve characterize
Rogowski Coil
6 (Oct
- Begin MSP430/XBee integration
11)
- Continue programming
processor
- Aid in sensor/op-amp tests
7 (Oct
- Begin sensor
18)
output/MSP430/XBee
integration
- Continue XBee radio limitation
testing
8 (Oct
- More sensor/MSP430/XBee
25)
integration
- Begin current reading accuracy
testing
- Prepare individual progress
reports
9 (Nov 1) - Request 1st version of PCB
- Optimize processor
programming
10 (Nov
- Test and revise 1st PCB
8)
- Request 2nd PCB at end of week
11 (Nov
- Test and verify 2nd PCBs
15)
operation
1 (Sept 6)

16

Tsvetan
- Meet with S&C to discuss
project
- Research parts
- Develop project proposal

- Design and simulate power

circuitry
- Prep for design review
- Conduct personal and peer
review
- Continue circuit simulations
- Begin CT testing
- Build and test power supply
circuitry
- Begin characterizing Rogowski
Coil
- Continue power supply testing
- Continue heavy sensor/op-amp
testing
- Test IC supply voltages
- Test over voltage protection
(crowbar)
- Begin op-amp optimization
work
- Continue same power supply
tests
- Test power supply cut-off and
capacitor energy discharge on
overcurrent
- Request 1st version of PCB
- Continue same tests as week 8
- Test and revise 1st PCB
- Prepare mock-up demo
- Test and verify 2nd PCBs
operation

Wireless Overcurrent Sensor Relay

12 (Nov
22)
13 (Nov
29)
14 (Dec
6)

Team 18 Zumbahlen, Rusev

- Mock-up presentations
- Thanksgiving Break
- Prepare presentations
- Demonstrate project and
present
- Prepare final report
- Submit Final Report and
checkout

- Mock-up presentations
- Thanksgiving Break
- Prepare presentations
- Demonstrate project and
present
- Prepare final report
- Submit Final Report and
checkout

VI.

References

[1]

Digi International, IEEE 802.15.4 RF Modules, XBee/XBee-PRO RF

Modules Datasheet,
November 23, 2009

[2]

A Montenegro, Requirements Specification for the Self-Powered OverCurrent Relay Fault Detection & Signal System, S&C Electric, Inc, Oswego,
IL, USA, Tech. Report. 17 Aug. 2010.

[3]

TAEHWATRANS INC, Rogowski Coil Datasheet, Rogowski Coil, March 27,

2009

[4]

IEEE, "IEEE - IEEE Code of Ethics." IEEE Board of Directors, Feb. 2006.
[Online]. Available:
http://www.ieee.org/portal/pages/iportals/aboutus/ethics/code.html
[Accessed: 25 Sept. 2010].

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