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Hello, A few of my buddies and I are attempting to build a device much like the Kill-A-Watt for a small project and we are at a halt, any help would be appreciated. So far our design is simple, we have shunt resistors for voltage measurement in a voltage divider circuit. We then have the measurement for each voltage we desire going into a microcontroller (yet to be determined), and we want to take this data to calculate the power, apparent power, pf, etc, then take this data from the microcontroller and output it to an LCD screen and have a backup storage device to store the data over certain time intervals and sampling periods. We are going to implement wireless into the equation but existing software and hardware already exiss for this, the hard part is determining which parts to use, circuit design via PCB, and we also plan to implement solid sate relays for power consumption control. If you or anyone you know is in this field of study, any hep would be appreciated GREATLY!! Thank you.
And got the following answer:
This is kind of dangerous, as I'm sure you are already aware. The construction of the project is crucial. The hot line is... hot. And anything it goes through must be considered in terms of vibration and component failure modes, as a minimum. Be careful. You need both voltage and current. The simple way of getting current is to pass the current through a resistor. I don't know what loads you are considering (or voltages, to be honest) but I'm guessing that a 0.01 ohm resistor would be in the roughly okay ballpark with opamps generally available today. That won't present anything compared to the wiring in the wall, so there is no reason to be concerned about inserting that resistor. However... do NOT insert it on the HOT side!! It goes on the ground side. You are going to tap off of that and there is no good reason to make that yet another point of failure to worry excessively about. So make sure it is the neutral side current sense. You still need the voltage. That's going to mean a connection to the hot side. This is going to be where you be very careful. The resistance should be in the 1/2 meg to 1 meg region, I think. The other side (opposite the hot line) will be part of a divider that is grounded to the microcontroller supply. Which gets to another issue. How are you planning on powering the micro? Wireless makes sense. Full galvanic isolation using optical or a transformer might also be considered if you use a wired interface of some kind. The biggest problem I have with what you are planning isn't so much the measurement side but the solid state relay side. You say "implement" not "buy." So this means you will be designing a system that will switch and control power, not just measure it. The load may be inductive, capacitive, or possibly these elements may vary with time in difficult ways. There are many kinds of "events" which may occur (lightening, for example, or perhaps you need to include some kind of ground fault protection as well.) Up until I read that, I was kind of okay. Then not so okay. This is where things will get difficult if you are going to do it safely and over a variety of load conditions. The rest didn't bother me so much. ADC conditioning isn't troublesome, etc. I think the measurement side is very doable. The switching of power is where the bad news is at for me. If I were doing just measurement, I'd use hard-wired connections to the load so I'd have no electronics in there except for that single current-sense resistor. That doesn't scare me. The power switching is where all your troubles will be.