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A3-102

Session 2004
CIGR

PCB ROGOWSKI COILS HIGH PRECISION LOW POWER SENSORS

Ljubomir A. Kojovic*
Cooper Power Systems
USA

Summary-This paper presents novel designs of high precision Rogowski coils (RC) for advanced
protection, control, and metering systems that use new multifunction relays and fiber optic
communication. The coils can be applied at any voltage level (low, medium, and high voltage). One
RC consists of two printed circuit boards with imprinted coils, located next to each other. They are
highly accurate because manufacturing process is computer controlled, providing accurate geometry
of the coil. New protection systems using RCs provide adaptive relaying and fast response times to
faults. Since the new RCs are very accurate, protection levels can be set to lower thresholds reducing
stress on the protected equipment.
Keywords: Relay Protection-Rogowski Coil-Low Power Sensor
1. INTRODUCTION
The printed circuit board (PCB) Rogowski coils presented in this paper operate on the same principle
as coils that were first time introduced in 1912 for magnetic field measurements. At that time, the
coils could not be used for protection because their output power was not sufficient to drive electromechanical relays. However, with todays microprocessor-based equipment, RCs are more suitable
for such applications. Current transformers (CTs) have been traditionally used for protection and
measurement applications in part because of their ability to produce the high power output needed by
electromechanical equipment. Microprocessor-based equipment makes high power output
unnecessary and opens the door for other measurement techniques such as RCs, which have many
advantages over conventional CTs.
Papers [1, 2] explain the theory of RC operation and describe traditional designs and applications.
Paper [3] presents an innovative and patented design of RCs that use PCBs. In that design both RC
windings are imprinted on the same PCB.
This paper presents novel RCs for which an U.S. patent was granted [4]. The RCs have been designed
as non-split-core and split-core styles [5-7]. Sections 3, 4, and 5 describe the RC designs,
characteristics, and applications for protection, control, and metering.
*

lkojovic@cooperpower.com

2. PRINCIPLE OF OPERATION
Traditional RCs consist of a wire wound on a non-magnetic core. The coil is then placed around
conductors whose currents are to be measured. The output voltage is proportional to the rate of change
of measured current (Equation 1).

v (t ) = 0nS

d
d
[ ij (t )] = M [ ij (t )]
dt j
dt j

(1)

0 is permeability of air, n is winding density (turns per unit length), S is core cross-section, and M is
mutual coupling. To obtain measured current, coil output voltages must be integrated. For an ideal
RC, measurement accuracy is independent of conductor location inside the coil loop.
To prevent influence of nearby conductors carrying high currents, RCs must be designed with two
wire loops connected in electrically opposite directions. This cancels all electromagnetic fields
coming from outside the coil loop. One or both loops can consist of wound wire. If only one loop is
constructed as winding on non-magnetic core, then the second wire loop can be constructed by
returning the wire through the center of this winding. If both loops are constructed as windings, then
they must be wound in opposite directions. In this way, the RC output voltage induced by currents
from the inside conductor(s) will be doubled. The traditional method of designing RCs was to use
flexible cores such as coaxial cables. The cable shield was removed and the wire wound over the
plastic cable core. The existing conductor through the cable core center served as the return (second)
loop. To design high performance coils, straight rods have been used. More uniform cross-sectional
area can be manufactured with straight rods than with flexible cores. It is also easier to control the
winding process using rods. RCs with straight rod design require shielding all ends where rods have to
be interconnected.
The RC output voltage is proportional to the rate of change of measured current (di/dt) enclosed by
the coil. This unique RC feature to measure the speed of current change can be used for special
protection algorithms that would make decisions based on the change in the current slope instead on
current magnitude. For special applications, it is possible to simultaneously use both the nonintegrated and integrated signals from the same coil.
3. PCB ROGOWSKI COIL DESIGNS
High precision Rogowski coils presented in this paper consist of two printed circuit boards (PCBs)
located next to each other (Figure 1). Each PCB contains one imprinted coil wound in opposite
directions (clockwise and counter-clockwise). The top and bottom sides of each PCB are imprinted to
form a coil around the center of the board. The conductive imprints on the upper and lower sides of
the PCB are interconnected by conductive-plated holes. High precision is obtained because the
manufacturing process is computer controlled, providing accurate geometry of the coils. New RC
designs use multi-layer PCBs, which provides higher accuracy and more proficient manufacturing.
PCB Rogowski coils can be designed with different shapes to adjust for the application and be
designed in split-core styles for installation without the need to disconnect primary conductors. Figure
2 shows non-encapsulated and encapsulated circular shape RC implemented on multi-layer PCBs.
Figure 3 shows an oval shape split-core style RC, designed to embrace all three-phase conductors (for
measurement of residual currents) or to embrace parallel conductors that carry heavy currents. The
split-core style RC consists of four half loops. The first two half loops are constructed with two PCBs
with imprinted windings wound in opposite directions, located next to each other. The remaining two
half loops are constructed in the same way, but wound in opposite directions and connected. Figure 3
shows principle of the PCB split-core style RC design and a completed coil.

The PCB Rogowski coil has the following characteristics: measurement accuracy reaching 0.1 %;
measurement range from 1 A to over 100 kA; frequency response linear up to 700 kHz; unlimited
short-circuit withstand; galvanically isolated from the primary conductors; can be installed around
bushings or cables, avoiding the need for high insulation. Rogowski coils can be connected in series
to increase output signal.

i(t)

v(t)

Figure 1. Principle of the PCB Rogowski Coil Design

Figure 2. PCB Rogowski Coils (Non Split-Core Design)

i(t)

v(t)

Figure 3. PCB Rogowski Coils (Split-Core Design)

4. PERFORMANCE TESTS
The RC output voltage is proportional to the rate of change of measured current (di/dt) enclosed by
the coil. Therefore, the RC non-integrated signal can be significantly different that the waveform of
the measured current since the fault current DC offset will be attenuated and higher frequency
components amplified. The waveform will be also shifted by 90. Figure 4 shows non-integrated and
integrated RC output signals, which are obviously different. However, the integrated signal is almost
identical to the waveform recorded by a precision laboratory current sensor (Figure 5).

8000

8000

Current [A]

6000

laboratory CT

6000

Primary current, 2400 A RMS

(non-integrated and
integrated signals)

4000

4000
2000
0
-2000
8000

integrated RC signal

6000

Current [A]

Current [A]

2000

-2000

4000
2000
0
-2000

0.1

0.2

Time [s]

0.1

Figure 4. PCB Rogowski Coil Non-Integrated

and Integrated Signals

Time [s]

0.2

Figure 5. Test Current recorded by a Precision

Laboratory CT and by PCB Rogowski
Coil (Integrated Signal)

Residual current measurements were performed to determine the low range of currents that a
residually connected coil can detect. Three split-core style coils were tested in a three-phase
arrangement. The test (load) current was maintained at approximately 1000 A. Residual current was
controlled in the range 1 to 10 A through a current transformer with a variable resistor connected on
the secondary side. The results are shown in Figure 6. All three coils have consistent results,
demonstrating that can provide sensitive ground fault protection.
Differential Current Measurements. The RC performance for capacitor bank differential protection
was tested to determine minimum differential currents that can be reliably detected. The RC was
connected in a differential mode representing a series capacitor bank carrying 2000 A line current.
Figure 7 shows test results for differential currents up to 5 A. The RC output was linear to bellow 1 A
differential current, demonstrating high performance. When RCs are connected in differential mode
shown in Figure 7, the RC insulation class can be much smaller as compared to RCs connected in
differential mode in H-connected capacitor bank.

RC #1
1

RC #3

I ground
0.8

mV

0.6
0.4

2000 A

0.4

RC

0.3

1000 A

0.2

0.1

0.2
0
0

1000 A

RC #2

I load=1000 A

1.2
RC Output Voltage [mV]

0.5

Three Split-Core Rogowski Coils

RC Output Voltage [mV]

1.4

6
8
Residual Current [A]

10

Figure 6. Residual Current Measurement

12

2
3
Differential Current [A]

Figure 7. Differential Current Measurement

Influence from nearby conductors is one of the most important tests to determine the RC accuracy.
The test was performed in a high power laboratory at test current of 60 kARMS. Two RCs were tested,
RC1 was installed to measure the test current and RC2 was located 5 cm next to the primary
conductor to test the influence from the primary conductor. Since the induced signal in RC2 was very
small, an amplifier with 100 times amplification was used to increase the signal to the level acceptable
by the recorder. The results are shown in Figure 9. The influence from the primary conductor was
bellow 0.01 %, verifying very good coil immunity to the external magnetic fields. In actual

applications, RCs will be installed at a distance from nearby conductors where the influence will be
near zero.
4

Transient
Recorder
O/E
Circuit
Breaker

Making
Switch

Fiber
Optic
Cables

R, X

E/O

Laboratory CT
RC1

RC Output Voltage [V]

3
Measured current, 60 kARMS
(non-integrated signal)

2
1
0
-1

Influence from the

Influence from the
nearby conductor, 5 cm distance
nearby conductor, 5 cm distance
(signal magnified 100 times)
(signal magnified 100 times)

-2

RC2

-3

Amplifier

-4

5 cm

Figure 8. High Power Test Setup

0.1

0.2

Time[s]

0.3

0.4

Figure 9. Influence from the Primary Conductor

5. Applications
5.1. Low Voltage Applications
Spot network systems have been widely applied in the U.S. to supply power to densely loaded urban
areas with a high level of reliability and operating flexibility. However, in case of a fault, arcing fault
currents in the collector bus are relatively low as compared to maximum available fault currents for
bolted faults (in some cases not much higher than the load currents). Since these low currents may not
be sufficient to operate the fuses, damage to network equipment can be extensive. PCB Rogowski
coils can provide reliable differential protection of spot networks that was not possible by
conventional methods [8].
5.2. Medium Voltage Applications
RCs can be designed as combination coils for installation in medium voltage (MV) switchgear to fit
around circuit breaker bushings (Figure 10). Combination coils consist of four coils in the same
frame, three coils for phase current measurements and one coil for residual current measurements. The
coils for phase current measurements are circular non-split-core design, while the coil for residual
current measurements is an oval split-core design. Paper [9] presents different designs of low power
sensors for applications in medium voltage systems (wire wound RC sensors, resistive dividers, and
combi sensor, combining RC and voltage sensors).
Secondary Signal
Split-Core Rogowski coil

Non-Split-Core (Phase) Rogowski Coils

(a)
(b)
Figure 10. Combination PCB Rogowski Coil, Three Phase Coils and One Neutral Coil,
(a)-design principle, (b)- prototype coil during high power tests

5.3. High Voltage Applications

Transformer Differential Protection. The most common form of protective relaying for large
substation transformers is differential relaying. However, CT saturation due to the high current
magnitudes is a recognized problem causing protection misoperation. Traditional schemes use
restraint currents and multiple slopes to prevent the protection misoperation. Increased setting is also
one of the solutions. Differential schemes have not been applied on electric arc furnace (EAF)
transformers due to the lack of commercially available current transformers for the secondary leads.
Now, PCB RCs and multifunction relays can provide reliable protection. Figure 11 shows RC
applications for transformer differential protection. High power tests were performed using test
scheme shown in Figure 11a. The results confirmed that the relay properly operates even at low fault
currents, 3% load current, confirming that the PCB RCs provide strong differential signal ensuring
reliable relaying. Figure 11b demonstrates a RC application for EAF transformer differential scheme
employing two sets of RCs and one multifunction relay. Designed as split-core style, coils can be
installed around the secondary conductors that normally cannot be opened. An external signal can be
supplied to the relay to indicate the operating tap of the transformer. With suitable delays and an
algorithm developed for this application, the relay can be programmed to ride through an on-load tap
change. The ability of the scheme to adjust to actual transformer operating conditions reduces the
main sources of error that force higher percentage differential settings in conventional schemes. The
tap position can be supplied to the relay in a variety of formats such as analog or digital. Figure 11c
shows installation of RCs around transformer bushings, allowing the use of low voltage insulation
class RCs.
EAF Transformer

R, X

60 kA

Fault
current

I1 P

SW
I1 S

Rf
RC1

RC1

RC2

Tap
Position

I2 P

I2 S
Water Cooled
Leads

RC2

EAF
Transformer Differential
Protection Algorithm

RC

Multifunction Relay

(a)
(b)
(c)
Figure 11. PCB Rogowski Coils for Transformer Differential Protection, (a)-laboratory test,
(b)-EAF transformer application, (c)-RC installation around transformer bushings
Gas Insulated Switchgear (GIS). A number of papers have been written on RC applications in GIS
because RCs provide superior performance as compared to conventional CTs. RCs have been also
effectively combined with capacitive voltage sensors to simultaneously measure voltages and currents
in GIS as described in Papers [10-12]. A new digital control panel and electronic instrument based
microprocessor techniques developed for GIS is presented in paper [13]. Wire wound type RCs were
used for current measurements and capacitive voltage dividers for voltage measurements. Papers [14
and 15] present non-conventional sensors developed and implemented on GIS from 145 kV to 550
kV. Rogowski coils are designed using multi-layer printed circuit boards. Electronic capacitive
dividers are used for voltage measurements.
Optically Powered Data Link (OPDL) technology has been introduced in high voltage systems to
transmit data from the high voltage potential to ground potential, using fiber-optic cables and laser
technology [16]. Recent applications include current measurement for protection and metering with
metering accuracy. RCs are installed at high-voltage levels, suspended from the primary conductor or
a busbar. This eliminates a need for a supporting insulator.

The advantages of these novel methods as compared to the conventional high voltage, free standing
iron core CTs are: no oil or SF6 gas, light weight, no seismic or explosion concerns, and use of low
voltage insulation class RCs.
The system consists of a RC and the OPDL system as shown in Figure 12. The RC output signal is fed
into the remote unit of the OPDL, located on the high voltage potential. The remote unit is interfaced
to the ground unit over two fiber-optical cables. One cable provides power for the remote unit and the
second cable transmits data from the RC. The remote unit is shielded against EMI or RFI noise and
converts the RC voltage into digital signals. The electrical power to operate this unit is provided by
the photovoltaic power converter that is connected to the laser over one of the fiber optical links with
a conversion efficiency of up to 40%. The fiber-optical cables are incorporated into a composite
insulator, a lightweight structure similar to suspension insulators made of composite, silicone
material. The OPDL ground unit includes the laser with its associated laser driver and the data
recovery circuitry. These lasers are reliable with MTBF > 100,000 h. A self-check function supervises
all vital functions of the system. One OPDL unit with two fiber connections (one for power, one for
data) can transmit signals out of two RCs to the ground level.
i(t)

HV Line

A/D

Fiber-Optical
Cables

Power
Converter

Data

RC and
Remote
Unit

Fiber-Optical Cables

Laser
Diode
Ground
Unit

Remote
Unit

Data
Receiver

Power

Data

HV Potential

RC

Power
Supply

D/A
Converter

Analog
Output

DSP

Ground
Unit
Digital
Output

Ground
Unit

Remote
Unit

Junction
Box

Figure 12. RC Applications fro High Voltage Current Measurements using OPDL Technology
Substation Applications. PCB Rogowski coils can provide advanced protection when applied in
substations by integrating primary, fast backup, and conventional backup protection [8]. Protection
functions are performed locally and over communication. The RC diagnostic routine, implemented in
the relay, continuously monitors the RC condition and performs a contingency operation in case of an
RC or secondary lead failure. Providing fast backup protection for another relay is a unique concept.
Relays receive direct signals from two RCs, one providing main protection for one feeder and the
second providing fast backup protection for another feeder. Relays receive information that other
relays are inoperative over peer-to-peer communication. In all cases when the primary relay becomes
inoperative, the backup relay will operate fast, without impacting the fault clearing time and
protection zone area.
Next generation protection systems can use data from low power sensors installed anywhere in the
substation over a large communication network. Multifunction relays are capable of executing
multiple protection schemes in parallel in the same relay, providing both primary and fast backup
protection. Object-oriented programming and code reuse are widely accepted in the industry.
Graphical programming languages are sufficiently developed for efficient protection schemes
customization. Standardization is becoming internationally unified by developing a global
communication standard for substation automation, IEC 61850.

6. CONCLUSIONS
Printed circuit board (PCB) Rogowski coils (RCs) can be designed with different shapes to adjust for
the application and be designed in split-core styles for installation without the need to disconnect
primary conductors. Extensive testing was performed on both types of PCB RCs (non-slit-core and
split-core style) to determine their performances. To test the extreme application conditions, no
shielding was applied to Rogowski Coils. High power test results confirmed that both the split-core
and non-slit-core RC output signals are almost identical to signals obtained by high-precision
laboratory current sensors and influence from external electromagnetic fields is minimal.
PCB Rogowski coils are accurate and have excellent performance for applications in advanced
protection, control, and metering systems with new multifunction relays.
7. REFERENCES
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[15]
[16]

K. Heumann, Magnetischer Spannungsmesser hoher Prazision, ETZ-A, 1962.

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Systems, Inc., Cupertino, CA.