TI Designs

Three-Phase AC Current Measurement Using Current

Transformer Reference Design

Design Overview Design Features

This reference design demonstrates high-accuracy, 0.5 % Accuracy (Uncalibrated) for 10% to 100% of
wide-range AC current measurement for a three-phase Full-Scale Primary Current
motor using the zero-drift architecture of the INA199. Power Consumption of 25 mW for Gain Stage
The design also features a low power consumption of
25 mW for a gain stage of 200 as compared to a Small Footprint Eliminates Requirement of External
discrete solution. The integrated high-precision Resistors for Amplification
resistors inside the INA199 device allow for a much
Featured Applications
smaller design footprint and BOM than with a discrete
solution. The design footprint and BOM cost is much Compressors, Chillers, and Blowers (HVAC)
smaller than a discrete solution due to the integrated ID and FD Fans, Screw Feeders, and Feed Pumps
high precision resistors inside the INA199. (Steam Boiler)
Design Resources Traction Motor (Escalator and Elevators)

TIDA-00753 Design Folder

INA199 Product Folder
TPS717 Product Folder
REF3212 Product Folder

ASK Our E2E Experts

R1 R2

VREF

VCC
C

Rsh
C
C

TDK CT 0.1E, 1W R4
R3
0 A to 300 A 15 ppm,
N = 3000 2515
INA199

VIN
VCC VREF

TPS71733 REF3212

Copyright 2016, Texas Instruments Incorporated

An IMPORTANT NOTICE at the end of this TI reference design addresses authorized use, intellectual property matters and other
important disclaimers and information.

Bluetooth is a registered trademark of Bluetooth SIG, Inc.

All other trademarks are the property of their respective owners.

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1 Key System Specifications

Table 1. Key System Specifications

SPECIFICATIONS
SYMBOL PARAMETER DETAILS
CONDITION MIN TYP MAX UNIT
IIN Input primary current 1 100 A As per CT specification
FIN Input current frequency 50 60 Hz As per CT specification
Te CT turns ratio 3000 As per CT specification
Rsh Burden resistance 0.1 Section 4.1
Uncalibrated at Section 4.2,
Measured accuracy at
% Vo_Error ambient 1 0.5 1 % Section 4.3,
INA199 output
temperature Section 4.4
IQ Quiescent current 5 mA
VIN Input power supply (DC) 3.5 5 6.5 V

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2 System Description
An electric motor is an essential moving element of any system. Electric motors are required in pumps,
compressors, and blowers in typical heating, ventilation, air conditioning (HVAC), and boiler systems.
Problems such as suction, jamming, flood back, and stalling can lead to catastrophic damage to motor
and process equipment. Detecting such events is crucial for process controllers to take corrective action.
Because load torque and current are directly proportional to each other, the user can implement a current
sense method to indirectly monitor the load profile. The diagram in Figure 1 shows the motor current
sensing in an HVAC compressor application.

U V W Expansion Valve

Thermal Bulb
Contactor
Evaporator

Condenser

Control Unit

Belt

Motor
Compressor
Copyright 2016, Texas Instruments Incorporated

Figure 1. Generic HVAC Control System Diagram

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The current flowing through a conductor can be detected using a resistive shunt, current transformer (CT),
Hall effect sensor, and so forth. CT-based monitoring is the most simple and cost-effective solution for
retrofitting systems. This design can be connected to any online system using a split-core CT. When
measuring isolated high current, a CT is preferred because of its better stability and dynamic range over
Hall effect.
Table 2 compares the various sensor techniques used to measure current. The diagram in Figure 2
provides an overview for testing the TIDA-00753 design with the existing analog-to-digital (ADC)
evaluation module (EVM).

Table 2. Current Sensor

CURRENT
SENSOR PARAMETER RESISTOR HALL EFFECT (1)
TRANSFORMER
Shunt resistive load range to m None m to s
Linearity over entire range Very good Poor Fair
Offset problem Yes Yes No
Saturation No Yes Yes
Isolation No Yes Yes
Stability over temperature Fair Poor Good
(1)
A generic open-loop Hall sensor has been used for comparison.

U V W

USB Cable
TIDA-00753 ADS131E08EVM

Current
Transformer
PC

Motor

Copyright 2016, Texas Instruments Incorporated

Figure 2. TIDA-00753 System Interface

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www.ti.com Block Diagram

3 Block Diagram
The TIDA-00753 design focuses on the front end of the CT signal chain, as the block diagram in Figure 3
shows. The reference has been generated using REF3212 for high-precision measurements; however,
REF2912 and REF2030 can be used as alternate parts.

R1 R2

VREF

VCC
C

Rsh
C
C

TDK CT 0.1E, 1W R4
R3
0 A to 300 A 15 ppm,
N = 3000 2515
INA199

VIN
VCC VREF

TPS71733 REF3212

Copyright 2016, Texas Instruments Incorporated

Figure 3. TIDA-00753 Block Diagram

3.1 Highlighted Products

The TIDA-00753 reference design features the following devices:
INA199: 26-V, bidirectional, zero-drift, low- or high-side, voltage output current shunt monitor
TPS717: Low-noise, high-bandwidth PSRR, low-dropout, 150-mA linear regulator
REF3212: 4-ppm/C, 100-A, SOT23-6 series voltage reference
For more information on each of these devices, see their respective product folders at www.ti.com.

3.1.1 INA199
Features: 10-ppm/C gain drift (maximum)
Wide common-mode range: 0.3 V to 26 V Choice of Gains:
Offset voltage: 150 V (maximum) INA199x1: 50 V/V
(Enables shunt drops of 10-mV full-scale) INA199x2: 100 V/V
Accuracy INA199x3: 200 V/V
1.5% gain error (maximum over Quiescent current: 100 A (maximum)
temperature)
Packages: 6-pin SC70, 10-pin UQFN
0.5-V/C offset drift (maximum)

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Applications Telecom equipment

Notebook computers Power management
Cell phones Battery chargers
Qi-compliant wireless charging transmitters Welding equipment
.
RSHUNT
Reference Supply Load
Voltage

REF OUT Output

GND R1 R3 IN-

2.7 V to 26 V IN+
V+
R2 R4
CBYPASS
0.01 mF
to
0.1 mF

Figure 4. INA199 Simplified Schematic

3.1.2 TPS717
Features 70 dB at 1 kHz and 67 dB at 100 kHz
Input voltage: 2.5 V to 6.5 V Excellent load and line transient response
Available in multiple output versions: Very low dropout: 170 mV typical at 150 mA
Fixed output with voltages from 0.9 V to Low noise: 30 VRMS typical (100 Hz to
5V 100 kHz)
Adjustable output voltage from 0.9 V to Small 5-pin SC-70, 2-mm 2-mm WSON-6,
6.2 V and 1.5-mm 1.5-mm WSON-6 packages
Ultra-high PSRR:
.
. .
Applications
Mobile phone handsets
Camera sensor power
PDAs and smartphones
Wireless LAN, Bluetooth
VIN IN OUT VOUT
TPS717xx
1 mF 1 mF
Ceramic EN GND NR Ceramic

VEN
0.01 mF
(Optional)

Figure 5. TPS717Typical Application Circuit for Fixed-Voltage Versions

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3.1.3 REF3212
Features: High output current: 10 mA
Excellent specified drift performance: High accuracy: 0.01%
7 ppm/C (max) at 0C to 125C Low quiescent current: 100 A
20 ppm/C (max) at 40C to 125C Low dropout: 5 mV
Microsize package: SOT23-6

. .
Applications:
Data acquisition systems
Portable equipment
Medical equipment
. Test equipment

GND_F 1 REF3212 6 OUT_F

REF3220
REF3225
GND_S 2 5 OUT_S
REF3230
REF3233
ENABLE 3 REF3240 4 IN

Figure 6. REF32xx Pinout

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4 System Design Theory

The TIDA-00753 TI Design has been designed to meet high accuracy demands when measuring wide AC
current ranges for motors.
The design uses current transformers (CT), which have a very high turns ratio and are used when
measuring the primary current range to achieve better linearity.
As a result of this higher turns ratio, the secondary burden resistor of the design can be specified from m
to k depending on the required range of measurement. The signal-to-noise ratio (SNR) is limited
because of the lower-value sense resistor. For a wide current range measurement and lower supply rails,
the burden resistor must be specified in m, which limits the SNR. By using an amplifier, the SNR can be
improved to obtain better accuracy.

4.1 CT Burden Calculations

Burden resistance affects the accuracy of a CT; as burden resistance increases, accuracy decreases.
Figure 7 shows a circuit with CT burden calculations where the magnetic impedance of the core is in
parallel with the burden resistance. As the burden resistance increases, the magnetic impedance draws
more current, which results in measurement error and nonlinearity for the entire range.

Figure 7. CT Burden Calculations

Use Equation 1, Equation 2, Equation 3, and the CT specifications available from the CT manufacturer to
calculate the theoretical error for different burden resistances.
(
(Zm (Zs + RL ) )
E2 = Is
)
(
(Zm + (Zs + RL ) )
) (1)
E2 = Im Zm (2)
Ib = Is - Im (3)

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4.2 Discrete AmplifierError Budgeting

Because the input full-scale voltage is very low, a gain stage is required to obtain a better SNR. The gain
stage can be a simple inverting amplifier or difference amplifier. A discrete, inverting amplifier with external
passive components limits the accuracy of a system.
Assume for the sake of this design that a basic inverting amplifier configuration has been used as shown
in Figure 8. This example uses an LMV321 amplifier with an R1, R2, and R3 of 1 k, 49.9 k, and 980
with a 0.1% tolerance and drift of 25 ppm.

Figure 8. Inverting Amplifier

For lower input voltage range offset voltage, input bias current error dominates, while at higher voltage
range gain error dominates. Op amp error budgeting can help to explain the error contribution of an
amplifier during input measurement (see Figure 9).

Figure 9. Simplified Model

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An error budget requires computing the total loop gain error and bias current error of the discrete amplifier
LMV321. Table 3 shows the calculations for the total loop gain and bias current error.

Table 3. Computation of DC Error

REFERENCE
PARAMETER EQUATION VALUE UNIT ERROR
NO

1
Open-loop gain at A open 15000
ambient

2
Closed-loop gain Bopen 49.800
at ambient

A open
3 Ideal gain IdealGain = 0.01999
1 + A open 50

A open
- IdealGain

1 + A open Bclosed
Total loop gain
100
3 error at ambient % 0.40
Tambient IdealGain


4
Open-loop gain A op _ drift 10000
drift at max temp

5
Closed-loop gain Bcl _ drift 49.651
drift at max temp

A op _ drift
- IdealGain

1 + A op _ drift Bcl _ drift
Total loop gain 100
6 error at max temp % 0.70
TMAX_TEMP IdealGain


7 Input bias current IBias 250 nA

8
Input offset IOffset 50 nA
current

9 In
(2 IBias - IOffset )
225 nA
2
10 Ip IOffset + In 275 nA

R
11
Input bias current
error
VIB = 1 + 1
R2
(((R1 P R2 ) In ) - (R3 Ip )) V 0.00244

12
Input bias current IBias _ Drift 500 nA
drift

13
Input offset IOffset _ Drift 150 nA
current drift

14 In_Drift
(2 IBias _ Drift - IOffset _ Drift ) 425 nA
2
15 Ip_Drift IOffset _ Drift + In _ Drift 575 nA

R1
16
Input bias current V
drift error IB _ Drift = 1 +


R2
(((R1 P R2 ) In _ Drift ) - (R3 Ip _ Drift )) V 0.0074

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The user can calibrate the offset voltage, bias current error, and gain error (at ambient temperature) by
using software calibration. The user can also calibrate error drifts as a result of temperature change by
using software logic for error drift with respect to the temperature; however, the output noise density
cannot be calibrated. Table 4 shows the contribution of each error for a full-scale voltage range of 3.33
mV, which corresponds to a full-scale primary current of 100 A.

Table 4. Error Budgeting for Inverting AmplifierFull-Scale Voltage 3.33 mV

REFERENCE ERROR ERROR
PARAMETER EQUATION VALUE UNIT
NO (PPM) VOLTAGE
Absolute error
Vos 6
1 Offset voltage 10 0.007 V 2100210
V
FS

Input bias VIB 6

2
current error 10 0.00244 V 733440
VFS
3 Gain error Tambient 104 % 4000

Absolute best-case error RMS (A) 1284371 0.0042

Absolute worst-case error SUM (A) 2837650 0.0095
Drift error

Offset voltage VOS VOS _ Drift (TempMAX - 25 ) 6

4 10 0.000005 V/C 630.006
drift V
FS

Input bias VIB _ Drift - VIB 6

5
current drift error 10 0.0050 V 1487268
V FS
6 Gain drift TMAX _ TEMP 104 0.7 % 7000

Drift best-case error RMS (A) 86705 0.0028

Drift worst-case error SUM (A) 157078 0.0049
Resolution

ENI(RMS) Bandwidth 39 nV
7 Noise voltage 106 7.45
VFS 2000 Hz

Resolution best-case error (C) 7.45 24.8 nV
Resolution worst-case error (C) 7.45 24.8 nV
Total error
Best-case error RMS (A + B + C) 1011424 0.0033
Worst-case error SUM (A + B + C) 4332566 0.0144

Table 4 shows that the worst-case error using a discrete amplifier is 14.4 mV. The gain error and noise
voltage affect the AC performance and contribute an error of 36 V in the output.

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4.3 INA199 AmplifierError Budgeting

Achieving a better performance requires an integrated precision amplifier. The INA199 is one example of
the zero-drift, low-power, integrated resistor difference amplifiers that can be used to monitor current
shunts in this design.
This amplifier comes with gain variants of 50,100, and 200. The lower offset voltage of 150 V and typical
gain error of 0.03% makes this amplifier a better solution for first-stage amplification. With a lower burden
resistance of 0.1 and a lower secondary current, the slew rate of 0.4 V/s is suitable for detecting high-
current amplitude faults.
Table 5 shows that the worst-case error using the INA199 amplifier is 156 V as compared to the 14.4 mV
when using a discrete solution (as shown in Table 4).
The error contributed by gain error, gain drift, gain nonlinearity, and noise voltage is 4.1 V. Using the
INA199 amplifier is the best choice to achieve better accuracy with low power and cost.

Table 5. Error Budgeting for INA199Full-Scale Voltage 3.33 mV

REFERENCE ERROR VOLTAGE
PARAMETER EQUATION VALUE UNIT
NO (PPM) ERROR
Absolute error
Vos 6
1 Offset voltage 10 0.000150 V 45004
VFS

Input offset Ios (R + + R - + RBurden ) 6 0.0000000

2
current error V 10 2
A 12
FS


VCM
CMRR (dB )
10
20 6
0.000002
3 CMRR 10 VCM = V 625
VFS 0.208





4 Gain error Gain error % 104 0.03 % 300
Absolute best-case error RMS (A) 22504 0.000075
Absolute worst-case error SUM (A) 45941 0.00153
Drift error
PPM
5 Gain drift Gain Drift (TempMAX - 25 ) 10 ppm 600
C
Drift best-case error RMS (B) 600 1.98 V
Drift worst-case error SUM (B) 600 1.98 V
Resolution
Gain Gain nonlinearity in ppm
6 1 ppm 1
nonlinearity
ENI(RMS) Bandwidth 25 nV
7 Noise voltage 106 335.44
VFS 2000 Hz

Resolution best-case error RMS (C) 237 780 nV
Resolution worst-case error SUM (C) 336 1.1 V
Total error
Resolution best-case error RMS (A + B + C) 17012 56 V
Resolution worst-case error SUM (A + B + C) 46878 156 V

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4.4 Reference for DC Biasing

Most of the integrated analog-to-digital converter (ADC) of the MSP430 microcontroller (MCU) has a
very low reference voltage, which limits the wide dynamic current measurement range; for example, the
MSP430I2041 device with an integrated 24-bit delta-sigma () ADC has an input range of 928 mV
(peak) for an interval reference of 1.5 V (max) and gain of 1X. Achieving a wide measurement range
requires an external reference in this case. Bipolar input signal measurement using a single-supply rail for
the INA199 amplifier requires an external reference chip to provide the DC bias voltage.
The REF3212 device has been used in the TIDA-00753 design to obtain very low drift in measurements.
The REF3212 is a series voltage reference of 1.25 V and has an accuracy of 0.01% and drift of 4 ppm.
As Table 6 shows, the worst-case error in a DC level change is 5.5 mV, as compared to 39.1 mV of the
REF2912 reference.

Table 6. REF3212 Error Budgeting

REF3212 REF2912
PARAMETER
VALUE PPM VALUE PPM
Initial accuracy 0.20 2000 2 20000
Noise voltage for
0.000039 2206.173157 0.00019 10748.02
bandwidth of 5 KHz
Temperature drift (PPM) 20 100
Thermal hysteresis
100 100
(PPM)
Line regulation (PPM/V) 65 410
Worst case (PPM) 4391.17 31358.02
Worst case (V) 0.005488966 0.039198

Depending on the requirements of the application, the reference used in this design can either be a simple
voltage divider with a buffer (see Figure 10) or a reference chip such as REF2030 or REF2912.

Figure 10. DC Reference

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5 Getting Started Hardware

The design is ready to operate directly out of the box. The required test point has been populated for
measuring signals at each interface point of the design. Refer to Table 7 for more details.

Table 7. Test Points

TEST POINT NO DESCRIPTION VOLTAGE RANGE
TP14 VCC 3.3 V
TP13 VREF 1.25 V
TP1 to TP4 Voltage across burden resistor for channel 1 0 mV to 3.3 mV (RMS)
TP5 to TP11 Voltage across burden resistor for channel 2 0 mV to 3.3 mV (RMS)
TP6 to TP12 Voltage across burden resistor for channel 3 0 mV to 3.3 mV (RMS)
TP2 Output voltage for channel 1 w.r.t. TP13 0 mV to 667 mV (RMS)
TP7 Output voltage for channel 2 w.r.t. TP13 0 mV to 667 mV (RMS)
TP8 Output voltage for channel 3 w.r.t.TP13 0 mV to 667 mV (RMS)
TP3, TP9, TP10, and TP19 GND 0V

NOTE: Before turning on the power supply and test equipment, make sure that the secondary of the
current transformer has been connected to the input connectors J2, J5, and J6.

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6 Test Setup
The test setup consists of the TIDA-00753 board, Keithley DC supply, Agilent 6 digital multimeter
(DMM), MTE current source, and TDK current transformer, as Figure 11 shows.

Figure 11. TIDA-00753 Test Setup

The TIDA-00753 design requires performing the following tests:

Testing the % voltage error across the burden resistor of 0.1 , 1 , and 10 at the full-scale primary
current
Testing the voltage at the difference amplifier output for channel 1 for the primary current range of 1 A
to 100 A
Testing the above conditions requires setting the Agilent 6 DMM with the following settings to average
the source and instrument errors:
Medium filter 1 seconds/reading
Number of samples 60 (approximately 1 minute)

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7 Test Results

7.1 Test Table

7.1.1 Burden Resistor Error

As Table 8 shows, the test results for the accuracy across the CT for burden resistors (0.1 , 1 , and
10 ) show that the measurement error increases as the burden resistor value increases.

Table 8. Voltage Error

BURDEN RESISTOR
REFERENCE OBSERVED % VOLTAGE ERROR PRIMARY
ACROSS CURRENT IDEAL VOLTAGE (V)
NO VOLTAGE (V) CURRENT = 100 A
TRANSFORMER
1 0.1 0.003335 0.003334 0.02999
2 1 0.03335 0.03339 0.11994
3 10 0.3335 0.332445 0.31634

7.1.2 Linearity for 0.1- Burden at 25C

0.7 0.7
Observed Output Voltage at INA199 Output (V)

0.6 0.6
Ideal Voltage at INA199 Output (V)

0.5 0.5

0.4 0.4

0.3 0.3
Y = 0.0067x Y = 0.0067x - 0.0002

0.2 0.2

0.1 0.1

0 0
0 20 40 60 80 100 120 0 20 40 60 80 100 120
Input Primary Current (A) D001
Input Primary Current (A) D002

Figure 12. Ideal Linearity Figure 13. Observed Linearity

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7.1.3 Linearity for 0.1- Burden at 85C

0.7 0.7

0.6 0.6

Observed Voltage at INA199 Output (V)

Ideal Voltage at INA199 Output (V)

0.5 0.5

0.4 0.4

0.3 0.3
Y = 0.0067x Y = 0.0066x - 0.0003

0.2 0.2

0.1 0.1

0 0
0 20 40 60 80 100 120 0 20 40 60 80 100 120
Input Primary Current (A) D001
Input Primary Current (A) D001

Figure 14. Ideal Linearity Figure 15. Observed Linearity

7.1.4 Linearity for 0.1- Burden at 25C

0.7 0.7

0.6 0.6
Observed Voltage at INA199 Output (V)
Ideal Voltage at INA199 Output (V)

0.5 0.5

0.4 0.4

0.3 0.3
Y = 0.0067x Y = 0.0066x + 0.0002

0.2 0.2

0.1 0.1

0 0
0 20 40 60 80 100 120 0 20 40 60 80 100 120
Input Primary Current (A) D001
Input Primary Current (A) D007

Figure 16. Ideal Linearity Figure 17. Observed Linearity

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7.1.5 Voltage Error at INA199 Output for Current Range of 5 A to 100 A (25C Uncalibrated)
0
% INA199 Voltage Error With Respect to Ideal Voltage

-0.1

-0.2

-0.3

-0.4

-0.5

-0.6
0 20 40 60 80 100 120
Input Primary Current (A)
D004

Figure 18. % Voltage Error at 25C

7.1.6 INA199 Output %Voltage Error for Current Range of 5 A to 100 A (85C Uncalibrated)
0
% INA199 Voltage Error With Respect to Ideal Voltage

-0.2

-0.4

-0.6

-0.8

-1

-1.2

-1.4
0 20 40 60 80 100 120
Input Primary Current (A) D005

Figure 19. % Voltage Error at 85C

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7.1.7 INA199 Output %Voltage Error for Current Range of 5 A to 100 A (25C Uncalibrated)
0
% INA199 Voltage Error With Respect to Ideal Voltage

-0.2

-0.4

-0.6

-0.8

-1

-1.2
0 20 40 60 80 100 120
Input Primary Current (A) D006

Figure 20. % Voltage Error at 25C

7.2 Timing Plots

Figure 21. Output at INA199 for 1-A Primary Current Figure 22. Output at INA199 for 100-A Primary Current

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8 Design Files

8.1 Schematics
To download the schematics, see the design files at TIDA-00753.

8.2 Bill of Materials

To download the bill of materials (BOM), see the design files at TIDA-00753.

8.3 PCB Layout Recommendations

The PCB layout recommendation is driven by low electromagnetic interference (EMI) and good thermal
performance. The layout has been implemented on a two-layer board with 1-oz copper. Figure 23 shows
the current path for the kelvin connection of burden resistor R3. The trace length between R3 and U1
(INA199) must be evenly matched to reduce the common-mode voltage error.

Figure 23. Burden Resistance and INA199 Placement

8.3.1 Layout Prints

To download the layer plots, see the design files at TIDA-00753.

8.4 Altium Project

To download the Altium project files, see the design files at TIDA-00753.

8.5 Gerber Files

To download the Gerber files, see the design files at TIDA-00753.

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9 References
1. Texas Instruments, INA199 26-V, Bidirectional, Zero-Drift, Low- or High-Side, Voltage Output Current
Shunt Monitor, INA199 Datasheet (SBOS469)
2. Texas Instruments, TPS717 Low-Noise, High-Bandwidth PSRR, Low-Dropout, 150-mA Linear
Regulator, TPS717 Datasheet (SBVS068)
3. Texas Instruments, 4ppm/C, 100A, SOT23-6 SERIES VOLTAGE REFERENCE, REF32xx Datasheet
(SBVS058)
4. CR MAGNETICS, Calculating Ratio Errors: UNDERSTANDING CURRENT TRANSFORMER RATIO
ERROR AND EXCITATION CURVES, Technical Reference
(http://www.crmagnetics.com/assets/technical-references/calculating_ratio_errors.pdf)

10 About the Author

Any other important terminology referred to in this documentation.
SRINIVASAN IYER is a Systems Engineer at Texas Instruments India where he is responsible for
developing reference design solutions for the building automation applications. Srinivasan has five years
of experience in analog circuit designs for field transmitter and signal chain.
MIROSLAV OLJACA is the End Equipment Lead for building automation applications and system
solutions. Miro has nearly 30 years of engineering experience and has been granted at least a dozen
patents, several related to high performance signal processing, and he has written many articles on the
subject. Miro received his BSEE and MSEE from the University of Belgrade, Serbia.

TIDUBK3A April 2016 Revised July 2016 Three-Phase AC Current Measurement Using Current Transformer 21
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22 Revision History TIDUBK3A April 2016 Revised July 2016

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