Three-phase power systems

Three-phase/Poly phase/Three-wire DC system

Split-phase power systems achieve their high conductor efficiency and low safety risk by splitting up the total voltage into lesser parts and powering multiple loads at those lesser voltages, while drawing currents at levels typical of a full-voltage system. This technique, by the way, works just as well for DC power systems as it does for single-phase AC systems. Such systems are usually referred to as three-wire systems rather than split-phasebecause "phase" is a concept restricted to AC.

But we know from our experience with vectors and complex numbers that AC voltages don't always add up as we think they would if they are out of phase with each other. This principle, applied to power systems, can be put to use to make power systems with even greater conductor efficiencies and lower shock hazard than with split-phase.

Suppose that we had two sources of AC voltage connected in series just like the split-phase system we saw before, except that each voltage source was 120^o out of phase with the other:

Since each voltage source is 120 volts, and each load resistor is connected directly in parallel with its respective source, the voltage across each load must be 120 volts as well. Given load currents of 83.33 amps, each load must still be dissipating 10 kilowatts of power. However, voltage between the two "hot" wires is not 240 volts (1200° - 120180^o) because the phase difference between the two sources is not 180^o. Instead, the voltage is:

Nominally, we say that the voltage between "hot" conductors is 208 volts (rounding up), and thus the power system voltage is designated as 120/208.

If we calculate the current through the "neutral" conductor, we find that it is not zero, even with balanced load resistances. Kirchhoff's Current Law tells us that the currents entering and exiting the node between the two loads must be zero:

So, we find that the "neutral" wire is carrying a full 83.33 amps, just like each "hot" wire.

Note that we are still conveying 20 kW of total power to the two loads, with each load's "hot" wire carrying 83.33 amps as before. With the same amount of current through each "hot" wire, we must use the same gage copper conductors, so we haven't reduced system cost over the split-phase 120/240 system. However, we have realized a gain in safety, because the overall voltage between the two "hot" conductors is 32 volts lower than it was in the split-phase system (208 volts instead of 240 volts).

The fact that the neutral wire is carrying 83.33 amps of current raises an interesting possibility: since it's carrying current anyway, why not use that third wire as another "hot" conductor, powering another load resistor with a third 120 volt source having a phase angle of 240^o? That way, we could transmit more power (another 10 kW) without having to add any more conductors. Let's see how this might look:

Superposition Theorem Theorem, Superposition

A full mathematical analysis of all the voltages and currents in this circuit would necessitate the use of a network theorem, the easiest being the Superposition Theorem. I'll spare you the long, drawn-out calculations because you should be able to intuitively understand that the three voltage sources at three different phase angles will deliver 120 volts each to a balanced triad of load resistors. For proof of this, we can use SPICE to do the math for us:

120/208 polyphase power system
v1 1 0 ac 120 0 sin
v2 2 0 ac 120 120 sin
v3 3 0 ac 120 240 sin
r1 1 4 1.44
r2 2 4 1.44
r3 3 4 1.44
.ac lin 1 60 60
.print ac v(1,4) v(2,4) v(3,4)
.print ac v(1,2) v(2,3) v(3,1)
.print ac i(v1) i(v2) i(v3)
.end


VOLTAGE ACROSS EACH LOAD
freq        v(1,4)      v(2,4)      v(3,4)
6.000E+01   1.200E+02   1.200E+02   1.200E+02

VOLTAGE BETWEEN "HOT" CONDUCTORS
freq        v(1,2)      v(2,3)      v(3,1)
6.000E+01   2.078E+02   2.078E+02   2.078E+02

CURRENT THROUGH EACH VOLTAGE SOURCE
freq        i(v1)       i(v2)       i(v3)
6.000E+01   8.333E+01   8.333E+01   8.333E+01

Sure enough, we get 120 volts across each load resistor, with (approximately) 208 volts between any two "hot" conductors and conductor currents equal to 83.33 amps. At that current and voltage, each load will be dissipating 10 kW of power. Notice that this circuit has no "neutral" conductor to ensure stable voltage to all loads if one should open. What we have here is a situation similar to our split-phase power circuit with no "neutral" conductor: if one load should happen to fail open, the voltage drops across the remaining load(s) will change. To ensure load voltage stability in the even of another load opening, we need a neutral wire to connect the source node and load node together:

So long as the loads remain balanced (equal resistance, equal currents), the neutral wire will not have to carry any current at all. It is there just in case one or more load resistors should fail open (or be shut off through a disconnecting switch).

Polyphase Three-phase

This circuit we've been analyzing with three voltage sources is called a polyphase circuit. The prefix "poly" simply means "more than one," as in "polytheism" (belief in more than one deity), polygon" (a geometrical shape made of multiple line segments: for example, pentagon and hexagon), and "polyatomic" (a substance composed of multiple types of atoms). Since the voltage sources are all at different phase angles (in this case, three different phase angles), this is a "polyphase" circuit. More specifically, it is a three-phase circuit, the kind used predominantly in large power distribution systems.

Let's survey the advantages of a three-phase power system over a single-phase system of equivalent load voltage and power capacity. A single-phase system with three loads connected directly in parallel would have a very high total current (83.33 times 3, or 250 amps:

This would necessitate 3/0 gage copper wire (very large!), at about 510 pounds per thousand feet, and with a considerable price tag attached. If the distance from source to load was 1000 feet, we would need over a half-ton of copper wire to do the job. On the other hand, we could build a split-phase system with two 15 kW, 120 volt loads:

Our current is half of what it was with the simple parallel circuit, which is a great improvement. We could get away with using number 2 gage copper wire at a total mass of about 600 pounds, figuring about 200 pounds per thousand feet with three runs of 1000 feet each between source and loads. However, we also have to consider the increased safety hazard of having 240 volts present in the system, even though each load only receives 120 volts. Overall, there is greater potential for dangerous electric shock to occur.

When we contrast these two examples against our three-phase system, the advantages are quite clear. First, the conductor currents are quite a bit less (83.33 amps versus 125 or 250 amps), permitting the use of much thinner and lighter wire. We can use number 4 gage wire at about 125 pounds per thousand feet, which will total 500 pounds (four runs of 1000 feet each) for our example circuit. This represents a significant cost savings over the split-phase system, with the additional benefit that the maximum voltage in the system is lower (208 versus 240).

One question remains to be answered: how in the world do we get three AC voltage sources whose phase angles are exactly 120^o apart? Obviously we can't center-tap a transformer or alternator winding like we did in the split-phase system, since that can only give us voltage waveforms that are either in phase or 180^o out of phase. Perhaps we could figure out some way to use capacitors and inductors to create phase shifts of 120^o, but then those phase shifts would depend on the phase angles of our load impedances as well (substituting a capacitive or inductive load for a resistive load would change everything!).

Alternator Generator

The best way to get the phase shifts we're looking for is to generate it at the source: construct the AC generator (alternator) providing the power in such a way that the rotating magnetic field passes by three sets of wire windings, each set spaced 120^o apart around the circumference of the machine:

Pole, alternator

Together, the six "pole" windings of a three-phase alternator are connected to comprise three winding pairs, each pair producing AC voltage with a phase angle 120^o shifted from either of the other two winding pairs. The interconnections between pairs of windings (as shown for the single-phase alternator: the jumper wire between windings 1a and 1b) have been omitted from the three-phase alternator drawing for simplicity.

Y configuration Star configuration

In our example circuit, we showed the three voltage sources connected together in a "Y" configuration (sometimes called the "star" configuration), with one lead of each source tied to a common point (the node where we attached the "neutral" conductor). The common way to depict this connection scheme is to draw the windings in the shape of a "Y" like this:

The "Y" configuration is not the only option open to us, but it is probably the easiest to understand at first. More to come on this subject later in the chapter.

Summery

A single-phase power system is one where there is only one AC voltage source (one source voltage waveform).
A split-phase power system is one where there are two voltage sources, 180o phase-shifted from each other, powering a two series-connected loads. The advantage of this is the ability to have lower conductor currents while maintaining low load voltages for safety reasons.

A polyphase power system uses multiple voltage sources at different phase angles from each other (many "phases" of voltage waveforms at work). A polyphase power system can deliver more power at less voltage with smaller-gage conductors than single- or split-phase systems. 

The phase-shifted voltage sources necessary for a polyphase power system are created in alternators with multiple sets of wire windings. These winding sets are spaced around the circumference of the rotor's rotation at the desired angle(s).

Construction and measuring concept of Multimeters

Multimeters

Seeing as how a common meter movement can be made to function as a voltmeter, ammeter, or ohmmeter simply by connecting it to different external resistor networks, it should make sense that a multi-purpose meter ("multimeter") could be designed in one unit with the appropriate switch(es) and resistors.

For general purpose electronics work, the multimeter reigns supreme as the instrument of choice. No other device is able to do so much with so little an investment in parts and elegant simplicity of operation. As with most things in the world of electronics, the advent of solid-state components like transistors has revolutionized the way things are done, and multimeter design is no exception to this rule. However, in keeping with this chapter's emphasis on analog ("old-fashioned") meter technology, I'll show you a few pre-transistor meters.

The unit shown above is typical of a handheld analog multimeter, with ranges for voltage, current, and resistance measurement. Note the many scales on the face of the meter movement for the different ranges and functions selectable by the rotary switch. The wires for connecting this instrument to a circuit (the "test leads") are plugged into the two copper jacks (socket holes) at the bottom-center of the meter face marked "- TEST +", black and red.

This multimeter (Barnett brand) takes a slightly different design approach than the previous unit. Note how the rotary selector switch has fewer positions than the previous meter, but also how there are many more jacks into which the test leads may be plugged into. Each one of those jacks is labeled with a number indicating the respective full-scale range of the meter.

Lastly, here is a picture of a digital multimeter. Note that the familiar meter movement has been replaced by a blank, gray-colored display screen. When powered, numerical digits appear in that screen area, depicting the amount of voltage, current, or resistance being measured. This particular brand and model of digital meter has a rotary selector switch and four jacks into which test leads can be plugged. Two leads -- one red and one black -- are shown plugged into the meter.

Note that the selector switch still has different positions for voltage and current measurement, so in order for the user to switch between these two modes of measurement they must switch the position of the red test lead and move the selector switch to a different position.A close examination of this meter will reveal one "common" jack for the black test lead and three others for the red test lead. The jack into which the red lead is shown inserted is labeled for voltage and resistance measurement, while the other two jacks are labeled for current (A, mA, and μA) measurement. This is a wise design feature of the multimeter, requiring the user to move a test lead plug from one jack to another in order to switch from the voltage measurement to the current measurement function. It would be hazardous to have the meter set in current measurement mode while connected across a significant source of voltage because of the low input resistance, and making it necessary to move a test lead plug rather than just flip the selector switch to a different position helps ensure that the meter doesn't get set to measure current unintentionally.

Also note that neither the selector switch nor the jacks are labeled with measurement ranges. In other words, there are no "100 volt" or "10 volt" or "1 volt" ranges (or any equivalent range steps) on this meter. Rather, this meter is "autoranging," meaning that it automatically picks the appropriate range for the quantity being measured. Autoranging is a feature only found on digital meters, but not all digital meters.

No two models of multimeters are designed to operate exactly the same, even if they're manufactured by the same company. In order to fully understand the operation of any multimeter, the owner's manual must be consulted.

Here is a schematic for a simple analog volt/ammeter:

In the switch's three lower (most counter-clockwise) positions, the meter movement is connected to the Commonand V jacks through one of three different series range resistors (R_multiplier1 through R_multiplier3), and so acts as a voltmeter. In the fourth position, the meter movement is connected in parallel with the shunt resistor, and so acts as an ammeter for any current entering the common jack and exiting the A jack. In the last (furthest clockwise) position, the meter movement is disconnected from either red jack, but short-circuited through the switch. This short-circuiting creates a dampening effect on the needle, guarding against mechanical shock damage when the meter is handled and moved.

If an ohmmeter function is desired in this multimeter design, it may be substituted for one of the three voltage ranges as such:

With all three fundamental functions available, this multimeter may also be known as a volt-ohm-milliammeter.

Obtaining a reading from an analog multimeter when there is a multitude of ranges and only one meter movement may seem daunting to the new technician. On an analog multimeter, the meter movement is marked with several scales, each one useful for at least one range setting. Here is a close-up photograph of the scale from the Barnett multimeter shown earlier in this section:

Note that there are three types of scales on this meter face: a green scale for resistance at the top, a set of black scales for DC voltage and current in the middle, and a set of blue scales for AC voltage and current at the bottom. Both the DC and AC scales have three sub-scales, one ranging 0 to 2.5, one ranging 0 to 5, and one ranging 0 to 10. The meter operator must choose whichever scale best matches the range switch and plug settings in order to properly interpret the meter's indication.

This particular multimeter has several basic voltage measurement ranges: 2.5 volts, 10 volts, 50 volts, 250 volts, 500 volts, and 1000 volts. With the use of the voltage range extender unit at the top of the multimeter, voltages up to 5000 volts can be measured. Suppose the meter operator chose to switch the meter into the "volt" function and plug the red test lead into the 10 volt jack. To interpret the needle's position, he or she would have to read the scale ending with the number "10". If they moved the red test plug into the 250 volt jack, however, they would read the meter indication on the scale ending with "2.5", multiplying the direct indication by a factor of 100 in order to find what the measured voltage was.

If current is measured with this meter, another jack is chosen for the red plug to be inserted into and the range is selected via a rotary switch. This close-up photograph shows the switch set to the 2.5 mA position:

Note how all current ranges are power-of-ten multiples of the three scale ranges shown on the meter face: 2.5, 5, and 10. In some range settings, such as the 2.5 mA for example, the meter indication may be read directly on the 0 to 2.5 scale. For other range settings (250 μA, 50 mA, 100 mA, and 500 mA), the meter indication must be read off the appropriate scale and then multiplied by either 10 or 100 to obtain the real figure. The highest current range available on this meter is obtained with the rotary switch in the 2.5/10 amp position. The distinction between 2.5 amps and 10 amps is made by the red test plug position: a special "10 amp" jack next to the regular current-measuring jack provides an alternative plug setting to select the higher range.

Resistance in ohms, of course, is read by a logarithmic scale at the top of the meter face. It is "backward," just like all battery-operated analog ohmmeters, with zero at the right-hand side of the face and infinity at the left-hand side. There is only one jack provided on this particular multimeter for "ohms," so different resistance-measuring ranges must be selected by the rotary switch. Notice on the switch how five different "multiplier" settings are provided for measuring resistance: Rx1, Rx10, Rx100, Rx1000, and Rx10000. Just as you might suspect, the meter .indication is given by multiplying whatever needle position is shown on the meter face by the power-of-ten multiplying factor set by the rotary switch.

Concept of Bridge circuits

Bridge circuits

Bridge circuit Bridge, Wheatstone

No text on electrical metering could be called complete without a section on bridge circuits. These ingenious circuits make use of a null-balance meter to compare two voltages, just like the laboratory balance scale compares two weights and indicates when they're equal. Unlike the "potentiometer" circuit used to simply measure an unknown voltage, bridge circuits can be used to measure all kinds of electrical values, not the least of which being resistance.

Wheatstone bridge

The standard bridge circuit, often called a Wheatstone bridge, looks something like this:

When the voltage between point 1 and the negative side of the battery is equal to the voltage between point 2 and the negative side of the battery, the null detector will indicate zero and the bridge is said to be "balanced." The bridge's state of balance is solely dependent on the ratios of R_a/R_b and R₁/R₂, and is quite independent of the supply voltage (battery). To measure resistance with a Wheatstone bridge, an unknown resistance is connected in the place of R_a or R_b, while the other three resistors are precision devices of known value. Either of the other three resistors can be replaced or adjusted until the bridge is balanced, and when balance has been reached the unknown resistor value can be determined from the ratios of the known resistances.

A requirement for this to be a measurement system is to have a set of variable resistors available whose resistances are precisely known, to serve as reference standards. For example, if we connect a bridge circuit to measure an unknown resistance R_x, we will have to know the exact values of the other three resistors at balance to determine the value of R_x:

Arm, Wheatstone bridge Rheostat arm, Wheatstone bridge Ratio arm, Wheatstone bridge

Each of the four resistances in a bridge circuit are referred to as arms. The resistor in series with the unknown resistance R_x (this would be R_a in the above schematic) is commonly called the rheostat of the bridge, while the other two resistors are called the ratio arms of the bridge.

Accurate and stable resistance standards, thankfully, are not that difficult to construct. In fact, they were some of the first electrical "standard" devices made for scientific purposes. Here is a photograph of an antique resistance standard unit:

This resistance standard shown here is variable in discrete steps: the amount of resistance between the connection terminals could be varied with the number and pattern of removable copper plugs inserted into sockets.

Wheatstone bridges are considered a superior means of resistance measurement to the series battery-movement-resistor meter circuit discussed in the last section. Unlike that circuit, with all its nonlinearities (logarithmic scale) and associated inaccuracies, the bridge circuit is linear (the mathematics describing its operation are based on simple ratios and proportions) and quite accurate.

Given standard resistances of sufficient precision and a null detector device of sufficient sensitivity, resistance measurement accuracies of at least +/- 0.05% are attainable with a Wheatstone bridge. It is the preferred method of resistance measurement in calibration laboratories due to its high accuracy.

There are many variations of the basic Wheatstone bridge circuit. Most DC bridges are used to measure resistance, while bridges powered by alternating current (AC) may be used to measure different electrical quantities like inductance, capacitance, and frequency.

Kelvin Double bridge Bridge, Kelvin Double

An interesting variation of the Wheatstone bridge is the Kelvin Double bridge, used for measuring very low resistances (typically less than 1/10 of an ohm). Its schematic diagram is as such:

The low-value resistors are represented by thick-line symbols, and the wires connecting them to the voltage source (carrying high current) are likewise drawn thickly in the schematic. This oddly-configured bridge is perhaps best understood by beginning with a standard Wheatstone bridge set up for measuring low resistance, and evolving it step-by-step into its final form in an effort to overcome certain problems encountered in the standard Wheatstone configuration.

If we were to use a standard Wheatstone bridge to measure low resistance, it would look something like this:

When the null detector indicates zero voltage, we know that the bridge is balanced and that the ratios R_a/R_x and R_M/R_N are mathematically equal to each other. Knowing the values of R_a, R_M, and R_N therefore provides us with the necessary data to solve for R_x . . . almost.

We have a problem, in that the connections and connecting wires between R_a and R_x possess resistance as well, and this stray resistance may be substantial compared to the low resistances of R_a and R_x. These stray resistances will drop substantial voltage, given the high current through them, and thus will affect the null detector's indication and thus the balance of the bridge:

Since we don't want to measure these stray wire and connection resistances, but only measure R_x, we must find some way to connect the null detector so that it won't be influenced by voltage dropped across them. If we connect the null detector and R_M/R_N ratio arms directly across the ends of R_a and R_x, this gets us closer to a practical solution:

Now the top two E_wire voltage drops are of no effect to the null detector, and do not influence the accuracy of R_x's resistance measurement. However, the two remaining E_wire voltage drops will cause problems, as the wire connecting the lower end of R_a with the top end of R_x is now shunting across those two voltage drops, and will conduct substantial current, introducing stray voltage drops along its own length as well.

Knowing that the left side of the null detector must connect to the two near ends of R_a and R_x in order to avoid introducing those E_wire voltage drops into the null detector's loop, and that any direct wire connecting those ends of R_a and R_x will itself carry substantial current and create more stray voltage drops, the only way out of this predicament is to make the connecting path between the lower end of R_a and the upper end of R_x substantially resistive:

We can manage the stray voltage drops between R_a and R_x by sizing the two new resistors so that their ratio from upper to lower is the same ratio as the two ratio arms on the other side of the null detector. This is why these resistors were labeled R_m and R_n in the original Kelvin Double bridge schematic: to signify their proportionality with R_M and R_N:

With ratio R_m/R_n set equal to ratio R_M/R_N, rheostat arm resistor R_a is adjusted until the null detector indicates balance, and then we can say that R_a/R_x is equal to R_M/R_N, or simply find R_x by the following equation:

The actual balance equation of the Kelvin Double bridge is as follows (R_wire is the resistance of the thick, connecting wire between the low-resistance standard R_a and the test resistance R_x):

So long as the ratio between R_M and R_N is equal to the ratio between R_m and R_n, the balance equation is no more complex than that of a regular Wheatstone bridge, with R_x/R_a equal to R_N/R_M, because the last term in the equation will be zero, canceling the effects of all resistances except R_x, R_a, R_M, and R_N.

In many Kelvin Double bridge circuits, R_M=R_m and R_N=R_n. However, the lower the resistances of R_m and R_n, the more sensitive the null detector will be, because there is less resistance in series with it. Increased detector sensitivity is good, because it allows smaller imbalances to be detected, and thus a finer degree of bridge balance to be attained. Therefore, some high-precision Kelvin Double bridges use R_m and R_n values as low as 1/100 of their ratio arm counterparts (R_M and R_N, respectively). Unfortunately, though, the lower the values of R_m and R_n, the more current they will carry, which will increase the effect of any junction resistances present where R_m and R_nconnect to the ends of R_a and R_x. As you can see, high instrument accuracy demands that all error-producing factors be taken into account, and often the best that can be achieved is a compromise minimizing two or more different kinds of errors.

Review

Bridge circuits rely on sensitive null-voltage meters to compare two voltages for equality. A Wheatstone bridge can be used to measure resistance by comparing unknown resistor against precision resistors of known value, much like a laboratory scale measures an unknown weight by comparing it against known standard weights. A Kelvin Double bridge is a variant of the Wheatstone bridge used for measuring very low resistances. Its additional complexity over the basic Wheatstone design is necessary for avoiding errors otherwise incurred by stray resistances along the current path between the low-resistance standard and the resistance being measured.

What is a meter?

What is a meter?

Most modern meters are "digital" in design, meaning that their readable display is in the form of numerical digits. Older designs of meters are mechanical in nature, using some kind of pointer device to show quantity of measurement. In either case, the principles applied in adapting a display unit to the measurement of (relatively) large quantities of voltage, current, or resistance are the same.A meter is any device built to accurately detect and display an electrical quantity in a form readable by a human being. Usually this "readable form" is visual: motion of a pointer on a scale, a series of lights arranged to form a "bargraph," or some sort of display composed of numerical figures. In the analysis and testing of circuits, there are meters designed to accurately measure the basic quantities of voltage, current, and resistance. There are many other types of meters as well, but this chapter primarily covers the design and operation of the basic three.

The display mechanism of a meter is often referred to as a movement, borrowing from its mechanical nature to move a pointer along a scale so that a measured value may be read. Though modern digital meters have no moving parts, the term "movement" may be applied to the same basic device performing the display function.

The design of digital "movements" is beyond the scope of this chapter, but mechanical meter movement designs are very understandable. Most mechanical movements are based on the principle of electromagnetism: that electric current through a conductor produces a magnetic field perpendicular to the axis of electron flow. The greater the electric current, the stronger the magnetic field produced. If the magnetic field formed by the conductor is allowed to interact with another magnetic field, a physical force will be generated between the two sources of fields. If one of these sources is free to move with respect to the other, it will do so as current is conducted through the wire, the motion (usually against the resistance of a spring) being proportional to strength of current.

The first meter movements built were known as galvanometers, and were usually designed with maximum sensitivity in mind. A very simple galvanometer may be made from a magnetized needle (such as the needle from a magnetic compass) suspended from a string, and positioned within a coil of wire. Current through the wire coil will produce a magnetic field which will deflect the needle from pointing in the direction of earth's magnetic field. An antique string galvanometer is shown in the following photograph:

Such instruments were useful in their time, but have little place in the modern world except as proof-of-concept and elementary experimental devices. They are highly susceptible to motion of any kind, and to any disturbances in the natural magnetic field of the earth. Now, the term "galvanometer" usually refers to any design of electromagnetic meter movement built for exceptional sensitivity, and not necessarily a crude device such as that shown in the photograph. Practical electromagnetic meter movements can be made now where a pivoting wire coil is suspended in a strong magnetic field, shielded from the majority of outside influences. Such an instrument design is generally known as a permanent-magnet, moving coil, or PMMC movement:

In the picture above, the meter movement "needle" is shown pointing somewhere around 35 percent of full-scale, zero being full to the left of the arc and full-scale being completely to the right of the arc. An increase in measured current will drive the needle to point further to the right and a decrease will cause the needle to drop back down toward its resting point on the left. The arc on the meter display is labeled with numbers to indicate the value of the quantity being measured, whatever that quantity is. In other words, if it takes 50 microamps of current to drive the needle fully to the right (making this a "50 μA full-scale movement"), the scale would have 0 μA written at the very left end and 50 μA at the very right, 25 μA being marked in the middle of the scale. In all likelihood, the scale would be divided into much smaller graduating marks, probably every 5 or 1 μA, to allow whoever is viewing the movement to infer a more precise reading from the needle's position.

The meter movement will have a pair of metal connection terminals on the back for current to enter and exit. Most meter movements are polarity-sensitive, one direction of current driving the needle to the right and the other driving it to the left. Some meter movements have a needle that is spring-centered in the middle of the scale sweep instead of to the left, thus enabling measurements of either polarity:

Common polarity-sensitive movements include the D'Arsonval and Weston designs, both PMMC-type instruments. Current in one direction through the wire will produce a clockwise torque on the needle mechanism, while current the other direction will produce a counter-clockwise torque.

Some meter movements are polarity-insensitive, relying on the attraction of an unmagnetized, movable iron vane toward a stationary, current-carrying wire to deflect the needle. Such meters are ideally suited for the measurement of alternating current (AC). A polarity-sensitive movement would just vibrate back and forth uselessly if connected to a source of AC.

While most mechanical meter movements are based on electromagnetism (electron flow through a conductor creating a perpendicular magnetic field), a few are based on electrostatics: that is, the attractive or repulsive force generated by electric charges across space. This is the same phenomenon exhibited by certain materials (such as wax and wool) when rubbed together. If a voltage is applied between two conductive surfaces across an air gap, there will be a physical force attracting the two surfaces together capable of moving some kind of indicating mechanism. That physical force is directly proportional to the voltage applied between the plates, and inversely proportional to the square of the distance between the plates. The force is also irrespective of polarity, making this a polarity-insensitive type of meter movement:

Unfortunately, the force generated by the electrostatic attraction is very small for common voltages. In fact, it is so small that such meter movement designs are impractical for use in general test instruments. Typically, electrostatic meter movements are used for measuring very high voltages (many thousands of volts). One great advantage of the electrostatic meter movement, however, is the fact that it has extremely high resistance, whereas electromagnetic movements (which depend on the flow of electrons through wire to generate a magnetic field) are much lower in resistance. As we will see in greater detail to come, greater resistance (resulting in less current drawn from the circuit under test) makes for a better voltmeter.

A much more common application of electrostatic voltage measurement is seen in an device known as a Cathode Ray Tube, or CRT. These are special glass tubes, very similar to television viewscreen tubes. In the cathode ray tube, a beam of electrons traveling in a vacuum are deflected from their course by voltage between pairs of metal plates on either side of the beam. Because electrons are negatively charged, they tend to be repelled by the negative plate and attracted to the positive plate. A reversal of voltage polarity across the two plates will result in a deflection of the electron beam in the opposite direction, making this type of meter "movement" polarity-sensitive:

The electrons, having much less mass than metal plates, are moved by this electrostatic force very quickly and readily. Their deflected path can be traced as the electrons impinge on the glass end of the tube where they strike a coating of phosphorus chemical, emitting a glow of light seen outside of the tube. The greater the voltage between the deflection plates, the further the electron beam will be "bent" from its straight path, and the further the glowing spot will be seen from center on the end of the tube.

A photograph of a CRT is shown at the left. In a real CRT, as shown in the above photograph, there are two pairs of deflection plates rather than just one. In order to be able to sweep the electron beam around the whole area of the screen rather than just in a straight line, the beam must be deflected in more than one dimension.

Although these tubes are able to accurately register small voltages, they are bulky and require electrical power to operate (unlike electromagnetic meter movements, which are more compact and actuated by the power of the measured signal current going through them). They are also much more fragile than other types of electrical metering devices. Usually, cathode ray tubes are used in conjunction with precise external circuits to form a larger piece of test equipment known as an oscilloscope, which has the ability to display a graph of voltage over time, a tremendously useful tool for certain types of circuits where voltage and/or current levels are dynamically changing.

Whatever the type of meter or size of meter movement, there will be a rated value of voltage or current necessary to give full-scale indication. In electromagnetic movements, this will be the "full-scale deflection current" necessary to rotate the needle so that it points to the exact end of the indicating scale. In electrostatic movements, the full-scale rating will be expressed as the value of voltage resulting in the maximum deflection of the needle actuated by the plates, or the value of voltage in a cathode-ray tube which deflects the electron beam to the edge of the indicating screen. In digital "movements," it is the amount of voltage resulting in a "full-count" indication on the numerical display: when the digits cannot display a larger quantity.

The task of the meter designer is to take a given meter movement and design the necessary external circuitry for full-scale indication at some specified amount of voltage or current. Most meter movements (electrostatic movements excepted) are quite sensitive, giving full-scale indication at only a small fraction of a volt or an amp. This is impractical for most tasks of voltage and current measurement. What the technician often requires is a meter capable of measuring high voltages and currents.

By making the sensitive meter movement part of a voltage or current divider circuit, the movement's useful measurement range may be extended to measure far greater levels than what could be indicated by the movement alone. Precision resistors are used to create the divider circuits necessary to divide voltage or current appropriately. One of the lessons you will learn in this chapter is how to design these divider circuits.

Review

A "movement" is the display mechanism of a meter.
Electromagnetic movements work on the principle of a magnetic field being generated by electric current through a wire. Examples of electromagnetic meter movements include the D'Arsonval, Weston, and iron-vane designs.
Electrostatic movements work on the principle of physical force generated by an electric field between two plates.
Cathode Ray Tubes (CRT's) use an electrostatic field to bend the path of an electron beam, providing indication of the beam's position by light created when the beam strikes the end of the glass tube.

Creating custom calibration resistances

Creating custom calibration resistances

Resistor, custom value

Often in the course of designing and building electrical meter circuits, it is necessary to have precise resistances to obtain the desired range(s). More often than not, the resistance values required cannot be found in any manufactured resistor unit and therefore must be built by you.

Winding, bifilar Resistor, wire-wound Wire-wound resistor

One solution to this dilemma is to make your own resistor out of a length of special high-resistance wire. Usually, a small "bobbin" is used as a form for the resulting wire coil, and the coil is wound in such a way as to eliminate any electromagnetic effects: the desired wire length is folded in half, and the looped wire wound around the bobbin so that current through the wire winds clockwise around the bobbin for half the wire's length, then counter-clockwise for the other half. This is known as a bifilar winding. Any magnetic fields generated by the current are thus canceled, and external magnetic fields cannot induce any voltage in the resistance wire coil:

As you might imagine, this can be a labor-intensive process, especially if more than one resistor must be built! Another, easier solution to the dilemma of a custom resistance is to connect multiple fixed-value resistors together in series-parallel fashion to obtain the desired value of resistance. This solution, although potentially time-intensive in choosing the best resistor values for making the first resistance, can be duplicated much faster for creating multiple custom resistances of the same value:

A disadvantage of either technique, though, is the fact that both result in a fixed resistance value. In a perfect world where meter movements never lose magnetic strength of their permanent magnets, where temperature and time have no effect on component resistances, and where wire connections maintain zero resistance forever, fixed-value resistors work quite well for establishing the ranges of precision instruments. However, in the real world, it is advantageous to have the ability to calibrate, or adjust, the instrument in the future.

However, most potentiometers provide too large a resistance span over their mechanically-short movement range to allow for precise adjustment. Suppose you desired a resistance of 8.335 kΩ +/- 1 Ω, and wanted to use a 10 kΩ potentiometer (rheostat) to obtain it. A precision of 1 Ω out of a span of 10 kΩ is 1 part in 10,000, or 1/100 of a percent! Even with a 10-turn potentiometer, it will be very difficult to adjust it to any value this finely. Such a feat would be nearly impossible using a standard 3/4 turn potentiometer. So how can we get the resistance value we need and still have room for adjustment?It makes sense, then, to use potentiometers (connected as rheostats, usually) as variable resistances for range resistors. The potentiometer may be mounted inside the instrument case so that only a service technician has access to change its value, and the shaft may be locked in place with thread-fastening compound (ordinary nail polish works well for this!) so that it will not move if subjected to vibration.

The solution to this problem is to use a potentiometer as part of a larger resistance network which will create a limited adjustment range. Observe the following example:

Here, the 1 kΩ potentiometer, connected as a rheostat, provides by itself a 1 kΩ span (a range of 0 Ω to 1 kΩ). Connected in series with an 8 kΩ resistor, this offsets the total resistance by 8,000 Ω, giving an adjustable range of 8 kΩ to 9 kΩ. Now, a precision of +/- 1 Ω represents 1 part in 1000, or 1/10 of a percent of potentiometer shaft motion. This is ten times better, in terms of adjustment sensitivity, than what we had using a 10 kΩ potentiometer.

If we desire to make our adjustment capability even more precise -- so we can set the resistance at 8.335 kΩ with even greater precision -- we may reduce the span of the potentiometer by connecting a fixed-value resistor in parallel with it:

Now, the calibration span of the resistor network is only 500 Ω, from 8 kΩ to 8.5 kΩ. This makes a precision of +/- 1 Ω equal to 1 part in 500, or 0.2 percent. The adjustment is now half as sensitive as it was before the addition of the parallel resistor, facilitating much easier calibration to the target value. The adjustment will not be linear, unfortunately (halfway on the potentiometer's shaft position will not result in 8.25 kΩ total resistance, but rather 8.333 kΩ).


ill, it is an improvement in terms of sensitivity, and it is a practical solution to our problem of building an adjustable resistance for a precision instrument!

Experiment-Basic Concept and Test Equipment-chapter-10

 Experiment-Electromagnetic Induction

PARTS AND MATERIALS

• Electromagnet from previous experiment
• Permanent magnet

See previous experiment for instructions on electromagnet construction.

CROSS-REFERENCE
 "Magnetism and Electromagnetism"

LEARNING OBJECTIVES

• Relationship between magnetic field strength and induced voltage

SCHEMATIC DIAGRAM

ILLUSTRATION

INSTRUCTIONS

Electromagnetic induction Induction, electromagnetic

Electromagnetic induction is the complementary phenomenon to electromagnetism. Instead of producing a magnetic field from electricity, we produce electricity from a magnetic field. There is one important difference, though: whereas electromagnetism produces a steady magnetic field from a steady electric current, electromagnetic induction requires motion between the magnet and the coil to produce a voltage.

Connect the multimeter to the coil, and set it to the most sensitive DC voltage range available. Move the magnet slowly to and from one end of the electromagnet, noting the polarity and magnitude of the induced voltage. Experiment with moving the magnet, and discover for yourself what factor(s) determine the amount of voltage induced. Try the other end of the coil and compare results. Try the other end of the permanent magnet and compare.

If using an analog multimeter, be sure to use long jumper wires and locate the meter far away from the coil, as the magnetic field from the permanent magnet may affect the meter's operation and produce false readings. Digital meters are unaffected by magnetic fields.

Experiment-Basic Concept and Test Equipment-chapter-9

 Experiment-Electromagnetism

PARTS AND MATERIALS

• 6-volt battery
• Magnetic compass
• Small permanent magnet
• Spool of 28-gauge magnet wire
• Large bolt, nail, or steel rod
• Electrical tape

Magnet wire Wire, magnet

Magnet wire is a term for thin-gauge copper wire with enamel insulation instead of rubber or plastic insulation. Its small size and very thin insulation allow for many "turns" to be wound in a compact coil. You will need enough magnet wire to wrap hundreds of turns around the bolt, nail, or other rod-shaped steel form.

Be sure to select a bolt, nail, or rod that is magnetic. Stainless steel, for example, is non-magnetic and will not function for the purpose of an electromagnet coil! The ideal material for this experiment is soft iron, but any commonly available steel will suffice.

CROSS-REFERENCES

 "Magnetism and Electromagnetism"

LEARNING OBJECTIVES

• Application of the left-hand rule
• Electromagnet construction

SCHEMATIC DIAGRAM

ILLUSTRATION

INSTRUCTIONS

Wrap a single layer of electrical tape around the steel bar (or bolt, or mail) to protect the wire from abrasion. Proceed to wrap several hundred turns of wire around the steel bar, making the coil as even as possible. It is okay to overlap wire, and it is okay to wrap in the same style that a fishing reel wraps line around the spool. The only rule you must follow is that all turns must be wrapped around the bar in the same direction (no reversing from clockwise to counter-clockwise!). I find that a drill press works as a great tool for coil winding: clamp the rod in the drill's chuck as if it were a drill bit, then turn the drill motor on at a slow speed and let it do the wrapping! This allows you to feed wire onto the rod in a very steady, even manner.

After you've wrapped several hundred turns of wire around the rod, wrap a layer or two of electrical tape over the wire coil to secure the wire in place. Scrape the enamel insulation off the ends of the coil wires for connection to jumper leads, then connect the coil to a battery.

Electromagnetism

When electric current goes through the coil, it will produce a strong magnetic field: one "pole" at each end of the rod. This phenomenon is known as electromagnetism. The magnetic compass is used to identify the "North" and "South" poles of the electromagnet.

With the electromagnet energized (connected to the battery), place a permanent magnet near one pole and note whether there is an attractive or repulsive force. Reverse the orientation of the permanent magnet and note the difference in force.

Electromagnetism has many applications, including relays, electric motors, solenoids, doorbells, buzzers, computer printer mechanisms, and magnetic media "write" heads (tape recorders, disk drives).

Inductive "kickback"

You might notice a significant spark whenever the battery is disconnected from the electromagnet coil: much greater than the spark produced if the battery is simply short-circuited. This spark is the result of a high-voltage surge created whenever current is suddenly interrupted through the coil. The effect is known as inductive "kickback" and is capable of delivering a small but harmless electric shock! To avoid receiving this shock, do not place your body across the break in the circuit when de-energizing! Use one hand at a time when un-powering the coil and you'll be perfectly safe. This phenomenon will be explored in greater detail in the next chapter 

Three-Phase Transformer Circuits

Since three-phase is used so often for power distribution systems, it makes sense that we would need three-phase transformers to be able to step voltages up or down. This is only partially true, as regular single-phase transformers can be ganged together to transform power between two three-phase systems in a variety of configurations, eliminating the requirement for a special three-phase transformer. However, special three-phase transformers are built for those tasks, and are able to perform with less material requirement, less size, and less weight from their modular counterparts.

Experiment-Basic Concept and Test Equipment-chapter-8

 Experiment-Circuit with a Switch

PARTS AND MATERIALS

• 6-volt battery
• Low-voltage incandescent lamp (Radio Shack catalog # 272-1130 or equivalent)
• Long lengths of wire, 22-gauge or larger
• Household light switch (these are readily available at any hardware store)

Switch

Household light switches are a bargain for students of basic electricity. They are readily available, very inexpensive, and almost impossible to damage with battery power. Do not get "dimmer" switches, just the simple on-off "toggle" variety used for ordinary household wall-mounted light controls.

CROSS-REFERENCES

Lessons In  "Basic Concepts of Electricity"

LEARNING OBJECTIVES

Ammeter design

Ammeter design

Ammeter

A meter designed to measure electrical current is popularly called an "ammeter" because the unit of measurement is "amps."

Taking the same meter movement as the voltmeter example, we can see that it would make a very limited instrument by itself, full-scale deflection occurring at only 1 mA:In ammeter designs, external resistors added to extend the usable range of the movement are connected in parallel with the movement rather than in series as is the case for voltmeters. This is because we want to divide the measured current, not the measured voltage, going to the movement, and because current divider circuits are always formed by parallel resistances.

Experiment-Basic Concept and Test Equipment-chapter-7

 Experiment-Power Dissipation

PARTS AND MATERIALS

• Calculator (or pencil and paper for doing arithmetic)
• 6 volt battery
• Two 1/4 watt resistors: 10 Ω and 330 Ω.
• Small thermometer

The resistor values need not be exact, but within five percent of the figures specified (+/- 0.5 Ω for the 10 Ω resistor; +/- 16.5 Ω for the 330 Ω resistor). Color codes for 5% tolerance 10 Ω and 330 Ω resistors are as follows: Brown, Black, Black, Gold (10, +/- 5%), and Orange, Orange, Brown, Gold (330, +/- 5%).

Do not use any battery size other than 6 volts for this experiment.

The thermometer should be as small as possible, to facilitate rapid detection of heat produced by the resistor. I recommend a medical thermometer, the type used to take body temperature.

CROSS-REFERENCES

Voltmeter design

Voltmeter design

Voltmeter

As was stated earlier, most meter movements are sensitive devices. Some D'Arsonval movements have full-scale deflection current ratings as little as 50 μA, with an (internal) wire resistance of less than 1000 Ω. This makes for a voltmeter with a full-scale rating of only 50 millivolts (50 μA X 1000 Ω)! In order to build voltmeters with practical (higher voltage) scales from such sensitive movements, we need to find some way to reduce the measured quantity of voltage down to a level the movement can handle.

Let's start our example problems with a D'Arsonval meter movement having a full-scale deflection rating of 1 mA and a coil resistance of 500 Ω:

Experiment-Basic Concept and Test Equipment-chapter-6

 Experiment-Nonlinear resistance

PARTS AND MATERIALS

• Calculator (or pencil and paper for doing arithmetic)
• 6-volt battery
• Low-voltage incandescent lamp (Radio Shack catalog # 272-1130 or equivalent)

CROSS-REFERENCES

 "Ohm's Law"

LEARNING OBJECTIVES

• Voltmeter use
• Ammeter use
• Ohmmeter use
• Use of Ohm's Law
• Realization that some resistances are unstable!
• Scientific method

SCHEMATIC DIAGRAM

Experiment-Basic Concept and Test Equipment-chapter-5

 Experiment-Ohm's Law

PARTS AND MATERIALS

• Calculator (or pencil and paper for doing arithmetic)
• 6-volt battery
• Assortment of resistors between 1 KΩ and 100 kΩ in value

I'm purposely restricting the resistance values between 1 kΩ and 100 kΩ for the sake of obtaining accurate voltage and current readings with your meter. With very low resistance values, the internal resistance of the ammeter has a significant impact on measurement accuracy. Very high resistance values can cause problems for voltage measurement, the internal resistance of the voltmeter substantially changing circuit resistance when it is connected in parallel with a high-value resistor.

At the recommended resistance values, there will still be a small amount of measurement error due to the "impact" of the meter, but not enough to cause serious disagreement with calculated values.

Experiment-Basic Concept and Test Equipment-chapter-4

Experiment-Ammeter usage Procedure

PARTS AND MATERIALS

• 6-volt battery
• 6-volt incandescent lamp

Basic circuit construction components such as breadboard, terminal strip, and jumper wires are also assumed to be available from now on, leaving only components and materials unique to the project listed under "Parts and Materials."

CROSS-REFERENCES

 "Basic Concepts of Electricity"

"DC Metering Circuits"

LEARNING OBJECTIVES

• How to measure current with a multimeter
• How to check a multimeter's internal fuse
• Selection of proper meter range

SCHEMATIC DIAGRAM

ILLUSTRATION

INSTRUCTIONS

Current, definition Ampere Amp Unit, ampere

Current is the measure of the rate of electron "flow" in a circuit. It is measured in the unit of the Ampere, simply called "Amp," (A).

The most common way to measure current in a circuit is to break the circuit open and insert an "ammeter" in series(in-line) with the circuit so that all electrons flowing through the circuit also have to go through the meter. Because measuring current in this manner requires the meter be made part of the circuit, it is a more difficult type of measurement to make than either voltage or resistance.

Some digital meters, like the unit shown in the illustration, have a separate jack to insert the red test lead plug when measuring current. Other meters, like most inexpensive analog meters, use the same jacks for measuring voltage, resistance, and current. Consult your owner's manual on the particular model of meter you own for details on measuring current.

When an ammeter is placed in series with a circuit, it ideally drops no voltage as current goes through it. In other words, it acts very much like a piece of wire, with very little resistance from one test probe to the other. Consequently, an ammeter will act as a short circuit if placed in parallel (across the terminals of) a substantial source of voltage. If this is done, a surge in current will result, potentially damaging the meter:

Fuse

Ammeters are generally protected from excessive current by means of a small fuse located inside the meter housing. If the ammeter is accidently connected across a substantial voltage source, the resultant surge in current will "blow" the fuse and render the meter incapable of measuring current until the fuse is replaced. Be very careful to avoid this scenario!

You may test the condition of a multimeter's fuse by switching it to the resistance mode and measuring continuity through the test leads (and through the fuse). On a meter where the same test lead jacks are used for both resistance and current measurement, simply leave the test lead plugs where they are and touch the two probes together. On a meter where different jacks are used, this is how you insert the test lead plugs to check the fuse:

Build the one-battery, one-lamp circuit using jumper wires to connect the battery to the lamp, and verify that the lamp lights up before connecting the meter in series with it. Then, break the circuit open at any point and connect the meter's test probes to the two points of the break to measure current. As usual, if your meter is manually-ranged, begin by selecting the highest range for current, then move the selector switch to lower range positions until the strongest indication is obtained on the meter display without over-ranging it. If the meter indication is "backwards," (left motion on analog needle, or negative reading on a digital display), then reverse the test probe connections and try again. When the ammeter indicates a normal reading (not "backwards"), electrons are entering the black test lead and exiting the red. This is how you determine direction of current using a meter.

Metric prefix

For a 6-volt battery and a small lamp, the circuit current will be in the range of thousandths of an amp, or milliamps. Digital meters often show a small letter "m" in the right-hand side of the display to indicate this metric prefix.

Try breaking the circuit at some other point and inserting the meter there instead. What do you notice about the amount of current measured? Why do you think this is?

Re-construct the circuit on a breadboard like this:

Students often get confused when connecting an ammeter to a breadboard circuit. How can the meter be connected so as to intercept all the circuit's current and not create a short circuit? One easy method that guarantees success is this:

• Identify what wire or component terminal you wish to measure current through.
• Pull that wire or terminal out of the breadboard hole. Leave it hanging in mid-air.
• Insert a spare piece of wire into the hole you just pulled the other wire or terminal out of. Leave the other end of this wire hanging in mid-air.
• Connect the ammeter between the two unconnected wire ends (the two that were hanging in mid-air). You are now assured of measuring current through the wire or terminal initially identified.

Again, measure current through different wires in this circuit, following the same connection procedure outlined above. What do you notice about these current measurements? The results in the breadboard circuit should be the same as the results in the free-form (no breadboard) circuit.

Building the same circuit on a terminal strip should also yield similar results:

The current figure of 24.70 milliamps (24.70 mA) shown in the illustrations is an arbitrary quantity, reasonable for a small incandescent lamp. If the current for your circuit is a different value, that is okay, so long as the lamp is functioning when the meter is connected. If the lamp refuses to light when the meter is connected to the circuit, and the meter registers a much greater reading, you probably have a short-circuit condition through the meter. If your lamp refuses to light when the meter is connected in the circuit, and the meter registers zero current, you've probably blown the fuse inside the meter. Check the condition of your meter's fuse as described previously in this section and replace the fuse if necessary.

Experiment-Basic Concept and Test Equipment-chapter-3

Experiment-A Very Simple Circuit

PARTS AND MATERIALS

• 6-volt battery
• 6-volt incandescent lamp
• Jumper wires
• Breadboard
• Terminal strip

From this experiment on, a multimeter is assumed to be necessary and will not be included in the required list of parts and materials. In all subsequent illustrations, a digital multimeter will be shown instead of an analog meter unless there is some particular reason to use an analog meter. You are encouraged to use both types of meters to gain familiarity with the operation of each in these experiments.

CROSS-REFERENCES

Lessons In Electric Circuits, Volume 1, chapter 1: "Basic Concepts of Electricity"

LEARNING OBJECTIVES