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CURRENT SENSORS
TECHNICAL GUIDE & SPECIFICATIONS

Standard & Custom AC Current Sensors for OEM Applications

BICRON Electronics Company

The BICRON Advantage . . .

ISO 9001 Certified A leader in electronic design and manufacturing since 1964 State-of-the-art engineering development tools offering: Finite element analysis Circuit simulation Products designed to meet national and international safety standards AY
D E CR L

Current transformers with window 2 sizes from 0.02 LYto 350 in and P current ratings UP to 10,000A S DC Long history servicing many of the Fortune 500 companies Capabilities to design/manufacture value added assemblies
BICRON Electronics Company

Our goal is to exceed our customers expectations by constantly seeking better ways to deliver service and value.

50 Barlow Street, Canaan, CT 06018 Tel: 860-824-5125, Fax: 860-824-1137 email: info@currentsensor.com or: info@BicronUSA.com

BICRON Electronics Company

Solutions for AC Current Sensing
PAGE

ISO9001 Certified
Bicron current sensors provide important advantages: Low cost AC current sensing Simple electronic interface Electrically isolated output No external power requirements Small size and weight Printed circuit board mounting Extreme reliability High linearity High repeatability U.S. and international safety recognitions Wide choice of configurations Current sensors are the simple, low cost and reliable solution to many design problems: Current measurements and control Power demand measurements Current signature of motors Load sensing

3 6 7 8

Product Guide . . . Choose Optimal Solutions Sensor Fundamentals . . . Important Background Sensor Applications . . . Typical Circuits & Uses Special Designs . . . Benefit From Our Experience

4 5 Product Specifications . . . Define The Details

Need help? Call our design and sales engineers 800-624-2766 or 860-824-5125

Bicrons Special Permeability (SP) Cores offer important advantages:

Improved Performance Over a Wide Temperature Range. Bicrons Current Sensors offer excellent stability over the temperature range of -35C to +80C. Improved Low Level Performance After Exposure to DC Shock A DC shock will leave most current sensors magnetized because of core hysteresis. This greatly limits performance, especially at low signal levels. Bicrons Current Sensors were designed to maintain a high permeability at levels as low as 1% of the CTs operating range. Minimal Phase Angle (Iprimary vs Isecondary) Typical phase lag, Ip/Is, will be less than one degree, making Bicron Current Sensors ideal for power measurement applications. Excellent Coupling of Primary and Secondary Currents The toroid is one of the most efficient geometries in magnetic design, offering very little leakage flux.

Bicrons Grain Oriented Silicon Steel (GOSS) Cores are the choice for high output voltages.
GOSS cores provide high output voltages suitable for selfpowered, remote sensing.

Hi Vo gh O lta u ge tpu t

Te S e mp e ns ra iti tu vit re y

Lo Re w E so nd lut ion

ur ac y

ea

Co st

rit

Ground fault sensing Monitoring of process parameters

Excellent Good Acceptable Poor

BICRON SP* Toroid Core

* Special Permeability

Lo w

Ac c

Lin

Status of lamps, heaters, etc. Power failure Loss of device

GOSS* Toroid Core

* Grain Oriented Silicon Steel

Laminated Core Ferrite Core

Current Sensor Selection Guide (See pages 4 & 5 for detailed specifications.)
Current Range (ARMS)
(CORE MATERIAL)

05
(SP)

0 20
(SP)

0 50
(SP)

0100
(SP)

0 30
(GOSS)

0 50
(GOSS)

0 50
(GOSS)

0 200
(GOSS)

VoutRMS Turns Ratio Part Number (PC Mount) Part Number (Leads)

0.1 200:1 EX9PA050 XXXX

1.0 2000:1 EX9PC200 EX9LC200

0.45 1100:1 EX9PC500 EX9LC500

0.5 1000:1 EX9PE101 EX9LE101

3.0 1000:1 EX9PC300 EX9LC300

10.0 1600:1 EX9PP500 EX9LP500

5.0 1000:1 EX9PG500 EX9LG500

10.0 5000:1 XXXX B5303*

Bold: Factory Stock Item Italic: Check with Factory XXXX: Not Available

* UL Recognized for indoor applications

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BICRON Electronics Company

CURRENT SENSOR SPECIFICATIONS Current Range (ARMS)
(CORE MATERIAL)

ISO9001 Certified

05
(SP)

0 20
(SP)

0 50
(SP)

0100
(SP)

0 30
(GOSS)

0 50
(GOSS)

0 50
(GOSS)

0 200
(GOSS)

VoutRMS Turns Ratio DCR (Ohms) Ratio Error (%) Frequency (Hz) Overload Current (ARMS) Ambient (C) Part Number (Leads) ID OD Thickness Lead Gauge Lead Length Part Number (PC Mount) ID Height Length Width Pinout

0.1 200:1 1.6 5.0 47 400 20 -35 to +80 XXXX na na na na na EX9PA050 0.15 (3.8) 1.11 (28.2) 0.77 (19.6) 0.48 (12.2) Fig. #1

1.0 2000:1 130.0 4.0 47 400 30 -35 to +80 EX9LC200 0.40 (10.2) 1.1 (27.9) 0.38 (9.7) #22 24 (610) EX9PC200 0.40 (10.2) 1.25 (31.2) 1.05 (26.7) 0.68 (17.2) Fig. #2

0.45 1100:1 18.0 3.0 47 400 75 -35 to +80 EX9LC500 0.31 (7.9) 1.1 (27.9) 0.40 (10.2) #22 24 (610) EX9PC500 0.31 (7.8) 1.25 (31.2) 1.07 (27.2) 0.68 (17.2) Fig. #2

0.5 1000:1 8.3 2.0 47 400 110 -35 to +80 EX9LE101 0.56 (14.2) 1.58 (40.1) 0.45 (11.4) #22 24 (610) EX9PE101 0.56 (14.2) 1.64 (41.7) 1.58 (40.1) 0.63 (15.9) Fig. #3

3.0 1000:1 19.0 3.0 47 400 50 -35 to +80 EX9LC300 0.48 (12.2) 1.1 (27.9) 0.44 (11.2) #18 36 (914) EX9PC300 0.48 (12.2) 1.25 (31.2) 1.05 (26.7) 0.68 (17.2) Fig. #2

10.0 1600:1 63.0 4.0 47 400 75 -35 to +80 EX9LP500 0.40(10.2) 1.25 (31.8) 0.46 (11.7) #22 24 (610) EX9PP500 0.40 (10.2) 1.37 (34.8) 1.2 (30.5) 0.68 (17.2) Fig. #2

5.0 1000:1 16.6 3.0 47 400 60 -35 to +80 EX9LG500 0.78 (19.8) 1.45 (36.8) 0.42 (10.7) #18 20 (508) EX9PG500 0.78 (19.8) 1.51 (38.4) 1.45 (36.8) 0.63 (15.9) Fig. #3

10.0 5000:1 210.0 2.0 50 400 300 -35 to +80 B5303 0.7 (17.8) 2.0 (50.8) 0.8 (20.3) #24 12 (305) XXXX na na na na na

Bold: Factory Stock Item Italic: Check with Factory XXXX: Not Available All Sizes shown in inches (mm)

Data subject to change.

.77 (19.6)

Length

Length

OD

1.11 (28.2)

.15 (3.8) dia.

Height

ID

Height

ID

ID

.20/.15 (5.1/3.8)

.03 (.76) sq. .03 (0.8) .04 (1.0)

2

.15 (3.8) .05 (1.3) .80 (20.3)

1

.20 (5.1)

Thickness

.30 3 (7.62) .68 (17.2)

.60 (15.2)
1 2

Lead Length .40 (10.2)

.48 (12.2) .50 (12.7)

.29 (7.4)
1 4

.25 (6.4)
4

.63 (16)
3 4

.71 (18.0)

1.25 (31.8)
2 1 2

Ip

Ip

Ip

Fig. #1

Fig. #2

Fig. #3

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BICRON Electronics Company

CURRENT SENSOR PERFORMANCE INFORMATION
BICRON SPECIAL PERMEABILITY (SP) CORES
Output Voltage vs. Buss Current:
0.12
8

ISO9001 Certified
BICRON GRAIN ORIENTED SILICON STEEL (GOSS) CORES
Output Voltage vs. Buss Current:
4.0

0 5A
Output Voltage Vs (Volts)
4

0 30A
200 150

Output Voltage Vs (Volts)

0.10 0.08 0.06 0.04 0.02 0.00 0

20

3.5

Rati o Er ror 5%

7%

3.0 2.5 2.0 1.5 1.0 0.5

Er ro r

Ra tio

Ra tio

tio Ra

or Err

5%

Er ro r

r ro Er io t Ra

io Rat

or Err

3%

100

EX9PA050
1.0 3.0 Buss Current Ip (Amps) 2.0 4.0 5.0

EX9LC300 / EX9PC300
0.0 0 5 10 15 20 25 30

Buss Current Ip (Amps) Output Voltage vs. Buss Current:

15

Output Voltage vs. Buss Current:

1.8
700

0 20A
Output Voltage Vs (Volts)

0 50A
600

800

4%

Output Voltage Vs (Volts)

ro r

300

6%

1.6

Rat io E rror

1.4 1.2 1.0 0.8 0.6 0.4 0.2 0.0 0

Er ro r

4%

12

r rro oE i t a

Ra tio

4%

Ra tio

167 100

tio Ra

r ro Er

5%

4% r rro E 400 o ati

r io E Rat

ro

% r4

Er

EX9LC200 / EX9PC200
5 10 15 20

0 0 10 20

EX9LP500 / EX9PP500
30 40 50

Buss Current Ip (Amps) Output Voltage vs. Buss Current:

Buss Current Ip (Amps) Output Voltage vs. Buss Current:

10
300

0.70 0.60

0 50A
Output Voltage Vs (Volts)

0 50A
200

24

Output Voltage Vs (Volts)

3%

Er ro r

Er ro r

0.50 0.40 0.30 0.20 0.10 0.00 0 10

8%

15

Ra tio

r rro oE i t a

3%
r rro io E Rat % 3
10

rro oE ati

Ra tio

5%
100

ror o Er Rati

3%

EX9LC500 / EX9PC500
30 Buss Current Ip (Amps) 20 40 50

0 0 10 20

EX9LG500 / EX9PG500
30 40 50

Buss Current Ip (Amps) Output Voltage vs. Buss Current:

10
500

Output Voltage vs. Buss Current:

1.0
20

0 100A
Output Voltage Vs (Volts)

0 200A
333 250

2 %

2%

Output Voltage Vs (Volts)

Ra tio Er ro r

0.8

Er ro r

0.6

R
0.4

r rro oE i t a

10

Ra tio

2%

tio Ra

r ro Er

2%

r rro oE i t a

2%

Er Ratio

ror

2%
5

0.2

0.0 0 20 40

EX9LE101 / EX9PE101
60 80 100

B5303
0 0 50 100 150 200

Buss Current Ip (Amps)

Buss Current Ip (Amps)

Data subject to change.

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BICRON Electronics Company

CURRENT SENSOR FUNDAMENTALS Introduction
Current transformers are used to measure or monitor the current in an AC power circuit.
Flux Density Gauss

ISO9001 Certified

Typical Core Loss vs. Flux Density Graph.

10,000

The ratio of the primary current to the secondary current is a function of the turns ratio and the loss associated with the conversion. For example, copper losses in a voltage transformer affect the voltage regulation. In a current transformer, copper losses cause an increase in core loss, or a reduction in accuracy. Accuracy ISN2 IPN1 IMN1 the secondary current the number of turns primary current the number of turns ampere-turns required for core loss

1,000

100

10 110-6 110-5 110-4 110-3 110-2 110-1

Core Loss Watts Per Pound

Where: ISN2 IPN1 IMN1

Excitation Current = (Reflected to Primary) core loss secondary voltage N1/N2

Where core loss = watts/lb lb of core

The excitation current, (IM), determines the maximum accuracy that can be achieved with a current transformer. This current is defined as that portion of the primary current which satisfies the core losses. While the excitation current can never be eliminated, it can, in some cases, be compensated by adjusting the turns ratio. If it were not for the core losses, the primary and secondary currents would be exactly inversely proportional to the number of turns in the two windings. The error due to leakage flux is negligible in most current transformers using toroidal cores, and utilizing proper winding methods. Burden The total impedance of the devices connected to the secondary terminals (leads, meters, relay coil, resistance, etc.) of a current transformer is defined as its burden. Burden is expressed in voltamperes (VA) or in ohms impedance. Burden resistance should be kept as low as possible, since an increase in burden increases the core flux density (B), thereby increasing the core loss. Utilizing Faraday's Law: B 108 IS(R WR) 4.44 f N2 AC secondary current (amps) burden (ohms) winding resistance frequency (Hz) turns cross section area (cm2) flux density (Gauss)

Ratio-Correction Factor The ratio-correction factor indicates the percentage amount that the secondary current value differs from the correct value. Phase Angle Error The phase angle error is not applicable to current actuated devices but will affect the accuracy of devices that respond to the products, the sums or difference of currents.
Phase Angle lp = 3000 ls = 5

Polarity Current transformer polarity can be defined by permanent markings (typically H1 X1) or polarity dots.
H1

X1

Short-Time Current Limits Current transformers may have to carry very large currents in the event of short circuit, motor starting, etc. The windings heat very rapidly at a rate nearly proportional to the square of the current.The majority of the heat will be stored in the copper. The short-time current limit is the time to raise the temperature of the winding to 105C, considering ambient temperature.

Where: IS R WR f N2 AC B

Continues on Page 7 >

Note: IS ( IPN1 IMN1)/ N2

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BICRON Electronics Company

CURRENT SENSOR FUNDAMENTALS
Current Transformer Ratio The relationship of ratio to turns is expressed in the formula: Ka (Kn Nsa)/NP new transformation ratio nameplate ratio number of secondary turns added or subtracted number of primary turns

ISO9001 Certified

CURRENT MONITOR CONTACT OUTPUT (SELF POWERED)

Where: Ka Kn Nsa Np

The following diagram shows various ways to adjust the turns ratio using primary and secondary turns.

CURRENT SENSOR

DC SUPPLY

DC RELAY

LOSS OF CURRENT INDICATOR

L.E.D.

Single Primary Turn

Two Primary Turns

Single Primary Single Primary Turn & Bucking Turn & Aiding Secondary Turn Secondary Turn

CURRENT SENSOR

VECTOR SUM OF n CURRENTS

For example, consider a CT with 1200:5 nameplate rating with three primary bucking turns and two secondary bucking turns (passed through window so that the generated flux is opposing): Kn 1200/5 240 Ka( 2402)/3 79.3/1396.66:5 Ka = 396.66 amps in primary provides 5 amps in secondary when configured per example. Consider the two secondary turns passed through the window in the other direction (adding),in this case,the ratio obtained would be: Ka( 2402)/3 80.66/1 403.33:5 Safety Precautions The secondary winding should always be loaded. If the secondary circuit is opened with primary current flowing, all the primary ampereturns become magnetizing ampere-turns and usually will produce an excessively high secondary voltage across the open circuit. Magnetization of the core, due to excessive fault currents or accidental open circuiting of the secondary, has the effect of increasing the ratio errors.
CURRENT SENSOR DC SUPPLY

ERMS

CURRENT SENSOR

SIGNAL CONDITIONER, 0 10Vdc OUTPUT

Vdc OUT

REGULATOR

Vdc OUT = 2-2 (VS 2VD VR) WHERE VS = 2IPRS104

4 20mA TRANSMITTER
+Vcc 0 10Vdc 4 20mA ZERO SPAN 250 OHMS

The diagrams to the right show application of current sensors to typical electrical circuits. Self-powered devices, as shown in the first diagram, would normally employ high voltage output sensors such as the B5303, EX9LP500,or the EX9LG500.

INSTRUMENT AMP

REMOTE LOCATION

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BICRON Electronics Company

Since our inception in 1964, Bicron Electronics has been a leader in designing and manufacturing coil based electrical products and assemblies to meet specific requirements. Today Bicron is a preferred supplier of specialized current sensors to many of the worlds largest and best known electrical equipment manufacturers. Our manufacturing program includes window sizes up to 350 square inches with current ratings up to 10,000A and current ratios from 10:1 to 6000:5. Bicron current sensors are UL recognized for indoor application. Because of our extensive design and manufacturing experience, we have a very large collection of proven designs which can be used as starting points for meeting closely related new requirements. Bicrons Modified Standard program permits us to substantially modify our standard electrical and mechanical specifications without incurring significant engineering or manufacturing charges. This allows you to optimize your system without delay, at the lowest possible cost.

ISO9001 Certified

UL recognized ground fault sensor with a 66 sq. in. window used in distribution switchgear

Current transformer designed for motor control applications

VALUE-ADDED ASSEMBLIES
Bicron can also be of great value when it comes to providing finished assemblies or sub-assemblies. We can: Custom design and fabricate, typically, power supplies and conditioning equipment, battery chargers, current monitoring or control systems, and sub-assemblies utilizing electromechanical/electromagnetic devices such as solenoids, transformers, inductors and coils. Produce virtually any quantity you need . . . from less than a hundred to hundreds of thousands . . . all at globally competitive pricing. Ensure highest quality and reliability, efficient workflow, very competitive pricing, and on-time delivery through the use of the well proven Bicron Production Management System. Exceed our customersexpectations by constantly seeking better ways to deliver service and value.

UL recognized current transformers with window sizes up to 35 sq, in.

Current sensor with a multiple turn primary for a special industrial control application

UL recognized current transformers with window sizes from 1 to 3.25 in. dia.

ADDITIONAL CAPABILITIES
Bicron is well known for its expertise in designing and manufacturing electrical coil based products covering a wide range of applications: Bicron Toroidal Power and Isolation Transformers Bicron High Isolation Voltage Magnetics Bicron Tubular and Frame DC Solenoids Please ask for specific literature or visit our web site at www.BicronUSA.com.

Three-phase current transformer assembly used in high voltage switchgear

Value-added Assembly

Limitation of Applicable Liability: Bicron Electronics Company assumes the buyer to be an expert in his intended application of Bicron Electronics products. Bicron Electronics claims no special expertise in the application of its products in the buyers equipment. Bicron Electronics accepts no responsibility in the buyers selection and use of Bicron Electronics products. Buyers interpretation and implementation of application suggestions and recommendations by Bicron Electronics, general or specific, transmitted verbally or in writing, published or unpublished, is strictly at the buyers own risk.

BICRON Electronics Company

50 Barlow Street, Canaan, CT 06018 Tel: 860-824-5125, 1-800-624-2766 Fax: 860-824-1137 email: info@currentsensor.com.com For fast, up to date information and complete product data sheets, visit our web site at www.currentsensor.com .
072001 - 12504